Office Action 4: Notice of Allowance (2025-08-22)

CLAIMS:
AMENDMENTS TO THE CLAIMS

Please amend claims 1-4, 7, 10, 12-14, 16, and 18; cancel claims 5, 6, 8, 9, 11, 19, and 20 without prejudice; and add claims 21-23, such that the status of the claims is as follows:

1\. (Currently Amended) A ceramic matrix composite vane for a gas turbine engine comprising:an airfoil comprising:
a leading edge;
a trailing edge;
a suction sidewall; and
a pressure sidewall joined to the suction sidewall at the leading edge and the trailing edge, the pressure sidewall comprising a locally- thickened region,
a first platform; and
a second platform, wherein the airfoil is connected to and extends between the first platform and the second platform;
wherein the locally-thickened region extends from one of the first platform and the second platform to a midspan region of the airfoil and wherein the locally- thickened region has a first thickness, the first thickness being a maximum thickness of the pressure sidewall;
wherein the suction sidewall has a second thickness, the second thickness being a maximum thickness of the suction sidewall;
wherein the first thickness is greater than the second thickness; and
wherein the airfoil comprises a plurality of fiber plies;
wherein at least one of the plurality of plies is disposed only in the locally thickened region of the airfoil and one of the first platform and the second platform.

2\. (Currently Amended) The vane of claim 1, wherein the first thickness is up to 30% greater than the second thickness.

3\. (Currently Amended) The vane of claim 1, wherein the locally-thickened region extends from 0% to at least 40% and not greater than 60% span of the airfoil.

4\. (Currently Amended) The vane of claim 1, wherein the locally-thickened region extends from 100% to at least 60% and not beyond 40% span of the airfoil.

5-6. (Cancelled)

7\. (Currently Amended) The vane of claim \[\[5\]\]1, wherein a first subset of the plurality of plies is disposed only in the locally thickened region of the airfoil and a second subset of the plurality of plies are disposed over the first subset of plies and wrap around the airfoil.

8-9. (Cancelled)

10\. (Currently Amended) A method of forming a ceramic matrix composite vane comprising a airfoil extending in span between a first platform and a second platform , the method comprising:identifying stress regions in the vane exceeding a threshold value;
subsequently, forming a preform by:
laying up a first subset of plies around a mandrel;
laying up at least one reinforcing ply over the first subset of plies, the at least one reinforcing ply coextensive with the stress regions; and laying up a second subset of plies over the at least one reinforcing ply; and densifying the preform with a ceramic matrix;
wherein the first subset of plies and the second subset of plies define the airfoil, the airfoil comprising a leading edge, a trailing edge, a suction sidewall, and a pressure sidewall;
wherein the at least one reinforcing ply covers only a portion of the span of the airfoil and forms a portion of one of the first platform and the second

platform; and
wherein the second set of plies wraps around the airfoil.

11\. (Cancelled)

12\. (Currently Amended) The method of claim \[\[11\]\]10, wherein the at least one reinforcing ply is disposed along the pressure sidewall between 0% span and 50% span.

13\. (Currently Amended) The method of claim \[\[11\]\]10, wherein the at least one reinforcing ply is disposed along the pressure sidewall between 50% span and 100% span.

14\. (Currently Amended) The method of claim \[\[11\]\]10 and further comprising: bending the at least one reinforcing ply to form the portion of the first platform of the second platfor.

15\. (Original) The method of claim 10, wherein the step of densifying the preform with a ceramic matrix comprises one or a combination of chemical vapor infiltration, melt infiltration, and polymer infiltration and pyrolysis.

16\. (Currently Amended) A vane assembly for a gas turbine engine, the vane assembly comprising:an inner case;
an outer case; and
at least one ceramic matrix composite (CMC) vane coupled between the inner case and the outer case, the at least one CMC vane comprising:
an inner diameter platform;
an outer diameter platform; and
an airfoil connected to and extending between the inner diameter platform and the outer diameter platform, the airfoil comprising:
a leading edge;

a trailing edge;
a suction sidewall; and
a pressure sidewall joined to the suction sidewall at the leading edge and the trailing edge, the pressure sidewall comprising a locally-thickened region extending from the inner diameter platform or the outer diameter platform toward a midspan region pressure sidewall,
wherein the locally-thickened region has a first thickness, the first thickness being a maximum thickness of the pressure sidewall;wherein the suction sidewall has a second thickness, the second thickness being a maximum thickness of the suction sidewall;
wherein the first thickness is greater than the second thickness; and wherein the airfoil comprises a plurality of fiber plies;
wherein at least one of the plurality of plies is disposed only in the locally thickened region of the of the pressure sidewall and one of the inner diameter platform and the outer diameter platform.

17\. (Original) The assembly of claim 16, wherein the first thickness is 30% greater than the second thickness.

18\. (Currently Amended) The assembly of claim 17, wherein the the plurality of plies comprises a first subset of plies and a second subset of plies, wherein the at least one reinforcing ply is disposed between the first subset of plies and the second subset of plies.

19-20. (Cancelled)

21\. (New) The assembly of claim 16, wherein the at least one additional ply has curved edge disposed in a midspan region of the airfoil.

22\. (New) The vane of claim 1, wherein the at least one additional ply has a curved edge disposed in an midspan region of the airfoil.

23\. (New) The method of claim 10, wherein the at least one additional ply has a curved edge disposed in a midspan region of the airfoil.

OFFICE ACTION:
EXAMINER’S COMMENT
Response to Remarks
Applicant’s remarks, see pages 7-10, filed 6/20/2025, with respect to the claim rejection2 have been fully considered and are persuasive.  The claim rejection2 have been withdrawn.
The amendment cancelled claims 5,6,8,9,11,19 and 20 and added claims 21-23. Claims 1, 2, 3, 4, 7, 10, 12, 13, 14, 15, 16, 17, 18, 21, 22, 23 remain and are allowed.
Allowable Subject Matter
Claims 1, 2, 3, 4, 7, 10, 12, 13, 14, 15, 16, 17, 18, 21, 22, 23 are allowed. The following is an examiner’s statement of reasons for allowance: claims 1, 2, 3, 4, 7, 10, 12, 13, 14, 15, 16, 17, 18, 21, 22, 23 are allowed primarily because the prior art of record cannot anticipate Applicant’s claimed invention by a single reference nor render Applicant’s claimed invention obvious by the combination of more than one reference.
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.”
Inquiry

APPLICANT REBUTTAL: REMARKSThis Amendment is in response to the Office Action dated March 24, 2025, in which claims 1-20 are rejected under 35 U.S.C. §103 as allegedly being obvious over varying combinations of U.S. Pub. No. 2022/0268165 (D1), U.S. Pat. No. 11,162,432 (D2), U.S. Pat. No.11,530,614 (D3), U.S. Pub. No. 2017/068345 (D4), U.S. Pub. No. 2015/0152734 (D5), and U.S.Pub. No. 2023/03838657 (D6). The rejections are traversed in view of the amendments and arguments presented herein and allowance of the present application is respectfully requested.The Applicant notes a minor inconsistency: although the Office Action is identified as non-final, the conclusion of the Office Action states that the action is made final. For the purpose of this Amendment, the Applicant presumes that this first Office Action following the RCE of March 6th, 2025, is indeed intended to be non-Final.Examiner Interview Summary An applicant-initiated examiner interview was conducted telephonically on May 28, 2025, between Examiner Newton and the Applicant's representative Thea Reilkoff. Proposed amendments to the independent claims were discussed. Examiner Newton indicated the proposed amendments overcame the prior art of record. No agreement was reached with regard to patentability.Claim Rejections under 35 U.S.C. X103 Claims 1-9 Claims 1-9 are rejected as allegedly being obvious over D1 in view of D2.Independent claim 1 is presently amended to further define the structure of the component and ply layup. Claim 5, 6, 8, and 9 are cancelled to avoid redundancy. Amended independent claim 1 recites (emphasis added):A ceramic matrix composite vane for a gas turbine engine comprising:an airfoil comprising:a leading edge;a trailing edge;a suction sidewall; and a pressure sidewall joined to the suction sidewall at the leading edge and the trailing edge, the pressure sidewall comprising a locally-thickened region, a first platform; and a second platform, wherein the airfoil is connected to and extends between the first platform and the second platform;wherein the locally-thickened region extends from one of the first platform and the second platform to a midspan region of the airfoil and wherein the locally-thickened region has a first thickness, the first thickness being a maximum thickness of the pressure sidewall;wherein the suction sidewall has a second thickness, the second thickness being a maximum thickness of the suction sidewall;wherein the first thickness is greater than the second thickness; and wherein the airfoil comprises a plurality of fiber plies;wherein at least one of the plurality of plies is disposed only in the locally thickened region of the airfoil and one of the first platform and the second platform.Amended independent claim 1 requires at least one ply to be disposed only in the locally thickened region of the airfoil and the first or second platform, with the locally-thickened region provided on the pressure sidewall and extending from the first or second platforms to a midspan region of the airfoil. D1 discloses varying a number of plies used to form tubes defining cavities 74a-74c. The tubes extend a full span of the airfoil and form portions of each of the pressure sidewall and suction sidewall. D1 teaches varying the number of plies to vary the wall thickness of the tubes. There is no teaching or suggestion of providing a ply to form a locally thickened portion that extends only a portion of the span on the pressure sidewall. D2 discloses a vane formed by additive manufacturing. While Applicant acknowledges that D2 discloses adjusting a wall thickness based on expected operational stresses, D2 is uninformative with respect to a ply layup.Because the combination of D1 and D2 fails to teach or suggest all of the limitations of amended independent claim 1, it is respectfully submitted that amended independent claim 1 and all claims depending therefrom are in condition for allowance. Notice to that effect is respectfully requested.Claims 16-20 Independent claim 16 is rejected as allegedly being obvious over D4 in view of D5.Independent claim 16 is presently amended in a manner consistent with amended independent claim 1. Claims 19 and 20 are presently cancelled to avoid redundancy. It is respectfully submitted that the combination of D4 and D5 fails to teach or suggest all of the limitations of amended independent claim 16. Specifically, neither D4 nor D5 teaches or suggests that "the at least one of the plurality of plies is disposed only in the locally thickened region of the of the pressure sidewall and one of the inner diameter platform and the outer diameter platform." Furthermore, D4 does not teach or suggest "a locally-thickened region extending from the inner diameter platform or the outer diameter platform toward a midspan region" of the pressure sidewall having a maximum thickness greater than a maximum thickness of the suction sidewall and D5 fails to make up for this deficiency. D5 teaches an increased thickness T' in the region Z2 on a pressure sidewall but this thickness is the same as the maximum thickness T' on the suction sidewall shown in region Z1. As such, the maximum thickness on the pressure sidewall is not greater than a maximum thickness on the suction sidewall as required. D1 and D2 fail to make up for the deficiencies of D4 and D5 for the reasons discussed with respect to amended independent claim 1.Because no combination of the prior art of record teaches or suggests all of the limitations of independent claim 16, it is respectfully submitted that amended independent claim 16 and call claims depending therefrom are in condition for allowance. Notice to that effect is respectfully requested.Claims 10-15 Independent claim 10 is rejected as allegedly being obvious over D2 in view of D3.Independent claim 10 is directed to a method of manufacture. Independent claim 10 is presently amended to further define the structure of the component (vane) and further define the ply layup in a manner consistent with independent claims 1 and 16. Claim 11 is presently cancelled to avoid redundancy. Amended independent claim 10 recites, in relevant part:wherein the first subset of plies and the second subset of plies define the airfoil, the airfoil comprising a leading edge, a trailing edge, a suction sidewall, and a pressure sidewall;wherein the at least one reinforcing ply covers only a portion of the span of the airfoil and forms a portion of one of the first platform and the second platform; and wherein the second set of plies wraps around the airfoil.As previously discussed, D2 discloses a vane formed by an additive manufacturing method (3D printing, rapid prototyping, direct digital manufacturing, binder jetting, selective laser melting, and direct metal laser melting) and is, therefore, uninformative to a ply layup method to form a CMC component. D3 is the issued patent of D1. As discussed with respect amended independent claim 1, D1 (and thereby D3) does not teach or suggest a reinforcing ply that covers only a portion of the span of the airfoil and forms a portion of one of the platforms. None of the other prior art of record makes up for the deficiencies of D2 and D3 and as such, it is respectfully submitted that independent claim 10 and all claims depending therefrom are in condition for allowance. Notice to that effect is respectfully requested.New Claims Claims 21-23 are newly added to depend from claims 1, 10, and 16. Claims 21-23 recite "the at least one additional ply has curved edge disposed in a midspan region of the airfoil," as shown, for example, in FIGS. 3 and 5 of the present application. No new matter is added.Conclusion By addressing particular positions taken by the Patent Office in the above remarks, Applicant does not acquiesce to other positions that have not been explicitly addressed. In addition, Applicant's arguments for the patentability of a claim should not be understood as implying that no other reasons exist for the patentability of that claim. Nothing in this response should be construed as a concession of or an intent to concede any issue with regard to any claim, except as specifically stated in this response, and the amendment or cancellation of any claim does not necessarily signify concession of unpatentability of the claim prior to its amendment or cancellation. Applicant reserves the right to prosecute the rejected claims in further prosecution of this or related applications.In view of the amendments and arguments presented herein, pending claims 1-4, 7, 10, 12-18, and 21-23 are in condition for allowance. Notice to that effect is respectfully requested.If a telephone conference would be beneficial in resolving remaining issues, please contact the Applicant's attorney, Thea Reilkoff, at 612-337-7207.The Commissioner is hereby authorized to charge any additional fees which may be required under 37 C.F.R. 1.16 and 1.17, or credit any overpayment, to Deposit Account No.210279.Respectfully submitted, KINNEY & LANGE, P.A.Date:   June 20, 2025