Method for manufacturing a tree-dimensional puzzle

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.