Candle making process

A jar candle includes at least two decorative elements located adjacent the interior of the jar and positioned in a predetermined relationship with respect to one another. A manufacturing method for forming the jar candle includes proving a jar having an interior surface defining an interior region. A sleeve having a predetermined pattern is slid over the jar. The sleeve and jar are aligned and a decorative element is applied to the interior surface of the jar element in alignment with the pre-determined pattern on the sleeve. The jar is then filled with wax.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of candles and candle making. More specifically, the invention relates to ajar candle having decorative items embedded therein.

Candles made from paraffin or wax are well known and are manufactured and sold in a variety of shapes and styles. In one style the candle is a stand alone product formed from a wax material and having a wick extending there through. It is known to embed material into the candle by adding the material into a mold as the wax is being poured into the mold. As the wax hardens the material is embedded within the candle. The candle is then removed from the mold. Alternatively, material may be affixed to the outer surface of a candle after the hardened wax is removed from the mold. If the decorative material is formed from wax, the decorative material may be affixed to the outer surface of the candle by the application of heat. This method allows for the placement of decorative material to the outer surface of a candle.

Another type of candle that is sold is ajar candle. This type of candle includes a wax portion that is located and sold within ajar. The jar may of be any shape and it may be tinted or clear. Typically, jar candles may include decorative elements that are mixed with the candle wax. However, the position of the decorative elements are haphazard and not necessarily adjacent the jar. It would be desirable to locate decorative material on the outer surface of the wax portion so that the decorative material may be viewed through the jar. Further, it would be desirable to place the decorative material in a consistent pattern within the jar.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to ajar candle having an interior surface and a candle located within the jar. At least two decorative elements are located adjacent the interior and positioned in a predetermined relationship with respect to one another.

In another embodiment, a method for forming ajar candle includes proving a jar having an interior surface defining an interior region. A sleeve having a pre-determined pattern is slid over the jar. The sleeve and jar are aligned and a decorative element is applied to the interior surface of the jar element in alignment with the pre-determined pattern on the sleeve. The jar is then filled with wax.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring toFIG. 1, a jar candle10includes a jar12having a candle14located therein. Candle14includes a plurality of decorative elements16adjacent an inner surface18of jar12. Decorative elements16maybe formed from a wax material such as paraffin, vegetable wax, beeswax or any other type of wax known in the art. Alternatively, decorative elements may be formed from natural or non-natural materials, such as wood, metal or any other type of material. The decorative elements16maybe placed in a predetermined relationship relative to one another and/or relative to jar12. Jar12may also include a cover20that fits within an opening22of jar12.

In a preferred embodiment, jar12includes a non-uniform profile that includes an upper portion24that has a cross section less than a cross section of a lower portion26. Alternatively, jar12could include a profile in which the walls taper outward from a bottom28toward the top30of jar12. Where the profile of the jar is not uniform, it is not possible to simply slide a pre-formed candle into the jar once the candle has hardened and have the candle be adjacent the entire inner surface of jar12. Accordingly, in order for the pre-formed decorative elements16to be adjacent the inner surface of jar12for a non-uniform jar, the candle and elements need to be formed within the jar.

Referring toFIGS. 2–9, the process for manufacturing ajar candle with decorative elements16will now be described. In a preferred embodiment, decorative elements are formed from a wax material. A mold32includes at least one recess34. A wax material is poured into recesses34of mold32and allowed to cool. Once the wax is cooled, a preformed decorative elements16are removed and decorated with paint36or other material such as glitter or any other material known in the art.

A clear sleeve38that has an open ended tubular shape is slid over an outer surface39of jar12. Clear sleeve38includes an upper end40and a lower end42. The inner surface44or an outer surface46of sleeve38includes a printed outline48of the decorative elements to be applied.

Jar12is placed on a support surface such as a table or work area and the bottom42of clear sleeve38is also supported on the support surface. In this manner clear sleeve38and jar12are vertically aligned. If jar12is non circular, it is possible to use a non-circular sleeve that has a shape corresponding to the non-circular jar. It is also possible to align clear sleeve38about the periphery of jar12in order to properly align the printed outline48. For example, it may be desirable to align printed outline48with a label that may already be affixed to jar12.

Referring toFIG. 5, decorative elements16are secured to the inner surface18of jar12at the location that aligns with the printed outline48of sleeve38. Each element16may be secured to inner surface18with an adhesive50such as glue or the actual wax itself to form a temporary bond with the inner surface18of jar12. In one embodiment, both jar12and sleeve38are clear so a user can easily align the decorative elements to fit within the printed outline48of sleeve38. However, jar12and sleeve36may be tinted or otherwise not completely clear.

Referring toFIG. 6, once all of the decorative elements16are applied to the inner surface18of jar12, sleeve38is slid off of jar12. Sleeve38can then be used again for a second jar. In order to fully secure decorative elements within jar12, a first wax52may be applied within jar12. The application of first wax52may be accomplished by simply filling the interior of jar12to a level that covers the decorative elements. However, it may also be desirable to apply a first wax to only cover inner surface18of jar12and the decorative elements with a layer of wax, but not fill the entire jar. For example if the jar12has an inner diameter of 3 inches, the layer of first wax adjacent inner surface18may be 0.25 inches. This layer of wax can be poured in a melted state as the jar is being rotated about its longitudinal axis to evenly apply the first wax layer. If the decorative element is less than 0.25 inches an outer periphery and the face of the decorative element opposite a first side proximate the inner surface of the jar will be covered with the first layer of wax. It may be desirable that the first wax52have certain characteristics with regard to color, sheen or opacity that is not required of the entire candle.

Once, the first layer of wax52is applied, a second pre-formed candle54with a wick is inserted in the remaining opening that fits within opening22of jar12. In one embodiment, the diameter of opening22is 2.5 inches, and pre-formed candle54has a diameter slightly less than the diameter of opening22, to allow easy insertion of candle54within jar12and within the opening formed by first wax52. It may be desirable to use a wax with coloring on the first wax layer and then eliminate the color in the second wax layer. Further, it may be desirable to have the first layer be translucent, so that the color of the second wax layer is seen though the first wax layer. The use of two layers or more of wax provides a cost effective approach to the manufacturing of the candle, thereby providing a less expensive product to the consumer.

A filler wax56is then poured into jar12to fully secured pre-formed candle54within jar12. Filler wax56may be the same type of wax as first wax52thereby providing the appearance a uniform appearance of the wax within jar12. The first, second and filler or finishing wax may be formed of any known wax material. In a preferred embodiment some of the wax may be a blend of palm oil and paraffin.

It is important to note that the construction and arrangement of the elements of the media as shown in the preferred and other exemplary embodiments is illustrative only. Although only a few embodiments of the present invention have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g. variations in sizes, dimensions, structures, shapes and proportions of the various elements values of parameters, mounting arrangements, use of materials, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, the decorative elements may be placed via an electronic device such as a robot in a predetermined pattern, eliminating the need for the sleeve. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present invention as expressed in the appended claims.