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° 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.

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.