U.S. patent application number 10/316272 was filed with the patent office on 2003-07-17 for candle with controlled wick placement.
Invention is credited to Ferguson, Kathryn H., Gray, Robert G., Kotary, Kara L., Placzkowski, Eugene, Tenhagen, Georgia A..
Application Number | 20030134246 10/316272 |
Document ID | / |
Family ID | 23353373 |
Filed Date | 2003-07-17 |
United States Patent
Application |
20030134246 |
Kind Code |
A1 |
Gray, Robert G. ; et
al. |
July 17, 2003 |
Candle with controlled wick placement
Abstract
The wick of a candle is anchored above the bottom of the candle
a flame extinguishing distance so that the wick is extinguished by
the candle's molten solid fuel when the wick is consumed. Placement
of the wick in this manner helps to eliminate bum through.
Additionally, a bottom cavity may be formed in the candle. The
cavity may be used for the purpose of helping to anchor the wick a
desired flame extinguishing distance above the bottom surface of
the candle. The cavity may be advantageously filled with scrap wax
material since it will not be consumed by the burning wick.
Inventors: |
Gray, Robert G.; (Brantford,
CA) ; Ferguson, Kathryn H.; (Chicago, IL) ;
Tenhagen, Georgia A.; (Elkhorn, WI) ; Kotary, Kara
L.; (Racine, WI) ; Placzkowski, Eugene;
(Racine, WI) |
Correspondence
Address: |
S.C. JOHNSON & SON, INC.
1525 HOWE STREET
RACINE
WI
53403-2236
US
|
Family ID: |
23353373 |
Appl. No.: |
10/316272 |
Filed: |
December 11, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60345072 |
Jan 4, 2002 |
|
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|
Current U.S.
Class: |
431/289 |
Current CPC
Class: |
C11C 5/008 20130101;
C11C 5/006 20130101 |
Class at
Publication: |
431/289 |
International
Class: |
F23D 003/16 |
Claims
1. A meltable solid fuel candle having a substantially horizontal
top surface, a substantially horizontal bottom surface, one or more
side surfaces communicating with the top and bottom surfaces to
define a shape, and one or more vertical wick cavities running
substantially vertically from the top surface to the bottom surface
of said shape, each vertical wick cavity having disposed therein a
combustible wick having an upper wick end and a lower wick end to
form a shaped candle, the upper wick end extending above the candle
top surface a flame sustaining distance, and which upper wick end
when ignited can sustain a flame with the solid fuel, the flame
generating sufficient heat to melt at least a portion of the solid
fuel below the upper wick end to form a pool of the molten solid
fuel immediately below the upper wick end, and to cause the molten
solid fuel to move up a portion of the wick by capillary action to
the upper wick end to be consumed by the flame, the lower wick end
of each wick being located substantially near the bottom horizontal
surface of the candle, the improvement comprising placing the lower
wick end a flame extinguishing distance above the bottom horizontal
surface of the candle whereby the pool of molten solid fuel formed
by the flame heating the solid fuel extinguishes the flame upon the
consumption of each wick and prior to any contact of the flame or
the molten solid fuel with a surface communicating with the bottom
surface.
2. The improvement of claim 1 wherein the solid fuel is
paraffin.
3. The improvement of claim 1 wherein the candle shape is prepared
by compressing solid fuel particles to form a candle shape, wherein
the candle shape is compressed with a bottom cavity defined by an
upper surface a flame extinguish distance from the bottom
horizontal surface, and one or more side surfaces extending from
the horizontal bottom surface of the candle shape to the top
surface, the top of such bottom cavity communicating with the
bottom of each wick cavity, inserting the combustible wick into
each of said wick cavities, the lower wick end of each wick
extending downward substantially no further than the top surface of
said bottom cavity.
4. The improvement of claim 1 wherein the wick is anchored using
molten paraffin wax.
5. The improvement of claim 3 wherein the flame extinguishing
distance is greater or equal to about one-half inch.
6. The improvement of claim 3 wherein and the bottom cavity is
filled with additional solid fuel after the wick is anchored.
7. The improvement of claim 3 wherein a microcrystalline wax is
used to anchor the wick in the wick cavity substantially no further
down than the top surface of the bottom cavity prior to the bottom
cavity being filled with additional solid fuel.
8. The improvement of claim 4 wherein the solid fuel is paraffin
wax.
9. The improvement of claim 6 wherein the additional solid fuel is
wax scrap.
10. The improvement of claim 9 wherein the bottom cavity is filled
with waste paraffin wax
11. The improvement of claim 1 wherein the candle shape is prepared
by pouring molten wax to form a candle shape, wherein the candle
shape is molded with a bottom cavity defined by an upper surface a
flame extinguish distance from the bottom horizontal surface, and
one or more side surfaces extending from the horizontal bottom
surface of the candle shape to the top surface, the top of such
bottom cavity communicating with the bottom of each wick cavity,
inserting the combustible wick into each of said wick cavities, the
lower wick end of each wick extending downward substantially no
further than the top surface of said bottom cavity.
12. The improvement of claim 11 wherein the bottom cavity is filled
with additional solid fuel after wick placement.
13. The improvement of claim 11 wherein the flame extinguishing
distance is greater or equal to about one-half inch.
14. The improvement of claim II wherein the wick is anchored in
place using a microcrystalline wax prior to the bottom cavity being
filled with additional solid fuel.
15. The improvement of claim 1 wherein the candle shape is prepared
by pouring molten wax to form a candle shape, wherein the candle
shape after formation is machined to form a bottom cavity defined
by an upper surface a flame extinguish distance from the bottom
horizontal surface, and one or more side surfaces extending from
the horizontal bottom surface of the candle shape to the top
surface, the top of such bottom cavity communicating with the
bottom of each wick cavity, inserting the combustible wick into
each of said wick cavities, the lower wick end of each wick
extending downward substantially no further than the top surface of
said bottom cavity.
16. The improvement of claim 16 wherein the bottom cavity is filled
with additional solid fuel after wick placement.
17. The improvement of claim 16 wherein the flame extinguishing
distance is greater or equal to about one-half inch.
18. The improvement of claim 16 wherein the wick is anchored in
place using a microcrystalline wax prior to the bottom cavity being
filled with additional solid fuel.
19. The improvement of claim 16 wherein the wick is anchored in
place using a molten microcrystalline wax, and the bottom cavity is
not filled.
20. A meltable solid fuel candle having a substantially horizontal
top surface, a substantially horizontal bottom surface and one or
more side surfaces communicating with the top and bottom surfaces
to define a shape, a wick cavity running substantially vertically
from the top surface to the bottom surface of said shape the wick
cavity having disposed therein a combustible wick having an upper
wick end and a lower wick end to form a shaped candle, the upper
wick end extending above the candle top surface a flame sustaining
distance, and which upper wick end when ignited can sustain a flame
with the solid fuel, the flame generating sufficient heat to melt
at least a portion of the solid fuel below the upper wick end to
form a pool of the molten solid fuel immediately below the upper
wick end, and to cause the molten solid fuel to move up a portion
of the wick by capillary action to the upper wick end to be
consumed by the flame, the lower wick end being located
substantially near the bottom horizontal surface of the candle, the
improvement comprising anchoring the lower wick end a flame
extinguishing distance above the bottom horizontal surface of the
candle whereby the pool of molten solid fuel formed by the flame
heating the solid fuel extinguishes the flame upon the consumption
of the wick and prior to any contact of the flame or the molten
solid fuel with a surface communicating with the bottom
surface.
21. The improvement of claim 21 wherein the candle shape is made by
pouring molten wax into a mold.
22. The improvement of claim 21 wherein the candle shape is made by
compressing wax prill in a mold.
23. The improvement of claim 21 wherein the flame extinguishing
distance is greater or equal to about one-half inch.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/345,072 filed Jan. 4, 2002.
TECHNICAL FIELD
[0002] This invention relates to the controlled placement of wicks
in a candle product. The invention specifically relates to the
placement of a candle wick a sufficient distance from the bottom of
a candle product in order to create a product in which a burning
wick will be extinguished by the molten solid fuel pool when the
wick is expended. By quenching the burning wick with molten solid
fuel, burn through of freestanding candles placed on a combustible
surface is minimized. In a preferred embodiment of the invention,
this invention relates to a process for manufacturing a compression
molded candle product having a contour in the bottom of the candle
form that allows for the controlled placement and sealing of wicks
in free-standing candles.
BACKGROUND OF THE INVENTION
[0003] Candles have become a very popular form of air freshening
for the home in recent years. Candles are offered that appeal to
the olfactory as well as the visual sense, and come in a variety of
forms and shapes and combination of both decorative and fragrances.
A popular form of candles offered are in the form of freestanding,
or pillar candles.
[0004] A common manufacturing practice for insertion of wicks on
freestanding candles is during the formation of the candle.
Specifically, wicks are place into die molds, then a fuel source,
such as paraffin wax is poured into the mold and allowed to cool,
or prilled wax is poured into a mold and compressed to form a
candle shape and a wick is then inserted. It is common practice
that the bottom of the wick be in contact with the bottom of the
candle shape. The result is a wick that extends the full length of
the candle.
[0005] The recent increase in candle sales also resulted in an
increase of accidents by candle fires in consumer's home. A closer
study of the cause of fires can be attributed to candles that are
allowed to bum until the flames bum through bottom and cause
surface damage from heat or worse combustion of near by flammables.
More commonly, freestanding candles can present fire issues when
left unattended and allowed to bum to the bottom of the candle and
thus cause surface damage or worse ignition of near-by
combustibles, or become tipped over allowing the flame to extend
beyond the sidewall or bottom of the candle resulting the same
effect of ignition of near-by combustibles.
[0006] Another manufacturing practice is to form a freestanding
candles in molds and insert the wicks afterwards. The practice is
to insert the wick and secure to the candle from the bottom, but
has drawbacks and limitations. Wicks are inserted into the candles
for positioning away from the bottom, there is no assurance of
controlled placement. To be accurate, and to control the problems
mentioned above, careful wick placement is required. If the bottom
of the wick is placed too high in a candle, this will limit the
enjoyment obtained by the consumer in burning the candle, and a
large portion of the candle will be wasted. Conversely, if the
bottom of the wick is placed too close to the bottom of the candle
bum through, and combustion of the surface on which the candle is
placed can occur.
[0007] For purposes of commercial-scale manufacture, there can be
an economic advantage in utilizing a design to the bottom of a
freestanding candle that allows for the controlled placement and
securing of wicks by means of forming the candles in molds.
[0008] The description of the present invention includes the
advantages of inserting wicks to a specified depth from the bottom
of the candle as a way to address any issues of bum through, as
well as economic advantages to manufacturing by providing a contour
to the candle which allows for the reclamation of scrap
materials.
[0009] A further advantage, with respect to the production of
multilayer, multicolored candles is the ability to dispose of place
scrap wax in the bottom cavity.
THE INVENTION
[0010] Wright et al, U.S, patent application no 0010030195
describes the dangers of flash-over from candles allowed to burn to
a shallow pool which can ignite if the temperature of the wax
reaches its ignition points. Moreover, this invention describes the
phenomenon associated with candles in metal containers.
[0011] Candle compositions comprised of mineral oil and various
polymeric additives are known to develop the phenomenon of
flashover due to the inherent nature of these compositions to build
up heat in the melt pools which can reach the ignition point.
Flashover can occur any time during the combustion of these
compositions, so placement of the wicks away from the bottom can
offer only limited benefits.
[0012] Candle compositions comprised of wax and respective
additives and molded into the form of freestanding candles can only
exhibit flashover when the pools are contaminated with objects
intentionally, and when contained in some form of a container. A
more common observation associated with freestanding candles is the
loss of sidewalls from other means such as improper selection of
wicks, or contamination of pools.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 shows a freestanding candle;
[0014] FIG. 2 is a bottom perspective view of the freestanding
candle of this invention showing the bottom cavity;
[0015] FIG. 3 is a cutaway view of a freestanding candle showing
the cavity and wick placement;
[0016] FIG. 4 is a bottom perspective view of the free standing
candle of this invention showing the bottom cavity filled with a
fuel source, optionally scrap wax.
DETAILED DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 shows a freestanding candle 2 having horizontal top
4, sides 6 and bottom 8. Axially disposed wick 10 runs the length
of candle 2 from the top 4 to the bottom 8. The top 4, sides 6, and
bottom 8 define a candle shape which can be prepared by a variety
of methods. Among the methods that can be used are the pouring of
molten solid fuel, generally a paraffin or vegetable wax into a
mold defining the desired candle shape, such mold optionally
containing, placed therein a wick material of suitable construction
which will burn with the desired properties. Optionally, the wick
10 may be placed into the candle shape after it has been removed
from the mold by forming a wick channel or cavity, and then
inserting the wick. The wick should extend a flame sustaining
distance, generally 1/4 to 1 inch above the top 4 of candle 2 and
more preferably generally at least 1/2 inch above the top of the
bottom cavity. Wicks longer than 1 inch may bend over and create
undesirable wax pools when the candle is burnt. Wicks shorter than
1/4 inch are difficult to light, and are sometimes difficult to
sustain a flame since they can be quenched by the capillary action
of the solid fuel source, generally a vegetable or paraffin
wax.
[0018] Another method of forming candles is by compression. In this
method prill or powder is formed from the wax, inserted into the
mold, and then the wax is compressed in the mold to form the candle
shape. The shape is removed from the mold, a wick cavity created,
and a wick inserted. The fuel for either poured or compression
molded candles may contain colorants, volatile active ingredients
such as fragrances, insect control chemicals, sanitizers,
deodorants, or the like. In addition the fuel may contain
microcrystalline wax to provide improved candle properties, and
C.sub.14-C.sub.20 fatty acids to also enhance the properties of the
particular wax fuel employed. Sometimes synthetic wax crystal
modifiers such as ethylene-alpha-olefin copolymers such as those
sold under the trademark Vybar may be added to the mixture as well.
It is not within the scope of this specification, or this invention
to specify particular wax or fuel formulations used for candles,
and the method of this invention will perform with any candle made
in accordance with the teachings herein. Likewise, it is not within
the scope of this specification to discuss the choice of proper
candle wicks, and those skilled in the art of candlemaking will
readily appreciate the various wick materials that are available
for particular uses. It is not important in the function of this
invention that the candle contain a volatile active material, this
invention having applicability to candles providing light only.
Likewise, the invention is applicable to any candle shape, for
example the common cylindrical shape, square shapes, parallelogram
shapes, triangles, etc. so long as the candle 2 has a relatively
flat surface for balancing on a surface without falling over.
[0019] With specific reference to the drawings, this invention is
directed to a meltable solid fuel candle 2 having a substantially
horizontal top surface 4, a substantially horizontal bottom surface
8, one or more side surfaces 6 communicating with the top 4 and
bottom 8 surfaces to define a shape, and one or more vertical wick
cavities 40 running 20 substantially vertically from the top
surface 4 to the bottom surface 8 of said shape, each vertical wick
cavity 40 having disposed therein a combustible wick 10 having an
upper wick end 11 and a lower wick end 9 to form the shaped candle
2, the upper wick end 11 extending above the candle top surface a
flame sustaining distance, and which upper wick end when ignited
can sustain a flame with the solid fuel, the flame generating
sufficient heat to melt at least a portion of the solid fuel below
the upper wick end to form a pool of the molten solid fuel
immediately below the upper wick end, and to cause the molten solid
fuel to move up a portion of the wick 10 by capillary action to the
upper wick end 11 to be consumed by the flame, the lower wick end 9
of each wick 10 being located substantially near the bottom
horizontal surface of the candle 8, the improvement comprising
placing the lower wick end 9 a flame extinguishing distance 22
above the bottom horizontal surface of the candle whereby the pool
of molten solid fuel formed by the flame heating the solid fuel
extinguishes the flame upon the consumption of each wick 10 and
prior to any contact of the flame or the molten solid fuel with a
surface communicating with the bottom surface.
[0020] With further reference to the drawings, FIG. 2 shows a
bottom perspective view of a candle 2 of this invention showing
bottom cavity 20 of the invention. Bottom cavity 20 has sides 22
and top 24 which define the cavity. Wick hole 26 extends through
top 24 into the cavity 20. Cavity 20 can be prepared by various
means. It can be molded into the candle as it is poured, drilled
out of a candle after pouring, or in compression manufacturing
techniques, can be incorporated into either the bottom of the
compression mold, or the ram which is utilized to compress the fuel
source in the mold. Bottom cavity 20 does not extend the entire
width of the candle, leaving sides 6 and shoulder 30 to support the
candle. The sides 22 of cavity 20 can extend from the bottom of the
candle shoulder 30 to as high in the candle as it is desired to
eventually extinguish the flame on wick 10. Normally, sides 22
should extend a minimum of about 1/4 inch above the bottom of the
candle.
[0021] FIG. 3 shows a cross section view of candle 2. In this view
the bottom cavity 20 is shown along with sides 6, shoulder 30,
cavity sides 22, and bottom cavity top 24. In this view, the wick
cavity 40 is also shown. Wick cavity 40 shows a axially disposed
vertically placed wick cavity adapted to receive an appropriate
wick 10. In practice, wick 10 would be placed within wick cavity 40
and extend about 1/4 to about 1 inch above the top 4 of candle 2.
Likewise wick 10 would end at the top 24 of bottom cavity 20, or
slightly above top 24 where in practice it would be anchored with a
molten wax material. The placement of wick 10 slightly above the
top 24 of bottom cavity 20 helps insure that the flame when wick 10
is ignited will be extinguished with the wax pool formed, and will
not be in a sufficient downward location to ignite a flammable
surface onto which free standing candle 2 may be inadvertently
placed. Wick 10 may be held in place by a small amount of molten
fuel poured of the same or different composition as candle 2
provided that the material used to anchor wick 10 should be
compatible and adhere to the material used for candle 2. In a
preferred practice, wick 10 is placed 1/8th inch below the surface
of the top 24 of cavity 20 which is 3/8 inch to give a total flame
extinguishing distance of approximately 1/2 inch. In other words,
the wick is slightly recessed into the candle body and does not
extend into the cavity 20. This feature does not detract from the
utility of the invention when the wick is flush with top 24 or even
extends into cavity 20 so long as the wick is a flame extinguishing
distance above the horizontal bottom 8 of the candle. When a cavity
is utilized, the wick should preferably extend substantially no
further than the top surface of the bottom cavity.
[0022] FIG. 4 shows a bottom view of candle 2 showing bottom cavity
20, bottom cavity sides 22, bottom cavity top 24 and wick cavity
40. Also shown in dotted line is wax fill 44 which is added to hold
wick 10 in place and to provide a better foundation upon which
candle 2 may rest, hopefully on a non-combustible surface. One of
the surprising benefits of the flame extinguishing feature of this
invention, is that it provides both economic and safety
benefits.
[0023] Many times in the manufacture of candles different waxes are
employed. These waxes may contain different colorants or pigments,
and thus, must be carefully sorted if they are to be reused, or the
material, if commingled must be disposed of as a chemical waste.
This is of special concern when the solid fuel being used contains
different fragrance materials that may or may not be compatible to
the olfactory sense. Previously, waste wax from broken or scrap
candles was disposed of at great economic cost. If the solid fuel
being commingled contained different colorants, often a gray or
dark unpleasing color would result if the scrap was melted down and
reused. This melted down scrap was unsatisfactory for candle
production since it did not provide proper esthetics for a
commercially saleable product. We have found that when wax scrap is
collected and melted, it may be used to fill the bottom cavity 20
to provide additional support for candle 2 since the wax contained
in bottom cavity 20 is not consumed in the combustion of the
candle. This scrap wax is thus contained in the candle and provides
stability and support to the sides 4 and shoulder 30 of candle 2.
The scrap wax may also help maintain the wick at a satisfactory
location, preventing it from sliding down. In the absence of scrap
wax of course, new wax can be utilized, and this invention is not
meant to be limited to the use of scrap wax alone. Alternatively,
and assuming that shoulder 30 and sides 6 remain intact and are
strong enough to maintain the weight of the candle, the bottom
cavity may be left open. The scrap wax does not prevent the wick
from sliding down when a sealing wax is utilized, thus explaining
why the cavity can remain unfilled and the wick will extinguish. As
long as the melt point of the sealing wax, the wax that anchors the
wick, is not substantially higher than the melt point of the
formula, the wick will fall over and will not slide down. When no
sealing wax is utilized the wax placed into the cavity will help to
maintain the wick in its proper location. We prefer to use sealing
wax however to maintain the placement of the wick at a desired
location.
[0024] In the manufacture of candles by compression techniques,
such as that disclosed in my commonly assigned application filed of
even date, the compression candle is molded upside down with a
compression ram, having the desired shape to impart the bottom
cavity 20 incorporated into the ram. After compression, the candle
shape is removed from the mold, and still upside down, a wick of
suitable material is inserted. This wick 10 is in the wick cavity
40, placed about 1/8 th inch beneath the top 24 of candle bottom 8.
The wicks utilized may be of any conventional wick material
including but not limited to cotton, cotton/paper, cotton/linen, or
synthetic such as rayon. A preferred wick material is cotton with
or without paper braid or a paper core.
[0025] In practice, we prefer not to use metallic wick clips as are
commonly used for the support of wicks, in for instance votive
candles because free standing candles are often placed upon stands
having protrusions which engage the candle and steady the candle.
Such protrusions would damage a wick clip, and hence, while this
invention will function, we prefer not to use such devices. Another
disadvantage of a conventional metallic wick clip in the practice
of our invention is that the metal will conduct heat, melting
additional wax, and perhaps causing the fuel around the wick clip
to melt. This additional melted wax may cause breakthrough of the
wax to the bottom of the candle, exposing molten wax to the surface
upon which the candle is to be placed.
[0026] The example presented below illustrates the preparation of a
multiple layered compression molded candle product having the wick
shut off feature, and the scrap disposal feature of the subject
invention. As will be seen, while this invention is illustrated
with a compression candle making technique, those skilled in the
art will readily appreciate that the subject wick shut off
invention will have applicability with regard to candles that are
poured as well.
[0027] For each composition of a layer, a refined paraffin wax (IGI
Paraflex 1239 MP 60.degree. C.); is pre blended with an ethylene
derived polymer (Vybar 103, MP 76.degree. C.) until the polymer is
fully integrated into the refined paraffin wax. A fragrance/dye/UV
inhibitor concentrate of IFF Stargazer 18 (available from
International Flavors & Fragrances), Sandoplast Yellow 3G,
Sandoplast Red 2G (both available from Clariant Gmbh, Pigments and
Additives Division, Frankfurt) and Cyasorb UV 531 (available from
Cytec Industries, Inc., West Patterson, N.J.) is mixed until all
components are dissolved.
[0028] The following four streams: wax/polymer pre-blend and the
fragrance/dye/UV inhibitor concentrate, stearic acid (Emersol 150
MP 65.5.degree. C. available from Henkel Corp.), and
microcrystalline wax (Bareco's Victory Lite Wax MP 80.degree. C.)
are metered simultaneously to the formula (using a four stream
metering system) and are blended through an in-line blending
process.
[0029] Separately and simultaneously, additional compositions are
prepared using the same method of mixing process. For the second
layer, a refined paraffin wax (IGI Paraflex 1239 MP 60.degree. C.);
is pre blended with Vybar 103 until the polymer is fully integrated
into the refined paraffin wax. A fragrance/dye/UV inhibitor
concentrate of IFF 1814 HBA, Clariant Sandoplast yellow 3G and
Cyasorb UV 531 is mixed until all components are dissolved. The
wax/polymer pre-blend and the fragrance/dye/UV inhibitor
concentrate are further blended through an in-line blending process
with the same stearic acid and microcrystalline wax used in layer
mixture 1. A third layer using identical ingredients, except the
fragrance/dye/UV inhibitor concentrate was IFF Moonblossom 47,
Clariant Sandoplast Green 3G, Nitro Fast Blue 2B and Cyasorb UV 531
is mixed until all components are dissolved. The wax/polymer
pre-blend and the fragrance/dye/UV inhibitor concentrate are
further blended through an in-line blending process as with the
other two layers.
[0030] The separate layer mixture-candle wax compositions are held
at a temperature of approximately 65 to 80.degree. C. usually
75-80.degree. C., and preferably about 77.degree. C. and pumped
separately to respective surge tanks until the ingredient mixtures
are homogenous. The candle wax compositions are then pumped to
their respective separate wax reservoirs in Kurschner wax spray
drum system and the compositions are held at a temperature of 65 to
80.degree. C. The spray drums are set to a speed of approximately
42 meters/min. The spray room temperature is held to about
15.degree. C. and the relative humidity of approximately 50%
although this temperature parameter may vary depending on the
composition being dried, the humidity, the rate of spraying, and
the temperature of the material being sprayed. The candle wax
composition for each layer is pumped through a spray manifold
system from the spray drum reservoir and sprayed to 15 centimeters
above the drum from nozzles. The wax is sprayed into the air and
semi-solidifies before contacting the drum surface. The spray drum
is held to a temperature between about 7 and 24.degree. C. The
prilled wax is collected on the spray drum and them scraped from
the drum and transferred into a vibrating conveyer that leads
inside the drum for each of the compositions for further cooling.
The prilled wax is collected at the end of the drum and vacuum fed
into holding separate hoppers. For consistent cavity mold filling
and compression for multiple layers in a single mold, the prilled
waxes are maintained at temperatures between about 17 and
32.degree. C.
[0031] The target dimension for the candle directly from the press
is 7.60 cm by 10.16 centimeters in dimension. For a pillar candle
of this dimension, the total weight is about 366 grams and the
weight for each layer is about 122 grams. It should be noted that
the candles are made on the basis of volume and weights are given
for the purpose of illustration only.
[0032] The prilled candle waxes above are transferred from the
spray drum to three separate stationary hoppers and maintained at a
temperature between 20 and 32.degree. C. The prilled waxes are
transferred from the stationary hoppers to feed tube matrix of the
Progressive Automation compression mold pillar candle press.
[0033] The feed tube matrix consists of 3 rows each containing 6
cavities which are filled with prilled wax for each layer. The feed
tube matrix passes over the a stationary table of the press and
fills one of the two sets of 6 cavity head units with a volume of
122 grams from the feed tube matrix for a layer per candle, until
the cavity is filled with a total of 366 grams of prilled wax, thus
representing three distinct layers of prilled wax composition in a
single candle. The table then rotates one of the 6 head cavity
units filled with the three prilled wax compositions, 180 degrees
to a compression station, where the prilled wax is compressed in
the cavity from the top down, forming a contour pocket of
approximately 40 millimeters by 9.5 millimeters in dimension to the
bottom of the candle. The prilled waxes are compressed to a force
between 2400 and 2800 pounds, for a dwell time of approximately 1-5
seconds to produce a candle that is of a density of between 0.83
and 0.92 grams/cubic centimeter, at which time, the cavity molds
are heated through the use of a water jacket, to a temperature of
between 10 and 40.degree. C.
[0034] The compressed candles are then extracted from the cavity
molds, then placed onto a pocketed indexing conveyer system, bottom
side up to allow for a clearance space for the top of the candle,
and transferred to a Progressive Automation wicking machine where
cotton wicks, with or without paper braids or paper cores having a
length of from about 9 to about 11.5 cm. from Technical Braiding
Gmbh are inserted into the candles from the bottom to allow the
wicks to be placed flush to the upper portion of the pocket and to
a total depth of 1/2 inch from the bottom of the candle. While the
candles are inverted with the bottom up, the wicked candles are
dosed with approximately 0.2 to 0.5 grams of paraffin wax at a
temperature between 65 and 85.degree. C. to seal the wicks in
place. While microcrystalline wax can be advantageously used in
this step, it is preferred to utilize a material having the same
properties employed in the bottom layer so that the wax material is
compatible with, and has the same melting point as the main
structure. The candle is then transferred onto a second station
where the cavity is filled with between 8 and 10 grams of candle
wax that has been reclaimed from scrap candles, and at a
temperature between about 60 and about 80.degree. C. and generally
about 60-70.degree. C. This temperature range is not critical, and
molten paraffin of a higher or lower temperature can be used so
long as the temperature is not high enough to damage the structure,
or dislodge the wick. The candles that have been filled with wax
into the bottom cavity are then passed through cooling tunnel at a
temperature of from about 13 to about 25.degree. C. for a period of
approximately 12 to 20 minutes. In the practice of this invention
it is necessary that the selected wick extend out of the top of the
candle a flame sustaining distance. In practice this distance
ranges from about 1/4 inch to about 1 inch.
[0035] The resultant candles were esthetically pleasing, had
satisfactory burn characteristics and emitted fragrance as they
burned. When the candles of the subject invention were utilized the
wick was extinguished by the molten wax pool. Over a series of
candles that were tested, burn though was virtually eliminated.
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