3D Jigsaw Puzzle Cardboard Bending and Assembly
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Solution Overview
Problem
Existing three-dimensional jigsaw puzzles cannot be manufactured from traditional cardboard materials, resulting in a different user experience compared to assembling a traditional cardboard jigsaw puzzle.
Innovation Solution
A three-dimensional jigsaw puzzle design that uses traditional cardboard materials, combined with fiber-reinforced adhesive tape, flexible adhesive fixing sheets, and reinforcing bars, to create a structure that can be assembled and maintained in a planar shape before forming a three-dimensional object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If three-dimensional puzzle pieces are manufactured from foam material, then the pieces can be bent and connected to form three-dimensional structures, but the user experience differs from traditional cardboard jigsaw puzzles due to different material properties
Solution Approach 1:
The patent uses composite construction by laminating multiple layers of material (cardboard, paper, adhesive layers) to create puzzle pieces that combine the structural properties of cardboard with the flexibility needed for three-dimensional formation. This allows the pieces to maintain traditional cardboard feel and manipulation characteristics while enabling 3D configuration.
Solution Approach 2:
The patent modifies the physical parameters of the puzzle pieces by creating scored lines and cut patterns in the cardboard layers, allowing the rigid cardboard material to be bent and shaped into three-dimensional forms while maintaining its traditional material characteristics and user experience.
2Ease of operation
If traditional cardboard material is used for three-dimensional puzzle pieces, then the user experience matches traditional jigsaw puzzles, but the pieces cannot be effectively bent and connected to form three-dimensional structures
Solution Approach 1:
The patent divides the cardboard structure into multiple segmented layers (first cardboard layer, second cardboard layer, paper layers) that can be independently manipulated and connected. This segmentation allows the traditional cardboard material to be configured into three-dimensional shapes through layer-by-layer assembly while maintaining the familiar material experience.
Solution Approach 2:
The patent introduces adhesive layers as intermediaries between the cardboard layers and between the puzzle pieces. These adhesive layers enable the traditional cardboard material to be bonded together in three-dimensional configurations, allowing the pieces to maintain their traditional material properties while forming 3D structures.
3Adaptability or versatility
If multiple layers of materials are laminated together to create three-dimensional puzzle pieces, then the pieces can maintain traditional cardboard properties while forming three-dimensional structures, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies adhesive layers to the cardboard sheets before lamination, and pre-scores the cardboard at designated lines before assembly. These preliminary actions prepare the materials for easy assembly into three-dimensional structures, reducing the complexity of the final assembly process while maintaining multi-layer construction.
Solution Approach 2:
The patent combines multiple functions into the lamination process itself - bonding layers together, creating structural integrity, and enabling three-dimensional formation - all in a single manufacturing step. This merging of functions simplifies the overall manufacturing process despite the multi-layer construction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design allows for the creation of a three-dimensional jigsaw puzzle that replicates the user experience of assembling a traditional cardboard jigsaw puzzle, using materials and construction methods that are consistent with traditional jigsaw puzzles.
Implementation Method 1
a first adhesive layer, said first adhesive layer being present on an inner side of the bending line
Implementation Method 2
fiber-reinforced adhesive tape
Implementation Method 3
a sheet of paper bearing an image which is laminated on the cardboard using liquid glue
Implementation Method 4
using liquid glue
Implementation Method 5
reinforcing bars
Data Source
AI summary
A three-dimensional jigsaw puzzle consisting of one or more two-dimensional puzzle parts, each consisting of two or more jigsaw puzzle pieces. The puzzle parts can interconnect using leg and hole connectors to form the three-dimensional object. Each puzzle part is fixed using fixing sheets which are precut to match the format of its corresponding puzzle part. Each puzzle part can have puzzle pieces which can be bent to create corners. The bending is achieved by applying a reinforced tape along the bending line on the inner side, and by having a straight cut on the outer side of the corner penetrating the cut through the puzzle piece, but without cutting the tape. The puzzle pieces are laminated with paper that can bear an image on both sides. The puzzle parts can have a reinforcement bar glued on the non-visible side so that they retain the desired planar shape.