METHODS OF MANUFACTURE OF PUZZLE PIECES

摘要

The present invention relates to a method of manufacture of puzzle pieces (e.g. 11, 101) comprising the steps of dispensing from a roll (20) a sheet (21) of material and cutting puzzle pieces (e.g. 11, 101) in the dispensed sheet (21) of material by applying to the material a roller (22) which has a cutting surface which cuts the puzzle pieces (e.g. 11, 101) with selected shapes. In a first aspect of the invention the sheet of material (21) comprises a cardboard top layer (40) supported on a substrate (41) with a layer of adhesive (42) holding the cardboard layer (40) together with the substrate (41) during cutting of the puzzle pieces (e.g. 11, 101). The roller (22) cuts puzzle pieces (e.g. 11, 101) in the cardboard top layer (40) without cutting the substrate (41) supporting the cardboard top layer (40). In a second aspect of the invention the sheet of material (21) has three plies comprising a surface ply (110), an intermediate substrate (111) and a base substrate (112). The surface ply (110) is adhered to the intermediate substrate (111) by a first layer of adhesive (113) and the intermediate substrate (111) is adhered to the base substrate (112) by a second layer of adhesive (114). The roller (22) cuts puzzle pieces (e.g. 11, 101) in the sheet of material by cutting through both the surface ply (11) at the intermediate substrate (111) and without cutting the base substrate (112). In a third aspect of the invention the cutting surface cuts in the sheet of material (21) a first puzzle piece (172) which is a jigsaw piece having a shape which includes a lug for insertion into and for engagement with a cutout in a second puzzle piece (173), the cutting surface separately cuts in the sheet of material (21) the second puzzle piece (173) having the cutout matching the lug in the first puzzle piece (172) and the lug in the first puzzle piece (172) and the cutout in the second puzzle piece (173) are spaced apart on the sheet of material (21) at the time of cutting of the first (172) and second puzzle pieces (173).