Puzzle Piece Separation via Transverse Controlled Movement

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Solution Overview

Problem

Existing methods for producing puzzles result in incomplete separation of pieces, leading to missing pieces, damage, and dust issues during the separation process, making it difficult to assemble the puzzle correctly.

Innovation Solution

A method and device for controlled separation of puzzle pieces using a controlled movement perpendicular to the image plane, allowing for efficient and defined separation of puzzle pieces using various materials like cardboard, plastic, or wood, with options for punching, sawing, or laser cutting, and a device with moving elements and contact points to detach pieces in a predetermined manner.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If puzzle pieces are separated by punching and breaking on a conveyer belt, then separation efficiency is improved, but completeness of separation deteriorates (pieces remain connected or are damaged)

Engineering Contradiction:

Improveseparation efficiencyVSAvoidcompleteness of separation

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by performing a controlled detaching movement before complete separation. The puzzle piece is moved transversely to the image plane in a controlled manner, creating a defined separation path that ensures complete detachment while preventing damage. This preliminary controlled movement prepares the piece for clean separation without the chaotic breaking process of prior art.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces an intermediary controlled movement process between the punching stage and final separation. This intermediary step involves moving the puzzle piece transversely to the image plane, which acts as a mediator to achieve complete separation while maintaining piece integrity. This controlled intermediary movement replaces the direct chaotic breaking process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Speed

If puzzle pieces are indiscriminately broken up by rotating rods, then separation speed is improved, but piece integrity deteriorates (damage to image and pieces)

Engineering Contradiction:

Improveseparation speedVSAvoidpiece integrity

Core Design Contradiction:

SpeedVSStrength

Solution Approach 1:

The patent replaces the mechanical breaking system (rotating rods) with a controlled movement system. Instead of using mechanical force to break pieces apart, the system uses a controlled transverse movement to detach pieces along a defined path. This substitution eliminates the damaging impact forces while maintaining separation efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The controlled movement system allows the puzzle piece to separate itself through a predetermined motion path rather than being forcibly broken. The piece detaches through its own controlled movement transverse to the image plane, eliminating the need for external breaking forces that cause damage.

Inventive Principle:

Principle #25Self-service

3Strength

If manual separation is used, then piece integrity is maintained, but productivity deteriorates

Engineering Contradiction:

Improvepiece integrityVSAvoidseparation productivity

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent applies preliminary action by implementing an automated controlled movement system that replicates the careful handling of manual separation. The predetermined transverse movement path ensures each piece is detached with the same care as manual separation would provide, while the automation enables high-speed processing of multiple pieces simultaneously.

Inventive Principle:

Principle #10Preliminary action

4Loss of time

If chaotic breaking process is used, then separation is achieved quickly, but dust generation increases and pieces may be damaged

Engineering Contradiction:

Improveseparation timeVSAvoiddust generation

Core Design Contradiction:

Loss of timeVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the chaotic mechanical breaking process with a controlled movement system that detaches pieces through a predetermined path. This substitution eliminates the chaotic forces that generate dust while maintaining efficient separation speed through automated controlled motion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20220395997A1Method for producing a puzzle and separating device for the same

Publication Date: 2022.12.15 PUZZLEYOU GMBH

AI summary

A method for producing a puzzle including a plurality of puzzle pieces which, in an assembled state, form the puzzle, wherein, in the method, an image is laminated or printed onto a carrier plate so that the image defines an image plane on the carrier plate, and the puzzle pieces are punched out of the printed or laminated carrier plate or wherein the carrier plate is punched and an image is printed onto the punched carrier plate so that the image defines an image plane on the carrier plate, wherein the puzzle pieces are detached and separated from the punched carrier plate in a predetermined way by a controlled movement of at least one puzzle piece transverse to the image plane. A corresponding device is also disclosed.