Appeal No. 2006-2962
Application No. 10/252,177
therefrom. In re Preda, 401 F.2d 825, 826, 159 USPQ 342, 344 (CCPA 1968).
Cherry teaches that when the thermoplastic material used to make the soft
layer 60 is injected into the second mold and flows around the previously formed
hard layer 70, some of the thermoplastic material at the projecting portion 76 of the
hard layer 70 melts and chemically bonds with the soft thermoplastic material (see
col. 4, ll. 55-60). Cherry also teaches that as the melted thermoplastic materials
cool, a physical bond is formed between the interconnecting portion 66 of the soft
layer and the projecting portion 76 of the hard layer to hold these layers together
(col. 4, ll. 60-64).
As correctly pointed out by Appellant, these disclosures by Cherry refer only
to the interface between the hard layer projecting portion 76 and the soft layer
interconnecting portion 66 (Br. 5). Cherry gives no indication, however, that the
melting and bonding described therein are limited to this portion of the composite
door/cover. Appellant has not cogently explained or demonstrated, and it is not
apparent, why the melting and bonding would be so limited. The injection
temperature and pressure of the soft plastic material necessary to produce the
disclosed melting and bonding seemingly would also exist along the full extent of
contact between the hard layer 70 and the soft layer 60. The full extent of contact
would, of course, encompass the major side surface 77 on the body portion 78 of
the hard layer 70 and the major side surface 67 on the soft layer 60. The body
portion 78 and major side surface 67 correspond respectively to the “front panel”
and “contact surface” recited in claim 25. The apparent melting and bonding
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