Office Action 3: Non-Final Rejection (2024-10-29)
Rejection types: 103 - Obviousness

CLAIMS:
IN THE CLAIMS

The following listing of claims will replace all prior versions, and listings, of claims in the application.

1\. (Currently Amended) A fiber producing system, the system comprising:a housing having an inlet and an outlet;
one or more air pumps positioned in the housing;
a peristaltic pump positioned in the housing, the peristaltic pump being coupled to the inlet of the housing for receiving polymer solution into the peristaltic pump;
a manifold positioned at the outlet of the housing, wherein the manifold is coupled to an outlet of the peristaltic pump;
a nozzle positioned in the manifold, the nozzle being coupled to an outlet of the one or more air pumps, wherein the nozzle includes a convergent-shaped portion followed by a divergent-shaped portion to increase a velocity of air exiting an outlet of the nozzle; and
a nosepiece positioned in the manifold and coupled to the outlet of the nozzle, wherein the nosepiece includes a die with one or more channels acting as individual passages for flow of the polymer solution and the air, and wherein the channels are arranged in a flow of the air from the outlet of the nozzle inside the nosepiece such that the air is funneled around the polymer solution to move the polymer solution out of the channels andform fibers as the polymer solution exits the nosepiece.

2\. (Original) The system of claim 1, wherein the housing is a molded housing.

3\. (Original) The system of claim 1, wherein the nozzle and the manifold are positioned in the housing.
4\. (Original) The system of claim 1, wherein the housing includes a handle.

5\. (Previously Presented) The system of claim 1, further comprising a hopper coupled to the peristaltic pump.

6\. (Previously Presented) The system of claim 5, wherein the hopper is configured to provide the polymer solution to the peristaltic pump.

7\. (Previously Presented) The system of claim 1, wherein the peristaltic pump is configured to move the polymer solution into the manifold.

8\. (Cancelled).

9\. (Original) The system of claim 1, wherein the channels are configured to extrude the polymer solution to form fibers during use.

10\. (Original) The system of claim 1, wherein at least one of the channels has a shape and size configured to provide fibers of a desired shape and size.

11\. (Previously Presented) The system of claim 1, further comprising a divider in at least one of the channels to divide the polymer solution and form multi-lumen fibers.

12\. (Original) The system of claim 1, further comprising a portable power source coupled to the pumps.

13\. (Currently Amended) A method of making fibers, comprising:providing a polymer solution to a peristaltic pump positioned in a housing;
generating a flow of air in the housing using an air pump positioned in the housing;
moving, using the peristaltic pump, the polymer solution into a nosepiece in a manifold in the housing, wherein the nosepiece includes a die having one or more channels;
moving, using the air pump, air into and through a nozzle in the manifold, wherein the nozzle includes a convergent-shaped portion followed by a divergent-shaped portion that increases a velocity of the air exiting the nozzle; and

providing the air from the nozzle and through the nosepiece such that the air with the increased velocity funnels around the polymer solution in the channels to move the polymer solution out of the channels in the nosepiece and form fibers as the polymer solution exits the nosepiece.

14\. (Previously Presented) The method of claim 13, wherein the produced fibers have a shape and size determined by a shape and size of the one or more channels in the nosepiece.

15\. (Original) The method of claim 13, wherein the produced fibers have a length greater than 1 micron.

16\. (Previously Presented) The method of claim 13, further comprising extruding the polymer solution through the one or more channels to produce the fibers.

17\. (Previously Presented) The method of claim 13, wherein providing the polymer solution include providing the polymer solution to a hopper coupled to the peristaltic pump.

18\. (Original) The method of claim 13, further comprising providing the produced fibers onto a surface.

19\. (Original) The method of claim 13, further comprising controlling a temperature of the housing to control one or more properties of the fibers.

20\. (Original) The method of claim 19, further comprising controlling the temperature using a heater positioned in the housing.

OFFICE ACTION:
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 .
Claims 1 and 13 have been amended by applicants.
Claim 8 has been canceled by applicants.
Claims 1-7 and 9-20 are pending.
Response to Arguments
Applicant's arguments filed 9/18/2024 have been fully considered after further reconsideration and updated search, and wherein the arguments are unpersuasive in light of the latest reference.  The applicants have amended the independent claims 1 and 13 with additional features.  The arguments by the applicants have focused upon the features of the nozzle and of the convergent and divergent shaped portions and of the flow of the polymer solution and of the air.  The argument concerning the device operation of Ikegaya by the applicant is noted.
The applicants have made argument concerning the Wright teaching and how it lacks motivation to combine.  After further reconsideration and additional searching, it is noted that the Weigel reference is relevant to the teachings of Ikegaya.  As shown below, Weigel teaches further of the venturi effect in forming the filaments, and wherein, provides clearer teaching of the convergence and divergence portions provided at the nozzle portion.  The claims are rejected as shown below based upon this combination.
Additionally, the concepts of Wright remains relevant in regards of forming a device in a portable handheld device with the housing taught by Wright.  The argument concerning the electrostatic of Wright is noted, but the device of Wright being arranged into a handheld device is applicable to the teachings of Ikegaya in view of Weigel particularly in regards to the features of the device being within a handheld molded housing and in regards of a portable power source (or battery), wherein, this particular concept remains relevant and applicable in regards to the teachings and combination.
After further reconsideration, the claims are rejected as shown below.
Claim Rejections - 35 USC § 103
The text of those sections of Title 35, U.S. Code not included in this action can be found in a prior Office action.
Claim(s) 1, 7, 9, 11, 13-14, 16, and 19-20 is/are rejected under 35 U.S.C. 103 as being unpatentable over Ikegaya (US 2020/0173057) in view Weigel (US 2008/0038979), and further in view of Fong (US 2019/0292685).
Ikegaya teaches of nozzle head 20 and having solvent storage 11, and gas ejection unit 13, and gas flow passage 26, and raw material flow passage 25, and in Figures 2-27 of various different arrangements of the nozzle head and in Figures 25-26 with plural flow passages, and further in another embodiment, see Figures 28-40, with an extruder device with cylinder 63 and supply pipe 68 for gas, with the nozzle head 70, and with the plural gas passages 76 and the raw material passages 75.
Thereby, Regarding claim 1, Ikegaya teaches of a fiber producing system, the system comprising:
one or more air pumps positioned in the system (inherently taught by the flow of the gas flow passage within the system to the nozzle in Ikegaya as a source of the air flow through the system);
a nozzle (see nozzle head 20) coupled to the one or more air pumps (inherently due to the gas flow passages 76);
a manifold coupled to the pump; and
a nosepiece enclosed in the manifold, wherein the nosepiece includes a die with one or more channels acting as individual passages for forming fibers as polymer solution exits the nosepiece (see teaching of the nozzle head with the different arrangements for the raw material passages 75, see Figs. 25-26 and 28-40 and wherein, the structure of Ikegaya would encompass the claimed nosepiece structure);
and of channel for air/gas flow 26/76, while raw material flow 25, 75 flow into said gas flow in formation of the fibers (see Figures), wherein, the feature would encompass the claimed “a die with one or more channels acting as individual passages, and wherein the channels are arranged in a flow of the air from the outlet of the nozzle inside the nosepiece such that the air is funneled around the polymer solution exiting the channels to form fibers as the polymer solution exits the nosepiece”.
Ikegaya does not specifically teach of the particularly claimed convergent, divergent nozzle design, of the particular positioning all the elements within a housing.
Regarding the use of a peristaltic pump, Fong teaches of the use of a spinneret and electrospinning system in forming fibers.  Wherein, the solution is provided from the reservoir via a peristaltic pump, see [0096], that further the pump can be either a positive displacement pump or peristaltic pump, [0095].  Further, Wright teaches a variety of pumps used for transporting the raw materials within the system.
It would have been obvious for one of ordinary skill in the art to modify the pumping of the solution of Ikegaya in view of Wright with the use of a peristaltic pump as taught by Fong as a known alternate pump for use in the system, further, under KSR, this is seen as a simple substitution of one known element for another to obtain predictable results.
Regarding the convergent and then divergent portions of the nozzle, the Wright reference teaches of the nozzle forming a venturi effect.  In analogous prior art in the related teaching of forming filaments, the Weigel reference teaches in Fig. 2, see [0035], with the funnel in forming a venturi nozzle, and includes a funnel portion, which would encompass the claimed convergence portion.  Wherein, the divergence occurs via at the end 5.  Here, the fibre inlet 1 and further opening 3 provides for air.
It would have been obvious for one of ordinary skill in the art to have further modify the nozzle design of Ikegaya in view of Wright and Fong with the convergent-divergent nozzle in forming a venturi as taught by Weigel as known structures in forming fibers.  This is also seen under KSR regarding combining prior art elements (in this case of the Weigel nozzle design for venturi effect) according to known methods (see the modified Ikegaya with the teaching of venturi effect via nozzle design of Wright) to yield predictable results.
Re: claim 7 (upon 1), wherein the peristaltic pump is configured to move the polymer solution into the manifold.  See teaching of Fong.
Re: claim 9 (upon 1), wherein the channels are configured to extrude the polymer solution to form fibers during use.  See teaching of Ikegaya.
Re: claim 11 (upon 1), further comprising a divider in at least one of the channels to divide the polymer solution and form multi-lumen fibers.  See teaching in Ikegaya particularly of the plural channels formed for the raw material channels which correspond to the claimed channels.
Re: claim 13, see teaching of the above of Ikegaya in view of Wright, Fong, and Weigel Abramov teaches the claimed structure of claim 1, wherein, claim 13 is in regards to a method of making fibers and wherein the steps include the elements that would be encompassed by the teachings of references that have been applied to claim 1.
Re: claim 14 (upon 13), wherein the produced fibers have a shape and size determined by a shape and size of the one or more channels in the nosepiece.  This teaching would be a result of the channels that are taught in the teaching of the prior art references.
Re: claim 16 (upon 13), further comprising extruding the polymer solution through the one or more channels to produce the fibers.  See the claimed teachings as the polymer solution would form the fibers as it exits from the channels.
Re: claim 19 (upon 13), further comprising controlling a temperature of the housing to control one or more properties of the fibers.  See teaching by Ikegaya with temperature control, see [0065], that includes for both raw material temperature control function and for gas temperature control function, see [0133, 0134].
Re: claim 20 (upon 19), further comprising controlling the temperature using a heater positioned in the housing.  See teaching of heater 64 in Ikegaya, [0106, 0113].
Claim(s) 2-4, 10, 12, 15, and 18 is/are rejected under 35 U.S.C. 103 as being unpatentable over Ikegaya in view of Weigel, and Fong, as applied to claims 1 and 13 above, and further in view of Wright (US 11207510).
Ikegaya, Weigel, and Fong teaches the claimed invention as shown above.
Regarding all the elements being positioned in a housing and of the pump within the manifold/housing, Wright teaches of handheld applicator device 100 with nozzle 60 and cartridge 50 (for solution reservoir), and with pump P that includes piston pump, pneumatics micro pump acting with a solenoid, see Col. 19, lines 16-30. The device having a housing 10, and grip 15 (handle) and further the teaching of inlet and outlet stems from the source of the material as inlet and outlet from the nozzle.
Re: claim 2 (upon 1), wherein the housing is a molded housing.
The modified Ikegaya reference does not specifically teach of the claimed housing.
See housing of Wright, and further, a molded housing is a known type of forming such particularly when the housing is formed from a plastic material which is a known type of material used in constructing said elements.
It would have been obvious for one of ordinary skill in the art to further modify the system of modified Ikegawa with the arrangement of the features, pump, and venturi nozzle design of Wright into a single housing/manifold thereby allowing for a complete handheld system in forming of fibers.  The arrangement being further obvious to one skilled in the art under KSR in combining prior art elements of Ikegaya according to known methods, in this case of Wright, to yield predictable results, of a handheld system as it allows for a portable device.
Re: claim 3 (upon 1), wherein the nozzle and the manifold are positioned in the housing, see teaching of Wright of the nozzle and manifold that are within the housing, particularly in the arrangement to be handheld.
It would have been obvious for one of ordinary skill in the art to further modify the system of modified Ikegawa with the arrangement of the features into a single housing/manifold as taught by Wright thereby allowing for a complete handheld system in forming of fibers.  The arrangement being further obvious to one skilled in the art under KSR in combining prior art elements of Ikegaya according to known methods, in this case of Wright, to yield predictable results, of a handheld system as it allows for a portable device.
Re: claim 4 (upon 1), wherein the housing includes a handle.  See grip 15 in Wright.  Whereby, the teaching and combination is similar to the teaching for claim 3.
Re: claim 10 (upon 1), wherein at least one of the channels has a shape and size configured to provide fibers of a desired shape and size.  This is a broad interpretation and it would have been obvious for one of ordinary skill in the art to modify the channels of Ikegaya in view of Wright, Fong as a change in size and shape for the desired parameters in effecting the fibers formed, in particular see teaching of Wright, Col. 26, lines 19-25, see teaching of varying of nozzle size.
Re: claim 12 (upon 1), further comprising a portable power source coupled to the pumps.  See teaching of batteries B in Wright.  See teaching of the modification as set forth in claim 3 and further, the use of a portable power source taught in Wright.
Re: claim 15 (upon 13), wherein the produced fibers have a length greater than 1 micron. See teaching of Wright that includes forming particles that range from 0.5-20 micron, see Wright, Col. 6, lines 18-19.
Wherein, the claimed fibers formed as taught by Wright is noted and it would have been obvious for one of ordinary skill in the art to further modify the system of modified Ikegawa with the fiber sizing of Wright in forming the desired product size.  The arrangement being further obvious to one skilled in the art under KSR in combining prior art elements of Ikegaya according to known methods, in this case of Wright, to yield predictable results.
Re: claim 18 (upon 13), further comprising providing the produced fibers onto a surface.  See teaching of the references, particularly in the use of the device in forming fibers, see also Wright regarding site which would be the claimed surface, see Col. 26, lines 22, and of treatment site.
Claim(s) 5, 6, and 17 is/are rejected under 35 U.S.C. 103 as being unpatentable over Ikegaya in view of Weigel, and Fong, as applied to claim 1 and 13 above, and further in view of Fournier (US 2019/0390374).
Re: claim 5 (upon 1), further comprising a hopper coupled to the peristaltic peristatic pump.
Re: claim 6 (upon 5), wherein the hopper is configured to provide the polymer solution to the peristaltic pump.
Re: claim 17 (upon 13), wherein providing the polymer solution include providing the polymer solution to a hopper coupled to the peristaltic pump.
The references do not teach of a hopper coupled to the peristaltic pump.
In regards to the hopper, Fournier, see [0292] teaches of feeding hopper that includes peristaltic pump.  Wherein, the concept of the polymer supply being from a hopper and further associated with a pump would have been obvious as a known alternate configuration in supplying the polymer solution further into the system.
It would have been obvious for one of ordinary skill in the art to modify the system of Ikegaya in view of Weigel, and Fong with the additional hopper and associated peristaltic pump as taught by Fournier as under KSR as a known alternate configuration that can be applied in supplying polymer solution from Fournier within a system of Ikegaya in view of Weigel, and Fong with an expectation of success.
Conclusion
The prior art made of record and not relied upon is considered pertinent to applicant's disclosure.  See attached PTO-892 form, and of particular note with teachings by the references concerning the converging and diverging sections of the nozzle:
Yoneda (US 4285318, see abstract, and Figs. 1 and 3.
Mosseri (US 4282637), see abstract and Figs. 1 and 2.
Yelveington (US 10654009), see Figs. 1-3, and Col. 3, lines 33-47.
Davison (US 10492387), see Figs. 4 and 8 and Col. 9, lines 45-60.

APPLICANT REBUTTAL: REMARKS
Applicant is in receipt of the Final Office Action mailed April 18, 2024.
Claims 1-7 and 9-20 were pending. Claims 1 and 13 have been amended. Support for the amendments is found at least in FIGS. 2-4 along with the accompanying description at least in paragraphs [0019]-[0030]. No new matter has been added.
Reconsideration of the present case is respectfully requested in view of the following remarks.
Section 103 Re
j
ections:
The Office Action rejects claims 1-4, 7, 9-16, and 18-20 under 35 U.S.C. 103 as allegedly being unpatentable over lkegaya (US 2020/0173057) in view of Wright (US 11207510) and Fong (US 2019/0292685) and Abramov (US2019/0280561). The Office Action rejects claims 5, 6, and 17 under 35 U.S.C. 103 as allegedly being unpatentable over lkegaya in view of Wright, Fong, and Abramov as applied to claim 1 and 13 above, and further in view of Fournier (US 2019/0390374). Applicant respectfully disagrees with these rejections.
In order to reject a claim as obvious, the Examiner has the burden of establishing a prima facie case of obviousness. In re Warner et al., 379 F.2d 1011, 154 USPQ 173, 177-178 (C.C.P.A. 1967). To establish prima facie obviousness of a claimed invention,
all the claim limitations
must be taught or suggested by the prior art. In re Royka, 490 F.2d 981, 180 U.S.P.Q. 580 (C.C.P.A. 1974), MPEP §2143.03.
Claim 1 recites, in part:
a nozzle positioned in the manifold, the nozzle being coupled to an outlet of
the one or more air pumps, wherein the nozzle includes a convergent-shaped portion followed by a divergent-shaped portion to increase a velocity of air exiting
an outlet of the nozzle; and
a nosepiece positioned in the manifold and coupled to the outlet of the
nozzle, wherein the nosepiece includes a die with one or more channels acting as individual passages for flow of the polymer solution and the air, and wherein the channels are arranged in a flow of the air from the outlet of the nozzle inside the nosepiece such that the air is funneled around the polymer solution to move the polymer solution out of the channels and form fibers as the polymer solution exits
the nosepiece.
Claim 13 recites, in part:
moving, using the air pump, air into and through a nozzle in the manifold,
wherein the nozzle includes a convergent-shaped portion followed by a divergent- shaped portion that increases a velocity of the air exiting the nozzle; and
providing the air from the nozzle and through the nosepiece such that the
air with the increased velocity funnels around the polymer solution in the channels to move the polymer solution out of the channels in the nosepiece and form fibers
as the polymer solution exits the nosepiece.
The cited art does not appear to teach or suggest at least the above-quoted features of the claims, in combination with the other features of the claims. Specifically, beginning with Ikegaya, Ikegaya teaches separate passages for air/gas flow (e.g., "gas flow passage 26" or "gas flow passage 76") and raw material flow ((e.g., "raw material flow passage 25" or "raw material flow passage 75"). Further, Ikegaya teaches that the solvent with raw material flow meets the gas flow outside the openings to be carried by the gas flow for elongation and formation of the fibers. For instance, Ikegaya states:
The solvent discharged from the raw material flow passage 25 reaches at the opening of the gas flow passage 26 through the raw material flow groove 24 a, meets the gas flow ejected from the gas flow passage 26 with the angle a, and is carried out in the front direction while being elongated, so that the nanofibers are
manufactured.
(Ikegaya, paragraph [0101]).
Accordingly, Ikegaya does not teach or suggest the feature of "a nosepiece" where air enters the nosepiece from the nozzle with increased velocity, as claimed. In the claimed features, in the nosepiece, the air moves the polymer solution through the passages/channels of the nosepiece while also moving the polymer solution out of the nosepiece to form the fibers with properties based on the design of the channels in the nosepiece. Applicant specifically notes that in Applicant's claimed invention, the increased velocity air from the nozzle is used to move the polymer solution through the channels and the fibers are generated because of the air-supported movement of the polymer solution. As described above, Ikegaya relies on contact between gas (e.g., air) and the raw material
outside of the device.
Accordingly, Ikegaya does not teach or suggest at least the above-quoted features of claims 1 and 13, in combination with the other features of the claim.
Applicant further notes that the combination of features recited in Applicant's claimed invention (e.g., the combination and arrangement of claimed components of the device for producing fibers) provide specific advantages described throughout the current application. For instance, Applicant's claimed invention provides a hand held apparatus for forming fibers and directing the formed fibers onto a specific surface (e.g., a surface wound). The combination of features in Applicant's claimed invention allow the hand held apparatus to form the fibers without any rotating parts and without any electric fields. For instance, Applicant's Specification states: "It should be noted that there are no rotating parts in the disclosed embodiment of system 100 and thus there are no high electric fields such as is typically needed in centrifugal and electrospinning methods." (Paragraph [0019]). Accordingly, Applicant's claimed invention has advantages of not having rotating parts and not implementing electric fields that are not discussed or recognized by the cited art.  These advantages are achieved by the described combination and specific arrangement of the various components recited in Applicant's claims.
Some of the cited art discusses implementation of techniques specifically cited as being disadvantageous by the current application. For example, Wright, while teaching a venturi nozzle design, teaches that the venturi nozzle design is used in a system that requires electrostatic charging of the treatment solution. Thus, a person of ordinary skill in the art would have no motivation to implement the teachings of Wright, which involve electrostatic charging, in order to produce a device of Applicant's claimed invention, which clearly is designed to operate without any electric fields, as described above. Further, Fong, while teaching use of a peristaltic pump, teaches the use of the peristaltic pump in an environment that clearly involves electric fields - electrospinning. Thus, a person of ordinary skill in the art would have no motivation to implement the teachings of Fond, which involves electrospinning, in order to produce a device of Applicant's claimed invention, which clearly is designed to operate without any electric fields, as described above.
For at least these reasons, Wright and Fong do not overcome the above-described deficiencies in Ikegaya. Abramov is merely cited as an example of optimizing designs of convergent-divergent nozzles that increase velocity of fluid flowing through the nozzles. Abramov
has no teaching or suggestion related to the production of fibers. Thus, Abramov cannot, on its own, overcome the deficiencies in Ikegaya, Wright, and Fong.
For at least the above reasons, Applicant submits that the cited does not teach or suggest at least the above-quoted combinations of features in the claims. Accordingly, Applicant submits that claims 1, 13, and the claims dependent thereon are patentable over the cited art.
CONCLUSION

NEXT OFFICE ACTION: 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 .
Claims 1, 9-11, 13-16 and 18 have been amended by applicants.
Claim 8 has been canceled by applicants.
Claims 1-7 and 9-20 are pending.
Response to Arguments
Applicant's arguments and amendment filed 1/29/2025 have been reconsidered and is persuasive over the prior art references.
It is noted that the amended claims have issues regarding the specific passages, as the die of claim 1 (and also claim 13) states of one or more individual passages, however, later on in the claim and in dependent claims, there is a reference to the passages.  The Examiner’s amendment below is to remedy the issues raised.
EXAMINER’S AMENDMENT
An examiner’s amendment to the record appears below. Should the changes and/or additions be unacceptable to applicant, an amendment may be filed as provided by 37 CFR 1.312. To ensure consideration of such an amendment, it MUST be submitted no later than the payment of the issue fee.
Authorization for this examiner’s amendment was given in an interview with Gareth Sampson on 2/3/2025.
The application has been amended as follows:
In the claims:
1.  (currently amended) A fiber producing system, the system comprising:
a housing having an inlet and an outlet;
one or more air pumps positioned in the housing;
a peristaltic pump positioned in the housing, the peristaltic pump being coupled to the inlet of the housing for receiving polymer solution into the peristaltic pump;
a manifold positioned at the outlet of the housing, wherein the manifold is coupled to an outlet of the peristaltic pump and an outlet of the one or more air pumps, wherein the manifold includes:
a nozzle coupled to
a nosepiece coupled to the outlet of the nozzle, the nosepiece including a die with one or more individual passages for flow of the polymer solution from the outlet of the peristaltic pump and wherein, in the manifold, a flow of the air from the nozzle around the die and the one or more passages such that the air is being funneled around the polymer solution as the polymer solution exits the passages and moves the polymer solution out of the one or more passages to form fibers as the polymer solution exits the one or more passages and the nosepiece.
9. (currently amended) The system of claim 1, wherein the one or more passages are configured to extrude the polymer solution to form fibers during use.
10. (currently amended) The system of claim 1, wherein at least one of the one or more passages has a shape and size configured to provide fibers of a desired shape and size.
11. (currently amended) The system of claim 1, further comprising a divider in at least one of the one or more passages to divide the polymer solution and form multi-lumen fibers.
13. (currently Amended) A method of making fibers, comprising:
providing a polymer solution to a peristaltic pump positioned in a housing;
generating a flow of air in the housing using an air pump positioned in the housing;
moving, using the peristaltic pump, the polymer solution into a nosepiece in a manifold in the housing, wherein the nosepiece includes a die having one or more
moving, using the air pump, air into and through a nozzle in the manifold, wherein the nozzle includes a convergent-shaped portion followed by a divergent-shaped portion that increases a velocity of the air exiting the nozzle;
and funneling the air exiting the nozzle around the die and the one or more passages such that the air with the increased velocity funnels around the polymer solution as the polymer solution exits the one or more passages and moves the polymer solution out of the one or more passages to form fibers as the polymer solution exits the one or more passages and the nosepiece.
Clean copy of the amended claims:
1. A fiber producing system, the system comprising:
a housing having an inlet and an outlet;
one or more air pumps positioned in the housing;
a peristaltic pump positioned in the housing, the peristaltic pump being coupled to the inlet of the housing for receiving polymer solution into the peristaltic pump;
a manifold positioned at the outlet of the housing, wherein the manifold is coupled to an outlet of the peristaltic pump and an outlet of the one or more air pumps, wherein the manifold includes:
a nozzle coupled to
a nosepiece coupled to the outlet of the nozzle, the nosepiece including a die with one or more individual passages for flow of the polymer solution from the outlet of the peristaltic pump and wherein, in the manifold, a flow of the air from the nozzle around the die and the one or more passages such that the air is being funneled around the polymer solution as the polymer solution exits the passages and moves the polymer solution out of the one or more passages to form fibers as the polymer solution exits the one or more passages and the nosepiece.
9. The system of claim 1, wherein the one or more passages are configured to extrude the polymer solution to form fibers during use.
10. The system of claim 1, wherein at least one of the one or more passages has a shape and size configured to provide fibers of a desired shape and size.
11.  The system of claim 1, further comprising a divider in at least one of the one or more passages to divide the polymer solution and form multi-lumen fibers.
13. (Currently Amended) A method of making fibers, comprising:
providing a polymer solution to a peristaltic pump positioned in a housing;
generating a flow of air in the housing using an air pump positioned in the housing;
moving, using the peristaltic pump, the polymer solution into a nosepiece in a manifold in the housing, wherein the nosepiece includes a die having one or more
moving, using the air pump, air into and through a nozzle in the manifold, wherein the nozzle includes a convergent-shaped portion followed by a divergent-shaped portion that increases a velocity of the air exiting the nozzle;
and funneling the air exiting the nozzle around the die and the one or more passages such that the air with the increased velocity funnels around the polymer solution as the polymer solution exits the one or more passages and moves the polymer solution out of the one or more passages to form fibers as the polymer solution exits the one or more passages and the nosepiece.
Allowable Subject Matter
The following is a statement of reasons for the indication of allowable subject matter over the prior art references:
The prior art references fail to teach the claimed invention, particularly in light of the latest amendment.  Wherein, the features of the housing with peristaltic pump, air pump(s), and the claimed nozzle arrangement in relation to the die, housing, and nosepiece.
The closest prior art include:
Ikegaya (US 2020/0173057), wherein Ikegaya teaches of nozzle head 20 and having solvent storage 11, and gas ejection unit 13, and gas flow passage 26, and raw material flow passage 25, and in Figures 2-27 of various different arrangements of the nozzle head and in Figures 25-26 with plural flow passages, and further in another embodiment, see Figures 28-40, with an extruder device with cylinder 63 and supply pipe 68 for gas, with the nozzle head 70, and with the plural gas passages 76 and the raw material passages 75.  Ikegaya does not specifically teach of the particularly claimed convergent, divergent nozzle design, of the particular positioning all the elements within a housing,
Weigel (US 2008/0038979), only teaches of a convergent and then divergent portions of the nozzle, the Weigel reference teaches of the nozzle forming a venturi effect.  In analogous prior art in the related teaching of forming filaments, the Weigel reference teaches in Fig. 2, see [0035], with the funnel in forming a venturi nozzle, and includes a funnel portion, which would encompass the claimed convergence portion.  Wherein, the divergence occurs via at the end 5.  Here, the fibre inlet 1 and further opening 3 provides for air.   The Weigel reference does not teach the claimed arrangement and of the particular die and passage design.
Fong (US 2019/0292685), regarding the use of a peristaltic pump, Fong teaches of the use of a spinneret and electrospinning system in forming fibers.  Wherein, the solution is provided from the reservoir via a peristaltic pump, see [0096], that further the pump can be either a positive displacement pump or peristaltic pump, [0095].  The Fong reference does not teach the claimed arrangement and of the particular die and passage design.
Wright (US 11207510), see housing of Wright, and further, a molded housing is a known type of forming such particularly when the housing is formed from a plastic material which is a known type of material used in constructing said elements.  Further, Wright teaches a variety of pumps used for transporting the raw materials within the system.  The Wright reference does not teach the claimed arrangement and of the particular die and passage design.
Fournier (US 2019/0390374), in regards to the hopper, Fournier, see [0292] teaches of feeding hopper that includes peristaltic pump.  Wherein, the concept of the polymer supply being from a hopper and further associated with a pump would have been obvious as a known alternate configuration in supplying the polymer solution further into the system.  The Fournier reference does not teach the claimed arrangement and of the particular die and passage design.
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

CITED REFERENCE SUMMARIES: Ref US20080038979A1: [content unavailable]
Ref US20200173057: Claims:
1. An apparatus for producing nanofibers comprising
a raw material discharge surface on which a raw material flow passage for discharging a liquid raw material is arranged, and a gas discharge surface which is arranged with an angle α (0<α≤90°) toward said raw material discharge surface and on which a gas flow passage for ejecting gas is arranged, wherein said raw material flow passage is orthogonal to said raw material discharge surface, said gas flow passage is orthogonal to said gas discharge surface, and said raw material flow passage and said gas flow passage are arranged so that said liquid raw material discharged from said raw material flow passage meets gas ejected from said gas flow passage.
2. An apparatus for producing nanofibers claimed in claim 1 comprising one or more flow passage sat of said one raw material flow passage and said one gas flow passage.
3. An apparatus for producing nanofibers claimed in claim 2 wherein a plurality of flow passage sets are provided and these flow passage sets are arranged in one direction so that said raw material flow passage and said gas flow passage are arranged on two linear lines parallel each other.
4. An apparatus for producing nanofibers claimed in claim 2 wherein a plurality of flow passage sets are provided and the plurality of flow passage sets are arranged annularly so that said raw material flow passage and said gas flow passage are arranged on the circumference of two circles which become concentric.
5. An apparatus for producing nanofibers claimed in claim 1 wherein an axis line of said raw material flow passage and an axis line of said gas flow passage are provided on a plane.
6. An apparatus for producing nanofibers claimed in claim 1 comprising one or more flow passage sets of a plurality of said raw material flow passage and said gas flow passage.
7. An apparatus for producing nanofibers claimed in claim 6 wherein said flow passage set comprises said gas flow passage having a slit-like shape and extending in one direction, and said plurality of raw material flow passages arranged in said one direction.
8. An apparatus for producing nanofibers claimed in claim 6 wherein said flow passage set comprises said gas flow passage and a plurality of said raw material flow passage arranged around said gas flow passage.
9. An apparatus for producing nanofibers claimed in claim 1 wherein a discharge pipe projecting from said raw material discharge surface is provided and said raw material flow passage is arranged inside thereof.
10. An apparatus for producing nanofibers claimed in claim 1 wherein a discharge pipe projecting from said gas discharge surface is provided and said gas flow passage is arranged inside thereof.
11. An apparatus for producing nanofibers claimed in claim 1 comprising a first portion having said raw material discharge surface, and a second portion having said gas discharge surface, wherein said first portion and said second portion are connected detachably.
12. An apparatus for producing nanofibers comprising
a raw material discharge surface on which a raw material flow passage for discharging a liquid raw material is arranged, a gas discharge surface which is arranged downwardly from said raw material discharge surface and on which a gas flow passage for ejecting gas is arranged, a connecting surface which is connected with said raw material discharge surface and said gas discharge surface, and is arranged with an angle β (0≤β<90°) toward said raw material discharge surface, wherein said raw material flow passage is orthogonal to said raw material discharge surface, said gas flow passage is orthogonal to said gas discharge surface, an opening of said gas flow passage contacts with said connecting surface, and said raw material flow passage and said gas flow passage are arranged so that said liquid raw material discharged from said raw material flow passage reaches to the opening of said gas flow passage along said connecting surface.
13. A nozzle head used for an apparatus for producing nanofibers comprising:
a raw material discharge surface on which a raw material flow passage for discharging a liquid raw material is arranged, and a gas discharge surface which is arranged with an angle α (0<α≤90°) toward said raw material discharge surface and on which a gas flow passage for ejecting gas is arranged, wherein said raw material flow passage is orthogonal to said raw material discharge surface, said gas flow passage is orthogonal to said gas discharge surface, and said raw material flow passage and said gas flow passage are arranged so that said liquid raw material discharged from said raw material flow passage meets gas ejected from said gas flow passage.
14. A nozzle head used for an apparatus for producing nanofibers comprising:
a raw material discharge surface on which a raw material flow passage for discharging a liquid raw material is arranged, a gas discharge surface which is arranged downwardly from said raw material discharge surface, and on which a gas flow passage for ejecting gas is arranged, a connecting surface which is connected with said raw material discharge surface and said gas discharge surface, and is arranged with an angle β (0≤β<90°) toward said raw material discharge surface, wherein said raw material flow passage is orthogonal to said raw material discharge surface, said gas flow passage is orthogonal to said gas discharge surface, an opening of said gas flow passage contacts with said connecting surface, and said raw material flow passage and said gas flow passage are arranged so that said liquid raw material discharged from said raw material flow passage reaches to the opening of said gas flow passage along said connecting surface.
Ref US20080038979: Claims:
1. Method for the production of non-woven fabrics, in which a lyotropic solution of cellulose carbamate in N-methylmorpholine-N-oxide (NMMNO) is spun into a plurality of filament yarns by means of extrusion through a nozzle block containing at least 20 openings via an air gap into a regenerating bath, said filament yarns being intermingled subsequently by being subjected to a flow with gaseous medium and/or fluid.
2. Method according to claim 1, characterised in that a nozzle block with at least 10,000 openings is used.
3. Method according to claim 1, characterised in that the ratio of length to diameter of the nozzles is from 1 to 20.
4. Method according to claim 1, characterised in that the width of the air gap between nozzle and regenerating bath is 5 to 150 mm, in particular 10 to 50 mm.
5. Method according to claim 1, characterised in that the filament yarns are guided downwards after spinning into a slot-shaped funnel, the intermingling with the gaseous medium and/or fluid being effected at the outlet of the funnel.
6. Method according to claim 5, characterised in that a further intermingling of the filament yarns is achieved by a shaking movement of the funnel.
7. Method according to claim 1, characterised in that air and/or water are used as gaseous medium and/or fluid.
8. Method according to claim 1, characterised in that the filament yarns are laid on a conveyor belt after the intermingling.
9. Method according to 8, characterised in that a further intermingling of the filament yarns is achieved by a shaking movement of the conveyor belt.
10. Method according to claim 1, characterised in that the cellulose carbamate proportion of the lyotropic solution is at least 20% by weight, in particular 22 to 27% by weight, relative to the solution.
11. Method according to claim 1, characterised in that the lyotropic solution is produced by swelling of the cellulose carbamate in a 40 to 70%, in particular a 50% solution of NMMNO in water and subsequent removal of the water up to a ratio of NMMNO to water between 80:20 and 90:10.
12. Method according to claim 1, characterised in that the regenerating bath comprises a solution of NMMNO in water with an NMMNO proportion of 0.5 to 25% by weight, in particular 5 to 15% by weight, relative to the solution.
13. Method according to claim 1, characterised in that the extrusion is effected at a temperature between 80 to 110° C., in particular 85 to 95° C.
14. Method according to claim 1, characterised in that the non-woven fabric is subsequently washed, pressed and dried.
15. Method according to claim 14, characterised in that the washing is effected by a water jet at high pressure.
16. Method according to claim 1, characterised in that the cellulose carbamate is regenerated into cellulose in a regenerating bath.
17. Method according to claim 16, characterised in that the regenerating bath comprises 0.3 to 1% by weight sodium hydroxide in water and the regeneration is effected at a temperature of 60 to 95° C.
18. Method according to claim 16, characterised in that the regeneration is implemented between extrusion and intermingling.
19. Method according to claim 16, characterised in that the regeneration is implemented after the intermingling.
20. Non-woven fabric comprising a random orientation of filament yarns made of cellulose carbamate.
21. Non-woven fabric according to claim 20, characterised in that the filament yarns have a strength of at least 60 cN/tex.
22. Non-woven fabric according to claim 20, characterised in that the non-woven fabric can be produced according to the method according to a method for the production of non-woven fabrics, in which a lyotropic solution of cellulose carbamate in N-methylmorpholine-N-oxide (NMMNO) is spun into a plurality of filament yarns by means of extrusion through a nozzle block containing at least 20 openings via an air gap into a regenerating bath, said filament yarns being intermingled subsequently by being subjected to a flow with gaseous medium and/or fluid.
23. Non-woven fabric comprising a random orientation of filament yarns made of regenerated cellulose.
24. Non-woven fabric according to claim 23, characterised in that the residual N-content is from 0.3 to 0.5%, in particular 0.1 to 0.2%.
25. Non-woven fabric according to claim 23, characterised in that the non-woven fabric has a pore structure with a porosity of 1 to 10%.
26. Non-woven fabric according to claim 23, characterised in that the non-woven fabric has a specific internal surface between 20 and 50 m2/cm3, measured by means of small angle x-ray scattering (SAXS).
27. Non-woven fabric according to claim 23, characterised in that the non-woven fabric can be produced with a method for the production of non-woven fabrics, in which a lyotropic solution of cellulose carbamate in N-methylmorpholine-N-oxide (NMMNO) is spun into a plurality of filament yarns by means of extrusion through a nozzle block containing at least 20 openings via an air gap into a regenerating bath, said filament yarns being intermingled subsequently by being subjected to a flow with gaseous medium and/or fluid characterised in that the cellulose carbamate is regenerated into cellulose in a regenerating bath.
28. Use of the non-woven fabrics according to claim 20 in medicine, in particular as operating sheets, bed sheets, surgical dressings, gauzes or cotton wool pads.
29. Use of the non-woven fabrics according to claim 20 as hygiene materials or as household wipes.
30. Use of the non-woven fabrics according to claim 20 as decorative non-woven fabrics, in particular tablecloths, serviettes or curtains.
31. Use of the non-woven fabrics according to claim 20 as non-woven liners in the clothing industry.
32. Use of the non-woven fabrics according to claim 20 as reinforcing mats or isolating jackets in the building industry.
33. Use of the non-woven fabrics according to claim 20 as reinforcing material for fibre-reinforced thermoplastic and duroplastic plastic materials.
Ref US20190292685: Claims:
1. An air-assisted electrospinning spinneret comprising:
a spinneret needle, wherein the spinneret needle is electrically conductive and comprises a tip; an enclosure, wherein the enclosure has a nozzle that the spinneret needle passes through; and a plurality of air holes in the nozzle, wherein each air hole defines an air path converging at the spinneret needle tip.
2. The spinneret of claim 1, further comprising a spin dope plenum; wherein the spin dope plenum is housed within the enclosure, and wherein the spinneret needle is in fluid communication with the plenum.
3. The spinneret of claim 1, wherein the needle is made of a metal.
4. The spinneret of claim 2, wherein the spinneret needle further comprises an outer sleeve that forms a channel.
5. The spinneret of claim 4, wherein the channel is in fluid communication with a spin dope plenum or a spin dope reservoir.
6. The spinneret of claim 1, wherein the plurality of air holes is between 4 and 12 air holes.
7. The spinneret of claim 1, wherein there are an even number of air holes.
8. The spinneret of claim 1, wherein the spinneret needle has an inner diameter between about 0.4 mm and about 1.5 mm.
9. The spinneret of claim 1, wherein the spinneret needle is between about 0.5 inches in length and about 10 inches in length.
10. The spinneret of claim 1, wherein the spinneret needle extends beyond the enclosure a distance of between about 0.2 inches and about 4 inches.
11. A spinneret array comprising:
two or more air-assisted electrospinning spinnerets of claim 1, wherein the spinneret needles are separated to form a distance between the spinneret needles, and wherein the spinneret needles form a row or a circle.
12. The spinneret array of claim 11, wherein there are six or more spinnerets and the spinnerets are circularly arranged, or wherein the two or more spinnerets are in a row.
13. The spinneret array of claim 12, wherein the spinnerets are in a row, and wherein the row comprises between 3 spinnerets and 1000 spinnerets.
14. The spinneret array of claim 11, wherein the spinneret array when electrically charged produces a stable electrical field, and wherein the spinneret needles are spaced apart in a ratio of the non-adjacent spinneret needles to adjacent spinneret needles of between about 3:1 and about 4:1.
15. A method of preparing an electrospun nanofibrous mat with a spinneret of claim 1 comprising:
transferring a spin dope to the spinneret needle;
providing air pressure for an air-assist;
electrically charging the spinneret needle;
forcing the spin dope from within the spinneret needle to the needle tip and converging an air stream at the needle tip from the air-assist to form a Taylor Cone on the spinneret needle tip;
forming a filament from the Taylor Cone; and
collecting the filament on a collector.
16. The method of claim 15, wherein the spinneret further comprises a spin dope plenum; wherein the spin dope plenum is housed within the enclosure, and wherein the spinneret needle is in fluid communication with the plenum.
17. The method of claim 16, wherein the spinneret needle further comprises an outer sleeve that forms a channel, and wherein the channel is in fluid communication with a spin dope plenum or a spin dope reservoir.
18. The method of claim 15, wherein there are an even number of air holes.
19. The method of claim 15, further comprising blowing the filament.
20. The method of claim 15, further comprising venting solvent vapor from the filament.
Ref US20190390374: Claims:
1. A method for melt-preparation of lignin-based fibers, comprising:
a/ the intimate blending of the components of a formulation comprising:
lignin,
a plasticizer miscible with said lignin,
and a cross-linking agent capable of cross-linking with said lignin,
 in conditions in which no cross-linking of the cross-linking agent and of the lignin occurs, b/ the spinning of the intimate blend thus obtained in a hot extrusion device comprising an extrusion head in a terminal part, in order to form continuous threads, by application in said extrusion device of conditions such that:
the temperatures applied in said extrusion device are higher than the glass-transition temperature of said intimate blend,
and the temperatures, the residence time of said intimate blend in said extrusion device and the residence time of said intimate blend in said extrusion head are such that the cross-linking reaction of the cross-linking agent and lignin is initiated only in the extrusion head,
 c/ when appropriate, the drawing of the threads obtained in order to form lignin-based fibers of great length, with the cross-linking agent being chosen in such a way that the cross-linking reaction thereof with said lignin is initiated in a time less than said residence time of said intimate blend in said extrusion head at temperatures above a temperature at least 10° C. greater than the glass-transition temperature of said intimate blend of said lignin and of said plasticizer.
2. The method according to claim 1, wherein the step a/ of intimate blending of the components of said formulation comprises the following sub-steps:
a1/ preparation of said formulation, by blending of said lignin, said plasticizer and said cross-linking agent, a2/ the blending by extrusion of the components of said formulation, at a temperature greater than the glass-transition temperature of the lignin and than a softening temperature of the plasticizer, in order to form an extrudate in which the lignin, the plasticizer and the cross-linking agent are in an intimate blend.
3. The method according to claim 1, wherein the step b/ of spinning of the intimate blend of the components of the formulation, it is applied in the extrusion head a temperature that is greater than the glass-transition temperature of said intimate blend by a value of between 10 and 150° C.
4. The method according to claim 1, wherein the lignin and the plasticizer are such, and in proportions such, that the glass-transition temperature of said intimate blend of said lignin and of said plasticizer is between 0 and 180° C.
5. Method according to claim 1, wherein the lignin has a weight average molecular weight between 1,000 and 100,000 g/mol.
6. Method according to claim 1, wherein the plasticizer is a polymer, or blend of polymers.
7. Method according to claim 1, wherein the plasticizer is a fusible acrylonitrile polymer.
8. Method according to claim 1, wherein the plasticizer has a glass-transition temperature, where applicable glass-transition temperatures, of less than 150° C.
9. Method according to claim 1, wherein the cross-linking agent is chosen in the group consisting of:
benzoxazines, epoxies, oxazolines, polyoxymethylenes, aldehydes, hexamethylenetetramine and hexamethylenemethoxymelamine; compounds that have a functionality greater than or equal to two, of which the chemical functions are chosen in the group consisting of the functions: benzoxazine, epoxy (glycidyl ether in particular), isocyanate, anhydride, carboxylic acid, methylol and ester, with these chemical functions being identical or different, or any blend of such compounds.
10. Method according to claim 1, wherein the cross-linking agent is capable of initiating a cross-linking reaction with the lignin in less than 10 minutes at a temperature between 30 and 190° C.
11. Method according to claim 1, wherein the cross-linking agent is capable of cross-linking with the lignin at ambient temperature.
12. Method according to claim 1, wherein said formulation comprises the following percentages by weight, with respect to the total weight of the formulation:
50 to 98% of lignin, and/or 1 to 49% of plasticizer, and/or 1 to 25%, preferably 2 to 10%, preferentially 2.5 to 5%, of cross-linking agent.
13. Method according to claim 1, wherein said formulation comprises one or several additives chosen in the group consisting of carbon fillers of nanometric size, alone or in a mixture.
14. Method according to claim 1, wherein a final step of storage of said lignin-based fiber at ambient temperature.
15. Formulation for the implementing of a method of melt-preparation of
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