Multiple variable turn wave springs, methods of pre-loading components with said springs, and methods of manufacturing said springs

A method comprising:

• coiling a flat wire onto itself to produce a wave spring that comprises:
• a first end portion;
• a second end portion opposite with respect to the first end portion;
• active turns disposed between the first and second end portions and comprising waved or non-planar turns;
• a plurality of non-active turns disposed between the first and second end portions and comprising planar or non-waved turns;
• an aligned portion of the active and non-active turns having at least one first non-active turn disposed between at least two active turns;
• and
• a floating end of the first end portion having a cut off point adjacent to a wave trough of an adjacent active turn that is disposed between two wave crests of the adjacent active turn such that the first end portion is spaced apart from the active turns and the non-active turns of the wave spring,
• wherein
• a second non-active turn of the plurality of non-active turns comprises the first end portion that terminates at the floating end and the first end portion is axially bent with respect to the second non-active turn such that the floating end is axially bent towards the wave trough of the adjacent active turn.

A method comprising:

• applying at least one torsional load on or against a wave spring, wherein the wave spring comprises:
• an intermediate portion disposed between a first end portion and a second end portion opposite with respect to the first end portion;
• active turns disposed between the first and second end portions and comprising at least one wave crest, at least one wave trough, or at least one combination thereof;
• at least one first a-planar or non-waved turn disposed between at least two active turns;
• an aligned portion disposed at the intermediate portion, wherein the aligned portion comprises at least two active turns having wave crests, wave troughs, or at least one wave crest and at least one wave trough;
• and
• a floating end of the first end portion or floating ends of the first and second end portions, wherein
• each floating end has a cut off position adjacent a wave trough of an adjacent active turn that is disposed between two wave crests of the adjacent active turn such that each floating end is free of contact with the intermediate portion and the active turns of the wave spring, and
• a second planar or non-waved turn comprises the first end portion terminating at the floating end or two second planar or non-waved turns comprise the first and second end portions terminating at the floating ends,
• wherein
• the first end portion is axially bent with respect to the second non-active turn such that the floating end is axially bent towards the wave trough of the adjacent active turn or the first and second end portions are axially bent with respect to the two second planar or non-waved turns such that the floating ends are axially bent towards the wave troughs of the adjacent active turns.