“This invention relates to binders, particularly for the manufacture of mineral wool insulation (for example glass wool or stone wool insulation). WO 2007/014236 (incorporated herein by reference) relates to binders, including binders comprising Maillard reactants. One particular binder disclosed is based on a triammonium citrate – dextrose system derived from mixing dextrose monohydrate, anhydrous citric acid, water and aqueous ammonia. One of the many advantages of this binder system is that it is formaldehyde free. One aspect of the present invention provides a binder in accordance with claim 1; further aspects of the inventions are defined in other independent claims. The dependent claims define alternative and/or preferred embodiments. Binder solution in accordance with the present invention may be “substantially formaldehyde free”, that is to say that they liberate less than 5 ppm I.e. “parts per million”. formaldehyde as a result of drying and/or curing (or appropriate tests simulating drying and/or curing). Such binder solutions are preferably “formaldehyde free”, that is to say they liberate less than 1 ppm formaldehyde in such conditions. Products in accordance with the invention which incorporate binders (for example insulation materials) may be “substantially formaldehyde free”, that is to say they comprise less than 5 ppm or less than detectable limits of free formaldehyde and/or consist of materials which together comprise less than these amounts of free formaldehyde and/or release levels of formaldehyde in standardised tests adapted to simulate their ordinary use which allows them to be classified as having no or undetectable levels of formaldehyde release. It has been found that binders according to the present invention may have at least equivalent and indeed improved properties compared to, for example, the triammonium citrate – dextrose system of WO 2007/014236. WO 2007/014236 teaches binder systems based, inter alia, on a combination of a carbohydrate (for example a reducing sugar), ammonia and a carboxylic acid and suggests that a Maillard type reaction may form the basis of the curing chemistry. It would have been thought that the nature of the acid used would have a significant effect upon the properties of the cured binder, particularly if the acid precursor and/or derivative therefrom is incorporated into the structure of the cured binder. It is thus surprising that an acid precursor derivable from an inorganic salt should prove a suitable acid precursor in an otherwise apparently similar binder system. An acid precursor derivable from an inorganic salt may have significant advantages in terms of cost, availability and ease of handling. A particular advantage can be achieved by use of one or more inorganic ammonium salts, for example, an ammonium sulphate or ammonium phosphate. An ammonium salt may provide the or part of the acid precursor and/or the or part of the source of nitrogen and/or the or part of the pH control system. An ammonium nitrate may also work; however, ammonium nitrate may oxidise aldehyde groups of the carbohydrate (for example in the case of dextrose) and/or require precautions to avoid explosions.”
“A method of manufacturing a product selected from: a thermal insulation material a mineral fibre product; a wood board product including chip board, oriented strand board,particle board, medium density fibreboard, wood facing products; and foundry sandsinwhich the mineral fibre product is a mineral wool insulation product, comprising the stepsof: providing a collection of loose matter comprising non-woven materialmineral fibres; applying a binder solution to the collection of loose matter by spraying the binder solutionon to the mineral fibres between formation of the fibres and collection of the fibres to forma batt, the binder solution being a substantially formaldehyde free binder solution having a pH of greater than 6 comprising: a carbohydrate, an acid precursor derivable from an inorganic salt which makes up at least 5% by dry weight of the uncured binder solution, a source of nitrogen and water, and in which the acid precursor comprises one or moreinorganic ammonium salts; and curing the binder to form a thermoset binder in which the curing of the binder occurs in acuring oven using forced hot air circulation; and in which the quantity of binder in the finished material wool insulation is greater than1% and less than 20% measured by dry weight of the finished mineral wool insulationproduct.”
“2. The Hearing Officer erred in holding at §35 of the Decision that [Rockwool’s] evidence (and case) was that a detailed knowledge of the Maillard reaction was part of the [common general knowledge]. This error is repeated in §70. … 4. At §68 and §69, the Hearing Officer erred by ignoring that the teaching of D3 includes the detailed cross-reference material on the Maillard reaction, and as such, the Skilled Person, when reading D3, would know more than the proposed mechanism set out on page 17 of D3.” (2) Ground 2: failure to distinguish that the ‘951 Patent is much broader than the ‘719 Patent.Ground 2 is based upon paragraph 3 of the Grounds of Appeal, See paragraph 54 of Rockwool’s written appeal submissions. which provides as follows: “The Hearing Officer erred by failing to recognise the difference between the Patents. Specifically, he erred by holding in §50 the ‘951 Patent is aimed at acid precursors with sulphate, phosphate or nitrate groups, as the ‘951 Patent is much broader than its parent, the ‘719 Patent. His error in misconstruing the scope of the ‘951 Patent undermines his entire decision on the ‘951 Patent.” (3) Ground 3: failure to consider the different motivation for the broader ‘951 Patent.Ground 3 is based upon paragraph 5 of the Grounds of Appeal, See paragraph 62 of Rockwool’s written appeal submissions. which provides as follows: “Further, the Hearing Officer erred by holding that the ‘951 Patent was not obvious because there was no motivation to switch to sulphates, phosphates or nitrates. The ‘951 Patent is broader in scope and the Hearing Officer therefore erred by construing the claims of the ‘951 Patent too narrowly.” (4) Ground 4: failure by the Hearing Officer to give any reason for the added matter and plausibility findings.Ground 4 is based upon paragraph 6 of the Grounds of Appeal, See paragraph 66 of Rockwool’s written appeal submissions. which provides as follows: “The Hearing Officer erred by holding that the ‘951 Patent was plausible and/or that it did not contain added matter. The Hearing Officer has given no reasons for his Decision on this in §82 and it therefore must be overturned.” (5) Ground 5: added matter. Ground 5 is based upon paragraph 7 of the Grounds of Appeal, See paragraph 69 of Rockwool’s written appeal submissions. which provides as follows: “Furthermore, in light of the construction of the ‘951 Patent held by the Hearing Officer, the ‘951 Patent amended claims constitute added matter as they go beyond the scope of the inventive concept and/or the subject-matter disclosed in the ‘951 Patent.”
“Furthermore, in light of the construction of the ‘951 Patent held by the Hearing Officer, the ‘951 Patent amended claims constitute added matter as they go beyond the scope of the inventive concept and/or the subject matter disclosed in the ‘951 Patent.” (7) Ground 7: no basis for the entirety of the amended claims of the ‘951 Patent.Ground 7 appears to be based on paragraph 8 of the Grounds of Appeal, Although this is not specifically stated in Rockwool’s written appeal submissions. which provides as follows: “There is no basis in the ‘951 Patent to support the use of any inorganic ammonium salt. The evidence of Dr Preininger, which was relied on by the Hearing Officer, was that the Skilled Person would not know whether changing the acid would have an effect. Accordingly, the amended claims are not supported.”
“…the hypothetical addressee is a skilled technician who is well acquainted with workshop technique and who has carefully read the relevant literature. He is supposed to have an unlimited capacity to assimilate the contents of, it may be, scores of specifications but to be incapable of a scintilla of invention. When dealing with obviousness, unlike novelty, it is permissible to make a “mosaic” out of the relevant documents, but it must be a mosaic which can be put together by an unimaginative man with no inventive capacity.”
“An invention shall be taken to involve an inventive step if it is not obvious to a person skilled in the art, having regard to any matter which forms part of the state of the art by virtue only of section 2(2) above (and disregarding section 2(3) above.”
“43. The person skilled in the art is the person to whom the patent is addressed. It is through their eyes that I must read and interpret the patents before me and the prior art. Therefore, I must look to the ‘719 and ‘951 Patents and determine to whom they are addressed. Both Patents, including the claims, relate to binders, particularly for the manufacture of mineral wool insulation and to methods of manufacturing mineral wool insulation using such binders. Therefore, in my view, the person to whom the ‘719 and ‘951 Patents are addressed is one who is interested in the development of binders in the field of mineral wool insulation manufacture. Such a person would have knowledge of chemistry and detailed knowledge of binders used in mineral wool insulation. 44. In my view, the person skilled in the art would be aware of the Maillard reaction and its relevance to making formaldehyde free binders for mineral wool insulation. They are aware of this from the disclosure in D3 which shows the skilled person that it is possible to make sugar-based, formaldehyde-free binders from so-called Maillard reactants. I disagree with [Rockwool’s] view that the person skilled in the art would have a detailed knowledge of the reaction simple because they have read what is in D3 and other documents to which D3 refers. Literature on the Maillard reaction has been largely confined to the field of food chemistry and its relevance to binders for mineral wool insulation is relatively new. Therefore, I think it unlikely that the person skilled in the art of binders for the manufacture of mineral wool insulation would have a detailed knowledge of the Maillard reaction as part of their common general knowledge.”
“With respect to the present binder’s chemical constitutents, they may include ester and/or polyester compounds. The binders may include ester and/or polyester compounds in combination with a vegetable oil, suc as soybean oil. Furthermore, te binders may include ester and/or polyester compounds in combination with sodium salts of organic acids. The binders may include solium salts of inorganic acids. The binders may also include potassium salts of organic acids. Moreover, the binders may include potassium salts of inorganic acids. The described binders may include ester and/or polyester compounds in combination with a clay additive, such as montmorillonite.”
“At the hearing, [Rockwool] set out the view that if their case failed in relation to the ‘719 Patent, i.e. if I found the ‘719 Patent to be novel and inventive, then the same would be true of the ‘951 Patent. [Knauf] agreed with this view and, indeed, all of the arguments put before me at the hearing by both parties related to the ‘719 Patent.”
“Rockwool had no case or argument that there were any salts, outside those upon which it relied in relation to ‘719, which might be obvious to use. Thus, the Hearing Officer did not need to consider obviousness of ‘951 separately. If Rockwool failed to show that ‘719 was obvious, there was no basis in Rockwool’s case on which it might be said that ‘951 was obvious.”
“45. First, it is entirely unpleaded. The point came into the case via a document filed by Rockwool 5 days before the hearing (and long after the evidence had closed) entitled “Supplemental Grounds”
“81. The amended claims before me have been referred to an IPO examiner for a prima facie view on their allowability. I have had the benefit of their reports, which confirm their prima facie view that the amendments do not add matter or extend the scope of protection conferred by the patents. 82. Having considered all the information before me, I am satisfied that the claims as granted and as amended do not add matter nor do they extend the scope of protection conferred by the Patents. I am also satisfied that the Patents sufficiently disclose the inventions across the whole scope of the amended claims.”