Patent Application
20130154188
1. Field of the Invention
The present invention relates to jigsaw puzzles having a plurality of interlocking puzzle pieces that are assembled as complete puzzles and then overlaid on top of each other and locked together to form a three dimensional composite relief image.
2. Art Background
Jigsaw puzzles that are assembled by matching a number of interlocking pieces to form a three dimensional pictorial illustration are well-known. Scobbie et al. U.S. Pat. No. 5,860.650, describes three dimensional jigsaw puzzles that, when constructed, make a structural form, such as a skyscraper, where the surfaces of the structural form have images completed by assembling the puzzle pieces. Chuang 2003/0118756 describes a jigsaw puzzle wrapped around a three dimensional form such as a sphere. Parks U.S. Pat. No. 1,964,007 describes a 3D jigsaw puzzle assembled from 2D jigsaw puzzles with puzzle pieces having images on the upper surface of the puzzle pieces and on exposed sides such that the 2D puzzles can be assembled and then stacked on top of each other to form a 3D structural form with images on all sides. Miller et al. U.S. Pat. No. 3,682,479 describes a three dimensional jigsaw puzzle of interlocking layers where the layers contain voids so that lower layers can be seen through upper layers and where the layers can be aligned with a side-walled tray. In Miller the layers are not complete puzzles but only parts of a layered 3D puzzle composite Rinker U.S. Pat. No. 4,469,331 describes a jigsaw puzzle assembled in multiple layers that are locked together with multi-layered locking pieces where each layer of the multi-layered locking pieces has a jigsaw puzzle die-cut that will interlock only with a corresponding layer of a jigsaw puzzle Rinker's play value is in the complex assembly of a multi-layered puzzle with multi-layered locking pieces each with unique die-cuts for each layer, Rinker's puzzles are extremely complicated, difficult to align, and expensive to manufacture.
A plurality of jigsaw puzzles that can be assembled individually to compose completed images and then laid on top of each other and locked to form an integrated multilayered and dimensional composite relief image is proposed. Where the individual puzzles are complete in and of themselves but also serve as layers of a composite relief image such that the layers can be laid on top of each other and locked together. Where the layered puzzles can be staggered opaque or transparent or both such that underlying layered puzzles can be seen through or behind the upper layer puzzles. Where the images of each layered puzzle are completed images and compose, for example, a background scene, a middle-ground scene, and a foreground scene or, as a further example the layers can form the equivalent of strata where the first layer image might be the dungeons of a castle, the second layer image the first floor, and subsequent layer images might show other levels of the castle. Similarly the layers could compose a human body or a timeline.
One feature of the invention in its various embodiments is to make a 3D puzzle assembly that is simple to understand where the objective is to assemble individual puzzle layers as complete images and then simply combine the puzzle layers by laying one on top of another to form a composite layered relief image where the layers can be aligned and locked in position by locking pieces.
Another feature of the invention in its various embodiments is to provide layered jigsaw puzzle images that when stacked on top of each other simply create composite images. This is done by creating images very much like they are created for cell animations, where complete background scenes are visualized, complete middle-ground images are visualized, and complete foreground images are visualized.
Another feature of the invention in its various embodiments is to describe a manufacturing means to economically manufacture the type of multilayered jigsaw puzzle envisioned by this invention.
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.
With reference to
The individual layers 101, 102, 103, 104 can be made of various materials and combinations thereof. For example, in one embodiment, layers 101, 103 and 104 are made of opaque materials and layer 102 can be made of transparent plastic printed with opaque or transparent images. In one embodiment, the transparent plastic layer 102 is clear ABS plastic. However, other materials that would be suitable for this layer include, but are not limited to, clear PVC, PET, and Acrylic. For opaque puzzle piece layers materials that would be suitable include, but are not limited to, opaque plastic, board, laminated board, card, wood, and wood pulp. Where an image can be applied to wood, by heat transfer, by silkscreen, pad printing, or laminated with a 4c offset printed sheet, or by other methods, and then cut with a jigsaw, Where wood pulp can be molded into a puzzle piece layer with small molded rods of wood, connecting individual puzzle pieces, that can be snapped off after an image is applied to the surface. Where opaque plastic can be offset printed if thinner than, and in the order of, 0.6 mm and then die-cut. Where an opaque plastic puzzle piece layer over 0.6 mm can be molded in one piece with sprue that connect the individual puzzle pieces and that can be broken to separate the individual puzzle pieces after an image has been applied to the surface. Where an image can be applied to an opaque plastic puzzle piece layer by heat transfer, silkscreen, pad printing, or by laminating a die-cut offset printed clear film such as a clear PVC.
It has been discovered that the following methodologies are particularly well-suited for manufacturing the transparent layer 102 of the three dimensional jigsaw puzzle 100.
In the first method, a clear plastic layer is created through ABS plastic injection molding.
The layer can be molded as separate puzzle pieces or as an assembled puzzle that can easily be broken apart after applying images. Molding the transparent puzzle layer in one piece where the individual puzzle pieces are connected by small, breakable, connecting sprue, much like the sprue that connect the parts of a plastic aircraft kit, is the most efficient means of manufacturing by injection molding as images can be applied by heat transfer onto the puzzle layer surface before the puzzle pieces are separated. Images can be applied by silkscreen, pad printing, or even offset printing, but offset printing will only be practical if the injection molded layer is thinner than, and in the order of, 0.6 mm and flexible enough to pass through an offset press. However, the injection method can be used to manufacture puzzle pieces of almost any thickness and images can be applied by heat transfer, silkscreen, pad printing, or even laminating a die-cut 4c printed transparent film layer such as a clear PVC, on top of a molded puzzle piece layer.
In the second method, a user begins with a sheet of clear plastic of thickness under 0.8 mm. The user then determines the areas where opaque images are to be placed. An opaque white base is applied to these areas in one or more passes. In one embodiment, the white base is applied with silkscreen or offset printing. Offset printing can then be used to further define the images with additional colors as needed. The plastic sheet is then die-cut. In this method, the plastic can be clear PVC, PP, PET, or other clear plastics that can be offset and silkscreen printed, and then die-cut such that the puzzle pieces remain substantially flat after die-cutting. The offset method is much less expensive and not as labor intensive as the injection molding method. However, typically the plastic has to be no thicker than 0.7 mm or 0.8 mm to pass through an offset press and to be economically die-cut.
Wood mounted die-cut tools were found to distort the clear plastic during the die-cut process such that the puzzle pieces would not properly interlock whereas it was found that molded metal die-cutting tools would die-cut without distortion.
In yet another embodiment, an even less expensive way of manufacturing the transparent puzzle layer is to use clear static cling stickers that are die-cut to interlock or die-cut to be simply positioned in a free fashion over opaque layers 108. The static cling stickers can be 4c offset printed and die-cut as either individual picture elements or as characters or printed and die-cut as interlocking puzzle pieces. Static cling stickers and the clear film, normally a clear PVC film, are thin and in the order of thickness of 0.2 mm. Similarly transparent stickers with a light tack clear adhesive can be used as an alternative to static cling. Transparent plastics are not 100% transparent and that limits the number of possible transparent layers, or overlays, that can overlay each other without overly obscuring the images printed on lower layers.
The jigsaw puzzle layers 101, 103, 104 can be made of opaque materials such as laminated board or opaque plastic. When opaque jigsaw puzzle layers 101, 103, 104 are laid on top of each other the images of each layer are composed to combine in the same way as the images of cell animation are composed where the upper layers only cover the lower parts of the images on the layers below but where the layers align along at least one edge so that they can be easily locked together with corner or edge or both locking pieces.
Transparent layer 102, and opaque layers 101, 103, 104 can be combined in which case the transparent layers can cover all or part of the opaque layers.
Once assembled each layer 101, 102, 103, 104 of the jigsaw puzzle 100 can be stacked one on top of another aligning along at least one edge and locked in position with corner or edge or both locking pieces that can be die cut, see
As for securing the puzzle layers 101, 102, 103, 104, in one embodiment the layers 101, 102, 103, 104 align along at least one edge where the layers can be simply locked together using edge, or corner, or both, locking pieces.
Thus an economic and simple multilayered jigsaw puzzle where each layer can be assembled as a complete puzzle with a complete assembled image and then where the layers can be combined aligning along at least one edge and locked in position by edge or corner or both locking pieces to create a composite dimensional layered image is disclosed.
