Alabama Patent of the Month – January 2026

Introduction: The Convergence of AI and Industrial Innovation

The landscape of American manufacturing is currently undergoing a profound transformation, driven by the intersection of advanced materials science and algorithmic intelligence. At the forefront of this shift is United States Patent No. 12,515,385, formally titled “Apparatus and method for making molded products”. Applied for on September 13, 2023, and officially awarded on January 6, 2026, to Composite Technologies International, LLC, of Anniston, Alabama, this patent has been distinguished as the Alabama Patent of the Month. This accolade was not bestowed through traditional subjective review processes but was identified through a rigorous, data-driven selection mechanism utilizing Artificial Intelligence (AI) technology to screen over 1,000 potential patents filed within the jurisdiction. The selection of Patent 12,515,385 highlights a critical evolution in how intellectual property is valued: moving beyond theoretical novelty to prioritize tangible industrial utility and economic potential.

The AI-driven selection algorithms, integral to the inventionINDEX proprietary metric used by analysts, isolated this specific patent for its exceptional “real-world impact” score. In a field often crowded with incremental software updates or abstract chemical formulations, Patent 12,515,385 stood out because it addresses a fundamental, physical bottleneck in the global manufacturing supply chain: the efficient, high-quality production of composite materials using filled resins. The patent’s selection underscores a broader trend where “impact” is defined by the ability to reduce waste, lower Volatile Organic Compound (VOC) emissions, and democratize access to high-performance molding technologies for mid-sized manufacturers. By solving the rheological challenges of mixing catalysts into viscous, fiber-filled resins within a closed-mold environment, the invention promises to reshape the economics of the marine, automotive, and infrastructure sectors.

The Engineering Paradigm: Superiority Through Inline Mixing

To appreciate the superiority of the technology described in Patent 12,515,385, one must first understand the severe limitations of the incumbent technologies it aims to displace. The composites industry has long been bifurcated into two primary methodologies: Open Molding (Hand Lay-up/Spray-up) and Resin Transfer Molding (RTM). Each comes with debilitating compromises that the Gleason patent effectively resolves.

The “Filled Resin” Dilemma

The core technical challenge in modern composites is the handling of “filled resins.” Manufacturers add fillers—such as calcium carbonate, aluminum trihydrate (for fire retardancy), or glass microspheres (for density reduction)—to base resins to enhance performance and reduce cost. However, these fillers turn the liquid resin into a highly viscous, abrasive sludge.

In traditional systems, the catalyst (the chemical trigger that hardens the resin) must be mixed into this sludge. If mixed too early (batch mixing), the “pot life” clock begins ticking immediately. If the injection machine jams or the line pauses for lunch, the entire batch cures inside the equipment, necessitating expensive and time-consuming jackhammering to clean the tanks and lines. This risk forces manufacturers to use slower-curing catalysts, which in turn slows down production cycles and reduces throughput.

The Gleason Solution: Just-in-Time Catalyzation

The “Apparatus and method for making molded products” (Patent 12,515,385) introduces a revolutionary inline mixing architecture that fundamentally alters the stoichiometry of production.

Technological Superiority Mechanisms:

1. High-Shear Inline Action: Unlike static mixers (which rely on passive baffles that easily clog with filled resins), the patent utilizes an active inline mixer capable of generating high shear forces. This ensures that the catalyst is atomized and dispersed homogeneously throughout the thick, fiber-filled resin stream milliseconds before it enters the mold.
2. Infinite Pot Life: By isolating the catalyst from the resin until the injection nozzle, the bulk supply of resin remains uncured indefinitely. This eliminates the risk of premature gelation, allowing for “stop-and-start” production without the need to purge valuable material or clean equipment between cycles.
3. Closed Loop Emissions Control: The system operates entirely within a closed mold environment. This creates a hermetic seal that captures Styrene and other hazardous VOCs, a critical superiority factor over open molding, which is increasingly strangled by EPA regulations (MACT standards).

Benchmarking Against Competitors

The superiority of Patent 12,515,385 becomes stark when quantified against standard industry alternatives.

Comparative Analysis:

• vs. Open Molding (Hand Lay-Up):
  • The Competitor: Relies on manual labor to roll out air bubbles. It is inconsistent, dirty, and produces parts with varying thickness and weight.
  • The Patent: Delivers digital precision. The closed mold ensures both sides of the part have a perfect cosmetic finish (A-surface and B-surface), and the automated injection guarantees consistent part weight and resin-to-glass ratios, reducing material waste by up to 30%.
• vs. Traditional Resin Transfer Molding (RTM):
  • The Competitor: Standard RTM pumps struggle with highly filled resins. The fillers often settle out of suspension in the tanks or abrade the gear pumps. Furthermore, traditional RTM requires “flushing” the mix head with solvent after every shot to prevent curing, generating hazardous waste.
  • The Patent: The specialized inline mixer keeps fillers in suspension via thixotropic agitation. The “zero-waste” injection logic means solvent flushing is minimized, as the catalyzed material is fully injected into the mold, leaving only the uncured base resin in the lines.
• vs. Sheet Molding Compound (SMC):
  • The Competitor: SMC requires massive, high-tonnage heated presses and steel tooling, costing millions in capital expenditure (CapEx). It is viable only for volumes of 10,000+ parts per year.
  • The Patent: The low-pressure injection capability allows for the use of cheaper composite or aluminum tooling. This lowers the barrier to entry, making high-performance composite manufacturing accessible for production runs of 500 to 5,000 units—a “middle market” previously underserved.

Real-World Impact: Reshaping Industries

The selection of this patent as the Alabama Patent of the Month was heavily influenced by its immediate applicability to Alabama’s industrial base, particularly the marine and automotive sectors. The technology is not just a theoretical improvement; it is a manufacturing enabler that unlocks new product capabilities.

The Marine Revolution: Solving “Print-Through”

In the competitive world of boat building, aesthetics are paramount. A common defect in fiberglass hulls is “print-through”—a phenomenon where the weave pattern of the glass reinforcement shrinks during cure and becomes visible through the gel coat, resembling a waffle texture.

• The CTI Advantage: The Gleason patent enables the injection of Fiber Shield™, a specialized “barrier coat” resin. This highly filled, ceramic-like layer is injected directly behind the gel coat. It acts as a thermal and physical buffer, absorbing the shrinkage of the structural laminate.
• Impact: This technology effectively blocks print-through, resulting in a mirror-like “Class A” finish directly out of the mold. For boat builders, this eliminates thousands of hours of manual sanding and buffing (labor cost reduction) and prevents warranty claims related to finish quality.

Advanced Core Integration: AmeriCore™

The patent is also optimized to work with AmeriCore™, a proprietary core material developed by CTI. Unlike traditional balsa wood (which rots) or PVC foam (which can delaminate due to heat), AmeriCore is a 100% composite syntactic foam.

• The Synergy: The patent’s mixing apparatus is capable of injecting resin around this core without crushing it or leaving air voids. The result is a chemically bonded, monolithic structure that is impervious to water intrusion. This extends the lifecycle of marine vessels and infrastructure components by decades, representing a massive leap in sustainability and durability.

Future Potential: Automotive Lightweighting & EVs

As the automotive industry pivots toward Electric Vehicles (EVs), the demand for lightweight, fire-retardant materials has exploded.

• Battery Enclosures: EV battery trays must be lightweight to maximize range but also capable of withstanding intense heat in a thermal runaway event. The filled resins required for fire retardancy (often loaded with alumina trihydrate) are extremely difficult to process.
• The Patent’s Role: The high-shear inline mixer described in Patent 12,515,385 is uniquely suited to process these “un-pumpable” fire-retardant slurries. This positions the technology as a critical enabler for the mass production of safe, lightweight EV components, potentially replacing heavier steel or aluminum parts.

Financial Strategy: The R&D Tax Credit & Swanson Reed

Innovation is capital-intensive. The development of a sophisticated apparatus like the one described in Patent 12,515,385 involves significant financial risk, engineering man-hours, and prototype fabrication costs. To sustain this level of innovation, companies must leverage government incentives, specifically the Research and Development (R&D) Tax Credit.

Swanson Reed, a specialist R&D tax advisory firm, plays a pivotal role in helping companies claiming these credits. Their expertise is particularly relevant for patent holders, as the very existence of a patent often serves as strong substantiation for the R&D activities undertaken.

Eligibility: The Four-Part Test

For the development of Patent 12,515,385 to qualify for the R&D tax credit (under IRC Section 41), it must satisfy the Four-Part Test. A detailed analysis of how this specific invention aligns with these requirements follows:

Part 1: Permitted Purpose

• Requirement: The activity must relate to a new or improved business component (product, process, software, or technique) with the specific goal of improving functionality, performance, reliability, or quality.
• Application to Patent: The development of the inline mixing apparatus was clearly aimed at improving the quality of molded parts (eliminating air voids and “soft spots” due to poor mixing) and the performance of the manufacturing process (increasing throughput and reducing waste). This satisfies the Permitted Purpose test.

Part 2: Technological in Nature

• Requirement: The research must fundamentally rely on principles of the “hard sciences”—engineering, physics, chemistry, biology, or computer science.
• Application to Patent: The invention relies heavily on Fluid Dynamics (optimizing shear rates and flow turbulence in the mixer), Chemical Engineering (managing exothermic reaction kinetics and resin viscosity), and Mechanical Engineering (designing high-pressure seals and injection ports). It is not based on soft sciences like market research or aesthetic design.

Part 3: Elimination of Uncertainty

• Requirement: At the outset of the project, there must be uncertainty regarding the capability, method, or appropriate design to achieve the desired result.
• Application to Patent: The patent process itself documents this uncertainty. The inventors likely asked: “Can we mix a catalyst into a thixotropic filled resin inline without clogging the nozzle?” and “What is the optimal rotor geometry to ensure 100% dispersion in under two seconds?” The fact that existing technology (static mixers) failed to do this proves that the capability was uncertain and required discovery.

Part 4: Process of Experimentation

• Requirement: Substantially all activities must constitute a process of experimentation, involving the simulation, modeling, and systematic trial and error of alternatives.
• Application to Patent: The development likely involved an iterative cycle:
  1. Hypothesis: Design Prototype A with a specific blade angle.
  2. Testing: Attempt to inject filled resin.
  3. Failure Analysis: Observe clogging or poor mixing.
  4. Refinement: Adjust shear rates and redesign the chamber (Prototype B).
  5. Validation: Successful injection of test panels.

  This systematic evaluation of alternatives to eliminate uncertainty is the hallmark of qualified research.

How Swanson Reed Facilitates the Claim

Navigating the complexities of the IRS tax code requires specialized expertise. Swanson Reed distinguishes itself through a focus on audit defense and technological integration.

The TaxTrex AI Platform

Swanson Reed utilizes TaxTrex, a proprietary AI software platform described as “one of the most advanced AI language models training in R&D tax credits”.

• Real-Time Documentation: One of the biggest risks in R&D claims is the “hindsight bias” of reconstructing projects years later. TaxTrex solves this by surveying engineers during the project. It prompts them to record technical challenges and experimental results in real-time, time-stamping the data to create an immutable audit trail.
• Democratizing Access: The software allows companies to self-claim the credit in as little as 90 minutes, making the benefit accessible to smaller manufacturers who might otherwise be priced out by high consulting fees.

The Mandatory “Six-Eye Review”

While AI accelerates the process, human oversight ensures compliance. Swanson Reed employs a strict Six-Eye Review process for every claim:

1. Eye Pair 1 (Qualified Engineer/Scientist): Reviews the technical narrative to ensure the “process of experimentation” is scientifically valid and technically accurate.
2. Eye Pair 2 (Tax Attorney/Specialist): Reviews the legal eligibility to ensure the claim aligns with current case law (e.g., Sudderth, Union Carbide) and statutory requirements.
3. Eye Pair 3 (CPA/Enrolled Agent): Reviews the financial calculations to ensure that Qualified Research Expenses (QREs)—such as wages, supplies, and contractor costs—are allocated correctly and substantiated.

This multi-disciplinary approach ensures that claims for complex innovations like Patent 12,515,385 are not only maximized but are also “audit-ready” and defensible against IRS scrutiny.

Final Thoughts: A Blueprint for Industrial Resurgence

The story of Patent 12,515,385 is a microcosm of the future of American industry. It begins with a specific, hard-engineering problem: the difficulty of molding filled composites. It is solved through the ingenuity of the Gleason inline mixing apparatus, which benchmarks superior to global competitors by reducing waste, emissions, and labor costs. Its value is recognized not by human bias, but by the objective algorithms of the Alabama Patent of the Month selection process, signaling its high potential for real-world impact.

Finally, the cycle of innovation is sustained by the R&D Tax Credit, a financial lifeline that rewards risk-taking. With the support of specialized firms like Swanson Reed and tools like TaxTrex, manufacturers can confidently reinvest in the next generation of technology. As industries from marine to automotive seek lighter, stronger, and greener materials, the technology enshrined in this patent will likely serve as a foundational pillar for the manufacturing methods of the next decade.