DETAILED ACTION
Notice of 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 .
Claims 1-20 are pending. Claims 11-16 are allowed. Claims 1-10 and 17-20 are rejected.
Response to Amendment
This Office Action is responsive to the amendment filed on 04/10/2026.
Claims 1-4, 6, 8-9, 11-12, 14, 16-17, and 20 are amended and are being fully considered by the examiner.
In response to applicant’s amendments to claims 1-4, 6, 8-9 and 17, all the claim interpretations as set forth in the previous office action are moot.
In response to applicant’s amendments to claims 1, 6 and 16-17, all the 35 U.S.C. 112(b) rejections of claims 1-20 as set forth in the previous office action has been withdrawn.
In response to applicant’s amendments to claims 1, 6 and 17, all the 35 U.S.C. 112(a) rejections of claims 1-20 as set forth in the previous office action has been withdrawn. However, the amendments to claims 1 and 17 introduce new 35 U.S.C. 112(a) issues; therefore, in response to the amended claims 1 and 17, claims 1-10 and 17-20 are rejected under 35 U.S.C. 112(a).
Applicant's amendment necessitated the new ground(s) of rejection presented in this Office action. Accordingly, THIS ACTION IS MADE FINAL.
Claim Rejections - 35 USC § 112
35 U.S.C. 112(a)
The following is a quotation of the first paragraph of 35 U.S.C. 112(a):
(a) IN GENERAL.—The specification shall contain a written description of the invention, and of the manner and process of making and using it, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains, or with which it is most nearly connected, to make and use the same, and shall set forth the best mode contemplated by the inventor or joint inventor of carrying out the invention.
Claims 1-10 and 17-20 are rejected under 35 U.S.C. 112(a) as failing to comply with the written description requirement. The claim(s) contains subject matter which was not described in the specification in such a way as to reasonably convey to one skilled in the relevant art that the inventor or a joint inventor at the time the application was filed, had possession of the claimed invention.
Claim 1:
Claim further recites, a controller configured to selectively apply heat to one or more of the plurality of first heating elements to cause localized thermal expansion of the first rotating roll. This limitation describes “selective” application of heat “to one or more of the plurality of first heating elements” such that selectively applying heat to one or more of the plurality of first heating elements.
The specification doesn’t disclose selectively applying heat to one or more of the plurality of first heating elements such that there is no disclosure of selecting one or more of the plurality of first heating elements and then applying heat to that selected one or more of the plurality of first heating elements. Specification ¶8 describes: “means for heating the first rotating roll at a selected position along the length of the first rotating roll wherein a plurality of first heating elements is positioned along the length of the first rotating roll.” Such that specification describes plurality of first heating elements is positioned along the length of the first rotating roll and then heating the roller at a selected position. The most specification describes is heating the first rotating roll at a selected position along the length of the first rotating roll, but heating the first rotating roll at selected position is not the same as selectively applying heat to one or more of the plurality of first heating element.
Based on the description of the specification, one of the ordinary skilled in the art will not understand that selective application of heat to one or more of the plurality of first heating element.
Appropriate correction is required.
Claim 6:
Claim further recites, selectively apply heat to the one or more of the plurality of second heating elements to cause localized thermal expansion of the first rotating roll. This limitation describes “selective” application of heat “to one or more of the plurality of second heating elements” such that selectively applying heat to one or more of the plurality of second heating elements.
For similar reasons as described above in claim 1, the specification doesn’t disclose this limitation.
Based on the description of the specification, one of the ordinary skilled in the art will not understand that selective application of heat to one or more of the plurality of second heating element.
Appropriate correction is required.
Claims 2-10:
Based on their dependencies in claim 1, claims 2-10 are also rejected under 35 U.S.C. 112(a) for the same reasons.
Claim 17:
Claim recites, control application of the heat to one or more heating elements of the plurality of heating elements at selected positions. This limitation describes applying heat to one or more heating elements of the plurality of heating elements “at selected positions”.
The specification doesn’t disclose applying heat to one or more heating elements of the plurality of heating elements “at selected positions”. Specification ¶8 describes: “means for heating the first rotating roll at a selected position along the length of the first rotating roll wherein a plurality of first heating elements is positioned along the length of the first rotating roll.” Such that specification describes plurality of first heating elements is positioned along the length of the first rotating roll and then heating the roller at a selected position. The most specification describes is heating the first rotating roll at a selected position along the length of the first rotating roll, but heating the first rotating roll at selected position is not the same as applying heat to one or more heating elements of the plurality of heating elements “at selected positions”.
Based on the description of the specification, one of the ordinary skilled in the art will not understand that applying heat to one or more heating elements of the plurality of heating elements “at selected positions”.
Claim further recites, (iv) process a model of the calender that relates ….roll diameter of at least one of the first rotating roller or the second rotating roller that includes the one or more heating elements, …. This limitation describes process model of the calender relates diameter of the first or the second roller with the other parameters/variables of the model.
The specification doesn’t disclose process model of the calender relating diameter of the first or the second roller with the other parameters/variables of the model. Specification ¶48 equation (5) describes a model, but doesn’t describe any diameter of the first or the second roller parameter/variable and relating diameter of first or the second roller to the other parameter/variable of the model.
Based on the description of the specification, one of the ordinary skilled in the art will not understand that process model of the calender relating diameter of the first or the second roller with the other parameters/variables of the model.
Appropriate correction is required.
Claims 18-20:
Based on their dependencies in claim 17, claims 18-20 are also rejected under 35 U.S.C. 112(a) for the same reasons.
Allowable Subject Matter
Independent claims
Claim 11 is allowed.
Claims 1 and 17 would be allowable if rewritten or amended to overcome the rejection(s) under 35 U.S.C. 112 set forth in this Office action.
Reasons for allowance of claim 11 and Reasons for Indicating Allowable Subject Matter of claims 1 and 17
Claims 11 is allowed. Claims 1 and 17 are indicated to have allowable subject matter. The following is an examiner’s statement of reasons for indicating allowable subject matter:
35 USC § 112(b) rejections withdrawn:
In response to applicant’s amendments to claims 1, 6 and 16-17, all the 35 U.S.C. 112(b) rejections of claims 1-20 as set forth in the previous office action has been withdrawn.
35 USC § 103 rejections withdrawn:
Applicant’s amendments to claims 1, 11 and 17 have overcome all the 35 USC § 103 rejections of claims 1-20 as set forth in the previous office action; accordingly, all the 35 USC § 103 rejections of claims 1-20 as set forth in the previous office action has been withdrawn.
Applicant’s following arguments are persuasive:
“Independent claim 1 has been amended…Independent claim 11 has been amended in similar fashion.
QU does not teach selectively applying heat at selected positions along the length of a rotating roll to intentionally cause localized thermal expansion of the roll itself so that the roll diameter is locally varied to regulate the gap and thereby control a thickness profile along the cross direction.
Kinouchi does not remedy this. Kinouchi does not teach or suggest selectively applying heat at selected positions along a roller length to intentionally cause localized thermal expansion of the roller to locally vary roller diameter for regulating a calender gap and controlling an electrode coating thickness profile along the cross direction.
Independent claim 17 has been amended…QU and Kinouchi do not teach or suggest these limitations.
However, neither QU nor Kinouchi teaches or suggests controlling application of heat to one or more heating elements at selected positions along the length of a rotating roller so as to intentionally cause localized thermal expansion of the rotating roller, locally vary roller diameter, regulate the calender gap, and thereby control thickness profile along the cross direction.
Stephenson does not cure these deficiencies.
Stephenson does not teach or suggest processing a calender model that is then used to control application of heat to one or more heating elements at selected positions along the length of a rotating roller so as to cause localized thermal expansion of the rotating roller for gap regulation and cross-direction thickness-profile control.”
Applicant’s arguments as discussed above are persuasive. In response to applicant’s arguments and amendments to claims 1, 11 and 17, all the 35 U.S.C. § 103 rejections as set forth in the previous office action have been withdrawn.
Claims 1-10:
Regarding Claim 1 (indicated to have allowable subject matter):
Regarding the previously presented claim, QU et al. (US20230411582A1) and Kinouchi et al. (US20080118262A1) disclose all the elements of previously presented claim as described in the previous office action mailed on 01/12/2026.
Regarding the amended claim, QU et al. (US20230411582A1) further discloses, a first rotating roll and a second rotating roll arranged to form a gap through which the sheet of electrode moves in a machine direction (MD); [¶65: “The first roller 10 and the second roller 20 are arranged in parallel. A gap for allowing the passage of an electrode plate 100 is formed between the first roller 10 and the second roller 20. The protrusion 12 is positioned corresponding to the groove 22, and the protrusion 12 is configured to press against an uncoated region 101 of the electrode plate 100 to cause a plastic deformation of the uncoated region 101.”];
Regarding the amended claim, examiner also notes the applicant admitted prior arts, Chirico et al. (US8415595B2), Dohmeier et al. (US9756686B2) and Simcock (US5059762A) that applicant admits that these references teach Multizone induction heating system where controller regulating power to each coil (selective application of heat to different heating elements along the length of the roller). Therefore, these references teach the limitations: a controller configured to selectively apply heat to one or more of the plurality of first heating elements to cause localized thermal expansion of the first rotating roll.
Regarding the amended claim, Hager (US3310655A) discloses, to selectively apply heat to one or more of the plurality of first heating elements… [ col. 3; line 75 - col. 4; lines 1-2: FIG. 4 illustrates one example of the zones of temperature differentials that may be maintained on the surface of a calender roll…
Examiner notes that as shown in Hager figure 4; different sections/zones of the roller can be selectively heated to different temperatures such as 100, 200, 350 etc. along the length of the roller];
Regarding the amended claim, SONG (CN111890619A) discloses, a controller configured to selectively apply heat to one or more of the plurality of first heating elements… [ page 6; ¶4: During the calendering process, the roller has three high sections, you can set the preset temperature in the temperature controller to increase this section, and control the heating device to increase the temperature of this heating area. In the second low section, The preset temperature of this section is reduced, and the heating device is controlled to reduce the temperature of this heating area,…];
However, regarding the amended claim, none of the above described references, or any of the other prior arts listed in all the previous correspondence taken either alone or in obvious combination disclose, An apparatus, specifically including:
a controller configured to selectively apply heat to one or more of the plurality of first heating elements to cause localized thermal expansion of the first rotating roll,
wherein the localized thermal expansion locally varies a diameter of the first rotating roll to regulate the gap and thereby control a thickness profile of the electrode material layer along a cross direction that is perpendicular to the MD.
(in combination with other elements of the claim)
having all the claimed features of applicant’s instant invention, including:
An apparatus, for controlling the thickness of an electrode material layer on a moving sheet of electrode which includes a metal substrate that is coated on at least one side with an electrode material layer, comprising:
a first rotating roll and a second rotating roll arranged to form a gap through which the sheet of electrode moves in a machine direction (MD);
a plurality of first heating elements each positioned at a selected position along a length of the first rotating roll; and
a controller configured to selectively apply heat to one or more of the plurality of first heating elements to cause localized thermal expansion of the first rotating roll,
wherein the localized thermal expansion locally varies a diameter of the first rotating roll to regulate the gap and thereby control a thickness profile of the electrode material layer along a cross direction that is perpendicular to the MD.
Claims 2-10 are indicated to have allowable subject matter based on their dependencies on claim 1.
Claims 11-16:
Regarding Claim 11 (allowed):
Regarding the previously presented claim, QU et al. (US20230411582A1) and Kinouchi et al. (US20080118262A1) disclose all the elements of previously presented claim as described in the previous office action mailed on 01/12/2026.
Regarding the amended claim, examiner notes the applicant admitted prior arts, Chirico et al. (US8415595B2), Dohmeier et al. (US9756686B2) and Simcock (US5059762A) that applicant admits that these references teach Multizone induction heating system where controller regulating power to each coil (selective application of heat to different heating elements along the length of the roller). Therefore, these references teach the limitations: selectively applying heat, via one or more of the plurality of first heating elements, at one or more selected positions along the length of the first rotating roller.
Regarding the amended claim, Hager (US3310655A) discloses, selectively applying heat, via one or more of the plurality of first heating elements, at one or more selected positions along the length of the first rotating roller… [ col. 3; line 75 - col. 4; lines 1-2: FIG. 4 illustrates one example of the zones of temperature differentials that may be maintained on the surface of a calender roll…
Examiner notes that as shown in Hager figure 4; different sections/zones of the roller can be selectively heated to different temperatures such as 100, 200, 350 etc. along the length of the roller];
Regarding the amended claim, SONG (CN111890619A) also discloses the same limitation, selectively applying heat, via one or more of the plurality of first heating elements, at one or more selected positions along the length of the first rotating roller… [page 6; ¶4: During the calendering process, the roller has three high sections, you can set the preset temperature in the temperature controller to increase this section, and control the heating device to increase the temperature of this heating area. In the second low section, The preset temperature of this section is reduced, and the heating device is controlled to reduce the temperature of this heating area,…];
However, regarding the amended claim, none of the QU et al. (US20230411582A1), Kinouchi et al. (US20080118262A1), Hager (US3310655A), and SONG (CN111890619A), or any of the other prior arts listed in all the previous correspondence taken either alone or in obvious combination disclose, A method, specifically including:
selectively applying heat, via one or more of the plurality of first heating elements, at one or more selected positions along the length of the first rotating roller for locally expanding a diameter of the first rotating roller to regulate the gap and control a thickness of the electrode material layer along a cross direction that is perpendicular to the MD.
(in combination with other elements of the claim)
having all the claimed features of applicant’s instant invention, including:
A method of controlling the thickness of a continuous sheet of electrode that moves in a machine direction (MD) wherein the sheet of electrode comprises a metal substrate that is coated on at least one side with an electrode material, comprising:
advancing the sheet of electrode through a gap defined by a first rotating roller and a second rotating roller wherein a plurality of first heating elements is positioned along a length of the first rotating roller; and
selectively applying heat, via one or more of the plurality of first heating elements, at one or more selected positions along the length of the first rotating roller for locally expanding a diameter of the first rotating roller to regulate the gap and control a thickness of the electrode material layer along a cross direction that is perpendicular to the MD.
Claims 12-16 are allowed based on their dependencies on claim 11.
Claims 17-20:
Regarding Claim 17 (indicated to have allowable subject matter):
Regarding the previously presented claim, QU et al. (US20230411582A1), Kinouchi et al. (US20080118262A1) and Stephenson et al. (US20240372056A1) disclose all the elements of previously presented claim as described in the previous office action mailed on 01/12/2026.
Regarding the amended claim, Kinouchi et al. (US20080118262A1) further discloses, (b) one or more temperature sensors configured to measure a temperature of at least one of the first rotating roller or the second rotating roller that includes the plurality of heating elements; [¶32: a first and a second infrared sensors 56 a and 56 b of a thermopile system, which are temperature sensors to detect the surface temperature of the heat roller 20,];
Regarding the amended claim, Stephenson et al. (US20240372056A1) further discloses, ((c) one or more thickness sensors configured to measure a thickness of the electrode material layer exiting the calendar; [¶51: After the coated foil 12 is pulled between the pressing rollers 37, the width and/or thickness of the coated foil 12 may be measured….The thickness of the coated foil 12 is measured using a thickness gauge 47];
Regarding the amended claim, examiner also notes the applicant admitted prior arts, Chirico et al. (US8415595B2), Dohmeier et al. (US9756686B2) and Simcock (US5059762A) that applicant admits that these references teach Multizone induction heating system where controller regulating power to each coil (selective application of heat to different heating elements along the length of the roller). Therefore, these references teach the limitations: control application of the heat to one or more heating elements of the plurality of heating elements at selected positions along the length of at least one of the first rotating roller or the second rotating roller that includes the one or more heating elements.
However, regarding the amended claim, none of the QU et al. (US20230411582A1), Kinouchi et al. (US20080118262A1) and Stephenson et al. (US20240372056A1), or any of the other prior arts listed in all the previous correspondence taken either alone or in obvious combination disclose, A controller, specifically including:
(iv) process a model of the calender that relates roll temperature of at least one of the first rotating roller or the second rotating roller that includes the one or more heating elements, roll diameter of at least one of the first rotating roller or the second rotating roller that includes the one or more heating elements, the line load and the thickness of the electrode material;
(v) control application of the heat to one or more heating elements of the plurality of heating elements at selected positions along the length of at least one of the first rotating roller or the second rotating roller that includes the one or more heating elements to locally expand the rotating roller and regulate the gap to control a thickness profile of the electrode material layer along a cross direction.
(in combination with other elements of the claim)
having all the claimed features of applicant’s instant invention, including:
A controller for controlling the thickness of an electrode material layer on a moving sheet of electrode which includes a metal substrate that is coated on at least one side with an electrode material layer exiting a calender having a first rotating roller and a second rotating roller which define a gap through which the sheet of electrode passes, wherein at least one of the first rotating roller or the second rotating roller includes a plurality of heating elements that are positioned along a length thereof, the controller comprising:
(a) a processor;
(b) one or more temperature sensors configured to measure a temperature of at least one of the first rotating roller or the second rotating roller that includes the plurality of heating elements;
(c) one or more thickness sensors configured to measure a thickness of the electrode material layer exiting the calendar;
(d) a memory device coupled to the processor and comprising a readable program for execution by the processor to:
(i) receive an input comprising the thickness of an electrode material layer exiting the calender;
(ii) receive an input comprising the temperature of at least one of the first rotating roller or the second rotating roller that includes the one or more heating elements;
(iii) determine a line load applied by the calender;
(iv) process a model of the calender that relates roll temperature of at least one of the first rotating roller or the second rotating roller that includes the one or more heating elements, roll diameter of at least one of the first rotating roller or the second rotating roller that includes the one or more heating elements, the line load and the thickness of the electrode material; and
(v) control application of the heat to one or more heating elements of the plurality of heating elements at selected positions along the length of at least one of the first rotating roller or the second rotating roller that includes the one or more heating elements to locally expand the rotating roller and regulate the gap to control a thickness profile of the electrode material layer along a cross direction.
Claims 18-20 are indicated to have allowable subject matter based on their dependencies on claim 17.
It is for these reasons that applicant's invention defines over the prior art of the record.
Any comments considered necessary by applicant must be submitted no later than the payment of the issue fee and, to avoid processing delays, should preferably accompany the issue fee. Such submissions should be clearly labeled “Comments on Statement of Reasons for Allowance.”
Conclusion
Applicant's amendment necessitated the new ground(s) of rejection presented in this Office action. Accordingly, THIS ACTION IS MADE FINAL. See MPEP § 706.07(a). 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.
Any inquiry concerning this communication or earlier communications from the examiner should be directed to MOHAMMED SHAFAYET whose telephone number is (571)272-8239. The examiner can normally be reached M-F 8:30 AM-5:00 PM.
Examiner interviews are available via telephone, in-person, and video conferencing using a USPTO supplied web-based collaboration tool. To schedule an interview, applicant is encouraged to use the USPTO Automated Interview Request (AIR) at http://www.uspto.gov/interviewpractice.
If attempts to reach the examiner by telephone are unsuccessful, the examiner’s supervisor, Kenneth Lo can be reached at (571) 272-9774. The fax phone number for the organization where this application or proceeding is assigned is 571-273-8300.
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/M.S./
Patent Examiner,
Art Unit 2116
/KENNETH M LO/Supervisory Patent Examiner, Art Unit 2116
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