Coil design for improved rotational performance

A coil transmitting a torque, comprising:

• a wire extending along a helical path about a longitudinal axis such that portions of adjacent turns of the wire overlap one another, the wire including a plurality of slots extending laterally therethrough such that a length of each of the slots extends longitudinally along the coil and a plurality of tabs extending radially therefrom such that each of the tabs is received in a corresponding one of the slots extending through an overlapping portion of an adjacent turn of the wire, wherein the wire is bent along the helical path at an angular cast along a thickness of the wire so that each turn of the coil is conical, wherein distal ends of each turn are narrowed while proximal ends of each turn are enlarged so that the narrowed distal end of one turn fits within the enlarged proximal end of an adjacent turn.

A coil transmitting a torque, comprising:

• a wire extending along a helical path about a longitudinal axis such that portions of adjacent turns of the wire overlap one another, the wire including a plurality of slots extending laterally therethrough such that a length of each of the slots extends longitudinally along the coil and a plurality of tabs extending radially therefrom such that each of the tabs is received in a corresponding one of the slots extending through an overlapping portion of an adjacent turn of the wire, wherein the wire is bent along the helical path at an angular cast along a thickness of the wire so that each turn of the coil is conical, wherein distal ends of each turn are enlarged while proximal ends of each turn are narrowed so that the narrowed proximal end of one turn fits within the enlarged distal end of an adjacent turn.

A coil transmitting a torque, comprising:

• a wire extending along a helical path about a longitudinal axis such that portions of adjacent turns of the wire overlap one another, the wire including a plurality of slots extending laterally therethrough such that a length of each of the slots extends longitudinally along the coil and a plurality of tabs extending radially therefrom such that each of the tabs is received in a corresponding one of the slots extending through an overlapping portion of an adjacent turn of the wire, wherein the wire is bent along the helical path at an angular cast along a thickness of the wire so that each turn of the coil is conical, wherein an angle of the cast is selected relative to a size of the tabs so that the tabs do not extend beyond a radially outermost profile of the wire.

A coil transmitting a torque, comprising:

• a wire extending along a longitudinal axis, the wire including a plurality of slots extending laterally therethrough from a first longitudinal surface thereof to a second longitudinal surface thereof and a plurality of tabs extending radially from one of the first and second longitudinal surfaces in alignment with the plurality of slots so that, when the wire is wound into a helical coil such that adjacent turns of the coil overlap one another, each of the tabs is received within a corresponding one of the slots along an overlapping portion of an adjacent turn of the wire, the slots extending longitudinally along the helical coil.