DETAILED ACTION
Notice of Pre-AIA or AIA Status
The present application, filed on or after March 16, 2013, is being examined under the first inventor to file provisions of the AIA .
Claim Rejections - 35 USC § 103
The following is a quotation of 35 U.S.C. 103 which forms the basis for all obviousness rejections set forth in this Office action:
A patent for a claimed invention may not be obtained, notwithstanding that the claimed invention is not identically disclosed as set forth in section 102, if the differences between the claimed invention and the prior art are such that the claimed invention as a whole would have been obvious before the effective filing date of the claimed invention to a person having ordinary skill in the art to which the claimed invention pertains. Patentability shall not be negated by the manner in which the invention was made.
The factual inquiries for establishing a background for determining obviousness under 35 U.S.C. 103 are summarized as follows:
1. Determining the scope and contents of the prior art.
2. Ascertaining the differences between the prior art and the claims at issue.
3. Resolving the level of ordinary skill in the pertinent art.
4. Considering objective evidence present in the application indicating obviousness or nonobviousness.
Claim(s) 1-3 are rejected under 35 U.S.C. 103 as being unpatentable over Nahas, US2012/0282469.
Regarding claims 1-2, Nahas teaches spherical particles of Aluminum Nitride, AlN, containing 0.5-5 wt. % of an additive which can be zirconium nitride (ZrN) which contains zirconium atoms. See [0090] of Nahas. The Calculation section below shows this teaches a range of the molar ratio of Zr:Al of about 0.002 to 0.02 or 2 x 10-3 to 2 x 10-2. This completely lies within the claimed range and thus meets the claim limitation. Nahas teaches the total impurities are preferably less than 0.1 wt. % ([0090]) and thus the Aluminum nitride in Nahas has a conversion rate near 100% and in the range of the claim.
Nahas teaches forming a preform containing the spherical particles is sintered. See [0249].
Regarding the circularity, Nahas teaches a sphereicity index of the produced powder is preferably as high as possible (greater than 0.9). See [0214]. Such spheres would be nearly circular and have circularity values near 1 which would at least overlap the claimed range.
Regarding claim 3, Nahas teaches a composite containing resin. See [0090] and [0071].
Calculations for Nahas (US2012/0282469)
For minimum:
Assume: 100 g with 0.5 wt. % ZrN, 2.5% first binder, negligible impurities, and 97 wt. % AlN.
Mass of ZrN = 0.005 × 100 g = 0.5 g
Mass of AlN = 0.97 × 100 g = 97 g
Moles of ZrN =
M
o
l
e
s
Z
r
N
=
M
a
s
s
o
f
Z
r
N
(
M
o
l
a
r
m
a
s
s
o
f
Z
r
N
)
=
0.5
g
105.23
g
/
m
o
l
=
0.00475
m
o
l
Moles of AlN =
M
o
l
e
s
A
l
N
=
M
a
s
s
o
f
A
l
N
(
M
o
l
a
r
m
a
s
s
o
f
A
l
N
)
=
97
g
40.989
g
/
m
o
l
=
2.3664
m
o
l
Since the nitrogen in the compounds has a 1:1 molar ratio, the Minimum Molar ratio of Zr:Al = 0.00475 mol. Zr / 2.3664 mol. Al = 0.002.
For maximum
Assume 100 g with 5.0 wt. % ZrN, 4% first binder, and 91 wt.% AlN and complete above calculation with these assumptions. Result is about 0.02.
Response to Arguments
Applicant's arguments filed 1/23/2026 have been fully considered but they are not persuasive.
Applicant argues that Nahas does not teach the newly claimed limitation, “wherein the spherical AlN particles containing Zr atoms are sintered.” This is unpersuasive because Nahas teaches the particles are formed in to a preform and sintered. See [0249]. Thus, Nahas teaches a product wherein the spherical AlN particles containing Zr are sintered, meeting the claim limitation.
Conclusion
THIS ACTION IS MADE FINAL. Applicant is reminded of the extension of time policy as set forth in 37 CFR 1.136(a).
A shortened statutory period for reply to this final action is set to expire THREE MONTHS from the mailing date of this action. In the event a first reply is filed within TWO MONTHS of the mailing date of this final action and the advisory action is not mailed until after the end of the THREE-MONTH shortened statutory period, then the shortened statutory period will expire on the date the advisory action is mailed, and any nonprovisional extension fee (37 CFR 1.17(a)) pursuant to 37 CFR 1.136(a) will be calculated from the mailing date of the advisory action. In no event, however, will the statutory period for reply expire later than SIX MONTHS from the mailing date of this final action.
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ANTHONY J. ZIMMER
Supervisory Patent Examiner
Art Unit 1736
/ANTHONY J ZIMMER/Supervisory Patent Examiner, Art Unit 1736