Appeal No. 2004-1021
Application No. 09/707,450
motions in response to torque applied thereto, with the stress of
these motions being concentrated at bends in the bar (see column
1, lines 13 through 30). To prevent failure at these points
while maintaining some degree of cost and manufacturing
efficiency, Wycech provides a hollow or tubular torsion bar
formed of a mild or medium grade steel and internally reinforced
by a core composed of a resin and a filler. According to Wycech,
such a core is lightweight and strong, and has substantial
vibration damping and acoustic attenuation characteristics (see,
for example, column 11, lines 47 through 65). With regard to one
method of production, Wycech teaches that
the method includes the steps of selecting and cutting
a hollow tubular bar to a predetermined length and then
forming a core in at least a portion of the [hollow]
tubular bar. Preferably, the hollow tubular bar is
then shaped by bending the bar to define a spring
portion and a radius arm and to form end portions which
will mate appropriately with mounting locations on a
motor vehicle to form part of a suspension system. The
core reinforces the torsion bar during forming to
prevent collapse of the hollow tubular bar and
strengthens the hollow tubular bar to withstand
stresses during use. In one embodiment, the core
occupies only those portions of the torsion bar which
are angled. It is known that stresses are concentrated
at bends or angles in a torsion bar. By providing the
core at these angles, the torsion bar is substantially
strengthened [column 3, lines 17 through 33].
As conceded by the examiner (see page 5 in the answer), the
foregoing torsion bar and method disclosed by Wycech do not
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