US20060172241A1 - Decorative candle having an embedded design - Google Patents

Decorative candle having an embedded design Download PDF

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Publication number
US20060172241A1
US20060172241A1 US11/047,188 US4718805A US2006172241A1 US 20060172241 A1 US20060172241 A1 US 20060172241A1 US 4718805 A US4718805 A US 4718805A US 2006172241 A1 US2006172241 A1 US 2006172241A1
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candle
decorative
wick
design structure
decorative design
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US11/047,188
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Rodney Hohertz
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Individual
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Individual
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    • CCHEMISTRY; METALLURGY
    • C11ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
    • C11CFATTY ACIDS FROM FATS, OILS OR WAXES; CANDLES; FATS, OILS OR FATTY ACIDS BY CHEMICAL MODIFICATION OF FATS, OILS, OR FATTY ACIDS OBTAINED THEREFROM
    • C11C5/00Candles
    • C11C5/008Candles characterised by their form; Composite candles, e.g. candles containing zones of different composition, inclusions, or the like
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V35/00Candle holders

Definitions

  • the present invention relates generally to candles, and more particularly to translucent candles having embedded ornamental features or designs.
  • candles are frequently placed in containers having designs that are made into the container, or applied to the container, so that candlelight can be seen flickering through openings or transparent portions of the design.
  • the candlelight may cast a pleasing, decorative shadow on a nearby wall or other surface.
  • the decorative design on the container will remain rigid and supported while the flame descends along the wick, moving into the decorative container as the candle burns away. Shadows of candlelight are more beautiful and produced at more angles from the flame when the flame shines from within the decorative design, such as when the wick burns lower within a decorative container.
  • Candles have also been decorated by adding decorative designs to the outside of the body of the candle. Many times the design on the outside of a candle is made of candle wax, which means that the design may be consumed as the candle burns. Thus, a candle with a design on the outer surface that is consumed with the candle will not typically cast decorative shadows on nearby surfaces.
  • a candle's beauty may also be enhanced by using a translucent or transparent wax, or similarly, a more recently developed transparent gel for candles, such as the polymer gel disclosed in U.S. Pat. No. 6,066,329 issued to Morrison, et al.
  • a translucent or transparent wax or similarly, a more recently developed transparent gel for candles, such as the polymer gel disclosed in U.S. Pat. No. 6,066,329 issued to Morrison, et al.
  • a disadvantage of suspending design elements in wax surrounding the candle core is that the wax that supports the decorative elements may melt down as the candle is consumed. If this happens, the flame will cast light over the decorative elements rather than shining through the decorative elements, which does not create the most interesting shadows.
  • candles made with decorative elements in an outer layer usually require more time, effort, and expense to manufacture because the candle body is formed using a more complex process. For example, in one process molten transparent wax with decorative elements is poured into a mold to surround a previously solidified center portion of the candle. In another process, a transparent shell with decorative elements is rolled and applied around a previously solidified candle body.
  • the present invention provides a decorative candle having a wick extending along a wick axis for a distance equal to a wick length.
  • a decorative design structure is spaced radially apart from, and extending along, the wick axis for a distance greater than half the wick length, wherein the decorative design structure is self-supporting on a bottom surface. Portions of the decorative design structure are located over an angle of greater than 180 degrees with respect to the wick axis.
  • a translucent candle body material has a geometric shape that extends from the candle base along a portion of the wick axis, and surrounds a portion of the wick and the decorative design structure. The geometric shape of the candle body extends radially from the wick axis to an outer candle surface that is radially beyond the decorative design structure.
  • the design may be cut from flat metal stock and formed into a structure.
  • FIG. 1 is an elevation view of a decorative candle in accordance with the present invention, wherein the candle is in a glass container with a glass lid;
  • FIG. 2 is an elevation view of the decorative candle of FIG. 1 in a glass continuer without the glass lid;
  • FIG. 3 is a plan view of the decorative candle in accordance with the present invention.
  • FIG. 4 is a top perspective view of the decorative candle in accordance with the present invention.
  • FIGS. 5-7 are elevation views of various designs cut for a decorative design structure used in the decorative candle of the present invention.
  • FIG. 8 is a top perspective view of a self-supporting decorative design structure in accordance with the present invention.
  • the container 22 is transparent and is typically made of glass.
  • the container 22 has a bottom wall or base 32 and one or more side walls 25 , which define a cavity 27 .
  • the container side walls 25 and cavity 27 can form a cylinder as shown in the figures, or can be square, rectangular or other shape.
  • Decorative candle 20 also includes candle base 32 , which in a preferred embodiment is implemented by the circular bottom of candle container 22 , which is a glass jar.
  • Candle base 32 may be more broadly defined as the surface upon which candle body material 26 is supported when the candle is placed and oriented for burning. It should be noted that in some embodiments of decorative candle 20 additional objects or materials may be located at the bottom of the candle. Examples of these materials include sand, marbles, an additional layer of wax or gel, or the like.
  • candle base 32 includes such material, which may form a surface referred to as a “bottom surface,” which is defined as an upper surface of such initially added material or objects, which surface is suitable for supporting candle body material 26 or other decorative structures embedded within candle body material 26 .
  • Decorative design structure 34 is spaced radially apart from, and extends along a portion of, wick axis 30 for a distance 46 that is at least half the wick length 48 . This enables the decorative design to be seen from outside the candle and enhances the aesthetic appeal.
  • decorative design structure 34 is self-supporting, it will not bend, tip, or otherwise move with respect to wick axis 30 as wick 28 burns down into candle container 22 .
  • a self-supporting design structure 34 will remain in place relative to wick axis 30 so that decorative design structure 34 casts beautiful shadows of candlelight as the flame burns down through a center opening of the structure.
  • the self-supporting structure also maintains a safe distance between the candle flame and decorative design structure 34 so that the flame will not come in contact with anything except a localized melt pool of candle body material 26 .
  • decorative design structure 34 may also lower the cost of manufacturing decorative candle 20 because decorative design structure 34 does not need to be suspended, which requires additional skill and labor, when candle body material 26 is poured in to a mold or container 22 .
  • Decorative design structure 34 is capable of standing in place, either on candle base 32 or another bottom surface, without support while candle body material 26 is poured.
  • decorative design structure 34 is spaced radially apart from wick axis 30 .
  • the radial distance between wick axis 30 and decorative design structure 34 is shown at reference numeral 36 .
  • Distance 36 should be large enough so that a flame burning wick 28 will not overheat any portion of decorative design structure 32 .
  • distance 36 need not be constant when measured either at different angles around wick axis 30 or at different vertical positions along wick axis 30 .
  • decorative design structure 34 is cylindrical or tubular, and substantially surrounds wick axis 30 with distance 36 being substantially constant.
  • the vertical height 46 of decorative design structure 34 (See FIGS. 2 and 5 ) is preferably greater than half the length 48 of the wick 28 .
  • Decorative design structure 34 is preferably located at an angle 64 around wick axis 30 that extends at least 180 degrees or greater, as shown in FIG. 3 .
  • decorative design structure 34 is concentric with the jar, or candle container 22 . In this manner, decorative candle 20 is more aesthetically pleasing, and a person viewing the candle must look through candle body material 26 , including any tint or bubbles, in order to see decorative design structure 34 .
  • outer candle surface 38 is the surface of candle body material 26 that comes in contact with wall 44 of candle container 22 , which defines the geometric shape of decorative candle 20 . If decorative candle 20 is not in candle container 22 , outer candle surface 38 is the molded surface of candle body material 26 after it has been removed from the mold.
  • material used for decorative design structure 34 may be cast, molded, or otherwise formed from a liquefied material that is molded and allowed to cool or harden into the shape of a design.
  • material used for decorative design structure 34 may be cast, molded, or otherwise formed from a liquefied material that is molded and allowed to cool or harden into the shape of a design.
  • cutting flat stock, round stock material, or any other shaped tubular material may also be selectively cut to form a decorative pattern.
  • the design can be artistic shapes, silhouettes, etc.
  • the design shape can be solid material with an outline, like the letters of FIG. 5 and the stars of FIG. 7 .
  • the design shape can also be material with openings thereof, such as the space between the “E” and “X” in FIG. 5 and the shape of the state of Texas in FIG. 6 .
  • the designs can repeat as in FIGS. 6 and 7 or be non-repetitive.
  • the design shapes can include a cowboy on a horse, a fish catching a lure, birds in flight, etc.
  • the design can also incorporate business logos or trademarks.
  • Embedding the decorative design structure 34 into a candle adds an optical aspect not previously know in candles. This particularly true when the candle is provided in a container 22 and also where the design structure 34 is parallel to (or concentric with, in the case of, the cylindrical container) the container side walls or wall. By maintaining a constant gap between the design structure and the container side wall, the optical appearance is pleasing.
  • the embedded design allows an observer to view the refractive nature of the candle and its container.
  • the linking structure 58 is used as support structure. For example, if with the design of FIG. 7 , the center star is used by itself, without the two endmost stars, the bar 58 extends for about the same distance as shown in FIG. 7 . The bar 58 , when shaped into an arc as shown in FIG. 8 , provides support for the design.
  • the material may be formed into a self-supporting design structure 60 , which is shown in FIG. 8 standing upright on a flat surface.
  • the flat design is rolled into a cylindrical or semi-cylindrical shape, where the diameter is less than the inside diameter of the jar or candle container 22 .
  • the design can be bent or broken on a sheet metal break to form corners.
  • design structure 60 should contact a surface, such as candle base 32 , in at least three points.
  • Design structure 60 will contact candle base 32 at many points, all along edge 62 at the bottom of design 54 .
  • the center of gravity of an upright decorative design structure should be perpendicularly above the area on candle base 32 delineated by at least three of the points of contact on candle base 32 .
  • a decorative design structure 34 is located in the candle container, where it is free standing on the candle base 32 .
  • all radial distances from the wick axis to any portion of the decorative design structure should be maximized, which typically means the decorative design structure should be centered about the wick axis.
  • the distance or gap 42 between the decorative design structure 34 and the wall 44 of the candle container is approximately the same over the entire area of the decorative design structure. In order to present a clear view of the decorative design structure, this distance should be approximately 1 ⁇ 8 to 1 ⁇ 2 inch.
  • a candle wick 28 is suspended or located along a wick axis 30 in candle container (or mold) 22 .
  • Wick axis 30 is preferably a vertical straight line near the centroid of the shape of the container or some other vertical straight line that maximizes all the radial distances to the side walls of the container so that the candle flame will not burn too close to the container side wall.
  • the wick is suspended vertically into the container, typically by a rod resting across the top rim of the container.
  • decorative design structure 34 may located in candle container 22 after wick 28 .
  • translucent candle body material 26 is poured into the candle container or mold 22 , wherein the material nearly fills the container and preferably completely surrounds any inner and outer surfaces of the decorative design structure 34 .
  • Decorative design structure 34 is this embedded within the candle body material 26 .
  • the material also covers most of the wick 28 while the container is filled almost to the top rim of the candle container 22 . If the candle will have a lid, a distance is left between the candle body material and the rim of the candle container so that the lid 24 may be placed on the candle without contacting candle body material 26 .
  • decorative design structure 34 may include high temperature plastics, cast or sculpted ceramic, marble, plaster, or cementitious material. It is preferable that the material can withstand the heat from a candle flame and avoid producing an unpleasant burned odor.
  • the cutting pattern defines shapes that will be removed from the sheet of material. For example, to cut design 54 in FIG. 7 , five substantially “pie-shaped” pieces may be removed from a sheet of material in order to leave the star shape that is centered in the circle.
  • the design is bent into a self-supporting, three dimensional shape, where it is capable of standing vertically on the surface of a horizontal plane.
  • the design shape is curved or rolled to form a cylindrical or tubular shape that will fit within the cylindrical candle container with a clearance between the design structure 34 and the container walls 44 and with a clearance from wick axis 30 . If the container is rectangular or some other shape, the design may be bent to form corners.
  • Alternate methods for fabricating decorative design structure 34 include cutting the design from a wall of a tubular shape, or molding the decorative design structure from a non-flammable material.
  • a computer controlled laser beam may be used to cut metal from the side wall of round or tubular stock.
  • the tubular stock may have different cross sectional shapes, such as square tubular stock or triangular tubular stock.
  • decorative design structure 34 is preferably bent or rolled into a cylindrical shape for use in a cylindrical candle container, but the cross sectional shape of the design structure may be triangular, square, or have any number of sides.
  • the cross sectional shape of the decorative design structure 34 preferably matches or conforms to the cross sectional shape of the candle container 22 so that the distance 42 between the decorative design structure 34 and the container wall 44 is substantially the same, which produces a clear and uniform view of the design structure through the translucent candle body material 26 .
  • a decorative design structure 34 with a shape that does not conform to, or follow, the shape of container wall 44 , wherein distance or gap 42 varies somewhat over the surface of decorative design structure 34 .
  • a decorative design structure 34 having a star-shaped cross sectional area may be used in a cylindrical candle container 22 .
  • portions of decorative design structure 34 namely the star points, may follow the cross sectional shape of the cylindrical candle container 22 .
  • Other designs may include short or long segments that follow the contours of the container.
  • the decorative design structure should include some symmetry or design in the selection of a shape that has points or segments that conform to the container wall, and to the selection of a location in the container relative to the perimeter or cross sectional shape of the container.
  • the step of flowing the candle body material into the candle mold may include forming gas bubbles in the candle body material prior to the candle body material becoming set or gelled. Forming the gas bubbles may be accomplished by gently whipping molten candle body material to form small air bubbles in the material.
  • the gel may be gently whipped while the gel is heated to a temperature of between 185 to 203 degrees Fahrenheit. After introducing the bubbles, the gel should be cooled to below 131 Fahrenheit so that the bubbles will not rise and escape from the top to the gel.
  • a fragrance or a colorant may be added and mixed into the candle body material in order to enhance the aesthetic appeal of the candle.
  • colorant or fragrance should be mixed while the material is heated to a temperature of between 203 to 221 degrees Fahrenheit.
  • the decorative candle of the present invention has the advantages of having a candle lit design, like a perforated luminaria, wherein the design is surrounded by candle body material, such as transparent polymer gel, and the structure having the design is self-supporting so that its placement relative to the wick axis does not change as the candle wick burns down and consumes the candle body material. It is also important that the design is visible when the candle is not lit. When the decorative design structure is clearly visible within the candle body and with the candle container, the aesthetic appeal of the candle is enhanced at the point of sale display, where, for practical and safety reasons, many of the candles may not be displayed while they are burning. Candle purchasers will recognize that a beautiful unlit candle will only become more beautiful when it is lit.

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  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • General Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Wood Science & Technology (AREA)
  • Organic Chemistry (AREA)
  • Fats And Perfumes (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)

Abstract

A decorative candle includes a wick extending along a wick axis for a distance equal to a wick length. A decorative design structure is spaced radially apart from, and extending along, the wick axis for a distance greater than half the wick length, wherein the decorative design structure is self-supporting on a bottom surface. Portions of the decorative design structure are located over an angle of greater than 180 degrees with respect to the wick axis. A translucent candle body material has a geometric shape that extends from the candle base along a portion of the wick axis, and surrounds a portion of the wick and the decorative design structure. The geometric shape of the candle body extends radially from the wick axis to an outer candle surface that is radially beyond the decorative design structure. The design may be cut from flat metal stock and formed into a structure.

Description

    BACKGROUND OF THE INVENTION
  • 1. Field of the Invention
  • The present invention relates generally to candles, and more particularly to translucent candles having embedded ornamental features or designs.
  • 2. Description of the Prior Art
  • There are many ways for decorating and otherwise enhancing the beauty of a candle. For example, candles are frequently placed in containers having designs that are made into the container, or applied to the container, so that candlelight can be seen flickering through openings or transparent portions of the design. When the candle shines through the design, the candlelight may cast a pleasing, decorative shadow on a nearby wall or other surface. As the candle burns and is consumed, the decorative design on the container will remain rigid and supported while the flame descends along the wick, moving into the decorative container as the candle burns away. Shadows of candlelight are more beautiful and produced at more angles from the flame when the flame shines from within the decorative design, such as when the wick burns lower within a decorative container.
  • Candles have also been decorated by adding decorative designs to the outside of the body of the candle. Many times the design on the outside of a candle is made of candle wax, which means that the design may be consumed as the candle burns. Thus, a candle with a design on the outer surface that is consumed with the candle will not typically cast decorative shadows on nearby surfaces.
  • A candle's beauty may also be enhanced by using a translucent or transparent wax, or similarly, a more recently developed transparent gel for candles, such as the polymer gel disclosed in U.S. Pat. No. 6,066,329 issued to Morrison, et al. When a candle uses such translucent candle body materials, light from the candle flame may pass through most or all of the body of the candle.
  • It is also known in the prior art that decorative shapes and ornaments may be suspended in transparent wax or gel near the outer edges of a transparent candle so that the decorative elements are illuminated as the candle burns. This type of decorative candle is disclosed in U.S. Pat. No. 5,395,233 issued to Karp.
  • A disadvantage of suspending design elements in wax surrounding the candle core is that the wax that supports the decorative elements may melt down as the candle is consumed. If this happens, the flame will cast light over the decorative elements rather than shining through the decorative elements, which does not create the most interesting shadows. Additionally, candles made with decorative elements in an outer layer usually require more time, effort, and expense to manufacture because the candle body is formed using a more complex process. For example, in one process molten transparent wax with decorative elements is poured into a mold to surround a previously solidified center portion of the candle. In another process, a transparent shell with decorative elements is rolled and applied around a previously solidified candle body.
  • Therefore, it should be apparent that there is a need for an improved decorative candle and method for making a decorative candle wherein a decorative design is embedded in translucent candle body material, and the design remains in position as the candle burns and the flame moves through the decorative design, thereby enhancing aesthetic appeal and casting candlelight through the decorative design to create decorative silhouettes and shadows.
  • BRIEF SUMMARY OF THE INVENTION
  • The present invention provides a decorative candle having a wick extending along a wick axis for a distance equal to a wick length. A decorative design structure is spaced radially apart from, and extending along, the wick axis for a distance greater than half the wick length, wherein the decorative design structure is self-supporting on a bottom surface. Portions of the decorative design structure are located over an angle of greater than 180 degrees with respect to the wick axis. A translucent candle body material has a geometric shape that extends from the candle base along a portion of the wick axis, and surrounds a portion of the wick and the decorative design structure. The geometric shape of the candle body extends radially from the wick axis to an outer candle surface that is radially beyond the decorative design structure. The design may be cut from flat metal stock and formed into a structure.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which like numbers designate like parts, and in which:
  • FIG. 1 is an elevation view of a decorative candle in accordance with the present invention, wherein the candle is in a glass container with a glass lid;
  • FIG. 2 is an elevation view of the decorative candle of FIG. 1 in a glass continuer without the glass lid;
  • FIG. 3 is a plan view of the decorative candle in accordance with the present invention;
  • FIG. 4 is a top perspective view of the decorative candle in accordance with the present invention;
  • FIG. 4A is a more detailed view of a portion of the top perspective view of FIG. 4;
  • FIGS. 5-7 are elevation views of various designs cut for a decorative design structure used in the decorative candle of the present invention; and
  • FIG. 8 is a top perspective view of a self-supporting decorative design structure in accordance with the present invention.
  • DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • With reference now to the drawings, and in particular with reference to FIGS. 1 and 2, there is depicted decorative candle 20 in accordance with the method and apparatus of the present invention. As shown, decorative candle 20 includes candle container 22, which in the preferred embodiment shown is a glass jar having a glass lid 24. A portion of the candle container is filled with transparent candle body material 26. The candle 20 includes decorative design structure 34 embedded in the candle body material 26. Candle body material 26 is preferably transparent, but may be translucent, which means that it is almost transparent, allowing light to pass through diffusely. Candle body material 26 may also be tinted with an aesthetically pleasing colorant, and may include bubbles dispersed throughout the material, as shown in FIGS. 1 and 4A. The suspended gas or air bubbles may be introduced to further reflect or refract light from a candle flame. It is an important aspect of the present invention that candle body material 26 allow the transmission of light.
  • The container 22 is transparent and is typically made of glass. The container 22 has a bottom wall or base 32 and one or more side walls 25, which define a cavity 27. The container side walls 25 and cavity 27 can form a cylinder as shown in the figures, or can be square, rectangular or other shape.
  • While candle body material may be implemented with a translucent or transparent wax, a preferred embodiment of the invention uses a transparent gelling hydrocarbon, such as the gelling hydrocarbon sold under the trademark Versagel® C-Series, gelled mineral oil made by Penreco of Karns City, Pa., U.S.A. More detailed information about such transparent candle gels may be found in U.S. Pat. Nos. 5,578,089; 5,879,694 and 6,066,329.
  • As shown in FIGS. 1 and 2, wick 28 is located vertically near the center of candle container 22. As shown in FIG. 2, wick 28 has a wick length 48 and is extended along, and defines, wick axis 30. Note that wick 28, and hence wick axis 30, defines a line along which a candle flame will burn as the candle is consumed. In candles having more than one wick, wick axis 28 may be defined as a line that follows the geometric center of corresponding points along all wicks in the candle. For example, if there are three wicks, the wick axis would be the geometric center of the triangle formed by coplanar points in the three wicks. The wick can have a tab or disc (not shown), at the bottom end thereof.
  • Decorative candle 20 also includes candle base 32, which in a preferred embodiment is implemented by the circular bottom of candle container 22, which is a glass jar. Candle base 32 may be more broadly defined as the surface upon which candle body material 26 is supported when the candle is placed and oriented for burning. It should be noted that in some embodiments of decorative candle 20 additional objects or materials may be located at the bottom of the candle. Examples of these materials include sand, marbles, an additional layer of wax or gel, or the like. If items or material covers the bottom of candle container 22, such as a layer of objects or candle body material initially added to mold or container 22, candle base 32 includes such material, which may form a surface referred to as a “bottom surface,” which is defined as an upper surface of such initially added material or objects, which surface is suitable for supporting candle body material 26 or other decorative structures embedded within candle body material 26.
  • In some embodiments of the present invention, decorative candle 20 does not include candle container 22. Without the container, candle body material 26 must be stiff or rigid enough to maintain its form without relying upon the support of the base and walls of container 22. Note that container 22 may be used as a mold during fabrication of the candle, and then removed to produce a candle without a container. In candles without a container, candle base 32 may be defined as the surface upon which the candle sits when placed and oriented in a burning position. For example, candle base 32 may be the surface of the gel that was in contact with candle base 32 when candle body material 26 was poured into candle container 22.
  • Note that it may be advantageous to have candle base 32 made with a thick material in order to insulate or evenly disperse heat from a candle flame when wick 28 is very short, and the flame is close to candle base 32.
  • The decorative candle 20 includes decorative design structure 34. The purpose of decorative design structure 34 is to add an embedded design to filter candlelight and cast shadows when the candle is lit, and to provide a decorative design visible around the candle, which is visually enhanced and made more interesting by viewing the design through the candle body material and the candle container.
  • Decorative design structure 34 is spaced radially apart from, and extends along a portion of, wick axis 30 for a distance 46 that is at least half the wick length 48. This enables the decorative design to be seen from outside the candle and enhances the aesthetic appeal.
  • The decorative design structure 34 is self-supporting need not rely upon candle body material 26 for support. Decorative design structure 34 wraps around wick axis 30, so that portions of the decorative design structure are located over an angle 64 of equal to or greater than 180 degrees with respect to wick axis 30 (see FIG. 3). This wrap-around angle 64 may be measured by rotating a plane that contains wick axis 30 and determining the angle of an arc over which the plane continuously intersects portions of decorative design structure 34. The decorative design structure 34 can be partially cylindrical as shown in FIG. 3 or can have other shapes, such as a triangle, square etc.
  • Because decorative design structure 34 is self-supporting, it will not bend, tip, or otherwise move with respect to wick axis 30 as wick 28 burns down into candle container 22. A self-supporting design structure 34 will remain in place relative to wick axis 30 so that decorative design structure 34 casts beautiful shadows of candlelight as the flame burns down through a center opening of the structure. The self-supporting structure also maintains a safe distance between the candle flame and decorative design structure 34 so that the flame will not come in contact with anything except a localized melt pool of candle body material 26.
  • The self-supporting nature of decorative design structure 34 may also lower the cost of manufacturing decorative candle 20 because decorative design structure 34 does not need to be suspended, which requires additional skill and labor, when candle body material 26 is poured in to a mold or container 22. Decorative design structure 34 is capable of standing in place, either on candle base 32 or another bottom surface, without support while candle body material 26 is poured.
  • The views of decorative candle 20 in FIGS. 3 and 4 show that decorative design structure 34 is spaced radially apart from wick axis 30. In FIG. 3, the radial distance between wick axis 30 and decorative design structure 34 is shown at reference numeral 36. Distance 36 should be large enough so that a flame burning wick 28 will not overheat any portion of decorative design structure 32. Note that distance 36 need not be constant when measured either at different angles around wick axis 30 or at different vertical positions along wick axis 30. However, in a preferred embodiment, decorative design structure 34 is cylindrical or tubular, and substantially surrounds wick axis 30 with distance 36 being substantially constant. The vertical height 46 of decorative design structure 34 (See FIGS. 2 and 5) is preferably greater than half the length 48 of the wick 28. Decorative design structure 34 is preferably located at an angle 64 around wick axis 30 that extends at least 180 degrees or greater, as shown in FIG. 3.
  • FIGS. 3, 4, and 4A also clearly show that translucent candle body material 26 has a geometric shape that extends vertically from candle base 32 along a portion of wick axis 30. The geometric shape of candle body material 26—which in the embodiment shown is a cylinder—also surrounds wick 28 and decorative design structure 34, wherein the geometric shape extends radially from wick axis 30 to an outer candle surface 38, which is a radial distance 40 beyond the extent of decorative design structure 34. Thus, candle body material 26 fills a gap 42 (See FIGS. 3 and 4A) between any portion of design structure 34 and outer candle surface 38, thereby totally surrounding decorative design structure 34 so that it is embedded within candle body material 26. In a preferred embodiment, decorative design structure 34 is concentric with the jar, or candle container 22. In this manner, decorative candle 20 is more aesthetically pleasing, and a person viewing the candle must look through candle body material 26, including any tint or bubbles, in order to see decorative design structure 34.
  • In the embodiment shown in the figures, outer candle surface 38 is the surface of candle body material 26 that comes in contact with wall 44 of candle container 22, which defines the geometric shape of decorative candle 20. If decorative candle 20 is not in candle container 22, outer candle surface 38 is the molded surface of candle body material 26 after it has been removed from the mold.
  • The decorative design structure 34 can be made from a variety of materials. In the preferred embodiment, the material is cold rolled steel. The material of designs 50-54 is preferably a non-flammable material, such as sheet metal, which cannot burn or is very difficult to burn. Various designs can be cut or formed in the metal. One way to form a design is to use a plasma torch or a laser to cut from stock. Intricate designs, such as those shown in FIGS. 5-7, can be obtained. Designs may also be formed in a sheet of stock material by cutting, punching, grinding, drilling, pressing, or otherwise removing selected patterned shapes from the sheet of material to leave openings or transparent or translucent portions that form a design. The metal stock can have a finish, such as smooth, and it can be colored, such as by paint or an enamel coating. In the preferred embodiment, the steel stock is 22 gauge, which can be easily rolled or press broken and then rolled into shape.
  • In alternative embodiments, material used for decorative design structure 34 may be cast, molded, or otherwise formed from a liquefied material that is molded and allowed to cool or harden into the shape of a design. As an alternative to cutting flat stock, round stock material, or any other shaped tubular material, may also be selectively cut to form a decorative pattern.
  • The design of the decorative design structure 34 can have a large number of forms. FIGS. 5-7 show some design examples. The design 50 in FIG. 5 shows component shapes 56, which includes a letter string of “TEXAS”. The design could include letters of various styles and fonts, numbers or a combination of alphanumeric characters. The design 52 in FIG. 6 shows an outline of the state of Texas removed from a geometric shape (specifically shown as a circle). The design 54 at FIG. 7 shows a star surrounded by cutout material, which cutout space in turn is surrounded by a circular rim.
  • The design can be artistic shapes, silhouettes, etc. The design shape can be solid material with an outline, like the letters of FIG. 5 and the stars of FIG. 7. The design shape can also be material with openings thereof, such as the space between the “E” and “X” in FIG. 5 and the shape of the state of Texas in FIG. 6. The designs can repeat as in FIGS. 6 and 7 or be non-repetitive. For example, the design shapes can include a cowboy on a horse, a fish catching a lure, birds in flight, etc. The design can also incorporate business logos or trademarks.
  • Embedding the decorative design structure 34 into a candle adds an optical aspect not previously know in candles. This particularly true when the candle is provided in a container 22 and also where the design structure 34 is parallel to (or concentric with, in the case of, the cylindrical container) the container side walls or wall. By maintaining a constant gap between the design structure and the container side wall, the optical appearance is pleasing. The embedded design allows an observer to view the refractive nature of the candle and its container.
  • In order to facilitate the making of a free standing or self-supporting decorative design structure 34, component shapes 56 may be connected by abutting or overlapping the shapes, or by providing a linking structure 58 between component shapes 56 in order to provide support for component shapes 56 with respect to one another. In design 50, the serifs on the letters touch or slightly overlap to provide structure and strength to the design structure. Examples of linking structures 58 are shown in designs 52 and 54, where the designs may include a ribbon of material along the bottom of the design to support component shapes 56, or the designs may include small strips of material 66 to support portions of shapes, such as the strips of material at the two lower star points that support the star in the circle in design 54. If the design is non-repetitive and/or small in circumferential size, then the linking structure 58 is used as support structure. For example, if with the design of FIG. 7, the center star is used by itself, without the two endmost stars, the bar 58 extends for about the same distance as shown in FIG. 7. The bar 58, when shaped into an arc as shown in FIG. 8, provides support for the design.
  • Once selected patterns are cut from flat stock material to produce a decorative design, such as designs 50-54 in FIGS. 5-7, the material may be formed into a self-supporting design structure 60, which is shown in FIG. 8 standing upright on a flat surface. The flat design is rolled into a cylindrical or semi-cylindrical shape, where the diameter is less than the inside diameter of the jar or candle container 22. Alternatively, the design can be bent or broken on a sheet metal break to form corners. In order to be self-supporting, design structure 60 should contact a surface, such as candle base 32, in at least three points. Design structure 60 will contact candle base 32 at many points, all along edge 62 at the bottom of design 54. In order to be self-supporting, the center of gravity of an upright decorative design structure should be perpendicularly above the area on candle base 32 delineated by at least three of the points of contact on candle base 32.
  • A decorative candle according to the present invention may be fabricated by first selecting a candle container, such as candle container 22, which is shown in FIGS. 1-4. If the candle is scented, candle container 22 will preferably have a lid, such as glass lid 24 shown in FIG. 1. If the finished candle will not be in a container, a candle mold is selected instead of a candle container. Note that the candle container or mold of the present invention need not be cylindrical; the mold may be triangular, square, octagonal, or any of a variety of other forms.
  • Next, a decorative design structure 34 is located in the candle container, where it is free standing on the candle base 32. To prevent over heating decorative design structure 34, all radial distances from the wick axis to any portion of the decorative design structure should be maximized, which typically means the decorative design structure should be centered about the wick axis. In a preferred embodiment, the distance or gap 42 between the decorative design structure 34 and the wall 44 of the candle container is approximately the same over the entire area of the decorative design structure. In order to present a clear view of the decorative design structure, this distance should be approximately ⅛ to ½ inch.
  • Next, a candle wick 28 is suspended or located along a wick axis 30 in candle container (or mold) 22. Wick axis 30 is preferably a vertical straight line near the centroid of the shape of the container or some other vertical straight line that maximizes all the radial distances to the side walls of the container so that the candle flame will not burn too close to the container side wall. In a preferred embodiment, the wick is suspended vertically into the container, typically by a rod resting across the top rim of the container.
  • In alternative methods of making decorative candle 20, decorative design structure 34 may located in candle container 22 after wick 28.
  • Next, translucent candle body material 26 is poured into the candle container or mold 22, wherein the material nearly fills the container and preferably completely surrounds any inner and outer surfaces of the decorative design structure 34. Decorative design structure 34 is this embedded within the candle body material 26. The material also covers most of the wick 28 while the container is filled almost to the top rim of the candle container 22. If the candle will have a lid, a distance is left between the candle body material and the rim of the candle container so that the lid 24 may be placed on the candle without contacting candle body material 26.
  • A decorative design structure 34 according to a preferred embodiment of the invention may be fabricated by first selecting a sheet of suitable material for the structure and selecting a cutting pattern that fits the sheet of material. The material is preferably metal, such as brass, copper, aluminum, steel, tin, or other similar metals. The metal sheet should be thick enough to bend into a self-supporting structure once the pattern is cut from a flat sheet of material. The material should also be thin enough to cut by a selected cutting means, such as cutting with a computer-controlled laser beam.
  • Other materials that may be used for making decorative design structure 34 may include high temperature plastics, cast or sculpted ceramic, marble, plaster, or cementitious material. It is preferable that the material can withstand the heat from a candle flame and avoid producing an unpleasant burned odor.
  • The cutting pattern defines shapes that will be removed from the sheet of material. For example, to cut design 54 in FIG. 7, five substantially “pie-shaped” pieces may be removed from a sheet of material in order to leave the star shape that is centered in the circle.
  • Once a design has been cut into a sheet of material, the design is bent into a self-supporting, three dimensional shape, where it is capable of standing vertically on the surface of a horizontal plane. In a preferred embodiment, the design shape is curved or rolled to form a cylindrical or tubular shape that will fit within the cylindrical candle container with a clearance between the design structure 34 and the container walls 44 and with a clearance from wick axis 30. If the container is rectangular or some other shape, the design may be bent to form corners.
  • Alternate methods for fabricating decorative design structure 34 include cutting the design from a wall of a tubular shape, or molding the decorative design structure from a non-flammable material. For example, a computer controlled laser beam may be used to cut metal from the side wall of round or tubular stock. The tubular stock may have different cross sectional shapes, such as square tubular stock or triangular tubular stock.
  • Note that decorative design structure 34 is preferably bent or rolled into a cylindrical shape for use in a cylindrical candle container, but the cross sectional shape of the design structure may be triangular, square, or have any number of sides. The cross sectional shape of the decorative design structure 34 preferably matches or conforms to the cross sectional shape of the candle container 22 so that the distance 42 between the decorative design structure 34 and the container wall 44 is substantially the same, which produces a clear and uniform view of the design structure through the translucent candle body material 26.
  • However, different aesthetic effects may be produced by using a decorative design structure 34 with a shape that does not conform to, or follow, the shape of container wall 44, wherein distance or gap 42 varies somewhat over the surface of decorative design structure 34. For example, a decorative design structure 34 having a star-shaped cross sectional area may be used in a cylindrical candle container 22. In this example, portions of decorative design structure 34, namely the star points, may follow the cross sectional shape of the cylindrical candle container 22. Other designs may include short or long segments that follow the contours of the container. The decorative design structure should include some symmetry or design in the selection of a shape that has points or segments that conform to the container wall, and to the selection of a location in the container relative to the perimeter or cross sectional shape of the container.
  • To further enhance the aesthetic appeal of the candle, the step of flowing the candle body material into the candle mold may include forming gas bubbles in the candle body material prior to the candle body material becoming set or gelled. Forming the gas bubbles may be accomplished by gently whipping molten candle body material to form small air bubbles in the material. In a preferred embodiment that uses translucent polymer gel, the gel may be gently whipped while the gel is heated to a temperature of between 185 to 203 degrees Fahrenheit. After introducing the bubbles, the gel should be cooled to below 131 Fahrenheit so that the bubbles will not rise and escape from the top to the gel.
  • Other additives may be used in the translucent candle body material before it is flowed into the mold. For example, a fragrance or a colorant may be added and mixed into the candle body material in order to enhance the aesthetic appeal of the candle. When using a translucent polymer gel, colorant or fragrance should be mixed while the material is heated to a temperature of between 203 to 221 degrees Fahrenheit.
  • It should be apparent that the decorative candle of the present invention has the advantages of having a candle lit design, like a perforated luminaria, wherein the design is surrounded by candle body material, such as transparent polymer gel, and the structure having the design is self-supporting so that its placement relative to the wick axis does not change as the candle wick burns down and consumes the candle body material. It is also important that the design is visible when the candle is not lit. When the decorative design structure is clearly visible within the candle body and with the candle container, the aesthetic appeal of the candle is enhanced at the point of sale display, where, for practical and safety reasons, many of the candles may not be displayed while they are burning. Candle purchasers will recognize that a beautiful unlit candle will only become more beautiful when it is lit.
  • The foregoing description of a preferred embodiment of the invention has been presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described to provide the best illustration of the principles of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.

Claims (20)

1. A decorative candle comprising:
a wick extending along a wick axis for a distance equal to a wick length;
a decorative design structure spaced radially apart from, and extending along, the wick axis for a distance greater than half the wick length, wherein the decorative design structure is self-supporting on a bottom surface, and wherein portions of the decorative design structure are located over an angle of greater than 180 degrees with respect to the wick axis; and
a translucent candle body material having a geometric shape that extends from the candle base along a portion of the wick axis, and surrounds a portion of the wick and the decorative design structure, wherein the geometric shape extends radially from the wick axis to an outer candle surface that is radially beyond the decorative design structure.
2. The decorative candle according to claim 1 wherein the decorative design structure has a wall and a center axial opening positioned along the wick axis, wherein the wall has openings configured to form a design.
3. The decorative candle according to claim 1 wherein the decorative design structure is a cylindrically shaped structure made of a non flammable material.
4. The decorative candle according to claim 1 wherein the decorative design structure contacts the candle base on at least three points that form a triangle surrounding the wick axis, thereby providing self-supporting support.
5. The decorative candle according to claim 1 further including a transparent container for holding the translucent candle body material.
6. The decorative candle according to claim 5 wherein the transparent container is a cylindrical glass jar, and wherein the candle base is a circular bottom of the cylindrical glass jar.
7. The decorative candle according to claim 1 wherein the translucent candle body material is a polymer gel.
8. The decorative candle according to claim 1 wherein the decorative design structure is a metal sheet having shapes cut therefrom and rolled into a cylindrical structure.
9. The decorative candle according to claim 1 wherein the decorative design structure has a plurality of connected design shapes formed therein.
10. The decorative candle according to claim 1 wherein the decorative design structure includes a plurality of design shapes with bands connecting the design shapes.
11. A method of making a decorative candle comprising the steps of:
cutting a design from a plate of material;
forming the design into a shape that at least partially conforms to a cross sectional shape of a candle mold;
locating a wick along a wick axis in the candle mold;
locating a decorative design structure radially spaced apart from, and extending along a portion of, the wick axis, wherein the decorative design structure is self-supporting on a candle base; and
flowing a translucent candle body material into the candle mold to fill a geometric mold shape that extends from the candle base along a portion of the wick axis, and surrounds a portion of the wick and the decorative design structure, wherein the geometric shape extends radially from the wick axis to an outer candle surface radially beyond the decorative design structure.
12. The method of making a decorative candle according to claim 11 wherein the step of cutting a design further includes the step of cutting a plurality of designs connected by connecting bands.
13. The method of making a decorative candle according to claim 11 wherein the step of flowing a translucent candle body material further includes heating a translucent polymer gel.
14. A decorative candle comprising:
a transparent container having a bottom and a side wall defining a cavity
a wick located in the cavity;
a decorative design structure made of a thin plate material that has a design formed therein so as to have at least one opening through the plate material, the decorative design structure shaped to follow at least a portion of the container side wall, the decorative design structure located in the container cavity so as to be spaced apart from the wick and from the container side wall; and
a translucent candle body material filling the transparent container, and surrounding the wick and the decorative design structure, wherein the translucent candle body material fills a gap between the decorative design structure and the side wall.
15. The decorative candle according to claim 14 wherein the wick has a wick length, and wherein decorative design structure extends vertically for a distance of at least half of the wick length.
16. The decorative candle according to claim 14 wherein the decorative design structure is radially spaced apart from the wick axis and located around the wick axis extending over an angle of at least 180 degrees so as to be self-supporting on the container bottom.
17. The decorative candle according to claim 14 wherein a center of gravity of the decorative design structure is vertically over a point within a triangle delineated by three points of the decorative design structure that contact the container bottom.
18. The decorative candle according to claims 14 wherein the gap is constant.
19. The decorative candle according to claim 14 wherein the decorative design structure has a repeating design that is coupled together by a band.
20. The decorative candle according to claim 18 wherein the band is at the bottom of the decorative design structure.
US11/047,188 2005-01-31 2005-01-31 Decorative candle having an embedded design Abandoned US20060172241A1 (en)

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US20060070093A1 (en) * 2004-09-30 2006-03-30 Joy Mangano Combination candle centerpiece and side loading music CD player
US20090081600A1 (en) * 2007-09-26 2009-03-26 Global Candle Gallery Licensing Co Method of forming a candle with imbedded images
US20090323031A1 (en) * 2008-06-27 2009-12-31 Shlomo Haim Adler Candlelight image projecting apparatus and method
US20100251671A1 (en) * 2008-12-03 2010-10-07 Scentsy, Inc. Systems and methods for preparing and packaging wax, such as scented wax for use with wickless candles, and other similar products
US20140099586A1 (en) * 2012-10-04 2014-04-10 Sue Falk Wax Forms with Permanent Hardware
US8882496B2 (en) 2011-04-21 2014-11-11 S.C. Johnson & Son, Inc. Container candle, insert therefor and method of making
ES2526944A1 (en) * 2013-07-16 2015-01-16 Realitas Global, S.L. Customizable candle (Machine-translation by Google Translate, not legally binding)
USD817525S1 (en) * 2015-02-27 2018-05-08 Anchor Hocking, Llc Wax candle vessel

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