Abstract:
A process for adding objects to a candle. Methods are disclosed for adding an object before the fuel has assumed its final state and after the fuel has assumed its final state. Several related approaches for introducing the object are disclosed, including making an incision to insert the object, retracting the fuel away from its container in order to slip the object in between the fuel and the container, and creating a melted region in the fuel which will allow the object&#39;s insertion. Once the object is in place, the fuel is locally heated above its melting temperature in order to reflow the fuel around the object. The candle is then cooled so that the fuel transitions back into its normal state.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to the field of candles. More specifically, the invention comprises a method for inserting an object into a candle. 
   2. Description of the Related Art 
   Candles have been used for illumination and other purposes for many centuries.  FIG. 1  shows a decorative candle known in the art. Candle  10  includes jar  12  containing fuel  14  and wick  16 . Fuel  14  can be many materials. In the field of decorative candles, a transparent jar and transparent combustible fuel (often a “jelly”) are often used. The transparency allows objects placed within jar  12  to be viewed. As an example, decorative object  18  can be immersed in fuel  14  during the manufacturing process of the candle. The use of transparent fuel allows this decorative object to be viewed (Note that transparent fuels are often used even in the absence of decorative objects). 
   Numerous creative visual effects are possible. A variety of objects can be immersed to create a miniature scene within the candle. Metallic flakes or other objects of visual interest can be suspended within the fuel as well. Once the manufacturing process is complete, the fuel solidifies (though some fuels only harden to a Gel state). The candle is then in a complete form. 
   BRIEF SUMMARY OF THE INVENTION 
   The present invention comprises a process for adding objects to a candle. Methods are disclosed for adding an object before the fuel has assumed its final state and after the fuel has assumed its final state. Several related approaches for introducing the object are disclosed, including making an incision to insert the object, retracting the fuel away from its container in order to slip the object in between the fuel and the container, and creating a melted region in the fuel which will allow the object&#39;s insertion. Once the object is in place, the fuel is locally heated above its melting temperature in order to reflow the fuel around the object. The candle is then cooled so that the fuel transitions back into its normal state. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       FIG. 1  is an isometric view, showing a prior art decorative candle. 
       FIG. 2  is an isometric view, showing a personalizing object. 
       FIG. 3  is an isometric view with a cutaway, showing the insertion of a personalizing object. 
       FIG. 4  is an isometric view with a cutaway, showing the insertion of a personalizing object. 
       FIG. 5  is an isometric view, showing the insertion of a personalizing object. 
       FIG. 6  is an isometric view, showing the completion of the process. 
       FIG. 7  is an isometric view, showing a personalizing object inserted during the manufacturing process. 
   

   REFERENCE NUMERALS IN THE DRAWINGS 
   
     
       
             
             
             
             
           
         
             
                 
             
           
           
             
               10 
               candle 
               12 
               jar 
             
             
               14 
               fuel 
               16 
               wick 
             
             
               18 
               decorative object 
               20 
               personalizing object 
             
             
               22 
               text message 
               24 
               knife 
             
             
               26 
               incision 
               28 
               retractor 
             
             
               30 
               retracted cavity 
               32 
               melted region 
             
             
               34 
               solid region 
               36 
               upper surface 
             
             
               40 
               reflowed fuel 
               42 
               glue joint 
             
             
                 
             
           
        
       
     
   
   DESCRIPTION OF THE INVENTION 
   The primary object of the present invention is to add an object to a premanufactured candle. This operation is often done in order to “personalize” the candle to satisfy a purchaser&#39;s desires. A personalizing object can assume many forms.  FIG. 2  shows personalizing object  20 , which is a glass disk. Text message  22  has been etched or otherwise affixed to the surface of personalizing object  20 . The object must then be placed into the decorative candle. The actual method of creating the text message can be any one of a number of techniques known in the art, including printing a a clear transparent label that is then adhered to the glass disk, hand printing the message of a label, etc. 
     FIG. 3  shows candle  10  from a different perspective. Knife  24  is used to cut incision  26  into upper surface  36  of fuel  14 . Incision  26  is made deep enough to allow personalizing object  20  to be inserted into the incision (though not necessarily to be enclosed completely within the incision). Once personalizing object  20  is in place, it is preferable to reflow fuel  14  in order to remove the unsightly nature of incision  26 . As stated previously, fuel  14  is preferably a combustible jelly. While solid at room temperature, it melts with the addition of moderate heat. It is possible to melt the jelly at a temperature well below its ignition temperature, so that there is little concern about igniting the fuel. 
   Once fuel  14  around incision  26  has been heated above its melting temperature, it will liquify and flow around personalizing object  20 . Once allowed to cool, it will again solidify in a transparent state. Personalizing object  20  will be suspended within fuel  14 .  FIG. 6  shows the completed candle  10 , with personalizing object  20  suspended within fuel  14 . 
   The reheating of the fuel can be accomplished in a variety of ways. One simple approach is to apply a heat gun to the portion of jar  12  proximate incision  26 . Conductive heat transfer will tend to melt the fuel only in proximity to the heat gun. Once the liquified wax has flowed around personalizing object  20  and closed incision  26 , the heat gun is removed. 
   Another approach is to place candle  10  in a pot of hot water. The conductive heat transfer from the hot water will melt the portions of fuel  14  near jar  12  first, working its way inward. Once the liquified region has passed inside the location of incision  26 , candle  10  is removed from the hot water. 
   A convective oven can likewise be used, with candle  10  being placed within the oven. The heat transferred to the candle liquifies the fuel from the outside working inward. A microwave oven can also be used, though it may be necessary to liquify all the fuel, since the heat will not be transferred from the outside in. 
   Finally, the candle can simply be placed atop a heat source, such as a “hot plate.” This method is inefficient, since it tends to melt from the bottom up (meaning that the personalizing object likely cannot be inserted until all the fuel is melted). It does, however, take advantage of equipment that is widely available. Other known heating methods can be used as well. 
   In some instances, it may be desirable to rapidly cool the candle once the desired reflow has been achieved. This is particularly true where the personalizing object has a density significantly exceeding the density of the fuel. If a liquified region is created around the personalizing object, a dense personalizing object will begin to sink (Although, owing to the viscous nature of the fuel, it will not tend to sink very rapidly). It may then be desirable to rapidly cool the liquified region in order to arrest the downward movement of the personalizing object. Such rapid cooling can be accomplished via directing a jet of cold air onto the jar, immersing the candle in an ice water bath, or other prior art cooling methods. In many instances, however, the candle can be cooled satisfactorily by simply setting it aside and allowing it to cool slowly. 
   Other methods can be used to introduce the personalizing object into the fuel.  FIG. 4  shows one such alternate approach. Retractor  28  is inserted along the vertical wall of jar  12 . A portion of fuel  14  is then pried away from jar  12  to create retracted cavity  30 . Personalizing object  20  is then slipped into retracted cavity  30 . Retractor  28  may then be removed, or it may remain through the reflow process (A user&#39;s fingers or other prying object can be substituted for retractor  28 ). A melted region is created around personalizing object  20  using any of the methods previously described. Once the fuel liquifies, it flows around personalizing object  20  and adheres once again to the wall of jar  12 . The fuel is then allowed to cool (or forcibly cooled) until it turns back into a solid. The result is again the view shown in  FIG. 6 , with personalizing object  20  being completely immersed within fuel  14 . 
     FIG. 5  shows still another method for inserting the personalizing object. Heat is applied to candle  10  (using the techniques described previously) in order to create a melted region  32  of fuel  14 . Personalizing object  20  is then inserted into melted region  32  and allowed to sink to a desired depth. The candle is then cooled to solidify the fuel and once again create the configuration shown in FIG.  6 . 
   Although  FIG. 5  shows an annular melted region  32 , corresponding to the application of uniform external heat, this need not be the case. A localized melted region  32  can be created along one wall using a heat gun. Likewise, melted region  32  can comprise all the fuel within the jar (although melting all the fuel is generally undesirable since it will require much more time to heat and cool). 
   Although personalizing objects having a density greater than the fuel have been discussed, those skilled in the art will realize that many personalizing objects may have a density greater than the fuel. For these objects, an insertion tool (such as a pair of tweezers) is used to push the object toward the bottom of the liquified fuel. The fuel is then cooled and solidified before the personalizing object floats to the top. 
   The invention allows a purchaser to select a premanufactured candle and then add a personalizing object. As an example, a purchaser may wish to buy a decorative candle as a birthday present. The purchaser first selects a candle (which may have a festive “birthday” scene already imbedded in the fuel). The purchaser then selects a personalizing object. Exemplary objects are metal disks, glass beads, small plaques, metal ribbons, etc. The personalizing object may have a message already printed thereon. As an alternative, the purchaser may be given the option of creating a message. This message is then etched or engraved (preferably using known automating machinery) onto the personalizing object. Some personalizing objects (such as small statues or religious symbols) may have no printed message. 
   Whatever personalizing object is selected, one of the insertion methods heretofore described is then used to insert the personalizing object into the candle. The purchaser then pays for and receives a unique candle according to his or her wishes. 
   Of course, a personalizing object can also be added during the original manufacturing process itself.  FIG. 7  depicts one method of accomplishing this goal. Decorative candle manufacturing typically starts with jar  12  being empty. A wick, fuel, and decorative effects are then added.  FIG. 7  shows personalizing object  20  adhered to the bottom of glass  12  via glue joint  42 . In this process, the personalizing object is added to the empty glass. The fuel, wick, and other decorative effects (if desired) are then added after the adhesive on the personalizing object has set. Personalizing object  20  is thereby encapsulated in the completed candle. The same technique can be used to adhere the personalizing object to a side wall of the jar, using a fast-setting adhesive. 
   The preceding description contains significant detail regarding the novel aspects of the present invention. It is should not be construed, however, as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Thus, the scope of the invention should be fixed by the following claims, rather than by the examples given.