Puzzle machine and method of operating same

• US 20050230909A1
• Filed: 04/14/2005
• Published: 10/20/2005
• Est. Priority Date: 04/14/2004
• Status: Active Grant

• Current Assignee: Hasbro Inc.
• Original Assignee: Hasbro Inc.
• Inventors: Gallant, Paul
• Granted Patent: US 7,486,841 B2
• Time in Patent Office: Days
• US Class Current: 273/156
• CPC Class Codes: A63F 2009/1061 with electric features, e.g. light, wires
• CPC Class Codes: A63F 2009/1072 Manufacturing
• CPC Class Codes: A63F 2009/2435 using a video camera
• CPC Class Codes: A63F 2009/2455 Printers
• CPC Class Codes: A63F 9/10 Two-dimensional jig-saw puzzles
• CPC Class Codes: Y10T 83/929 Tool or tool with support

Abstract

A method and apparatus for producing a customized jigsaw puzzle is disclosed. The apparatus comprises an image capturing mechanism, such as a camera, that captures one or more images of one or more individuals, animals, or objects or combinations of these posed against a background. A computer that is linked to the mechanism and to a printer is programmed to print an image on flexible sheets having a printable surface. Then a press, having a platen carrying a jigsaw puzzle cutting die, when activated uses pressure to laminate together the flexible sheet bearing the printed image and a foam sheet thicker and more rigid than he flexible sheets, setting pressure responsive adhesive material used as a binder to form a laminated product, and substantially simultaneously to cut the laminated product into jigsaw puzzle pieces.

Claims

1. A puzzle machine for producing a custom puzzle, comprising:

selecting means for selecting a first digital image containing at least two layers of images, within a bank of digital images;

digital image capturing means for capturing a second digital image of a person or other subject;

image processing means for integrating the second digital image between the at least two layers of the first digital image to obtain a composite image; and

puzzle production means for producing the custom puzzle with the digital composite image.

2. A puzzle machine according to claim 1, wherein the puzzle production means comprise:

printing means for printing a first copy of the composite image onto a first sheet;

means for securing the first sheet onto a pre-glued surface of a second sheet made of foam, to obtain a double sheeted member; and

die cutting means for die cutting the double sheeted member to obtain the custom puzzle.

3. A puzzle machine according to claim 1, wherein the image processing means comprise a memory for storing pre-established parameters upon which the integrating is based.

4. A puzzle machine according to claim 3, wherein the image processing means and the selecting means are embodied by a computer provided with a display for displaying the composite image and a software for manipulating the composite image.

5. A puzzle machine according to claim 1, further comprising:

an external housing to cover the puzzle production means, the external housing comprising movable parts and an exit;

motor means for moving the movable parts;

sound generating means for generating a sound;

conveyer means for conveying the custom puzzle from inside of the housing to the outside thereof through the exit; and

a button for activating the motor means, the sound generating mean

and the conveyer means from outside of the housing.

6. A puzzle machine according to claim 2, wherein the second sheet is made of a polyethylene foam having a thickness of at least 3 mm.

7. A puzzle machine according to claim 2, wherein the pre-glued surface is provided with a glue of a type which remains flexible after setting thereof.

8. A puzzle machine according to claim 7, wherein the glue is pressure sensitive hot melt adhesive.

9. A puzzle machine according to claim 2, wherein the printing means is for printing at least one additional copy of the composite image onto the first sheet, the at least one additional copy being smaller than the first copy.

10. A puzzle machine according to claim 1, wherein the digital image capturing means comprises digital photographic means for taking the second digital image of the person or other subject in front of a uniformly coloured screen allowing a compositing technique.

11. A puzzle machine for producing a custom puzzle, comprising:

selecting means for selecting a first digital image within a bank of digital images;

digital image capturing means for capturing a second digital image;

image processing means for integrating the second digital image into the first digital image to obtain a composite image; and

puzzle production means for producing the custom puzzle on a sheet made of foam with the composite image.

12. A puzzle machine according to claim 11, wherein the puzzle production means comprise:

printing means for printing a first copy of the composite image onto a first sheet;

means for securing the first sheet onto a pre-glued surface of a second sheet made of foam, to obtain a double sheeted member; and

die cutting means for die cutting the double sheeted member to obtain the custom puzzle.

13. A puzzle machine according to claim 11, wherein the image processing means comprise a memory for storing preestablished parameters upon which the integrating is based.

14. A puzzle machine according to claim 13, wherein the image processing means and the selecting means are embodied by a computer provided with a display for displaying the composite image and a software for manipulating the composite image.

15. A puzzle machine according to claim 11, further comprising:

an external housing to cover the puzzle production means, the external housing comprising movable parts and an exit;

motor means for moving the movable parts;

sound generating means for generating a sound;

conveyer means for conveying the custom puzzle from inside of the housing to the outside thereof through the exit; and

a button for activating the motor means, the sound generating means and the conveyer means from outside of the housing.

16. A puzzle machine according to claim 12, wherein the second sheet is made of a polyethylene foam having a thickness of at least 3 mm.

17. A puzzle machine according to claim 12, wherein the pre-glued surface is provided with a glue of a type which remains flexible after setting thereof.

18. A puzzle machine according to claim 17, wherein the glue is pressure sensitive hot melt adhesive.

19. A puzzle machine according to claim 12, wherein the printing means is for printing at least one additional copy of the composite image onto the first sheet, the at least one additional copy being smaller than the first copy.

20. A puzzle machine according to claim 11, wherein the digital image capturing means comprises digital photographic means for taking the second digital image of the person or other subject in front of a uniformly coloured screen allowing a compositing technique.

21. A method for producing a custom puzzle, comprising steps of:

a) selecting a first digital image containing at least two layers of images, within a bank of digital images;

b) capturing a second digital image of a person or other subject;

c) integrating the second digital image between the at least two layers of the first digital image to obtain a composite image; and

d) producing the custom puzzle with the digital composite image.

22. A method according to claim 21, wherein step d) comprises steps of:

printing a first copy of the composite image onto a first sheet;

securing the first sheet onto a pre-glued surface of a second sheet made of foam, to obtain a double sheeted member; and

die cutting the double sheeted member to obtain the custom puzzle.

23. A method according to claim 21, wherein step c) comprises a step of storing pre-established parameters upon which the integrating is based.

24. A method according to claim 23, wherein step c) further comprises steps of displaying the composite image and manipulating the composite image.

25. A method according to claim 22, wherein, in step d), the second sheet is made of a polyethylene foam having a thickness of at least 3 mm.

26. A method according to claim 22, wherein, in step d), the pre-glued surface is provided with a glue of a type which remains flexible after setting thereof.

27. A method according to claim 26, wherein, in step d), the glue is pressure sensitive hot melt adhesive.

28. A method according to claim 22, wherein, step d) further comprises a step of printing at least one additional copy of the composite image onto the first sheet, the at least one additional copy being smaller than the first copy.

29. A method according to claim 21, wherein, in step b), the person or other subject is in a predetermined position in the second digital image to match a situation determined by the at least two layers of images of the first digital image.

30. A method according to claim 21, wherein step b) comprises a step of capturing a third digital image of another person or other subject, and step c) comprises a step of integrating the third digital image between the at least two layers of the first digital image within the composite image.

31. A method for producing a custom puzzle, comprising steps of:

a) selecting a first digital image, within a bank of digital images;

b) capturing a second digital image of a person or other subject;

c) integrating the second digital image into the first digital image to obtain a composite image; and

d) producing the custom puzzle on a sheet made of foam with the composite image.

32. A method according to claim 31, wherein step d) comprises steps of:

printing a first copy of the composite image onto a first sheet;

securing the first sheet onto a pre-glued surface of a second sheet made of foam, to obtain a double sheeted member; and

die cutting the double sheeted member to obtain the custom puzzle.

33. A method according to claim 31, wherein step c) comprises a step of storing pre-established parameters upon which the integrating is based.

34. A method according to claim 33, wherein step c) further comprises steps of displaying the composite image and manipulating the composite image.

35. A method according to claim 32, wherein, in step d), the second sheet is made of a polyethylene foam having a thickness of at least 3 mm.

36. A method according to claim 32, wherein, in step d), the pre-glued surface is provided with a glue of a type which remains flexible after setting thereof.

37. A method according to claim 36, wherein, in step d), the glue is pressure sensitive hot melt adhesive.

38. A method according to claim 32, wherein step d) further comprises a step of printing at least one additional copy of the composite image onto the first sheet, the at least one additional copy being smaller than the first copy.

39. A method according to claim 31, wherein, in step b), the person or other subject is in a predetermined position in the second digital image to match a situation determined by the first digital image.

40. A method according to claim 31, wherein step b) comprises a step of capturing a third digital image of another person or other subject, and step c) comprises a step of integrating the third digital image with the first two digital images within the composite image.

41. An apparatus for producing a custom made packaging, comprising:

memory for storing data;

means for selecting legal data within a first bank of data stored in the memory, in relation to a product;

means for selecting a UPC bar code within a second bank of data stored in the memory, in relation to the product;

means for selecting visual data within a third bank of data stored in the memory, in relation to the product; and

means for applying the legal data, the UPC bar code and the visual data on a generic packaging to obtain the custom made packaging.

42. An apparatus according to claim 41, wherein the means for selecting comprise a computer provided with a display, a keyboard and a mouse.

43. An apparatus according to claim 41, wherein the first bank of data comprises data chosen within the group including license data, copyright data, logo data and trademark data.

44. An apparatus according to claim 41, wherein the third bank of data comprises composite images including a person or other subject.

45. An apparatus according to claim 41, wherein the applying means comprises a printer for printing the legal data, the UPC bar code and the visual data on stickers to be applied on the generic packaging.

46. An apparatus according to claim 41, wherein the applying means comprises a printer for printing the legal data, the UPC bar code and the visual data on the generic packaging.

47. A method for producing a custom made packaging, comprising steps of:

a) selecting legal data within a first bank of data stored in a memory, in relation to a product;

b) selecting a UPC bar code within a second bank of data stored in the memory, in relation to the product;

c) selecting visual data within a third bank of data stored in the memory, in relation to the product; and

d) applying the legal data, the UPC bar code and the visual data on a packaging to obtain the custom made packaging.

48. A method according to claim 47 wherein the steps a), b) and c) are performed by means of a computer provided with a display, a keyboard and a mouse.

49. A method according to claim 47, wherein the first bank of data comprises data chosen within the group including license data, copyright data, logo data and trademark data.

50. A method according to claim 47, wherein the third bank of data comprises composite images including a person or other subject.

51. A method according to claim 47, wherein the step d) comprises a step of printing the legal data, the UPC bar code and the visual data on stickers to be applied on the generic packaging.

52. A method according to claim 47, wherein the step d) comprises a step of printing the legal data, the UPC bar code and the visual data on the generic packaging.

53. An apparatus for producing a customized jigsaw puzzle, comprising:

an image capturing mechanism that captures one or more images of one or more individuals, animals, or objects or combinations of these posed against a background;

a printer;

a supply of flexible sheets having a printable surface;

a computer linked to the image capturing mechanism and printer, and programmed to print an image on a flexible sheet;

a supply of foam sheets thicker and more rigid than the flexible sheets;

a pressure responsive adhesive material; and

a press having a platen that carries a jigsaw puzzle cutting die, the press when activated using pressure to laminate the flexible sheet bearing the printed image and the foam sheet together and to set the adhesive material used as a binder to form a laminated product, and substantially simultaneously to cut the laminated product into jigsaw puzzle pieces.

54. The apparatus of claim 53, comprising a memory containing information defining scenes or objects, wherein the computer is linked to the image capturing mechanism, memory, and printer and programmed to replace an image'"'"'s background or foreground or both with information taken from one or more scenes or objects to form and then to print a customized image on the flexible sheet.

55. The apparatus of claim 54, wherein the image capturing mechanism comprises a digital camera and a background between which persons, animals, or objects or combinations of these can be posed and then photographed using the camera, the background'"'"'s color being such that the computer may readily digitally erase the background from images captured by the camera and replace the image background with one or more scenes or objects selected from the memory.

56. The apparatus of claim 53 wherein the image capturing apparatus comprises a digital camera.

57. The apparatus of claim 53 wherein the image capturing mechanism comprises a scanner which can scan and digitally capture an image from at least one photograph.

58. The apparatus of claim 53 wherein the image capturing mechanism comprises a digital information port designed to accept digital information from a digital camera, a digital information memory, a computer or a like prerecorded digital image storage device.

59. The apparatus of claim 53, the foam sheets are pre-coated with the adhesive material applied thermally to each of the sheets of the supply of foam sheets.

60. The apparatus of claim 53, wherein the adhesive material is tacky prior to the application of pressure, and wherein the pre-coated foam sheets are stacked and held together by the tackiness of the adhesive material in a breakable bond prior to separation and lamination.

61. The apparatus of claim 53, wherein the jigsaw puzzle cutting die has cutting edges shaped to form complementary interlocking joints between the puzzle pieces and wherein the glue remains substantially flexible after setting such that the jigsaw puzzle is capable of being bent without its pieces detaching themselves from the puzzle.

62. The apparatus of claim 53 wherein a display is attached to the computer, and wherein the computer is programmed to display trial versions of the customized image and includes controls enabling an operator to rearrange elements of the customized image.

63. The apparatus of claim 53 which further comprises an external housing to cover the printer and press, the housing having an exit and a puzzle conveyor which can convey a customized jigsaw puzzle from inside the housing to the outside.

64. The apparatus of claim 53 wherein the foam sheets have a thickness of at least 3 millimeters.

65. The apparatus of claim 53 wherein the computer is programmed to print on a second flexible sheet information that may be placed on the outside of a box that is to contain the puzzle.