Office Action 2: Notice of Allowance (2024-12-23)

CLAIMS:
Reply to Office Action of June 27, 2024 Listing of Claims:

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

1\. (Previously Presented) A method for manufacturing a substrate, the method comprising:providing a first supply of fibers;
providing a second supply of fibers;
providing a headbox, the headbox comprising:
a machine direction;
a cross direction;
an inlet;
an outlet; and
a first cross-directional divider that separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner, the first cross-directional divider including a length that is at least 50% of the length of the headbox;
transferring the first supply of fibers to the first zone of the headbox and transferring the second supply of fibers to the second zone of the headbox; and
transferring the first supply of fibers and the second supply of fibers through the headbox to the outlet to provide the substrate.

2\. (Previously Presented) The method of claim 1, wherein the first supply of fibers is transferred to the first zone of the headbox at the inlet and the second supply of fibers is transferred to the second zone of the headbox at the inlet; and wherein transferring the first supply of fibers and the second supply of fibers through the headbox provides the substrate with a first zone comprising fibers from the first supply of fibers and a second zone comprising fibers from the second supply of fibers.

3\. (Original) The method of claim 1, wherein the headbox further comprises a z-directional divider comprising a first surface and a second surface, the second surface being opposite from the first surface, the z-directional divider providing a first z-directional layer in the headbox and a second z- directional layer in the headbox.

4\. (Previously Presented) The method of claim 1, further comprising a second cross-directional divider that separates the second zone of the headbox from a third zone of the headbox in a cross-directional manner.

5\. (Previously Presented) The method of claim 3, further comprising a second cross-directional divider that separates the second zone of the headbox from a third zone of the headbox in a cross-directional manner; wherein the first zone, the second zone, and the third zone each form part of the first z- directional layer of the headbox.

6\. (Original) The method of claim 5, wherein the first supply of fibers are transferred to the second zone of the headbox in the first z-directional layer of the headbox and the second supply of fibers are transferred to the second z-directional layer of the headbox; and wherein transferring the first supply of fibers and the second supply of fibers through the headbox provides the substrate with a first layer comprising fibers from the first supply of fibers and a second layer comprising fibers from the second supply of fibers.

7\. (Original) The method of claim 6, wherein the first supply of fibers comprise synthetic fibers and the second supply of fibers comprise absorbent fibers.

8\. (Previously Presented) The method of claim 5, further comprising:providing a third supply of fibers;
transferring the third supply of fibers to the headbox at the inlet; and
transferring the third supply of fibers through the headbox to provide the substrate.

Reply to Office Action of June 27, 2024

9\. (Original) The method of claim 8, wherein the first supply of fibers are transferred to the first zone and the third zone of the first z-directional layer of the headbox, the second supply of fibers are transferred to the second zone of the first z-directional layer of the headbox, and the third supply of fibers are transferred to the second z-directional layer of the headbox .

10\. (Original) The method of claim 9, wherein the first supply of fibers comprise at least one type of distribution fiber; the second supply of fibers comprise at least one type of intake fiber; and the third supply of fibers comprise absorbent fibers.

11\. (Previously Presented) The method of claim 1, further comprising:providing a supply of particulates to the headbox at the inlet; and
transferring the supply of particulates through the headbox to provide the substrate.

12\. (Original) The method of claim 11, wherein the particulates comprise superabsorbent material.

13\. (Original) The method of claim 1, wherein the first supply of fibers are provided in a first foam slurry and the second supply of fibers are provided in a second foam slurry.

14\. (Previously Presented) A divider for a headbox including a cross direction and a machine direction, the divider comprising:a first surface;
a second surface, the second surface being opposite from the first surface;
a width defined in the cross direction that provides a first z-directional layer of the headbox and a second z-directional layer of the headbox;
a length defined in the machine direction; and
a first cross-directional divider extending away from the first surface, the first cross-directional divider comprising a cross-directional thickness and a machine-directional length.

15\. (Original) The divider of claim 14, wherein the first cross-directional divider extends away from the first surface in a directional substantially perpendicular to a plane defined by the first surface of the divider.

16\. (Original) The divider of claim 15, wherein the first cross-directional divider further comprises a proximal end and a distal end, and wherein a height of the first cross-directional divider as measured at the proximal end of the first cross-directional divider is greater than a height of the first cross- directional divider as measured at the distal end of the first cross-directional divider.

17\. (Original) The divider of claim 14, further comprising a second cross-directional divider.

18\. (Original) The divider of claim 17, wherein the second cross-directional divider extends away from the first surface of the divider and is spaced apart from the first cross-directional divider in the cross direction.

19\. (Original) The divider of claim 17, wherein the second cross-directional divider extends away from the second surface of the divider.

Response dated November 26, 2024 Reply to Office Action of June 27, 2024

20\. (Previously Presented) A headbox for manufacturing a substrate, the headbox including a machine direction and a cross direction, the headbox comprising:an inlet;
an outlet;
an internal chamber; and
a divider at least partially within the internal chamber, the divider comprising:
a first surface;
a second surface, the second surface being opposite from the first surface;
a width defined in the cross direction that provides a first z-directional layer of the headbox and a second z-directional layer of the headbox;
a length defined in the machine direction; and a first cross-directional divider extending away from the first surface of the divider, the first cross-directional divider comprising a cross-directional thickness and a machine- directional length; and
wherein the first cross-directional divider separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner, the first zone and the second zone being in the first z-directional layer.

21\. (Original) The headbox of claim 20, wherein the divider further comprises a second cross-directional divider.
22.-25. (Cancelled)

OFFICE 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 .
Reasons for Allowance
The following is an examiner’s statement of reasons for allowance: the prior art fails to teach or fairly suggest a headbox divider/vane as claimed, i.e., a divider having a first and second surfaces opposite to each other and having cross-machine direction divider extending from the first surface, as claimed. The headbox containing the divider is allowable because the sub-combination, the divider, is novel and non-obvious and the method of using the divider is also allowable since it has been held that the method of making or using a new and novel product is also novel and non-obvious. In re Ochiai, 71 F.3d 1565, 37 USPQ2d 1127 (Fed. Cir. 1995) and In re Brouwer, 71 F.3d 1565, 37 USPQ2d 1663 (Fed. Cir. 1996). See also applicants’ arguments filed on January 31, 2022 on the parent case, PCT/US21/25046.
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

APPLICANT REBUTTAL: Application No. 18/522,405 Response dated November 26, 2024 Reply to Office Action of June 27, 2024
REMARKS
I
ARGUMENTS
Claims 1-21 are presented for the Examiner's consideration. No claims are being amended in this Response. Pursuant to 37 C.F.R. 1.111, reconsideration of the present application in view of the following remarks is respectfully requested.
1.  Allowable Subject Matter
Applicant thanks the Examiner for indicating that claims 1-21 constitute allowable subject matter and would be allowable upon overcoming the Double Patenting rejection set forth in the Office Action mailed June 27, 2024. Applicant is filing a Terminal Disclaimer herein to place the application in condition for allowance.
II.  Claim Rejections
Double Patenting Rejections
Claims 1-21 stand rejected on the ground of nonstatutory double patenting as being unpatentable over claims 1-25 of U.S. Patent No. 11,866,884 B2. Applicant is filing an electronic Terminal Disclaimer via EFS- Web contemporaneously herewith rendering this rejection moot.
Ill.  Conclusions


CITED REFERENCE SUMMARIES: Ref US20230149226A1: Claims:
A method for manufacturing a substrate, the method comprising: providing a first supply of fibers; providing a second supply of fibers; providing a headbox, the headbox comprising: a machine direction; a cross direction; an inlet; an outlet; a first z-directional layer having a height; and a first cross-directional divider that separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner in the first z-directional layer, the first cross-directional divider including a height that is at least 90% of the height of the first z-directional layer; transferring the first supply of fibers to the first zone of the headbox at the inlet and transferring the second supply of fibers to the second zone of the headbox at the inlet; and transferring the first supply offbers and the second supply of fibers through the headbox to the outlet to provide the substrate.
providing a first supply of fibers;
providing a second supply of fibers;
providing a headbox, the headbox comprising: a machine direction; a cross direction; an inlet; an outlet; a first z-directional layer having a height; and a first cross-directional divider that separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner in the first z-directional layer, the first cross-directional divider including a height that is at least 90% of the height of the first z-directional layer;
a machine direction;
a cross direction;
a first z-directional layer having a height; and
a first cross-directional divider that separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner in the first z-directional layer, the first cross-directional divider including a height that is at least 90% of the height of the first z-directional layer;
transferring the first supply of fibers to the first zone of the headbox at the inlet and transferring the second supply of fibers to the second zone of the headbox at the inlet; and
transferring the first supply offbers and the second supply of fibers through the headbox to the outlet to provide the substrate.
The method of claim 1 , wherein the first supply of fibers is transferred to the first zone of the headbox and the second supply of fibers is transferred to the second zone of the headbox; and wherein transferring the first supply of fibers and the second supply of fibers through the headbox provides the substrate with a first zone comprising fibers from the first supply of fibers and a second zone comprising fibers from the second supply of fibers.
wherein transferring the first supply of fibers and the second supply of fibers through the headbox provides the substrate with a first zone comprising fibers from the first supply of fibers and a second zone comprising fibers from the second supply of fibers.
The method of claim 1 , wherein the headbox further comprises a z-directional divider comprising a first surface and a second surface, the second surface being opposite from the first surface, the z-directional divider providing the first z-directional layer in the headbox and a second z-directional layer in the headbox.
The method of claim 1 , further comprising a second cross-directional divider that separates the second zone of the headbox from a third zone of the headbox in a cross-directional manner in the first z-directional layer.
The method of claim 3 , further comprising a second cross-directional divider that separates the second zone of the headbox from a third zone of the headbox in a cross-directional manner in the first z-directional layer; wherein the first zone, the second zone, and the third zone each form part of the first z-directional layer of the headbox.
The method of claim 5 , wherein the first supply of fibers are transferred to the second zone of the headbox in the first z-directional layer of the headbox and the second supply of fibers are transferred to the second z-directional layer of the headbox; and wherein transferring the first supply of fibers and the second supply of fibers through the headbox provides the substrate with a first layer comprising fibers from the first supply of fibers and a second layer comprising fibers from the second supply of fibers.
The method of claim 6 , wherein the first supply of fibers comprise synthetic fibers and the second supply of fibers comprise absorbent fibers.
The method of claim 5 , further comprising: providing a third supply of fibers; transferring the third supply of fibers to the headbox at the inlet; and transferring the third supply of fibers through the headbox to the outlet to provide the substrate.
providing a third supply of fibers;
transferring the third supply of fibers to the headbox at the inlet; and
transferring the third supply of fibers through the headbox to the outlet to provide the substrate.
The method of claim 8 , wherein the first supply of fibers are transferred to the first zone and the third zone of the first z-directional layer of the headbox, the second supply of fibers are transferred to the second zone of the first z-directional layer of the headbox, and the third supply of fibers are transferred to the second z-directional layer of the headbox.
The method of claim 9 , wherein the first supply of fibers comprise at least one type of distribution fiber; the second supply of fibers comprise at least one type of intake fiber; and the third supply of fibers comprise absorbent fibers.
The method of claim 1 , further comprising: providing a supply of particulates to the headbox; transferring the supply of particulate to the headbox at the inlet; and transferring the supply of particulates through the headbox to provide the substrate.
providing a supply of particulates to the headbox;
transferring the supply of particulate to the headbox at the inlet; and
transferring the supply of particulates through the headbox to provide the substrate.
The method of claim 11 , wherein the particulates comprise superabsorbent material.
The method of claim 1 , wherein the first supply of fibers are provided in a first foam slurry and the second supply of fibers are provided in a second foam slurry.
A divider for a headbox including a cross direction and a machine direction and a width in the cross direction, the divider comprising: a first surface; a second surface, the second surface being opposite from the first surface; a width defined in the cross direction that is at least 90% of the width of the headbox; a length defined in the machine direction; and a first cross-directional divider extending away from the first surface, the first cross-directional divider comprising a cross-directional thickness and a machine-directional length.
a first surface;
a second surface, the second surface being opposite from the first surface;
a width defined in the cross direction that is at least 90% of the width of the headbox;
a length defined in the machine direction; and
a first cross-directional divider extending away from the first surface, the first cross-directional divider comprising a cross-directional thickness and a machine-directional length.
The divider of claim 14 , wherein the first cross-directional divider extends away from the first surface in a directional substantially perpendicular to a plane defined by the first surface of the divider.
The divider of claim 15 , wherein the first cross-directional divider further comprises a proximal end and a distal end, and wherein a height of the first cross-directional divider as measured at the proximal end of the first cross-directional divider is greater than a height of the first cross-directional divider as measured at the distal end of the first cross-directional divider.
The divider of claim 14 , further comprising a second cross-directional divider.
The divider of claim 17 , wherein the second cross-directional divider extends away from the first surface of the divider and is spaced apart from the first cross-directional divider in the cross direction.
The divider of claim 17 , wherein the second cross-directional divider extends away from the second surface of the divider.
A headbox for manufacturing a substrate, the headbox including a machine direction and a cross direction, the headbox comprising: an inlet; an outlet; an internal chamber; and a divider at least partially within the internal chamber, the divider comprising: a first surface; a second surface, the second surface being opposite from the first surface; a width defined in the cross direction that is at least 90% of a width of the internal chamber of the headbox; a length defined in the machine direction; and a first cross-directional divider extending away from the first surface of the divider, the first cross-directional divider comprising a cross-directional thickness and a machine-directional length; wherein the divider separates a first z-directional layer of the headbox from a second z-directional layer of the headbox; and wherein the first cross-directional divider separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner, the first zone and the second zone being in the first z-directional layer.
an internal chamber; and
a divider at least partially within the internal chamber, the divider comprising: a first surface; a second surface, the second surface being opposite from the first surface; a width defined in the cross direction that is at least 90% of a width of the internal chamber of the headbox; a length defined in the machine direction; and a first cross-directional divider extending away from the first surface of the divider, the first cross-directional divider comprising a cross-directional thickness and a machine-directional length; wherein the divider separates a first z-directional layer of the headbox from a second z-directional layer of the headbox; and wherein the first cross-directional divider separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner, the first zone and the second zone being in the first z-directional layer.
a width defined in the cross direction that is at least 90% of a width of the internal chamber of the headbox;
a first cross-directional divider extending away from the first surface of the divider, the first cross-directional divider comprising a cross-directional thickness and a machine-directional length;
wherein the divider separates a first z-directional layer of the headbox from a second z-directional layer of the headbox; and
wherein the first cross-directional divider separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner, the first zone and the second zone being in the first z-directional layer.
The headbox of claim 20 , wherein the divider further comprises a second cross-directional divider.
A method for manufacturing a substrate including a first layer and a second layer, the method comprising: providing a first supply of fibers; providing a supply of particulates; providing a headbox, the headbox comprising: a machine direction; a cross-direction; a z-direction, the z-direction being perpendicular to a plane defined by the machine direction and the cross-direction; and a divider comprising a first surface, a second surface opposite the first surface, a width extending in the cross-direction, and a length extending in the machine direction, the divider separating a first z-directional layer of the headbox from a second z-direction al layer of the headbox; setting a z-directional position of the divider in the headbox to provide a target relative thickness setting of the second z-directional layer of the headbox; transferring the first supply of fibers and the supply of particulates to the headbox such that the first supply of fibers enter the first z-directional layer of the headbox and the supply of particulates enter the second z-directional layer of the headbox; and controlling the first supply of fibers and the supply of particulates through the headbox to a forming surface such that a relative thickness of the second layer of the substrate is provided with less than 20% variation of the target relative thickness setting of the second z-directional layer of the headbox.
providing a supply of particulates;
providing a headbox, the headbox comprising: a machine direction; a cross-direction; a z-direction, the z-direction being perpendicular to a plane defined by the machine direction and the cross-direction; and a divider comprising a first surface, a second surface opposite the first surface, a width extending in the cross-direction, and a length extending in the machine direction, the divider separating a first z-directional layer of the headbox from a second z-direction al layer of the headbox;
a cross-direction;
a z-direction, the z-direction being perpendicular to a plane defined by the machine direction and the cross-direction; and
a divider comprising a first surface, a second surface opposite the first surface, a width extending in the cross-direction, and a length extending in the machine direction, the divider separating a first z-directional layer of the headbox from a second z-direction al layer of the headbox;
setting a z-directional position of the divider in the headbox to provide a target relative thickness setting of the second z-directional layer of the headbox;
transferring the first supply of fibers and the supply of particulates to the headbox such that the first supply of fibers enter the first z-directional layer of the headbox and the supply of particulates enter the second z-directional layer of the headbox; and
controlling the first supply of fibers and the supply of particulates through the headbox to a forming surface such that a relative thickness of the second layer of the substrate is provided with less than 20% variation of the target relative thickness setting of the second z-directional layer of the headbox.
The method of claim 22 , wherein the controlling of the first supply of fibers and the supply of particulates through the headbox comprises providing a divider including a length in the machine direction of greater than 50% of a length of the headbox.
The method of claim 22 , wherein a relative thickness of a second layer of the substrate is provided with less than 10% variation of the target relative thickness setting of the second z-directional layer of the headbox.
The method of claim 22 , wherein the target relative thickness setting of the second z-directional layer of the headbox is 50% of a total thickness of the headbox.
Ref US20230131582A1: Claims:
A substrate including a machine direction, a cross-direction, and a z-direction perpendicular to a plane defined by the machine direction and the cross-direction, the substrate comprising: a first layer, the first layer comprising: a first zone comprising a plurality of fibers; a second zone comprising a plurality of fibers, the second zone being offset from the first zone in the cross-direction; and an interface between the first zone and the second zone, the interface between the first zone and the second zone comprising at least some of the plurality of fibers of the first zone being mixed with at least some of the plurality of fibers of the second zone to provide a purity gradient with a transition width less than 3.8 cm as defined by a Purity Gradient Test Method as described herein.
a first layer, the first layer comprising: a first zone comprising a plurality of fibers; a second zone comprising a plurality of fibers, the second zone being offset from the first zone in the cross-direction; and an interface between the first zone and the second zone, the interface between the first zone and the second zone comprising at least some of the plurality of fibers of the first zone being mixed with at least some of the plurality of fibers of the second zone to provide a purity gradient with a transition width less than 3.8 cm as defined by a Purity Gradient Test Method as described herein.
a first zone comprising a plurality of fibers;
a second zone comprising a plurality of fibers, the second zone being offset from the first zone in the cross-direction; and
an interface between the first zone and the second zone, the interface between the first zone and the second zone comprising at least some of the plurality of fibers of the first zone being mixed with at least some of the plurality of fibers of the second zone to provide a purity gradient with a transition width less than 3.8 cm as defined by a Purity Gradient Test Method as described herein.
The substrate of claim 1 , wherein the purity gradient provides the transition width to be less than 3.0 cm.
The substrate of claim 1 , wherein the purity gradient provides a transition slope greater than 28 gray/cm as defined by the Purity Gradient Test Method.
The substrate of claim 3 , wherein the transition slope is greater than 40 gray/cm.
The substrate of claim 1 , wherein the first layer further comprises: a third zone, the third zone being offset from the first zone and the second zone in the cross-direction, the second zone being between the first zone and the third zone; and an interface between the second zone and the third zone, the interface between the second zone and the third zone comprising at least some of the plurality of fibers of the second zone being mixed with at least some of the plurality of fibers of the third zone to provide a purity gradient with at least one of a transition width less than 3.8 cm as defined by the Purity Gradient Test Method and a transition slope greater than 28 gray/cm as defined by a Purity Gradient Test Method.
a third zone, the third zone being offset from the first zone and the second zone in the cross-direction, the second zone being between the first zone and the third zone; and
an interface between the second zone and the third zone, the interface between the second zone and the third zone comprising at least some of the plurality of fibers of the second zone being mixed with at least some of the plurality of fibers of the third zone to provide a purity gradient with at least one of a transition width less than 3.8 cm as defined by the Purity Gradient Test Method and a transition slope greater than 28 gray/cm as defined by a Purity Gradient Test Method.
The substrate of claim 5 , further comprising: a second layer, the second layer being offset from the first layer in the z-direction.
a second layer, the second layer being offset from the first layer in the z-direction.
The substrate of claim 6 , wherein the second layer comprises superabsorbent material.
The substrate of claim 6 , wherein the plurality of fibers in the first zone and the plurality of fibers in the third zone each comprise cellulosic fibers, and wherein the first zone and the third zone each comprise a binder.
The substrate of claim 6 , wherein the plurality of fibers in the second zone comprise synthetic fibers, and wherein the second zone further comprises a binder.
A substrate including a machine direction, a cross-direction, and a z-direction perpendicular to a plane defined by the machine direction and the cross-direction, the substrate comprising: a first layer, the first layer comprising: a first zone comprising a plurality of fibers; a second zone comprising a plurality of fibers, the second zone being offset from the first zone in the cross-direction; and an interface between the first zone and the second zone, the interface between the first zone and the second zone comprising at least some of the plurality of fibers of the first zone being mixed with at least some of the plurality of fibers of the second zone to provide a purity gradient with a transition slope greater than 28 gray/cm as defined by a Purity Gradient Test Method as described herein.
a first layer, the first layer comprising: a first zone comprising a plurality of fibers; a second zo
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