`
`
`
`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. IPR2017-1011
`Patent No. 7,964,034
`
`
`
`
`PETITION FOR INTER PARTES REVIEW OF
`UNITED STATES PATENT NO. 7,964,034
`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
`
`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 ............................................................................... 1
`
`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 ........................................................................................... 2
`
`VI. TECHNICAL BACKGROUND OF THE ’034 PATENT .............................. 4
`A.
`Basics of Gypsum Products ................................................................... 4
`B.
`The ’034 Patent ..................................................................................... 5
`C.
`Enhancing Materials .............................................................................. 6
`D. Accelerators ........................................................................................... 7
`
`VII. PROSECUTION HISTORY OF THE ’034 PATENT .................................... 8
`
`VIII. CLAIM CONSTRUCTION ............................................................................ 9
`A. Accelerator ..........................................................................................11
`B.
`Set Gypsum-Containing Product .........................................................12
`C.
`Enhancing Material(s) .........................................................................12
`
`IX. PRIOR ART REFERENCES ........................................................................15
`A. Graux ...................................................................................................15
`B.
`Satterthwaite ........................................................................................16
`C.
`ASTM ..................................................................................................18
`D. Hjelmeland ..........................................................................................19
`
`X.
`
`THERE IS A REASONABLE LIKELIHOOD THAT AT LEAST
`ONE CLAIM OF THE `034 PATENT IS UNPATENTABLE ....................21
`
`XI. GROUND 1: OBVIOUSNESS OF CLAIMS 1, 2, 4, 5, AND 7-9 BY
`GRAUX IN VIEW OF ASTM C473-95 AND HJELMELAND ..................21
`A.
`Reasons for Combining Graux, ASTM C473-95, and
`Hjelmeland ..........................................................................................21
`
`i
`
`
`

`

`
`
`B. Mapping of Claim Elements ...............................................................25
`Claim 1a: A method for producing a set gypsum-containing
`product comprising; ..................................................................25
`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, and .....................................................26
`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. ....................................................31
`Claim 2: The method 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; .................................................................33
`Claim 4: The method of claim 1, wherein the calcined gypsum
`comprises one or more of: calcium sulfate anhydrite;
`calcium sulfate hemihydrate; or ions of calcium and
`sulfate; .......................................................................................35
`Claim 5: The method 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; .........................................................36
`
`ii
`
`
`

`

`
`
`Claim 7a: A method for producing a set gypsum-containing
`product comprising: ..................................................................36
`Claim 7b: forming a mixture of calcined gypsum, water, 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, and ................................................................................36
`Claim 7c: maintaining the mixture under conditions sufficient
`for the calcined gypsum to form a set gypsum material, ..........37
`Claim 7d: 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; .....................38
`Claim 8: The method of claim 7 wherein the set gypsum
`material comprises an interlocking matrix of set gypsum; .......39
`Claim 9: The method of claim 7 wherein said mixture includes
`an accelerator; ...........................................................................39
`
`XII. GROUND 2: OBVIOUSNESS OF CLAIMS 1, 2, 4, 5, AND 7-9 BY
`SATTERTHWAITE IN VIEW OF ASTM C473-95 AND
`HJELMELAND .............................................................................................40
`A.
`Reasons for Combining Satterthwaite, ASTM C473-95, and
`Hjelmeland ..........................................................................................40
`B. Mapping of Claim Elements ...............................................................44
`Claim 1a: A method for producing a set gypsum-containing
`product comprising; ..................................................................44
`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-
`
`iii
`
`
`

`

`
`
`3000 repeating phosphate units, and acids, salts, or the
`anionic portions thereof, and .....................................................44
`Claim 1c: maintaining the mixture under conditions sufficient
`for the calcined gypsum to form an interlocking matrix of
`set gypsum, ................................................................................48
`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, .....................50
`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. ....................................................52
`Claim 2: The method 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; .................................................................54
`Claim 4: The method of claim 1, wherein the calcined gypsum
`comprises one or more of: calcium sulfate anhydrite;
`calcium sulfate hemihydrate; or ions of calcium and
`sulfate; .......................................................................................56
`Claim 5: The method 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; .........................................................58
`Claim 7a: A method for producing a set gypsum-containing
`product comprising: ..................................................................58
`Claim 7b: forming a mixture of calcined gypsum, water, 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
`
`iv
`
`
`

`

`
`
`phosphate units, and acids, salts, or the anionic portions
`thereof, and ................................................................................59
`Claim 7c: maintaining the mixture under conditions sufficient
`for the calcined gypsum to form a set gypsum material, ..........59
`Claim 7d: 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; .....................60
`Claim 8: The method of claim 7 wherein the set gypsum
`material comprises an interlocking matrix of set gypsum; .......61
`Claim 9: The method of claim 7 wherein said mixture includes
`an accelerator; ...........................................................................61
`
`XIII. SECONDARY CONSIDERATIONS ...........................................................62
`
`XIV. CONCLUSION ..............................................................................................63
`
`XV. CERTIFICATE OF WORD COUNT ...........................................................64
`
`
`
`
`
`v
`
`
`

`

`
`
`
`CASES
`
`TABLE OF AUTHORITIES
`
`Page(s)
`
`Atlas Powder Co. v. Ireco, Inc.,
`190 F.3d 1342 (Fed. Cir. 1999) .......................................................................... 30
`
`Cisco Sys., Inc., et al. v. Crossroads Sys., Inc.,
`IPR2014-01544 ................................................................................................... 20
`
`Cisco Sys., Inc. v. AIP Acquisition, LLC,
`IPR2014-00247 (Final Decision, May 20, 2015) ............................................... 10
`
`In re Papesch,
`315 F.2d 381 (CCPA 1963) ................................................................................ 30
`
`In re Skoner,
`517 F.2d 947 (CCPA 1975) ................................................................................ 30
`
`In re Translogic Tech., Inc.,
`504 F.3d 1249 (Fed. Cir. 2007) ............................................................................ 9
`
`Int’l Business Machines Corp. v. Intellectual Ventures I LLC,
`IPR2015-00302 ................................................................................................... 20
`
`Mexichem Amanco Holdings v. Honeywell Int’l Inc.,
`Reexamination Appeal 2015-007833 (Decision on Appeal, March
`30, 2016) ............................................................................................................. 29
`
`Microsoft Corp. v. Multi-Tech Sys., Inc.,
`357 F.3d 1340 (Fed. Cir. 2004) .......................................................................... 14
`
`Microsoft Corp. v. Parallel Networks Licensing, LLC,
`IPR2015-00483 ................................................................................................... 20
`
`Microsoft Corp. v. Parallel Networks Licensing, LLC,
`IPR2015-00486 ................................................................................................... 20
`
`Microsoft Corp. v. Proxyconn, Inc.,
`789 F.3d 1292 (Fed. Cir. 2015) .......................................................................... 15
`
`vi
`
`
`

`

`
`
`NTP, Inc. v. Research in Motion, Ltd.,
`418 F.3d 1282 (Fed. Cir. 2005) .......................................................................... 14
`
`Phillips v. AWH Corp.,
`415 F.3d 1303 (Fed. Cir. 2005) ................................................................ 9, 14, 15
`
`Praxair Distribution, Inc. v. Ino Therapeautics, LLC,
`IPR2015-00889 ................................................................................................... 19
`
`Praxair Distribution, Inc. v. Ino Therapeautics, LLC,
`IPR2015-00893 ................................................................................................... 19
`
`Titanium Metals Corp. v. Banner,
`778 F.2d 775, 227 USPQ 773 (Fed. Cir. 1985) ............................................ 35, 36
`
`United States Gypsum Company v. New NGC, Inc.,
`Case No. 1:17-cv-00130 (D. Del. Feb. 6, 2017) ................................................... 1
`
`RULES
`
`42.22(a)(1) .................................................................................................................. 2
`
`42.104(b)(1)–(2) ......................................................................................................... 2
`
`STATUTES
`
`35 U.S.C. § 102(a) ................................................................................................... 15
`
`35 U.S.C. § 102(b) ....................................................................................... 16, 17, 18
`
`35 U.S.C. § 102(e) ................................................................................................... 19
`
`35 U.S.C. § 103(a) ..................................................................................................... 2
`
`OTHER AUTHORITIES
`
`37 C.F.R § 42.8 .......................................................................................................... 1
`
`37 C.F.R § 42.10(b) ................................................................................................... 1
`
`37 C.F.R. § 42.100(b) ................................................................................................ 9
`
`37 C.F.R. § 42.104(a) ................................................................................................. 2
`
`
`
`vii
`
`
`

`

`
`
`
`
`NGC034-1001
`
`Expert Declaration of Gerry Harlos
`
`EXHIBITS
`
`NGC034-1002
`
`U.S. Patent No. 6,632,550 (“the ʼ550 patent”)
`
`NGC034-1003
`
`U.S. Patent No. 6,342,284 (“the ’284 patent”)
`
`NGC034-1004
`
`Selections from the Prosecution History of the ʼ284 Patent
`
`NGC034-1005
`
`Selections from the Prosecution History of the ʼ550 Patent
`
`NGC034-1006
`
`U.S. Patent No. 5,932,001 (“Graux”)
`
`NGC034-1007
`
`U.S. Patent No. 3,234,037 (“Satterthwaite”)
`
`NGC034-1008
`
`U.S. Patent No. 5,980,628 (“Hjelmeland”)
`
`NGC034-1009
`
`ASTM C473-95
`
`NGC034-1010
`
`U.S. Patent No. 2,884,413 (“Kerr”)
`
`NGC034-1011
`
`U.S. Patent No. 3,770,468 (“Knauf”)
`
`NGC034-1012
`
`NGC034-1013
`
`Thomas Koslowski & Udo Ludwig, The Chemistry and
`Technology of Gypsum, ASTM STP 861, 103 (R. A. Kuntze,
`ed., 1984)
`Lydia M. Luckevick & Richard A. Kuntze, The Relationship
`Between Water Demand and Particle Size Distribution of
`Stucco, in The Chemistry and Technology of Gypsum, ASTM
`STP 861, 84-85 (R.A. Kutze, ed., 1984).
`
`viii
`
`
`

`

`
`
`NGC034-1014
`
`ASTM C472-93
`
`NGC034-1015
`
`Robert F. Acker, Physical Testing of Gypsum Board Per
`ASTM C 473, 3-7 (R.A. Kuntze, ed., 1984)
`
`NGC034-1016
`
`L. Amathieu, Improvement of Mechanical Properties of Set
`Plasters, 79 J. of Crystal Growth 169, 176 (1986)
`
`NGC034-1017
`
`U.S. Patent No. 2,985,219
`
`NGC034-1018
`
`U.S. Patent No. 3,179,529
`
`NGC034-1019
`
`U.S. Patent No. 2,090,625
`
`NGC034-1020
`
`U.S. Patent No. 3,190,787
`
`NGC034-1021
`
`U.S. Patent No. 2,346,999
`
`NGC034-1022
`
`U.S. Patent No. 3,573,947
`
`NGC034-1023
`
`U.S. Patent No. 4,009,062
`
`NGC034-1024
`
`U.S. Patent No. 5,320,677
`
`NGC034-1025
`
`U.S. Patent No. 5,534,059
`
`NGC034-1026
`
`U.S. Patent No. 5,395,438
`
`NGC034-1027
`
`U.S. Patent No. 3,246,063
`
`NGC034-1028
`
`Redacted Complaint
`
`ix
`
`
`

`

`
`
`NGC034-1029
`
`U.S. Patent No. 7,964,034
`
`NGC034-1030
`
`[RESERVED]
`
`NGC034-1031
`
`ASTM C473-81
`
`NGC034-1032
`
`U.S. Patent No. 5,085,929
`
`NGC034-1033
`
`[RESERVED]
`
`NGC034-1034
`
`[RESERVED]
`
`x
`
`
`

`

`
`
`I. MANDATORY NOTICES UNDER 37 C.F.R § 42.8
`
`A. Real Party-In-Interest under 37 C.F.R. § 42.8(b)(1)
`
`The real party in interest for Petitioner is New NGC, Inc. dba National
`
`Gypsum Company.
`
`B. Related Matters under 37 C.F.R. § 42.8(b)(2)
`
`U.S. Patent No. 7,964,034 (the “ ’034 patent”) is at issue in the following case:
`
`(1) United States Gypsum Company v. New NGC, Inc., Case No. 1:17-cv-00130 (D.
`
`Del. Feb. 6, 2017). Petitioner is concurrently filing a Petition for IPR challenging
`
`the claims of related U.S. Patent Nos. 6,632,550 (the “ ’550 patent”) and 7,425,236
`
`(the “ ’236 patent”).
`
`C. Lead and Back-Up Counsel under 37 C.F.R. § 42.8(b)(3)
`
`Lead counsel is Ross R. Barton (Reg. No. 51,438) and backup counsel are S.
`
`Benjamin Pleune (Reg. No. 52,421), Lauren E. Burrow (Reg. No. 70,447), Tasneem
`
`D. Delphry (Reg. No. 72,506), Stephen R. Lareau (Reg. No. 63,273), and Adam
`
`Doane (Reg. No. 73,568) all of Alston & Bird LLP, 101 S. Tryon St., Ste. 4000,
`
`Charlotte, NC 28280, 704-444-1000. Pursuant to 37 C.F.R § 42.10(b), Powers of
`
`Attorney are being submitted with this Petition.
`
`D.
`
`Service Information
`
`Petitioner consents to electronic service directed to ross.barton@alston.com,
`
`ben.pleune@alston.com, lauren.burrow@alston.com, stephen.lareau@alston.com,
`
`tasneem.delphry@alston.com, and adam.doane@alston.com.
`
`1
`
`
`

`

`
`
`II. GROUNDS FOR STANDING UNDER 37 C.F.R. § 42.104(a)
`
`Petitioner certifies that the ’034 patent is available for IPR and that Petitioners
`
`are not barred or estopped from requesting an IPR challenging Claims 1, 2, 4, 5, and
`
`7-9 of the ’034 patent on the grounds identified herein.
`
`III. PAYMENT OF FEES
`
`Petitioner authorizes Deposit Account No. 16-0605 to be charged for the
`
`payment of any fees.
`
`IV. OVERVIEW OF CHALLENGES AND RELIEF REQUESTED
`
`Pursuant to Rules 42.22(a)(1) and 42.104(b)(1)–(2), Petitioner requests
`
`cancellation of claims 1, 2, 4, 5, and 7-9 of the ’034 patent on the following grounds:
`
`Count 1: Claims 1, 2, 4, 5, and 7-9 of the ’034 patent are unpatentable under
`
`at least 35 U.S.C. § 103(a) over Graux, ASTM C473-95, and Hjelmeland.
`
`Count 2: Claims 1, 2, 4, 5, and 7-9 of the ’034 patent are unpatentable under
`
`at least 35 U.S.C. § 103(a) over Satterthwaite, ASTM C473-95, and Hjelmeland.
`
`V.
`
`INTRODUCTION
`
`The ’034 patent claims commonplace ingredients in identified combinations
`
`to yield known results. NGC034-1001, ¶ 62. The ʼ034 patent is very broadly
`
`directed to gypsum-containing building products, including “gypsum boards,
`
`reinforced gypsum composite boards, plasters, machinable materials, joint treatment
`
`materials, and acoustical tiles.” NGC034-1029, 1:23-27; see also NGC034-1001,
`
`2
`
`
`

`

`
`
`¶¶ 57-58, 60, 61-63. Claim 1 of the ʼ034 patent is representative and can be
`
`summarized as follows:
`
`A method for producing a set gypsum-containing product by
`
`(1) 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,
`
`(2) maintaining the mixture to allow it to set,
`
`(3) including enough of the chosen enhancing material(s) from the list
`
`provided in the mixture so that the resulting product has greater resistance
`
`to permanent deformation to provide a sag resistance of less than about
`
`0.1 per two foot of gypsum board cast from the gypsum containing
`
`product; and
`
`(4) including enough accelerator that the product has improved strength.
`
`Every single one of these steps was known in the prior art. In fact, the specification
`
`reveals that the inventors only considered one step – the addition of certain
`
`“enhancing materials” – to be new, admitting that the mixture of water, calcined
`
`gypsum, and accelerators was “employed in the prior art” using “conventional
`
`3
`
`
`

`

`
`
`additives…in customary amounts.” NGC034-1029, 7:47-59, 8:59-9:10; see also
`
`NGC034-1001, ¶ 52. The use of “enhancing materials” to improve sag resistance,
`
`however, was widely known in the prior art. NGC034-1001, ¶¶ 47, 64. In particular,
`
`the use of “enhancing materials,” including the specific chemicals claimed in claim
`
`1 of the ’034 patent such as sodium trimetaphosphate, had been used in the prior art
`
`specifically to provide improved sag resistance. Id. When the claims are viewed
`
`against this backdrop, there is nothing nonobvious or inventive about the claims of
`
`the ’034 patent, and the claims are not patentable.
`
`VI. TECHNICAL BACKGROUND OF THE ’034 PATENT
`
`A. Basics of Gypsum Products
`
`Gypsum-containing products, such as boards, plasters, and acoustical tiles,
`
`have been used in modern building applications for more than a century, and the
`
`basic recipe for the manufacture of gypsum-containing products has been known for
`
`nearly as long. See, e.g., NGC034-1017, 1:13-35; see also NGC034-1001, ¶ 55.
`
`Gypsum is a naturally occurring mineral that, when found in nature in its “raw” or
`
`rock form, has the chemical name “calcium sulfate dihydrate” and the chemical
`
`formula CaSO4•2H2O. NGC034-1001, ¶¶ 33-34. Gypsum can also be synthesized
`
`to have the same chemical name and chemical formula as naturally occurring
`
`gypsum. Id.
`
`4
`
`
`

`

`
`
`When raw gypsum is heated, much of the water is driven out from the
`
`material, resulting in a different form of gypsum called calcined gypsum or
`
`stucco. NGC034-1029, 2:6-19, 23:5-20; NGC034-1003, 1:62-2:8, 23:3-15; see also
`
`NGC034-1001, ¶ 35. Calcined gypsum contains the hemihydrate form of gypsum
`
`and, when it is subsequently mixed with water, spontaneously reacts to return to its
`
`original crystalline composition, calcium sulfate dihydrate. Id. The resulting
`
`product is often referred to as “set gypsum.” NGC034-1013, 84-8; see also
`
`NGC034-1029, 4:24-39; NGC034-1003, 4:26-41; NGC034-1001, ¶ 35.
`
`B.
`
`The ’034 Patent
`
`As noted in the ’034 patent, the claimed “set gypsum-containing products”
`
`can take many different forms, such as gypsum boards, plasters, joint compound,
`
`and acoustical tiles. NGC034-1029, 1:23-27; see also NGC034-1001, ¶¶ 34-35. In
`
`gypsum boards, the prior art method of manufacturing a board included mixing
`
`water, calcined gypsum, and one or more additional additives such as accelerators,
`
`foams, retarders, or starches and depositing the mixture between two layers of paper
`
`and allowing it to harden. NGC034-1001, ¶¶ 36-39. The specification of the ’034
`
`patent acknowledges that the use of these materials in the manufacture of set
`
`gypsum-containing products was well-known in the prior art. NGC034-1029, 7:49-
`
`59; see also id. at 9:3-10, 9:11-22, 9:51-61, 11:2-9, 11:21-28, 11:33-39, 12:7-14;
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`NGC034-1001, ¶ 60. According to the ’034 patent, however, what the inventors
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`(incorrectly) believed to be missing in the prior art was the use of certain “enhancing
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`materials” that, when added in sufficient amounts, would yield a product that had
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`increased resistance to sag. Id. The use of these “enhancing materials” was, in fact,
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`known in the prior art.
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`C. Enhancing Materials
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`The specification of the ʼ034 patent describes enhancing materials as additives
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`that improve one or more of the following attributes: strength, sag resistance, or
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`maintenance of original dimensions
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`(i.e.
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`resistance
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`to shrinkage when
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`drying). NGC034-1001, ¶¶ 40-43, 46-47. The challenged claims require that the
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`enhancing materials be “chosen from
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`the group consisting of: sodium
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`trimetaphosphate,
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`tetrapotassium pyrophosphate,
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`tetrasodium pyrophosphate,
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`aluminum
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`trimetaphosphate,
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`sodium
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`acid
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`pyrophosphate,
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`ammonium
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`polyphosphate having 1000-3000 repeating phosphate units, and acids, salts, or the
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`anionic portions thereof.” NGC034-1029, Claims 1, 7. According to the
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`specification, the preferred “enhancing material” was a condensed phosphate called
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`sodium trimetaphosphate (“STMP”). Id. at 9:22-33.
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`Since the 1930s, the use of “enhancing materials” to improve these attributes
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`has been known in the art. NGC034-1001, ¶¶ 45, 64. U.S. Patent No. 2,090,625,
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`which was filed in 1936, discloses treating gypsum with additives such as
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`orthophosphoric acid, monosodium orthophosphate or sodium metaphosphate, and
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`silica. NGC034-1019, 5:45-52; see also NGC034-1001, ¶ 45. The resulting
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`gypsum-containing product showed increased strength when these additives were
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`introduced into the manufacturing process. See NGC034-1019, 6:30-35, 6:65-75,
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`8:55-65; NGC034-1001, ¶ 45. Satterthwaite, which is discussed below in detail,
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`discloses the use of STMP – which the ’034 patent identifies as the “preferred”
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`enhancing material claimed in the patents – to improve gypsum-containing products
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`by “increas[ing] wet strength, increas[ing] density and increas[ing] resistance to
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`warp or sag.” NGC034-1007, 1:60-63; see infra at ¶ IX(B); see also NGC034-1001,
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`¶ 48. Graux, which is also discussed below in detail, discloses the manufacture of
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`set-gypsum containing products using STMP as an additive to enhance the finished
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`product. NGC034-1006, 9:29-30; see also NGC034-1001, ¶ 49. Quite simply, the
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`use of enhancing materials, including but not limited to STMP, to improve resistance
`
`to sag had been known in the industry for more than 30 years before the earliest
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`priority date of the ’034 patent. NGC034-1001, ¶ 48.
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`D. Accelerators
`
`The claims of the ’034 patent also recite the use of “accelerators” in the
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`manufacturing method to improve the strength of the set gypsum-containing
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`product. Accelerators have been known since at least the late 1960s to “shorten[]
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`the setting time of plaster by providing seed crystals.” NGC034-1022, 2:14-16; see
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`also NGC034-1001, ¶¶ 52-55. The use of an accelerator in manufacturing provides
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`the additional advantage of
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`increasing
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`the strength of
`
`the
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`resulting
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`product. NGC034-1001, ¶ 53. The specification of the ʼ034 patent confirms that
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`accelerators and other additives were known in the prior art, noting that “[o]ther
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`conventional additives can be employed in the practice of the invention in customary
`
`amounts to impart desirable properties and to facilitate manufacturing, such as, for
`
`example, aqueous foam, set accelerators….” NGC034-1029, 9:3-10 (emphasis
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`added); NGC034-1003, 9:18-25; see also NGC034-1001, ¶ 52. As with the claimed
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`“enhancing materials,” the use of accelerators to improve the strength of set gypsum-
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`containing products was well-known for decades before the earliest priority date of
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`the ’034 patent.
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`VII. PROSECUTION HISTORY OF THE ’034 PATENT
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`The relevant prosecution history is contained in U.S. Application Nos.
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`09/138,355 (that ultimately issued as the ’284 patent) and 09/249,814 (that
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`ultimately issued as the ’550 patent). NGC034-1001, ¶ 65. The examination of
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`these two applications was nearly identical, and the pending claims in both
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`applications were rejected as obvious over U.S. Patent Nos. 3,770,468 to Knauf and
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`4,126,599 to Sugahara. NGC034-1004; NGC034-1005; see also NGC034-1001, ¶
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`65. In both applications, the applicant made similar arguments and amendments to
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`distinguish its alleged invention, including the factually incorrect argument that the
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`cited references do not disclose “condensed phosphoric acids, and/or the condensed
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`phosphates as described and claimed by applicants,” despite the fact that the prior
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`art references specifically disclose STMP, which is indisputably a condensed
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`phosphate. NGC034-1004, 9; NGC034-1005, 7; see also NGC034-1001, ¶ 66. The
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`examiner appears to have been misled by applicant’s arguments, and allowed the
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`claims to issue.
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`In any event, none of Graux, Satterthwaite, and ASTM C473-95 were
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`considered by the examiner during the examination of the application that issued as
`
`the ʼ034 patent or its priority applications. NGC034-1001, ¶ 67. Although
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`Hjelmeland was disclosed to the PTO during the prosecution of the ʼ034 patent, it
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`was not cited in an Office Action or referred to during prosecution, and Petitioner
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`notes that the fact that a reference was disclosed to the PTO is not a bar to institution.
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`See infra at 19.
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`VIII. CLAIM CONSTRUCTION
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`In an IPR, claim terms are given their broadest reasonable interpretation
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`(“BRI”) in light of the specification. 37 C.F.R. § 42.100(b). Under the BRI standard,
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`claim terms are given their ordinary and customary meaning, as would be understood
`
`by a person having ordinary skill in the art (“PHOSITA”) in the context of the entire
`
`disclosure. In re Translogic Tech., Inc., 504 F.3d 1249, 1257 (Fed. Cir. 2007).
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`Because the ʼ034 patent will expire soon after institution, however, Petitioner will
`
`also address the Phillips v. AWH Corp., 415 F.3d 1303 (Fed. Cir. 2005) standard.
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`Cisco Sys., Inc. v. AIP Acquisition, LLC, IPR2014-00247 at *7-*8 (Final Decision,
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`May 20, 2015); see also NGC034-1001, ¶ 70.
`
`Claim 1 of the ’034 patent, which is representative for purposes of claim
`
`construction, is reproduced below:
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`1. A method for producing a set gypsum-containing product comprising
`
`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, and
`
`maintaining the mixture under conditions sufficient for the calcined
`
`gypsum to form an interlocking matrix of set gypsum,
`
`the enhancing material or materials having been included in the mixture
`
`in an amount such that the set gypsum-containing product has
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`greater resistance to permanent deformation than