Fred Whitaker Company v. E. T. Barwick Industries, Inc.

551 F.2d 622, 194 U.S.P.Q. (BNA) 113, 1977 U.S. App. LEXIS 13622
CourtCourt of Appeals for the Fifth Circuit
DecidedApril 28, 1977
Docket74-3112
StatusPublished
Cited by10 cases

This text of 551 F.2d 622 (Fred Whitaker Company v. E. T. Barwick Industries, Inc.) is published on Counsel Stack Legal Research, covering Court of Appeals for the Fifth Circuit primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
Fred Whitaker Company v. E. T. Barwick Industries, Inc., 551 F.2d 622, 194 U.S.P.Q. (BNA) 113, 1977 U.S. App. LEXIS 13622 (5th Cir. 1977).

Opinion

GODBOLD, Circuit Judge:

Plaintiff Fred Whitaker Co. (Whitaker) charges that E. T. Barwick Industries, Inc. (Barwick) has infringed the ex- *624 elusive rights Whitaker owns under claims 4 1 and 10 2 of U.S. Patent No. 3,012,303. The patent in suit is a combination process patent. It describes a process of dyeing and treating yarn for use in carpets and upholstery fabrics. The district court held that the patent is invalid and, even if valid, uninfringed. We agree that the patent is invalid, and, for this reason, hold that the district court properly'dismissed the action.

I. Description of the patent

There are five basic elements which, in combination, comprise the process Whitaker claimed as its invention when it applied for a patent in December 1959.

1. Use of continuous filament yarn. In recent years carpet and upholstery manufacturers have had available to them two kinds of yarns, staple yarns and continuous filament yarns. The district court explained the difference between them: “Spun staple yarns are made from short fibers called staple fibers, for example cotton, wool and chopped nylon fibers. Continuous filament yarn is made from individual filaments which are formed in a continuous, unbroken length.” Whitaker sought patent rights for a general process (claim 1) and specific embodiments of it in both staple (claim 5) and continuous filament (claim 4) yarn. Continuous filament yarn is the only kind at issue in this case. 3

In this litigation Whitaker has defended the validity of its patent by arguing that use of its techniques on bulked continuous filament nylon yarn (known as “BCF yarn”) would not have been obvious in light of the prior art. Bulked continuous filament yarn is manufactured with its individual filaments “crimped,” creating air spaces between the filaments. The claims of the patent do not, however, limit the invention to bulked continuous filament yarn. Claim 4 simply refers to “the process of claim 1, in which the yarn is continuous filament yarn.” Nor do the specifications even imply that the process should be employed only with bulked yarn. Indeed, they suggest the contrary by noting that “[t]he invention may be applied to yarn previously texturized or bulked by some other process” (emphasis added). Much trial testimony was devoted to an explanation of how Whitaker restores bulk put in by the manufacturer, but the record supports the construction that the 1959 patent application intended to make use of both kinds of yarns. 4 Accordingly, we interpret claims 4 and 10 as describing a process for unbulked (or “feeder”), as well as bulked, continuous fiber yarn.

2. The knit-deknit process. Whitaker’s patent describes a process by which yarn is knit into an endless tube called a prefabric. The yarn is dyed in that form and then unwound again. The district court ex *625 plained: “Use of the knit-deknit prefabric, ungainly though it seems to the uninitiated, so facilitates the handling of the yarn during the dyeing operations that it offsets the added cost of knitting and deknitting.”

3. Multicolor dyeing. In initial experimentation with the knit-deknit process, Whitaker encountered problems when it had dyed its yarn with a single color. Streaks appeared because of the uneven dye affinity of the yarn along its length. 5 In response to this difficulty, Whitaker began to dye its yarn by printing a multicolored striped pattern onto the prefabric. When unravelled, the yarn would display a variegated pattern. With many shades blending into each other, the undesirable streaking effect would be somewhat disguised.

4. Heat-setting. One of the approaches Whitaker describes (embodied in claim 10) 6 includes a heat-setting step. Before being unravelled, the yarn is heated in an autoclave 7 at 180° to 270° for a period of time ranging from one to 30 minutes.

Heat-setting appears to serve two purposes. When used after the multicoloring step, it can set the dye permanently and dry the yarn. Also, heat-setting imparts a curl to the yarn by fixing it in the position into which it is formed when knitted into the tubular prefabric. As seen immediately after the heating process, this curl (referred to also as a “kink”) does more harm than good with respect to the objective of imparting (or re-establishing) bulk. While the bundle of individual filaments (i. e., the yarn) becomes kinked within the bundle, the individual filaments also become more tightly bound together:

Q. And when the yarn is knitted or in a captured position then and it’s heat-set, how does that affect the yarn? A. Well, it closes the stitches together.
Q. Is that desirable or undesirable? A. It’s undesirable.
Q. Why is it undesirable? A. Well, you want to maintain the original bulk as it comes in from a producer or as you start with and, therefore, you don’t want to shrink it and lock those curls together.
Q. If it’s undesirable, why do you do it? A. Well, we can’t help from doing it because we set the color and it also sets the yarn at the same time. Simultaneously.
Q. Suppose you didn’t heat it enough to heat-set it, what would that do to the colors? A. Well, the colors would wash right off.
Q. Would that make a satisfactory salable yarn? A. Oh, no. No. 8

Additionally, the dye becomes concentrated in the apexes of the resulting kinks. 9 However, the subsequent opening up process, explained below, turns this relative disadvantage into an advantage. Opening up preserves the heat-setting curl but spreads apart the individual filaments and distributes their uneven dye concentration:

Q. You have also told us about the curl of the knit. A. Yes.
Q. Which is formed where the curl is formed into a loop. A. Yes.
*626 Q. Was that curl desirable or undesirable? A. Well, I would say it was desirable. Once we reoriented it.
Whether it was more desirable than the original crimp of DuPont’s — that area of the loop — we didn’t take out all of the DuPont crimp but we must have taken some out. The tension took some of it out and we superimposed this curl on it.
Now when that’s fluffed open it must be quite desirable because everybody wanted it and they didn’t complaint about it.
Q. Was it desirable until you fluffed it open? A. No. We had to — oh, no.

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Bluebook (online)
551 F.2d 622, 194 U.S.P.Q. (BNA) 113, 1977 U.S. App. LEXIS 13622, Counsel Stack Legal Research, https://law.counselstack.com/opinion/fred-whitaker-company-v-e-t-barwick-industries-inc-ca5-1977.