PETITION FOR INTER PARTES REVIEW OF UNITED STATES PATENT ... · PDF file Patent Owner _____...

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Transcript of PETITION FOR INTER PARTES REVIEW OF UNITED STATES PATENT ... · PDF file Patent Owner _____...

  • UNITED STATES PATENT AND TRADEMARK OFFICE

    _____________

    BEFORE THE PATENT TRIAL AND APPEAL BOARD

    _____________

    NEW NGC, INC. dba NATIONAL GYPSUM COMPANY,

    Petitioner

    v.

    UNITED STATES GYPSUM COMPANY,

    Patent Owner

    _____________

    Case No. IPR2017-01353

    Patent No. 8,500,904

    PETITION FOR INTER PARTES REVIEW OF

    UNITED STATES PATENT NO. 8,500,904

    PURSUANT TO 35 U.S.C. §§ 311–319, 37 C.F.R. § 42

    Mail Stop PATENT BOARD

    Patent Trial and Appeal Board

    US Patent and Trademark Office

    PO Box 1450

    Alexandria, Virginia 22313-1450

  • i

    TABLE OF CONTENTS

    I. MANDATORY NOTICES UNDER 37 C.F.R § 42.8 .................................... 1

    A. Real Party-In-Interest under 37 C.F.R. § 42.8(b)(1) ............................. 1

    B. Related Matters under 37 C.F.R. § 42.8(b)(2) ...................................... 1

    C. Lead and Back-Up Counsel under 37 C.F.R. § 42.8(b)(3) ................... 1

    D. Service Information ............................................................................... 2

    II. GROUNDS FOR STANDING UNDER 37 C.F.R. § 42.104(a) ..................... 2

    III. PAYMENT OF FEES ..................................................................................... 2

    IV. OVERVIEW OF CHALLENGES AND RELIEF REQUESTED .................. 2

    V. INTRODUCTION ........................................................................................... 3

    VI. TECHNICAL BACKGROUND OF THE ʼ904 PATENT .............................. 4

    A. Basics of Gypsum Products ................................................................... 4

    B. The ʼ904 Patent ..................................................................................... 5

    C. Enhancing Materials .............................................................................. 6

    D. Accelerators ........................................................................................... 8

    VII. PROSECUTION HISTORY OF THE ʼ904 PATENT .................................... 8

    VIII. CLAIM CONSTRUCTION ............................................................................ 9

    A. Accelerator ..........................................................................................11

    B. Set Gypsum-Containing Product .........................................................11

    C. Enhancing Material(s) .........................................................................12

    IX. PRIOR ART REFERENCES ........................................................................ 14

    A. Graux ...................................................................................................15

    B. Satterthwaite ........................................................................................16

    C. ASTM ..................................................................................................17

    D. Hjelmeland ..........................................................................................18

    E. Sucech..................................................................................................20

    F. Kincade ................................................................................................20

    X. THERE IS A REASONABLE LIKELIHOOD THAT AT LEAST ONE

    CLAIM OF THE `904 PATENT IS UNPATENTABLE ............................. 21

  • ii

    XI. GROUND 1: OBVIOUSNESS OF CLAIMS 1-4, 6, 8, 11-13, 15 AND 18

    BASED ON GRAUX IN VIEW OF ASTM C473-95, HJELMELAND,

    SUCECH, AND KINCADE .......................................................................... 21

    A. Reasons for Combining Graux, ASTM C473-95, Hjelmeland, Sucech,

    and Kincade .........................................................................................21

    B. Element by Element Analysis .............................................................26

    Claim 1a: A set gypsum-containing product prepared by a

    method comprising: ................................................................. 26

    Claim 1b: forming a mixture of calcined gypsum, water, an

    accelerator, and one or more enhancing materials chosen

    from the group consisting of: sodium trimetaphosphate,

    tetrapotassium pyrophosphate, tetrasodium

    pyrophosphate, aluminum trimetaphosphate, sodium acid

    pyrophosphate, ammonium polyphosphate having 1000-

    3000 repeating phosphate units, and acids, salts, or the

    anionic portions thereof, .......................................................... 27

    Claim 1c: maintaining the mixture under conditions sufficient

    for the calcined gypsum to form an interlocking matrix of

    set gypsum, ............................................................................... 27

    Claim 1d: the enhancing material or materials having been

    included in the mixture in an amount such that the set

    gypsum-containing product has greater resistance to

    permanent deformation than it would have if the

    enhancing material had not been included in the mixture,

    such that when the mixture is cast in the form of 1/2 inch

    gypsum board, said board has a sag resistance, as

    determined according to ASTM C473-95, of less than

    about 0.1 inch per two foot length of said board, .................... 28

    Claim 1e: the accelerator having been included in an amount

    such that the set gypsum-containing product has greater

    strength than it would have if the accelerator had not

    been included in the mixture. ................................................... 30

    Claim 2: The set gypsum-containing product of claim 1,

    wherein the calcined gypsum comprises one or more of:

    calcium sulfate anhydrite; calcium sulfate hemihydrate;

    or ions of calcium and sulfate. ................................................. 31

  • iii

    Claim 3: The set gypsum-containing product of claim 1,

    wherein the concentration of the enhancing material in

    the mixture is from about 0.004 to about 2.0 percent by

    weight, based on the weight of the calcined gypsum. ............. 32

    Claim 4: The set gypsum-containing product of claim 1,

    wherein the concentration of the enhancing material in

    the mixture is from about 0.04 to about 0.16 percent by

    weight, based on the weight of the calcined gypsum. ............. 34

    Claim 6: The set gypsum-containing product of claim 1,

    wherein the enhancing material comprises one or more of

    the following salts, or the anionic portions thereof:

    sodium trimetaphosphate and ammonium polyphosphate

    having 1000-3000 repeating phosphate units. ......................... 34

    Claim 8: The set gypsum-containing product of claim 1,

    wherein the accelerator is a heat resistant accelerator

    (HRA). ...................................................................................... 35

    Claim 11: The set gypsum-containing product of claim 1,

    wherein the mixture further comprises a pregelatinized

    starch. ....................................................................................... 36

    Claim 12: The set gypsum-containing product of claim 11,

    wherein the concentration of the pregelatinized starch in

    the mixture is from about 0.08 to about 0.5 percent by

    weight, based on the weight of the calcined gypsum. ............. 37

    Claim 13: The set gypsum-containing product of claim 1,

    wherein the concentration of the pregelatinized starch in

    the mixture is from about 0.16 to about 0.4 percent by

    weight, based on the weight of the calcined gypsum. ............. 38

    Claim 15: The set gypsum-containing product of claim 1,

    wherein: the interlocking matrix of set gypsum has voids

    uniformly distributed therein; and the mixture further

    comprises an aqueous foam. .................................................... 39

    Claim 18: The set gypsum-containing product of claim 1,

    wherein the mixture further comprises a pregelatinized

    starch and an aqueous foam. .................................................... 40

    XII. GROUND 2: OBVIOUSNESS OF CLAIMS 1-4, 6, 8, 11-13, 15 AND 18

    BASED ON SATTERTHWAITE IN VIEW OF ASTM C473-95,

    HJELMELAND, SUCECH, AND KINCADE ............................................. 40

  • iv

    A. Reasons for Combining Satterthwaite, ASTM C473-95, Hjelmeland,

    Sucech, and Kincade ...........................................................................40

    B. Element by Element Analysis .............................................................46

    Claim 1a: A set gypsum-containing product prepared by a

    method comprising: ................................................................. 46

    Claim 1b: forming a mixture of calcined gypsum, water, an

    accelerator, and one or more enhancing materials chosen

    from the group consisting of: sodium trimetaphosphate,

    tetrapotassium pyrophosphate, tetrasodium

    pyrophosphate, aluminum trimetaphosphate, sodium acid

    pyrophosphate, ammonium polyphosphate having 1000-

    3000 repeating phosphate units, and acids, salts, or the

    anionic por