Compliant joint drive assembly

A method of forming a dielectric barrier and torque transfer member between a drive shaft and a driven shaft of a torque transfer assembly, the method comprising:

• assembling the drive shaft and the driven shaft in axially adjacent relationship to one another, the drive shaft and the driven shaft each having a recess formed therein such that when the shafts are assembled, the recesses cooperate to define a chamber extending across the interface between the drive and driven shaft and into the interior of both the drive and the driven shaft;
• injecting a dielectric adhesive or resin material into the chamber to fill the chamber and to extend across the interface between the drive and the driven shaft;
• curing the dielectric material to form a dielectric barrier between and to provide torque transfer between the drive and the driven shaft;
• and
• providing a support structure for the dielectric material in the chamber between and extending across the interface between the driven and the drive shafts to provide a frame for the injected dielectric material;
• and
• wherein the support structure is formed as a thin lattice or cage structure around which the dielectric material can shape and cure.

A method of forming a dielectric barrier and torque transfer member between a drive shaft and a driven shaft of a torque transfer assembly, the method comprising:

• assembling the drive shaft and the driven shaft in axially adjacent relationship to one another, the drive shaft and the driven shaft each having a recess formed therein such that when the shafts are assembled, the recesses cooperate to define a chamber extending across the interface between the drive and driven shaft and into the interior of both the drive and the driven shaft;
• injecting a dielectric adhesive or resin material into the chamber to fill the chamber and to extend across the interface between the drive and the driven shaft;
• curing the dielectric material to form a dielectric barrier between and to provide torque transfer between the drive and the driven shaft;
• and
• providing a support structure for the dielectric material in the chamber between and extending across the interface between the drive and the driven shafts to provide a frame for the injected dielectric material;
• and
• wherein the support structure is at least partly removed after injection of the dielectric material.