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 § 112
The following is a quotation of 35 U.S.C. 112(b):
(b) CONCLUSION.—The specification shall conclude with one or more claims particularly pointing out and distinctly claiming the subject matter which the inventor or a joint inventor regards as the invention.
The following is a quotation of 35 U.S.C. 112 (pre-AIA ), second paragraph:
The specification shall conclude with one or more claims particularly pointing out and distinctly claiming the subject matter which the applicant regards as his invention.
Claims 1-9 and 13-17 are rejected under 35 U.S.C. 112(b) or 35 U.S.C. 112 (pre-AIA ), second paragraph, as being indefinite for failing to particularly point out and distinctly claim the subject matter which the inventor or a joint inventor (or for applications subject to pre-AIA 35 U.S.C. 112, the applicant), regards as the invention.
Claim 1 recites, in in lines 3-5, “a matrix powder comprising a zirconia co-doped with a transition metal or a lanthanide and a ceramic filler precursor powder comprising a hydrate or a hydroxyl group”.
It is unclear if the claim is intended to include, ‘ “a zirconia co-doped with a transition metal” or “a lanthanide and a ceramic filler precursor powder comprising a hydrate or a hydroxyl group” ‘ or for example: “a zirconia co-doped with a transition metal or a lanthanide, and a ceramic filler precursor powder comprising a hydrate or a hydroxyl group” and renders the claim indefinite for failing to particularly point out and distinctly claim the subject matter which the inventor regards as the invention.
Claim 1 recites the limitation "the loading rate of the mixture" in lines 5-6. There is insufficient antecedent basis for this limitation in the claim.
Claims 2-9 and 13-17 are rejected based on their dependencies.
Claim 5 recites the limitation "the loading rate" in line 2. There is insufficient antecedent basis for this limitation in the claim.
Claim 9 recites the limitation "a pulverulent composition" in line 2. However, there already exists antecedent basis for “a pulverulent composition” in claim 1, line 3; therefore, it is unclear if there is intended to be a second “a pulverulent composition” in claim 9, or if the claim is referring to the “a pulverulent composition” from claim 1.
Claim 13 recites the limitation "a pulverulent composition" in lines 1-2. However, there already exists antecedent basis for “a pulverulent composition” in claim 1, line 3; therefore, it is unclear if there is intended to be a second “a pulverulent composition” in claim 9, or if the claim is referring to the “a pulverulent composition” from claim 1.
Claim 14 recites, “flash sintering” in line 2. However; claim 1, already recites “reactive sintering” in line 9. The Examiner understands “reactive sintering” to be the process of sintering the matrix powder composition through a chemical reaction of the precursor powders under pressure and a particular temperature, and “flash sintering” to be the process of sintering the matrix powder composition by applying a voltage under pressure. It is unclear from the language of the claims if reactive sintering step of claim 1 is also intended to include flash sintering or if the step is mutually exclusive.
Allowable Subject Matter
Claims 1-9 and 13-17 would be allowable if rewritten or amended to overcome the rejection(s) under 35 U.S.C. 112(b) or 35 U.S.C. 112 (pre-AIA ), 2nd paragraph, set forth in this Office action.
Regarding claim 1,
Zhao Meng et al. (Properties of Yttria-Stabilized-Zirconia Based Ceramic Composite Abradable Coastings) discloses a 8mol% YSZ “Yttria-stabilized Zirconia” and LaPO4 “Lanthanum Phosphate” sintered by either pressureless sintering at 1600C, and spark plasma sintering (e.g., Flash Sintering) at 1250C at 20MPa (see “Material preparation”).
However, Zhao Meng et al. does not disclose, teach, or suggest, “a ceramic filler hydrated precursor powder comprising a hydrate or hydroxyl group”, “compressing the obtained pulverulent composition at a pressure greater than 150 MPa”, “reactive sintering of the obtained pulverulent composition during which the compression is maintained, at a temperature of less than 550C”, and “the particles of the matrix powder in the sintered pulverulent composition have an aspect ratio of 2 or greater.”
Roussaddle Melanie et al. (“Phase Evolution and Sinterability of Lanthanum Phosphate – Towards a Below 600C Spark Plasma Sintering” teaches using a Lanthanum Phosphate hydrate (See Material and Method) “a lanthanide and a ceramic filler hydrated precursor powder comprising a hydrate or hydroxyl group” in a low temperature sintering (< 350C) at 400MPA.
However, they do not teach, “A loading rate of the mixture being comprised between 5 and 40% in volume” or “and the particle of the matrix powder in the sintered pulverulent composition have an aspect ratio of 2 or greater”
Selezneff et al. teaches in the field of abradable layers for gas turbine engines, nanometric ceramic particles having a number-average form factor grater than or equal to 3 ([0007]) and, “The presence of nanometric ceramic particles in the indicated contents advantageously further improves the erosion resistance of the abradable layer obtained without affecting the abradability. [0012]”
Neither Zhao Meng et al., Roussaddle Melanie et al., or Selezneff et al. disclose, teach, or suggest, “wherein the loading rate of the mixture being comprises between 5 and 40% in volume”
Claims 2-9 and 13-17 would be allowable based on their dependencies.
Conclusion
The prior art made of record and not relied upon is considered pertinent to applicant's disclosure.
US PGPUB 2021/0172331 A1 discloses an abradable coating for rotating blades of a turbomachine.
WO 2017/158265 A1 discloses a method for manufacturing an abradable plate and repairing a turbine shroud.
FR 3044945 A1 discloses an abradable coating with variable density.
US PGPUB 2017/0088471 A1 discloses cold sintering ceramics and composites.
US PGPUB 2015/0211382 A1 discloses an abradable coating made of a material having a low surface roughness.
US PGPUB 2013/0177740 A1 discloses a powder-based material system with stable porosity.
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/RYAN C CLARK/Examiner, Art Unit 3745