CUSTOM MULTI-COLORED IMAGES APPLIED TO THREE DIMENSIONAL PRODUCTS, SUCH AS POLYSTYRENE POST PRODUCTION ON AN INDIVIDUAL BASIS
A base plate for supporting a plurality of interlocking building bricks includes a planar sheet having a top surface and a bottom surface, with a plurality of nodes projecting from the top surface. The plurality of nodes includes a node having a vertical cylindrical wall and a horizontal top wall, the vertical cylindrical wall tapering along its vertical height; the node also having a bevel extending around a circumference of the node at an edge where the vertical cylindrical wall transitions to the horizontal top wall. A method of assembling a composite base plate includes securing two component base plates to one another via a common backing material. A method of printing on a base plate includes applying ultraviolet ink to at least the top surface of the base plate from an ultraviolet light printer, the base plate having a plurality of studs or nodes projecting from the top surface.
1 - 17 . (canceled)
18 . A method of assembling a composite base plate, comprising:
aligning a first component base plate having a first interlocking mechanism extending along a peripheral edge with a second component base plate having a second interlocking mechanism extending along a peripheral edge, wherein
aligning the first and second component base plates includes mating the first interlocking mechanism and the second interlocking mechanism.
19 . The method of assembling a composite base plate according to claim 18 , wherein
the first interlocking mechanism is in the form of a two-tier annular ledge comprising a top ledge and a bottom ledge, the top ledge extending further horizontally from the planar sheet than the bottom ledge,
the second interlocking mechanism is in the form of a two-tier annular ledge comprising a top ledge and a bottom ledge, the bottom ledge extending further horizontally from the planar sheet than the top ledge, and
aligning the first and second component base plates, by mating the first interlocking mechanism and the second interlocking mechanism, includes aligning the top ledge of the first interlocking mechanism to overlap the bottom ledge of the second interlocking mechanism.
20 . The method of assembling a composite base plate according to claim 18 , wherein
the first component base plate has an interlocking mechanism extending along each peripheral edge,
the second component base plate has an interlocking mechanism extending along each peripheral edge, and
aligning the first and second component base plates includes mating the first interlocking mechanism and the second interlocking mechanism in a manner to form a composite base plate that has an interlocking mechanism extending along each peripheral edge.
21 . The method of assembling a composite base plate according to claim 18 , wherein
aligning the first component base plate and the second component base plate comprises:
placing the first component base plate in a forming container, using at least one wall of the forming container to position the first component base plate, and
placing the second component base plate in the forming container, using at least one wall of the forming container to position the second component base plate.
22 . The method of assembling a composite base plate according to claim 21 , wherein
positioning the first component base plate includes orienting the first interlocking mechanism of the first component base plate for receiving the second interlocking mechanism of the second component base plate, and
positioning the second component base plate includes orienting the second interlocking mechanism of the second component base plate to mate with the first interlocking mechanism of the first component base plate.
23 . The method of assembling a composite base plate according to claim 21 , wherein
aligning the first component base plate and the second component base plate comprises:
prior to positioning of the first component base plate in the forming container, placing a backing substrate in the forming container, using at least one wall of the forming container to position the backing substrate.
24 . The method of assembling a composite base plate according to claim 23 , wherein
placing the first component base plate in the forming container includes positioning the first component base plate on the backing substrate and aligning at least one edge of the first component base plate with at least one edge of the backing substrate, and
placing the second component base plate in the forming container includes positioning the second component base plate on the backing substrate and aligning at least one edge of the second component base plate with at least one edge of the backing substrate.
25 . The method of assembling a composite base plate according to claim 24 , further comprising:
securing the first component base plate to the second component base plate by applying a bonding material between contact points of the first component base plate and the backing substrate, and applying a bonding material between contact points of the second component base plate and the backing substrate.
26 . The method of assembling a composite base plate according to claim 25 , further comprising:
exposing the backing substrate and the first and second component base plates to an air flow through air vents in the forming container to promote setting of the bonding material.
27 . The method of assembling a composite base plate according to claim 25 , further comprising:
applying a pressure to the first and second component base plates to promote setting of the bonding material.
28 . The method of assembling a composite base plate according to claim 25 , wherein
securing the first component base plate to the second component base plate further comprises temporarily interlocking the first and second component base plates to one another while the bonding material sets.
29 . The method of assembling a composite base plate according to claim 23 , wherein
placing the backing substrate includes positioning a substrate having a composition comprising medium density fiberboard, a honeycomb paper backing, and/or a polyvinyl chloride sheet as a backing substrate.
30 . The method of assembling a composite base plate according to claim 23 , further comprising:
placing at least one component base plate in the forming container, and positioning the at least one component base plate on the backing substrate such that at least one edge of the at least one component base plate protrudes beyond at least one edge of the backing substrate, wherein
the at least one edge of the at least one component base plate that protrudes beyond the at least one edge of the backing substrate is an edge having an interlocking mechanism.
31 . The method of assembling a composite base plate according to claim 18 , further comprising:
securing the first component base plate to the second component base plate by applying a bonding material between contact points of the first and second interlocking mechanisms.