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 .
Response to Amendment
This office action is in response to remarks and amendments filed on 5/1/2026. Claims 1-20 are pending.
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.
Claims 1-2,4, 6, and 9 are rejected under 35 U.S.C. 103 as being unpatentable over U.S. Patent Publication No. 2019/0393814 ("Chang") in view of U.S. Patent Publication No. 2022/0035418 ("Holung") further in view of Japanese Patent Publication No. JP-2014-071160-A ("Takeda").
Regarding claim 1, Chang discloses a motor apparatus comprising:
a housing (306, Figs. 3A-3B, 10) comprising a first opening (opening on 318, Fig. 3B, 4, 10) positioned on a first side (318, Figs. 4-10), the housing being characterized [as significantly smaller than conventional stepper motors with external encoder units] (paragraph [0033]);
a motor (300, Figs. 3-10) comprising a shaft (304, Figs, 3-10) and positioned inside the housing (306, Fig. 10), the shaft comprising a first portion extending through the first opening (see Fig. 10, shaft 304 extends through opening of 318);
a code wheel (302, Figs. 5-10) coupled to the shaft (304, Fig. 6A via the rotor 322, Fig. 6A) and positioned inside the housing (306, Fig. 10), the code wheel (Figs. 5-6B) comprising a code region (inherent, see Fig. 5, paragraph [0030]); and
an encoder (308, 316, Figs. 8A-10) comprising a second opening (see opening in Fig. 8A-8B), the first portion of the shaft (304, Fig. 10) extending through the second opening (Fig. 10),
the encoder further comprising a first layer (308, Fig.10) and second layer (316, Fig. 10),
the encoder being positioned between the first side (318, Fig. 10) and the code wheel (302, Fig. 10),
the first layer (308, Fig. 10) being positioned between the second layer (316, Fig. 10) and the code wheel (302, Fig. 10),
the first layer (308, Fig.10) comprising a light source (812, Figs. 8A-8B, paragraph [0031]),
the second layer (316, Fig.10) comprising a circuit (PCB, paragraph [0031]), the light source being coupled to the circuit (encoder is mounted on the PCB, paragraphs [0030]-[0031]).
Chang does not disclose that the housing has a diameter no greater than 16mm, that the second opening comprises a C-shape cut extending from a center of the encoder to a periphery of the encoder, and a clearance of 0.5 mm or greater is maintained between the first portion of the shaft and the encoder in the C-shape cut.
However, Holung discloses a stepper motor can include an encoder (paragraph [0130]) and has a diameter less than 16mm (paragraph [0131]).
It would have been an obvious matter of design choice to one of ordinary skill in the art before the effective filing date to size the motor as small as possible as disclosed by Holung in the device of Chang in order to ensure it functions as required, such as accurate rotational control, for a specific application.
Chang in view of Holung does not disclose that the second opening comprises a C-shape cut extending from a center of the encoder to a periphery of the encoder, and a clearance of 0.5 mm or greater is maintained between the first portion of the shaft and the encoder in the C-shape cut.
However, Takeda discloses an opening comprises a C-shape cut (see grooves 31A, 32A, in Figs. 6-7) extending from a center of the encoder to a periphery of the encoder (Figs. 6-7), and a clearance of 0.5 mm or greater is maintained between the first portion of the shaft and the encoder in the C-shape cut (paragraphs [0036], [0038]: “Further, a predetermined gap in the radial direction with respect to the motor shaft 12 (for example, a gap of about 0.5 mm) is provided between the outer peripheral surface of the motor shaft 12 of the second drive unit 22 and the inner peripheral surface of the cutout groove 31A. ) Is formed.”).
It would have been obvious to one of ordinary skill in the art before the effective filing date to use a C-shape cut encoder having a clearance of 0.5mm from the shaft as disclosed by Takeda in the device of Chang in view of Holung in order to facilitate mounting and ensuring that the encoder does not come into contact with the rotating shaft.
Regarding claim 2, Chang in view of Holung and Takeda discloses the motor apparatus of claim 1, and Chang further discloses that:
the housing (306, Figs. 3A-3B, 10) comprising a third opening (opening on 312, Fig. 3B, 4, 10) positioned on a second side (312, Figs. 4-10);
the second side (312, Fig. 10) is opposite relative to the first side (318, Fig. 10); and
the shaft (304, Fig. 10) comprises a second portion extending through the third opening (see Fig. 10, shaft 304 extends through opening of 312).
Regarding claim 4, Chang in view of Holung and Takeda discloses the motor apparatus of claim 1, and Chang further discloses that the circuit further comprises a sensor (814, Fig. 8A, paragraph [0031]).
Regarding claim 6, Chang in view of Holung and Takeda discloses the motor apparatus of claim 1, and Chang further discloses that the encoder further comprises a substrate (semiconductor chip, paragraph [0031], inherently includes a substrate) coupled to the second layer (316, Fig. 8A, paragraph [0031]).
Regarding claim 9, Chang in view of Holung and Takeda discloses the motor apparatus of claim 1, and Chang further discloses that the light source (812, Fig. 8A) is configured to project light to the code region of the code wheel (302, Fig. 10, paragraph [0031]).
Claim 3 is rejected under 35 U.S.C. 103 as being unpatentable over Chang in view of Holung and Takeda further in view of U.S. Patent No. 5,923,032 ("Carlson").
Regarding claim 3. Chang in view of Holung and Takeda discloses the motor apparatus of claim 1, but does not disclose that the first layer comprises a material coupled to the second layer, the material is characterized by a transmittance of at least 50%.
However, Carlson discloses a first layer (60, Fig. 4) comprises a material (clear epoxy, col. 5, lines 11-14) coupled to the second layer (54, Fig. 4), the material is characterized by a transmittance of at least 50% (clear epoxy has a transmittance of at least 50%).
It would have been obvious to one of ordinary skill in the art before the effective filing date to include a material coupled to the second layer as disclosed by Carlson in the device of Chang in view of Holung and Takeda in order to secure the two layers in place.
Claim 5 is rejected under 35 U.S.C. 103 as being unpatentable over Chang in view of Holung and Takeda further in view of U.S. Patent Publication No. 2004/0212261 ("Uchiyama").
Regarding claim 5, Chang in view of Holung and Takeda discloses the motor apparatus of claim 4, and Chang further discloses calculating a rotation of the motor based on an output of the sensor (paragraph [0035]).
Chang in view of Holung and Takeda does not disclose that the circuit further comprises a processor configured to do the calculation.
However, Uchiyama discloses a circuit (42, Fig. 8A) further comprises a processor (25, Fig. 8A) configured to do the rotation calculation (paragraphs [0064], [0088]-[0089]).
It would have been obvious to one of ordinary skill in the art before the effective filing date to include the processor on the circuit as disclosed by Uchiyama in the device of Chang in view of Holung and Takeda in order to obtain a more immediate calculation and provide more accurate control of the rotation of the motor as required.
Claims 7-8 are rejected under 35 U.S.C. 103 as being unpatentable over Chang in view of Holung and Takeda further in view of U.S. Patent Publication No. 2014/0034819 ("Mutschler").
Regarding claim 7, Chang in view of Holung and Takeda discloses the motor apparatus of claim 6, but does not disclose that the encoder further comprises a wire coupled to the circuit and the substrate.
However, Mutschler discloses a wire (54, Fig. 1) coupled to the circuit (26, Fig. 1) and the substrate (30, Fig. 1, paragraph [0044]).
It would have been obvious to one of ordinary skill in the art before the effective filing date to use a wire for coupling components together as disclosed by Mutschler in the device of Chang in view of Holung and Takeda as it is well known in the industry and can accommodate variations in die size or pad placement.
Regarding claim 8, Chang in view of Holung and Takeda discloses the motor apparatus of claim 1, but does not disclose that the second layer comprises a contact coupled to a ball grid array.
However, Mutschler discloses a layer comprises a contact coupled to a ball grid array (paragraph [0041]).
It would have been obvious to one of ordinary skill in the art before the effective filing date to use a contact coupled to a ball grid array as disclosed by Mutschler in the device of Chang in view of Holung and Takeda in order to shorten electrical paths and lower the parasitic impedances.
Claim 10 is rejected under 35 U.S.C. 103 as being unpatentable over Chang in view of Holung and Takeda further in view of U.S. Patent No. 5,103,225 ("Dolan").
Regarding claim 10, Chang discloses a motor apparatus comprising:
a housing (306, Figs. 3A-3B, 10) comprising a first opening (opening on 318, Fig. 3B, 4, 10) positioned on a first side (318, Figs. 4-10), the housing being characterized [as significantly smaller than conventional stepper motors with external encoder units] (paragraph [0033]);
a motor (300, Figs. 3-10) comprising a shaft (304, Figs, 3-10) and positioned inside the housing (306, Fig. 10), the shaft comprising a first portion extending through the first opening (see Fig. 10, shaft 304 extends through opening of 318);
a code wheel (302, Figs. 5-10) coupled to the shaft (304, Fig. 6A via the rotor 322, Fig. 6A) and positioned inside the housing (306, Fig. 10); and
an encoder (308, 316, Figs. 8A-10) comprising a second opening (see opening in Fig. 8A-8B), the first portion of the shaft (304, Fig. 10) extending through the second opening (Fig. 10), the encoder further comprising
a first layer (308, Fig.10) and second layer (316, Fig. 10),
the encoder being positioned between the first side (318, Fig. 10) and the code wheel (302, Fig. 10),
the first layer (308, Fig. 10) being positioned between the second layer (316, Fig. 10) and the code wheel (302, Fig. 10), the second layer (316, Fig.10) comprising a first light source (812, Figs. 8A-8B, is mounted on PCB, paragraph [0031]), the second layer (316, Fig.10) comprising a circuit (PCB, paragraph [0031]) coupled to the first the light source (paragraphs [0030]-[0031]), the circuit comprising a first sensor (814, Fig. 8A, is mounted on PCB, paragraph [0031]).
Chang does not disclose that the housing has a diameter no greater than 16mm, that the second opening comprises a C-shape cut extending from a center of the encoder to a periphery of the encoder, and a clearance of 0.5 mm or greater is maintained between the first portion of the shaft and the encoder in the C-shape cut, nor a second light source and a second sensor.
However, Holung discloses a stepper motor can include an encoder (paragraph [0130]) and has a diameter less than 16mm (paragraph [0131]).
It would have been an obvious matter of design choice to one of ordinary skill in the art before the effective filing date to size the motor as small as possible as disclosed by Holung in the device of Chang in order to ensure is function as required for a specific application.
Chang in view of Holung does not disclose that the second opening comprises a C-shape cut extending from a center of the encoder to a periphery of the encoder, and a clearance of 0.5 mm or greater is maintained between the first portion of the shaft and the encoder in the C-shape cut, nor a second light source and a second sensor.
However, Takeda discloses an opening comprises a C-shape cut (see grooves 31A, 32A, in Figs. 6-7) extending from a center of the encoder to a periphery of the encoder (Figs. 6-7), and a clearance of 0.5 mm or greater is maintained between the first portion of the shaft and the encoder in the C-shape cut (paragraphs [0036], [0038]: “Further, a predetermined gap in the radial direction with respect to the motor shaft 12 (for example, a gap of about 0.5 mm) is provided between the outer peripheral surface of the motor shaft 12 of the second drive unit 22 and the inner peripheral surface of the cutout groove 31A. ) Is formed.”).
It would have been obvious to one of ordinary skill in the art before the effective filing date to use a C-shape cut encoder having a clearance of 0.5mm from the shaft as disclosed by Takeda in the device of Chang in view of Holung in order to facilitate mounting and ensuring that the encoder does not come into contact with the rotating shaft.
Chang in view of Holung and Takeda does not disclose a second light source and a second sensor.
However, Dolan discloses a second light source and a second sensor (see Fig. 6, two encoder track sensors 40 are on PCB 36, Fig. 6, see col. 7, lines 43-46).
It would have been obvious to one of ordinary skill in the art before the effective filing date to include a second light source and a second sensor as disclosed by Dolan in the device of Chang in view of Holung and Takeda in order to improve the resolution of the measurement and create redundancy.
Claim 11 is rejected under 35 U.S.C. 103 as being unpatentable over Chang in view of Holung, Takeda, and Dolan further in view of Carlson.
Regarding claim 11, Chang in view of Holung, Takeda and Dolan discloses the motor apparatus of claim 10, but does not disclose that the first layer comprises a material coupled to the second layer, the material is characterized by a transmittance of at least 50%.
However, Carlson discloses a first layer (60, Fig. 4) comprises a material (clear epoxy, col. 5, lines 11-14) coupled to the second layer (54, Fig. 4), the material is characterized by a transmittance of at least 50% (clear epoxy has a transmittance of at least 50%).
It would have been obvious to one of ordinary skill in the art before the effective filing date to include a material coupled to the second layer as disclosed by Carlson in the device of Chang in view of Holung, Takeda, and Dolan in order to secure the two layers in place.
Claim 12 is rejected under 35 U.S.C. 103 as being unpatentable over Chang in view of Holung, Takeda, and Dolan further in view of U.S. Patent Publication No. 2011/0298411 ("Yoshida").
Regarding claim 12, Chang in view of Holung, Takeda, and Dolan discloses the motor apparatus of claim 10, but does not disclose the first layer further comprises a first block and a second block, the first block is positioned between the first light source and the first sensor, the second block is positioned between the second light source and the second sensor.
However, Yoshida discloses a first block (120, Fig. 4, within 130A, Fig. 2, is a mask with some depth, therefore, under the broadest reasonable interpretation, it is a block, paragraph [0124]) and a second block (120, Fig. 4, within 130B, Fig. 2), the first block is positioned between the first light source (131, Fig. 4, within 130A, Fig. 2) and the first sensor (132, Fig. 4, within 130A, Fig. 2), the second block is positioned between the second light source and the second sensor (130B, Fig. 2, has similar masking block, paragraph [0128]).
It would have been obvious to one of ordinary skill in the art before the effective filing date to use a masking block as disclosed by Yoshida in the device of Chang in view of Holung, Takeda, and Dolan in order to reduce noise and improve detection precision.
Claim 13 is rejected under 35 U.S.C. 103 as being unpatentable over Chang in view of Holung, Takeda, and Dolan further in view of U.S. Patent Publication No. 2001/0013765 ("Yamamoto").
Regarding claim 13, Chang in view of Holung, Takeda, and Dolan discloses the motor apparatus of claim 10, but does not explicitly discloses that the first sensor comprises a photodiode.
However, Yamamoto discloses a first sensor (any one of 5b or 6b, Figs. 1, 5) comprises a photodiode (paragraph [0033]).
It would have been obvious to one of ordinary skill in the art before the effective filing date to use a photodiode as the first sensor as disclosed by Yamamoto in the device of Chang in view of Holung, Takeda, and Dolan in order to generate a photocurrent depending upon the amount of incident light.
Claims 14, 16-17, 19-20 are rejected under 35 U.S.C. 103 as being unpatentable over U.S. Patent Publication No. 2022/0161416 ("Toyama") in view of Holung and Takeda.
Regarding claim 14, Toyama discloses a motor apparatus comprising:
a housing (60, 54, Fig. 2, form housing, paragraph [0020]) comprising a first opening (top opening of 60, Fig. 2) positioned on a first side (top side, Fig. 2);
a motor (5, Fig. 2) comprising a shaft (51, Fig. 2) and positioned inside the housing (54, Fig. 2), the shaft comprising a first portion extending through the first opening (shaft 54 extends to the opening on the top, Fig. 2);
a code wheel (611, Fig. 2) coupled to the shaft (51, Fig. 2, paragraph [0021]) and positioned inside the housing (60, Fig. 2); and
an encoder (61, 612, 62, 63, Fig. 2, encoder interpreted to mean the encoder reader) comprising a second opening (see Fig. 2, 63 has shaft extending through it, therefore it has an opening), the first portion of the shaft extending through the second opening (Fig. 2), the encoder further comprising a first layer (612 interpreted as first layer, Fig. 2) and second layer (624, 63, interpreted as forming second layer, Fig. 2), the encoder being positioned between the first side (top side, Fig. 2) and the code wheel (611, Fig. 2), the first layer (612, Fig. 2) being positioned between the second layer (624, 63, Fig. 1) and the code wheel (611, Fig. 2), the second layer comprising a first circuit (63 is a wiring board, therefore it is a circuit, paragraph [0030]), the first circuit comprising a first magnetic sensor (any one of 624a or 624b, Fig. 2, paragraph [0024]).
Toyama does not disclose that the housing has a diameter no greater than 16mm, that the second opening comprises a C-shape cut extending from a center of the encoder to a periphery of the encoder, and a clearance of 0.5 mm or greater is maintained between the first portion of the shaft and the encoder in the C-shape cut.
However, Holung discloses a stepper motor can include an encoder (paragraph [0130]) and has a diameter less than 16mm (paragraph [0131]).
It would have been an obvious matter of design choice to one of ordinary skill in the art before the effective filing date to size the motor as small as possible as disclosed by Holung in the device of Toyama in order to ensure it functions as required, such as accurate rotational control, for a specific application.
Toyoma in view of Holung does not disclose that the second opening comprises a C-shape cut extending from a center of the encoder to a periphery of the encoder, and a clearance of 0.5 mm or greater is maintained between the first portion of the shaft and the encoder in the C-shape cut.
However, Takeda discloses an opening comprises a C-shape cut (see grooves 31A, 32A, in Figs. 6-7) extending from a center of the encoder to a periphery of the encoder (Figs. 6-7), and a clearance of 0.5 mm or greater is maintained between the first portion of the shaft and the encoder in the C-shape cut (paragraphs [0036], [0038]: “Further, a predetermined gap in the radial direction with respect to the motor shaft 12 (for example, a gap of about 0.5 mm) is provided between the outer peripheral surface of the motor shaft 12 of the second drive unit 22 and the inner peripheral surface of the cutout groove 31A. ) Is formed.”).
It would have been obvious to one of ordinary skill in the art before the effective filing date to use a C-shape cut encoder having a clearance of 0.5mm from the shaft as disclosed by Takeda in the device of Toyama in view of Holung in order to facilitate mounting and ensuring that the encoder does not come into contact with the rotating shaft.
Regarding claim 16, Toyama in view of Holung and Takeda discloses the motor apparatus of claim 14, and Toyama further discloses that the first circuit further comprises a second magnetic sensor (other one of 624a or 624b, Fig. 2, paragraph [0024]).
Regarding claim 17, Toyama in view of Holung and Takeda discloses the motor apparatus of claim 14, and Toyama further discloses that the second layer (63, Fig. 2) further comprises a second circuit (under the broadest reasonable interpretation, first and second circuits are merely labels with no limiting effect given that there is no structure defining the first and second circuits, therefore, the right side of 63 is interpreted as the first circuit and the left side of 63 is interpreted as the second circuit), the second circuit comprises a second magnetic sensor (624b, Fig. 2).
Regarding claim 19, Toyama in view of Holung and Takeda discloses the motor apparatus of claim 14, and Toyama further discloses that the first circuit further comprises a processor (64, Fig. 2, paragraph [0033]) configured to calculate a rotation of the motor based on an output of the first magnetic sensor (paragraph [0033]).
Regarding claim 20, Toyama in view of Holung and Takeda discloses the motor apparatus of claim 14, and Toyama further discloses that the code wheel comprises a code region (detection pattern not shown, paragraph [0021]).
Claim 15 is rejected under 35 U.S.C. 103 as being unpatentable over Toyama in view of Holung and Takeda further in view of U.S. Patent Publication No. 2017/0264159 ("Kitamura").
Regarding claim 15, Toyama in view of Holung and Takeda discloses the motor apparatus of claim 14, but does not disclose that the first magnetic sensor comprises a Hall effect sensor.
However, Kitamura discloses that a first magnetic sensor comprises a Hall effect sensor (paragraph [0028]).
It would have been obvious to one of ordinary skill in the art before the effective filing date to include a Hall effect sensor as disclosed by Kitamura in the device of Toyama in view of Holung and Takeda in order to detect the magnetic pole position of the rotor.
Claim 18 is rejected under 35 U.S.C. 103 as being unpatentable over Toyama in view of Holung and Takeda further in view of Carlson.
Regarding claim 18, Toyama in view of Holung and Takeda discloses the motor apparatus of claim 14, and Toyama further discloses that the first layer is coupled to the second layer (see paragraph [0030], this is typically done with solder or other adhesive), but does not disclose that the first layer comprises a material coupled to the second layer.
However, Carlson discloses a first layer (60, Fig. 4) comprises a material (clear epoxy, col. 5, lines 11-14) coupled to the second layer (54, Fig. 4).
It would have been obvious to one of ordinary skill in the art before the effective filing date to include a material coupled to the second layer as disclosed by Carlson in the device of Toyama in view of Holung and Takeda discloses the in order to secure the two layers in place.
Response to Arguments
Applicant’s arguments with respect to claims 1, 10, and 14 have been considered but are moot because the new ground of rejection does not rely on any reference applied in the prior rejection of record for any teaching or matter specifically challenged in the argument.
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.
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/MONICA T TABA/Examiner, Art Unit 2878
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