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. IPR2017-1350
`Patent No. 6,342,284
`
`
`
`PETITION FOR INTER PARTES REVIEW OF
`UNITED STATES PATENT NO. 6,342,284
`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.
`
`B.
`
`C.
`
`D.
`
`Real Party-In-Interest under 37 C.F.R. § 42.8(b)(1) ............................. 1
`
`Related Matters under 37 C.F.R. § 42.8(b)(2) ...................................... 1
`
`Lead and Back-Up Counsel under 37 C.F.R. § 42.8(b)(3) ................... 1
`
`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 ʼ284 PATENT .............................. 4
`
`A.
`
`B.
`
`C.
`
`Basics of Gypsum Products ................................................................... 4
`
`The ʼ284 Patent ..................................................................................... 5
`
`Enhancing Materials .............................................................................. 6
`
`VII. PROSECUTION HISTORY OF THE ʼ284 PATENT .................................... 7
`
`VIII. CLAIM CONSTRUCTION ............................................................................ 8
`
`A.
`
`B.
`
`Enhancing Material(s) ........................................................................... 9
`
`Host Particle(s) ....................................................................................11
`
`IX. PRIOR ART REFERENCES ........................................................................ 12
`
`A. Graux ...................................................................................................13
`
`B.
`
`C.
`
`Satterthwaite ........................................................................................14
`
`ASTM ..................................................................................................16
`
`D. Hjelmeland ..........................................................................................17
`
`E.
`
`F.
`
`G.
`
`Sucech..................................................................................................18
`
`Baig ......................................................................................................19
`
`Summerfield ........................................................................................19
`
`X.
`
`THERE IS A REASONABLE LIKELIHOOD THAT AT LEAST ONE
`CLAIM OF THE `284 PATENT IS UNPATENTABLE ............................. 20
`
`i
`
`
`

`

`
`
`XI. GROUND 1: OBVIOUSNESS OF CLAIMS 1-7, 10-15, 18, 22, 26, 29, 32-
`34, AND 40 BASED ON GRAUX IN VIEW OF ASTM C473-95,
`HJELMELAND, SUCECH, BAIG, AND SUMMERFIELD ....................... 21
`
`A.
`
`Reasons for Combining Graux, ASTM C473-95, Hjelmeland, Sucech,
`Baig, and Summerfield ........................................................................21
`
`B.
`
`Element by Element Analysis .............................................................26
`
`i.
`
`ii.
`
`Claim 1a: A composition comprising a mixture of: ............... 26
`
`Claim 1b: a calcium sulfate material, water, a
`pregelatinized starch and one or more enhancing
`materials . . . , ........................................................................... 26
`
`iii. Claim 1c: wherein when said composition is cast in the
`form of ½ inch gypsum board, said board has a sag
`resistance. . . . ........................................................................... 27
`
`iv.
`
`v.
`
`vi.
`
`Claim 2a: A composition comprising a mixture of: ............... 29
`
`Claim 2b: a calcium sulfate material, water, an aqueous
`foam, and one or more enhancing materials . . . , .................... 29
`
`Claim 2c: wherein when said composition is cast in the
`form of ½ inch gypsum board, said board has a sag
`resistance. . . . ........................................................................... 30
`
`vii. Claim 3: The composition of claim 2, wherein the
`mixture further comprises a pregelatinized starch. .................. 30
`
`viii. Claim 4a: A composition comprising set gypsum and
`host particles. . . ; ..................................................................... 31
`
`ix.
`
`x.
`
`xi.
`
`Claim 4b: calcium sulfate hemihydrate, at least a portion
`of which is in the form of crystals in and about the voids
`of the host particles; and one or more enhancing
`materials . . . , ........................................................................... 32
`
`Claim 4c: wherein when said composition is cast in the
`form of ½ inch gypsum board, said board has a sag
`resistance. . . . ........................................................................... 33
`
`Claim 5: Gypsum board comprising set gypsum and at
`least one trimetaphosphate compound, said gypsum
`board having a sag resistance . . . . ........................................... 34
`
`ii
`
`
`

`

`
`
`xii. Claim 6: The gypsum board of claim 5, wherein said set
`gypsum and trimetaphosphate compound are in the form
`of a core material sandwiched between cover sheets. ............. 34
`
`xiii. Claim 7: The gypsum board of claim 6, wherein the
`cover sheets comprise paper. ................................................... 35
`
`xiv. Claim 10: Gypsum board comprising set gypsum formed
`from at least calcined gypsum, water and at least one
`trimetaphosphate compound, said gypsum board having a
`sag resistance. . . ...................................................................... 35
`
`xv. Claim 11: The gypsum board of claim 10, wherein the
`amount of said trimetaphosphate compound is from about
`0.004 to about 2.0% by weight of said calcined gypsum. ....... 35
`
`xvi. Claim 12: The gypsum board of claim 10, wherein said
`set gypsum is in the form of a core material sandwiched
`between cover sheets. ............................................................... 38
`
`xvii. Claim 13: The gypsum board of claim 12, wherein said
`cover sheets comprise paper. ................................................... 38
`
`xviii. Claim 14: The gypsum board of claim 10, wherein said
`trimetaphosphate compound is selected from the group
`consisting of . . .. ...................................................................... 38
`
`xix. Claim 15: The gypsum board of claim 10, wherein said
`trimetaphosphate is sodium trimetaphosphate. ........................ 38
`
`xx. Claim 18: The gypsum board of claim 5, wherein said
`gypsum board further comprises a pregelatinized starch. ....... 38
`
`xxi. Claim 22: The gypsum board of claim 10, wherein said
`gypsum board further comprises a pregelatinized starch. ....... 38
`
`xxii. Claim 26: The gypsum board of claim 5, wherein said
`set gypsum has voids uniformly distributed therein. ............... 39
`
`xxiii. Claim 29: The gypsum board of claim 10, wherein said
`set gypsum has voids uniformly distributed therein. ............... 39
`
`xxiv. Claim 32: The gypsum board of claim 26, wherein the
`set gypsum further comprises a pregelatinized starch and
`at least one foaming agent. ....................................................... 39
`
`xxv. Claim 33: The gypsum board of claim 29, wherein the
`set gypsum is further formed from a pregelatinized starch ..... 39
`
`iii
`
`
`

`

`
`
`xxvi. Claim 34a: Gypsum board comprising an interlocking
`matrix of set gypsum and at least one material selected
`from the group consisting of, ................................................... 40
`
`xxvii. Claim 34b: said gypsum board having a sag resistance . .
`.. 40
`
`xxviii. Claim 40a: A gypsum board comprising a core of
`material sandwiched between cover sheets. . . having
`been prepared by a method comprising: .................................. 41
`
`xxix. Claim 40b: forming or depositing a mixture between the
`cover sheets, wherein the mixture comprises a calcium
`sulfate material, water, and one or more enhancing
`materials . . . ............................................................................. 41
`
`xxx. Claim 40c: maintaining the mixture . . . , ............................... 41
`
`xxxi. Claim 40d: the enhancing material or materials having
`been included in the mixture in an amount such that the
`gypsum board has a sag resistance. . . . ................................... 42
`
`XII. GROUND 2: OBVIOUSNESS OF CLAIMS 1-7, 10-15, 18, 22, 26, 32-34,
`AND 40 BASED ON SATTERTHWAITE IN VIEW OF HJELMELAND,
`ASTM C473-95, SUCECH, BAIG, AND SUMMERFIELD ....................... 42
`
`A.
`
`Reasons for Combining Satterthwaite, ASTM C473-95, Hjelmeland,
`Sucech, Baig, and Summerfield ..........................................................42
`
`B.
`
`Element by Element Analysis .............................................................48
`
`i.
`
`ii.
`
`Claim 1a: A composition comprising a mixture of: ............... 48
`
`Claim 1b: a calcium sulfate material, water, a
`pregelatinized starch and one or more enhancing
`materials . . . , ........................................................................... 48
`
`iii. Claim 1c: wherein when said composition is cast in the
`form of ½ inch gypsum board, said board has a sag
`resistance. . .. ............................................................................ 50
`
`iv.
`
`v.
`
`vi.
`
`Claim 2a: A composition comprising a mixture of: ............... 52
`
`Claim 2b: a calcium sulfate material, water, an aqueous
`foam, and one or more enhancing materials . . . , .................... 52
`
`Claim 2c: wherein when said composition is cast in the
`form of ½ inch gypsum board, said board has a sag
`resistance. . .. ............................................................................ 53
`
`iv
`
`
`

`

`
`
`vii. Claim 3: The composition of claim 2, wherein the
`mixture further comprises a pregelatinized starch. .................. 53
`
`viii. Claim 4a: A composition comprising set gypsum and
`host particles. . . ; ..................................................................... 53
`
`ix.
`
`x.
`
`xi.
`
`Claim 4b: calcium sulfate hemihydrate, at least a portion
`of which is in the form of crystals in and about the voids
`of the host particles; and one or more enhancing
`materials . . . , ........................................................................... 56
`
`Claim 4c: wherein when said composition is cast in the
`form of ½ inch gypsum board, said board has a sag
`resistance. . .. ............................................................................ 57
`
`Claim 5: Gypsum board comprising set gypsum and at
`least one trimetaphosphate compound, said gypsum
`board having a sag resistance. . .. ............................................. 57
`
`xii. Claim 6: The gypsum board of claim 5 . . . in the form
`of a core material sandwiched between cover sheets. ............. 57
`
`xiii. Claim 7: The gypsum board of claim 6, wherein the
`cover sheets comprise paper. ................................................... 58
`
`xiv. Claim 10: Gypsum board comprising set gypsum formed
`from at least calcined gypsum, water and at least one
`trimetaphosphate compound, said gypsum board having a
`sag resistance. . ........................................................................ 58
`
`xv. Claim 11: The gypsum board of claim 10, wherein the
`amount of said trimetaphosphate compound is from about
`0.004 to about 2.0% . . .. .......................................................... 59
`
`xvi. Claim 12: The gypsum board of claim 10. . . in the form
`of a core material sandwiched between cover sheets. ............. 60
`
`xvii. Claim 13: The gypsum board of claim 12, wherein said
`cover sheets comprise paper. ................................................... 61
`
`xviii. Claim 14: The gypsum board of claim 10, wherein said
`trimetaphosphate compound is selected from the group
`consisting of . . . . ..................................................................... 61
`
`xix. Claim 15: The gypsum board of claim 10, wherein said
`trimetaphosphate is sodium trimetaphosphate. ........................ 61
`
`xx. Claim 18: The gypsum board of claim 5, wherein said
`gypsum board further comprises a pregelatinized starch. ....... 61
`
`v
`
`
`

`

`
`
`xxi. Claim 22: The gypsum board of claim 10, wherein said
`gypsum board further comprises a pregelatinized starch. ....... 61
`
`xxii. Claim 26: The gypsum board of claim 5, wherein said
`set gypsum has voids uniformly distributed therein. ............... 62
`
`xxiii. Claim 29: The gypsum board of claim 10, wherein said
`set gypsum has voids uniformly distributed therein. ............... 62
`
`xxiv. Claim 32: The gypsum board of claim 26, wherein the
`set gypsum is further comprises a pregelatinized starch
`and at least one foaming agent. ................................................ 62
`
`xxv. Claim 33: The gypsum board of claim 29, wherein the
`set gypsum is further formed from a pregelatinized
`starch. ....................................................................................... 62
`
`xxvi. Claim 34a: Gypsum board comprising an interlocking
`matrix of set gypsum and at least one material selected
`from the group consisting of. . . , ............................................. 62
`
`xxvii. Claim 34b: said gypsum board having a sag resistance . .
`. . ............................................................................................... 63
`
`xxviii. Claim 40a: A gypsum board comprising a core of
`material sandwiched between cover sheets . . . said board
`having been prepared by a method comprising: ...................... 63
`
`xxix. Claim 40b: forming or depositing a mixture between the
`cover sheets, wherein the mixture comprises a calcium
`sulfate material, water, and one or more enhancing
`materials . . . ............................................................................. 64
`
`xxx. Claim 40c: maintaining the mixture . . . , ............................... 64
`
`xxxi. Claim 40d: the enhancing material or materials having
`been included in the mixture in an amount such that the
`gypsum board has a sag resistance. . .. .................................... 66
`
`XIII. SECONDARY CONSIDERATIONS ........................................................... 66
`
`XIV. CONCLUSION .............................................................................................. 67
`
`XV. CERTIFICATE OF WORD COUNT ........................................................... 68
`
`
`
`
`
`vi
`
`
`

`

`
`
`
`
`
`CASES
`
`TABLE OF AUTHORITIES
`
`Page(s)
`
`Atlas Powder Co. v. Ireco, Inc.,
`190 F.3d 1342 (Fed. Cir. 1999) .................................................................... 32, 59
`
`Cisco Sys., Inc. v. AIP Acquisition, LLC,
`IPR2014-00247 (Final Decision, May 20, 2015) ................................................. 9
`
`Mexichem Amanco Holdings,
`Reexamination Appeal 2015-007833 ................................................................. 59
`
`Mexichem Amanco Holdings v. Honeywell Int’l Inc.,
`Reexamination Appeal 2015-007833 (Decision on Appeal, March
`30, 2016) ............................................................................................................. 32
`
`Microsoft Corp. v. Multi-Tech Sys., Inc.,
`357 F.3d 1340 (Fed. Cir. 2004) .......................................................................... 11
`
`Microsoft Corp. v. Parallel Networks Licensing, LLC,
`IPR2015-00483 ..................................................................................................... 9
`
`NTP, Inc. v. Research in Motion, Ltd.,
`418 F.3d 1282 (Fed. Cir. 2005) .......................................................................... 11
`
`Phillips v. AWH Corp.,
`415 F.3d 1303 (Fed. Cir. 2005) ................................................................ 9, 11, 12
`
`Praxair Distribution, Inc. v. Ino Therapeutics, LLC,
`IPR2015-00893 ..................................................................................................... 9
`
`Titanium Metals Corp. v. Banner,
`778 F.2d 775, 227 USPQ 773 (Fed. Cir. 1985) ...........................................passim
`
`United States Gypsum Company v. New NGC, Inc.,
`Case No. 1:17-cv-00130 (D. Del. Feb. 6, 2017) ................................................... 1
`
`
`
`
`
`vii
`
`
`

`

`
`
`RULES
`
`42.22(a)(1) .................................................................................................................. 2
`
`42.104(b)(1)–(2) ......................................................................................................... 2
`
`STATUTES
`
`35 U.S.C. § 102(a) ................................................................................................... 19
`
`35 U.S.C. § 102(b) ................................................................................. 15, 17, 20, 21
`
`35 U.S.C. § 102(e) ............................................................................................. 14, 18
`
`35 U.S.C. § 103(a) ................................................................................................. 2, 3
`
`OTHER AUTHORITIES
`
`37 C.F.R § 42.8 .......................................................................................................... 1
`
`37 C.F.R § 42.10(b) ................................................................................................... 1
`
`37 C.F.R. § 42.104(a) ................................................................................................. 2
`
`
`
`
`
`viii
`
`
`

`

`
`
`
`
`NGC284-1001
`
`Expert Declaration of Gerry Harlos
`
`EXHIBITS
`
`NGC284-1002
`
`U.S. Patent No. 6,632,550 (“the ʼ550 patent”)
`
`NGC284-1003
`
`U.S. Patent No. 6,342,284 (“the ʼ284 patent”)
`
`NGC284-1004
`
`Selections from the Prosecution History of the ʼ284 Patent
`
`NGC284-1005
`
`Selections from the Prosecution History of the ʼ550 Patent
`
`NGC284-1006
`
`U.S. Patent No. 5,932,001 (“Graux”)
`
`NGC284-1007
`
`U.S. Patent No. 3,234,037 (“Satterthwaite”)
`
`NGC284-1008
`
`U.S. Patent No. 5,980,628 (“Hjelmeland”)
`
`NGC284-1009
`
`ASTM C473-95
`
`NGC284-1010
`
`U.S. Patent No. 2,884,413 (“Kerr”)
`
`NGC284-1011
`
`U.S. Patent No. 3,770,468 (“Knauf”)
`
`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)
`
`NGC284-1012
`
`NGC284-1013
`
`ix
`
`
`

`

`
`
`NGC284-1014
`
`ASTM C472-93
`
`NGC284-1015
`
`Robert F. Acker, Physical Testing of Gypsum Board Per
`ASTM C 473, 3-7 (R.A. Kuntze, ed., 1984)
`
`NGC284-1016
`
`L. Amathieu, Improvement of Mechanical Properties of Set
`Plasters, 79 J. of Crystal Growth 169, 176 (1986)
`
`NGC284-1017
`
`U.S. Patent No. 2,985,219
`
`NGC284-1018
`
`U.S. Patent No. 3,179,529
`
`NGC284-1019
`
`U.S. Patent No. 2,090,625
`
`NGC284-1020
`
`U.S. Patent No. 3,190,787
`
`NGC284-1021
`
`U.S. Patent No. 2,346,999
`
`NGC284-1022
`
`U.S. Patent No. 3,573,947
`
`NGC284-1023
`
`U.S. Patent No. 4,009,062
`
`NGC284-1024
`
`U.S. Patent No. 5,320,677
`
`NGC284-1025
`
`U.S. Patent No. 5,534,059
`
`NGC284-1026
`
`U.S. Patent No. 5,395,438
`
`NGC284-1027
`
`U.S. Patent No. 3,246,063
`
`x
`
`
`

`

`
`
`NGC284-1028
`
`Redacted Complaint
`
`NGC284-1029
`
`[RESERVED]
`
`NGC284-1030
`
`[RESERVED]
`
`NGC284-1031
`
`ASTM C473-81
`
`NGC284-1032
`
`U.S. Patent No. 5,085,929
`
`NGC284-1033
`
`[RESERVED]
`
`NGC284-1034
`
`[RESERVED]
`
`NGC284-1035
`
`[RESERVED]
`
`NGC284-1036
`
`U.S. Patent No. 5,643,510
`
`NGC284-1037
`
`[RESERVED]
`
`NGC284-1038
`
`[RESERVED]
`
`NGC284-1039
`
`[RESERVED]
`
`xi
`
`
`

`

`
`
`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. 6,342,284 (the “’284 patent”) is at issue in a district court case
`
`styled United States Gypsum Company v. New NGC, Inc., Case No. 1:17-cv-00130
`
`(D. Del. Feb. 6, 2017). Petitioner filed Petitions for IPR challenging the claims of
`
`related U.S. Patent Nos. 6,632,550 (the “ʼ550 patent”), 7,425,236 (the “’236
`
`patent”), and 7,964,034 (the “’034 patent”) in petitions styled IPR2017-01011,
`
`IPR2017-01086, and IPR2017-01088. Petitioner is concurrently filing Petitions for
`
`IPR challenging the claims of related U.S. Patent Nos. 7,758,980 (the “ʼ980 patent”),
`
`8,142,914 (the “ʼ914 patent”), and 8,500,904 (the “’904 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.
`
`1
`
`
`

`

`
`
`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.
`
`II. GROUNDS FOR STANDING UNDER 37 C.F.R. § 42.104(a)
`
`Petitioner certifies that the ’284 patent is available for IPR and, Petitioner is
`
`not barred or estopped from requesting an IPR challenging Claims 1-7, 10-15, 18,
`
`22, 26, 29, 32-34, and 40 of the ʼ284 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 1-7, 10-15, 18, 22, 26, 29, 32-34, and 40 of the ʼ284 patent on
`
`the following grounds:
`
`Count 1: claims 1-7, 10-15, 18, 22, 26, 29, 32-34, and 40 of the ʼ284 patent
`
`are unpatentable under 35 U.S.C. § 103(a) as obvious over Graux, ASTM C473-95,
`
`Hjelmeland, Sucech, Baig, and Summerfield.
`
`2
`
`
`

`

`
`
`Count 2: claims 1-7, 10-15, 18, 22, 26, 29, 32-34, and 40 of the ʼ284 patent
`
`are unpatentable under 35 U.S.C. § 103(a) as obvious over Satterthwaite, ASTM
`
`C473-95, Hjelmeland, Sucech, Baig, and Summerfield.
`
`V.
`
`INTRODUCTION
`
`The ’284 patent claims commonplace ingredients in identified combinations
`
`to yield known results. NGC284-1001, ¶ 32-40, 48, 62. The ʼ284 patent is broadly
`
`directed to gypsum-containing building products, including “gypsum boards,
`
`reinforced gypsum composite boards, plasters, machinable materials, joint treatment
`
`materials, and acoustical tiles.” NGC284-1003, 1:10-16; NGC284-1001, ¶¶ 57-59.
`
`Claims 1 and 2 of the ʼ284 patent are representative and can be summarized as
`
`follows:
`
`A composition comprising a mixture of:
`
`(1) a calcium sulfate material
`
`(2) water
`
`(3) additives such as a pregelatinized starch and/or aqueous foam
`
`(4) one or more enhancing materials selected from the group consisting of:
`
`condensed phosphoric acids, each of which comprises 2 or more phosphoric
`
`acid units; and salts or ions of condensed phosphates, each of which comprises
`
`2 or more phosphate units
`
`3
`
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`(5) wherein the resulting board has a sag resistance, as determined according
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`to ASTM C473-95, of less than about 0.1 inch per two foot length of said
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`board.
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`Every single one of these ingredients was known in the prior art. In fact, the
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`specification reveals that the inventors only considered one aspect – the addition of
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`certain “enhancing materials” – to be new, admitting that the mixture of water,
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`calcined gypsum, and additives was “employed in the prior art” using “conventional
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`additives…in customary amounts.” NGC284-1003, 9:18-25; NGC284-1001, ¶ 60.
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`The use of “enhancing materials” to improve sag resistance, however, was also
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`widely known in the prior art. NGC284-1001, ¶¶ 55-56, 64. “Enhancing materials,”
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`including sodium trimetaphosphate, had been used in the prior art specifically to
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`provide improved sag resistance. Id. When the claims are viewed against this
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`backdrop, there is nothing nonobvious or inventive about the claims of the ’284
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`patent.
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`VI. TECHNICAL BACKGROUND OF THE ʼ284 PATENT
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`A. Basics of Gypsum Products
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`Gypsum-containing products, such as boards, plasters, and acoustical tiles,
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`have been used in modern building applications for more than a century, and the
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`basic recipe for the manufacture of gypsum-containing products has been known for
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`nearly as long. See, e.g., NGC284-1017, 1:13-35; NGC284-1001, ¶ 33. Gypsum is
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`4
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`a naturally occurring mineral that, when found in nature in its “raw” or rock form,
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`has the chemical name “calcium sulfate dihydrate” and the chemical formula
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`CaSO4•2H2O. NGC284-1001, ¶¶ 32-33.
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`When raw gypsum is heated, much of the water is driven out from the
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`material, resulting in a different form of gypsum called calcined gypsum or stucco.
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`NGC284-1003, 1:62-2:8, 23:3-15; NGC284-1001, ¶ 34. Calcined gypsum contains
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`the hemihydrate form of gypsum and, when subsequently mixed with water,
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`spontaneously reacts to return to its original crystalline composition: calcium sulfate
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`dihydrate. Id. The resulting product is commonly known as “set gypsum.”
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`NGC284-1013, 84-85; NGC284-1003, 4:26-41; NGC284-1001, ¶ 34.
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`B.
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`The ʼ284 Patent
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`
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`As noted in the ’284 patent, the claimed “composition[s]” can take many
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`different forms, such as gypsum boards, plasters, joint compound, and acoustical
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`tiles. NGC284-1003, 1:10-16; NGC284-1001, ¶¶ 57. In gypsum boards, the prior
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`art method of manufacturing a board included mixing water, calcined gypsum, and
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`one or more additional additives such as enhancing materials, accelerators, foams,
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`retarders, or starches, both pregelatinized and non-pregelatinized, and depositing the
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`mixture between two layers of paper and allowing it to harden. NGC284-1001, ¶¶
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`35-39, 52-55, 58, 60. The ’284 patent acknowledges that the use of these materials
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`in the manufacture of set gypsum-containing products was well-known in the prior
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`art. NGC284-1003, 7:58-8:4; id. at 9:26-40, 11:19-26, 11:40-46, 12:27-34, 17:20-
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`35, 20:50-63, 21:25-40; NGC284-1001, ¶¶ 59-60. What the inventors incorrectly
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`believed to be missing in the prior art was the use of certain “enhancing materials”
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`that, when added in sufficient amounts, would yield a product that had increased
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`resistance to sag. Id. The use of these “enhancing materials” was, in fact, known in
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`the prior art. Id.
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`C. Enhancing Materials
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`The ʼ284 patent describes enhancing materials as additives that improve one
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`or more of the following attributes: strength, sag resistance, or maintenance of
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`original dimensions (i.e. resistance to shrinkage when drying). See NGC284-1001,
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`¶¶ 41-44. The challenged claims require that the enhancing material be either a
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`“trimetaphosphate compound” or “chosen from the group consisting of: condensed
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`phosphoric acids, each of which comprises 2 or more phosphoric acid units; and salts
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`or ions of condensed phosphates, each of which comprises 2 or more phosphate
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`units.” See, e.g., NGC284-1003, Claims 1, 2, 4, & 5; NGC284-1001, ¶¶ 60-63, 69.
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`According to the specification, the preferred “enhancing material” was a condensed
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`phosphate called sodium trimetaphosphate (“STMP”). Id. at 4:14-24, 8:12 (“Sodium
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`trimetaphosphate is preferred.”); NGC284-1001, ¶¶ 60, 63.
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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. NGC284-1001, ¶¶ 45-47. 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. NGC284-1019, 5:45-52; NGC284-1001, ¶ 45. The resulting set gypsum-
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`containing product showed increased strength when these additives were introduced
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`into the manufacturing process. See NGC284-1019, 6:30-35, 6:65-75, 8:55-65;
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`NGC284-1001, ¶ 45. Graux, which is also discussed below in detail, discloses the
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`manufacture of set-gypsum containing products using STMP as an additive to
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`enhance the finished product. NGC284-1006, 9:29-30; NGC284-1001, ¶ 49. In
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`short, enhancing materials, including but not limited to STMP, to improve resistance
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`to sag were known in the industry for more than 30 years before the earliest priority
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`date of the ’284 patent. NGC284-1001, ¶¶ 40-51, 70. Satterthwaite, which is
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`discussed below in detail, discloses the use of STMP – which the ’284 patent
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`identifies as the “preferred” enhancing material claimed in the patents – to improve
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`gypsum-containing products by “increas[ing] wet strength, increas[ing] density and
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`increas[ing] resistance to warp or sag.” NGC284-1007, 1:60-63; see infra at ¶
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`IX(B); NGC284-1001, ¶¶ 48-51.
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`VII. PROSECUTION HISTORY OF THE ʼ284 PATENT
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`The original claims of U.S. Application No. 09/138,355 (that ultimately
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`issued as the ’284 patent) were rejected as obvious over U.S. Patent Nos. 3,770,468
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`to Knauf and 4,126,599 to Sugahara. NGC284-1004; NGC284-1005; NGC284-
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`7
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`1001, ¶ 66. During prosecution, the applicant made the factually incorrect argument
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`that the cited references do not disclose “condensed phosphoric acids, and/or the
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`condensed phosphates as described and claimed by applicants,” despite the fact that
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`the prior art references specifically disclose STMP, which is indisputably a
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`condensed phosphate. NGC284-1004, 9; NGC284-1005, 7; NGC284-1001, ¶ 66-
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`67. The examiner appears to have been misled by applicant’s arguments, and
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`allowed the claims to issue. See NGC284-1001, ¶ 66-67.
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`In any event, none of Graux, Satterthwaite, ASTM C473-95, and Hjelmeland
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`were considered by the examiner during the examination of the application that
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`issued as the ’284 patent or its priority application. NGC284-1001, ¶ 68. And
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`although Sucech, Baig, and Summerfield were cited in the ’284 patent and disclosed
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`to the PTO during the prosecution of the ʼ284 patent, and even though Baig and
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`Summerfield were incorporated by reference in the ’284 patent, Sucech, Baig, and
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`Summerfield were not cited in an Office Action or referred to during prosecution by
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`the Examiner. Disclosure of a reference to the PTO is not a bar to institution. See,
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`e.g., Praxair Distribution, Inc. v. Ino Therapeutics, LLC, IPR2015-00893
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`(Institution Decision, Paper 14) at pp. 7-8 (Sept. 22, 2015); NGC284-1001, ¶ 68.
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`VIII. CLAIM CONSTRUCTION
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`The ’284 patent will expire no later than August 21, 2017. Because the ʼ284
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`patent will be expired at institution, Petitioner addresses the meaning of the claim
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`terms under 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); NGC284-1001, ¶ 71.
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`Claim 1 of the ’284 patent, which is representative for purposes of claim
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`construction, is reproduced below:
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`1. A composition comprising a mixture of:
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`a calcium sulfate material, water, a pregelatinized starch and one or more
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`enhancing materials selected from the group consisting of: condensed
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`phosphoric acids, each of which comprises 2 or more phosphoric acid
`
`units; and salts or ions of condensed phosphates, each of which
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`comprises 2 or more phosphate units,
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`wherein when said composition is cast in the form of ½ inch gypsum board,
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`said board has a sag resistance, as determined according to ASTM
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`C473-95, of less than about 0.1 inch per two foot length of said board.
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`A. Enhancing Material(s)
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`The term “enhancing materials” appears throughout the claims of the ’284
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`patent and its related family of patents. Although the challenged claims of the ’284
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`patent further limit “enhancing materials” to a specific Markush