Paper No. 1
`
`UNITED STATES PATENT AND TRADEMARK OFFICE
`
`BEFORE THE PATENT TRIAL AND APPEAL BOARD
`
`Owens Coming Corporation,
`Petitioner
`
`go
`
`CertainTeed Corporation,
`Patent Owner
`
`Patent No. 8,409,689
`Issued: April 2, 2013
`Filed: May 2, 2012
`Husnu M. Kalkanoglu and Stephen A. Koch
`
`Inventors:
`
`Title: SHINGLE WITH REINFORCEMENT LAYER
`
`Inter Partes Review No. 2014-01402
`
`PETITION FOR INTER PARTES REVIEW
`
`FAST FELT 2028, pg. 1
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
`
`TABLE OF CONTENTS
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`Compliance with Requirements of an Inter Partes Review Petition .............. 1
`
`A.
`
`Certification that the Patent May Be Contested via Inter Partes
`Review by the Petitioner ....................................................................... 1
`
`B.
`
`Fee for Inter Partes Review (§ 42.15(a)) ............................................... 1
`
`C. Mandatory Notices (37 CFR § 42.8(b)) ................................................ 1
`Real Party in Interest (§ 42.8(b)(1)) ............................................ 1
`
`1.
`
`2.
`
`3.
`
`4.
`
`Other Proceedings (§ 42.8(b)(2)) ................................................ 2
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`Lead and Backup Lead Counsel (§ 42.8(b)(3)) .......................... 2
`
`Service on Petitioner ................................................................... 2
`
`D. Proof of Service (§§ 42.6(e) and 42.105(a)) ......................................... 2
`
`II.
`
`Identification of Claims Being Challenged (§ 42.104(b)) ............................... 2
`
`III.
`
`Relevant Information Concerning the Contested Patent ................................. 3
`
`A. Background of the Technology ............................................................. 3
`The Basic Asphalt Shingle Coated on Both Sides with
`Asphalt and Granules Had Been Known for Decades ................ 3
`
`1.
`
`2.
`
`The Prior Art Disclosed a Generally Longitudinal Second
`Thickness Layer For Reinforcement in the Nailing Zone .......... 7
`3. The Prior Art Taught Thin Reinforcement Material ................. 10
`Laminated Shingles Including Multiple Reinforcement
`Layers Were Known ................................................................. 12
`
`4.
`
`B.
`
`General Overview Of The ’689 Patent ................................................ 15
`The ’689 Patent Recognizes the Basic Asphalt Shingle
`1.
`Was Known ............................................................................... 15
`2. Only a Rear Exterior Surface Reinforcement Layer Is
`Disclosed in the ’689 Patent ..................................................... 15
`The Reinforcement Layer Is "Adhered" to the Surface
`in All the Claims ....................................................................... 17
`
`3.
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`FAST FELT 2028, pg. 2
`Owens Corning v. Fast Felt
`IPR2015-00650
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`

`
`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
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`4. The Reinforcing Layer Provides Strength and Stability ........... 18
`
`C.
`
`Prosecution History and Effective Filing Date of the ’689 Patent ...... 18
`
`2.
`
`1.
`
`Prosecution of the ’689 Patent .................................................. 18
`Prosecution of Related Patent Applications .............................. 19
`a) U.S. Appl. No. 10/871,911 ............................................. 19
`b) U.S. Appl. No. 12/857,868 ............................................. 20
`3. Effective Filing Date of the Claims .......................................... 23
`
`D. Person of Ordinary skill ...................................................................... 23
`
`E.
`
`2.
`
`3.
`
`Construction of Terms Used in the Claims ......................................... 23
`1.
`Elements (a)-(d) of Claim 1 ...................................................... 24
`"said shingle" ............................................................................ 24
`"adhered to an exterior surface of said shingle" ....................... 27
`"reinforcement... layer" .......................................................... 31
`"substantially thinner" .............................................................. 31
`
`4.
`
`5.
`
`IV.
`
`Precise Reasons for Relief Requested ........................................................... 32
`
`A.
`
`Claims 1-13 Are Unpatentable Over Venrick 1939 ........................... 32
`
`1. Venrick 1939 Renders Obvious Claim 1 .................................. 32
`
`o
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`3.
`
`4.
`
`5.
`
`6.
`
`7.
`
`8.
`
`9.
`
`10.
`
`Venrick 1939 Renders Obvious Claim 3 .................................. 37
`Venrick 1939 Renders Obvious Claim 4 .................................. 37
`Venrick 1939 Renders Obvious Claim 9 .................................. 38
`Venrick 1939 Renders Obvious Claims 2, 8, and 13 ................ 38
`Venrick 1939 Renders Obvious Claim 6 .................................. 39
`Venrick 1939 Renders Obvious Claims 7 and 12 ..................... 39
`Venrick 1939 Renders Obvious Claim 5 .................................. 40
`Venrick 1939 Renders Obvious Claim 10 ................................ 40
`Venrick 1939 Renders Obvious Claim 11 ................................ 40
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`go
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`Claims 1-13 Are Unpatentable Over Venrick 1939 in View of
`Frankoski 1998 .................................................................................... 41
`
`ii
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`FAST FELT 2028, pg. 3
`Owens Corning v. Fast Felt
`IPR2015-00650
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`

`
`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
`
`Venrick 1939 in View of Frankoski 1998 Renders
`Obvious Claim 1 ....................................................................... 41
`
`Venrick 1939 in View of Frankoski 1998 Renders
`Obvious Claim 3 ....................................................................... 46
`
`Venrick 1939 in View of Frankoski 1998 Renders
`Obvious Claim 4 ....................................................................... 46
`
`Venrick 1939 in View of Frankoski 1998 Renders
`Obvious Claim 9 ....................................................................... 47
`
`Venrick 1939 in View of Frankoski 1998 Renders
`Obvious Claims 2, 8 and 13 ...................................................... 47
`Venrick 1939 in View of Frankoski 1998 Renders
`Obvious Claim 6 ....................................................................... 48
`
`Venrick 1939 in View of Frankoski 1998 Renders
`Obvious Claim 7 and Claim 12 ................................................. 49
`
`Venrick 1939 in View of Frankoski 1998 Renders
`Obvious Claim 5 ....................................................................... 49
`
`Venrick 1939 In View Of Frankoski 1998 Renders
`Obvious Claim l0 ..................................................................... 49
`
`o
`
`o
`
`o
`
`o
`
`°
`
`°
`
`°
`
`°
`
`10.
`
`Venrick 1939 In View Of Frankoski 1998 Renders
`Obvious Claim 11 ..................................................................... 50
`
`Co
`
`Claims 1-13 Are Unpatentable Over Venrick 1939 in View
`of Kiik 2001 ......................................................................................... 50
`1.
`
`Venrick 1939 in View of Kiik 2001 Renders Obvious
`Claim 1 ...................................................................................... 50
`
`2.
`
`3.
`
`Venrick 1939 in View of Kiik 2001 Renders Obvious
`Claim 3 ...................................................................................... 55
`
`Venrick 1939 in View of Kiik 2001 Renders Obvious
`Claim 4 ...................................................................................... 55
`
`4. Venrick 1939 in View of Kiik 2001 Renders Obvious
`Claim 9 ...................................................................................... 56
`
`5.
`
`Venrick 1939 in View of Kiik 2001 Renders Obvious
`Claims 2, 8, and 13 .................................................................... 56
`
`iii
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`FAST FELT 2028, pg. 4
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
`
`°
`
`°
`
`°
`
`°
`
`Venrick 1939 in View of Kiik 2001 Renders Obvious
`Claim 6 ...................................................................................... 56
`
`Venrick 1939 in View of Kiik 2001 Renders Obvious
`Claims 7 and 12 ......................................................................... 57
`
`Venrick 1939 in View of Kiik 2001 Renders Obvious
`Claim 5 ...................................................................................... 57
`
`Venrick 1939 In View of Kiik 2001 Renders Obvious
`Claim 10 .................................................................................... 58
`
`10.
`
`Venrick 1939 In View of Kiik 2001 Renders Obvious
`Claim 11 .................................................................................... 58
`
`Do
`
`Secondary Considerations Do Not Weigh In Favor of
`Nonobviousness ................................................................................... 59
`
`go
`
`CONCLUSION .............................................................................................. 60
`
`Attachment A.
`
`Proof of Service of the Petition
`
`Attachment B.
`
`List of Evidence and Exhibits Relied Upon in Petition
`
`iv
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`FAST FELT 2028, pg. 5
`Owens Corning v. Fast Felt
`IPR2015-00650
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`

`
`I.
`
`Compliance with Requirements of an InterPartes Review Petition
`
`A.
`
`Certification that the Patent May Be Contested via InterPartes
`Review by the Petitioner
`
`Petitioner certifies it is not barred or estopped from requesting interpartes
`
`review of U.S. Patent No. 8,409,689 ("the ’689 patent") (Ex. 1036). Neither
`
`Petitioner, nor any party in privity with Petitioner: (i) has filed a civil action
`
`challenging the validity of any claim of the ’689 patent; or (ii) has been served a
`
`complaint alleging infringement of the ’689 patent more than one year prior to the
`
`present date. Also, the ’689 patent has not been the subject of a prior interpartes
`
`review or a finally concluded district court litigation involving Petitioner.
`
`Petitioner also certifies this petition for interpartes review is filed in
`
`compliance with 35 U.S.C. § 315(b). Petitioner Owens Coming was served a
`
`complaint alleging infringement of the ’689 patent on April 22, 2014 resulting in
`
`Civ. A. No. I:14-cv-00510-SLR (D. Del.). See Ex. 1045 (Complaint).
`
`B. Fee for Inter Partes Review (§ 42.15(a))
`
`The Director is authorized to charge Deposit Account No. 50-1597.
`
`C. Mandatory Notices (37 CFR § 42.8(b))
`
`1. Real Party in Interest (§ 42.8(b)(1))
`
`The real party in interest is Owens Coming, located at One Owens Coming
`
`Parkway, Toledo, OH 43659.
`
`FAST FELT 2028, pg. 6
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
`
`2. Other Proceedings (§ 42.8(b)(2))
`
`The ’689 patent is the subject of litigation in the District of Delaware (Cir.
`
`A. No. I:14-cv-00510-SLR), which names Owens Coming as defendant. Patents
`
`related to the ’689 patent, by continuation, are the subject of petitions for inter
`
`partes review filed concurrently herewith (IPR Nos. 2014-01397,
`
`2014-01401,
`
`2014-01403, -01404).
`
`3.
`
`Lead and Backup Lead Counsel (§ 42.8(b)(3))
`
`Lead Counsel
`Jeffrey P. Kushan
`Reg. No. 43,401
`j kushan~sidley.com
`(202) 736-8914
`
`Backup Lead Counsel
`Peter S. Choi
`Reg. No. 54,033
`peter.choi(~sidley.com
`(202) 736-8076
`
`4.
`
`Service on Petitioner
`
`Service on Petitioner may be made by mail or hand delivery to:
`
`Sidley
`
`Austin LLP, 1501 K Street, N.W., Washington, D.C. 20005.
`
`The fax number for
`
`Petitioner’s counsel is (202) 736-8711.
`
`D. Proof of Service (§§ 42.6(e) and 42.105(a))
`
`Proof of service of this petition is provided in Attachment A.
`
`II.
`
`Identification of Claims Being Challenged (§ 42.104(b))
`
`Claims 1-13 of the ’689 patent are unpatentable. Specifically:
`
`(1) Claims 1-13 would have been obvious under § 103 based on Venrick
`
`1939.
`
`(2) Claims 1-13 would have been obvious under § 103 based on Venrick
`
`2
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`FAST FELT 2028, pg. 7
`Owens Corning v. Fast Felt
`IPR2015-00650
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`

`
`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
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`1939 in view of Frankoski 1998.
`
`(3)
`
`Claims 1-13 would have been obvious under § 103 based on Venrick
`
`1939 in view of Kiik 2001.
`
`Petitioner’s proposed claim construction, the evidence relied upon, and precise
`
`reasons why the claims are unpatentable are provided below. A list of evidence
`
`relied upon in support of this petition is set forth in Attachment B.
`
`III. Relevant Information Concerning the Contested Patent
`
`A.
`
`Background of the Technology
`
`1.
`
`The Basic Asphalt Shingle Coated on Both Sides with
`Asphalt and Granules Had Been Known for Decades
`
`Asphalt shingles have been used to cover roofs since the late-1800s. See,
`
`e.g., Ex. 1005, Cash, "Asphalt Roofing Shingles," Proc. 11t5 Conf. Roofing Tech.
`
`(1995) (Cash 1995), at 1; Ex. 1003 (Bryson Decl.), at ¶ 46. By the mid-1990s,
`
`three styles predominated: (1) the individual shingle; (2) the strip shingle (with or
`
`without tabs), and (3) the laminated shingle. Ex. 1005 (Cash 1995), Figs. 10-12;
`
`Ex. 1003 (Bryson Decl.), at ¶¶ 46-47.
`
`Asphalt waterproofs the shingle. Ex. 1007, Noone, "Asphalt-Shingles -A
`
`Century of Success and Improvement," Proc. 11t5 Conf. Roofing Tech. (1993)
`
`(Noone 1993), at 2; Ex. 1003 (Bryson Decl.), at ¶ 48. In general, making an
`
`asphalt shingle involves passing a base mat through a coater, where layers of hot
`
`asphalt are applied to the top and back surfaces. Ex. 1007 (Noone 1993), at 2; Ex.
`
`3
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`FAST FELT 2028, pg. 8
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`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
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`1003 (Bryson Decl.), at 1 48. Colored or non-colored granules are then dropped on
`
`the front surface and other granular materials are applied to the back. Ex. 1007
`
`(Noone 1993), at 2, 5; Ex. 1003 (Bryson Decl.), at 1 48. The granular material on
`
`the front adds color and texture. Finely ground talc and sand or other granular
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`materials are added on the back to prevent sticking during storage and shipment.
`
`Ex. 1007 (Noone 1993), at 2, 5-6; Ex. 1003 (Bryson Decl.), at 1 48.
`
`The basic steps for making an asphalt shingle, including coating both sides
`
`of the base mat (i. e., substrate) with asphalt and applying granular material on both
`
`sides, have remained the same for decades. Ex. 1003 (Bryson Decl.), at 11 49-50.
`
`U.S. Patent No. 2,099,131 to Miller (issued in 1937) (Miller 1937) (Ex. 1008)
`
`states, for example:
`
`It has heretofore been common practice to manufacture prepared
`
`roofing by saturating a suitable absorbant fabric, such as roofing felt,
`
`with a liquid bituminous material, e.g., asphalt, coating botl~ sides of
`
`the saturated fabric with a bituminous material, surl~aeing tlte
`
`bituminous coating on one side ol~tlte l~abrie witlt mineral grit, such
`
`as crushed slate, and applFing mica, soapstone, or otlter anti-stick
`
`material to tlte coating on tlte otlter side ol~tlte l~abrie.
`
`!d. at 4, col. 1:13-24 (emphasis added); Ex. 1003 (Bryson Decl.), at 1 50.
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`A typical shingle includes a plurality of tabs (i. e., flaps) that extend
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`downwardly from a headlap area. !d. at 11 56-57. Each asphalt shingle has a
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`nailing zone or fastening zone for attachment to a roof. !d. As shown below in the
`
`4
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`FAST FELT 2028, pg. 9
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`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
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`1997 edition of the ARMA Roofing Manual (ARMA Manual 1997) (Ex. 1009),
`
`Fig. 10, the nailing zone typically is located just above the tabs. Also shown is the
`
`generally longitudinal dimensions of the typical strip shingle, i.e., 36"x 12".
`
`Headlap Area
`
`Ex. 1003 (Bryson Decl.), at ¶ 57. As shown, the nailing zone is (a) generally
`
`longitudinal like the shingle itself, (b) located between the right and left edges, and
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`(c) generally intermediate of the upper and lower edges. Id. at ¶¶ 57-58.
`
`Claim 1 of the ’689 patent provides: "[a] laminated shingle having front and
`
`rear surfaces, one being an anterior layer and the other being a posterior layer, with
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`the posterior layer having front and rear surfaces, a width defined by upper and
`
`lower eidges and a length defined by right and left edges." Elements (a)-(d) of
`
`claim 1 require the following of the "posterior layer":
`
`(a) a base layer of mat having front and rear surfaces;
`
`(b) a coating of asphaltic material on both front and rear surfaces of
`
`the mat;
`
`(c) coatings of granular material on both front and rear surfaces and
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`adhered thereto, which, together with said base layer of mat and
`
`coatings of asphaltic material comprise a first thickness layer; and
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`FAST FELT 2028, pg. 10
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`IPR2015-00650
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`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
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`(d) a longitudinal fastening zone between right and left shingle edges
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`generally intermediate said upper and lower edges. Ex. 1036 (’689
`
`patent), at col. 6:56-7:5.
`
`These elements describe nothing more than the basic asphalt shingle, or what was
`
`"common practice" since at least the 1930s and what had been applied to laminated
`
`shingles for decades. Ex. 1003 (Bryson Decl.), at ¶1 59-68. The ’689 patent
`
`acknowledges that these components of the "basic" laminated asphalt shingle were
`
`known. Ex. 1036 (’689 patent), at col. 3:3-6; Ex. 1003 (Bryson Decl.), at 11 59-68.
`
`To the basic laminated asphalt shingle, claim 1 of the ’689 patent adds and
`
`describes a "reinforcement second thickness layer":
`
`and an at least partially externally visible generally longitudinal
`
`reinforcement second thickness layer of a substantially thinner
`
`dimension than said first thickness layer, adhered to an exterior
`
`surface of said shingle and extending at least substantially between
`
`right and left edges of the shingle; and
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`said reinforcement layer extending at least lower than the fastening
`
`zone, toward the lower edge of the shingle or at least partially into the
`
`fastening zone toward the upper edge of the shingle.
`
`Ex. 1036 (’689 patent), at col. 7:6-16; see also id. col. 3:16-17 ("the shingle
`
`20 is similar to that of the [prior art] shingle 10 of FIG. 1, but with a reinforcement
`
`layer"). Reinforcement layers having the claimed features were known in the prior
`
`art. Ex. 1003 (Bryson Decl.), at 11 69-120.
`
`6
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`FAST FELT 2028, pg. 11
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`IPR2015-00650
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`

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`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
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`2.
`
`The Prior Art Disclosed a Generally Longitudinal Second
`Thickness Layer For Reinforcement in the Nailing Zone
`
`U.S. Patent No. 2,161,440 to Venrick (Venrick 1939) describes a
`
`"reinforcing strip" for "strengthening" to "reduce ... tear," and to "provide a
`
`reinl~oreed area for nailing the shingle to the roof." Ex. 1013 (Venrick 1939), at 3,
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`col. 1:1:40-46 (emphasis added); Ex. 1003 (Bryson Decl.), at ¶7 93-97.
`
`The Venrick 1939 strip, which may be made of, inter alia, felt, metal, or
`
`"layers of roofing tape," Ex. 1013 (Venrick 1939), at 4, col. 2:2:74-75, also
`
`functions to add "rigidity" to "resist[] the action of the wind." Id. at 5, col. 3:1:1-9;
`
`Ex. 1003 (Bryson Decl.), at ¶ 94. "[I]mproved resistance to failure upon bending"
`
`is also a function of the reinforcement layer in the ’689 patent. Ex. 1036 (’689
`
`patent), col. 5:54-55; Ex. 1003 (Bryson Decl.), at ¶ 94. The reinforcing strip is
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`shown in Fig. 1 of Venrick 1939 as 15 on the front surface of a shingle.
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`Ex. 1003 (Bryson Decl.), at ¶ 95. Venrick 1939 also teaches that the
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`reinforcement strip can be placed on the "undersurface," or rear. Ex. 1013
`
`(Venrick 1939), at 4, col. 2:60-63, see also Figs. 8-14; Ex. 1003 (Bryson Decl.), at
`
`¶ 96. Also, the strip is preferably "cemented" onto the granule surfacing, Ex. 1013
`
`7
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`FAST FELT 2028, pg. 12
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`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
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`(Venrick 1939), at 4, col. 1:32-37, and overlaps with the nailing zone to "give
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`greater nailing strength," Id. at 4, col. 2:2:11-23; Ex. 1003 (Bryson Decl.), at ¶ 96.
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`Figs. 8 and 9 of Venrick 1939 show the reinforcement strip 45 as a visible
`
`component that is adhered to the exterior rear surface of the shingle and extending
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`at least partially into the zone having nailing holes 47. Ex. 1013 (Venrick 1939);
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`Ex. 1003 (Bryson Decl.), at ¶ 97. It extends at least partially into the zone having
`
`nailing holes 47, and as shown by the hashed lines, it also extends at least partially
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`lower than the nailing zone (i. e., into the tab portion toward the lower edge of the
`
`shingle). Id. It also extends toward the upper edge into the headlap area. Id. The
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`reinforcement strip clearly forms a second thickness layer. Id. The strip is also
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`generally longitudinal. Id.
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`It was known in the art that nailing through multiple layers of shingle
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`material provided strength and contributed to roofing integrity. Id. at ¶ 98. E.g.,
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`U.S. Patent No. 6,145,265 (Malarkey) (Ex. 1011), at col. 1:60-62 ("[N]ailing
`
`through a double layer of material provides strength, which is essential for roofing
`
`integrity in windy conditions."). Because the nailing zone was generally
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`FAST FELT 2028, pg. 13
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`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
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`longitudinal, see ARMA Manual 1997 (Ex. 1009), at Fig. 10, it would only make
`
`sense to make the reinforcement layer generally longitudinal while extending it at
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`least partially into the nailing zone. Ex. 1003 (Bryson Decl.), at 1 98. This is what
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`Venrick 1939 teaches. See Ex. 1013 (Venrick 1939), at 5, col. 1:50-54 ("The
`
`shingles are nailed preferably ... where the raised median strip is."); Ex. 1003
`
`(Bryson Decl.), at 1 98.
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`Examples of reinforcing layers affixed to the rear surface abound. U.S.
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`Patent No. 4,875,321 (Rohner 1989) (Ex. 1015) discloses a "backing strip" (Fig. 2,
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`25) that can be made of "light-weight ... material" to "provide a stiffer shingle
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`which grips the nails." Id. at col. 1:55-59; Ex. 1003 (Bryson Decl.), at I 103. Fig.
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`2 exemplifies a shingle with a reinforcing backing layer 25. Fig. 3 confirms that
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`the rear facing reinforcing layer 25 extends at least partially into the nailing zone
`
`37. Ex. 1015 (Rohner 1989); Ex. 1003 (Bryson Decl.), at 11 103-104.
`
`Rohner 1989~ Fi~. 2
`
`Rohaer 1989~ Fi~. 3
`
`29
`
`--~~~, ~5 33
`~;~’’ :5;5 Zl
`
`F1G, 3
`
`The Rohner 1989 "backing strip" forms a second thickness layer on the rear,
`
`9
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`FAST FELT 2028, pg. 14
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`IPR2015-00650
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`

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`Petition for Inter Partes Review of U.S. Patent No. 8,409,689
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`and is longitudinal like the shingle itself. Ex. 1003 (Bryson Decl.), at ¶1 103-104.
`
`Similarly, U.S. Patent No. 5,860,263 to Sieling (Sieling 1999) (Ex. 1016)
`
`shows a "reinforcement" strip 60 affixed to the back portion of an asphalt shingle.
`
`Ex. 1003 (Bryson Decl.), at I 105.
`
`FIG.5
`
`2a
`
`45
`
`~ 57
`
`\
`SOB 34 45a
`
`48
`
`59
`
`50D
`~
`
`46a
`
`55
`
`Sieling 1999 describes the reinforcing strip as having dimensions that fall
`
`within the nailing zone of the shingle. Ex. 1016 (Sieling 1999), at col. 3:23-28;
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`Ex. 1003 (Bryson Decl.), at I 106. The reinforcing strip in Sieling 1999 is on the
`
`exterior surface, forms a second thickness layer, and is longitudinal in orientation.
`
`Ex. 1003 (Bryson Decl.), at I 106.
`
`3. The Prior Art Taught Thin Reinforcement Material
`
`As Venrick 1939, Rohner 1989, and Sieling 1999 show, the concept of using
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`a reinforcing layer on the back of a shingle was not new. Id. at 11 69-120. Nor
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`was the concept of using thin material for reinforcement. Id.
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`U.S. Patent No. 3,813,280 to Olszyk (Olszyk 1974) (Ex. 1014) shows a web
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`layer 16 affixed to the back of an asphalt shingle. Ex. 1003 (Bryson Decl.), at I
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`99.
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`A purpose of the web is "adding reinforcement ... and providing additional
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`tear strength." Ex. 1014 (Olszyk 1974), at col. 4:17-27 (emphasis added); Ex.
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`1003 (Bryson Decl.), at ¶ 100. The thickness of the web is on the order of 1/1000th
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`of an inch. Ex. 1014 (Olszyk 1974), at col. 3:59-60 ("a thickness of between 10
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`mils or less to about 30 mils."); Ex. 1003 (Bryson Decl.), at ¶ 101.
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`U.S. Patent Publ. No. 2001/0055680 to Kiik (Kiik 2001) (Ex. 1018)
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`discloses an asphalt roof shingle having a "backing material" that can be made of
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`woven polyester and latex fiber bound by latex. Id. at [0004]; Ex. 1003 (Bryson
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`Decl.), at ¶ 110. The exemplary backing materials have a thickness of 13-23
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`1/1000th of an inch. Ex. 1018 (Kiik 2001), at [Table 1]; Ex. 1003 (Bryson Decl.),
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`at ¶ 110. Data in Kiik 2001 shows that the reinforced shingles exhibited improved
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`tear strength and nail pull strength. Ex. 1018 (Kiik 2001), at Table I and II; Ex.
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`1003 (Bryson Decl.), at ¶ 113. Thus, like Venrick 1939 and Olszyk 1974, Kiik
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`2001 showed that thin material could be affixed to the back of an asphalt shingle to
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`provide reinforcing properties. Ex. 1003 (Bryson Decl.), at ¶ 113.
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`4.
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`Laminated Shingles Including Multiple Reinforcement
`Layers Were Known
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`As discussed, laminated shingles, which have been around for decades, are
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`shingles that are made of two layers of shingle material. Fig. 2 of U.S. Patent No.
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`3,921,358 (Ex. 1042) (Bettoli 1975), for example, shows the two layers.
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`23c/’~<"~7-~" L 24
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`In general, each layer was understood to have a front and rear surface, a
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`width defined by upper and lower edges and a length defined by right and left
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`edges. Ex. 1003 (Bryson Decl.), at ¶ 62. In the example shown, each layer is
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`made of (a) a base layer of mat having front and rear surfaces; (b) a coating of
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`asphaltic material on both front and rear surfaces of the mat; and (c) coatings of
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`granular material on at least part of both front and rear surfaces and adhered
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`thereto. Id. Each layer would also be understood to include a longitudinal
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`fastening zone between right and left shingle edges, and generally intermediate of
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`said upper and lower. Id.
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`U.S. Patent No. 5,822,943 to Frankoski (Frankoski 1998) (Ex. 1010)issued
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`in 1998. Ex. 1003 (Bryson Decl.), at ¶ 71. The ’689 patent incorporates by
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`reference Frankoski 1998 and says that the "basic" asphalt shingle can be made
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`according to its teachings. Ex. 1036 (’689 patent), at col. 3:3-6.
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`Frankoski 1998 (Ex. 1010) also discloses a laminated shingle. Ex. 1003
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`(Bryson Decl.), at ¶ 71. This is shown in Figure 1 of Frankoski 1998 (Ex. 1010).
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`~ ~o FIG. 1
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`55
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`9
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`5
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`7
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`The shingle comprises an upper layer 5 and a lower layer 7, which are glued
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`together with a sealant 9. Ex. 1003 (Bryson Decl.), at ¶ 72. The upper layer
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`includes a headlap area 10 and a number of tabs 35. Id. The lower layer is
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`longitudinal, and extends between the right and left edges. Id.
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`It was widely known that gluing an extra shingle layer to the back surface of
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`what was essentially a single layer strip shingle, as in a laminated shingle, provided
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`reinforcement by enabling a roofer to nail through two, rather than one, layer of
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`material. Id. at ¶ 76. U.S. Patent No. 6,145,265 issued to Malarkey et al.
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`(Malarkey 2000) (Ex. 1011) explains this common sense principle by noting that
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`"nailing through a double lm:er o[material provides strength." Id. at col. 1:54-
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`62 (emphasis added); Ex. 1003 (Bryson Decl.), at ¶ 76. Laminated shingles, which
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`by the late 1990s and early 2000s were among the most popular shingles made and
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`sold, therefore utilized a second thickness layer of material that were recognized to
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`add reinforcement. Id. at ¶1 51-52, 76.
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`Fig. 2 of Frankoski 1998 (Ex. 1010) also shows a scrim layer 60 in the
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`laminated shingle. Ex. 1003 (Bryson Decl.), at 11 77-78.
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`?o
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`Scrim is thin material that can be made from any number of different fabrics,
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`synthetic, or composite materials. Id. The scrim layer "provides a superior
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`strength and nail pull-through resistance to withstand, for example, hurricane force
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`winds." Ex. 1010 (Frankoski 1998), at col. 3:20-24; Ex. 1003 (Bryson Decl.), at 1
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`78. Frankoski 1998 states that the reinforcing scrim preferably extends the entire
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`length of the shingle. Id. at col. 5:27-28. This would be understood to mean the
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`reinforcing scrim is generally longitudinal given that most shingles were longer
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`than they were wide. Ex. 1003 (Bryson Decl.), at 11 78-81. Frankoski 1998 also
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`explicitly states that the scrim should "coincide with at least a portion of the nail
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`zone." Ex. 1010, at col. 5:38-39; Ex. 1003 (Bryson Decl.), at 1 81.
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`As discussed infra at § III.C.2., the Patent Owner distinguished the alleged
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`invention over Frankoski 1998 by arguing that the reinforcing layer of the alleged
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`invention is not "embedded" within the shingle as the scrim 60 is in Frankoski
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`1998, and that it instead is affixed to the exterior, rear surface of the shingle. At
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`the time these arguments were made, neither Venrick 1939, Rohner 1989, nor
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`Sieling 1999 (each discussed above) were before the Patent Office. See generally,
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`Ex. 1003 (Bryson Decl.) §§ III.F.-III.H.
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`B. General Overview Of The ’689 Patent
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`The ’689 patent issued on April 2, 2013, to inventors Kalkanoglu and Koch.
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`The title of the ’689 patent is "Shingle With Reinforcement Layer." Ex. 1036
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`(’689 patent), at col. 1:1.
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`1.
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`The ’689 Patent Recognizes the Basic Asphalt Shingle Was
`Known
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`The ’689 patent acknowledges that the basic components of an asphalt
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`shingle were known in the prior art. Ex. 1036 (’689 patent), at col. 2:49-3:6.
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`Referring to Fig. 1, the ’689 patent describes the "prior art shingle" as being made
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`of a mat covered with asphalt on "each exposed surface" with "granular material"
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`on the upper exposed surface to withstand weather and "smaller granules" on the
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`"undersurface." Id. at col. 2:49-59. The ’689 patent states that the "basic" prior
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`art shingle can be made by the methods disclosed in, among other references,
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`Frankoski 1998. Id. at col. 3:3-6; Ex. 1003 (Bryson Decl.), at ¶ 70.
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`2.
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`Only a Rear Exterior Surface Reinforcement Layer Is
`Disclosed in the ’689 Patent
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`The person of ordinary skill would understand that the reinforcement layer
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`disclosed in the ’689 patent is affixed to the rear surface of the asphalt shingle, and
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`nowhere else. Ex. 1003 (Bryson Decl.), at I 192.
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`The specification states: the "present invention is directed toward providing
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`a shingle, wherein a separate, exterior reinforcement layer is provided outside the
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`rear surface of the shingle .... " Ex. 1036 (’689 patent), at col. 1:51-53 (emphasis
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`added); Ex. 1003 (Bryson Decl.), at 11 137, 177,192.
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`The figures in the ’689 patent show the reinforcement layer to be located on
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`the rear. Ex. 1003 (Bryson Decl.), at 11 138-143,177,192. Fig. 2 shows the prior
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`art shingle with "a reinforcement la!:er applied to the rear surface thereof, in
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`accordance with the present invention." Ex. 1036 (’389 patent), at col. 2:17-19
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`(emphasis added); Ex. 1003 (Bryson Decl.), at 11 139, 177, 192. Figure 3 also
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`shows the "rear surface" of the shingle, ld. at 11 141,177,192.
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`Indeed, the specification consistently emphasizes that the reinforcement
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`layer is located on the "rear surface." See, e.g., Ex. 1036 (’689 patent), at Figs. 4
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`and 4A (reinforcement layer 29 on rear surface of shingle); col. 1:52-53
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`("reinforcement layer is provided outside the rear surface"); col. 3:17-20
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`reinforcement layer.., added on the rear 21 of the shingle"); col. 4:11-12 ("the
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`scrim 46 applied to the undersurface"); col. 5:50-6:50 (extolling performance of
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`"scrim reinforcement embedded on their rear sides," a "polyester mat
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`reinforcement layer on their rear surfaces," a heavier "reinforcement layer on the
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`Petition for Inter Partes Re