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 .
Continued Examination Under 37 CFR 1.114
A request for continued examination under 37 CFR 1.114, including the fee set forth in 37 CFR 1.17(e), was filed in this application after final rejection. Since this application is eligible for continued examination under 37 CFR 1.114, and the fee set forth in 37 CFR 1.17(e) has been timely paid, the finality of the previous Office action has been withdrawn pursuant to 37 CFR 1.114. Applicant's submission filed on 04/07/2026 has been entered.
Response to Amendment
The Amendments filed 03/20/2026 responsive to the Office Action filed 02/25/2026 has been entered. Claims 1, 8 and 16 have been amended. Claims 1, 4, 5, 7-10, 13-16, 19, 22 and 24-30 are pending in this application.
Response to Arguments
The rejection of claims 4, 5, 9, 10, 14 and 25-30 under 112(b) has been withdrawn in view of the amendments.
Applicant’s arguments, see Amendment filed 03/20/2026, with respect to claims 1, 8 and 16 under 103 rejection have been fully considered but are not persuasive.
Applicant argues that “The Office Action cites column 7, lines 41-61 of Engwall to show the claimed tack-free gel releasable gap filler. However, in column 7, lines 41-61 Engwall explicitly teaches covering the Engwall self-skinning foam with a smooth molded caul sheet. A caul sheet is a tool and is not part of the Engwall composite part. This means the composite part of Engwall is not directly over the self-skinning foam of Engwall as claimed. In addition, Engwall covers the caul sheet with a vacuum bag. The vacuum bag of Engwall is also a tool and is not part of the Engwall composite part. Consequently, the composite part of Engwall is most definitely not directly over the self-skinning foam of Engwall as claimed. The Office Action cannot properly read the claims on the self-skinning foam of Engwall without the caul sheet and vacuum bag of Engwall abrogating the claimed limitation of applying an uncured composite material directly over the releasable gap filler and onto the mold without a release agent or a release layer between the uncured composite material and the releasable gap filler.” (page 10)
These arguments are found to be unpersuasive because:
Applicant misinterpreted the reference of Engwall. Engwall clearly teaches the claimed limitation of applying an uncured composite material directly over the releasable gap filler and onto the mold (“The grooves and/or recesses receive a sacrificial material 64 (see FIG. 3) on which the constituent materials forming the composite part 220 can be laid up on the top plate 32 flush with the upper surface 60.”, co 6 li 56-60). The paragraph which Applicant cited in the arguments (column 7, lines 41-61) teaches curing the sacrificial material 64 in the groove 62 in the expanded condition. The caul sheet and the vacuum bag are used only during curing the sacrificial material 64 to make the sacrificial material 64 in the groove 62 flush with the upper surface 60 of the top plate 32.
Claim Rejections - 35 USC § 103
In the event the determination of the status of the application as subject to AIA 35 U.S.C. 102 and 103 (or as subject to pre-AIA 35 U.S.C. 102 and 103) is incorrect, any correction of the statutory basis (i.e., changing from AIA to pre-AIA ) for the rejection will not be considered a new ground of rejection if the prior art relied upon, and the rationale supporting the rejection, would be the same under either status.
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.
This application currently names joint inventors. In considering patentability of the claims the examiner presumes that the subject matter of the various claims was commonly owned as of the effective filing date of the claimed invention(s) absent any evidence to the contrary. Applicant is advised of the obligation under 37 CFR 1.56 to point out the inventor and effective filing dates of each claim that was not commonly owned as of the effective filing date of the later invention in order for the examiner to consider the applicability of 35 U.S.C. 102(b)(2)(C) for any potential 35 U.S.C. 102(a)(2) prior art against the later invention.
Claims 1, 4, 5, 7-10, 13-16, 19, 22 and 24-30 are rejected under 35 U.S.C. 103 as being unpatentable over Engwall et al. (US 7,141,191) in view of Knutson et al. (US 2023/0391026). Additional Supporting evidence provided herewith by ROJAC (“Integral Skin Foam”, 2021) (All of record).
With respect to claim 1, Engwall teaches a method of forming a composite product (“a method and apparatus for use in forming, constructing and/or assembling a composite part”, co 3 li 50-52):
applying a releasable gap filler within a recess of a mold (“Upwardly opening recesses are machined into the upper surface 60 of the top plate 32”, co 6 li 44-46; “The grooves and/or recesses receive a sacrificial material 64”, co 6 li 56-57);
curing the releasable gap filler to a tack-free gel (“The sacrificial material 64 …The preferred material used in this embodiment is B.F. Goodrich #PL657 heat expandable self-skinning foam. It can be applied as a bead or a cut strip in the groove 62 and covered with a smooth molded caul sheet. Vacuum tracks may be molded into the underside of the caul sheet by laying a bead of sealing tape. The sacrificial material 64 is expanded and cured in the holes and/or grooves by covering the holes and/or groove with the caul sheet and a vacuum bag, and sealing the edges of the vacuum bag to the facing surface 60 of the top plate 32 with putty-like sealing tape known in the art for this purpose. The vacuum bag is evacuated to a vacuum of about 10 inches of vacuum and vacuum is applied in the vacuum tracks to help hold the caul sheet down against the top surface 60 of the tool over the groove 62 while the foam expands against the underside of the caul sheet over the groove 62 and then cures in the expanded condition.”, co 7 li 41-61; Additional supporting reference provided herewith (ROJAC) teaches that “Integral skin PU foam is otherwise known as “self-skinning foam” gives you a component with a tough, flexible skin that is moulded over a softer foam core, this type of polyurethane foam moulding is ideal for many applications including grab handles, armrests, headrests etc. Integral skin polyurethane moulded foam has a moulded, flexible, tear-resistant outer skin. This skin is formed during the moulding process and protects a microcellular foam core with a predefined hardness.” (“What is integral skin foam?”, pages 1-2). Namely, the cured self-skinning foam is tack-free.);
applying an uncured composite material directly over the releasable gap filler and onto the mold without a release agent or a release layer between the uncured composite material and the releasable gap filler (“The grooves and/or recesses receive a sacrificial material 64 (see FIG. 3) on which the constituent materials forming the composite part 220 can be laid up on the top plate 32 flush with the upper surface 60.”, co 6 li 56-60; “A release coating can be previously applied to the tool face 60 to ensure that the composite part will not adhere to the tool face.”, co 7 li 66-co 8 li 1);
curing the uncured composite material to form a cured composite material on the mold (“The lay-up tool 30 is transferred to an autoclave where pressure and heat causing the preimpregnated resin in the plies to flow and then cure while any out gassing from the curing resin is evacuated through the vacuum line.”, co 8 li 10-14), wherein the releasable gap filler is configured to not adhere to the cured composite material (“The sacrificial material 64 …The preferred material used in this embodiment is B.F. Goodrich #PL657 heat expandable self-skinning foam.”, co 7 41, 45-47);
trimming the cured composite material over the recess such that trimming the cured composite material cuts through the cured composite material and into the releasable gap filler (“Once the composite part 220 is molded or formed within the lay-up tool 30, the tool is transported and positioned on the machine tool bed 42.”, co 9 li 32-34; “the controller guides a cutter 68 along a predefined path to cut the peripheral edge of the composite part... the cutter extends beyond the facing surface 60 of the top plate 32 and cuts into the sacrificial material 64 within the groove 62. Again, the cutting and other machining can be achieved without having to remove the composite part 220 from the lay-up tool 30.”, co 13 li 16-27); and
removing the cured composite material from the mold and a remaining releasable gap filler, wherein the remaining releasable gap filler remains within the mold and does not adhere to the cured composite material when cured composite material is removed from the mold (“the composite part can be removed from the lay-up tool 30 following the drilling of the positioning holes 244”, co 14 li 42-44; “The sacrificial material 64 …The preferred material used in this embodiment is B.F. Goodrich #PL657 heat expandable self-skinning foam.”, co 7 41, 45-47).
Engwall further teaches removal of the sacrificial material 64 from the groove 62 after the composite part is removal from the lay-up tool (co 7 li 7-8), but does not explicitly teach applying an additional releasable gap filler over the remaining releasable gap filler in the recess after trimming; and applying a subsequent uncured composite material directly over the additional releasable gap filler and onto the mold.
In the same field of endeavor, composite material processing, Knutson teaches that after any desired processing of uncured composite material 402, tool 200 can be used to support additional uncured composite materials for cutting, in some illustrative examples, after removing uncured composite material 402 from tool 200 and prior to performing cutting operations on additional uncured composite materials on tool 200, remaining groove filler 508 is removed from groove 204 of tool 200, additional groove filler is placed into groove 204 after removal of remaining groove filler 508, and in some illustrative examples, after removing uncured composite material 402 from tool 200 and prior to performing cutting operations on additional uncured composite materials on tool 200, an additional groove filler is placed on top of remaining groove filler 508 to refill groove 204 of tool 200 (Pa [0069]).
It would have been obvious to one of ordinary skill in the art before the effective filing date of the invention to modify Engwall with the teachings of Knutson and substitute placing an additional gap filler on top of remaining gap filler for removing the sacrificial material out of the groove in order to refill the groove of mold and applying a subsequent uncured composite material directly over the additional releasable gap filler onto the mold.
With respect to claim 4, Engwall as applied to claim 1 above further teaches removing the additional releasable gap filler and the remaining releasable gap filler from the recess after the cured composite material is removed from the mold (“To facilitate removal of the sacrificial material 64 from the groove 62 after the composite part is removal from the lay-up tool, a separate strip of resin-impregnated fabric may be inserted into the groove 62 prior to applying the sacrificial material therein.”, co 7 li 6-11), but is silent to removing the additional releasable gap filler and the remaining releasable gap filler from the recess by hand.
However, one would have found it obvious to perform the step of removing the releasable gap filler from the recess either by hand or by mechanical or automatic means, since it has been held that to provide a mechanical or automatic means to replace manual activity, which accomplishes the same result, is within the ambit of a person of ordinary skill in the art. See In re Venner, 120 USPQ 192 (CCPA 1958) (see MPEP § 2144.04).
With respect to claim 5, Engwall as applied to claim 4 above does not explicitly teach applying a second releasable gap filler into the recess after removing the additional releasable gap filler and the remaining releasable gap filler; and applying a subsequent uncured composite material directly over the second releasable gap filler and onto the mold. However, one would have found it obvious to perform the claimed steps in order to start a subsequent manufacturing of a new composite product using the same mold.
With respect to claims 7 and 28, Engwall as applied to claims 1 and 5 above further teaches shaping the releasable gap filler to match a contour of a surface of the mold prior to applying the uncured composite material directly over the releasable gap filler (“It can be applied as a bead or a cut strip in the groove 62 and covered with a smooth molded caul sheet. Vacuum tracks may be molded into the underside of the caul sheet by laying a bead of sealing tape. The sacrificial material 64 is expanded and cured in the holes and/or grooves by covering the holes and/or groove with the caul sheet and a vacuum bag, and sealing the edges of the vacuum bag to the facing surface 60 of the top plate 32 with putty-like sealing tape known in the art for this purpose. The vacuum bag is evacuated to a vacuum of about 10 inches of vacuum and vacuum is applied in the vacuum tracks to help hold the caul sheet down against the top surface 60 of the tool over the groove 62 while the foam expands against the underside of the caul sheet over the groove 62 and then cures in the expanded condition.”, co 7 li 47-61).
With respect to claim 8, Engwall teaches a method of forming a composite product (“a method and apparatus for use in forming, constructing and/or assembling a composite part”, co 3 li 50-52):
placing an uncured composite material over and in direct contact with a releasable gap filler within a recess in a mold without a release agent or a release layer between the uncured composite material and the releasable gap filler (“Upwardly opening recesses are machined into the upper surface 60 of the top plate 32”, co 6 li 44-46; “The grooves and/or recesses receive a sacrificial material 64 (see FIG. 3) on which the constituent materials forming the composite part 220 can be laid up on the top plate 32 flush with the upper surface 60.”, co 6 li 56-60; “A release coating can be previously applied to the tool face 60 to ensure that the composite part will not adhere to the tool face.”, co 7 li 66-co 8 li 1);
curing the releasable gap filler to a tack-free gel (“The sacrificial material 64 …The preferred material used in this embodiment is B.F. Goodrich #PL657 heat expandable self-skinning foam. It can be applied as a bead or a cut strip in the groove 62 and covered with a smooth molded caul sheet. Vacuum tracks may be molded into the underside of the caul sheet by laying a bead of sealing tape. The sacrificial material 64 is expanded and cured in the holes and/or grooves by covering the holes and/or groove with the caul sheet and a vacuum bag, and sealing the edges of the vacuum bag to the facing surface 60 of the top plate 32 with putty-like sealing tape known in the art for this purpose. The vacuum bag is evacuated to a vacuum of about 10 inches of vacuum and vacuum is applied in the vacuum tracks to help hold the caul sheet down against the top surface 60 of the tool over the groove 62 while the foam expands against the underside of the caul sheet over the groove 62 and then cures in the expanded condition.”, co 7 li 41-61; Additional supporting reference provided herewith (ROJAC) teaches that “Integral skin PU foam is otherwise known as “self-skinning foam” gives you a component with a tough, flexible skin that is moulded over a softer foam core, this type of polyurethane foam moulding is ideal for many applications including grab handles, armrests, headrests etc. Integral skin polyurethane moulded foam has a moulded, flexible, tear-resistant outer skin. This skin is formed during the moulding process and protects a microcellular foam core with a predefined hardness.” (“What is integral skin foam?”, pages 1-2). Namely, the cured self-skinning foam is tack-free.);
curing the uncured composite material while in direct contact with the releasable gap filler to form a cured composite material (“The lay-up tool 30 is transferred to an autoclave where pressure and heat causing the preimpregnated resin in the plies to flow and then cure while any out gassing from the curing resin is evacuated through the vacuum line.”, co 8 li 10-14), wherein the releasable gap filler is configured to not adhere to the cured composite material (“The sacrificial material 64 …The preferred material used in this embodiment is B.F. Goodrich #PL657 heat expandable self-skinning foam.”, co 7 41, 45-47);
trimming the cured composite material prior to removing the cured composite material from the mold, wherein trimming comprises cutting through the cured composite material and into the releasable gap filler to form a cut gap filler (“Once the composite part 220 is molded or formed within the lay-up tool 30, the tool is transported and positioned on the machine tool bed 42.”, co 9 li 32-34; “the controller guides a cutter 68 along a predefined path to cut the peripheral edge of the composite part... the cutter extends beyond the facing surface 60 of the top plate 32 and cuts into the sacrificial material 64 within the groove 62. Again, the cutting and other machining can be achieved without having to remove the composite part 220 from the lay-up tool 30.”, co 13 li 16-27); and
removing the cured composite material from the mold and the cut gap filler, leaving the releasable cut gap filler within the recess (“the composite part can be removed from the lay-up tool 30 following the drilling of the positioning holes 244”, co 14 li 42-44).
Engwall further teaches removal of the sacrificial material 64 from the groove 62 after the composite part is removal from the lay-up tool (co 7 li 7-8), but does not explicitly teach applying an additional releasable gap filler over the cut gap filler; and applying a subsequent composite material directly over and in direct contact with the additional releasable gap filler.
In the same field of endeavor, composite material processing, Knutson teaches that after any desired processing of uncured composite material 402, tool 200 can be used to support additional uncured composite materials for cutting, in some illustrative examples, after removing uncured composite material 402 from tool 200 and prior to performing cutting operations on additional uncured composite materials on tool 200, remaining groove filler 508 is removed from groove 204 of tool 200, additional groove filler is placed into groove 204 after removal of remaining groove filler 508, and in some illustrative examples, after removing uncured composite material 402 from tool 200 and prior to performing cutting operations on additional uncured composite materials on tool 200, an additional groove filler is placed on top of remaining groove filler 508 to refill groove 204 of tool 200 (Pa [0069]).
It would have been obvious to one of ordinary skill in the art before the effective filing date of the invention to modify Engwall with the teachings of Knutson and substitute placing an additional gap filler on top of the cut gap filler for removing the sacrificial material out of the groove in order to refill the groove of mold and applying a subsequent composite material directly over and in direct contact with the additional releasable gap filler.
With respect to claim 9, Engwall as applied to claim 8 above further teaches removing the additional releasable gap filler and the cut gap filler from the recess after removing the cured composite material from the mold (“To facilitate removal of the sacrificial material 64 from the groove 62 after the composite part is removal from the lay-up tool, a separate strip of resin-impregnated fabric may be inserted into the groove 62 prior to applying the sacrificial material therein.”, co 7 li 6-11).
With respect to claim 10, Engwall as applied to claim 9 above does not explicitly teach applying a second releasable gap filler into the recess after removing the additional releasable gap filler and the cut gap filler; and applying a subsequent uncured composite material directly over and in direct contact with the second releasable gap filler. However, one would have found it obvious to perform the claimed steps in order to start a subsequent manufacturing of a new composite product using the same mold.
With respect to claim 13, Engwall as applied to claim 8 above further teaches applying release material onto the mold and the recess (“A release coating can be previously applied to the tool face 60 to ensure that the composite part will not adhere to the tool face.”, co 7 li 66-co 8 li 1). but silent to applying release material onto the mold and the recess after a plurality of uses.
However, one would have found it obvious to coat the release agent onto the mold and the recess after a plurality of uses in order to ensure that the composite part will not adhere to the tool face after a plurality of uses.
With respect to claim 14, Engwall as applied to claim 9 above further teaches that removing the additional releasable gap filler and the cut gap filler comprises: removing the additional releasable gap filler and the cut gap filler using a plastic scraper or other non-marring hand tools (“To facilitate removal of the sacrificial material 64 from the groove 62 after the composite part is removal from the lay-up tool, a separate strip of resin-impregnated fabric may be inserted into the groove 62 prior to applying the sacrificial material therein.”, co 7 li 6-11).
With respect to claim 15, Engwall as applied to claim 8 above further teaches applying the releasable gap filler within a hole in the mold (“recesses located on the top plate 32 where holes can be drilled through the composite part 220… The grooves and/or recesses receive a sacrificial material 64”, co 6 li 51-53, 56-57); and drilling through the cured composite material and into the releasable gap filler within the hole (“the controller 46 guides a drill to match drill a plurality of securing holes 248 through the hardware 240, 241 and into the composite part 220 while the composite part is still in the lay-up tool 30.”, co 12 li 32-35).
With respect to claim 16, Engwall teaches a method of forming a composite product (“a method and apparatus for use in forming, constructing and/or assembling a composite part”, co 3 li 50-52):
applying a releasable gap filler into trim channels in a mold (“The recesses include groove 62, such as a peripheral groove, located on the top plate 32 where the peripheral edge of the part can be cut”, co 6 li 49-51; “The grooves and/or recesses receive a sacrificial material 64”, co 6 li 56-57);
applying the releasable gap filler into drill holes in the mold (“recesses located on the top plate 32 where holes can be drilled through the composite part 220… The grooves and/or recesses receive a sacrificial material 64”, co 6 li 51-53, 56-57);
curing the releasable gap filler to a tack-free gel (“The sacrificial material 64 …The preferred material used in this embodiment is B.F. Goodrich #PL657 heat expandable self-skinning foam. It can be applied as a bead or a cut strip in the groove 62 and covered with a smooth molded caul sheet. Vacuum tracks may be molded into the underside of the caul sheet by laying a bead of sealing tape. The sacrificial material 64 is expanded and cured in the holes and/or grooves by covering the holes and/or groove with the caul sheet and a vacuum bag, and sealing the edges of the vacuum bag to the facing surface 60 of the top plate 32 with putty-like sealing tape known in the art for this purpose. The vacuum bag is evacuated to a vacuum of about 10 inches of vacuum and vacuum is applied in the vacuum tracks to help hold the caul sheet down against the top surface 60 of the tool over the groove 62 while the foam expands against the underside of the caul sheet over the groove 62 and then cures in the expanded condition.”, co 7 li 41-61; Additional supporting reference provided herewith (ROJAC) teaches that “Integral skin PU foam is otherwise known as “self-skinning foam” gives you a component with a tough, flexible skin that is moulded over a softer foam core, this type of polyurethane foam moulding is ideal for many applications including grab handles, armrests, headrests etc. Integral skin polyurethane moulded foam has a moulded, flexible, tear-resistant outer skin. This skin is formed during the moulding process and protects a microcellular foam core with a predefined hardness.” (“What is integral skin foam?”, pages 1-2). Namely, the cured self-skinning foam is tack-free.);
placing an uncured composite material onto the mold and in direct contact with the releasable gap filler without a release agent or a release layer between the uncured composite material and the releasable gap filler (“The grooves and/or recesses receive a sacrificial material 64 (see FIG. 3) on which the constituent materials forming the composite part 220 can be laid up on the top plate 32 flush with the upper surface 60.”, co 6 li 56-60; “A release coating can be previously applied to the tool face 60 to ensure that the composite part will not adhere to the tool face.”, co 7 li 66-co 8 li 1);
curing the uncured composite material to form a cured composite material (“The lay-up tool 30 is transferred to an autoclave where pressure and heat causing the preimpregnated resin in the plies to flow and then cure while any out gassing from the curing resin is evacuated through the vacuum line.”, co 8 li 10-14), wherein the releasable gap filler is configured to not adhere to the cured composite material (“The sacrificial material 64 …The preferred material used in this embodiment is B.F. Goodrich #PL657 heat expandable self-skinning foam.”, co 7 41, 45-47);
trimming the cured composite material at locations over the trim channels in the mold such that trimming removes some releasable gap filler from the trim channels (“Once the composite part 220 is molded or formed within the lay-up tool 30, the tool is transported and positioned on the machine tool bed 42.”, co 9 li 32-34; “the controller guides a cutter 68 along a predefined path to cut the peripheral edge of the composite part... the cutter extends beyond the facing surface 60 of the top plate 32 and cuts into the sacrificial material 64 within the groove 62. Again, the cutting and other machining can be achieved without having to remove the composite part 220 from the lay-up tool 30.”, co 13 li 16-27);
drilling into the cured composite material at locations over the drill holes such that drilling removes some releasable gap filler from the drill holes (“the controller 46 guides a drill to match drill a plurality of securing holes 248 through the hardware 240, 241 and into the composite part 220 while the composite part is still in the lay-up tool 30.”, co 12 li 32-35); and
removing the cured composite material from the mold, leaving a remaining releasable gap filler within the trim channels (“the composite part can be removed from the lay-up tool 30 following the drilling of the positioning holes 244”, co 14 li 42-44).
Engwall further teaches removal of the sacrificial material 64 from the groove 62 after the composite part is removal from the lay-up tool (co 7 li 7-8), but does not explicitly teach applying additional releasable gap filler over the remaining releasable gap filler.
In the same field of endeavor, composite material processing, Knutson teaches that after any desired processing of uncured composite material 402, tool 200 can be used to support additional uncured composite materials for cutting, in some illustrative examples, after removing uncured composite material 402 from tool 200 and prior to performing cutting operations on additional uncured composite materials on tool 200, remaining groove filler 508 is removed from groove 204 of tool 200, additional groove filler is placed into groove 204 after removal of remaining groove filler 508, and in some illustrative examples, after removing uncured composite material 402 from tool 200 and prior to performing cutting operations on additional uncured composite materials on tool 200, an additional groove filler is placed on top of remaining groove filler 508 to refill groove 204 of tool 200 (Pa [0069]).
It would have been obvious to one of ordinary skill in the art before the effective filing date of the invention to modify Engwall with the teachings of Knutson and substitute placing an additional gap filler on top of remaining gap filler for removing the sacrificial material out of the groove in order to refill the groove of mold before another operation of a new uncured composite material.
With respect to claim 19, Engwall as applied to claim 8 above further teaches removing the remaining releasable gap filler from within the trim channels without use of abrading or sanding (“To facilitate removal of the sacrificial material 64 from the groove 62 after the composite part is removal from the lay-up tool, a separate strip of resin-impregnated fabric may be inserted into the groove 62 prior to applying the sacrificial material therein.”, co 7 li 6-11).
With respect to claim 25, Engwall as applied to claim 16 above further teaches removing the additional releasable gap filler and the remaining releasable gap filler after the cured composite material is removed from the mold (“To facilitate removal of the sacrificial material 64 from the groove 62 after the composite part is removal from the lay-up tool, a separate strip of resin-impregnated fabric may be inserted into the groove 62 prior to applying the sacrificial material therein.”, co 7 li 6-11).
With respect to claim 26, Engwall as applied to claim 25 above does not explicitly teach applying a second releasable gap filler after removing the additional releasable gap filler and the remaining releasable gap filler; and applying a subsequent uncured composite material directly over the second releasable gap filler and onto the mold. However, one would have found it obvious to perform the claimed steps in order to start a subsequent manufacturing of a new composite product using the same mold.
With respect to claim 27, Engwall as applied to claim 25 above further teaches that removing the additional releasable gap filler and the remaining releasable gap filler comprises: removing the additional releasable gap filler and the remaining releasable gap filler using a plastic scraper or other non-marring hand tools (“To facilitate removal of the sacrificial material 64 from the groove 62 after the composite part is removal from the lay-up tool, a separate strip of resin-impregnated fabric may be inserted into the groove 62 prior to applying the sacrificial material therein.”, co 7 li 6-11).
With respect to claims 22, 24, 29 and 30, Engwall as applied to claims 8, 10, 16 and 26 above further teaches shaping the releasable gap filler to match a contour of a surface of the mold prior to applying the uncured composite material directly over the releasable gap filler (“It can be applied as a bead or a cut strip in the groove 62 and covered with a smooth molded caul sheet. Vacuum tracks may be molded into the underside of the caul sheet by laying a bead of sealing tape. The sacrificial material 64 is expanded and cured in the holes and/or grooves by covering the holes and/or groove with the caul sheet and a vacuum bag, and sealing the edges of the vacuum bag to the facing surface 60 of the top plate 32 with putty-like sealing tape known in the art for this purpose. The vacuum bag is evacuated to a vacuum of about 10 inches of vacuum and vacuum is applied in the vacuum tracks to help hold the caul sheet down against the top surface 60 of the tool over the groove 62 while the foam expands against the underside of the caul sheet over the groove 62 and then cures in the expanded condition.”, co 7 li 47-61).
Conclusion
Any inquiry concerning this communication or earlier communications from the examiner should be directed to YUNJU KIM whose telephone number is (571)270-1146. The examiner can normally be reached on 8:00-4:00 EST M-Th; Flexing Fri.
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/YUNJU KIM/Primary Examiner, Art Unit 1742
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