US20080007837A1 - Method for manufacturing a tree-dimensional puzzle - Google Patents
Method for manufacturing a tree-dimensional puzzle Download PDFInfo
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- US20080007837A1 US20080007837A1 US11/900,963 US90096307A US2008007837A1 US 20080007837 A1 US20080007837 A1 US 20080007837A1 US 90096307 A US90096307 A US 90096307A US 2008007837 A1 US2008007837 A1 US 2008007837A1
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- puzzle
- approximately
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- cutting
- ultraviolet light
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 8
- 238000000034 method Methods 0.000 title claims description 37
- 239000000123 paper Substances 0.000 claims abstract description 15
- 239000000853 adhesive Substances 0.000 claims abstract description 7
- 230000001070 adhesive effect Effects 0.000 claims abstract description 7
- 238000005520 cutting process Methods 0.000 claims description 45
- 239000000976 ink Substances 0.000 claims description 40
- 239000003086 colorant Substances 0.000 claims description 21
- 238000003825 pressing Methods 0.000 claims description 7
- 229910000760 Hardened steel Inorganic materials 0.000 claims description 3
- 230000037452 priming Effects 0.000 claims description 2
- 238000012216 screening Methods 0.000 claims description 2
- 239000000839 emulsion Substances 0.000 abstract description 3
- 239000000203 mixture Substances 0.000 description 3
- 238000004806 packaging method and process Methods 0.000 description 3
- 238000009472 formulation Methods 0.000 description 2
- 230000008447 perception Effects 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000013615 primer Substances 0.000 description 1
- 239000002987 primer (paints) Substances 0.000 description 1
- 230000000135 prohibitive effect Effects 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63F—CARD, BOARD, OR ROULETTE GAMES; INDOOR GAMES USING SMALL MOVING PLAYING BODIES; VIDEO GAMES; GAMES NOT OTHERWISE PROVIDED FOR
- A63F9/00—Games not otherwise provided for
- A63F9/06—Patience; Other games for self-amusement
- A63F9/10—Two-dimensional jig-saw puzzles
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63F—CARD, BOARD, OR ROULETTE GAMES; INDOOR GAMES USING SMALL MOVING PLAYING BODIES; VIDEO GAMES; GAMES NOT OTHERWISE PROVIDED FOR
- A63F9/00—Games not otherwise provided for
- A63F9/06—Patience; Other games for self-amusement
- A63F9/0613—Puzzles or games based on the use of optical filters or elements, e.g. coloured filters, polaroid filters, transparent sheets with opaque parts
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
- G02B27/10—Beam splitting or combining systems
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63F—CARD, BOARD, OR ROULETTE GAMES; INDOOR GAMES USING SMALL MOVING PLAYING BODIES; VIDEO GAMES; GAMES NOT OTHERWISE PROVIDED FOR
- A63F9/00—Games not otherwise provided for
- A63F9/06—Patience; Other games for self-amusement
- A63F9/0613—Puzzles or games based on the use of optical filters or elements, e.g. coloured filters, polaroid filters, transparent sheets with opaque parts
- A63F2009/0629—Puzzles or games based on the use of optical filters or elements, e.g. coloured filters, polaroid filters, transparent sheets with opaque parts with lenses or other refractive optical elements
- A63F2009/0633—Fresnel lenses
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63F—CARD, BOARD, OR ROULETTE GAMES; INDOOR GAMES USING SMALL MOVING PLAYING BODIES; VIDEO GAMES; GAMES NOT OTHERWISE PROVIDED FOR
- A63F9/00—Games not otherwise provided for
- A63F9/06—Patience; Other games for self-amusement
- A63F9/10—Two-dimensional jig-saw puzzles
- A63F2009/1072—Manufacturing
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63F—CARD, BOARD, OR ROULETTE GAMES; INDOOR GAMES USING SMALL MOVING PLAYING BODIES; VIDEO GAMES; GAMES NOT OTHERWISE PROVIDED FOR
- A63F9/00—Games not otherwise provided for
- A63F9/06—Patience; Other games for self-amusement
- A63F9/10—Two-dimensional jig-saw puzzles
- A63F2009/1083—Two-dimensional jig-saw puzzles having plural layers on top of each other
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63F—CARD, BOARD, OR ROULETTE GAMES; INDOOR GAMES USING SMALL MOVING PLAYING BODIES; VIDEO GAMES; GAMES NOT OTHERWISE PROVIDED FOR
- A63F9/00—Games not otherwise provided for
- A63F9/06—Patience; Other games for self-amusement
- A63F9/12—Three-dimensional jig-saw puzzles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/04—Processes
- Y10T83/0491—Cutting of interdigitating products
Definitions
- This invention pertains to puzzles in general and, more particularly, to three-dimensional puzzles.
- Puzzles have long been a source of entertainment and enjoyment for individuals both young and old. For the youngest child, puzzles which usually involve a few large pieces, serve not only as entertainment, but also help to develop coordination along with color and shape recognition. As children get older, puzzles with many smaller pieces become popular as they offer more of a challenge to build than puzzles with large pieces.
- puzzle manufacturers must continue to come up with new ways to make the puzzle challenging. This is done, for example, by making the puzzle from a multi-colored picture or using scenes where colors blend in with one another such as the reds, yellows and orange of a sunset or the various shades of blue and green involved with a seascape.
- a three-dimensional puzzle gives the added dimension of depth to the scene, thereby making it more difficult to construct.
- U.S. Pat. No. 6,547,243 discloses a portable three-dimensional puzzle having a magnetic backing that makes it easier to use when traveling.
- U.S. Pat. No. 5,896,230 discloses a method for producing a multidimensional image using a lenticular lens.
- Three-dimensional puzzles that can be cut into several small pieces, such as a 500 piece puzzle set, are not well known, however. This is because when cutting the photographic sheet into a puzzle, the greater the amount of rule in a square inch, the greater the amount of tension or pressure in the sheet. In other words, the larger the pieces of the puzzle, the less pressure involved in cutting them.
- the invention is directed to a puzzle comprised of a lenticular lens layer having a lens surface and a flat surface.
- a layer of four colors of ink is applied to the flat surface and a layer of opaque ink is applied to the four colors of ink.
- a white paper backing is adhered to the layer of opaque ink using an emulsion based adhesive having a viscosity of approximately 1,600 mPas at 23° C., and a backer board comprised of four layers of cardboard is applied to the white paper backing.
- a method for cutting the puzzle involves the steps of (a) providing a cutting platform; (b) cutting at least one groove in the platform, the groove forming the shape of at least one puzzle piece; (c) positioning a cutting instrument in the at least one groove; (d) placing a piece of rubber over the cutting instrument; (e) inserting at least one insert in at least one location between the rubber and the cutting platform; and (f) pressing the three-dimensional puzzle over the cutting instrument, thereby cutting the three-dimensional puzzle into at lest one puzzle piece.
- FIG. 1 is a schematic showing the layers of the three-dimensional puzzle.
- FIG. 2 is a schematic view of the steps of the puzzle manufacturing method.
- FIG. 3 is a top view of a puzzle piece.
- the invention involves a puzzle 10 comprised of a lenticular lens layer 12 having a lens surface 14 and a flat surface 16 .
- a layer of four colors of ink 18 is applied to the flat surface 16
- a layer of opaque ink 20 applied to the four colors of ink 18 .
- a white paper backing 22 is adhered to the layer of opaque ink 20 using an emulsion-based adhesive having a viscosity of approximately 1,600 mPas at 23° C., and a backer board 24 comprised of four layers of cardboard is applied to the white paper backing 22 .
- the puzzle 10 is further comprised of a layer of primer 26 located between the flat surface 16 of the lenticular lens layer 12 and the layer of four colors of ink 18 .
- the primer is a UV/EB Curable adhesive, primer, coating that is sold under various trade names including Rad-Cure, Rad-Kote and Rad-Prime.
- the lenticular lens layer 12 used with the puzzle 10 has a thickness in the range of approximately at least 10 to approximately at least 15 mil, and more preferably approximately 14 mil. Furthermore, each of the layers of the four layer backer board 24 is perpendicular to their adjoining layers, and the four layer backer board 24 has a thickness of approximately 1.25 mm.
- the layer of four colors of ink 18 used with the puzzle 10 can be an ultraviolet lamination formulation or a hybrid ultraviolet formulation.
- the opaque ink may be white.
- the invention also involves a method for manufacturing a three-dimensional puzzle 10 , the method comprising the steps of: (a) providing a lenticular lens layer 12 having a lens surface 14 and a flat surface 16 ; (b) priming the flat surface 16 of the lenticular lens layer 12 ; (c) exposing the primed flat surface 16 of the lenticular lens layer 12 to ultraviolet light; (d) applying a layer of four colors of ink 18 to the flat surface 16 of the lenticular lens layer 12 ; (e) providing a first exposure 28 of ultraviolet light to the layer of four colors of ink 18 ; (f) adding a layer of opaque ink 20 to the layer of four colors of ink 18 ; (g) providing a second exposure 30 of ultraviolet light to all layers of the puzzle 10 ; (h) providing a third exposure 32 of ultraviolet light to all layers of the puzzle 10 ; (i) providing a fourth exposure 34 of ultraviolet light to all layers of the puzzle 10 ; (j) providing a fifth exposure 36
- the primed flat surface 16 of the lenticular lens 12 is cured using exposure to ultraviolet light of approximately 840 watts for less than one second.
- the puzzle is exposed to approximately 1 , 120 watts of ultraviolet light for less than one second.
- a layer of opaque ink 20 which may be white, is added.
- the layers of the puzzle are then given another exposure to ultraviolet light, this time the exposure being approximately 1,330 watts of ultraviolet light for less than one second.
- the layers of the puzzle are exposed to approximately 840 watts of ultraviolet light for less than one second.
- This exposure is followed by a still another exposure of ultraviolet light to the layers of the puzzle 10 . This latest exposure being approximately 1,120 watts of light for less than one second.
- the layers of the puzzle 10 are exposed to ultraviolet light for a final time, this final time being approximately 1,190 watts of light for less than one second.
- the layer of white paper backing 22 is applied to the layer of opaque ink 20 using a polyacid adhesive.
- the backer board layer 24 is then applied to the white paper backing layer 22 using a conventional glue or adhesive.
- the lenticular lens 12 used in constructing the puzzle 10 has a thickness in the range of approximately 10 to approximately 15 mil, and more preferably approximately 14 mil. This is because a lenticular lens having a thickness less than approximately 10 mil tends to alter the visual appearance of the puzzle by distorting the perception of depth. On the other hand, although a thickness greater than 15 mil produces a greater perception of depth to the viewer, it is more difficult to cut without causing the images on the puzzle pieces to delaminate, thereby decreasing the sharpness of the image.
- puzzles having a lenticular lens with a thickness of approximately 18 mil are known, these puzzles are a 2-image flip lenticular, not three-dimensional puzzles.
- a 2-image flip lenticular is a puzzle that allows one to see two different images depending on how the puzzle is tilted. Because of the thickness of the lens, it is difficult to cut the puzzle into anything smaller than a few large pieces that are common in children's puzzle. In fact, puzzles utilizing a lenticular lens that is 18 mil thick have been discontinued in that it is cost prohibitive to cut a puzzle having a lens of this thickness into smaller pieces such as those used in 250 or 500 piece puzzles.
- the backer board 24 used in the inventive puzzle is comprised of four layers of cardboard.
- This four-layer backer board 24 has a thickness of approximately 1.25 mm and each of the four layers of cardboard are oriented perpendicular to their adjacent layers.
- the method of manufacturing the puzzle 10 may also involve the steps of (a) providing a cutting platform; (b) cutting at least one groove in the platform, the groove forming the shape of at least one puzzle piece; (c) positioning a cutting instrument in the at least one groove; (d) placing a piece of rubber over the cutting instrument; (e) inserting at least one insert in at least one location between the rubber and the cutting platform; and (f) pressing the three-dimensional puzzle over the cutting instrument, thereby cutting the three-dimensional puzzle into at least one puzzle piece 40 , as shown in FIG. 3 .
- the at least one groove is part of a plurality of grooves.
- This plurality of grooves form the shapes of a plurality of puzzle pieces, and the pressing of the three-dimensional puzzle over the cutting instrument, cuts the three-dimensional puzzle into a plurality of puzzle pieces. Once the puzzle has been cut into a plurality of pieces, the plurality of puzzle pieces are then separated from one another. This is done when the puzzle is “crushed” for packaging. When the puzzle is crushed for packaging, special rubber tips are affixed to the “teeth” in the delivery portion of the packaging machine. These rubber tips provide the additional force needed to separate the pieces without marring the image on the puzzle.
- the cutting instrument used to cut the puzzle may be a double-sharpened, hardened steel rule or knife that uses harder steel than is normally associated with puzzle die-cutting.
- This knife has a body and a blade with the hardness of the body being at least approximately 39 HRC, and the hardness of the blade being at least approximately 57 HRC.
- the rubber used in the cutting process may be ejection rubber having a thickness of approximately 7 mm and a hardness of approximately 45 shore. This is a more rigid material than is normally used in puzzle cutting. Additionally, a plurality of inserts may be positioned in a plurality of locations between the rubber and the cutting platform. This plurality of inserts may vary the height of the ejection rubber from approximately 0.001 mm to approximately 0.01 mm at certain locations in the die. This altering of the height of the ejection rubber allows for a clean cut across the entire surface of the puzzle.
Abstract
Description
- This patent application is a divisional of copending U.S. patent application Ser. No. 10/993,120, filed Nov. 19, 2004, the content of which is incorporated herein by reference in its entirety for all purposes.
- This invention pertains to puzzles in general and, more particularly, to three-dimensional puzzles.
- Puzzles have long been a source of entertainment and enjoyment for individuals both young and old. For the youngest child, puzzles which usually involve a few large pieces, serve not only as entertainment, but also help to develop coordination along with color and shape recognition. As children get older, puzzles with many smaller pieces become popular as they offer more of a challenge to build than puzzles with large pieces.
- Because the pieces of a puzzle can only be cut so small in order for the puzzle to be practical to construct, puzzle manufacturers must continue to come up with new ways to make the puzzle challenging. This is done, for example, by making the puzzle from a multi-colored picture or using scenes where colors blend in with one another such as the reds, yellows and orange of a sunset or the various shades of blue and green involved with a seascape. A three-dimensional puzzle gives the added dimension of depth to the scene, thereby making it more difficult to construct.
- Three-dimensional puzzles are known in the art. For example, U.S. Pat. No. 6,547,243 (Juenger) discloses a portable three-dimensional puzzle having a magnetic backing that makes it easier to use when traveling. Furthermore, U.S. Pat. No. 5,896,230 discloses a method for producing a multidimensional image using a lenticular lens.
- Three-dimensional puzzles that can be cut into several small pieces, such as a 500 piece puzzle set, are not well known, however. This is because when cutting the photographic sheet into a puzzle, the greater the amount of rule in a square inch, the greater the amount of tension or pressure in the sheet. In other words, the larger the pieces of the puzzle, the less pressure involved in cutting them.
- The greater pressure involved in cutting a puzzle into numerous small pieces causes the backing board to weaken, thus causing the images on the puzzle pieces to delaminate. This decreases the sharpness of the image and results in cloudy condition on the edges of the puzzle piece. For this reason, a three-dimensional puzzle that is capable of being cut into numerous small pieces without causing deterioration of the image of the puzzle would be an important improvement in the art.
- The invention is directed to a puzzle comprised of a lenticular lens layer having a lens surface and a flat surface. A layer of four colors of ink is applied to the flat surface and a layer of opaque ink is applied to the four colors of ink. A white paper backing is adhered to the layer of opaque ink using an emulsion based adhesive having a viscosity of approximately 1,600 mPas at 23° C., and a backer board comprised of four layers of cardboard is applied to the white paper backing.
- The invention also involves a method of manufacturing a three-dimensional puzzle. The method is comprised of the steps of: (a) providing a lenticular lens layer having a lens surface and a flat surface; (b) applying a layer of four colors of ink to the flat surface of the lenticular lens layer; (c) providing a first exposure of ultraviolet light to the layer of four colors of ink; (d) adding a layer of opaque ink to the layer of four colors of ink; (e) providing a second exposure of ultraviolet light to all layers of the puzzle; (f) providing a third exposure of ultraviolet light to all layers of the puzzle; (g) providing a fourth exposure of ultraviolet light to all layers of the puzzle; (h) providing a fifth exposure of ultraviolet light to all layers of the puzzle; (i) adhering a layer of white paper backing on top of the layer of opaque ink; and (j) attaching a backer board on top of the layer of white paper backing.
- A method for cutting the puzzle is also disclosed. This involves the steps of (a) providing a cutting platform; (b) cutting at least one groove in the platform, the groove forming the shape of at least one puzzle piece; (c) positioning a cutting instrument in the at least one groove; (d) placing a piece of rubber over the cutting instrument; (e) inserting at least one insert in at least one location between the rubber and the cutting platform; and (f) pressing the three-dimensional puzzle over the cutting instrument, thereby cutting the three-dimensional puzzle into at lest one puzzle piece.
-
FIG. 1 is a schematic showing the layers of the three-dimensional puzzle. -
FIG. 2 is a schematic view of the steps of the puzzle manufacturing method. -
FIG. 3 is a top view of a puzzle piece. - The following examples further illustrate the invention but, of course, should not be construed as in any way limiting its scope. As shown in
FIGS. 1-3 , the invention involves apuzzle 10 comprised of alenticular lens layer 12 having alens surface 14 and aflat surface 16. A layer of four colors ofink 18 is applied to theflat surface 16, and a layer ofopaque ink 20 applied to the four colors ofink 18. Awhite paper backing 22 is adhered to the layer ofopaque ink 20 using an emulsion-based adhesive having a viscosity of approximately 1,600 mPas at 23° C., and abacker board 24 comprised of four layers of cardboard is applied to thewhite paper backing 22. - In one embodiment, the
puzzle 10 is further comprised of a layer ofprimer 26 located between theflat surface 16 of thelenticular lens layer 12 and the layer of four colors ofink 18. The primer is a UV/EB Curable adhesive, primer, coating that is sold under various trade names including Rad-Cure, Rad-Kote and Rad-Prime. - The
lenticular lens layer 12 used with thepuzzle 10 has a thickness in the range of approximately at least 10 to approximately at least 15 mil, and more preferably approximately 14 mil. Furthermore, each of the layers of the fourlayer backer board 24 is perpendicular to their adjoining layers, and the fourlayer backer board 24 has a thickness of approximately 1.25 mm. - The layer of four colors of
ink 18 used with thepuzzle 10 can be an ultraviolet lamination formulation or a hybrid ultraviolet formulation. The opaque ink may be white. - As shown in
FIG. 3 , the invention also involves a method for manufacturing a three-dimensional puzzle 10, the method comprising the steps of: (a) providing alenticular lens layer 12 having alens surface 14 and aflat surface 16; (b) priming theflat surface 16 of thelenticular lens layer 12; (c) exposing the primedflat surface 16 of thelenticular lens layer 12 to ultraviolet light; (d) applying a layer of four colors ofink 18 to theflat surface 16 of thelenticular lens layer 12; (e) providing a first exposure 28 of ultraviolet light to the layer of four colors ofink 18; (f) adding a layer ofopaque ink 20 to the layer of four colors ofink 18; (g) providing asecond exposure 30 of ultraviolet light to all layers of thepuzzle 10; (h) providing athird exposure 32 of ultraviolet light to all layers of thepuzzle 10; (i) providing afourth exposure 34 of ultraviolet light to all layers of thepuzzle 10; (j) providing afifth exposure 36 of ultraviolet light to all layers of thepuzzle 10; (k) adhering a layer of white paper backing 22 on top of the layer ofopaque ink 20; and (l) attaching abacker board 24 on top of the layer ofwhite paper backing 22. - In the inventive method, once the primer is applied, the primed
flat surface 16 of thelenticular lens 12 is cured using exposure to ultraviolet light of approximately 840 watts for less than one second. - The four colors of ink used with the invention are comprised of black, cyan, magenta and yellow inks. In one embodiment, the black ink is first applied to the
lenticular lens 12, the cyan ink is applied second, the magenta ink is applied third, and the yellow ink is applied fourth. These four colors of ink may be printed using stochastic screen printing methods; however, conventional screening methods may also be used without departing from the scope and spirit of the invention. - When performing the inventive method, after the layer of the four colors of
ink 18 is applied, the puzzle is exposed to approximately 1,120 watts of ultraviolet light for less than one second. Following this exposure, a layer ofopaque ink 20, which may be white, is added. The layers of the puzzle are then given another exposure to ultraviolet light, this time the exposure being approximately 1,330 watts of ultraviolet light for less than one second. Once this exposure is complete, the layers of the puzzle are exposed to approximately 840 watts of ultraviolet light for less than one second. This exposure is followed by a still another exposure of ultraviolet light to the layers of thepuzzle 10. This latest exposure being approximately 1,120 watts of light for less than one second. Finally, the layers of thepuzzle 10 are exposed to ultraviolet light for a final time, this final time being approximately 1,190 watts of light for less than one second. - In constructing the
puzzle 10, the layer ofwhite paper backing 22 is applied to the layer ofopaque ink 20 using a polyacid adhesive. Thebacker board layer 24 is then applied to the whitepaper backing layer 22 using a conventional glue or adhesive. - The
lenticular lens 12 used in constructing thepuzzle 10 has a thickness in the range of approximately 10 to approximately 15 mil, and more preferably approximately 14 mil. This is because a lenticular lens having a thickness less than approximately 10 mil tends to alter the visual appearance of the puzzle by distorting the perception of depth. On the other hand, although a thickness greater than 15 mil produces a greater perception of depth to the viewer, it is more difficult to cut without causing the images on the puzzle pieces to delaminate, thereby decreasing the sharpness of the image. - Although puzzles having a lenticular lens with a thickness of approximately 18 mil are known, these puzzles are a 2-image flip lenticular, not three-dimensional puzzles. A 2-image flip lenticular is a puzzle that allows one to see two different images depending on how the puzzle is tilted. Because of the thickness of the lens, it is difficult to cut the puzzle into anything smaller than a few large pieces that are common in children's puzzle. In fact, puzzles utilizing a lenticular lens that is 18 mil thick have been discontinued in that it is cost prohibitive to cut a puzzle having a lens of this thickness into smaller pieces such as those used in 250 or 500 piece puzzles.
- The
backer board 24 used in the inventive puzzle is comprised of four layers of cardboard. This four-layer backer board 24 has a thickness of approximately 1.25 mm and each of the four layers of cardboard are oriented perpendicular to their adjacent layers. - The method of manufacturing the
puzzle 10 may also involve the steps of (a) providing a cutting platform; (b) cutting at least one groove in the platform, the groove forming the shape of at least one puzzle piece; (c) positioning a cutting instrument in the at least one groove; (d) placing a piece of rubber over the cutting instrument; (e) inserting at least one insert in at least one location between the rubber and the cutting platform; and (f) pressing the three-dimensional puzzle over the cutting instrument, thereby cutting the three-dimensional puzzle into at least onepuzzle piece 40, as shown inFIG. 3 . - In one embodiment of the inventive method, the at least one groove is part of a plurality of grooves. This plurality of grooves form the shapes of a plurality of puzzle pieces, and the pressing of the three-dimensional puzzle over the cutting instrument, cuts the three-dimensional puzzle into a plurality of puzzle pieces. Once the puzzle has been cut into a plurality of pieces, the plurality of puzzle pieces are then separated from one another. This is done when the puzzle is “crushed” for packaging. When the puzzle is crushed for packaging, special rubber tips are affixed to the “teeth” in the delivery portion of the packaging machine. These rubber tips provide the additional force needed to separate the pieces without marring the image on the puzzle.
- The cutting instrument used to cut the puzzle may be a double-sharpened, hardened steel rule or knife that uses harder steel than is normally associated with puzzle die-cutting. This knife has a body and a blade with the hardness of the body being at least approximately 39 HRC, and the hardness of the blade being at least approximately 57 HRC.
- The rubber used in the cutting process may be ejection rubber having a thickness of approximately 7 mm and a hardness of approximately 45 shore. This is a more rigid material than is normally used in puzzle cutting. Additionally, a plurality of inserts may be positioned in a plurality of locations between the rubber and the cutting platform. This plurality of inserts may vary the height of the ejection rubber from approximately 0.001 mm to approximately 0.01 mm at certain locations in the die. This altering of the height of the ejection rubber allows for a clean cut across the entire surface of the puzzle.
- All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
- The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
- Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the invention.
Claims (25)
Priority Applications (1)
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US11/900,963 US20080007837A1 (en) | 2004-11-19 | 2007-09-14 | Method for manufacturing a tree-dimensional puzzle |
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US10/993,120 US7441776B2 (en) | 2004-11-19 | 2004-11-19 | Three-dimensional puzzle |
US11/900,963 US20080007837A1 (en) | 2004-11-19 | 2007-09-14 | Method for manufacturing a tree-dimensional puzzle |
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CN108854050A (en) * | 2018-06-06 | 2018-11-23 | 美盈森集团股份有限公司 | A kind of manufacturing method of track jigsaw |
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US20110127718A1 (en) * | 2009-12-01 | 2011-06-02 | Patch Products, Inc. | Apparatus and Method for an Illusionary Three-Dimensional Puzzle |
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US20060108734A1 (en) | 2006-05-25 |
US7441776B2 (en) | 2008-10-28 |
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