THREE DIMENSIONAL PUZZLE WITH TACTILE RESPONSE

Abstract

A jigsaw puzzle kit is provided having a plurality of interlocking puzzle pieces configured for assembly to form a three dimensional image, each puzzle piece having a surface an image applied thereon, a resilient layer for generating a tactile response when the puzzle piece is depressed, and a rigid backing layer below the resilient layer for providing support. Also provided is a method of manufacturing a jigsaw puzzle which includes the steps of applying an image onto the surface of a resilient material; applying a mold to the resilient material so as to create variations in the height of the resilient layer; adhering a rigid backing material to the molded resilient material; and die cutting the resilient material and the rigid backing material to create a plurality of interlocking puzzle pieces.

Description

TECHNICAL FIELD

Jigsaw puzzles with tactile response

BACKGROUND

The following paragraphs are not an admission that anything discussed in them is prior art or part of the knowledge of persons skilled in the art.

Jigsaw puzzles are typically made of interlocking cardboard, wood, or plastic that are assembled to form a complete image. The completed images are typically a two dimensional printed image, and are not able to display a three dimensional or multi-layered image. Typical jigsaw puzzles also do not provide a tactile response when depressed.

SUMMARY

What is provided is a jigsaw puzzle kit having a plurality of interlocking puzzle pieces configured for assembly to form an image, each puzzle piece having a surface having a portion of the image applied thereon, a resilient layer for generating a tactile response when the puzzle piece is depressed, and a rigid backing layer below the resilient layer for providing support. Due to the molding, the height of the resilient layer varies in the assembled image. The resilient layer may be comprised of a material selected from one of polyvinyl chloride, polyurethane leather, and leather.

Also provided is a method of manufacturing a jigsaw puzzle which includes the steps of applying an image onto the surface of a resilient material; applying a heated mold to the resilient material so as to create variations in the height of the resilient layer; adhering a rigid backing material to the molded resilient material; and die cutting the resilient material and the rigid backing material to create a plurality of interlocking puzzle pieces.

These and other aspects of the device and method are set out in the claims, which are incorporated here by reference.

BRIEF DESCRIPTION OF THE FIGURES

Embodiments will now be described with reference to the figures, in which like reference characters denote like elements, by way of example, and in which:

FIG. 1 is a perspective view of a completed three dimensional puzzle with tactile response.

FIG. 2 is a side cross-sectional view of a puzzle piece in its natural state.

FIG. 3 is a side cross-sectional view of a puzzle piece when depressed.

FIG. 4 is a top view of a die cut outline for a jigsaw puzzle.

FIG. 5 is a close-up perspective view of a character element having an elevated profile, according to another embodiment.

FIG. 6 is a close-up perspective view of a background element according to the embodiment shown in FIG. 1.

FIG. 7 is a close-up perspective view of a character element according to the embodiment shown in FIG. 1.

FIG. 8 is a perspective view of a puzzle kit having a PU leather resilient layer, according to yet another embodiment.

FIG. 9 is a process flowchart of a method of manufacturing a puzzle kit.

DETAILED DESCRIPTION

Immaterial modifications may be made to the embodiments described here without departing from what is covered by the claims.

As shown in FIG. 1, provided is a textured, multi-dimensional puzzle 200 with tactile response. In the specific embodiment shown in FIG. 1, the profile of characters 202 in the image are raised over other elements in the image, including buildings 204 and background element 206, which each also have their own elevations. The elevations of the various elements are determined by the thickness of the resilient material underneath the printed surface. Various elements of the puzzle may be depressed by the user to provide a tactile response.

Typically, the elements with the greatest thickness also provide the greatest tactile response. These elements may be the main subject of the image, in this case being the characters 202. A close-up view of the background element 206 with an elevated profile is shown in FIG. 6, and similarly, a close-up perspective view of another piece containing a character 202 with an elevated profile is shown in FIG. 7, as well as yet another character 402 according to a different embodiment in FIG. 5. However, the elements with raised profiles are not limited to any particular type of characters, objects or backgrounds, but could be any object, pattern or random part of the image.

The puzzle pieces are manufactured using a resilient layer which may comprise material selected from one of polyvinyl chloride (PVC), polyurethane (PU) leather, and leather. These types of materials have been found to be able to permanently retain an applied (e.g., printed) image while also being able to be depressed to generate a tactile response. They may also be readily heat molded or hot embossed into various shapes and structures to create a three-dimensional structure. Other resilient and moldable materials such as rubber or sponge may also be used to generate the tactile response when depressed, but the surface of the material may need to be treated (or an additional printable layer added) so that it can permanently retain an image that is printed thereon. The resilient layer is not limited to the materials described above, and may include any other resilient material that has a printable surface or the ability to be attached to a printable surface. Preferably, the resilient layer itself is of a single piece construction as opposed to multiple pieces bonded on top of each other or adjacent to each other, which may become detached over time through use, especially by young children.

For young children, the tactile response provided by the resilient layer may be beneficial in that it adds an additional sensory element during the assembly process. For those who are visually impaired, the various textures would allow them to assemble the puzzle which would not normally be possible with flat puzzle pieces. Where the resilient layer is made of leather or PU leather, it may also appeal to adults or as a collectible item by providing a more premium or traditional feel to the completed puzzle, akin to a book having a leather cover. An example of puzzle pieces 500 having a PU leather resilient layer is shown in FIG. 8.

Shown in FIG. 2 is a cross-sectional view of a puzzle piece in its uncompressed state, showing printed surface 102, resilient layer 104, and the paper backing layer 106. When depressed, as shown in FIG. 3, the resilient layer 104 will provide a tactile response. When released, resilient layer 104 reverts to its uncompressed state as shown in FIG. 2. Through the application of a three-dimensional mold, even in the uncompressed state, the thickness or height of the resilient layer will vary throughout the image and between each puzzle piece. However, the overall thickness of this layer, if using a PVC material such as blank foam PVC, is preferably within a range between 2 mm to 5 mm. Through experimentation, it has been discovered that where the layer is thinner than 2 mm, it may not have the necessary resiliency to create a tactile response when being depressed, and thickness greater than 5 mm may cause additional difficulty during the molding or die-cutting stages. The weight and density of the PVC may also vary depending on the thickness of the material. For example, 3 mm thick PVC foam material may have a weight of approximately 1.06 kg/m², whereas a 5 mm thick PVC foam material may have a weight of approximately 1.74 kg/m². For other materials, such as PU leather and leather, the optimal range may be slightly different, as it may be difficult or costly to produce PU leather or leather material having thickness of 5 mm.

The backing layer 106 is preferably provided as rigid support and to provide a flat back surface. The inclusion of backing layer 106 may also create a typical jigsaw puzzle “click” sound, feel and additional support when being assembled. Without backing layer 106, the softness of the resilient layer 104 may produce a less satisfying feel when being assembled. The backing layer 106 also adds weight to the resilient layer 104, which if using a material such as PU leather or PVC, may be light on its own. The increased toughness of the backing layer 106 will also prevent folding of the puzzle pieces during transport or assembly, and also helps keep the puzzle connected when assembled. While the backing layer may be a separate material such as cardboard or plastic, it may also be integral with the resilient layer. For example, it may comprise a one-piece PVC foam with greater density at one end (thus being more rigid) than the other (resilient) end.

Also provided is a method of manufacturing a multi-dimensional jigsaw puzzle with tactile response, a process flowchart 600 of which is shown in FIG. 9. In accordance with this method, a two-dimensional image is applied via process 602 onto the surface of a resilient layer such as that described above. For ease of applying an image, the surface of the resilient layer is preferably flat, although depending on the method of application, the resilient layer may also already be at least partially textured or molded. Depending on the resilient layer, the image may be applied directly on the resilient layer (e.g., if using a material such as PU leather, leather or PVC), or the surface may need to first be treated (or additional surface layer added) to receive the ink or other forms of print if using other types of resilient material such as rubber.

The method of image application may vary, although two forms of image printing that have been shown to work include a heat transfer method using aqueous ink, and a silkscreen method using sedimentary ink. The method of image application may also affect the feel of the surface—the heat transfer method may produce a deeper and softer textured image, while the silkscreen method may produce a more shallow and coarse texture, similar to the printing found on clothing such as t-shirts. It has also been found that the silkscreen method of printing may create odors that are more apparent than when the heat transfer method. The image application process is not limited to the types of print technology described above, and may also include the additional application of jewelry and other ornaments to specific elements within the image, and may even include hand drawn and painted designs on the surface of the resilient material.

After the image application has been completed, via process 604 a multi-layered mold (e.g., a heated mold) may be applied to the resilient layer to create texture, and to compress certain portions of the image to give it a three-dimensional feel. It is through this process that the thickness of the resilient layer is changed throughout the image. It has been found that when using a resilient layer made of PVC or PU leather, the printed ink is able to stretch together with the change in thickness of the resilient layer, thus not requiring any touch-up printing to any angled or raised areas. However, if necessary, the image may be re-applied or touched up after molding if necessary. Preferably, the edges of any raised areas are smoothed (which may be dictated by the mold) to create a more gentle feel for the user when handling the puzzle pieces. A gradual angle of elevation (for example, less than 45 degrees) for raised areas may also allow for easier diecutting (to prevent clipping or cracking during the die-cutting process), and may prevent ink from stretching to the point of cracking, which would require additional touch ups. Depending on the desired design, the mold may comprise multiple elevations, for example, where the deepest (or tallest) layer is reserved for main characters or subjects in the image, with the lowest layer being reserved for the background elements such as the sky. A two-sided mold (to mold both the top surface and raise the bottom surface) may be used to create greater height, particularly when creating embodiments employing materials such as PU leather where the thickness of the material may be somewhat limiting. In some embodiments where a two-sided mold is used, the backing layer will especially important as raised portions of the resilient layer may not otherwise have the proper support. As described above, the resilient layer may already be molded or textured prior to the printing process, although depending on the degree of elevation and the printing process used, a pre-molded resilient layer may create difficulty during the printing process. For example, a flat heat transfer print will likely not be able to transfer the image in its original form when used against an already molded or textured resilient layer. It may also be possible to have the mold designed to apply colour or inject ink during the molding process. However, for ease of manufacturing, typically the printing is performed before the mold is applied.

Before or after the printing, a backing layer is adhered to the resilient layer via process 606, which may be done through bonding or gluing. The backing layer may consist of standard jigsaw puzzle material such as cardboard, so as to allow the user to create the typical “click” feeling when assembling the pieces, although other flat, rigid materials such as plastic may be used. However, as also described above, it may also be integral with the resilient layer (such as through a PVC material with variable density).

Once the backing layer has been adhered to the resilient layer, the entire puzzle is die cut into jigsaw pieces via process 608. Shown in FIG. 4 is a top view of a die cut outline 300 that may be used to create the puzzle shown in FIG. 1. The die cutting may be performed in the typical random jigsaw patterns, although for aesthetic reasons, it is preferable to design the die such that it cuts around elevated objects such as main characters in the image, for example as shown in FIG. 4. This method would allow the elevated characters to stand out on their own, and also allow for additional designs such as jewelry and other ornaments to be added to the characters before the die cutting process without the risk of damaging those additional elements.

Note that the steps in the disclosed method may be performed in any order. For example, as described above, the image application may be performed before, during or after the molding process. Also, the die cut process may be performed prior to the bonding of the rigid layer to the resilient layer, although two components would then need to be die cut separately and may also increase the risk of the rigid layer not fully matching the resilient layer during the bonding process.

In the claims, the word “comprising” is used in its inclusive sense and does not exclude other elements being present. The indefinite articles “a” and “an” before a claim feature do not exclude more than one of the feature being present. Each one of the individual features described here may be used in one or more embodiments and is not, by virtue only of being described here, to be construed as essential to all embodiments as defined by the claims.

Claims

1. A jigsaw puzzle kit comprising:

a plurality of interlocking puzzle pieces configured for assembly to form an image, each puzzle piece having: a surface having a portion of the image applied thereon; a resilient layer for generating a tactile response when the puzzle piece is depressed; a rigid backing layer below the resilient layer for providing support;

wherein the height of the resilient layer varies in the assembled image.

2. The apparatus of claim 1, wherein the resilient layer comprises a material selected from one of polyvinyl chloride, polyurethane leather, and leather.

3. The apparatus of claim 1, wherein the surface is integral with the resilient layer.

4. The apparatus of claim 1, wherein the resilient layer is bonded to the backing layer.

5. The apparatus of claim 1, wherein the elevated portions of the resilient layer comprise characters within the assembled image.

6-9. (canceled)