U.S. patent application number 11/900963 was filed with the patent office on 2008-01-10 for method for manufacturing a tree-dimensional puzzle.
This patent application is currently assigned to Hobbico, Inc.. Invention is credited to Gordy Cockburn, Aleksandra Emmanouilidou, Krzysztof Furmanczyk, Roman Kornela, Grzegorz Traczykowski, Krzysztof Ustarbowski.
Application Number | 20080007837 11/900963 |
Document ID | / |
Family ID | 36460214 |
Filed Date | 2008-01-10 |
United States Patent
Application |
20080007837 |
Kind Code |
A1 |
Ustarbowski; Krzysztof ; et
al. |
January 10, 2008 |
Method for manufacturing a tree-dimensional puzzle
Abstract
A three-dimensional puzzle including a lenticular lens layer
having a lens surface and a flat surface. A four color ink is
applied to the flat surface and a layer of opaque ink is applied to
the four color 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.degree. C., and a backer board
comprised of four layers of cardboard is applied to the white paper
backing. A method of manufacturing the three-dimensional puzzle is
also disclosed.
Inventors: |
Ustarbowski; Krzysztof;
(Gdynia, PL) ; Emmanouilidou; Aleksandra; (Gdynia,
PL) ; Traczykowski; Grzegorz; (Gdynia, PL) ;
Kornela; Roman; (Gdynia, PL) ; Cockburn; Gordy;
(Champaign, IL) ; Furmanczyk; Krzysztof; (Gdynia,
PL) |
Correspondence
Address: |
DRINKER BIDDLE & REATH LLP;ATTN: PATENT DOCKET DEPT.
191 N. WACKER DRIVE, SUITE 3700
CHICAGO
IL
60606
US
|
Assignee: |
Hobbico, Inc.
Champaign
IL
|
Family ID: |
36460214 |
Appl. No.: |
11/900963 |
Filed: |
September 14, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10993120 |
Nov 19, 2004 |
|
|
|
11900963 |
Sep 14, 2007 |
|
|
|
Current U.S.
Class: |
359/619 ;
83/32 |
Current CPC
Class: |
A63F 9/0613 20130101;
G02B 27/10 20130101; A63F 9/12 20130101; Y10T 83/0491 20150401;
A63F 2009/0633 20130101; A63F 9/10 20130101; A63F 2009/1083
20130101; A63F 2009/1072 20130101 |
Class at
Publication: |
359/619 ;
083/032 |
International
Class: |
G02B 27/10 20060101
G02B027/10; A63F 9/12 20060101 A63F009/12; B26D 1/02 20060101
B26D001/02 |
Claims
1. A method of manufacturing a three-dimensional puzzle, comprising
the steps of: providing a lenticular lens layer having a lens
surface and a flat surface; priming the flat surface of the
lenticular lens layer; exposing the primed flat surface of the
lenticular lens layer to ultraviolet light; applying a layer of
four colors of ink to the flat surface of the lenticular lens
layer; providing a second exposure of ultraviolet light to the
layer of four colors of ink; adding a layer of opaque ink to the
layer of four colors of ink; providing a third exposure of
ultraviolet light to all layers of the puzzle; providing a fourth
exposure of ultraviolet light to all layers of the puzzle;
providing a fifth exposure of ultraviolet light to all layers of
the puzzle; providing a sixth exposure of ultraviolet light to all
layers of the puzzle; adhering a layer of white paper backing on
top of the layer of opaque ink; and attaching a backer board on top
of the layer of white paper backing.
2. The method of claim 1, wherein the primed flat surface of the
lenticular lens layer is cured using exposure to ultraviolet light
of approximately 840 watts for less than one second.
3. The method of claim 1, wherein the four colors of ink is
comprised of black, cyan, magenta and yellow inks.
4. The method of claim 1, wherein the layer of four colors of ink
is applied using stochastic screening.
5. The method of claim 1, wherein the second exposure of
ultraviolet light to the layer of four color is approximately 1,120
watts for less than one second.
6. The method of claim 1, wherein the third exposure of ultraviolet
light to the layers of the puzzle is approximately 1,330 watts for
less than one second.
7. The method of claim 1, wherein the fourth exposure of
ultraviolet light to the layers of the puzzle is approximately 840
watts for less than one second.
8. The method of claim 1, wherein the fifth exposure of ultraviolet
light to the layers of the puzzle is approximately 1,120 watts for
less than one second.
9. The method of claim 1, wherein the sixth exposure of ultraviolet
light to the layers of the puzzle is of approximately 1,190 watts
for less than one second.
10. The method of claim 1, wherein the layer of white paper backing
is applied to the layer of opaque ink using a polyacid
adhesive.
11. The method of claim 1, wherein the lenticular lens has a
thickness of at least approximately 10 mil.
12. The method of claim 1, wherein the lenticular lens has a
thickness in the range of approximately 10 mil to approximately 15
mil.
13. The method of claim 1, wherein the backer board is comprised
of: four layers of cardboard; each of the four layers of cardboard
are oriented perpendicular to their adjacent layers; and the
four-layer backer board has a thickness of approximately 1.25
mm.
14. The method of claim 1, further comprising the steps of:
providing a cutting platform; cutting at least one groove in the
platform, the groove forming the shape of at least one puzzle
piece; positioning a cutting instrument in the at least one groove;
placing a piece of rubber over the cutting instrument; inserting at
least one insert in at least one location between the rubber and
the cutting platform; and pressing the three-dimensional puzzle
over the cutting instrument, thereby cutting the three-dimensional
puzzle into at least one puzzle piece.
15. The method of claim 14, wherein: the at least one groove is
part of a plurality of grooves; the plurality of grooves forms the
shape of a plurality of puzzle pieces; and pressing the
three-dimensional puzzle over the cutting instrument, cuts the
three-dimensional puzzle into a plurality of puzzle pieces.
16. The method of claim 14, wherein: the cutting instrument is
comprised of a double-sharpened, hardened steel knife; the knife
has a body and a blade; the hardness of the body is at least
approximately 39 HRC; and the hardness of the blade is at least
approximately 57 HRC.
17. The method of claim 14, wherein the rubber is ejection rubber
having a thickness of approximately 7 mm and a hardness of
approximately 45 shore.
18. The method of claim 14, wherein a plurality of inserts are
positioned in a plurality of locations between the rubber and the
cutting platform.
19. The method of claim 14, wherein the plurality of inserts vary
in height from approximately 0.001 mm to approximately 0.01 mm.
20. A method for cutting a puzzle, the method comprising the steps
of: providing a cutting platform; cutting at least one groove in
the platform, the groove forming the shape of at least one puzzle
piece; positioning a cutting instrument in the at least one groove;
placing a piece of rubber over the cutting instrument; inserting at
least one insert in at least one location between the rubber and
the cutting platform; and pressing the three-dimensional puzzle
over the cutting instrument, thereby cutting the three-dimensional
puzzle into at least one puzzle piece.
21. The method of claim 20, wherein: the at least one groove is
part of a plurality of grooves; the plurality of grooves forms the
shape of a plurality of puzzle pieces; and pressing the
three-dimensional puzzle over the cutting instrument, cuts the
three-dimensional puzzle into a plurality of puzzle pieces.
22. The method of claim 20, wherein: the cutting instrument is
comprised of a double-sharpened, hardened steel knife; the knife
has a body and a blade; the hardness of the body is at least
approximately 39 HRC; and the hardness of the blade is at least
approximately 57 HRC.
23. The method of claim 20, wherein the rubber is ejection
rubber.
24. The method of claim 23, wherein the ejection rubber has a
thickness of approximately 7 mm and a hardness of approximately 45
shore.
25. The method of claim 23, wherein a plurality of inserts are
positioned in a plurality of locations between the rubber and the
cutting platform.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] 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.
FIELD OF THE INVENTION
[0002] This invention pertains to puzzles in general and, more
particularly, to three-dimensional puzzles.
BACKGROUND OF THE INVENTION
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
BRIEF SUMMARY OF THE INVENTION
[0008] 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.degree. C., and a backer board comprised of four layers
of cardboard is applied to the white paper backing.
[0009] 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.
[0010] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic showing the layers of the
three-dimensional puzzle.
[0012] FIG. 2 is a schematic view of the steps of the puzzle
manufacturing method.
[0013] FIG. 3 is a top view of a puzzle piece.
DETAILED DESCRIPTION OF THE INVENTION
[0014] 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 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, and 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.degree. C., and a
backer board 24 comprised of four layers of cardboard is applied to
the white paper backing 22.
[0015] In one embodiment, 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.
[0016] 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.
[0017] 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.
[0018] 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 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 of ultraviolet light to all
layers of the puzzle 10; (k) adhering a layer of white paper
backing 22 on top of the layer of opaque ink 20; and (l) attaching
a backer board 24 on top of the layer of white paper backing
22.
[0019] In the inventive method, once the primer is applied, 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.
[0020] 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.
[0021] 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 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. 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 the puzzle 10. This
latest exposure being approximately 1,120 watts of light for less
than one second. Finally, 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.
[0022] In constructing the puzzle 10, 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.
[0023] 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.
[0024] 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.
[0025] 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.
[0026] 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.
[0027] 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.
[0028] 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.
[0029] 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.
[0030] 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.
[0031] 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.
[0032] 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.
* * * * *