"Isn't that a disclaimer of reading the claimed top surface to cover the [tip of] a sharp object"?
Karen: I guess I missed that, or posts crossed. Yes, IMO that’s a decent argument-based estoppel argument that a sharp point is not a top surface, as that term is used in the claims.
"So once you argue "prior art doesn't teach claimed element X" at the BPAI, then fail to appeal to Fed Cir, you may be estopped from bringing up the same argument in litigation?" If you lost the point and fail to appeal, yea, I’d argue that if it had a fair hearing and was somehow central to Board's decision. But wait a minute! according to the OP, applicant (now a patentee) came away from the Office (Board) with allowed claims that include element / limitation X and with which they were satisfied. How? Why? The agency found, as a matter of fact, that PA disclosed X. There must have been other arguments for patentability of the claims reciting X, like no articuable reason to combine? But applicant failed to appeal that there was no substantial evidence to support the finding that X was taught.
"If you make the same argument in prosecution, but don't appeal, can this give rise to estoppel?" Karen, what’s the procedural posture here? Examiner says PA discloses X and you don’t argue, accept arguendo that X may be disclosed, but prevail anyway on say, no motivation / hindsight reconstruction. Claims reciting X get allowed w/ no need to appeal to the Board. The “fact” of whether X was disclosed was not finally determined by the agency and was never even argued by applicant. No final agency determination to appeal from. I say I’d be free to raise it, but I prevailed on other grounds anyway.
Getting back to the OP. The questions is deceptively simple; is each and every limitation of the claim, A, B. C. D. and X, whether it has patentable weight or not, found in the accused device, literally or equivalently (you noted how equivalents could get cabined). A court can’t write X out of the claim whether it has "patentable weight" or not. Construction of “X” is a different issue.