In re Leithem, No. 11-1030 (Fed. Cir. 2011)
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The patent application discloses an improved diaper; traditional diapers are constructed using an absorbent core of fluff pulp, interposed between a water barrier sheet and a permeable layer. For highest absorption, fluff pulp is treated with a chemical cross-linking agent. The application described a diaper that would avoid the expense of using chemically cross-linked fluff pulp while retaining superior absorbency properties, by extracting wood pulp with a caustic substance at low temperature, followed by dry and fluff. The examiner rejected the application (35 U.S.C. 103) as obvious from a prior patent. The Board sustained the rejection. The Federal Circuit vacated and remanded because the basis of the Board's rejection differed from the basis given by the examiner.
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