TECHNICAL FIELD

[0001] The present invention relates to the field of flexible supports. In particular, the invention is directed to flexible supports for use with conductors designed to transmit electromagnetic energy and/or conduits that carry gases or fluids. The flexible supports described herein provide a wide range of motion in one direction, while limiting sag, torsion and/or shear stress. The invention is also directed to assemblies incorporating the flexible supports.

BACKGROUND

[0002] The desire to have movable ribbon cables and other assemblies of electrical conductors, optical conductors, or pneumatic conduits in industrial machinery lead to the development of flexible supports for the assemblies. One type of flexible support is based on mechanical interlocking designs referred to as“cable tracks.” Cable tracks are made of a linear series of interlocking segments that partially surround and cradle a group of conductors or conduits. US Pat. No. 7,392,650 describes one variation of cable tracks. The interlocking segments often have surface features that interact to confine the range of motion of the cable tracks and the associated conductors or conduits to prevent excessive bending or kinking of the conductors or conduits. In some applications, the motion of a cable track ranges between a flattened

configuration and a configuration that bends in only one direction. Cable tracks are limited in many applications by their bulky size, weight, large bend radius, mechanical vibration, power consumption, and rapid wear. In some applications, such as manufacturing in a clean room environment, wear of the cable track material often produces particulates that contaminate the work area or work product.

[0003] As demand increases for high precision manufacturing, clean room

environments, and other mechanically rigorous applications, conventional cable supports with mechanical interlocking segments need to be replaced. [0004] As an alternative flexible support members made of motion-limiting elements fixed to a flexible material have been developed. Similar to the interlocking segments, these support materials have a wide range of motion in one direction, but are restricted in an opposite direction. The support member can be incorporated into an assembly of conductors and cables. In manufacturing applications requiring a clean environment, the cable assembly having the support member may be jacketed in an envelope and the assembly generate very few particulates during use. In addition, a supported assembly has applications for machines that perform rapid and precise mechanical movements over long periods of time.

[0005] US Pat. No. 6,858,797 discloses support members for assemblies of conductors, conduits, or other means of conveying energy, gases, or liquids. As described therein, there is a series of non-interlocking solids disposed along the length of a flexible base material. The non-interlocking solids have motion-limiting portions that contact similar portions on adjacent solids to restrict the movement of the support member in one direction, while permitting the support member to curve or bend in an opposite direction.

[0006] US Pat. No. 9,576,705 discloses a support module of a sleeve for a transmission line, which is inserted into a part of a plurality of accommodation spaces formed at a flexible sleeve for a transmission line to prevent the sleeve for a

transmission line from being slack, including a flexible flat plate; a plurality of bases fixed to the flat plate so as to be arranged in a longitudinal direction of the flat plate; a plurality of slack-preventing blocks that is connected to the bases to be positioned at a top of the flat plate and prevents the flat plate from being slack by coming in contact with each other; and a plurality of bending-degree restricting blocks that is connected to the bases and the slack-preventing blocks to be positioned a bottom of the flat plate and restricts a bending degree of the flat plate by coming in contact with each other.

[0007] There continues to be a need for improved support members that are easier to manufacture and are durable. SUMMARY

[0008] In the embodiments described herein, the present invention provides a support member comprising a flexible elongated material, a plurality of base members, and a plurality of corresponding covers that contact an adjacent covers to provide torsion control of the support member. In particular, one embodiment describes a plurality of base members arranged in a longitudinal direction on the flexible elongated material, each of the base members comprise an upper region, central region, and lower region, and wherein each of the base members are fixed to the flexible elongated material in the central region, wherein the lower regions define a minimum bend radius of the support member, and a plurality of corresponding covers that engages the upper region, wherein the plurality of corresponding covers contact each other to reduce sag of the support member, and wherein a portion of each of the plurality corresponding covers contact an adjacent one of the corresponding cover to provide torsion control of the support member. In one embodiment, the upper region, central region, and lower region of the base member are integrated to form a unitary structure. In other embodiments, these regions may be assembled together to form the base member. In some embodiments, the flexible elongated material comprises one or more holes for attaching the plurality of adjacent base members thereto.

[0009] The base member may be over molded to the flexible elongated material to fix the flexible elongated material in the central region. In one embodiment, the lower portion of the base member comprises a first inclined end wall and a second inclined end wall. The first inclined end wall comprises one or more projections. In one further embodiment, the first inclined end wall comprises at least two offset projections. The second inclined end wall may comprises one or more recesses corresponding to the one or more projections or the at least two offset projections on the first inclined end wall. Each of the plurality of base members and plurality of corresponding covers may have a rounded cross-sectional shape.

[0010] Turning to the covers, in one embodiment, the each of the plurality of corresponding covers are releasable from the upper region. Each of the plurality of adjacent covers may also comprise a first side comprising a ridge and a second side comprising a recess corresponding to the ridge on the first side.

[0011] Another embodiment describes a support member comprising a flexible elongated material, a plurality of base members arranged in a longitudinal direction on the flexible elongated material, each of the base members comprise an upper region, central region, and lower region, and wherein each of the base members are fixed to the flexible elongated material in the central region, wherein the lower portion of the base member comprises a first inclined end wall and a second inclined end wall and the first inclined end wall comprises at least two offset projections, and a plurality of corresponding covers that engages the upper region. The plurality of corresponding covers contact each other to reduce sag of the support member, and wherein a portion of each of the plurality corresponding covers contact an adjacent one of the corresponding cover to provide torsion control of the support member. In one embodiment, the upper region, central region, and lower region of the base member are integrated to form a unitary structure. In one embodiment, the lower regions define a minimum bend radius of the support member. In other embodiments, these regions may be assembled together to form the base member. In some embodiments, the flexible elongated material comprises one or more holes for attaching the plurality of adjacent base members thereto. The base member may be over molded to the flexible elongated material to fix the flexible elongated material in the central region. In this embodiment, the second inclined end wall may comprises offset recesses

corresponding to the at least two offset projections on the first inclined end wall. Each of the plurality of base members and plurality of corresponding covers may have a rounded cross-sectional shape. In one embodiment, the each of the plurality of corresponding covers are releasable from the upper region. Each of the plurality of adjacent covers may also comprise a first side comprising a ridge and a second side comprising a recess corresponding to the ridge on the first side.

[0012] In another embodiment, there is provided an envelope surrounding the support members described herein and at least one channel disposed substantially in parallel with the support member and attached to the envelope, which comprises a polymeric material such as polytetrafluoroethylene. The at least one channel is contiguous with the envelope. In addition, at least one conductor may be located within the at least one channel.

[0013] While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 A is a perspective view of an assembly having channels and conduits comprising multiple support members, in accordance with some embodiments.

[0015] FIG. 1 B is a cross-sectional view of the assembly having one support member in a conduit, in accordance with some embodiments.

[0016] FIG. 1 C is a cross-sectional view of an envelope of two laminated sheets to form the conduit for housing the support member, in accordance with some embodiments.

[0017] FIG. 2A is a side view of a support member in accordance with some embodiments.

[0018] FIG. 2B is a perspective view of the support member in FIG. 2A.

[0019] FIG. 3A is a support member that is bent in one direction toward the maximum radial bend in accordance with some embodiments.

[0020] FIG. 3B is detailed view of the bent support member in FIG. 3A.

DETAILED DESCRIPTION

[0021] In general the present invention provides a support member capable of supporting an assembly of conductors, conduits, cables, channels, or other components. The support member comprises a flexible elongated material having a plurality of base members fixed to the flexible elongated material and a plurality of corresponding covers that engage a portion of the base members. The support member does not have joints or mechanical interlocking segments to connect adjacent base members and/or covers. By having no mechanical interlocking or moving pieces that cause friction, the embodiments of the present invention reduce particulate accumulation and increase the durability of the support member.

[0022] One challenge of having no joints or interlocking segments is that the support member may have sag when supporting the load of the assembly, including its weight. As the assembly becomes longer, this challenge becomes more difficult. To overcome this challenge, the embodiments disclosed herein have adjacent covers that contact each other to limit the sag of the support member. The adjacent covers contact each other when the assembly is in a horizontal configuration and a portion of the adjacent covers contact an adjacent one of the corresponding cover to provide torsion control of the support member. In one embodiment, a portion of the adjacent covers remain in physical contact at the minimum bend radius. In other embodiments, the adjacent covers are in contact with each other when there is torsion on the assembly as the assembly begins to bend from the horizontal configuration. The contact between adjacent covers may maintain the length of the support member in a taut configuration and reduce shrinking, stretching, sagging or deformation that would lead to problems in supporting the load.

[0023] The support members described herein allow bending in one direction. In one embodiment, the support member comprises base members that define the minimum bend radius and limit the bending in an opposite direction. The minimum bend radius refers the radius of the support member when bent to its fullest extent in one direction. The support member is allowed to bend in the desired direction and the bending is limited by the base members. In particular, the minimum bend radius is limited when the lower portions of adjacent base members contact each other. For longer assemblies, having a range of motion is particularly useful.

[0024] The assembly may be repeatedly bent and stretched while limiting dust and while protecting conductors, conduits, and cables. The assemblies exhibit excellent fatigue resistance to repeated bending achieved by the support members disclosed herein.

[0025] In addition, the support members may provide torsion control to limit twisting or kinking of the support member and the assembly in which the support member is incorporated. When used in longer applications the torsion on the support member creates excess movement or stress out of the radial bending plane in multiple directions, including the x-direction, y-direction and z-direction. The assembly may be moved in the x-direction along its length, side-to-side in the y-direction or up and down in the z-direction as well as rotation about these axes. The movement may be rapid, which can further increase the stress and torsion on the assembly. The torsion may be limited by the base members in some embodiments and in other embodiments torsion may be limited by a combination of the base members and/or corresponding covers.

In one embodiment, as described herein, torsion is limited by at least two offset projections on either the base members or corresponding covers. Limiting the torsion may improve the lifespan and durability of the support member.

[0026] An assembly of conduits, cables, conductors, channels and/or other electro- mechanical elements employing one or more of the above-discussed support members can be constructed in a variety of ways. In general conduits as used herein are for housing the support members of the various embodiments. Conductors are substances or media that permit electricity, light, heat, or other forms of energy to pass through and contain them, such as but not limited to electrical or optical cables. These channels may be pathways for conveying energy, fluids, or gases, or may be hollow tubes or ducts for transferring gases or liquids. In addition, channels can house conductors and cables.

[0027] FIGS. 1A and 1 B show an assembly 1 comprising a support member 10 having a base member 12 fixed to a flexible elongated material 14, and a

corresponding cover 16. The base member 12 and corresponding cover 16 forms one unit and the number of units arranged in a longitudinal direction may depend on the length of the assembly, and for example can vary from 10 to 1000 units or more. The details of the support members 10 are further described herein. [0028] The assembly 1 connects equipment (not shown), such as semiconductor processing equipment, and does not include any joints along its length, but is still flexible so that the assembly 1 can bend in one direction. The support member 10 restricts bending and also advantageously reduces sagging, shear tension, as well as torsion. For purposes of illustration in FIG. 1A, the support member 10 is shown being insert into the conduit 20. It is understood that when in use the support member 10 is enclosed within the conduit 20. In one embodiment, the support member is not fixed within the conduit 20 and may be freely moved within the conduit. Clamping braces 26 positioned along the assembly 1 may hold the support member 10 within the conduit 20. The support member 10 may be removed from the conduit 20 and can be replaced if damaged or repairs are needed. In other embodiments, the support member 10 may be fixed at certain points to the conduit 20. The assembly 1 may comprise other channels 22 and these channels 22 may house conductors 24. A variety of devices can be placed inside the channels 22, and may be used to transmit gas, fluid, or energy. The channels 22 and conduits 20 are substantially parallel to each other. A clamping brace 26 may be used to hold the channels 22 and conduits 20 along the length of the assembly. Other sufficient brackets may also be used to hold assembly 1 together. Each assembly 1 may have a plurality of conduits 20 for the support members 10 and a plurality of channels 22. In general as the number of channels 22 increases it is desirable to have additional conduits 20 with support members 12.

[0029] In other embodiments, the cables or conductors may be substantially parallel to the conduit having the support member without being housed in a channel. In still further embodiments, the support member may be adjacent to cables or conductors without either component being housed in a conduit or channel.

[0030] In one embodiment, the conduits 20 and channels 22 are formed as separate hollow tubes and arranged in a parallel configuration. The tubes may have a square, rectangle, circle, oval or rounded cross-sectional shape. Each conduit and channel may be made from a suitable flexible material including, but not limited to,

fluoropolymers, such as polytetrafluoroethylene, porous polytetrafluoroethylene, expanded polytetrafluoroethylene (ePTFE), perfluoroaxoxy (PFA), fluorinated ethylene polymer (FEP), ethylene-tetrafluoroethylene copolymer (ETFE) available from E. I. du Pont de Nemours and Company, Wilmington, Del., under the tradename TEFZEL® ETFE Fluoropolymer Resin, and polyvinydene fluoride (PVDF), thermoplastics, such as polyethylene, polypropylene, polystyrene, acrylonitrile butadiene styrene (ABS), polyetheretherketone (PEEK), thermoplastic polyamide, such as NYLON®,

polyurethane, polyvinylchloride (PVC), fluorothermoplastics such as DYNEON™ THV™ fluorothermoplastic available from Dyneon, Oakdale, Minn., thermoplastic elastomers such as HYTREL® polyester thermoplastic elastomer available from E. I. du Pont de Nemours and Company, Wilmington, Del., and thermoplastic rubbers such as SANTOPRENE® thermoplastic rubbers available from Advanced Elastomer Systems, Akron, Ohio, and composites thereof.

[0031] FIG. 1 B shows a cross-section of assembly 1 , having a conduit 20 for housing support member 10 and one or more adjacent channels 22. Cables 24 are shown within one of the adjacent channels 22 for illustration but it is understood that other configurations are contemplated by the various embodiments described herein.

[0032] As shown in FIG. 1 B, support member 10 has a rounded cross-section that corresponds to the interior curvature of the conduit 20, for example in the form an circle or oval. Each of the plurality of base members and plurality of corresponding covers that when assembled together from the rounded cross-sectional shape. In some embodiments, the rounded cross-section of the support member may be circular. The rounded cross-section may reduce the free space between the support member 10 and the conduit 20. The rounded configuration may also allow space savings when the conduits and channels are arranged in a stacked configuration.

[0033] In another embodiment, an assembly is constructed with at least one conductor or conduit disposed substantially in parallel with at least one support member and enclosed, jacketed, or surrounded, in a polymeric envelope. As shown in FIG. 1 C the envelope 30 is formed by laminating an upper sheet 32 and a lower sheet 34 at contact regions 36, both of which are made of a plastic materials that are joined together with an appropriate adhesive. This forms the conduits 20 for the support members 10 and also forms parallel channels 22. In one embodiment, two sheets of a thermoplastic material may be laminated together. Suitable envelope materials include, but are not limited to fluoropolymers, such as polytetrafluoroethylene, porous polytetrafluoroethylene, expanded polytetrafluoroethylene (ePTFE), perfluoroaxoxy (PFA), fluorinated ethylene polymer (FEP), ethylene-tetrafluoroethylene copolymer (ETFE) available from E. I. du Pont de Nemours and Company, Wilmington, Del., under the tradename TEFZEL® ETFE Fluoropolymer Resin, and polyvinydene fluoride (PVDF), thermoplastics, such as polyethylene, polypropylene, polystyrene, acrylonitrile butadiene styrene (ABS), polyetheretherketone (PEEK), thermoplastic polyamide, such as NYLON®, polyurethane, polyvinylchloride (PVC),

fluorothermoplastics such as DYNEON™ THV™ fluorothermoplastic available from Dyneon, Oakdale, Minn., thermoplastic elastomers such as HYTREL® polyester thermoplastic elastomer available from E. I. du Pont de Nemours and Company, Wilmington, Del., and thermoplastic rubbers such as SANTOPRENE® thermoplastic rubbers available from Advanced Elastomer Systems, Akron, Ohio, and composites thereof.

[0034] Turning now to the support members, FIGS. 2A and 2B illustrate a support member 100 having a base member 120 fixed to a flexible elongated material 140 and a corresponding cover 160. Base member 120 comprises a lower region 122, a central region 124 and an upper region 126. The flexible elongated material 140 is fixed to the central region 124. In one embodiment, the central region 124 is mounted to the flexible elongated material 140 by over molding the base member 120. In an optional embodiment, a pin or fastener, may fix the base member 120 and flexible elongated material 140 together by extending through holes (not shown).

[0035] In one embodiment, the regions of the base members 120 are integrated and have a unitary construction. By being integrated the lower, central and upper regions are not formed separately and are not separable. This reduces the assembly steps and does not require separately connecting the lower region to the flexible elongated material or using another member such as a post fixed to the flexible elongated material for mounting the regions thereto. Having integrated regions above and below the flexible elongated material may make the assembly process steps faster and easier. In addition, the integrated structure of the base member 120 may provide for more rigidity for the support member 100.

[0036] In another embodiment, the regions of the base members 120 may be separated and assembled together to form the base members. For example, the upper and central regions may be formed on flexible material 140 and the lower region is mounted thereto to form the base members. A fastener, such as a screw or pin, may be used to connect the regions together.

[0037] The lower region 122 defines the minimum bend radius of the support member 100 by contacting adjacent base members as shown in FIGS. 3A and 3B.

The lower region 122 comprises a first inclined wall 128 and an opposing second inclined wall 130. The walls are inclined (Q) inward toward the middle of the lower region 122. Both walls are angled at a degree from 1 ° to 8°, e.g., 2° to 5°, or about 3°. The walls are inclined to define the diameter of the radial bend of the support member 100. The minimum allowed diameter increases as the angle of the incline wall decreases.

[0038] The first inclined wall 128 comprises an upper projection 132 and lower projection 134. In one embodiment, the upper projection 132 and lower projection 134 are offset to limit the torsion as well as shear stress of the support member 100. Offset refers to separating and/or spacing apart the projections on different planes. The offset projections may be in the same direction but each extend independently on different planes from a centerline towards the outer edge. The upper projection 132 and lower projection 134 may have a variety of shapes, including rounded, angled or squared. In one embodiment, the upper projection 132 and the lower projection 134 may each independently have triangular shape. Each recess may have a

corresponding shape to receive the projections and enclose the projections on multiple sides. On the second inclined wall 130 there is an upper recess 136 and a lower recess 138 which correspond to the projections on the adjacent base member. When the projections on one inclined end wall are offset, the recesses on the other inclined end wall are also offset. The upper recess 136 encloses the upper projection 132 and the lower recess 138 encloses the lower projection 134. Although two projections are shown in FIGS. 2A and 2B, in other embodiments there may be more offset projections and recesses.

[0039] The recesses may be positioned in offset manner to correspond to the projections on an opposing first wall. The projections of one lower region are received within the recess of an adjacent lower region but are not interconnected, fixed or locked into the recess. This allows the projections to freely move as the support member is bent. In one embodiment, the base members may be separated from each other without needing to disconnect or reconfigure the support member. This may allow the support members, and in particular the base members, to be replaced if damaged or worn.

[0040] The central region 124 is fixed to the elongated flexible material 140 to maintain the flexible material 140 in a spaced-apart relationship to the interior surface 142 of the lower region 122 and interior surface 144 of the cover 160. In one embodiment, the interior surface 142 may be a level surface or may be a concave surface. As shown in FIGS. 2A and 2B, the central region 124 is a column having a length that does not extend towards the inclined walls 128, 130 of the base member 120. This provides a free space between the central regions on adjacent support members so that the central regions do not contact each other and allows the elongated flexible member to flex or bend in the desired direction. The thickness of the column may be sufficient to provide a sufficient connection to the elongated flexible material 140. In some embodiments, there may be multiple central regions, e.g., multiple columns, through which the elongated flexible material 140 is fixed.

[0041] The upper region 126 of the base member 100 engages a corresponding cover 160. The cover may engage the upper region 126 in a sliding manner in any direction, such as the horizontal or vertical direction in relation the upper region 126. This allows the cover 160 to be formed separately from the base member 120. In other embodiments, the sliding engagement may be in the longitudinal direction, and the covers may be attached as each base member is over molded on the elongated flexible material 140. As shown in FIGS. 2A and 2B the cover 160 is engaged with the upper region 126 in a horizontal direction. The upper region 126 comprises one or more rails 162 align the cover 160. The cover 160 may have a snap fit connector 164, such as a cantilever, for connecting with the upper region 126. This allows the cover 160 to be removably engaged with the upper region 126 by releasing the connector 164. The cover 160 has a first surface 166 having a ridge 168. The ridge 168 may extend in the direction of the engagement of cover 160 with the upper region 126. As shown in FIGS. 2A and 2B, the ridge 168 extends in a horizontal direction to follow the slide engagement of the cover 160. The cover 160 also has a second surface 170 having a slot 172 for receiving the ridge 168 from an adjacent cover. The ridge 168 may be rounded, angled or squared. Slot 172 may have a corresponding shape to receive a portion of the ridge 168 therein. Slot 172 may extend from one end of the second surface 170 to the other to allow the ridge to engage by a sliding motion. In one optional embodiment, one side of the slot may have a closed portion to stop the movement of the ridge. The relationship between slot 172 and ridge 168 further serves to maintain linear alignment of the support member 100 and further reduces torsion. When engaged in a horizontal direction, one ridge 168 may be used to allow easier assembly. In other embodiments, there may be multiple ridges, which may be offset. For example, a cover 160 that slideably engages the upper region 126 in a vertical direction may have offset ridges to limit torsion of the covers.

[0042] In some embodiments, the first surface 166 may also have a bumper 174 that abuts the second surface 170 on an adjacent cover. In other embodiments, the bumper 174 may be on the second surface. The bumper maintains a minimal separation distance between adjacent covers that are abutted together to prevent sag. In addition, the thickness of the bumper may define a pre-bow of the support member. A pre-bow indicates that the support member has an initial bend and is not in a flat configuration. As the bumper becomes thicker the pre-bow increases and this in turn may decrease the sag of the support member. The thickness of the bumper may be adjusted as desired for the cable load. In one embodiment, the bumper has a profile that is less than the ridge, which allows the ridge to remain at least partially in contact with the adjacent cover when the bumper is separated. [0043] After the cover 160 engages the upper region 126 of the base member 120 the combined piece may have the following dimensions: length from 5 to 25 mm, e.g., from 6 to 20 mm or from 7 to 15 mm; width from 4 to 20 mm, e.g., from 5 to 15 mm or from 8 to 12 mm; and a height from 2 to 15 mm, e.g., from 3 to 10 mm or from 4 to 8 mm. These dimensions may vary depending on the application of the support member.

[0044] The flexible elongated material 140 may be a strip or similar piece of material having a uniform width and thickness. The width of the flexible elongated material may be from 2 to 20 mm, e.g., from 4 to 15 mm, or from 5 to 10 mm. The width of the flexible elongated material 140 may be less than the width of the combined piece of the cover 160 and base member 120. The thickness of the flexible elongated material may be very thin and in one embodiment is from 0.05 to 2 mm, e.g., from 0.1 to 1 mm, or from 0.125 to 0.3 mm. The length of the flexible elongated material can vary depending on the assembly. In one embodiment, the flexible elongated material is elongated in the horizontal direction with a perimeter substantially in the shape of a rectangle. In other embodiments, the flexible elongated material can have a cross- section in the form of a square, circular, elliptical, ovoid, or other shape and be solid or hollow along its length. For example, the flexible elongated material may have ridges or curvatures that run along its length.

[0045] In another embodiment, the flexible elongated material may comprise a plurality of filaments or fibers. The filaments or fibers may be spaced apart and aligned in a planar configuration, e.g., a parallel alignment. The filaments or fibers may be encapsulated by a polymeric coating. In some embodiments, a combination of a strip of material and filaments or fibers may be used as the flexible elongated material.

[0046] The flexible elongated material is made of metallic or polymeric materials. Preferred metallic materials include, but are not limited to, stainless steel, carbon steel, spring steel, or nickel and titanium alloys. Preferred polymeric materials include, but are not limited to, polyester, thermoplastic polyamide, such as nylon, polyolefins, polyurethane, polystyrene, polyvinyl chloride, fluoropolymers, fluorothermoplastics, natural and synthetic rubbers, aramid fibers, such as KEVLAR® brand fiber, fiberglass, or composite reinforcements thereof. The flexible material can include composite of a metallic and polymeric material.

[0047] The base members and the corresponding covers can be made of a variety of materials such as metals, polymers, or combinations thereof. In some embodiments, the base members and the corresponding covers may be made of different materials. Preferred metallic and polymeric materials have high compression resistance and good impact resistance. Consequently, the materials are robust, light in weight, inexpensive, and easy to shape or form. Examples of suitable metallic materials include, but are not limited to, aluminum, brass, zinc, magnesium, and alloys of these materials. Preferred metals are zinc-based alloys with differing amounts of aluminum and small amounts of copper and magnesium. These preferred alloys are available from Eastern Alloys, Inc., Maybrook, N.Y., under the tradename ZAMACK™ as part numbers ZA-8, ZA-12, and ZA-27. Suitable polymeric materials include, but are not limited to, engineered thermoplastics such as p-hydroxybenzoic acid-6 hydroxyl- naphthoic acid copolymer, commonly referred to as liquid crystal polymer (LCP), glass filled LCP, glass filled nylon and polypropylene, acrylonitrile butadiene styrene (ABS), carbon filled and thermosets such as epoxy and made from fibers etc. from the materials outlined above and other composite materials. A preferred liquid crystal polymer is available from Polyplastics Co., Ltd., Osaka, Japan, under the tradename VECTRA® liquid crystal polymer. The solids are made by molding, casting, carving, and/or stamping. The preferred method is heat injection over-molding, also commonly referred to as insert molding.

[0048] In one embodiment, the base member is fixed by directly mounting on the flexible elongated material by an over molding technique. The flexible elongated material may be maintained in a curved configuration in a mold to provide space between each base member as the central region of the base members are formed and attached to the flexible elongated material. The cover may be made by suitable injection molding techniques. The cover engages the base member to form the support member. The cover is engaged with the base member in a manner that allows the covers to be releasable so that the covers can be replaced, if needed. As shown in FIGS. 2A and 2B the base member 120 and cover 160 may have one or more cavities. This reduces the weight of the support member, provides a sufficiently thick wall of the plastic material when injection molding is used and reduces volumetric shrinkage of the polymer.

[0049] According to one embodiment, the maximum radial bend of the support member 100 is shown in FIGS. 3A and 3B. A plurality of base members 120 are arranged in a longitudinal direction on the flexible elongated material 140. Individual covers 160 engage the upper regions 126 of the base members 120. The minimum bend radius refers to the tightest radius (r) possible when bending the support members 100 in one direction. The radius is tight when, as described above, the lower regions 122 of adjacent base members abut each other, thus defining the maximum radial bend. In other words, the lower regions 122 abut against each other to restrict the radial bend in one direction. When at the maximum radial bend a first inclined wall abuts against the second inclined wall of an adjacent base member. The projections are received in the recesses to allow the support member to bend. In other

embodiments, when the support members 100 are partially bent and the lower regions 122 are partially abutting each other the radius may be larger. The radial bend occurs in one direction and prevents bending in the opposite direction by restriction of the covers. In addition, torsion on the support member is reduced by at least two offset projections.

[0050] The projections 132, 134 on the first inclined wall 128 are received within the recesses 136, 138 of the second wall 130. By having offset projections, the torsion on the support member 100 is reduced. While at the minimum bend radius, adjacent covers 160 of the support members contact each other to provide torsion control. In one embodiment, the adjacent covers remain in contact with each other and do not separate. The bumper 174 on the cover 160 may lose contact with the adjacent surface at the minimum bend radius. Flowever, in one embodiment the ridge 168, or a portion of the ridge 168, of the cover 160 remains partially in contact with the slot 172 to provide torsion control. This further prevents sag when being bent. Previous conventional support members have designs that disengage and separate at the minimum bend radius thereby increasing the torsion and decreasing the sag preventing characteristics.

[0051] In the following, further examples are described to facilitate understanding of the disclosure:

[0052] E1. A support member comprising: a flexible elongated material; a plurality of base members arranged in a longitudinal direction on the flexible elongated material, each of the base members comprise an upper region, central region, and lower region, and wherein each of the base members are fixed to the flexible elongated material in the central region, wherein the lower regions define a minimum bend radius of the support member; and a plurality of corresponding covers that engages the upper region, wherein the plurality of corresponding covers contact each other to reduce sag of the support member, and wherein a portion of each of the plurality corresponding covers contact an adjacent one of the corresponding cover to provide torsion control of the support member.

[0053] E2. The support member of example E1 , wherein the upper region, central region, and lower region are integrated to form a unitary structure.

[0054] E3. The support member of example E1 , wherein the lower portion of the base member comprises a first inclined end wall and a second inclined end wall.

[0055] E4. The support member of example E3, wherein the first inclined end wall comprises one or more projections.

[0056] E5. The support member of example E3, wherein the first inclined end wall comprises at least two offset projections.

[0057] E6. The support member of any one of examples E4 or E5, wherein the second inclined end wall comprises one or more recesses corresponding to the one or more projections or the at least two offset projections on the first inclined end wall.

[0058] E7. The support member of any of the preceding examples, wherein each of the plurality of corresponding covers are releasable from the upper region. [0059] E8. The support member of any of the preceding examples, wherein each of the plurality of adjacent covers comprise a first side comprising a ridge and a second side comprising a recess corresponding to the ridge on the first side.

[0060] E9. The support member of any of the preceding examples, wherein each of the adjacent base members are over molded to the flexible elongated material.

[0061] E10. The support member of any of the preceding examples, wherein the flexible elongated material comprises one or more holes for attaching the plurality of adjacent base members thereto.

[0062] E 11. The support member of any of the preceding examples, wherein each of the plurality of base members and plurality of corresponding covers have a rounded cross-sectional shape.

[0063] E12. A support member comprising: a support member comprising a flexible elongated material, a plurality of base members arranged in a longitudinal direction on the flexible elongated material, each of the base members comprise an upper region, central region, and lower region, and wherein each of the base members are fixed to the flexible elongated material in the central region, wherein the lower portion of the base member comprises a first inclined end wall and a second inclined end wall and the first inclined end wall comprises at least two offset projections, and a plurality of corresponding covers that engages the upper region, wherein the plurality of corresponding covers contact each other to reduce sag of the support member, and wherein a portion of each of the plurality corresponding covers contact an adjacent one of the corresponding cover to provide torsion control of the support member.

[0064] E13. The support member of example E12, wherein the lower regions define a minimum bend radius of the support member.

[0065] E14. The support member of any one of examples E12 or E13, wherein the upper region, central region, and lower region are integrated to form a unitary structure. [0066] E15. The support member of any one of examples E12-E14, wherein the second inclined end wall comprises at least two recesses corresponding to the at least two offset projections on the first inclined end wall.

[0067] E16. The support member of any of examples E12-E15, wherein each of the plurality of corresponding covers are releasable from the upper region.

[0068] E17. The support member of any of examples E12-E16, wherein each of the plurality of adjacent covers comprise a first side comprising a ridge and a second side comprising a recess corresponding to the ridge on the first side.

[0069] E18. The support member of any of examples E12-E17, wherein each of the adjacent base members are over molded to the flexible elongated material.

[0070] E19. The support member of any of examples E12-E18, wherein the flexible elongated material comprises one or more holes for attaching the plurality of adjacent base members thereto.

[0071] E20. The support member of any of examples E12-E19, wherein each of the plurality of base members and plurality of corresponding covers have a rounded cross-sectional shape.

[0072] E21. The support member of any of the preceding examples, further comprising an envelope surrounding the support member and at least one channel disposed substantially in parallel with the support member and attached to the envelope.

[0073] E22. The support member of example 21 , wherein the at least one channel is contiguous with the envelope.

[0074] E23. The support member of example 21 , further comprising at least one conductor located within the at least one channel.

[0075] E24. The support member of example 21 , wherein the envelope comprises a polymeric material.

[0076] E25. The support member of example 21 , wherein the polymeric materials comprises polytetrafluoroethylene. [0077] Various modifications and additions can be made to the exemplary embodiments of the disclosed treatment systems discussed without departing from the scope of the present invention. While the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the above described features. It will be appreciated that features of the various

embodiments and examples described herein may be combined with one another in any suitable combination and that the disclosed embodiments are not limiting. For example, features in one embodiment may optionally be imported into another embodiment if it is possible to do so.