( 12 ) United States Patent
`Jackson et al .
`
`US 10,968,629 B2
`( 10 ) Patent No .:
`( 45 ) Date of Patent :
`Apr. 6 , 2021
`
`USO10968629B2
`
`( * ) Notice :
`
`( 54 ) MINERAL FIBRE BOARD
`( 71 ) Applicants : Knauf Insulation SPRL , Vise ( BE ) ;
`Knauf Insulation , Inc. , Shelbyville , IN
`( US )
`( 72 ) Inventors : Roger Jackson , St. Helens ( GB ) ; Tony
`Aindow , St. Helens ( GB ) ; George
`Baybutt , St. Helens ( GB )
`( 73 ) Assignees : Knauf Insulation , Inc. , Shelbyville , IN
`( US ) ; Knauf Insulation SPRL , Vise
`( BE )
`Subject to any disclaimer , the term of this
`patent is extended or adjusted under 35
`U.S.C. 154 ( b ) by 269 days .
`( 21 ) Appl . No .: 15 / 690,623
`Aug. 30 , 2017
`( 22 ) Filed :
`( 65 )
`Prior Publication Data
`Apr. 26 , 2018
`US 2018/0112403 A1
`Related U.S. Application Data
`( 63 ) Continuation of application No. 12 / 524,512 , filed as
`application No. PCT / EP2007 / 050749 on Jan. 25 ,
`2007 .
`
`( 2006.01 )
`( 2018.01 )
`( 2006.01 )
`
`( 51 )
`
`( 52 )
`
`( 58 )
`
`( 56 )
`
`Int . Cl .
`E04C 2/16
`CO3C 25/321
`E04B 1/80
`U.S. CI .
`E04C 2/16 ( 2013.01 ) ; C03C 25/321
`???
`( 2013.01 ) ; E04B 1/80 ( 2013.01 ) ; Y1OT 428/24
`( 2015.01 )
`Field of Classification Search
`CPC . E04C 2/16 ; CO3C 25/321 ; E04B 1/80 ; Y10T
`428/24
`See application file for complete search history .
`References Cited
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`( Continued )
`
`AU
`AU
`
`OTHER PUBLICATIONS
`Notice of Intent to Issue Ex Parte Reexamination Certificate for U.S.
`Pat . No. 7,854,980 ( 3 pages ) Oct. 29 , 2019 .
`Court of Appeals for Federal Circuit Decision re Consolidated
`Appeal of PTAB Decision in Inter Partes Reexamination of U.S.
`Pat . No. 7,772,347 and U.S. Pat . No. 7,888,445 ( 14 pages ) Oct.
`15 , 2019 .
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`International Search Report for PCT / EP2008 / 060185 , completed
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`
`( Continued )
`Primary Examiner Robert S Walters , Jr.
`( 74 ) Attorney , Agent , or Firm — Knauf Insulation , Inc .;
`James K. Blodgett
`( 57 )
`ABSTRACT
`A method of manufacturing a mineral fiber insulating board
`comprising i ) spraying a formaldehyde free aqueous binder
`solution onto a plurality of mineral fibers , the aqueous
`binder solution comprising binder reactants comprising a ) a
`reducing sugar reactant and b ) an amine reactant , wherein
`the reducing sugar reactant is selected from the group
`consisting of : a reducing sugar ; a reducing sugar yielded by
`a carbohydrate in situ under thermal curing conditions ; and
`combinations thereof , wherein the percent by dry weight of
`the reducing sugar reactant with respect to the total weight
`of the binder reactants in the binder solution ranges from
`about 73 % to about 96 % , and wherein the percent by dry
`weight of the amine reactant with respect to the total weight
`of the binder reactants in the binder solution ranges from
`about 4 % to about 27 % , ii ) dehydrating the aqueous binder
`solution such that a dehydrated binder is disposed on the
`plurality of mineral fibers , and iii ) curing the dehydrated
`binder on the plurality of mineral fibers to provide cured
`binder in about 0.5 % -15 % by weight as determined by loss
`on ignition .
`
`19 Claims , No Drawings
`
`PGR2022-00022 - Petitioner’s Exhibit 1001 – Page 1
`
`

`

`( 56 )
`
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`PGR2022-00022 - Petitioner’s Exhibit 1001 – Page 2
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`

`

`( 56 )
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`US 10,968,629 B2
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`
`PGR2022-00022 - Petitioner’s Exhibit 1001 – Page 3
`
`

`

`US 10,968,629 B2
`Page 4
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