U.S. patent application number 11/271356 was filed with the patent office on 2006-05-04 for candleholder with a melting plate alignment feature.
Invention is credited to Chris A. Kubicek, Nathan R. Westphal.
Application Number | 20060093980 11/271356 |
Document ID | / |
Family ID | 37770679 |
Filed Date | 2006-05-04 |
United States Patent
Application |
20060093980 |
Kind Code |
A1 |
Kubicek; Chris A. ; et
al. |
May 4, 2006 |
Candleholder with a melting plate alignment feature
Abstract
A candleholder for a fuel element, such as a votive candle,
includes a melting plate carried by a base portion. The melting
plate is generally dish-shaped and disposed within a generally
complementarily shaped recess in a top end of the base portion. An
alignment mechanism including an inner peripheral step protruding
into the recess and a complementary ledge in a bottom surface of
the melting plate helps ensure that the melting plate is disposed
at a predetermined position in the recess. The ledge rests on the
peripheral step with an adhesive disposed therebetween when the
melting plate is in the predetermined position. A ring protrusion
from the base portion is disposed under a cavity defined under a
capillary lobe in the melting plate. The ring protrusion helps
retain a magnet in a predetermined location in the cavity and may
also serve as part of the alignment mechanism. The magnet may be
used to help retain a ferro-magnetic wick holder of the votive
candle on the capillary lobe.
Inventors: |
Kubicek; Chris A.; (East
Troy, WI) ; Westphal; Nathan R.; (Union Grove,
WI) |
Correspondence
Address: |
S.C. JOHNSON & SON, INC.
1525 HOWE STREET
RACINE
WI
53403-2236
US
|
Family ID: |
37770679 |
Appl. No.: |
11/271356 |
Filed: |
November 10, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11123809 |
May 6, 2005 |
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11271356 |
Nov 10, 2005 |
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11123461 |
May 6, 2005 |
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11271356 |
Nov 10, 2005 |
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11124313 |
May 6, 2005 |
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11271356 |
Nov 10, 2005 |
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11123372 |
May 6, 2005 |
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11271356 |
Nov 10, 2005 |
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10978744 |
Nov 1, 2004 |
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11123372 |
May 6, 2005 |
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10938434 |
Sep 10, 2004 |
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10978744 |
Nov 1, 2004 |
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11185174 |
Jul 20, 2005 |
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11271356 |
Nov 10, 2005 |
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11182689 |
Jul 15, 2005 |
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11271356 |
Nov 10, 2005 |
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11197839 |
Aug 5, 2005 |
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11271356 |
Nov 10, 2005 |
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11140683 |
May 31, 2005 |
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11271356 |
Nov 10, 2005 |
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10938453 |
Sep 10, 2004 |
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11271356 |
Nov 10, 2005 |
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Current U.S.
Class: |
431/291 |
Current CPC
Class: |
F21V 35/00 20130101;
F23D 3/26 20130101; F23D 3/18 20130101 |
Class at
Publication: |
431/291 |
International
Class: |
F23D 3/16 20060101
F23D003/16 |
Claims
1. A candleholder for carrying a fuel element thereon, the
candleholder comprising: a base portion including a sidewall
defining a recess at a top end of the base portion and a shoulder
spaced from the top end projecting from the wall within the recess;
and a melting plate disposed within the recess and adapted to
retain the fuel element, the melting plate having a peripheral edge
and a ledge spaced from the peripheral edge defined in a bottom
surface of the plate, wherein the ledge engages the shoulder.
2. The candleholder of claim 1 further comprising a medial wall
spaced from the top end, the recess defined by the sidewall and the
medial wall, the medial wall defining a bottom of the recess.
3. The candleholder of claim 2, wherein the melting plate is spaced
from the medial wall.
4. The candleholder of claim 2 further comprising a retainer
projecting from the medial wall into the recess; and a cavity
defined in the bottom surface of the melting plate, wherein the
retainer is disposed inside the cavity.
5. The candleholder of claim 4, wherein the retainer at least
partly surrounds a magnet disposed in the cavity.
6. The candleholder of claim 5, wherein the retainer comprises a
circular, ring-shaped protrusion.
7. The candleholder of claim 6, wherein the retainer is spaced from
the bottom surface of the melting plate.
8. The candleholder of claim 1, wherein the melting plate has a
substantially non-circular peripheral footprint.
9. The candleholder of claim 8, wherein the ledge extends entirely
around a central portion of the melting plate.
10. The candleholder of claim 9, wherein the sidewall extends
entirely around the recess, and the shoulder extends entirely
around the recess.
11. The candleholder of claim 1, wherein the ledge is disposed in
an upturned peripheral portion.
12. The candleholder of claim 1 further comprising an adhesive
disposed between the ledge and the shoulder.
13. The candleholder of claim 12, wherein the adhesive forms a seal
between the melting plate and the base portion, the seal extending
completely around the melting plate.
14. A candleholder comprising: a base portion including a recess in
an upper end thereof, the recess defined by a peripheral inner wall
surface and a bottom wall surface, a shoulder protruding from the
peripheral inner wall surface, and a ring protruding from the
bottom wall surface; and a melting plate including a bottom central
wall portion surrounded by an upturned peripheral wall portion, a
ledge defined in a bottom surface of the upturned peripheral wall
portion, the ledge spaced from a peripheral edge of the melting
plate, and a cavity defined in the bottom surface of the central
wall portion; wherein the melting plate is disposed in the recess
with the ledge disposed on the shoulder and the ring disposed
inside the cavity.
15. The candleholder of claim 14, wherein the central wall portion
of the melting plate is spaced above the bottom wall surface of the
base.
16. The candleholder of claim 15, wherein the ring is spaced from
the bottom surface of the central wall portion.
17. The candleholder of claim 14, wherein the cavity is at least
partly defined by a capillary lobe, and a magnet is disposed within
the cavity and surrounded at least partly by the ring.
18. A candleholder comprising: a base portion having a recess for
supporting a concave melting plate therein; and an alignment
mechanism to align the melting plate in the recess in a
pre-selected spaced relationship to a portion of the base
portion.
19. The candleholder of claim 18, wherein the alignment mechanism
includes at least one of a ledge extending at least partly around
an upturned peripheral portion of the melting plate and a shoulder
projecting from a wall portion into the recess.
20. The candleholder of claim 19, wherein the ledge is disposed on
the shoulder and a bottom portion of the melting plate is spaced
above a bottom surface of the recess in a substantially level
position when the candleholder is disposed in an operative
position.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. Nos. 11/123,809, 11/123,461, 11/124,313, and
11/123,372, each of which was filed May 6, 2005, and each of which
is a continuation-in-part of U.S. patent application Ser. No.
10/978,744, filed Nov. 1, 2004, which is a continuation-in-part of
U.S. patent application Ser. No. 10/938,434, filed Sep. 10, 2004.
This application is also a continuation-in-part of U.S. patent
application Ser. No. 11/185,174, filed Jul. 20, 2005, and U.S.
patent application Ser. No. 11/182,689, filed Jul. 15, 2005.
Further, this application is a continuation-in-part of U.S. patent
application Ser. Nos. 11/197,839, filed Aug. 5, 2005, Ser. No.
11/140,683, filed May 31, 2005, and Ser. No. 10/938,453, filed Sep.
10, 2004.
REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
SEQUENTIAL LISTING
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to candleholders.
[0006] 2. Description of the Background of the Invention
[0007] Many different assemblies for holding a candle are known. In
one candle assembly, a wicked candle is disposed inside a
cylindrical container having a recessed stepped ring encircling an
open top end thereof. A circular shade body fits within the open
top end and has an outer peripheral flange that rests on the
recessed stepped ring.
[0008] Another candleholder includes a standard for receiving a
candlestick, which extends from a base of the candleholder. The
standard has a socket with an out-turned flange at an upper end
thereof for receiving the candlestick therein. A funneled split
tube is disposed in the socket. The split tube has an out-turned
peripheral flange that rests on the out-turned flange of the
socket. A cap spans the out-turned flange of the socket and rests
on a peripheral edge thereof spaced above the split tube.
[0009] An electric candle is known that has a hollow cylindrical
body portion extending up from a mounting base. A votive candle is
carried within an open upper end of the body portion by a bracket
having a plurality of arms extending radially outwardly from a
central frustoconical rim. The votive is carried inside the rim,
and the peripheral edges of the arms rest on a recessed inner
annular rim at the open upper end of the body portion.
[0010] A candle having a constant elevation flame includes a wax
body contained within a tubular outer casing. A spring urges the
wax body upwardly toward a wick carried over an open end of the
outer casing by a thermally-insulated cover. The wick extends
through a central aperture in the cover and is retained at a
constant elevational position by a wire. An outturned peripheral
lip of the cover rests in a peripheral recess in the tubular
casing.
SUMMARY OF THE INVENTION
[0011] According to one aspect of the invention, a candleholder for
carrying a fuel element thereon includes a base portion having a
sidewall defining a recess at a top end of the base portion and a
shoulder spaced from the top end projecting from the wall within
the recess. A melting plate adapted to retain the fuel element is
disposed within the recess. The melting plate has a peripheral edge
and a ledge spaced from the peripheral edge defined in a bottom
surface of the plate. The ledge engages the shoulder.
[0012] According to another aspect of the invention, a candleholder
includes a base portion and a melting plate. The base portion
includes a recess in an upper end thereof. The recess is defined by
a peripheral inner wall surface and a bottom wall surface. A
shoulder protrudes from the peripheral inner wall surface, and a
ring protrudes from the bottom wall surface. The melting plate
includes a bottom central wall portion surrounded by an upturned
peripheral wall portion, a ledge defined in a bottom surface of the
upturned peripheral wall portion, and a cavity defined in the
bottom surface of the central wall portion. The ledge is spaced
from a peripheral edge of the melting plate. The melting plate is
disposed in the recess with the ledge disposed on the shoulder and
the ring disposed inside the cavity.
[0013] In yet another aspect of the present invention, a
candleholder includes a base portion having a recess for supporting
a concave melting plate therein and an alignment mechanism to align
the melting plate in the recess in a pre-selected spaced
relationship to a portion of the base portion.
[0014] Other aspects and advantages of the present invention will
become apparent upon consideration of the figures and the following
detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an exploded isometric view of a candle assembly
according to one aspect of the present invention;
[0016] FIG. 2 is an enlarged isometric view of a wick holder shown
in FIG. 1;
[0017] FIG. 3 is a cross-sectional view of a fuel element along the
line 3-3 of FIG. 1;
[0018] FIG. 4 is a cross-sectional view generally transverse to
line 3-3 of FIG. 1 with the candle assembly in assembled form;
[0019] FIG. 5 is an enlarged partial cross-sectional view along the
line 5-5 of FIG. 4;
[0020] FIG. 6 is an enlarged isometric view of a wick holder and a
portion of a melting plate according to yet another aspect of the
invention;
[0021] FIG. 7 is an isometric view of still another wick holder
according to the present invention;
[0022] FIG. 8 is an enlarged cross-sectional view of the wick
holder shown in FIG. 7 in a similar view as shown in FIG. 5;
[0023] FIG. 9 is an isometric view of a candleholder according to
another aspect of the present invention;
[0024] FIG. 10 is an exploded isometric view of a candleholder
according to a further aspect of the present invention; and
[0025] FIG. 11 is an exploded cross-sectional view of the
candleholder of FIG. 10 along a vertical plane at a centerline
thereof.
DETAILED DESCRIPTION
[0026] Referring now to FIGS. 1-5, a candle assembly 100 includes a
support base 102, a melting plate 104, a wick holder 106, a wick
108, and a fuel element 110. The support base 102 carries the
melting plate 104, which is generally saucer shaped, and includes a
centrally disposed capillary pedestal 112. Optional decorative
etchings 114 are disposed on an upper exposed surface of the
melting plate 104 to provide enhanced attractiveness or visual
information. The wick holder 106 includes a base portion 116 that
fits over the capillary pedestal 112, a wick retainer sleeve in the
shape of an elongate cylindrical barrel 118, and heat conductive
elements, such as fins 120. The barrel 118 receives the wick 108
therein such that the wick extends from the base portion 116 with a
portion of the wick exposed above the barrel. The fuel element 110
is disposed over and around the wick holder 106 and includes a duct
or slot 122 through which the wick 108 extends. The slot 122 has a
width w.sub.1 sufficient to allow the wick 108 to extend through
the slot and a length l.sub.1 sufficient to accept at least a
portion of the fins 120 therethrough. In one embodiment, the fuel
element 110 has a mass of wax approximately 15 grams, and the
melting plate candle 100 burns continuously between about 3 and
31/2 hours on a single fuel element, such as the wax fuel element
110, before the fuel is completely consumed.
[0027] As seen in FIG. 2, the base portion 116 of the wick holder
106 includes an end plate 124 encompassed by a generally conical
base skirt 126, and an upper portion including the barrel 118
extending upwardly from the base skirt and the fins 120 extending
from the barrel and end plate 124. The base portion 116 is adapted
to fit closely over and around the capillary pedestal 112 such that
the barrel 118 is maintained in an upright, or substantially
vertical, orientation when placed on the capillary pedestal. The
base skirt 126 includes indentations or spacers 128, and holes 130
extend through the end plate 124. Ferromagnetic structures, such as
steel rivets 132 or magnets (not shown), are secured to the base
portion 116, such as through the holes 130, so that the wick holder
106 may be releasably secured over the capillary pedestal 130 by
magnetic forces. The barrel 118 is sized to receive the wick 108
with either a close fit or interference fit so as to retain the
wick therein and defines an opening 134 in the end plate 124 such
that the wick can extend through the end plate. The fins 120 extend
laterally outwardly on opposite sides of the barrel 118 and extend
upwardly above the barrel. In one embodiment, the fins 120 are
shaped to simulate a flame outline. In other embodiments, the fins
120 may have square, circular, oval, triangular, or other
non-geometric shapes, and in still other embodiments, the fins 120
may have insulated areas (not shown) as described more fully in
U.S. patent application Ser. No. 10/939,039, filed Sep. 10, 2004,
and incorporated herein by reference in its entirety. The fins 120
are relatively thin strips of heat conductive material, such as
metal, for transmitting heat from a flame burning on the wick 108
outwardly toward the fuel element 110. In one embodiment, the wick
holder 106 is formed from a single sheet of aluminum that is cut
and folded about a fold 136 and thereby forming a capillary space
138 between opposite sides 140 and 142 and channels or gaps 144 in
the base skirt 126. In other embodiments, the wick holder 106 may
be formed by other methods from other heat resistant materials,
such as ceramic, other metals, heat resistant plastics, etc. If the
wick holder 106 is formed of a ferromagnetic material, such as
steel, the steel rivets 132 may optionally be omitted. The two
sides 140 and 142 are secured together by any convenient means,
such as with rivets 146 through holes 148 in the heat fins 120,
welds, clips, heat resistant adhesives, etc. The gaps 144 and the
holes 130 allow melted fuel material from the fuel element 110, to
drip or seep underneath the base skirt 126, and the capillary space
138 allows melted fuel material to traverse up the fins 120 by
capillary action and thereby provide a source of fuel material in
non-consumable wick areas 150. An example of such capillary action
is described in U.S. patent application Ser. No. 10/938,453, filed
Sep. 10, 2004, and incorporated herein by reference in its
entirety.
[0028] As seen in detail in FIG. 3, the fuel element 110 includes a
body 152 of fuel material and has an upper surface 154 and a lower
surface 156. The fuel element 110 in one embodiment is a wax puck
and in other embodiments may have other shapes and include other
meltable or flowable fuel materials, such as paraffin or animal
fat, having a solid or semi-solid state or otherwise maintainable
in a fixed form at room temperature. The lower surface 156 of the
fuel element 110 defines a cavity 158 having an upper cavity wall
160 shaped to conform closely to the base portion 116 of the wick
holder 106. The slot 122 extends from the upper surface 154 to the
cavity wall 160 and has a width w.sub.1 at the upper surface that
is smaller than a width w.sub.2 at the cavity wall. The width
w.sub.1 is adapted to prevent melted wax from the fuel element 110
from falling or trickling down the slot 122 without engaging the
wick 108, or put another way, the width w.sub.1 is narrow enough to
ensure that melted fuel material from near the upper portion of the
slot 122 will engage the wick 108 as it falls or trickles down the
slot. In one embodiment, w.sub.1 is not more than approximately
0.02'' (0.5 mm) larger than a diameter of the wick at an upper end
of the slot 122. In another embodiment, w.sub.1 is approximately
the same as a diameter of the wick 108. In yet another embodiment,
the width w.sub.1 is less than a width of the wick 108 so that an
interference fit exists between the wick and the body 152 at the
upper end of the slot 122. In a further embodiment, the width
w.sub.1 is less than or equal to approximately 0.12'' (3 mm), and
the wick 108 has a diameter of approximately 0.1'' (2.5 mm). In yet
a further embodiment (not shown), the slot 122 may have a width
that is initially more than 0.02'' (0.5 mm) larger than a diameter
of the wick 108 to allow for easy insertion of the wick 108 and
wick holder 106 into the slot 122, and the slot is filled
subsequently with additional fuel material in a second
manufacturing step so that the width w.sub.1 is less than 0.02''
(0.5 mm) larger than the diameter of the wick.
[0029] As shown in FIG. 4, the support base 102 carries the melting
plate 104 within an upper chamber 162, which is generally
bowl-shaped. The melting plate 104 in one embodiment is secured to
a sidewall 164 of the upper chamber 162 with adhesive 166 thereby
providing an empty air space 168 between the melting plate and an
intermediate wall 170 of the support base 102. The air space 168
provides additional insulation between the melting plate and the
support base 102 to reduce heat loss through the melting plate to
the support base. In another embodiment (not shown) the melting
plate 104 is adjacent to the intermediate wall 170 with adhesive
166 placed therebetween such that no air space 168 is disposed
between melting plate and the intermediate wall. Of course, other
arrangements and support configurations for the melting plate 104
are also suitable for supporting the melting plate 104.
[0030] In one embodiment of the fuel element 110, the slot 122 has
a length l.sub.1 in the upper surface 154 that is longer than a
length l.sub.2 in the lower surface 156. The length l.sub.1 is
shorter than a largest width w.sub.f of the fins 120 and the length
l.sub.2 is longer than the largest width w.sub.f of the heat fins.
Such a configuration of the slot lengths l.sub.1 and length l.sub.2
in relation to w.sub.f, in addition to the slot widths w.sub.1 and
w.sub.2 as described herein above, facilitates inserting the wick
holder 106 fully into the slot from the lower surface 156. Such
configuration of the slot 122 and cavity 158 also prevents the slot
from fully receiving the wick holder if the fins 120 are inserted
into the slot through the upper surface 154 rather than through the
lower surface 156, thereby preventing or discouraging improper
assembly of the fuel element 110 and the wick holder 106.
[0031] As illustrated in FIG. 5, a portion of the melting plate
104, capillary pedestal 112, wick holder 106, fuel element 110, and
wick 108 are shown assembled and ready for use or initial ignition
by a user. In one embodiment, the capillary pedestal 112 includes
an inclined sidewall 172 having an annular groove 174 extending
therearound in a medial position between a floor 176 of the melting
plate 104 and a top wall 178 of the capillary pedestal. A magnet
180 is secured to an underside of the top wall 166 with adhesive
182. In another embodiment, the magnet 180 may be disposed on an
upper side of the top wall 178 or at another location sufficient to
attract the wick holder 106. The spacers 128 are adapted to seat in
the annular groove 174 to provide a capillary space 184 between the
base skirt 126 and the inclined sidewall 172 sized to facilitate
capillary movement of melted or liquid fuel material toward the
wick 108. The spacers 128 also help retain the wick holder 106 on
the capillary pedestal 112 by seating in the annular groove 174. In
addition, the steel rivet 132 in the wick holder 106 is attracted
to the magnet 186 when placed over the capillary pedestal 112 and
thereby prevents the wick holder from accidentally falling or
slipping off of the capillary pedestal. When placed on an underside
of the end plate 124, the steel rivets 132 also act as spacers to
help maintain the capillary space 184. In another embodiment,
magnets 186 may be secured to the end plate 124 by any convenient
means, such as with an adhesive or by a rivet, in order to maintain
the wick clip 106 in position on the capillary pedestal 112. The
cavity wall 160 of the fuel element 110 is shaped to closely fit
around the base skirt 126 and barrel 118 of the wick holder 106 and
rest on the floor 176 of the melting plate in order to minimize
open space 188 between the fuel element and the wick 108, the wick
holder 106, and the melting plate floor 176. Minimizing the open
space 188 increases the likelihood of having melted fuel material
being fed directly to the wick 108 rather than falling downwardly
to the floor 176 or accumulating in the open space and thereby
potentially starving the wick of fuel material while burning.
However, as melted liquid fuel material accumulates about the base
of the capillary pedestal, whether due to melting from the melting
plate 104 or from direct melting by a flame on the wick 108, the
liquid fuel material is drawn upwardly along the capillary space
184 by capillary action toward the non-consumable wick areas 150
while the candle is burning. The wick 108 in one embodiment extends
through the open end 134 of the barrel 118 to touch or nearly touch
the top wall 178 of the capillary pedestal 112 so that liquid fuel
material drawn up the capillary space 184 will engage the wick 108
and be drawn upwardly therein for eventual burning by a flame
burning atop the wick. The wick barrel 118 has an inside diameter
sufficient to receive the wick 108. The inside diameter of the
barrel 118 may be larger, smaller, or the same as the diameter of
the wick and may be uniform or have different diameters along a
length thereof. In one embodiment, the inside diameter of the
barrel 118 is larger than the diameter of the wick 108 so that the
wick may be easily inserted into the barrel. In another embodiment,
the inside diameter of the barrel 118 is uniformly approximately
0.012'' (0.3 mm) larger than the diameter of the wick 108. In yet
other embodiments, the inside diameter of the barrel 118 is the
same size as or smaller than the wick 108. Melted fuel material can
seep into the capillary space 184 through the weep holes 130 and
thereby prime or facilitate capillary action upward through the
capillary space 184. Liquid fuel material may also be drawn
upwardly in the capillary space 138 between opposing sides 140, 142
of the fins 120 and drawn to the non-combustible wick areas 150
where the fuel material may be vaporized and ignited by a flame on
the wick 108.
[0032] Turning now to FIG. 6, another wick holder 200 and melting
plate 202 are shown that are similar to the wick holder 106 and
melting plate 104 shown in FIGS. 1-5, except that a capillary
pedestal 204 includes a smooth inclined sidewall 206 without the
annular groove 174, and the wick holder 200 does not include the
spacers 128 in the base skirt 126. A capillary space (not shown),
similar to 184, is maintained between the base skirt 126 and the
sidewall 206 by steel rivets 132 protruding below an end wall, such
as 124, of a base portion 116 of the wick holder 200. In this
embodiment, the wick holder 200 is maintained on the capillary
pedestal 204 substantially by the attraction between the steel
rivets 132 and magnet 180 (not shown in FIG. 6) in the capillary
pedestal and any weight of the fuel element 110.
[0033] Turning to FIGS. 7 and 8, a wick holder 300 of another
embodiment for use in a candle assembly, such as 100, is similar to
the wick holder 106 (or 200) except that the wick holder 300 also
includes a medial portion of the barrel 118 having a
cross-sectional area that is less than a cross-sectional area of
any other portion of the wick barrel. An indentation 302 in a
sidewall 304 of the barrel 118 defines a constricted portion 306 of
the barrel located or disposed intermediate opposite ends 308 and
310 of the barrel and having a cross-sectional area less than any
other portion of the barrel. The wick 108 extends through the
barrel 118 such that a portion or end of the wick adapted to absorb
melted or fluid fuel material extends downwardly through the end
310 and another portion or end of the wick adapted for ignition
extends upwardly through end 308. The constricted portion 306
reduces an effective wick cross-sectional area, and thereby may
reduce or restrict a capillary fluid flow capacity of the wick
between the first open end and the second open end. The restricted
flow capacity, and subsequently reduced volume flow rate, of fluid
fuel material up the wick from end 310 toward a flame region above
end 308, in turn may reduce the fuel material burn rate and extend
the life of the fuel element 110. Because the constricted portion
306 having a larger cross-sectional area allows a faster volume
flow rate, or increased capillary fluid flow capacity, than a
constricted portion having a smaller cross-sectional area, the
capillary fluid flow capacity of the wick may be substantially
reduced by reducing the cross-sectional area of the constricted
portion. Such a constriction on the flow rate of fuel material
upwardly along the wick 108 past the constricted portion 306 is
enhanced when the sidewall 304 is substantially liquid impervious
(e.g., does not allow fuel material to pass therethrough to the
wick 108) which thereby restricts the flow of fuel material into
the wick to coming only through the end 310 located in the end
plate 124 or above the end 308 of the barrel 118. The indentation
302 may also help maintain the wick 108 in a predetermined position
within the barrel 118 such that, for example, an end portion of the
wick extends through or to the end 310 in order to prevent the wick
from being pulled out of the barrel and thus potentially losing
contact with the flow of fuel material toward the wick through the
capillary space 184 and weep holes 130.
[0034] Other variations and embodiments of the candle assembly and
wick holder 300 described in detail herein are also specifically
contemplated. For example, in one embodiment, the barrel 118 may
take the form of a sleeve having a cylindrical shape or a tubular
shape having other cross-sectional areas and shapes. In another
embodiment, the constricted portion 306 in the barrel 118 is formed
by an inner annular ridge (not shown), which may be formed by
indenting or crimping the sidewall 304 entirely around the wick
barrel 118 or by an inner annular shoulder disposed on an inner
surface of the sidewall 304. The constricted portion 306 in another
embodiment may be formed by a single indentation 302 or by a
plurality of indentations, which may be either in opposing
relationship or offset from each other. In another embodiment (not
shown) the barrel 118 may have form of a wick casing that is not
generally tubular, but rather includes a longitudinally curved
sidewall that encases a portion of the wick 108 and has first and
second openings in the sidewall through which the wick extends.
[0035] In another aspect of the present invention, which is shown
in FIG. 8 but which is also applicable to any combination of any of
the capillary pedestals and any of the capillary pedestals
described herein, the capillary space 184 defines a volume, or
capillary well 350, between the base portion 116 of the wick holder
300 and the capillary pedestal 204 that has a dimension preselected
to promote a successful sustained relight of the wick 108 after a
pool 352 (shown in dashed lines) of wax or other meltable fuel has
been formed in melting plate 202 around the peripheral skirt 126
and capillary pedestal and then allowed to solidify. During a
sustained burn, liquefied wax from the pool 352 is drawn into the
capillary well 350 and up to the wick 108 by capillary action to
feed a flame 354 at wick 108. If the flame 354 is extinguished
prior to consuming the entire fuel element 110, the pool 352 of wax
solidifies and extends across the bottom of the melting plate 202,
through the capillary well 350, and into the wick 108. In one
embodiment, when the wick 108 is re-lit after the pool 352 of wax
has solidified, the capillary space 184 is dimensioned such that a
supply of liquefied wax is quickly formed and available in the
capillary well 350 to feed the flame 354 via the wick 108 until the
wax surrounding the peripheral skirt 126 has melted sufficiently to
provide a supply of liquefied fuel to replace the wax in the
capillary well. For example, if the capillary space 184 is
dimensioned too small, there may not be enough wax in the capillary
well 350 to sustain the flame 354 on the wick 108 during a
sustained relight before the wax pool 352 surrounding the
peripheral skirt 126 has melted enough to provide additional
liquefied fuel to the wick 108. Also for example, if the capillary
space 184 is too large, heat transfer through the solidified wax in
the capillary well 350 may be too slow to melt enough of the wax
therein to provide liquefied fuel to the wick 108 before wax in the
wick is burned. Under either circumstance, the flame 354 may run
out of fuel and extinguish prior to melting a sufficient amount of
wax in the pool 352 to begin or sustain substantially continuous
capillary movement of the melted wax from outside of the capillary
space 184, into the capillary well 350, and up the wick 108 to feed
the flame 354. Therefore, to assist in a successful sustained
relight of the wick 108 in one embodiment, the capillary well 350
has a volume not less than a volume sufficient to provide melted
fuel to the relit wick 108 until a sufficient amount of liquefied
fuel is formed from the pool 352 of solidified wax adjacent to or
surrounding the peripheral skirt 126 to continuously feed the flame
354 by capillary action through the capillary space 184, and in
another embodiment, the volume of the capillary well 350 is not
more than a volume able to allow heat from the flame 354 to melt
the solidified fuel disposed in the capillary space 184
sufficiently rapidly to feed the flame 354 after solidified fuel
carried in the wick is burned. In a further embodiment, a
successful relight can be achieved if the volume of the capillary
well 350 is proportional to a thermal mass of an entire candle
assembly, such as 100, in order to provide a sufficient source of
melted fuel to the wick until the pool 352 of solidified wax has
melted sufficiently to provide an adequate flow of fuel to the wick
108 to maintain a sustained burn of the flame 354. The thermal mass
of the candle assembly 100 is a measure of the amount of energy
needed to change the temperature of the entire melting plate candle
by a measured amount and is equal to the sum of the products of the
mass of each portion of the candle assembly multiplied by the
specific heat of that portion. According to one aspect, the volume
of the capillary well 350 is between about 0.00006 cubic inches per
calorie per degree centigrade (hereinafter, in.sup.3/cal/.degree.
C.) (1 mm.sup.3/cal/.degree. C.) and about 0.0006
in.sup.3/cal/.degree. C. (10 mm.sup.3/cal/.degree. C.), or between
about 0.0001 in.sup.3/cal/.degree. C. (2 mm.sup.3/cal/.degree. C.)
and about 0.0004 in.sup.3/cal/.degree. C. (6 mm.sup.3/cal/.degree.
C.), or between about 0.00018 in.sup.3/cal/.degree. C. (3
mm.sup.3/cal/.degree. C.) and about 0.00024 in.sup.3/cal/.degree.
C. (4 mm.sup.3/cal/.degree. C.). Accordingly, in one embodiment,
the thermal mass of the candle assembly is between about 135
cal/.degree. C. and 10 cal/.degree. C., or between about 75
cal/.degree. C. and 40 cal/.degree. C., or between about 61
cal/.degree. C. and about 50 cal/.degree. C., and the volume of the
capillary well 350 is between about 0.006 in.sup.3 (100 mm.sup.3)
and about 0.03 in.sup.3 (500 mm.sup.3), or between about 0.009
in.sup.3 (150 mm.sup.3) and 0.018 in.sup.3 (300 mm.sup.3), or about
0.012 in.sup.3 (200 mm.sup.3).
[0036] For example, the thermal mass of an embodiment of a candle
assembly, such as 100, includes the support base 102, the melting
plate 202, and the wick holder 300 having a combined thermal mass
of about 50 cal/.degree. C. and the fuel element 110 of
approximately 0.53 oz. (15 g) of wax having a thermal mass of about
10.5 cal/.degree. C. before being burned. The capillary pedestal
204 has a generally frustoconical shape with a height h1 between
about 0.39'' (10 mm) and 0.04'' (1 mm), or about 0.2'' (5 mm), a
bottom radius .PHI.1 between about 1.18'' (30 mm) and 0.39'' (10
mm), or about 0.83'' (21 mm), and a top radius .PHI.2 between about
0.04'' (1 mm) and 0.79'' (20 mm), or about 0.43'' (11 mm). The base
116 has a frustoconical shape generally complementary to the
capillary pedestal with the peripheral skirt 126 having an upper
diameter .PHI.3 of between about 0.08'' (2 mm) and about 0.83'' (21
mm), or between about 0.43'' (11 mm) and about 0.55'' (14 mm), or
about 0.51'' (13 mm); a bottom diameter .PHI.4 between about 1.22''
(31 mm) and about 0.43'' (11 mm), or about 0.79'' (20 mm) and about
0.91'' (23 mm), or about 0.87'' (22 mm); a height h2 between about
0.43'' (11 mm) and 0.08'' (2 mm), or between about 0.28'' (7 mm)
and about 0.16'' (4 mm), or about 0.2'' (5 mm); and a height h3 of
the rivets 132 from the end plate 124 of between about 0.004'' (0.1
mm) and 0.04'' (1 mm), or between about 0.03'' (0.8 mm) and about
0.02'' (0.5 mm), or about 0.02'' (0.6 mm). In another embodiment,
the capillary pedestal 204 has a height h1 about 0.18'' (4.7 mm), a
bottom radius .PHI.1 about 0.81'' (20.5 mm), a top radius .PHI.2
about 0.44'' (11.1 mm), and the base 126 has a skirt 126 having an
upper diameter .PHI.3 about 0.5'' (12.6 mm), a bottom diameter
.PHI.4 about 0.85'' (21.6 mm), and a height h2 about 0.2'' (5.05
mm). When the base 116 is placed on top of the capillary pedestal
204, the end plate 124 is a perpendicular distance of about 0.03''
(0.65 mm) from a top wall 178 of the capillary pedestal, and the
peripheral skirt 126 is perpendicular distance of about 0.02''
(0.38 mm) from the sidewall 206, which defines a capillary well 350
having a volume of approximately 0.012 in.sup.3 (200 mm.sup.3).
[0037] Turning now to FIG. 9, a candleholder 400 for a melting
plate candle assembly according to another aspect of the invention
is shown including a holder or base 402 and a generally concave
melting plate 404 carried within a recessed portion 406 of the
base. A solid fuel element and wick holder similar to those already
described herein that rest on the melting plate are not shown for
purposes of clarity. The melting plate 404 has high thermal
conductivity and is similar to other melting plates described
previously herein, including a capillary pedestal 408 protruding
upwardly therefrom at a centrally disposed wick location. The base
402 includes a wall 410 extending around and angularly disposed
outwardly at a zenith angle .theta. from the melting plate 404 and
having an uppermost or top edge 412 disposed above the melting
plate. In one aspect, the base 402 and the melting plate 404 have a
geometry that is adapted to increase or promote substantially
laminar air flow (when surrounded by a calm atmospheric
environment) over a pool of molten or liquefied fuel when a flame
is disposed in close proximity above the pool during a burn, such
as, for example, when a flame is present on a wick such as the wick
108. Such laminar air flow controls the overall temperature of the
pool by reducing eddy currents over the pool and/or reducing or
minimizing localized hot spots in the pool, which slows
volatilization of active volatile ingredients in the fuel, such as
a fragrance or insecticide, and thereby extends an effective
fragrancing period of the fuel until the fuel is completely burned.
When all the fuel is liquefied in the pool during the burn of the
melting plate candle, air may be drawn in substantially laminar
flow over the top edge 412 of the wall 410 into the recessed
portion 406, over the melting plate 404 and a pool of liquefied
fuel, such as melted wax, by a heat chimney, or upward air
currents, caused by a flame on a wick (not shown) disposed over the
capillary pedestal 408. The air currents ascending up the heat
chimney also distribute the volatilized active ingredient into the
surrounding environment.
[0038] In one embodiment, the base 402 and the melting plate 404
have a geometry to increase or promote substantially laminar air
flow described by the following equations: 20,000
mm.sup.2+(Pmin.sup.2-Pmax.sup.2).gtoreq.SA.gtoreq.2,500
mm.sup.2+(Pmax.sup.2-Pmin.sup.2); 1. Dpmax.ltoreq.(SA/1,000
mm)+{[(Hmin-Pmin)/2]sin .theta.}; 2. Pmin.gtoreq.6(Dp)(cos
.theta.); and/or 3. Hmin.apprxeq.Pmin+2[R+(Dp-R)tan .theta.]; 4 in
which:
[0039] Pmax is a maximum width across the melting plate 404 in
mm;
[0040] Pmin is a minimum width across the melting plate 404 in
mm;
[0041] SA is a projected surface area, or surface area of a
two-dimensional projection of an outline, of the melting plate 404
in square millimeters;
[0042] Hmin is a minimum width of the base 402 at the top edge 412
in mm;
[0043] Dp is a depth of the melting plate 404 from the top edge 412
of the base 402 in mm;
[0044] Dpmax is a maximum value for Dp in mm;
[0045] R is an outside radius of the upper edge of the base 402 in
mm; and
[0046] .theta. is the zenith angle of the wall 410 in degrees.
[0047] Equation 1 quantifies an approximate relationship of the
projected surface area of the melting plate and the width across
the melting plate, within upper and lower constant boundaries, to
promote the laminar air flow. Equation 2 quantifies an approximate
relationship of the projected surface area of the melting plate 404
and the depth of the melting plate 404 from the top edge 412 of the
base 402 to promote the laminar air flow. Equation 3 quantifies an
approximate relationship of the minimum melting plate across the
melting plate and the depth of the melting plate 404 from the top
edge 412 of the base 402 and the zenith angle of the base wall 410
to promote the laminar air flow. Equation 4 quantifies an
approximate minimum width of the base 402 at the top edge 412 as a
function of the geometries of the melting plate 404 and the base to
promote the laminar airflow. Although the equations 1-4 above have
been described in relation to a generally rectangular base and
holder, the relationships may also be used with other candleholder
shapes, such as oval and circular, in order to approach an
optimized candleholder geometry. For example, in one embodiment
comprising a circular base and melting plate, such as the base 102
and melting plate 104 shown in FIG. 7, Hmin is approximately 3.94''
(100 mm), Pmax and Pmin are both equal to approximately 3.15'' (80
mm), Dp is approximately 0.4'' (10 mm), R is approximately 0.08''
(2 mm), and .theta. is approximately 45.degree..
[0048] FIGS. 10 and 11 show a candleholder 500, which is generally
similar to the candleholder 400 except that the candleholder 500
includes an alignment mechanism for ensuring proper alignment of a
melting plate 504 with a base portion 502. The candleholder 500
includes the base portion 502 and the melting plate 504 for
supporting a votive candle such as the combination of the fuel
element 110, wick holder 106, and wick 108. The base portion 502 is
made of a non-flammable material with low heat transmissivity, such
as glass or ceramic, and the melting plate is made of a
non-flammable material with high heat transmissivity, such as
aluminum or other metal, although other materials may also be used.
The base portion includes a recess 506 in a top end thereof defined
by four upstanding sidewalls 508 and a medial wall 510 spanning the
sidewalls spaced below an upper rim 512 of the sidewalls. A bottom
end of the base 502 is hollow under the medial wall 510. It is to
be understood that the specific shape and configuration of the
sidewalls 508 and the bottom end of the base 512 may take almost
any shape and form and are not limited to the specific shapes
described herein. The melting plate 504 is dish- or bowl-shaped
that concaves upwardly with a bottom surface shaped generally
complementary to the recess 506 so as to be received in the recess
in an operative position. The melting plate 504 has a generally
square footprint with a relatively flat bottom wall 514 surrounded
by a raised or upwardly curved peripheral portion 516 adjacent an
outer peripheral edge 518 and a capillary lobe 520 protruding
upwardly from a central portion of the bottom wall 518 for
receiving the votive candle (not shown) disposed centrally thereon
in a similar manner as described previously herein. An alignment
mechanism for ensuring proper alignment of the melting plate 504
within the recess 506 of the base 502 includes a shoulder, such as
horizontal step 522, that projects inwardly from an interior side
524 of the sidewalls and extends entirely around the recess 506,
and a complementary ledge, such as horizontal ledge 526, that rests
on the shoulder. The ledge 526 extends around the melting plate and
is vertically disposed between the peripheral edge 518 and the
bottom wall 514 of the melting plate 504 and rests on the
horizontal step 522 with the peripheral edge pressed against the
inner surface 524 of the sidewalls 508 around the entire recess
506. The entire melting plate, including the capillary lobe 520 and
the peripheral edge 518, is disposed below the upper rim 512. The
melting plate 504 is spaced above the medial wall 510 in the recess
506 with the raised peripheral edge portions 516 pressed against
the inner surface 524 of the sidewalls 508 and the capillary lobe
520 projecting upwardly. The melting plate 504 is secured to the
base 502 with a bead of adhesive, such as the adhesive 166 (not
shown), disposed between the ledge 526 and the shoulder 522. The
adhesive may also provide a seal between the peripheral edge 518 of
the melting plate 504 and the interior surface 524 of the sidewalls
508 to prevent melted wax or other liquids from seeping under the
melting plate. Other substantially complementary alignment
configurations may also or alternatively be used for alignment
mechanisms within the scope of the present invention. For example,
the base shoulder may only include one or more discrete spaced
apart step portions, and the melting plate ledge may be continuous
or match the discrete ledge portions to provide only one possible
correct mating fit between the melting plate and the base. In one
embodiment, the alignment feature helps ensure that the melting
plate 504 is located in a predetermined relation to the base 502 so
that the bottom wall 514 of the melting plate is substantially
level and spaced above the medial wall 510 to ensure that melted
wax pools around the capillary lobe when the candleholder 450 is
placed on a level support surface and minimize heat loss from the
melted wax into the base. Of course, the alignment feature may be
readily modified to cause a melting plate to rest within the recess
in other alignment configurations, such as with the bottom wall 514
contacting the medial wall 510 and/or with the bottom wall 514
disposed at a non-level angle. In yet another embodiment (not
shown), the alignment feature may include one or more raised
protrusions disposed anywhere within the recess 506 that engage
complementary ledges or cavities in the melting plate 504 so as to
provide a predetermined alignment between the base 502 and the
melting plate. Further, the protrusions may be integral with the
base 502, or the protrusions may be formed by a separate object,
such as a wire or button (not shown), placed in the cavity. Another
alignment mechanism (not shown) within the scope of the present
invention may include only one of the ledge and the shoulder
without an opposing complementary shoulder or ledge, respectively,
wherein the ledge or shoulder urges the melting plate into a
predetermined alignment or orientation to the base.
[0049] A retainer feature for a magnet 528, such as a circular ring
530 projecting upwardly from a central area of the medial wall 510,
is disposed below a cavity 532 in the bottom surface of the melting
plate 504 underneath the capillary lobe 520. The ring 530 extends
upwardly into the cavity 532 without engaging the bottom surface of
the melting plate. The ring 530 acts as a retainer for the magnet
528, which is glued to the melting plate 504 inside the cavity 532,
in case the magnet should become unglued from the melting plate. In
one embodiment, the ring 530 does not engage, or is spaced from,
the bottom surface of the melting plate in order to minimize loss
of heat from the melted wax to the base. The retainer is not
limited to the specific circular ring form shown in the drawings,
but may take other shapes that would help retain the magnet 528 in
a predetermined position underneath the capillary lobe 520. For
example, the retainer may be a plurality of spaced projections that
partially surround the magnet 528, and the magnet may be shaped so
as to interfit with the spaced projections in a predetermined
orientation. In another example, the retainer may engage the bottom
surface of the cavity 532 to help align the melting plate 504
within the recess 506 in addition to the shoulder 522 and ledge
526. In addition, the alignment feature and retainer feature may be
readily adapted to work with any other combination of base and
melting plate disclosed herein, such as the base 102 and circular
melting plate 104, and are not limited to the particular base and
melting plate of this embodiment.
[0050] The invention having been described in an illustrative
manner, it is understood that the terminology used is intended to
be in the nature of description rather than of limitation. The
various components of the various melting plate candle assemblies
described herein may be packaged as an assembled unit, as an
unassembled kit including all or a portion of the components, as
individual components, and in any combination thereof. Different
and various combinations of the above-mentioned components of the
various melting plate candle assemblies can also be used in the
apparatuses, methods, kits, and combinations herein described.
Other variations, modifications, and equivalents of the present
invention possible in light of the above teachings are specifically
included within the scope of the impending claims.
INDUSTRIAL APPLICABILITY
[0051] The candleholder of the present invention may be used to
support a votive-type candle, such as the fuel element described
herein, to provide rapid melting of the candle wax fuel charge and
rapid dispersion of any volatile active contained in the fuel
charge. Further, the alignment feature is useful for providing
positive placement of a non-circular melting plate in a
pre-determined location within a complementary recess, such as the
generally square melting plate and recess shown in FIGS. 10 and 11.
In addition, the retainer feature in one embodiment may help
maintain a magnet in a predetermined location under the capillary
lobe.
[0052] Numerous modifications to the present invention will be
apparent to those skilled in the art in view of the foregoing
description. Accordingly, this description is illustrative only and
is presented for the purpose of enabling those skilled in the art
to make and use the invention and to teach the best mode of
carrying out the same. The exclusive rights to all modifications
within the scope of the impending claims are reserved.
* * * * *