Milliken & Co. v. Mohawk Industries, Inc.

335 F. Supp. 2d 712, 2004 U.S. Dist. LEXIS 22248, 2004 WL 2070525
CourtDistrict Court, D. South Carolina
DecidedSeptember 15, 2004
DocketC.A. 7:02-3631-20
StatusPublished

This text of 335 F. Supp. 2d 712 (Milliken & Co. v. Mohawk Industries, Inc.) is published on Counsel Stack Legal Research, covering District Court, D. South Carolina primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
Milliken & Co. v. Mohawk Industries, Inc., 335 F. Supp. 2d 712, 2004 U.S. Dist. LEXIS 22248, 2004 WL 2070525 (D.S.C. 2004).

Opinion

MEMORANDUM OF DECISION

HERLONG, District Judge.

This matter is before the court on Mohawk Industries, Inc., Mohawk Carpet Corporation, Aladdin Manufacturing Corporation, and Mohawk Commercial, Inc.’s (collectively “Mohawk”) counterclaim of inequitable conduct alleging that the Patents-In-Suit, U.S. 6,203,881 (“'881 patent”) and U.S. 6,468,623 (“'623 patent”), are unenforceable because Milliken & Company (“Milliken”) engaged in inequitable conduct before the United States Patent and Trademark Office (“PTO”). Mil-liken brought a patent infringement suit against Mohawk alleging that Mohawk infringed certain claims in the Patents-in-Suit. A jury trial was held from May 4, 2004 through May 24, 2004. The jury returned a verdict finding both Patents-In-Suit invalid. On July 26, 2004, a bench trial was held to resolve Mohawk’s counterclaim of inequitable conduct.

After consideration of all of the relevant evidence of record and the arguments of the parties, the court now declares its findings of fact and conclusions of law. Should a finding of fact constitute a conclusion of law, or vice versa, the court adopts it as such and directs that it be treated accordingly.

I. Findings op Fact

1. Milliken is the owner of the Patents-in-Suit.

2. Ken Higgins (“Higgins”), a Milliken engineer with considerable experience in the carpet industry, is the named inventor on the '881 and '623 patents.

3. The Patents-In-Suit generally concern a cushion carpet tile comprised of (from bottom to top) a backing material, a foam cushion layer, a stabilizing layer, an adhesive layer, and a primary carpet fabric. The inventive concept is the single stabilizing layer between the adhesive layer and the foam cushion layer, which is in contact with the adhesive and partially embedded in the foam cushion.

4. Mohawk alleges that Milliken engaged in inequitable conduct because (1) Higgins and James Robertson (“Robertson”), a patent attorney substantially involved in the prosecution of the Parent Application, U.S. Patent Application No. 08/205,834 for the Patents-In-Suit, failed to disclose Textile Rubber & Chemical Company’s (“TRC”) prior art to the PTO, and (2) Higgins made intentional misrepresentations in Claim 1 of the Parent Application for the Patents-In-Suit when he falsely declared that he was “the original, first, and sole inventor” of the claimed invention in the Declaration of Patent Application. Specifically, Mohawk alleges that TRC was the first to invent the single stabilizing layer carpet tile and that Higgins and Robertson learned of TRC’s single stabilizing layer carpet tile structure and engaged in inequitable conduct by not disclosing TRC’s prior art to the PTO. Further, Mohawk alleges that Higgins falsely declared that he was the first inventor of the claimed inventions in the Parent Application that ultimately led to the Patents-In-Suit because initially Claim 1 of the Parent Application was directed to carpet and not limited to carpet tile. Higgins admits that he did not invent Claim 1 as originally drafted, but that the failure to limit the claims to carpet tile was an innocent mistake. In order to evaluate Mohawk’s claim of inequitable conduct, it *715 is necessary to discuss Milliken’s history of carpet tile development, TRC’s history of carpet tile development, Milliken’s contacts with TRC, Robertson’s knowledge of TRC’s prior art, and Milliken’s representations to the PTO during the prosecution of the Patents-In-Suit.

A. History of Milliken’s Carpet Tile Development

5. In the 1980’s and 1990’s, Higgins’ primary focus was on the development of cushion back carpet tile.

6. In the 1984 to 1985 time frame, Mil-liken and Dow Chemical Company (“Dow”), a supplier of chemicals to the carpet industry, including the raw chemicals used to formulate polyurethane, began working together on ways to produce carpet tiles. Dow worked with Milliken to test cushion back carpet tile structures and to develop a range on which carpet tile could be manufactured.

7. Randall Jenkines (“Jenkines”) of Dow assisted Higgins with the testing and development of cushion back carpet tile structures.

8. In addition, Jim Jennings (“Jennings”) of Dow worked with Higgins in connection with the testing and development of cushion back carpet tile structures and the design of a range on which such structures could be manufactured.

9. Initially, Milliken developed a carpet tile with two stabilizing layers known as the “Comfort Plus” product which was manufactured in two steps. Custom Coating, Inc. (“Custom Coating”) manufactured a polyurethane foam cushion pad comprised of (from top to bottom), a felt or polypropylene backing layer, a polyurethane foam layer, and a secondary backing layer made of woven polypropylene that was sold to Milliken. The foam cushion pad was then laminated to its carpet face using hot-melt adhesive. Because the cushion pad lacked internal stability, Mil-liken inserted a layer of open mesh fiberglass into the hot melt adhesive during the lamination process. Therefore, there was a stabilizing layer in the cushion pad and an additional stabilizing layer inserted by Milliken prior to lamination to provide stability to the carpet tile.

10. The Comfort Plus product with two stabilizing layers is embodied in Higgins’ U.S.Patent No. 4,522,857 (“the '857 patent”), which issued in June 1985.

11. However, Milliken experienced problems with the consistency of the thickness of the cushion pad purchased from Custom Coating and wanted to lower the cost of the cushion pads.

12. Consequently, Milliken began to research alternatives to Custom Coating’s cushion pads including the possibility of bringing the technology in-house or engaging another company to manufacture the pads.

13. Vince Foody (“Foody”), a Milliken development engineer who reported directly to Higgins, and Higgins, along with others at Milliken, were involved in investigating alternative sources of the cushion pads, including locating possible alternate suppliers or the possibility of bringing the manufacturing of the cushion pad in-house.

14. In addition, Higgins, with the assistance of Dow, continued to test different carpet tile structures in an effort to develop new carpet tile structures.

15. In 1992 and 1993, Milliken and Dow conducted a number of trials on various cushion back carpet tile structures using Dow’s small testing polyurethane range.

16. Further, trials were conducted at TRC because it had the only full size range on which to test carpet tile structures.

17. In the fall of 1993, after research and experimentation, Higgins believed that he invented the cushion back carpet tiles *716 with a single stabilizing layer claimed in the Patents-In-Suit.

B. TRC’s History in Carpet Tile Development

18. TRC supplies polyurethane chemicals to carpet companies such as Milliken and Mohawk for use in the manufacture of carpet backings.

19. At some point between 1989 and 1991, TRC developed a cushion back carpet structure with a single stabilizing layer for six-foot wide products.

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335 F. Supp. 2d 712, 2004 U.S. Dist. LEXIS 22248, 2004 WL 2070525, Counsel Stack Legal Research, https://law.counselstack.com/opinion/milliken-co-v-mohawk-industries-inc-scd-2004.