Wilbur T. Bolkcom and William E. Knapp v. The Carborundum Company

523 F.2d 492, 187 U.S.P.Q. (BNA) 466, 1975 U.S. App. LEXIS 12544
CourtCourt of Appeals for the Sixth Circuit
DecidedSeptember 30, 1975
Docket73-1320
StatusPublished
Cited by29 cases

This text of 523 F.2d 492 (Wilbur T. Bolkcom and William E. Knapp v. The Carborundum Company) is published on Counsel Stack Legal Research, covering Court of Appeals for the Sixth Circuit primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
Wilbur T. Bolkcom and William E. Knapp v. The Carborundum Company, 523 F.2d 492, 187 U.S.P.Q. (BNA) 466, 1975 U.S. App. LEXIS 12544 (6th Cir. 1975).

Opinion

McCREE, Circuit Judge.

This is an appeal from the dismissal of an action by appellants, Bolkcom and Knapp, for infringement of a combination patent protecting the invention of a novel plant for the manufacture of silicon carbide. The patent in suit is Patent Re. 27,018 (hereinafter Patent ’018) dated January 5, 1971, a reissue of Patent No. 3,432,605 (hereinafter Patent ’605), dated March 11, 1969. The district court held that claims 11 — 14, which were added by the reissue, were invalid because they were an unauthorized enlargement of the disclosures of the original patent. It also held that the claims that were carried over from the original Patent ’605 to the reissue were valid, but were not infringed by the appellee’s plant because it employed an element not disclosed as part of the patented combination.

We agree that the broader claims added by reissue are invalid, that the original claims are valid, and that the accused plant does not infringe the original claims. We therefore affirm.

Silicon carbide (SiC), a compound said to be second in hardness only to a diamond, is used primarily for grinding wheels, other abrasive uses, and in refractories. It is made by fusing sand and a source of carbon like coke or graphite. Silica (Si02) and Carbon (C) react under extreme heat to produce silicon carbide. After the raw materials are mixed together and placed in a furnace, an electric resistant core is fired by passing an electrical current through it to raise the charge to the extremely high temperature (about 4,000 degrees F.) necessary to achieve the reaction product, silicon carbide. Silicon carbide was first made by Edward Acheson in 1891 and he founded The Carborundum Company, which today still enjoys the largest share of the total market for silicon carbide.

A significant feature of Acheson’s process is that the furnaces must be fired in close proximity to the source of electrical power because of the capital expense and power losses which result from lengthened electrical leads. Insofar as the record shows, before appellants’ invention was put into practice, all manufacturers of silicon carbide in North America relied upon the use of stationary, horizontal furnaces set in banks of four to six, close to one another and to the electrical source. The firing of a charge sufficient to form silicon carbide in the Acheson process takes about thirty hours. Hand labor is used in loading and unloading the furnaces, and the cramped working conditions resulting from the close proximity of the furnaces to each other and to the electrical source made this activity difficult and dangerous. After firing, the stationary furnaces required about three days to cool before workmen could unload them and load a new charge. Typically, the four furnaces in a bank attached to an electrical source were employed in a cycle of operations, with one furnace being loaded, one charging, one cooling, and one being unloaded. The total cycle — loading, charging, cooling, and unloading— took about five to seven days for each furnace.

The recognized industry need for more efficient and economical means of manufacturing silicon carbide was described in appellants’ patent as follows:

In the past silicon carbide has been manufactured in stationary electric furnaces. Such stationary furnace installations usually require four to six furnaces for each transformer in order *495 to utilize the transformer to its maximum efficiency, with one furnace heating, one being unloaded, one loading, and the remainder cooling. This requires very large capital investment in buildings and furnaces. The unloading of such furnaces is quite difficult and tedious because of the adjacent hot furnaces and because of the necessity of using large amounts of hand labor to remove the silicon carbide from the furnace due to the proximity of the adjacent furnaces and the difficulty of using mechanical unloading equipment in the restricted floor space available. This also requires that the furnaces be cooled [a]n extraordinary long time before unloading in order to get the temperature down to the point where the hand labor can be effectively used. A further problem arises in the loading of such furnaces because of the adjacent other furnaces. This means lengthy conveyor belts from the mixing bins to the furnaces or overhead cranes carrying successive bucket loads to the furnace.

The district court found that “[tjhere has always been a need in the industry for a more facile, economical and efficient way of making silicon carbide.”

To meet this need, appellants in 1964 conceived of a method of using mobile furnaces that could be removed from the electrical source after being fired, placed at a distance for cooling and stripping, and then moved to another area of the plant for reloading before again being moved to the electrical source for charging. Appellants’ layout for manufacture also embraced the advantage of selectivity — the ability to move any furnace car for cooling, unloading, and loading, without disturbing the position of any other furnace car. This was to be accomplished by means of a “transfer car” on a set of rails transverse to the primary rails leading to the firing area and to another set of rails leading to other areas in the plant where loading and unloading operations could more efficiently be accomplished. Thus, a mobile furnace could be rolled atop the transfer car, and the loaded car could be moved selectively in and out of alignment with the various trackways leading, on the one hand, to the firing area and, on the other hand, to the other plant areas for cooling, loading, and unloading.

Appellants successfully put their invention into practice in April 1966 by constructing their Satellite Plant at Springdale, Pennsylvania, where they began the commercial manufacture of silicon carbide. After this plant began operations, appellants’ patent counsel prepared and filed the application that matured into the original Patent ’605. The preferred mode of their invention was disclosed in the patent, coupled with the required detailed specification, as follows:

This invention relates to silicon carbide furnaces and plants and particularly to a silicon carbide furnace which can be fired in one position, removed to a second position for cooling and unloading and to a plant incorporating a plurality of such furnaces.
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Preferably we provide an electrical power source, a main trackway adjacent said power source, a furnace bottom mounted on wheels on said trackway movable to and away from said power source, said furnace bottom having a substantially flat heat resistant surface, removable sides along each side of said surface and removable ends on said surface, said sides and ends defining a heating chamber, electrode means in each of said ends, removable connections between said electrode ends and said power source, a transfer car movable transversely to the main trackway and having a corresponding trackway adapted to be aligned with the main trackway to receive the furnace bottom wheels and furnace whereby said furnace may be moved transversely to said main trackway, a service area spaced from said main trackway by said transfer car, secondary trackways in said service area receiving said furnace from said transfer 'car, loading means at said *496

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Bluebook (online)
523 F.2d 492, 187 U.S.P.Q. (BNA) 466, 1975 U.S. App. LEXIS 12544, Counsel Stack Legal Research, https://law.counselstack.com/opinion/wilbur-t-bolkcom-and-william-e-knapp-v-the-carborundum-company-ca6-1975.