Flameless candle with simulated flame and wick

A simulated flame and wick device for use with a flameless candle and other devices requiring the appearance of a natural flame. A flame shaped housing, comprising an upper and lower cover, contains a flexible LED filament bulb, with the positive and negative leads passing through dedicated channels within a housing designed to have the appearance of a candle wick. The combination of the material used for the wick housing along with the positive and negative leads from the flexible LED filament bulb are designed to provide strength and flexibility to the wick component. In turn these leads pass through a positioning housing to orient the simulated flame and wick correctly when used with flameless candles and other devices. The simulated flame and wick along with the other components described are contained within the internal housing of a simulated candle shell or other appropriate device, thus simulating the appearance of a flame burning atop a blackened wick.

CROSS-REFERENCE TO RELATED APPLICATIONS

BACKGROUND

Field of the Disclosure

This disclosed technology relates generally to simulated flame lighting devices, such as flameless candles and candle-shaped electric lightbulbs.

Description of Certain Art

Flameless candles are electronic devices that simulate a traditional wick candle, which uses the flame of a burning wick to create light. Flameless candles use an electric light source, such as a light emitting diode (LED). Flameless candles do not require a flame and thus reduce the fire hazard risk associated with a traditional candle.

Because no wick is consumed during operation of a flameless candle, the operational lifetime of a flameless candle may be substantially longer than the lifetime of a traditional wick candle.

SUMMARY

In one broad aspect, a flameless candle device is provided, including a flame-simulating element including a cover defining a hollow cavity therein, first and second bulb leads, and a flexible light-emitting diode (LED) bulb disposed within the hollow cavity, a light-emitting section of the flexible LED bulb bent within the cavity such that a first portion of the light emitting section of the flexible LED bulb extends generally parallel to a second portion of the light emitting section of the flexible LED bulb, and a wick-simulating element supporting the flame-simulating element, the wick-simulating element including first and second discrete channels extending therethrough, the first and second bulb leads extending through the first and second discrete channels, respectively.

The cover may include an upper cover section and a lower cover section, the wick-simulating element extending through an aperture in the lower cover section. The upper cover section may be more opaque than the lower cover section. The lower cover section may be substantially transparent. An inner surface of the upper cover section may include a diffusive texture.

The device may additionally include a positioning holder supporting the wick-simulating element, where the first and second bulb leads are retained within the positioning holder. The device may additionally include a candle shell, where the positioning holder is embedded at least partially within the candle shell. The device may additionally include a circuit board disposed within the candle shell and in electrical connection with the flexible LED bulb through the positioning holder, and a power supply structure disposed at least partially within the candle shell.

In another broad aspect, a flameless candle device is provided, including a cover including an upper cover section, and a lower cover section secured relative to the upper cover section to define a hollow cavity and a flexible light-emitting diode (LED) bulb disposed within the hollow cavity, the flexible LED bulb bent into an elongated U-shape, a candle housing, a tube supporting the flame-simulating element away from the candle housing, and a positioning holder supporting the tube, the positioning holder disposed at least partially within the candle housing.

The positioning holder may include a first receptacle configured to receive and retain a positive lead extending from the LED bulb, and a second receptacle configured to receive and retain a negative lead extending from the LED bulb. The tube may include a first channel through which the positive lead extends and a second channel through which the negative lead extends, the first and second channels separated from one another along at least a portion of the length of the tube by an internal divider. The positioning holder may include a first internal connection between the positive lead and a first wire extending from the positioning holder and a second internal connection between the negative lead and a second wire extending from the positioning holder. The first receptacle may include a push-in receptacle in electrical communication with the first wire, and the second receptacle may include a push-in receptacle in electrical communication with the second wire.

In another broad aspect, a flameless candle device is provided, including a flame-simulating element including a cover including a hollow cavity, and a flexible light-emitting diode (LED) bulb disposed within the hollow cavity, the flexible LED bulb including a positive lead and a negative lead extending therefrom, a wick-simulating element supporting the flame-simulating element, the wick-simulating element including an insulating sheath including a first discrete passage through which the positive lead extends and a second discrete passage through which the negative lead extends, and a positioning holder supporting the wick-simulating element, the positioning holder disposed at least partially within the candle housing.

The positioning holder may include a first positioning holder component configured to engage with a second positioning holder component to retain portions of the positive and negative leads therebetween. The device may additionally include an internal sleeve disposed within the hollow cavity and surrounding at least a portion of the flexible LED bulb to prevent contact between the flexible LED bulb and the cover. The interior surface of the cover may include a diffusive texture.

The device may additionally include a printed circuit board and a power supply component in electrical communication with the LED bulb. The power supply component may include a lightbulb base. The power supply component may include a power cord.

In another broad aspect, a method of assembling a flameless candle component is provided, including inserting a first lead extending from a flexible light-emitting diode (LED) bulb into a first channel within a supporting tube, an exposed section of the first lead extending from an end of the supporting tube opposite the LED bulb, inserting a second lead extending from the flexible LED bulb into a second channel within the supporting tube, the second channel at least partially separate from the first channel by an internal divider within the supporting tube, an exposed section of the second lead extending from an end of the supporting tube opposite the LED bulb, inserting a portion of the supporting tube through an aperture in a light-transmissive component of a cover configured to encapsulate the LED bulb, and forming a positioning holder retaining a portion of each of the exposed sections of the first and second leads.

Forming a positioning holder retaining a portion of each of the exposed sections of the first and second leads may include forming a seamless positioning holder encapsulating the retained portions of each of the exposed sections of the first and second leads. Forming a seamless positioning holder may include molding a seamless positioning holder around the retained portions of each of the exposed sections of the first and second leads, after the supporting rube has been inserted through the aperture in the light-transmissive component of the cover.

Forming a positioning holder retaining a portion of each of the exposed sections of the first and second leads may include assembling a first discrete positioning holder component and a second discrete positioning holder component to retain the retained portion of each of the exposed sections of the first and second leads therebetween.

Where used in the various figures of the drawings, the same reference numerals designate the same or similar parts. Furthermore, when the terms “front,” “back,” “first,” “second,” “upper,” “lower,” “height,” “top,” “bottom,” “outer,” “inner,” “width,” “length,” “end,” “side,” “horizontal,” “vertical,” and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawing and are utilized only to facilitate describing the subject of this disclosure.

All figures are drawn for ease of explanation of the basic teachings of the present technology only; the extensions of the figures with respect to number, position, relationship, and dimensions of the parts to form various embodiments will either be explained or will be within the skill of persons of ordinary skill in the art after the following teachings of the present disclosure have been read and understood. Further, the exact dimensions and dimensional proportions to conform to specific width, length, and similar requirements will likewise be within the skill of the art after the following teachings of the present disclosure have been read and understood.

Certain embodiments of the simulated flame and wick on an LED flameless candle according to the present disclosure will now be described in detail with reference to the accompanying drawings.

DETAILED DESCRIPTION

Various embodiments of flameless candles and flameless candle components are described herein. Some embodiments of flameless candles include a single diode LED concealed within a flame shaped cap, also referred to as a “flamecap,” mounted directly to a wax surface of the flameless candle. Some embodiments of flameless candles include a “shroud” to cover a light source to simulate a flame, by utilizing movement of the shroud generated via a fan, pump or other source. Some embodiments of artificial candles include a light bulb that includes a single-sided LED strip and a simple black cover concealing wiring to the LED strip, to attempt to simulate a flame and a black wick.

These and other embodiments of flameless candles have drawbacks that limit their ability to achieve a more realistic simulation of a traditional wick burning candle. Embodiments of flameless candle which rely on a flamecap fail to deliver a realistic candle simulation, as the simulated flame appears to “float” on the top of the wick, and as the flamecap candle designs can lack a simulated black wick. Embodiments of flameless candles which rely on a shroud move in a manner which is inconsistent with the behavior of an actual flame, and require a dedicated power source in order to move the flame shroud. Embodiments of flameless candles which rely on a single sided LED strip generate light in an irregular pattern, due to the generation of light on only one side of the LED strip. In addition, the complexity of the components in various embodiments of flameless candles can hinder light output, preventing an effective simulation of an exposed candle flame. In embodiments of flameless candles which utilize thin wires and a simple black cover to simulate a wick, the wiring may not be strong enough to consistently maintain the flame in a realistic position vertically above the candle surface.

The drawbacks mentioned above have not been adequately addressed by existing flameless candle designs. Various embodiments of the disclosed technology address, at least in part, one or more of these deficiencies, or other deficiencies.

FIG. 1is a cross-sectional view schematically illustrating an embodiment of a flameless candle. The flameless candle100includes a candle assembly1which is partially housed within a candle shell16. The candle assembly1in the illustrated embodiment includes a flame-simulating element2supported by a wick-simulating element4. In the illustrated embodiment, the wick-simulating element4extends partially into the upper surface of the candle shell16, such that the wick-simulating element4and the flame-simulating element2are the only portions of the candle assembly1extending upward from the candle shell16.

Within the candle shell16, the wick-simulating element4is connected at its lower end to a positioning holder6or other suitable retention mechanism. In the illustrated embodiment, the positioning holder6is located within the upper surface of the candle shell to properly locate the flame-simulating element2. The positioning holder may be exposed partially or concealed under another material, such as wax, to give a more realistic impression that the wick and flame are natural. The candle shell16may also have various shaped top surfaces such as, flat, domed, or recessed, which may be used to simulate the appearance of a candle that has been burned to some degree.

The positioning holder6is in turn connected via internal leads144and145to a printed circuit board (PCB)15, which may comprise control circuitry and other suitable electronic components, as discussed in greater detail below. The PCB15is in electrical connection with a power source structure17. In some embodiments, the positioning holder6may not be embedded below the upper surface of the candle shell16as illustrated, but may instead be flush with the upper surface of the candle shell16, or arranged in any other suitable configuration relative to the candle shell16. The positioning holder6and other components may be concealed within the candle shell16.

In the illustrated embodiment, the candle shell16is generally cylindrical in shape, giving the flameless candle100the appearance of a pillar candle. In some embodiments, however, the candle shell16may have any other suitable shape to give the flameless candle100a desired appearance, including that of a tapered candle, a votive, a tea light, a figurine, or any other shape suitable for use as a candle. In some embodiments, the candle shell16may include real wax, such as paraffin wax, soy wax, beeswax, or another suitable wax. In some embodiments, the candle shell16may include a more durable material, such as resin, plastic, or any other material suitable to the intended application. In some particular embodiments, the candle shell16may include a combination of materials, such as a wax overlay over an underlying structure such as a plastic or resin structure.

Features of these flameless candles and components thereof may be utilized in conjunction with a wide variety of devices, which may be powered in any suitable fashion. For example, the flameless candles may utilize batteries as a power source. In some embodiments, the batteries may be removable or may be integrated batteries which are not intended to be replaced. The batteries may be replaceable, or may be rechargeable in any suitable fashion, including the use of a removable or integrated A/C power source, wireless recharging, solar recharging, or any other suitable recharging process. In some embodiments, the flameless candles may be directly powered, such as through the use of a hard-wired electrical cord or external power adapter, through the use of solar cells, or by utilizing a conventional lightbulb base or other electrical connector as described below with respect toFIG. 5.

In the illustrated embodiment, a portion of the power source structure17is exposed at the base of the candle shell16. The exposed portion of the power source structure may include components with which a user can interact to power or control the operation of the flameless candle100. For example, the power source structure17may include an on/off control, a timer control, or any other suitable control mechanism. These control mechanisms may include a switch, button, or any other suitable interface mechanism with which a user can interact. The power source structure17may also include an outwardly extending power cord, charging port or other socket for receiving a plug of a power adapter or cable, a battery receptacle and cover, or any other suitable mechanism for providing power to the candle assembly1. In an embodiment in which a cord extends from or is configured to be connected to the power source structure17, the cord may extend from a side of the candle shell16, rather than the base of the candle shell16.

FIG. 2is a cross-sectional view schematically illustrating a flame-simulating element and a wick-simulating element. In the illustrated embodiment, the flame-simulating element2includes a cover surrounding a light source, which in the illustrated embodiment is a flexible LED filament bulb12which serves as a multi-directional light-emitting element. In the illustrated embodiment, the cover includes an upper cover portion10and a lower cover portion11. In some embodiments, these upper and lower cover portions10and11may be discrete elements which are bonded or otherwise connected together to form the cover encapsulating the bulb12. In some embodiments, the discrete elements may be sealed together using glue, ultrasonic welding, a snap-fit or press-fit engagement, or any other suitable sealing method or combination of sealing methods.

In the illustrated embodiment, the lower cover portion11is generally rounded and somewhat spherical in shape, while the upper cover portion10is more elongated and somewhat conical in shape. Collectively, the upper and lower cover portions10and11resemble a natural candle flame undisturbed by airflow such as a breeze, or other outside influences.

The cover defines a hollow interior space in which the LED filament bulb12is positioned. In the illustrated embodiment, the LED filament bulb12is in the shape of a narrow arch, with both ends of the arched filament extending into a positioning head131at the upper end of the wick-simulating element4, which can have an outwardly flared shape. The wick-simulating element4may include a sheath13which extends downward from the positioning head131, and surrounds the positive lead121and the negative lead122extending from the bulb12. In various embodiments, the wick-simulating element4comprises a tube, is elongated, and/or is hollow.

In some embodiments, the upper cover portion10may have a color that generally corresponds to the shell16, such as a white or cream color, to provide a desired overall appearance in combination with the LED filament bulb13. The LED filament bulb may, in some embodiments be a warm white color, or may range in color from a bright white to a yellow or yellowish-orange color, or be another color. Any other suitable colors for both the upper cover portion10and the LED filament bulb13may also be used to provide any desired appearance.

In some embodiments, a surface of the upper cover portion10, such as the inner surface101of the upper cover portion10, may comprise a texture or coating configured to affect alter the passage of light therethrough. In particular, the texture and/or coating may be configured to act as a diffuser to scatter the light emitted from the LED bulb12. By diffusing the light, the appearance of localized bright spots will be reduced, balancing the light emitted by the LED bulb12. In some embodiments, a diffusing texture or coating may be provided during a molding process for forming the upper cover portion10.

In some embodiments, the lower cover portion11may be generally transparent or translucent with minimal tinting, to simulate the lack of color at the base of a natural candle flame. In some embodiments, the lower cover portion11may be similar or identical in color to the upper cover portion10. Because the lower cover portion11may in some embodiments be clear or almost clear, the portion of the sheath13of the wick-simulating element4extending through the lower cover portion11may be visible. In some embodiments, the sheath13of the wick-simulating element4may in some embodiments be black, substantially black, brown or white, to simulate the appearance of a real candle wick. In some embodiments, the sheath13of the wick-simulating element4may include a texture on the outside surface to more accurately simulate the physical attributes of a real candle wick.

In some embodiments, the upper cover portion10and the lower cover portion11may comprise plastic, resin, or another suitable material which is sufficiently transparent to light. In some embodiments, the sheath13of the wick-simulating element4may comprise rubber, plastic, silicone, elastomer, or another other material that exhibits relative strength, flexibility and stiffness. The wick-simulating element4may fit snugly through an aperture in the lower cover portion11, allowing the candle-simulating element2to be securely supported by the wick-simulating element4. The material used for the wick-simulating structure4, along with the positive and negative leads121and122extending from the flexible LED filament bulb12may combine to provide significant strength to the wick-simulating structure4in supporting the flame-simulating structure2in a desired orientation above the surface of an object to which it is attached, such as a candle shell or housing of a flameless candle.

FIG. 3is a cross-sectional view schematically illustrating a wick-seating element connected to a positioning holder. The wick-simulating element4is connected to the positive lead121and the negative lead122of the LED filament bulb12. In particular, it can be seen that the positive lead121has been fed into a first dedicated channel132awithin the sheath13of the wick-simulating element4, and that the negative lead122has been fed into a second dedicated channel132bwithin the sheath13. In the illustrated embodiment, the sheath13appears from the outside to be a single tube despite include discrete dedicated channels132aand132bextending at least a portion of the length of the sheath13. These discrete dedicated channels132aand132bmaintain a separation between the positive lead121and the negative lead122to isolate the positive lead121and the negative lead122from one another when power is provided to the flexible LED filament bulb12.

The positive lead121and negative lead122of the flexible LED filament bulb12are inserted into the dedicated channels132aand132bof the sheath13of the wick-simulating element4. The sheath13is then inserted downward through a hole in the lower cover, and the flared shape of the positioning head131at the top of the wick-simulating structure4prevents the wick-simulating structure4from sliding completely through the lower cover. In certain embodiments, the positioning head131provides stability, aids in assembly, and/or maintains the flexible LED filament bulb12in the proper position within the upper cover portion10of the flame-simulating element. In some embodiments, the positioning head131is pushed against and/or abutted with the lower cover portion11. As can be seen inFIGS. 2 and 3, the positive lead121and negative lead122are longer than the sheath13and will extend beyond the bottom of the sheath13.

The portions of the positive lead121and negative lead122which extend beyond the bottom of the sheath13are inserted into respective slots141aand141bwithin the positioning holder6. Within the slots141aand141b, push-in receptacles143aand142breceive and retain the positive lead121and the negative lead122. The push-in receptacles143aand143bin the illustrated embodiment comprise directional retaining structures, such as barbed conductors, which allow the positive lead121and the negative lead122to be inserted therein, while inhibiting their removal. In some embodiments, the push-in receptacles143aand143bpermit movement of the conductors relative to the push-in receptacles143aand143bin one direction and inhibit or prevent movement of the conductors in an opposite direction. Each push-in receptacles143aand143bis electrically connected to a wire or other conductor, placing the retained positive lead121in electrical communication with the positioning holder positive lead144, and placing the retained negative lead122in electrical communication with the positioning holder negative lead145.

The bottom of the positioning holder6is, in the illustrated embodiment, sealed with the positioning holder bottom cap142. The positioning holder bottom cap142can comprise a plurality (e.g., a pair) of through holes, through which the positioning holder positive lead144and the positioning negative lead145may pass. The positioning holder6and the positioning holder bottom cap142can comprise plastic, resin or any other material suitable for this purpose.

FIG. 4is a side view of a candle assembly including a flame-simulating element, a wick-simulating element and a positioning holder such as those depicted inFIG. 3, connected to a printed circuit board (PCB). The candle assembly1includes the upper cover portion10and the lower cover portion11of the flame-simulating element2, the wick-simulating element4, and the positioning holder6. The positioning holder positive lead144and the positioning negative lead145are connected to a printed circuit board (PCB)15.

Any suitable attachment mechanism or structure may be used to electrically connect the positioning holder positive lead144and the positioning negative lead145are connected to a printed circuit board (PCB)15. For example, some embodiments may utilize male/female connectors, such as a plug/socket arrangement, soldering, push-in receptacles, or any other suitable method or structure.

The PCB15may comprise a variety of electronic controls and/or circuitry configured to control the operation of a flameless candle. For example, the PCB15may include control circuitry configured to control the operation of the LED bulb12to operate in a flickering pattern, to simulate the appearance and behavior of a real candle flame. The PCB15may include control circuitry configured to alter this flickering pattern in accordance with a given operating mode, as selected by a user. The PCB15may also include control circuitry configured to include automatic and/or variable timers for turning on and/or off the flameless candle, or for enabling reception of instructions from a remote control device to control the operation of the flameless candle.

A candle assembly such as the candle assembly ofFIG. 4can be integrated into (e.g., included in) a wide variety of devices to simulate the operation of a candle flame and wick. For example, a candle assembly can be integrated into a candle shell or housing such as the pillar candle shell15depicted inFIG. 1, to simulate a candle of a desired shape. In some embodiments, a candle assembly can be used in conjunction with other components to operate the candle assembly using an existing device or structure, such as a light socket.

FIG. 5is another cross-sectional view of an embodiment of a flameless candle incorporating a candle assembly such as the candle assembly ofFIG. 3. The flameless candle device200ofFIG. 5includes a candle assembly1used in conjunction with a lightbulb base19to power the candle assembly1. The candle shell18of flameless candle device200is a generally cylindrical shape having a narrower cross-section in comparison to the candle shell16ofFIG. 1, Despite the narrower cross-sectional area, the bulk of the candle assembly1may nevertheless be retained within a cavity in the interior of the candle shell18. The assembly1is arranged relative to the candle shell18such that the positioning holder6of the assembly is retained at least partially within the candle shell18. In the illustrated embodiment, the upper surface of the positioning holder6is flush with the top of the candle shell18, although in some embodiments the positioning holder6may be recessed within the candle shell18, in a manner similar to that depicted inFIG. 1.

The PCB15at the lower portion of the assembly1is in electrical connection with a light bulb base19. For example, positive and negative leads extending from the PCB15may be connected to the light bulb base19to allow electricity to operate the device when the light bulb base19is screwed or otherwise inserted into a light socket. The lightbulb base19may comprise, for example, any suitable lightbulb base, including but not limited to conventional light bulb base E12, E17, E26, B15, and G38 bases, among others.

FIG. 6is a perspective view of another embodiment of a flame-simulating element, a wick-simulating element, and a positioning holder. The cover20of the flame-simulating element is connected to a wick-simulating element30. The wick-simulating element30is in turn connected to a positioning holder40. In its assembled state, a male connector head50of the positioning holder40can be used to connect to a PCB (not shown).

FIG. 7is a perspective exploded assembly view of the flame-simulating element, the wick-simulating element, and the positioning holder ofFIG. 6, illustrating certain components of these structures. The flame cover20of the flame-simulating element includes an upper flame cover21and a lower flame cover22. A flexible LED filament bulb60, which in the illustrated embodiment is bent into a narrow inverted U-shape, is arranged such that a negative lead61and a positive lead62extend through dedicated channels within the wick-simulating element30.

The negative lead61and a positive lead62extend beyond the base of the wick-simulating element30. The positioning holder40(seeFIG. 6) includes a female positioning holder component41and a male positioning holder component42. In the illustrated embodiment, the negative lead61and a positive lead62are inserted into an opening in an upper surface of the female positioning holder component41. The male positioning holder component42secures the negative lead61and a positive lead62into position, minimizing the likelihood that the negative lead61and a positive lead62can be pulled out.

A male connector head50, which may be connected to wiring extending between the male connector head50and a PCB, is configured to be inserted into the bottom of the positioning holder40. This connection can complete the electrical connection from the male connector head50to the flexible LED filament bulb60. The male connector head50has two outwardly extending locking teeth51that may be used to engage locking teeth receptacles422(seeFIG. 9) in the male positioning holder component42.

FIG. 8is a partially assembled view of the components ofFIG. 7. InFIG. 8, the flame cover20of the flame-simulating element is shown in an assembled view, in which the upper cover portion21abuts the lower cover portion22. The positive and negative leads extending from the base of the wick-simulating element30are inserted into the male connector head50, with the female positioning holder component41and a male positioning holder component42shown in an exploded state on either side.

FIG. 9is a perspective view of the male positioning holder component ofFIG. 7. In particular,FIG. 9provides an interior view of the male positioning holder component42. It can be seen inFIG. 9that the male positioning holder component42comprises two outwardly extending pins421configured to engage corresponding receptacles in the female positioning holder component41(seeFIG. 10). Locking teeth receptacles422are configured to engage with the locking teeth51of the male connector head50(seeFIGS. 7 and 8).

FIG. 10is a perspective view of the female positioning holder component ofFIG. 7. The female positioning holder component41of the illustrated embodiment includes a cap411. While certain embodiments of flameless candles described herein recess the positioning holder beneath a surface of a candle shell or other structure, in some embodiments, a cap411or other structure can be used as a finished external part, visible to the user, depending on the design of the specific product.

The cap411includes a hole413in the center of the cap411. The hole411connects to a lower section of the female positioning holder component41in which the hole separates into discrete channels spaced apart from one another by a divider416. The negative lead channel414and positive lead channel415on either side of the divider416guide the respective negative lead61and a positive lead62from the flexible LED filament bulb60to engage with the connector head50configured to be retained at least partially within the connector head receptacle417.

The female positioning holder component41includes two female receptacles412that receive the male pins421from the male positioning holder component42, One or both of the male pins421or the female receptacles412may comprise detents or other contour features to improve tension when these parts are press-fit together. When the female positioning holder component41and the male positioning holder component42are pressed together, the positive and negative leads61and62are compressed therebetween, retaining the leads in place.

FIG. 11is a perspective view of the connector head inserted into the lower portion of the assembled positioning holder. The connector head50in this illustrated embodiment comprises an orientation guide52in the form of a ridge to ensure that the connector head50is properly oriented when inserted into the positioning holder40. Ensuring the correct orientation of the connector head50relative to the positioning holder40will ensure that the positive wire53extending from the connector head50is connected to the positive lead61extending from the flexible LED bulb12, and that the negative wire54extending from the connector head50is similarly connected to the negative lead62. The locking teeth51(seeFIG. 7) of the connector head50are configured to engage the locking teeth receptacles422in the positioning holder40to ensure a secure connection without the need for soldering

FIG. 12is a perspective view schematically illustrating another embodiment of a flame-simulating element and a wick-simulating element.FIG. 13is a perspective view of the wick-simulating element ofFIG. 12. In contrast to the wick-simulating element30ofFIG. 7, which includes a positioning head surrounding the base of the flexible LED bulb60, the wick-simulating element70does not provide direct lateral support to the flexible LED bulb60. Instead, the structure ofFIG. 12includes a sleeve element80which may be dimensioned to press-fit onto the wick-simulating element70. The sleeve element80may provide lateral support to retain the flexible LED bulb60in a desired position within the upper cover portion. In some embodiments, the sleeve element80may be transparent or translucent, and may include diffusing structures or coatings, tinting, or any other suitable feature or mechanism which may alter the appearance of the flexible LED bulb60.

The use of an internal sleeve element80and the alternate design of wick-simulating element70may improve the overall performance of a flameless candle device. The sleeve element80may ensure that the flexible LED bulb60remains spaced apart from the interior surface of the upper cover portion, preventing the incidence of localized bright spots. In addition, because the wick-simulating element70does not block the light-emitting portions of the flexible LED bulb60near the base of the flexible LED bulb60, the overall brightness of the flameless candle can be increased.

The overall dimensions of a flameless candle device may place structural constraints on the type of components that may be included in the flameless candle device. For example, while a candle shell dimensioned to correspond to a relatively large pillar candle may have ample space within the candle shell to house desired components, other flameless candle devices may be smaller. For example, in an embodiment where a candle shell is dimensioned to correspond to a tea light or votive candle, there may not be sufficient space within the design to include all of the elements of certain candle assemblies described herein. For example, in some such embodiments, the positioning holder may be omitted. In such an embodiment, a thicker wick-simulating structure or wiring may be used to provide additional structural support, or the wick-simulating structure may be supported directly by another component, such as the PCB or a power source structure. Even without the additional support provided by the use of the positioning holder, embodiments including certain of the other features described herein may provide a flameless candle device which more effectively simulates a natural burning flame.

In some embodiments discussed herein, a positioning holder may be assembled by forming a plurality of separately molded or formed components and assembling those components in a manner which retains at least a portion of the LED bulb leads therein.FIG. 14is a process flow diagram schematically illustrating an example process for assembling a component of a flameless candle.

The process400begins at a stage405, where at least two positional holder components are formed as discrete components. These discrete positional holder components may be formed, for example, in two distinct molding processes, or as separate components formed in a single molding process. Specific embodiments of such discrete positional holder components are illustrated inFIGS. 9 and 10, although a wide variety of other multicomponent positional holder designs can be used in other embodiments.

The process then moves to a stage410, wherein the leads of an LED filament bulb are inserted through discrete channels in a wick-simulating element and the wick is inserted through an aperture in a portion of a flame-simulating cover. An example of the resulting structure is illustrated inFIG. 7, in which the leads61and62of the LED bulb60have been inserted through discrete channels in the wick-simulating structure30, and a portion of the wick-simulating structure30has been inserted through an aperture in the lower cover portion22of the flame simulating cover. Once inserted into the wick-simulating structure, portions of the bulb leads extend from the end of the wick-simulating element opposite the LED bulb. While illustrated as occurring after stage405, some or all of the processes described with respect to stage410may be performed before some or all of the processes described with respect to stage405.

The process then moves to a step410, where the discrete positional holder components are brought together to retain portions of the exposed ends of the LED leads therebetween, forming a positional holder which supports the wick-simulating structure and the LED bulb and cover supported thereon. Subsequently, connections may be made with a PCB to form a candle assembly as described above, and the candle assembly may be integrated into a candle shell and connected to a power source to form a suitable flameless candle device. The assembly of the discrete positional holder components allows the assembly of the flameless candle components to be completed after all of the individual components have been fabricated.

In some embodiments, however, the positioning holder may be molded as a single component. In some particular embodiments, the positioning holder may be molded in situ around the leads of the LED filament bulb, which may reduce the labor required to assemble a flameless candle device.FIG. 15is a process flow diagram schematically illustrating an example process for assembling a component of a flameless candle.

The process500begins at a stage505where the leads of an LED filament bulb are inserted through discrete channels in a wick-simulating element and the wick is inserted through an aperture in a portion of a flame-simulating cover.

The process then moves to a stage510where a seamless positional holder is formed. In contrast to the position holders formed from interlocking position holder components assembled around portions of the LED bulbs, a seamless positional holder will not require assembly of the positioning holder after production. In some embodiments, the seamless positional holder is formed in situ around portions of the LED bulb leads. In some embodiments, one or more spacer elements may be inserted onto one more both of the LED bulb leads to maintain the bulb leads in a desired arrangement during the molding process, and the seamless position holder may be molded over the spacer element or elements. In some embodiments, a mold used to form the seamless position holder may include a retention figure configured to retain a portion of the LED bulb leads for consistency in manufacturing.

FIG. 16Ais a side view of an embodiment of a bulb, cover, and wick assembly prior to the formation of a seamless positioning holder.FIG. 16Bis a side view of the embodiment of the bulb, cover, and wick assembly after the formation of a seamless positioning holder. InFIG. 16A, it can be seen that the leads261and262extending from a filament LED bulb260have been inserted into discrete channels within a tube that serves as at least a portion of a wick-simulation structure270. A portion of the wick-simulation structure270has been inserted through an aperture in a lower cover portion222, forming an intermediate assembly280In some embodiments, although not illustrated specifically herein, an upper portion of the cover may be sealed to the lower cover portion to provide a flame-simulating cover encapsulating the LED bulb260. InFIG. 16B, a seamless positioning holder241has been molded onto exposed portions of the leads261and262of the intermediate assembly280ofFIG. 16A.

Certain terminology may be used in the following description for the purpose of reference only, and thus is not intended to be limiting. For example, terms such as “upper”, “lower”, “upward”, “downward”, “above”, “below”, “top”, “bottom”, “left”, and similar terms refer to directions in the drawings to which reference is made. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first”, “second”, and other such numerical terms referring to structures neither imply a sequence or order unless clearly indicated by the context.

Terms relating to circular shapes as used herein, such as diameter or radius, should be understood not to require perfect circular structures, but rather should be applied to any suitable structure with a cross-sectional region that can be measured from side-to-side. Terms relating to shapes generally, such as “spherical” or “circular” or “cylindrical” or “semi-circular” or “semi-cylindrical” or any related or similar terms, are not required to conform strictly to the mathematical definitions of spheres, circles, cylinders or other structures, but can encompass structures that are reasonably close approximations.

The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. Likewise, the terms “some,” “certain,” and the like are synonymous and are used in an open-ended fashion. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list.

Overall, the language of the claims is to be interpreted broadly based on the language employed in the claims. The language of the claims is not to be limited to the non-exclusive embodiments and examples that are illustrated and described in this disclosure, or that are discussed during the prosecution of the application.

Although the invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that this disclosure extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the embodiments and certain modifications and equivalents thereof. The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future.