Superhard components and powder metallurgy methods of making the same

Abstract

A method of forming a super hard polycrystalline construction comprises forming a liquid suspension of a first mass of nano-ceramic particles and a mass of particles or grains of super hard material having an average particle or grain size of 1 or more microns, dispersing the particles or grains in the liquid suspension to form a substantially homogeneous suspension, drying the suspension to form an admix of the nano-ceramic and super hard grains or particles, and forming a pre-sinter assembly comprising the admix. The pre-sinter assembly is then sintered to form a body of polycrystalline super hard material comprising a first fraction of super hard grains and a second fraction, the nano-ceramic particles forming the second fraction. The super hard grains are spaced along at least a portion of the peripheral surface by one or more nano-ceramic grains, the super hard grains having a greater average grain size than that of the grains in the second fraction which have an average size of less than around 999 nm.

1 . A knob adapted for insertion into the hollow end of a sports stick, the knob comprising
 a central longitudinal axis, a tang for insertion into the hollow end of the sports stick, a grip adapted for being grasped by the hand of an athlete, and a step between the tang and the grip adapted for abutting the end surface of the hollow end of the sports stick when the tang is inserted therein, the grip comprising a grip end distal to the tang, a dorsal cantle region and a ventral cantle region, the dorsal and ventral cantle regions being between the tang and the grip end and on opposing sides of an imaginary coronal plane containing the central longitudinal axis and divided by an imaginary sagittal plane that contains the central longitudinal axis and is orthogonal to the imaginary coronal plane, the dorsal and ventral cantle regions each providing a curved support surface for the hand of the athlete when the athlete is gripping the sports stick, the dorsal cantle region and the ventral cantle region each having a radius of curvature in the sagittal plane, the radius of curvature of the ventral cantle region being greater than the radius of curvature of the dorsal cantle region.   
     
     
         2 . The knob of  claim 1  wherein a ratio of the radius of curvature of the ventral cantle region to the radius of curvature of the dorsal cantle region is (i) at least 2:1, respectively; or (ii) at least 3:1, respectively, or (iii) at least 5:1, respectively. 
     
     
         3 - 4 . (canceled) 
     
     
         5 . The knob of  claim 1  wherein a ratio of the radius of curvature of the ventral cantle region to the radius of curvature of the dorsal cantle region is (i) less than 20:1; or (ii) less than 15:1; or (iii) less than 10:1. 
     
     
         6 - 7 . (canceled) 
     
     
         8 . The knob of  claim 1  wherein the imaginary sagittal plane bisects each of the dorsal and the ventral cantle regions into symmetrical halves, respectively. 
     
     
         9 . A knob adapted for insertion into the hollow end of a sports stick, the knob comprising
 a central longitudinal axis, a tang for insertion into the hollow end of the sports stick, a grip adapted for being grasped by the hand of an athlete, and a step between the tang and the grip adapted for abutting the end surface of the hollow end of the sports stick when the tang is inserted therein, the grip comprising a grip end distal to the tang, a dorsal cantle region and a ventral cantle region, the dorsal and ventral cantle regions being between the tang and the grip end and on opposing sides of an imaginary coronal plane containing the central longitudinal axis and bisected by an imaginary sagittal plane that contains the central longitudinal axis and is orthogonal to the imaginary coronal plane, the dorsal and ventral cantle regions each providing a curved support surface for the hand of the athlete when the athlete is gripping the sports stick, wherein the dorsal cantle region and ventral cantle region are asymmetric relative to each other about the coronal plane and the sagittal plane bisects each of the ventral and the dorsal cantle regions into symmetrical halves, respectively.   
     
     
         10 . The knob of  claim 1  wherein the ventral cantle region smoothly transitions about the central longitudinal axis to the dorsal cantle region. 
     
     
         11 . The knob of  claim 1  wherein the grip end has a circumference that (i) is at least 110% of the circumference of the neck; or (ii) at least 150% of the circumference of the neck; or (iii) at least 200% of the circumference of the neck; or (iv) at least 300% of the circumference of the neck. 
     
     
         12 - 14 . (canceled) 
     
     
         15 . The knob of any of  claim 1  wherein the tang has a length measured along the central longitudinal axis of about 2 to about 12 inches, and optionally wherein the tang has an end that is beveled at an angle of about 30° to 60° from the longitudinal sides of the tang and toward the longitudinal central axis to allow for easier initial guided insertion of the tang into the hollow end of the stick. 
     
     
         16 . (canceled) 
     
     
         17 . The knob of  claim 1  wherein (i) the grip has a length, as measured along central longitudinal axis 1.2, that is about 5 to about 95% of the length of the knob and the tang has a complementary length, as measured along the central longitudinal axis, that is about 95 to about 5% of the length of the knob; or (ii) the grip has a length, as measured along central longitudinal axis 1.2, that is about 15 to about 85% of the length of the knob and the tang has a complementary length, as measured along the central longitudinal axis, that is about 85 to about 15% of the length of the knob; or (iii) the grip has a length, as measured along central longitudinal axis 1.2, that is about 25 to about 75% of the length of the knob and the tang has a complementary length, as measured along the central longitudinal axis, that is about 75 to about 25% of the length of the knob; or (iv) the grip has a length, as measured along central longitudinal axis 1.2, that is about 35 to about 65% of the length of the knob and the tang has a complementary length, as measured along the central longitudinal axis, that is about 65 to about 35% of the length of the knob; or (v) the grip has a length, as measured along central longitudinal axis 1.2, that is about 40 to about 60% of the length of the knob and the tang has a complementary length, as measured along the central longitudinal axis, that is about 60 to about 40% of the length of the knob. 
     
     
         18 - 21 . (canceled) 
     
     
         22 . The knob of  claim 1  wherein the grip comprises a neck between the flange and the tang. 
     
     
         23 . The knob of  claim 22  wherein (i) the neck has a length measured along the central longitudinal axis of at least about 0.25 inches, or (ii) the neck has a length measured along the central longitudinal axis in the range of about 0.25 to about 4 inches, or (iii) the neck has a length measured along the central longitudinal axis in the range of about 1 to about 4 inches, or (iv) the neck has a length measured along the central longitudinal axis in the range of about 1 to about 2 inches. 
     
     
         24 - 26 . (canceled) 
     
     
         27 . The knob of  claim 1  wherein (i) the knob comprises a ceramic, metal, polymer, composite, wood or a composite or laminate thereof, or (ii) the knob comprises a ceramic, metal, polymer, composite, or a composite or laminate thereof. 
     
     
         28 . (canceled) 
     
     
         29 . A combination of a sport stick and a knob, the knob corresponding to the knob of  claim 1  and being inserted into a hollow end of the sport stick. 
     
     
         30 . The combination of  claim 29  wherein (i) the sport stick is a hockey stick, a lacrosse stick, a golf club, or a baseball bat; or (ii) the sport stick is a hockey stick, a lacrosse stick, or a golf club. 
     
     
         31 . (canceled) 
     
     
         32 . A combination of a hockey stick and a knob, the knob corresponding to the knob of  claim 1  and being inserted into a hollow end of the hockey stick wherein the ventral cantle region of knob is on the same side of the hockey stick as the blade of the hockey stick. 
     
     
         33 . A combination of (i) a lacrosse stick and a knob, the knob corresponding to the knob of  claim 1  and being inserted into a hollow end of the lacrosse stick wherein the ventral cantle region of knob is on the same side of the lacrosse stick as the net-side of the head of the lacrosse stick; or (ii) a golf club and a knob, the knob corresponding to the knob of  claim 1  and being inserted into a hollow end of the golf club wherein the ventral cantle region of knob and the head of the golf club are on the same side of the imaginary sagittal plane and the dorsal cantle region and the head of the golf club are on opposite sides of the imaginary sagittal plane; or (iii) a combination of a baseball bat and a knob, the knob corresponding to the knob of any of  claims 1 - 28  and being inserted into a hollow end of the baseball bat wherein the tang and step have a circular cross-section. 
     
     
         34 - 35 . (canceled) 
     
     
         36 . The combination of  claim 33  wherein the knob comprises a cavity at grip end of the knob sized to accommodate a motion sensor. 
     
     
         37 . The combination of  claim 33  wherein the knob comprises a cavity at grip end of the knob sized to accommodate a motion sensor, and the combination further comprises an electronic motion sensor housed in the cavity. 
     
     
         38 . The combination of  claim 29  wherein the knob is securely affixed to the sports stick, optionally by welding, screws, nails, staples, glue, adhesive, heat-activated glue, or epoxy. 
     
     
         39 . (canceled)