JPH04322685A - Jigsaw puzzle and production thereof - Google Patents

Abstract

PURPOSE:To provide a complicated jigsaw puzzle for which the number of puzzle pieces is increased, by a method wherein the puzzle pieces are precisely worked into desired small pieces without enlarging the size of the jigsaw puzzle perse. CONSTITUTION:A jigsaw puzzle 100 consists of puzzle pieces 20 having a thickness of 0.2 to 0.3mm which is made of a metal sheet 10 stamped-out into a small piece by etching, and a base 30 having recesses 40 in which the puzzle pieces 20 are fitted.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a jigsaw puzzle and a method for manufacturing the same.

0002

[Prior Art] Conventionally, jigsaw puzzles have been manufactured by forming them from materials such as wooden fiberboard, wooden particle board, cardboard, or plastic, and forming puzzle pieces using a press punching method. .

0003

[Problems to be Solved by the Invention] However, the above-mentioned press punching method requires a precision mold to form small puzzle pieces.
There is a limit to the method of press punching when it comes to forming puzzle pieces that are smaller than the width of the pieces, and the materials used include wooden fiberboard, wooden particle board, cardboard, and plastic. , the edge of the printed surface of each puzzle piece becomes curved, making it difficult to see the curved surface from above the printing surface, and the joints between the puzzle pieces become unclear.
Also, during the manufacturing process, the puzzles were separated and scattered.
There was a problem that pieces were easily lost.

On the other hand, the jigsaw puzzle itself can be made smaller by forming small puzzle pieces as described above to increase the number of puzzle pieces, but in cases where small puzzle pieces cannot be formed, complex jigsaw puzzles can be manufactured. In order to do this, you will only need to increase the number of puzzle pieces, but
Not only do the jigsaw puzzles themselves become larger and the manufacturing process becomes more complicated, but there are also problems in that playing with jigsaw puzzles requires a large space and is inconvenient to carry.

[0005] In addition, when press punching is performed on metals, plastics, etc., burrs generally form on the punched item, and it is necessary to remove the burrs and finish the work to prevent injury from the burrs. There is. However, many puzzles
It is actually impossible to deburr a jigsaw puzzle made of pieces in this way, and if the jigsaw puzzle is not deburred, there will be problems with precision, and there will be problems with the fit between the puzzle pieces or between the puzzle pieces. There was a problem in that each puzzle piece was out of balance with respect to the base surface.

The present invention has been made in view of the above circumstances, and in the invention according to claim 1, the printing surface of each puzzle piece is clear and precise, and the puzzle - The purpose is to provide a complex jigsaw puzzle with a large number of puzzle pieces, in which the connections between the pieces are clear, the jigsaw puzzle itself is not large in size, and the invention according to claim 2 also provides a puzzle.・Peace,
The object of the present invention is to provide a manufacturing method that can supply jigsaw puzzles precisely machined into small pieces of desired dimensions.

[0007]

[Means for Solving the Problems] As a means for achieving the above object, the invention as set forth in claim 1 provides a puzzle in which a metal plate 10 having a picture pattern printed on its surface is cut into small piece shapes using an etching solution. Piece 10 and the puzzle piece 10
A jigsaw puzzle 100 characterized in that a base 30 having a groove 40 into which the jigsaw puzzle 100 is fitted is disposed.

[0008] The invention according to claim 2 also provides the following steps: ``Preparing a metal plate 10 with a picture pattern printed on its surface, applying a photosensitive resist 11 to the surface of the metal plate, and applying a photoresist 11 to the surface of the metal plate; , a step of pasting a heat-resistant thin film tape 12 on the back surface of the metal plate, a step of dissolving and removing metal other than the masked portion using an etching solution, and a step of peeling off the mask. A jigsaw puzzle 100 and a method for manufacturing the same, characterized in that in the step of melting and removing metal other than the masked portion, the metal plate 10 is die-cut into small puzzle pieces 20. This is the summary.

[0009]

[Operation] Since the jigsaw puzzle according to claim 1 is a puzzle piece cut out by etching, unlike a puzzle piece punched out by a press, the puzzle piece does not curve into a curved shape or have burrs. The puzzle pieces fit together with the base, which has precise grooves, making it difficult for them to fall out.

[0010] The thickness of this puzzle piece is 0.2~0.
The optimum thickness is 3 mm, and the thickness of the base is a metal plate with a thickness of 1 mm or more, and the concave groove has a size of 0.0 mm in which the puzzle piece 20 is fitted.
Create a recess of 2 to 0.3 mm. If the thickness of the puzzle piece is 0.2 mm or less, the strength is not bad, and if it is 0.3 mm or more, it becomes difficult to etch and the precision deteriorates.

Further, in the method for manufacturing a jigsaw puzzle according to claim 2, this will be explained using the process diagram shown in FIG. 3 as an example. In the method, a mask film is used to expose the mask to form a mask portion, and the portion other than the mask portion is dissolved and removed by etching, so that a puzzle piece 20 of a desired size is formed.

Furthermore, because of the mask film, by changing the mask pattern during photo printing, the type of puzzle piece pattern can be freely selected, making it suitable for producing a large number of products in small quantities.

Furthermore, in this manufacturing method, by pasting the heat-resistant thin film tape 12 on the back surface of the metal plate 10, the puzzle pieces 20 can be easily cut until the final process in which the metal plate 10 is formed into a large number of puzzle pieces 20. A jigsaw puzzle 100 that does not fall apart when separated is obtained.

Therefore, in this manufacturing method, unlike the manufacturing method in which puzzle pieces are formed by press punching, the shape of the punched puzzle pieces can be freely changed using the mask film, and the production efficiency is extremely high.
We can supply jigsaw puzzles cut into the smallest and most precise puzzle pieces.

[0015]

[Embodiments] Hereinafter, according to the embodiments shown in the drawings, claim 1
The jigsaw puzzle described above and the method for manufacturing the jigsaw puzzle according to claim 2 will be specifically explained.

FIG. 1 shows a jigsaw puzzle 10 according to claim 1.
0 is a partially enlarged cross-sectional view of 0. jigsaw puzzle 10
0 consists of a base 30 made by etching a metal plate 10, as well as a large number of puzzle pieces 20 made by etching a metal plate 10 with a picture pattern printed on its surface and cutting it into small pieces.

Next, a method for manufacturing such a jigsaw puzzle 100 will be explained with reference to FIG. 2, which is a partial sectional view showing each step. A metal plate 10 with a picture pattern printed on its surface is prepared. However, the material to be processed is not limited as long as the metal plate can be etched. Here, explanation will be given using aluminum as the metal plate.

For example, if the metal plate 10 is made of aluminum, it is printed with alumite to give it a picture pattern. Alternatively, a metal plate 10 without a pattern printed thereon may be used.

Next, a photosensitive resist 11 is applied to the surface of the metal plate 10 to a thickness of about 7 μm, and is dried and cured at 80° C. for 15 minutes.

Furthermore, this photosensitive resist 11 is exposed and developed to form an etching-resistant mask on the puzzle piece 20, and a heat-resistant thin film tape 12 is placed on the back side of the metal plate.
Then, use an etching solution to dissolve and remove the exposed metal.

Furthermore, the base 30 is also formed with grooves 40 into which each puzzle piece 20 is fitted, using the same method as described above.

Then, the mask is removed with a 10% aqueous sodium hydroxide solution at 50°C, and finally dried at 130°C for 20 minutes to form a jigsaw puzzle 100 consisting of puzzle pieces 20 and base 30, as shown in FIG. Completed.

[0023]

As described above, in the jigsaw puzzle according to claim 1, since the puzzle pieces are cut into small pieces using etching, the printed surface of each puzzle piece and the jigsaw puzzle itself may be blurred or The edges of the pieces are not curved and there is no imbalance between each puzzle piece.

Further, according to the method for manufacturing a jigsaw puzzle according to claim 2, puzzle pieces can be formed from small pieces of desired dimensions, and in order to perform an etching process by applying a heat-resistant thin film tape to the back surface of the metal plate, Jigsaw puzzles do not come apart during manufacturing, do not lose puzzle pieces, and do not have burrs that occur with the press punching method, so we can supply jigsaw puzzles with extremely high production efficiency without the risk of injury. .

[Brief explanation of the drawing]

FIG. 1 is a partially enlarged sectional view of a jigsaw puzzle according to claim 1.

FIG. 2 is a partially enlarged sectional view showing each step of the jigsaw puzzle manufacturing method according to claim 2.

FIG. 3 is a partially enlarged cross-sectional view of the puzzle piece and base of the present invention.

[Explanation of symbols]

100 jigsaw puzzle 10 Metal plate 11 Photosensitive resist 12 Heat-resistant thin film tape 20 Puzzle Piece 30 base 40 Concave groove

Claims (2)

[Claims] 1. A puzzle piece formed by cutting out a metal plate with a picture pattern printed on its surface into a small piece shape using an etching solution, and a base having a groove into which the puzzle piece is fitted are arranged. A jigsaw puzzle featuring 2. A step of preparing a metal plate with a picture pattern printed on the surface, a step of applying a photosensitive resist to the surface of the metal plate, a step of forming a mask by a photoprinting method, and a step of forming a mask on the back side of the metal plate. A jigsaw puzzle and its manufacturing method comprising the steps of pasting a heat-resistant thin film tape, dissolving and removing metal other than the masked portion using an etching solution, and peeling off the mask, wherein the metal other than the masked portion A method for manufacturing a jigsaw puzzle, which is characterized by cutting a metal plate into small puzzle pieces in a process of melting and removing metal.