Office Action 2: Notice of Allowance (2025-09-04)

CLAIMS:
Amendments to the Claims:

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

1\. (Currently Amended) A wire rope, comprising:
a strand that is formed by winding a plurality of metal wires, wherein:
the strand includes a core wire arranged in a center of the plurality of metal wires, and side wires that make up a remainder of the plurality of metal wires, each of the side wires being arranged on an outer periphery of the core wire,
in a transverse section of the strand, each of the side wires includes end portions positioned at opposite ends in a circumferential direction of the core wire,
each of the end portions includes a contact portion in contact with an end portion of an adjacent side wire, and a non-contact portion not in contact with the adjacent side wire,
a Vickers hardness of the contact portion is higher by 1% or more than a Vickers hardness of the non-contact portion,
a surface roughness Ra of an outer peripheral surface of each of the side wires is 0.10 m or less,
the strand is obtained by die-drawing a twisted wire including a plurality of circular- cross-section metal wires, and
a cross-sectional width of the strand is 42.9% to 85.7% of a diameter of the twisted wire before the die-drawing.
2\. (Original) The wire rope according to claim 1, wherein at each of the end portions, the Vickers hardness of the contact portion is higher by 3% or more than the Vickers hardness of the non-contact portion.

3\. (Original) The wire rope according to claim 1, further comprising a plurality of strands including the strand, wherein the wire rope is formed by winding the plurality of the strands.

OFFICE ACTION:
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 as a result of an interview with Patrick de la Pena on 8/14/25.
The application has been amended as follows:
Claim 1 Line 16 delete “42.9% to 85.7%” and substitute – “57.2% to 85.7%, or 42.9% to 71.4%,--
Claim(s) 1-3 is/are allowed over the art of record.
Reasons for Allowance
The following is an examiner’s statement of reasons for allowance:
None of the prior art of record discloses a wire rope comprising a strand obtained by die-drawing a twisted wire including a plurality of circular cross-section metal wires, and a cross-sectional width of the strand is 57.2% to 85.7%, or 42.9% to 71.4%, of a diameter of the twisted wire before the die drawing, in conjunction with the other structural limitations, such as the strand having a core wire arranged in a center of the plurality of metal wires, wherein each of the side wires include end portions in a transverse section of the strand, each of the end portions includes a contact portion and a non-contact portion, along with a Vickers hardness of the contact portion as recited and a surface roughness of each of the sides as recited, as set forth in the independent claim.  The use of wire rope comprising a strand with a core wire arranged in a center of the plurality of metal wires, each of the end portions including a contact portion and a non-contact portion is known in the art of wire rope, but the specific Vickers hardness and surface roughness resulting from the strand being obtained by die-drawing a twisted wire including a plurality of circular-cross-section metal wires, the cross-sectional width of the strand being the range percentages (%) relative to a diameter of the twisted wire before the die-drawing as claimed by the applicant is novel.  Specifically, prior art Hallidie (USPN 0251114) discloses a wire rope with a core arranged in a center of a plurality of sides, there being contact portions and non-contact portions as recited in the application.  Prior art Glaze (USPN 3131469) also discloses a core wire arranged in a center of a plurality of metal wires, the strand obtained by die-drawing a twisted wire including a plurality of circular cross-section metal wires, with contact portions.  However, none of the prior art discloses, teaches, or suggests a strand with a core wire arranged in a center of the plurality of metal wires, the strand obtained by die-drawing a twisted wire including a plurality of circular-cross-section metal wires, the cross-sectional width of the strand being the recited percentage (%) range of a diameter of the twisted wire before the die-drawing, the strand also having contact and non-contact portions.  To modify Hallidie such that the strand is obtained by die-drawing a twisted wire of circular cross-section metal wires merely to be as recited in the current application would be impermissible hindsight reconstruction of the applicant’s invention without any disclosure, teaching, or suggestion from the prior art of record, as is presently the case, especially in light of remarks 8/5/25 page 9 (“wires are individually shaped and then twisted in Hallidie”), as opposed to the claimed die-drawn/shaped after twisting together.  Though Glaze teaches stranded/twisted and then die-drawn (Col. 2 Lines 22-24), the final structure (Fig. 1) does not have non-contact portions; the claims would be that of Fig. 4A, but there is no disclosure, teaching, or suggestion from the prior art of record to stop the processing at Fig. 4A, especially as there is no disclosure of the claimed cross-sectional width of the strand being 57.2% to 85.7%, or 42.9% to 71.4%, of a diameter of the twisted wire before the die drawing which, in light of the rest of the structural limitations, would result in the claimed Vickers hardness and surface roughness, as indicated in remarks 8/5/25 pages 7, 9, differentiating the die-drawing from the prior art swaging.
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
The prior art made of record and not relied upon but is considered pertinent to applicant’s disclosure: Pourladian et al (WO 2012/050997) directed in Fig. 3 to multiple core wires surrounded by side wires, there being contact and non-contact portions, formed from twisting and then compaction; Kurata et al (AU 745343) directed in Fig. 4A to a core wire arranged in a center of a plurality of metal wires, there being contact and non-contact portions, formed from twisting and then die-drawn, but without a recitation of cross-sectional width of the resulting strand relative to the diameter before being die-drawn.

APPLICANT REBUTTAL: REMARKSClaims 1-3 are pending in this application. By this Amendment, claim 1 is amended.Support may be found at least in ¶ ¶ [0023] and [0024] of the specification as filed. No new matter is added.I.
Drawing Objection The Office Action objects to the drawings for informalities. By this Amendment, Fig. 3 is amended by the attached replacement sheet, responsive to this objection. Accordingly, withdrawal of the objection is respectfully requested.II.    Specification Objection The Office Action objects to the specification for informalities.The Office Action states that "it is unclear how applicant's die-drawing method differs from that of swaging methods" and cites Suncor NPL as evidence that "swaging is also performed via a die." However, this reflects a misunderstanding of the differences between these processes. As acknowledged in the cited Suncor NPL, swaging encompasses two distinct categories: (1) extrusion of a workpiece through a confining die to reduce diameter, and (2) using two or more dies to hammer a round workpiece to a smaller diameter. Die-drawing, as disclosed in the present application, involves pulling material through a die using tensile force, which creates different stress patterns and deformation characteristics than the compressive forces used in either category of swaging.The specification clearly distinguishes the results achieved by die-drawing from those of swaging processes. ¶ [0004] of the publication notes that swaging produces "substantially uniform" hardness distribution in the transverse section, while the present die-drawing method produces the claimed hardness differential between contact and non-contact portions. Similarly, ¶ [0030] shows that swaging produces a minimum surface roughness Ra of 0.12  m, while the present die-drawing achieves the claimed 0.10  m or less. These structural differences demonstrate that the die-drawing process disclosed in the specification produces measurably different results than swaging, regardless of whether both processes might involve a "die" as a tool.Moreover, claim 1 is amended to define that "the strand is obtained by die-drawing a twisted wire including a plurality of circular-cross-section metal wires, and a cross-sectional width of the strand is 42.9% to 85.7% of a diameter of the twisted wire before the die-drawing." The claimed diameter reduction through die-drawing creates the specific deformation pattern that results in the claimed hardness differential at the contact portions and the smooth surface finish that distinguishes the present claims from swaging methods.¶ [0024] is amended, responsive to the issues regarding referring to the "diameter" of the core strand 10 and the side strand 20.Accordingly, withdrawal of the objection is respectfully requested.III.   35 U.S.C. §112(b) The Office Action rejects claims 1-3 under 35 U.S.C. §112(b). This rejection is respectfully traversed for the following reasons.The Office Action takes issue with reciting that features have specified "Vickers hardness" and "surface roughness." Vickers hardness is a well-established industry-standard measurement of structural features with defined testing procedures, as discussed in the specification at at least ¶ [0026] of the publication of this application. Similarly, surface roughness is a standard parameter with defined testing procedures, as discussed in the specification at at least ¶ [0029] of the publication of this application. In other words, Vickers hardness and surface roughness are measurable structural properties, analogous to specifying dimensions or mass, and are thus not indefinite.Accordingly, withdrawal of the rejection is respectfully requested.IV.    35 U.S.C. §103 The Office Action rejects claims 1 and 2 under 35 U.S.C. §103 over Hallidie (U.S.251,114) in view of Schoerner (U.S. 3,383,704). The Office Action rejects claim 3 under 35 U.S.C. §103 over Hallidie in view of Schoerner and Warren (U.S. 2,400,181). These rejections are respectfully traversed.As discussed above, independent claim 1 is amended and now recites that "the strand is obtained by die-drawing a twisted wire including a plurality of circular-cross-section metal wires, and a cross-sectional width of the strand is 42.9% to 85.7% of a diameter of the twisted wire before the die-drawing." The cited art, alone or in combination, fails to teach at least these features of claim 1, as amended.A.
Distinguishing Die-Drawing from Swaging The present specification uses "swaging" to refer specifically to the second category described in Suncor NPL, which is a process where a round workpiece is hammered into a smaller diameter using two or more dies. The first category in Suncor NPL involves "extrusion" of the workpiece, which is also distinct from the die drawing process of the present application.Importantly, swaging processes involves relatively small reductions in cross sectional area, which do not produce the claimed differences in Vickers hardness between contact and non- contact portions or the claimed surface roughness.In contrast, the present application employs die drawing with a substantial reduction in cross sectional area, specifically reducing the strand diameter to 42.9% to 85.7% of its original diameter. This large deformation creates the claimed differences in Vickers hardness and achieves the claimed surface roughness of 0.10  m or less. Amended claim 1 now explicitly recites both the die drawing process and the specific diameter reduction range.B.
The Claimed Structure Cannot be Achieved by the Cited References The claimed strand is obtained by die-drawing a twisted wire including a plurality of circular-cross-section metal wires. During die-drawing, the portions of the wires that are in contact with each other become harder, whereas the portions not in contact are less hard. As a result, "a Vickers hardness of the contact portion is higher by 1% or more than a Vickers hardness of the non-contact portion." In contrast, Hallidie discloses that the individual wires are shaped separately and then twisted into a strand. In other words, Hallidie does not disclose a die-drawing or swaging process in which the strand is compressed and shaped. Since the wires are individually shaped and then twisted in Hallidie, die-drawing is not performed while the wires are in contact with each other as in the present invention, and therefore, no difference in hardness arises between contact portion and non-contact portion in Hallidie. Thus, Hallidie does not disclose the feature:"a Vickers hardness of the contact portion is higher by 1% or more than a Vickers hardness of the non-contact portion." Schoerner does not disclose a process of die-drawing a twisted wire including a plurality of wires. Therefore, Schoerner also does not disclose the feature: "a Vickers hardness of the contact portion is higher by 1% or more than a Vickers hardness of the non-contact portion." For at least these reasons, withdrawal of the rejections is respectfully requested.C.
The Claimed Diameter Reduction Range Further Distinguishes the Claimed Features Furthermore, the following feature: "the strand is obtained by die-drawing a twisted wire including a plurality of circular-cross-section metal wires, and a cross-sectional width of the strand is 42.9% to 85.7% of a diameter of the twisted wire before the die-drawing" is not disclosed in Suncor NPL and in JPH11-47153. In JPH11-47153, ¶ [0022] states that the degree of diameter change during the swaging process should be in the range of (D'-D)/D'= 0.08 to 0.105, where D' is the diameter before processing and D is the diameter after processing. Hence, the reduction in diameter is: 89.5 to 92% in JPH11-47153. Therefore, the features recited in claim 1 are not obvious even in view of Suncor NPL and JPH11-47153.For these additional reasons, withdrawal the rejections is respectfully requested.*
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*In view of the foregoing, it is respectfully submitted that this application is in condition for allowance. Favorable reconsideration and prompt allowance of the claims are earnestly solicited.Should the Examiner believe that anything further would be desirable in order to place this application in even better condition for allowance; the Examiner is invited to contact the undersigned at the telephone number set forth below.Respectfully submitted, Electronic signature: / Patrick A. de la Pena / Patrick A. de la Pena Registration No.: 79,692 PADAttachment:One (1) Replacement Sheet Date: August 5, 2025 DEPOSIT ACCOUNT USEOLIFF PLC


CITED REFERENCE SUMMARIES: Ref US3131469A: Claims:
THE PROCESS OF PRODUCING A UNITARY MULTIPLE WIRE STRAND WHICH INCLUDES THE STEPS OF STRANDING A PLURALITY OF MAIN WIRES AS A CORE WIRE AND SPIRALLY RELATED OUTER WIRES WITH A PLURALITY OF SMALLER WIRES OF BRAZING MATERIAL IN THE SPACES BETWEEN THE OUTER WIRES AND THE CORE WIRE, SUBJECTING THE ASSEMBLY TO A SERIES OF DRAWING OPERATIONS, AND SUBJECTING THE DRAWN PRODUCT TO A BRAZING TEMPERATURE TO BRAZE THE MAIN WIRES TO EACH OTHER THROUGHOUT THE LENGTH OF THE STRAND.
Ref WO2012050997A1: [content unavailable]
Ref AU745343B2: Claims:
A wire rope comprising: a core rope including a specified number of strands, each core strand having a specified number of core strand wires; a specified number of outer strands twisted together to surround the core rope, each of the outer strands including a specified number of outer strand wires; each core strand of the core rope having a substantially flattened outside so as to provide a contact section where two or more core strand wires of at least one core strand come into contact with one of the outer strand wires of an outer strand; and wherein the core rope has a total number of contact sections corresponding to the number of core strands such that the total of the contact sections Tz is 20 percent or more of the circumference of a circumscribed circle of the core rope, the contact section Tz being defined in Equation Tz T1 C x 100 (1) S is wherein Ti denotes the circumferential component of the contact section, C denotes the *circumference of the circumscribed circle of the core rope. V
A wire rope according to claim 1, wherein the core rope further has a plurality of non-contact sections where no core strand wires of the core strands of the core V'. S- rope come into contact with any outer strand such that a non-contact section rate Gz is below 20 percent of the circumference of the circumscribed circle of the core rope, the non-contact section rate Gz being defined in Equation SGz {100 (n x Tz)} n (2) where n denotes the number of the core strands.
A method for manufacturing a wire rope, comprising the steps of: twisting a specified number of wires and a flexible core member into a core strand; twisting a specified number of the core strands into a core rope; reducing the diameter of the core rope; twisting a specified number of outer strands on the reduced core rope; and wherein the reducing step includes reducing the diameter of the core rope so that two or more wires of at least one core strand come into contact with one of the wires of an /.ter strand, and the core rope has a total number of contact sections corresponding to the [R:\LIBLL] 12380.doc:TCW:vjp 16 number of core strands such that the total of the contact sections Tz is 20 percent or more of the circumference of a circumscribed circle of the core rope, the contact section Tz being defined in Equation Tz T C x 100 (1) wherein T1 denotes the circumferential component of the contact section, C denotes the circumference of the circumscribed circle of the core rope.
A method for manufacturing a wire rope according to claim 4, wherein the core rope further has a plurality of non-contact sections where no core strand wires of the core strands of the core rope come into contact with the outer strand such that a non-contact section rate Gz is below 20 percent of the circumference of the circumscribed circle of the core rope, the non-contact section rate Gz being defined in Equation Gz {100 (n x Tz)} n (2) wherein n denotes the number of core strands.
A wire rope substantially as hereinbefore described with reference to 15 Figs. 1A to 4D of the accompanying drawings.
A method for manufacturing a wire rope, the method substantially as hereinbefore described with reference to Figs. 1A to 4D of the accompanying drawings. o Dated 24 January, 2002 '.Shinko Kosen Kogyo Kabushiki Kaisha 20 Patent Attorneys for the Applicant/Nominated Person SPRUSON FERGUSON 0 S* [R:\LIBLL] 12380.doc:TCW:vjp i
Ref WO2012050997: Claims:
1. A wire rope used for theatrical productions comprising:
a plurality of strands having a closed spiral arrangement with each other and being compacted, wherein each said strand includes a center wire spirally surrounded by a plurality of inner wires spirally surrounded by a plurality of outer wires, wherein said outer wires completely encompass said inner wires, wherein said center wire and said inner wires are made from a galvanized material and coated with a lubricant, wherein said outer wires are made from non-coated steel, and wherein each said strand is compacted so said outer wires create a tight mechanical seal that protects said inner wires; and
a blackened finish.
2. The wire rope of claim 1 wherein said plurality of strands is four.
3. The wire rope of claim 1 wherein said lubricant is a solid that is baked or dried onto an outer surface of said inner wires.
4. The wire rope of claim 3 wherein said lubricant is selected from the group consisting of wax, molybdenum disulfide powder, graphite powder, polytetrafluoroethylene tape, polytetrafluoroethylene coating, and boric acid powder.
5. The wire rope of claim 1 wherein said lubricant is selected from the group consisting of wax, molybdenum disulfide powder, graphite powder, polytetrafluoroethylene tape, polytetrafluoroethylene coating, and boric acid powder.
6. The wire rope of claim 1 wherein a stress relieving heat treatment is applied to said center wire and said inner wires.
7. The wire rope of claim 1 wherein upon said compaction of said strand said lubricant flows into any space between said center wires and said inner wires.
8. The wire rope of claim 1 wherein said compaction is by a swaging process or a roller die compaction process.
9. The wire rope of claim 1 wherein said strand comprises said center wire, eighteen inner wires, and twelve outer wires.
10. The wire rope of claim 1 wherein said blackened finish is due to said wire rope undergoing a black oxide coating treatment, wherein said treatment is selected from the group consisting of cold applied treatment, low temperature treatment, and high temperature treatment.
11. A wire rope used for theatrical productions comprising:
four strands having a closed spiral arrangement with each other and being compacted, wherein each said strand includes a center wire spirally surrounded by eighteen inner wires spirally surrounded by twelve outer wires, wherein said outer wires completely encompass said inner wires, wherein said center wire and said inner wires are made from a galvanized material and coated with a lubricant, wherein said outer wires are made from non-coated steel, and wherein each said strand is compacted so said outer wires create a tight mechanical seal that protects said inner wires from a black oxide coating treatment; and
a blackened finish, wherein said finish is due to said wire rope undergoing said coating treatment.
12. The wire rope of claim 11 wherein said lubricant is a solid that is baked or dried onto an outer surface of said inner wires and is selected from the group consisting of wax, molybdenum disulfide powder, graphite powder, tetrafluoroethylene tape, tetrafluoroetnylene coating, boric acid powder.
13. The wire rope of claim 11 wherein a stress relieving heat treatment is applied to said center wire and said inner wires.
14. A method of producing a blackened wire rope for theatrical productions comprising the steps of:
producing a galvanized center wire;
producing a plurality of galvanized inner wires that surround said center wire; applying a lubricant to said center wires and said inner wires;
producing a plurality of non-coated steel outer wires that completely surround said inner wires;  producing a strand b spirally arranging said inner and outer wires around said center wire;
compacting said strand using an in-line compaction method thereby creating a mechanical seal between said outer wires;
closing a plurality of said strands to produce said wire rope;
compacting said wire rope; and
applying a black finish to said wire rope.
15. The method of claim 14 wherein said plurality of strands is four.
16. The method of claim 14 further comprising the step of applying a stress-relieving heat treatment to said center wire and said inner wires.
17. The method of claim 14 wherein said applying step is a process of baking or drying said lubricant onto an outer surface of said center wire and onto outer surfaces of said inner wires.
18. The method of claim 14 wherein said lubricant is selected from the group consisting of wax, molybdenum disulfide powder, graphite powder, polytetrafluoroethylene tape, polytetrafluoroethylene coating, and boric acid powder.
19. The method of claim 14 wherein said producing a strand step uses eighteen inner wires and twelve outer wires.
20. The method of claim 14 wherein said applying step is a black oxide coating treatment, wherein said treatment is selected from the group consisting of cold applied treatment, low temperature treatment, and high temperature treatment.
Ref US0251114: Claims:
1. A wire rope eomprising one or more series of wires, the enter wires of whiel are n eireular in cross-section and are laid spira. around an interier eore or strand, the non-e enlar wires being spirally formed, with the sar piteh or lay as the lay of the strand of whie they form a pnrt, snbstantially as herein se forth.
2. As a new article of mannfaeture, a. wire rope or eable having its Component wires noneirenlar in section and spirally forned, so that they will present the same faee on the outside ot' the trand tlereol, substantially as herein described.
3. A wire 'ope forned of twisted strands or wires having interstitia-l wires laid in the outer spaces between adjoining wires, said Supplementnl wires being formed in cross-section, so as to npproximately fill the spaces and present a, convex or flattened exterior surface, snbstan- 45 tiztlly as herein described.