DETAILED DESCRIPTION

[0016] Referring to FIG. 1, a prior die-cutting system 100 for forming two-dimensional puzzles includes a die 105 and a base 107. Once formed, the two-dimensional puzzle includes two or more irregularly-shaped pieces that, when properly assembled, form a visual rendering such as a picture. The base 107 includes a backboard 110 and an image 115 formed on, or adhered to, one side of the backboard 110. The die 105 is positioned on the print side of the base 107 such that the die 105 is first pressed into the image 115, and then pressed into the backboard 110.

[0017] The die 105 is made of thin strips of material (such as, metal) shaped into intricate patterns and fastened to a base (not shown). The edges of the die material on the exposed side of the die 105 are sharpened to cut the print 115 and the backboard 110 when pressed into the image 115 and backboard 110, so as to form the puzzle.

[0018] The backboard 110 is made of any well-known material that permits die cutting. For example, the backboard 110 may be made of cardboard, sponge, or any soft board. The image 115 may be a visual rendering on a pliable material, such as, for example, paper or plastic, or may be rendered directly on the backboard 110. When formed on paper, plastic, or some other material, the image 115 may be applied to the backboard 110 using, for example, glue or any suitable adhesive.

[0019] FIGS. 2A-2D show an enlarged cross-section of the die-cutting system 100 is shown in various stages in which the die 105 is pressed into the base 107 to form adjacent pieces of a two-dimensional puzzle. Adjacent pieces 200, 205 are formed from a cut due to a segment 210 of the die 105 pressing into the base 107. However, as the die 105 is pressed into the base 107, the pressure of the die 105 crushes the image 115. Because of this, the puzzle pieces are accentuated relative to the image 115, as shown in FIG. 3. After the die 105 has cut the base 107, the two-dimensional puzzle is complete.

[0020] Referring to FIG. 4, an improved die-cutting system 400 for forming two-dimensional puzzles includes a die 405 and a base 407. The base 407 includes a backboard 410 and an image 415 adhered to, or printed on, one side of the backboard 410. The die 405 and base 407 have attributes comparable to those described with respect to die 105 and base 107 of FIGS. 1, 2A-2D, and 3.

[0021] Referring also to FIGS. 5A-5D, adjacent pieces 500, 505 are formed from a cut due to a segment 510 of the die 405 pressing into the base 407. The die 405 is positioned on the backboard side of the base 407 such that the die 405 is first pressed into the backboard 410, and then pressed into a backside of the image 415. In this way, the image 415 is not crushed by the pressure of the die 405 during die cutting. Thus, the puzzle pieces are less noticeable when assembled into the puzzle, as shown in FIG. 6.

[0022] Referring also to FIG. 7, the pattern of the die 405 may be a jigsaw pattern 700. In such a jigsaw pattern, the boundaries of the pieces each have one or more projecting portions and/or one or more recessed portions. The portions of the puzzle piece are cooperative with the complementarily shaped portions of adjacent puzzle pieces such that the pieces interfit and releasably interlock.

[0023] Other embodiments are within the scope of the following claims.