Boeing Co. v. United States

86 Fed. Cl. 303, 2009 WL 931532
CourtUnited States Court of Federal Claims
DecidedApril 2, 2009
DocketNo. 00-705C
StatusPublished
Cited by13 cases

This text of 86 Fed. Cl. 303 (Boeing Co. v. United States) is published on Counsel Stack Legal Research, covering United States Court of Federal Claims primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
Boeing Co. v. United States, 86 Fed. Cl. 303, 2009 WL 931532 (uscfc 2009).

Opinion

OPINION

ALLEGRA, Judge.

This case is before the court following a trial in Washington, D.C. and New Orleans, Louisiana. In this patent ease, the Boeing Company (Boeing) seeks compensation from the United States, under 28 U.S.C. § 1498(a), for the unlawful use of U.S. Patent No. 4,840,682 (the '682 patent), which is directed to the low temperature underaging of aluminum lithium alloys. In two prior opinions, this court construed the '682 patent, found it valid, and held that the United States, through the National Aeronautics and Space Administration (NASA), had infringed the patent when it employed the underaging technique in manufacturing parts of the Space Shuttle. See The Boeing Co. v. United States, 69 Fed.Cl. 397 (2006) (Boeing II) (validity and infringement opinion); The Boeing Co. v. United States, 57 Fed.Cl. 22 (2003) (Boeing I) (Markman opinion). In this third installment, the court determines the amount of damages and prejudgment interest owed by defendant to plaintiff.

[307]*307I. FINDINGS

Based upon the record, including the parties’ stipulation of facts, the court finds as follows:

In the 1970s and 1980s, prompted by high jet fuel prices, Boeing began to investigate ways to reduce the structural weight of its airplanes to make them more fuel efficient. It knew that there were three main ways to do this — use lighter engines, alter the design of the airframe, or utilize improved structural materials. Prior to Boeing’s efforts, the industry had focused primarily on the first two of these. In terms of structural materials, a combination of aluminum and steel had been used consistently on aircraft since the 1930s. However, by the early 1980s, advances in metallurgy led Boeing to conclude that aluminum alloys could play a major role in reducing the weight of airplanes.

For these purposes, lithium — the lightest metallic element — held the greatest potential as an alloying substance. Aluminum-lithium (Al-Li) alloys are lightweight, yet offer a high payload capacity, ostensibly a perfect match for Boeing. See Boeing II, 69 Fed.Cl. at 401-02. Historically, however, such alloys had been shunned by aircraft manufacturers because they tended to have poor “fracture toughness,” meaning that a crack in a part constructed of such alloys could very quickly propagate when stressed, potentially leading to a catastrophic failure. The industry’s concerns stemmed, in part, from several well-publicized airline crashes in the 1950s that were attributed to poor fracture toughness.

To address this problem, Boeing experimented with several Al-Li alloys, varying the amount of time they were heat-treated (or “aged”) and adjusting their chemical composition by adding differing amounts of other elements, such as zirconium, magnesium, zinc, copper, and silicon. See Boeing II, 69 Fed.Cl. at 402-08 (describing, in greater detail, this development process). Eventually, Boeing found a composition that, when subjected to a heat-treatment process called “low-temperature underaging,” produced the desired mix of density and fracture toughness, making it suitable for aircraft structures.

Boeing applied for, and, on June 20, 1989, was granted a patent for this process. The patent so issued, the '682 patent, consists of seven claims, the latter six of which are dependent, in some fashion, upon the first. That first claim recites as follows:

A process for improving the fracture toughness of an aluminum-lithium alloy without detracting from the strength of said alloy, said alloy consisting essentially of:
Element Amount (wt.%)
Li [Lithium] 1.0 to 3.2
Mg [Magnesium] 0 to 5.5
Cu [Copper] 0 to 4.5
Zr [Zirconium] 0.08 to 0.15
Mn [Manganese] 0 to 1.2
Fe [Iron] 0.3 max
Si [Silicon] 0.5 max
Zn [Zinc] 0.25 max
Ti [Titanium] 0.15 max
Other trace elements
Each 0.05 max
Total 0.25 max
A1 [Aluminum] Balance,
said alloy first being formed into an article, solution heat treated and quenched, said process comprising the step of aging said alloy article to a predetermined underaged strength level at from about 200° F. to less than 300° F.

Claim 7 of the patent reads “[t]he product produced by the process of Claim 1” and is a “product-by-process” claim, meaning that it covers any structure made by the process articulated in the first claim.

In 1991, Boeing granted three aluminum suppliers — Aluminum Company of America (Alcoa), Reynolds Metal Company (Reynolds), and Pechiney Rhenalu (Pechiney) — licenses to make products using the underag-ing process laid out in the '682 patent. Each of these licenses was retroactive to specified dates in 1989. Typical of the granting language in these licenses is the following taken from the Pechiney agreement: “Subject to the terms and conditions set forth herein, BOEING hereby grants to PECHINEY a nontransferable, nonexclusive license under the Licensed Property to use the Licensed Processes and to make and sell Licensed Products within the Licensed Territory.” Under each license, Boeing was entitled to a royalty of 1.25 percent of the “Net Sales [308]*308Price of Each Licensed Product sold.” The Net Sales Price was defined as “the invoiced sale price (exclusive of prepaid freight charges, insurance, taxes, duties, and discounts actually allowed) of Licensed Products sold to a non-Affiliate Customer.” In the event there were no such sales, the agreements stipulated that an “Equivalent Sales Price” would be used to calculate the royalties due Boeing. That price was defined as “the manufacturing cost of each Licensed Product plus overhead and a reasonable profit.”

Around the time Boeing began working on Al-Li alloys to lighten its aircraft, NASA faced a similar task in seeking to reduce the weight of the Space Shuttle, officially called the Space Transportation System. The latter effort centered, in part, on the shuttle’s external tank — the large, brownish-orange tank upon which the orbiter sits during launch. That tank not only contains the propellant used by the orbiter’s main engines, but also functions as the structural backbone of the spaceship during launch, providing support for the solid rocket boosters and the orbiter. NASA’s efforts led to a redesigned external tank, known as the Lightweight Tank (LWT), which was about five tons lighter than the original Standard Weight Tank (SWT) — 75,569 versus 65,539 pounds.

In the late 1980s and early 1990s, NASA was planning the orbital laboratory that would become the International Space Station (ISS). Originally, the ISS was to orbit the Earth at an angle of inclination of 28.5 degrees, to coincide with the latitude of the NASA launch center at Cape Canaveral, Florida.

Free access — add to your briefcase to read the full text and ask questions with AI

Related

Cite This Page — Counsel Stack

Bluebook (online)
86 Fed. Cl. 303, 2009 WL 931532, Counsel Stack Legal Research, https://law.counselstack.com/opinion/boeing-co-v-united-states-uscfc-2009.