Appeal No. 96-2513
Application 08/037,064
dramatically (layer of diamond particles and a layer of
metal matrix).
The wear rate is rapid before the embedded diamond particles have
been reached, and then the wear rate drops off dramatically since
"[t]he rate of wear of the diamond is close to zero" (Cullen at
2635).
But the problem is that embedded diamond particles and the
metal matrix do not form a plasma-enhanced chemical vapor
deposited or sputter-deposited homogenous inner and outer layer.
The examiner specifically acknowledged in Paper No. 6, page 3,
lines 14-15, that Cullen discloses "substantially one
heterogenous layer" (Emphasis added). Moreover, the examiner has
pointed to no evidence that Cullen's metal matrix and diamond
particles are formed by plasma-enhanced chemical vapor deposition
or sputtering. The examiner has failed to demonstrate a
reasonable motivation or suggestion from the prior art to form
the contact pad 34 of the EP Reference as two separate layers,
each being homogenous and plasma-enhanced chemical vapor
deposited or sputter-deposited. We note further that zero or
minimum abrasion appears to be the goal of Cullen, rather than
two levels of wear. The fact that an initial rapid wear level
exists appears to be mere incidental and due to the process used
for embedding diamond particles in the metal matrix.
-5-5
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