Derivative works — US Patent 12377343

This Defensive Disclosure document provides a series of technical derivations and improvements based on the core concepts disclosed in US Patent 12,377,343. The purpose of this document is to place these concepts into the public domain, thereby establishing them as prior art for patentability purposes. Each derivative includes a technical enabling description and a visual diagram.

Publication Date: May 13, 2026

I. Derivatives of Claim 1: One-Piece Board/Assembly with Detachable Hook-on Border

The core concept involves a puzzle board and its reinforcing support structure being a single monolithic unit, with a separate upper border attaching via a hook-and-hole mechanism.

Derivative 1.1: Advanced Composite and Co-Molded Elastomer Construction

Concept: A high-performance version using advanced composites for the main body and a multi-material co-molded border for improved feel and durability.
Enabling Description: The one-piece board and reinforcing assembly are fabricated from a carbon fiber reinforced polymer (CFRP) composite using a resin transfer molding (RTM) process. A preform of T700 carbon fiber is placed in a mold and injected with an epoxy resin system (e.g., Hexion EPON™ 828 with an amine-based curing agent). This creates a lightweight structure with a very high stiffness-to-weight ratio, preventing warp in large-format platforms. The detachable upper part is produced via a two-shot co-molding process. The structural hooks are molded from a 30% glass-filled nylon 6/6 for rigidity and wear resistance. In the second shot, a high-durometer thermoplastic elastomer (TPE), such as a Shore 85A Santoprene™, is molded over the nylon skeleton to form a soft-touch, non-slip outer surface. The hooks are designed as a cantilever snap-fit with a calculated deflection to achieve an insertion force of 5-7N.

Diagram:

flowchart TD
    A[Lay up T700 Carbon Fiber Preform] --> B{Resin Transfer Mold};
    B --> C[Cure Epoxy Resin];
    C --> D[Demold Monolithic Board/Assembly];
    subgraph Upper Part Manufacturing
        E[Inject Glass-Filled Nylon for Hooks] --> F{2-Shot Co-Molding};
        G[Inject TPE Over-mold] --> F;
    end
    F --> H[Final Upper Part];
    D & H --> I[Assemble Platform];

Derivative 1.2: Magnetic Self-Aligning Latching System

Concept: The mechanical hook-and-hole system is replaced with a magnetic latching system for wear-free, self-aligning attachment.
Enabling Description: The detachable upper part is injection molded from high-impact polystyrene (HIPS) with integrated cavities. N52 grade neodymium-iron-boron (NdFeB) disc magnets (5mm diameter, 2mm thickness) are press-fit into these cavities post-molding. The fixing portion (104) of the main board assembly is molded with corresponding cavities containing embedded 1018 steel discs of the same diameter, which act as ferromagnetic targets. The magnets are arranged with alternating polarities (N-S-N-S...) along the periphery to create a strong shear and tensile holding force, preventing sliding and ensuring precise alignment upon attachment. The clamping force is calculated to be approximately 2N per magnet pair.

Diagram:

classDiagram
    class PuzzleBoard {
        +fixingPortion
        +ferromagneticTargets[]
    }
    class UpperPart {
        +body
        +neodymiumMagnets[]
    }
    PuzzleBoard "1" -- "1" UpperPart : Attaches Via Magnetic Force
    UpperPart o-- "N" NdFeBMagnet
    PuzzleBoard o-- "N" SteelDisc
    class NdFeBMagnet {
        grade: "N52"
        polarity: string
    }
    class SteelDisc {
        material: "1018 Steel"
    }

Derivative 1.3: Modular Surgical Instrument Tray

Concept: A cross-domain application adapting the platform as a modular, sterilizable surgical tray.
Enabling Description: The platform is repurposed for organizing surgical instruments in an operating room. The main one-piece board/assembly, serving as the primary tray, is injection molded from a high-performance, autoclavable polymer such as Radel® polyphenylsulfone (PPSU). The integrated reinforcing assembly forms cavities for smaller, removable instrument trays (the "drawers"), which are also molded from PPSU. The detachable upper part is a USP Class VI silicone rubber gasket with a tongue-and-groove profile that mates with the tray's perimeter. This creates a spill-proof lip and a soft bumper. Attachment is achieved via a cam-lock mechanism molded into the silicone part, which engages with undercuts on the main tray, allowing for secure attachment and removal with gloved hands.

Diagram:

erDiagram
    SURGICAL_TRAY ||--o{ SUB_TRAY : houses
    SURGICAL_TRAY ||--|{ SILICONE_GASKET : attaches_to
    SUB_TRAY ||--o{ SURGICAL_INSTRUMENT : contains

    SURGICAL_TRAY {
        string material "PPSU"
        string sterilizationMethod "Autoclave"
    }
    SILICONE_GASKET {
        string material "USP Class VI Silicone"
        string attachment "Cam-Lock"
    }

Derivative 1.4: IoT-Enabled Progress Tracking Platform

Concept: Integration with IoT sensors for real-time monitoring of puzzle progress and piece management.
Enabling Description: The puzzle plate (120) is constructed as a multi-layer printed circuit board (PCB). The top layer is a grid of interconnected capacitive touch pads, shielded by a thin layer of matte solder mask and a protective polycarbonate sheet. An ESP32 microcontroller, housed in the detachable upper part, continuously scans the grid to create a bitmap of piece placement. Within the reinforcing assembly (200), each drawer cavity is equipped with a 13.56 MHz RFID/NFC reader (e.g., MFRC522). Each puzzle drawer has a unique NFC tag. The ESP32 monitors which drawers are inserted or removed. This data, along with the piece placement bitmap, is published over Wi-Fi using the MQTT protocol to a cloud service or local server, allowing a companion application to visualize progress, track time, and help locate piece categories stored in the drawers.

Diagram:

sequenceDiagram
    participant User
    participant CompanionApp
    participant PuzzlePlatform
    participant MQTT_Broker

    User->>PuzzlePlatform: Places puzzle piece
    PuzzlePlatform->>PuzzlePlatform: Capacitive grid detects change
    PuzzlePlatform->>MQTT_Broker: PUBLISH topic=`.../plate/state`
    MQTT_Broker->>CompanionApp: PUSH updated state
    CompanionApp->>User: Display progress update

    User->>PuzzlePlatform: Opens drawer
    PuzzlePlatform->>PuzzlePlatform: NFC reader detects drawer removal
    PuzzlePlatform->>MQTT_Broker: PUBLISH topic=`.../drawer/4/status`
    MQTT_Broker->>CompanionApp: PUSH drawer status

II. Derivatives of Claim 16: Drawer Retention Mechanism

The core concept involves a specific drawer retention system using a "limiting bar" mating with a "limiting groove," and a "drawer holder" with a flexible "bending portion."

Derivative 16.1: Spring-Loaded Roller Detent System

Concept: An alternative mechanical system providing superior tactile feedback and durability compared to a simple flexible bar.
Enabling Description: The flexible limiting bar (244) and groove (225) are replaced with a more robust detent mechanism. A commercially available spring-loaded ball plunger (e.g., Vlier P/N 563-CN) is threaded into the reinforcing wall. The corresponding puzzle drawer side panel, molded from acetal (POM) for low friction, features a series of hemispherical divots. As the drawer slides, the ball plunger clicks into these divots, creating distinct stop positions (e.g., closed, fully open). The "bending portion" of the drawer holder is replaced by a rigid, fixed guide rail, as the detent system now provides the retention force.

Diagram:

classDiagram
    direction LR
    class ReinforcingAssembly {
        +install(BallPlunger)
    }
    class PuzzleDrawer {
        +detentDivots[]
        +slide()
    }
    class BallPlunger {
        +spring
        +ball
        +body
        +engage()
        +disengage()
    }
    ReinforcingAssembly -- PuzzleDrawer
    ReinforcingAssembly o-- BallPlunger
    BallPlunger ..> PuzzleDrawer : engages with

Derivative 16.2: Solenoid-Actuated Electronic Lock for Inventory Control

Concept: An electromechanical integration for access control in applications like secure parts storage or medical supply cabinets.
Enabling Description: The passive limiting bar is replaced by a 5V linear push-pull solenoid. The solenoid's plunger acts as the locking pin, engaging with a hole in the drawer side. Each drawer is supported by a strain gauge load cell to monitor its weight. A central microcontroller (e.g., an STM32 series MCU) manages the system. Access is requested via an NFC card reader. The controller verifies credentials, then actuates the solenoid to unlock the drawer. It logs the weight before and after access, correlating the change to the inventory management system. If an unauthorized attempt is made, the solenoid remains engaged, and an alert is triggered.

Diagram:

sequenceDiagram
    participant User
    participant Controller
    participant Solenoid
    participant WeightSensor

    User->>Controller: Scans NFC Card
    Controller->>Controller: Verify Credentials
    alt Authorized
        Controller->>WeightSensor: Get initial weight
        Controller->>Solenoid: Actuate (Unlock)
        User->>User: Access drawer contents
        Controller->>WeightSensor: Get final weight
        Controller->>Controller: Log transaction (user, time, weight_delta)
        Controller->>Solenoid: De-actuate (Lock)
    else Unauthorized
        Controller->>User: Deny Access (e.g., red LED)
    end

Derivative 16.3: Failsafe Tilt-Lock for Mobile Carts

Concept: A purely mechanical, gravity-actuated locking system that secures drawers when a cart is tilted, preventing spills.
Enabling Description: The retention mechanism is designed for failsafe operation in mobile environments. A weighted pendulum made of brass is mounted on a low-friction pivot pin inside the reinforcing assembly. A rigid locking bar is mechanically linked to the pendulum. When the platform is on a level surface (less than 15° tilt), gravity holds the pendulum in a vertical position, which retracts the locking bar. If the platform is tilted beyond 15°, the pendulum swings, driving the locking bar horizontally into a dedicated locking channel on the drawer's side panel, preventing it from opening. This system is passive, requiring no power, and automatically resets when the platform is returned to a level position.

Diagram:

flowchart TD
    A{Platform Tilted > 15°?}
    A -- Yes --> B[Pendulum Swings];
    B --> C[Linked Bar Engages Drawer Lock];
    C --> D[Drawer is Locked];
    A -- No --> E[Pendulum Hangs Vertically];
    E --> F[Linked Bar is Retracted];
    F --> G[Drawer is Unlocked];

III. Derivatives of Claim 23: Rotating Assembly Attachment

The core concept is a rotating assembly attached to the one-piece board/assembly via a screw that engages an integrated "coupling portion."

Derivative 23.1: Motorized and Indexed Rotation Stage

Concept: A motorized turntable for automated or precision applications, controlled by a microcontroller.
Enabling Description: The passive rotating assembly (500) is replaced with an active system. A NEMA 17 stepper motor is mounted to the stationary base. The motor shaft is fitted with a 20-tooth GT2 pulley, which drives a 200-tooth GT2 timing belt bonded to the underside of the rotatable puzzle platform assembly. The original coupling portion (209) now serves as a central, non-driven pivot bearing for stability. An Arduino UNO with a CNC Shield and A4988 stepper driver controls the motor. The system accepts G-code commands via USB serial, allowing for precise angular positioning (e.g., G0 A90 for a 90-degree rotation). A limit switch is included for homing the rotational axis.

Diagram:

sequenceDiagram
    participant Operator
    participant Arduino
    participant StepperDriver
    participant StepperMotor

    Operator->>Arduino: Send G-code "G0 A180"
    Arduino->>Arduino: Parse command
    Arduino->>StepperDriver: Send step and direction pulses
    StepperDriver->>StepperMotor: Energize coils in sequence
    StepperMotor->>StepperMotor: Rotate platform

Derivative 23.2: Microscope X-Y-Theta Manual Probe Stage

Concept: A cross-domain application in laboratory equipment, repurposing the platform as a high-precision manual stage for microscopy.
Enabling Description: The puzzle board is replaced with a 250mm x 250mm anodized aluminum plate, precision-ground to a flatness of ±0.01mm. The plate features a grid of M6 tapped holes for mounting scientific apparatus. The rotating assembly (500) is a high-precision, pre-loaded cross-roller bearing with a laser-etched 360° vernier scale, providing an angular resolution of 0.1 degrees. The drawers are lined with foam to store microscope objectives, probes, and samples. The integrated coupling portion (209) provides the critical rigid connection point between the mounting plate and the rotary bearing to minimize axial and radial runout during fine positioning tasks.

Diagram:

erDiagram
    PROBE_STAGE ||--|{ ROTARY_BEARING : provides
    PROBE_STAGE ||--|{ MOUNTING_PLATE : has
    MOUNTING_PLATE ||--o{ SAMPLE_HOLDER : mounts_on
    PROBE_STAGE ||--o{ DRAWER : holds

    ROTARY_BEARING {
        string type "Cross-Roller"
        string resolution "0.1 degrees"
    }
    MOUNTING_PLATE {
        string material "Anodized Aluminum"
        string features "M6 tapped grid"
    }

Derivative 23.3: Torque-Limiting Safety Clutch

Concept: An inverse/failure mode design that incorporates a safety clutch to prevent damage from obstructions or excessive rotational force.
Enabling Description: The rotating assembly (500) is designed as two primary components: a stationary base and a rotating plate, connected by a friction clutch. The puzzle board assembly connects to the rotating plate via the coupling portion (209). The clutch mechanism consists of two friction plates (one keyed to the base, one to the rotating plate) compressed by a set of Belleville washers. A central bolt, corresponding to the fixing screw (531), adjusts the compression of the washers, thereby setting the slip torque. If the rotational force applied to the board exceeds this preset torque (e.g., 5 Nm), the clutch slips, protecting the bearing, the board assembly, and the user from damage.

Diagram:

stateDiagram-v2
    [*] --> Stationary
    Stationary --> Rotating: Apply Torque < Slip_Torque
    Rotating --> Stationary: Remove Torque
    Rotating --> Slipping: Apply Torque >= Slip_Torque
    Slipping --> Rotating: Torque drops < Slip_Torque
    Slipping --> Stationary: Remove Torque

IV. Combination with Open-Source Standards

V-Slot Extrusion Frame (Combination with Claim 1): The monolithic reinforcing assembly is conceptually combined with the open-source V-Slot linear rail standard. The frame is built from 20mm series aluminum extrusions, creating a modular and reconfigurable support structure. The puzzle plate and drawers are sized to fit within this open standard, and drawers can use V-wheels running in the extrusion channels for guidance.
GRBL Firmware Control (Combination with Claim 23): The motorized rotating stage (Derivative 23.1) is controlled by an Arduino running the open-source GRBL firmware. This allows the platform to be controlled using the widely adopted G-code standard for CNC machines, making it easy to integrate into automated workflows and leverage a vast ecosystem of control software.
Home Assistant Integration via MQTT (Combination with Claim 1): The IoT-enabled platform (Derivative 1.4) uses the open MQTT protocol to publish its sensor data. This allows for direct, out-of-the-box integration with open-source home automation platforms like Home Assistant, enabling users to create dashboards, log progress over time, and trigger automations based on puzzle activity (e.g., "dim the lights when the puzzle board has been inactive for 30 minutes").