Plastic sheets with lenticular lens array

A lenticular sheet comprising:

• at least one pattern of lenticular lenses defined on a first surface of said lenticular sheet;
• at least one alignment ridge extending from a second surface of said lenticular sheet, said second surface opposing said first surface and being free of a lenticular lens pattern;
• and
• at least one of:
• at least one score line;
• at least one opening extending through said sheet and interrupting at least one of said lenticular lens;
• at least one area free of said lenticular lens pattern on said first surface and interrupting at least one of said lenticular lens pattern on said first surface;
• at least one of a lip, a foot, a stop, and a ledge, wherein said at least one of said lip, said foot, said stop, and said ledge extend from said first surface of said lenticular sheet;
• and
• at least one hinge area on said first surface.

A method of manufacturing a lenticular sheet comprising the steps of:

• providing a substrate sheet, the substrate sheet having a first surface and an opposing second surface;
• forming at least one lenticular lens pattern in the first surface of the substrate sheet by contacting the first surface of the substrate sheet with an embossing device having a negative pattern of said at least one lenticular lens pattern;
• forming at least one alignment ridge extending from the second surface of the substrate sheet, the second surface being free of said at least one lenticular lens pattern;
• and
• forming at least one of:
• at least one score line;
• at least one opening extending through the sheet and interrupting said at least one lenticular lens pattern;
• at least one area free of said at least one lenticular lens pattern on the first surface of the substrate sheet and interrupting said at least one lenticular lens pattern on the first surface;
• at least one of a lip, a foot, a stop, and a ledge, wherein the at least one of the lip, the foot, the stop, and the ledge extend from the first surface of the substrate sheet;
• and
• at least one hinge area on the first surface of the substrate sheet.

A lenticular lens embossing device configured to emboss a pattern on a first surface of a sheet, the sheet including a second surface opposing the first surface, said device comprising:

• an engagement member having an outer surface;
• and
• a negative of at least one lenticular lens pattern on said outer surface of said engagement member, the negative configured to form the at least one lenticular lens pattern in the first surface of the sheet;
• wherein said engagement member comprises:
• at least one projection configured to form at least one alignment ridge that extends from the second surface of the sheet, wherein the second surface is free of the at least one lenticular lens pattern;
• and
• at least one of:
• at least one projection configured to form at least one score line through the sheet;
• at least one projection configured to form a plurality of hinge areas on the first surface of the sheet;
• at least one projection configured to form at least one opening extending through the sheet, each said opening interrupting the at least one lenticular lens pattern;
• and
• at least one projection configured to form at least one of a lip, a foot, a stop, and a ledge, wherein said at least one of said lip, said foot, said stop, and said ledge extend from the first surface of the sheet.

A lenticular sheet assembly comprising:

• a first sheet having a first end and an opposing second end, the first sheet further having a first surface and an opposing second surface, each of the first surface and the second surface extending between the first end and the second end, the first surface and the second surface each being substantially flat, the first sheet comprising a notch defined in the first surface at the first end of the first sheet;
• and
• a second sheet having a first end and an opposing second end, the second sheet further having a first surface and an opposing second surface, each of the first surface and the second surface extending between the first end and the second end, the second surface of the second sheet being adjacent to the first surface of the first sheet such that the first end of the second sheet is adjacent to the first end of the first sheet, the second sheet comprising:
• a lenticular lens pattern defined on the first surface of the second sheet, wherein the second surface of the second sheet is free of lenticular lens patterns;
• and
• an alignment ridge extending from the second surface of the second sheet, the alignment ridge being received in the notch defined in the first sheet to align the second sheet with the first sheet.