Method for manufacturing a magnetic puzzle, set for use therewith and consisting of parts, and magnetic jigsaw puzzles

Abstract

 A method for manufacturing a magnetic jigsaw puzzle, wherein a mixture (15) from a binding agent and a magnetically attractable filler, mixed therethrough, is applied to a surface of a support (12), the binding agent adhering to the support (12) and hardening. The mixture (15) is applied to the supports (12) in the form of a plate cut into puzzle pieces (2-10), so that cutting tools for cutting out the puzzle pieces (2-10) do not contact the iron particles of the magnetically attractable mixture. There are further described a set for use in this method and puzzles obtained through special elaborations of the method.

Description

[0001] The invention relates to a method for manufacturing a magnetic jigsaw puzzle according to the introductory part of claim 1, a set for use therewith and consisting of parts, and magnetic jigsaw puzzles according to the introductory parts of claims 8 and 9.

[0002] In this context, "attractable by magnetism" is understood to mean the property of undergoing a force under the influence of a magnetic field. The magnetically attractable object or material can itself maintain a permanently magnetic field or undergo a force primarily under the influence of a magnetic field.

[0003] A method and jigsaw puzzles of the above type are known from European patent application 0 149 326. Magnetic jigsaw puzzles offer various advantages. They can be laid out on an inclined or even vertical face, so that the puzzle pieces are more properly accessible, a better view of the picture in the making is obtained, and a greater choice is obtained with regard to the location where the puzzle is laid out. Moreover, when the laying-out of the puzzle should be interrupted, the base with the puzzle partly laid out thereon can be put aside in a substantially vertical position without the risk that the laid-out part of the puzzle falls to pieces again. This is in particular advantageous if one wishes to lay out puzzles of larger sizes. After the laying out has been completed, the puzzle can be hung as wall decoration. During puzzling, it is further pleasant that the laid-out pieces are held in position and are not easily displaced unintentionally.

[0004] A further advantage of magnetic puzzles is that there is greater freedom with regard to the design possibilities of the puzzle pieces, because the puzzle pieces need not have interlocking shapes.

[0005] In spite of these advantages, that have been known for a long time already, the magnetic jigsaw puzzle has thus far had little commercial success and, as far as is known to applicant, is not even commercially available. The lack of success can perhaps be attributed to the drawbacks associated with the magnetic jigsaw puzzles known so far. In above-cited European patent application 0 149 326, it is for instance proposed that first a layer of magnetizable material be provided on a board and that the board be subsequently cut to pieces to obtain the desired puzzle pieces. However, this entails the drawback that in each case, the cutting tool cuts into the iron of the magnetizable material and, accordingly, wears quickly.

[0006] The object of the invention is to provide a jigsaw puzzle whose pieces can be drawn against a lay-out face by magnetism without involving high additional manufacturing costs due to increased wear of cutting tools.

[0007] In accordance with the invention, this object is realized by carrying out a method of the type described in the preamble in accordance with the characterizing part of claim 1.

[0008] Since the application of the mixture is carried out after the plate has been cut to puzzle pieces, the tool for manufacturing the puzzle does not contact the iron particles of the magnetically attractable mixture.

[0009] By applying the mixture before the puzzle pieces, cut from the plate, are broken apart or at least while the jigsaw puzzle is in laid-out condition, the application of the mixture can nevertheless be performed in one operation and fouling of the front of the puzzle pieces with the mixture is prevented. When the puzzle pieces are being broken apart, the hardened mixture breaks along the incisions of the plate and the puzzle pieces, now provided with magnetically attractable material, are as yet obtained. A particular advantage of the bridgings formed by the mixture between the puzzle pieces is that puzzles intended for being sold in laid-out form, such as puzzles for children, exhibit more cohesion and are hence less prone to fall to pieces prematurely.

[0010] It is also possible to provide the puzzle pieces with the mixture attractable by magnetism after breaking off. This offers the advantage that puzzle pieces of virtually any jigsaw puzzle, also of a used one, can as yet be provided with a layer attractable by magnetism.

[0011] To this end, the invention provides a set, composed of parts, according to claim 5, whereby a durable and pleasantly manageable puzzle pack can be manufactured in a simple manner from an existing, non-magnetic jigsaw puzzle, of which puzzle pack, in use, the puzzle pieces are retained against the base by magnetism.

[0012] A particular elaboration of the invention further provides that a jigsaw puzzle of the initially indicated type is constructed in conformity with the characterizing part of claim 8. Such a jigsaw puzzle is obtained by applying the magnetically attractable mixture to the back of the plate divided into puzzle pieces.

[0013] A further particular elaboration of the invention provides that a jigsaw of the initially indicated type is constructed in conformity with the characterizing part of claim 9. If the mixture is applied to separate puzzle pieces, it is relatively simple to manufacture puzzle pieces whose backs are not entirely covered with the mixture, because in that case, the contour of the puzzle pieces need not be precisely followed and there is less danger of the fronts of the puzzle pieces being smeared with the mixture.

[0014] Further particular elaborations of the invention are described in the dependent claims.

[0015] Hereinafter, the invention is further illustrated and specified on the basis of some exemplary embodiments, with reference to the accompanying drawings, wherein:

Fig. 1 is a view of a back of a jigsaw puzzle according to a first exemplary embodiment of the invention;

Fig. 2 is a view of a back of a jigsaw puzzle according to a second exemplary embodiment of the invention;

Fig. 3 is an enlarged view, in section, of an edge portion of a puzzle piece of a jigsaw puzzle according to the invention;

Fig. 4 is an enlarged schematic view, in section, of a puzzle piece of a jigsaw puzzle as shown in Fig. 1, sitting on a base for use as part of a set according to the invention;

Fig. 5 is a schematic side elevation, in section, of an applicator for use as part of a set according to the invention;

Fig. 6 is a side elevation of another applicator for use as part of a set according to the invention;

Fig. 7 is a front view of the applicator according to Fig. 6; and

Fig. 8 is an enlarged schematic view, in section, of adjoining puzzle pieces of a jigsaw puzzle according to a further exemplary embodiment of the invention.

[0016] In the drawings, corresponding parts of different exemplary embodiments are designated by mutually identical reference numerals.

[0017] In Fig. 1, the back 1 (the side facing away from the picture side which, during laying out, bears the picture to be formed) of a jigsaw according to the invention is shown in laid-out condition. The puzzle comprises a number of pieces 2-10, of which in Fig. 4 one puzzle piece 2 is shown in a condition sitting on a base 11. The puzzle pieces are each built up from a support 12 and, applied thereto at a front 13, a portion 14 of a paper or film provide with an image (see Fig. 4). These portions 14 together form, if the puzzle pieces are laid out in a suitable configuration as shown in Fig. 1, the above-mentioned picture.

[0018] Applied to the back 1 of each of the puzzle pieces 2-10 is a mixture 15 comprising a binding agent adhering to the support 12, and a filler that is attractable by magnetism and retained in the binding agent.

[0019] Because the magnetically attractable material can, as part of a mixture 15, be directly applied to the backs of puzzle pieces of a conventional puzzle made of, for instance, cardboard, a puzzle can be obtained, at low costs, whose pieces can be held in place on a lay-out surface 11 by magnetism. The binding agent of the mixture adhering directly to the support 12 of the puzzle provides a firm connection between the mixture 15 and the support 12 of the puzzle piece 2-10, which connection is very hard to peel off from an edge 16.

[0020] For materials applied to the backs 1 of puzzle pieces, a proper resistance to peeling off from an edge 16 is particularly critical, because during punching, a rounded depression is generally formed at the front 13 of each puzzle piece 2-10, along the edge 16, while at the back 1, an edge 16 is formed which, by contrast, is relatively sharp or projects even slightly bur-like. Owing to the depression along the circumferential edge at the front 13 of each puzzle piece, the paper is prevented from being peeled off at that front 13 to which the image has been applied. However, if a layer is stuck to the backs of the puzzle pieces, precisely the opposite effect occurs: because of the sharp edge 16 that is or has been formed at that location during punching, the edge of the material stuck is relatively exposed along the edge and, accordingly, susceptible to curling and peeling.

[0021] If the mixture 15 is applied up to and along the edge 16 of each puzzle piece, as shown in Fig. 3, it is advantageous that powdered or liquid mixtures by themselves tend to exhibit a thickness decreasing towards the edge, owing to shear or surface tension. This thickness decreasing towards the edge compensates the raised edge 16 at least partly. As a matter of fact, an additional advantage of the construction according to Fig. 3 is that the mixture 15 applied to the back 1 moreover prevents the support 12 from fraying along the edge 16 and hence increases the durability of the jigsaw puzzle.

[0022] A further advantage of applying the magnetically attractable material as a component of a mixture with a binding agent is that it is readily possible to cover the puzzle pieces 2-10 only partly with the mixture 15. Of this, use can for instance be made if the puzzle pieces are manually provided, one by one, with the mixture 15. Thus, the mixture need not be accurately applied up to the edges of the puzzle pieces, but can be applied rather at random and, accordingly, quickly. An example hereof is shown in Fig. 2. This readily enables applying the magnetically attractable material to the backs of the puzzle within a reasonable time, for instance by the user at home. The fact that the mixture need not be applied with a great accuracy is further of particular advantage to motor-disabled users.

[0023] Also if the mixture 15 is applied mechanically, for instance through stamping or spraying, it is advantageous to keep the backs 1 of at least a number of the puzzle pieces 2-10 clear, along an edge zone 17, from the mixture 15 described, as is shown, by way of example, in Figs. 1 and 4. For the sake of convenience, not all edge zones kept clear from mixture 15 are provided with reference numerals.

[0024] Because the mixture 15 is provided to near the edge 16, there is formed, when the puzzle piece is laid down with its back 1 facing a base 11, a narrow open recess along the edge of the puzzle piece, whose height and width can be controlled more properly than in the case where an amount of the mixture 15 is more randomly applied to portions of the back of each puzzle piece, as described hereinabove. Thus, when a puzzle piece is being picked up, a rim of a nail can be pressed below the edge 16 more easily.

[0025] A puzzle piece according to this embodiment can also be picked up from a flat base as follows: first, the puzzle piece is pressed on near an edge of the puzzle piece, causing the puzzle piece to lift up around an edge of the mixture applied thereto, and then, a finger or thumb is placed against the lift-up back of the puzzle piece, whereupon the puzzle piece is held fast through engagement of the front and back thereof.

[0026] The binding agent of the mixture 15 is preferably a material hardened from a liquid form. In liquid form, the binding agent can optimally adapt itself to the support material of the puzzle and enter into a strong bond with that support material.

[0027] A particularly strong bond between the binding agent and the support 12 is obtained if the support 12 is manufactured from a porous or at least absorbing material, such as cardboard, wood or foam, and at the back 1 of the support 12, a portion of the binding agent is absorbed by the support 12, as is indicated in Figs. 3 and 4 by the hatching of the mixture 15, which hatching continues slightly into the support material.

[0028] A rough texture of the back of the support, which may also be manufactured from non-absorbing material, such as for instance a suitable type of plastic, also contributes to obtaining a proper bond between the binding agent of the mixture and the support.

[0029] As discussed hereinabove, the mixture can, in a suitable embodiment, be applied to the backs of the puzzles by, for instance, users themselves or in a factory or workshop.

[0030] A particularly suitable material for use as filler is iron powder. This is relatively cheap and, under normal conditions, does not by itself maintain a magnetic field of any practical significance, so that it can be properly processed without being attracted by tools and machine parts. Optionally, in order to impart permanently magnetic properties to the attractive force of the puzzle pieces, a permanently magnetic or magnetizable filler, such as for instance an iron oxide, can be used, which, during the hardening of the binding agent, is held in a given magnetic field, so that the mixture applied to the back of the puzzle forms a permanent magnet itself. Accordingly, the puzzle is also attracted by materials which do not maintain a magnetic field of significance but which are in fact attractable by magnetism, such as iron and most steel types, which for instance opens the possibility of laying out the puzzle on the door of a refrigerator.

[0031] The magnetically attractable filler preferably has a granular size less than 50 µm, and most preferably a granular size of less than 25 µm. According as the filler is smaller, it sags less quickly as long as the mixture is still liquid. This prevents accumulation of the filler on the bottom of a package. Also, the filler is prevented from sagging towards the puzzle piece after the mixture has been applied. This sagging has the adverse effect that the density of the magnetically attractable material in the mixture becomes relatively great precisely at a distance from the surface of the mixture 15 which surface, in laid-out condition, faces the lay-out face, causing the puzzle pieces to be attracted by a given magnetic surface with relatively little force.

[0032] A fine filler further offers the advantage that a smooth mixture is obtained, which, after the application thereof, yields a smooth surface.

[0033] Sagging of the filler can further be prevented by incorporating a thixotropy agent into the mixture, as a result of which the viscosity of the mixture is increased. The use of a thixotropy agent (preferably up to a weight percentage of 2-7%) is also advantageous in that it allows applying a relatively thick layer of the mixture at once and prevents the applied mixture from flowing out. The mixture can even be rendered so thick that it can be applied as a paste with a preferably suitably profiled spatula.

[0034] The weight percentage of magnetically attractable filler in the mixture to be applied is preferably at least 70%. Owing to this high proportion of this filler, a correspondingly strong attractive force is obtained when a puzzle piece provided with the mixture is placed on a magnetic lay-out base. This large proportion of this filler in the mixture is in particular of advantage in combination with the feature that only a portion of the back of each puzzle piece is provided with the mixture. Because of the high proportion of magnetically attractable material in the mixture, the application of very little of the mixture - for instance some strokes of a brush or spatula - on the back of a puzzle piece suffices for obtaining sufficient attractive force towards a magnetic base.

[0035] As binding agent, for instance many different polymers, known in the field of coatings and adhesives, can be used, which may be natural as well as synthetic and the hardening of which may be based on different principles.

[0036] To serve the user's convenience, it is preferred that there is also provided a set, composed of parts, for processing a jigsaw puzzle. Such sets should preferably contain the above-mentioned underlay 11 having a lay-out surface for laying out a puzzle. Such an underlay 11 is provided with a magnetically attractable material 18 for attracting magnetically attractable puzzle pieces 2-10 against the lay-out surface, and a package containing a mixture to be applied, for instance as described hereinabove. At least the filler in the mixture or the magnetically attractable material 18 of underlay 11 should be permanently magnetic, to ensure that these components of the set attract each other through magnetism.

[0037] As described hereinabove, preferably the filler is not permanently magnetic. Accordingly, the magnetically attractable material of the underlay 11 is preferably permanently magnetic. This further offers the advantage that in a one-piece underlay, the magnetic material can be incorporated more easily than in the puzzle that has been or is to be divided into pieces, and that an underlay with a relatively costly permanently magnetic material can be used for successively laying out several magnetically attractable puzzles. Further, without any particular problem, a thick, powerful magnetic layer can then be used in the underlay, enabling a further limitation of the required mass of the mixture applied to the puzzle pieces. The underlay 11 further contains a top layer 19 and a back 20.

[0038] Preferably, such a set further also contains an applicator 21 for applying the mixture 15 to the puzzle pieces 2-10. Examples of such aids for applying the mixture 15 are shown in Figs. 5-7.

[0039] The applicator shown in Fig. 5 is essentially built up of a reservoir 22 having a filling hole that is closed off by a cap 35 and can be filled with the mixture 15. The bottom side of the reservoir 22 is provided with passages 32 which open opposite a circumferential surface 34 of a transfer roller 26. Opposite the passages 32, the circumferential surface 34 of the transfer roller 26 extends along or against the circumferential surface 33 of an application roller 23. If the application roller 23 and the transfer roller 26 do not abut against each other at such a pressure that the transfer roller 26 can be entrained by the application roller 23, provisions are required for driving the transfer roller 26, for instance a transmission coupled to the application roller 23 or a separate drive mechanism.

[0040] In operation, the application roller 23 is rolled over the back 1 of a puzzle piece, with the transfer roller 26 entraining mixture 15 from the reservoir 22 and dispensing it to the application roller 23, which, in turn, transfers the mixture 15, at least largely, in the form of an evenly distributed layer to parts of the puzzle piece that contact the circumferential surface of that roller 26. The transfer roller 26 provides that during the transfer to the application roller 23, the mixture 15, initially delivered from the passages 32 to the roller 26 so as to be substantially line-shaped, changes into a film of an even thickness. Optionally, if the passages are sufficiently finely divided or designed as a slot, it is possible to use an application roller only, receiving the mixture directly from the passage or passages in the reservoir.

[0041] The applicator 21 according to Figs. 6 and 7 is of a simple design and has, as basic components, a squeezable reservoir 22 and a nozzle 27 mounted thereon. Extending through the nozzle 27 is a channel 28 via which channel the mixture can be dispensed. The channel 28 opens adjacent a free end of a spatula 29 formed on the nozzle. This spatula is provided with recesses 30, the dimensioning of which determines the height and width of strips of the mixture 15 applied to the back 1 of the puzzle. For forming these strips, the spatula 29 should be displaced over the back 1 of a puzzle piece 2 and, simultaneously, the reservoir 22 should be squeezed in order to introduce before the spatula 29 an amount of the mixture to be spread and to maintain that amount during the displacement of the spatula 29.

[0042] When the mixture 15 is applied to the surface of the back 1 of the support 12, the binding agent adheres to the support 12. Then, the binding agent is allowed to harden, which may or may not be promoted by, for instance, heat or UV radiation, depending on the type of binding agent that is employed.

[0043] If the application of the mixture is carried out by the user himself, an existing puzzle can be adjusted to become a magnetic puzzle. In that case, existing puzzle pieces are started from, each containing a plate-shaped support 12 and a portion 14 of an image provided thereon on a front 13. If the puzzle pieces 2-10 are laid out in a specific configuration, these portions 14 together form the picture to be composed.

[0044] If the puzzle pieces 2-10 are individually provided with mixture 15, it is not necessary to lay out the puzzle first, before the mixture 15 can be applied to the back 1 of the puzzle pieces 2-10. Due to the fact that only little of the mixture has to be applied to each puzzle piece, or that an applicator as shown in Fig. 5 is used, a puzzle can be provided with magnetically attractable material within a reasonable time, in spite of the puzzle pieces being treated separately or even one by one.

[0045] If it is desired to provide the puzzles with magnetically attractable material already during the manufacture thereof, the mixture 15 is preferably applied to the back of all puzzle pieces 2-10 to be formed and the binding agent is preferably hardened at least partly, before the support 12 is divided into puzzle pieces separated from one another. In the first place, the one-piece puzzle is easy to handle. After the puzzle pieces have been formed, mixture 15 applied to the entire surface of the back of the puzzle forms again connections 31 between the priorly formed puzzle pieces 2, 3, as can be seen in Fig. 8. These connections 31 hold the puzzle pieces 2, 3 together as long as this is desired. In particular, the puzzle pieces are thus prevented from accidentally overlying each other during drying, as a consequence of which they are stuck to each other and/or the picture side of one of those pieces becomes smeared.

Claims

1. A method for manufacturing a magnetic jigsaw puzzle, wherein a mixture (15) comprising a binding agent and a magnetically attractable filler mixed therethrough is applied to a surface of a support (12), the binding agent adhering to the support (12) and hardening, characterized in that the mixture (15) is applied to supports in the form of a plate cut into puzzle pieces (2-10).

2. A method according to claim 1, wherein puzzle pieces (2-10) are started from that each comprise said plate-shaped support (12) and a portion (14) of a picture provided thereon at a front (13), said portions, if the puzzle pieces (2-10) are laid out in a specific configuration, together forming said picture.

3. A method according to claim 1 or 2, wherein the puzzle pieces are broken apart after the mixture (15) has been applied.

4. A method according to claim 1 or 2, wherein the puzzle pieces (2-10) are separately provided with binding agent and said filler mixed therethrough.

5. A set, composed of parts, for processing a jigsaw puzzle into a magnetic jigsaw puzzle assembly, comprising an underlay (11) having a lay-out surface for laying out a puzzle, said underlay being provided with a magnetically attractable material (18) for attracting magnetically attractable puzzle pieces (2-10) against the lay-out surface, and a mixture (15) for rendering pieces of a jigsaw puzzle magnetically attractable, comprising a binding agent and a filler, mixed therethrough, from a magnetically attractable material, wherein at least the filler or the magnetically attractable material of the underlay (11) is permanently magnetic.

6. A set according to claim 5, wherein the magnetically attractable material (18) of the underlay (11) is permanently magnetic.

7. A set according to claim 5 or 6, further comprising an applicator (21) for applying the mixture (15) to the puzzle pieces (2-10) one by one.

8. A jigsaw puzzle comprising a number of magnetically attractable puzzle pieces (2-10), each comprising a support (12) having a portion (14) of a picture provided thereon at a front (13), said portions, if the puzzle pieces (2-10) are laid out in a specific configuration, together forming said picture, and a mixture (15) applied to a back (1) thereof, said mixture comprising a binding agent adhering to the support (12) and a magnetically attractable filler retained in the binding agent, wherein the puzzle pieces are separated from each other by incisions, characterized in that the puzzle pieces are in a laid-out condition and said mixture forms a continuous, breakable layer interconnecting the pieces.

9. A jigsaw puzzle comprising a number of magnetically attractable puzzle pieces (2-10), each comprising a support (12) having a portion (14) of a picture provided thereon at a front (13), said portions, if the puzzle pieces (2-10) are laid out in a specific configuration, together forming said picture, and a mixture (15) applied to a back (1) thereof, said mixture comprising a binding agent adhering to the support (12) and a magnetically attractable filler retained in the binding agent, wherein the puzzle pieces are separated from each other by incisions, characterized in that the puzzle pieces (2-10) are only partly covered with the mixture (15).

10. A jigsaw puzzle according to claim 9, wherein the backs (1) of at least a number of the puzzle pieces (2-10) have at least an edge zone (17) that is clear from said mixture (15).

Drawing