Abstract:
A flameless candle molded into a jar is described. The jar is designed with an open bottom and is tooled for engagement with an electronic insert having batteries, control circuitry and at least one LED light. A candle is then formed in the jar with the electronic insert by molding a candle shell along the sidewalls of the jar. The candle shell is formed such that the sidewalls extend above the LED light of the electronic insert to allow the LED light to illuminate at a position below the sidewalls. The wax or waxen shell is formed only along the sidewalls, creating a hollow region above the electronic insert. Once the wax on the sidewalls sets, wax is then poured in the hollow regions above the electronic insert to a position just below or above the LED light.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority of U.S. Provisional Patent Application Ser. No. 61/922,628, filed on Dec. 31, 2013, titled LED MASON JAR CANDLE, which application is incorporated by reference in this application in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The application relates to flameless candles and, in particular, to methods and systems for molding flameless candles within glass jars having battery and/or electrical compartments on the bottom of the jar. 
     2. Related Art 
     Candles having light emitting diodes (LEDs) are increasingly popular for both home and commercial use. Such LED candles have become known as flameless candles. The flameless candle designs use candle shells that have wax or waxen material. The use of these waxen shells allows the flameless candle to appear more like a traditional candle while being relatively inexpensive to produce as compared to traditional candles. 
     Generally, the flameless candles have hollow regions within the candle body, which also decreases the manufacturing cost of the candle. Electronic inserts are placed, at least partially, into the hollow portions of the candle shell. Electronic inserts generally include at least one LED, a circuit board, and a power source. Circuitry may also be included that creates a flickering effect, making the candle appear more realistic. 
     Inserting the electronics into the hollow insert of the shell involves more than one step. For example, the candle shell is first molded. Electronics are then inserted into the hollow portion of the candle shell. Subsequently, hot wax or another sealant can be added between the electronic insert and the candle shell to secure the electronic insert to the candle shell. 
     More recently, it has become desirable to include flameless candles within containers or jars. This has added a different level of complexity to the manufacturing process. As a result, the jar walls have replaced the candle shell walls, resulting in a more basic candle design being constructed within the jars. This more basic design is, however, less realistic in appearance. In particular, the candle designs in current jars lack the realistic depression commonly formed within real candles. This is a less desirable design because it not only lacks the depression but also causes the LED, when positioned above the wax line, to be clearly visible through the sides of the jar when the jar walls are clear. Having the LED clearly visible through the jar walls detracts from the realistic appearance of the candle. It is therefore desirable to have a candle design with a depressed flame below the sidewalls of the candle within the jar to create a more realistic appearance. 
     A need therefore exists for a method of manufacturing a flameless candle within a jar that provides for the candle shell sidewalls to extend upward within the jar, allowing for the flame to appear in a depression within the candle, rather than even with, or above, the candle. 
     SUMMARY 
     A flameless candle molded into a jar is claimed, depicted, and described. The jar has an open bottom tooled with a ring hole for engaging an electronic insert positioned at the bottom of the jar. The electronic insert includes batteries, control circuitry and at least one LED light. Within the jar, a candle shell is formed along the sidewalls of the jar. The candle shell has an open center or hollow region above the electronic insert. The sidewalls of the candle shell are formed to extend above the LED light of the electronic insert to allow the LED light to illuminate at a position below the sidewalls. A separate wax center portion fills the hollow regions above the electronic insert to a position just below or above the LED light yet below the top of the sidewalls of the candle shell. 
     A method for making a flameless candle in a jar is also claimed, depicted, and described. According to the method, the tooled ring hole opening in a bottom of the jar receives the electronic insert that engages with the ring hole of the jar through an engagement mechanism. Such engagement mechanism may be a friction or snap fit. A silicone mold is then inserted in the jar to create the wax sidewalls of the candle within the jar. The mold may provide for the walls to have flat top. Liquid wax is then poured into the mold to a point above the LED light. The wax is then allowed to cool. The silicone mold is removed and additional wax is poured above the electronic insert to a position just above or below the LED but lower than the top of the sidewalls. 
     Alternatively, the sidewalls can be poured first with a silicone mold insert and then the electronic insert can be inserted into the jar through an engagement mechanism. Additional wax is then poured over the electronic insert to a position just above or below the LED but lower than the top of the sidewalls. 
     Other devices, apparatus, systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       The invention may be better understood by referring to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views. 
         FIG. 1  is prior art flameless candle in a jar illustrating the illuminating element positioned above the top of the waxen material in the jar. 
         FIG. 2  is the bottom of the prior art flameless candle in  FIG. 1  illustrating the electronic insert positioned at the bottom of the jar. 
         FIG. 3  is a perspective top view of a flameless candle in a jar that is designed in accordance with the present invention. 
         FIG. 4  is a bottom perspective view of the flameless candle of  FIG. 3 . 
         FIG. 5  is a bottom view of the flameless candle of  FIG. 3 . 
         FIG. 6  is a bottom perspective view of the flameless candle of  FIG. 3  with part of the electronic insert removed. 
         FIG. 7  is a bottom view of the flameless candle of  FIG. 6 . 
         FIG. 8  is a top view of the flameless candle of  FIG. 3  illustrating the LED positioned above the wax indentation but below the top of the side walls of the candle. 
         FIG. 9  is a cross-section of a flameless candle of the present invention illustrating the sidewalls being molded in the jar. 
         FIG. 10  is a cross-section of the flameless candle of the present invention illustrating the sidewalls and a center depressed wax portion molded in the jar. 
         FIG. 11  is a cross-section of another example of a flameless candle of the present invention illustrating the sidewalls being molded in the jar. 
         FIG. 12  is a cross-section of the flameless candle of  FIG. 11  illustrating the sidewalls and a center depressed wax portion molded in the jar after the placement of the electronic insert in the jar. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is a prior art flameless candle in a jar illustrating the illuminating element positioned above the top of the waxen material in the jar. As illustrated, creating a flameless candle within a jar is somewhat difficult and is typically done by filling an opened bottomed jar having an electronic insert position in the bottom with a waxen material to a fill line. The waxen material is formed entirely around the electronic insert and holds the electronic insert within the jar. The waxen material is generally filled to a point just below the illuminating mechanism of the flameless candle but may be filled above the LED when an ornamental wick is used just above the LED. 
       FIG. 2  is the bottom of the prior art flameless candle in  FIG. 1  illustrating the electronic insert positioned at the bottom of the jar. As illustrated in  FIG. 2 , the wax material is formed around the electronic insert between the jar walls to hold the electronic insert in position at the bottom of the jar. 
       FIG. 3  is a perspective top view of a flameless candle in a jar  100  that is designed in accordance with the present invention.  FIGS. 4 and 5  illustrate a bottom perspective view and bottom view of the flameless candle of  FIG. 3  illustrating the jar  100  having an open bottom defined by a ring hole  104  for receiving an electronic insert  102 . 
       FIGS. 6 and 7  illustrate a bottom perspective view and bottom view of the flameless candle of  FIG. 3  with part of the electronic insert  102  removed. As illustrated in  FIGS. 6 and 7 , the electronic insert  102  is a housing having side walls  610 , top surface  612  and a bottom end cap  608 . Within the bottom end cap  608  is a battery compartment  602  and an electronic circuit board  604  for powering and controlling an LED  108  ( FIG. 8 ) that rests on the outside of the top surface  612  of the electronic insert  102 . 
       FIG. 8  is a top view of the flameless candle of  FIG. 3  illustrating the LED  108  with a flame cap  110  positioned above a wax indentation  114  but below the top of the side walls of the candle shell  112 . The LED  108  is positioned on the top surface  612  of the electronic insert  102 , as illustrated in  FIGS. 6 and 7 . 
       FIGS. 9 and 10  show cross-section views of a flameless candle according to one implementation of the invention.  FIG. 9  illustrates the sides  112  of the candle shell  105  being molded into the jar  100 . As illustrated, the jar  100  has an open bottom for engaging an electronic insert  102 , which may be defined by a ring hole  104  for engagement of the electronic insert  102 . The electronic insert  102  is positioned at the open bottom of the jar  100 . The electronic insert  102  includes a battery compartment  602  along with and LED  108  and a diffuser, light chamber or cap  110  that contains the LED  108 . The diffuser  100  may take the form of imitation flame. In other implementations, an ornamental wick may be positioned above the LED  108 . 
     The electronic insert  102  may be slightly smaller in circumference then the opening of the jar  100  but may include, at its edges, a snap feature  104  for securing the electronic insert to the ring hole  104  of the jar  100 . Once the electronic insert  102  is fitted within the jar  100 , a silicone mold  106  is positioned in the jar for creating wax or waxen sides or sidewalls  112 . The silicone mold  106  has a top for preventing and stopping the flow of wax beyond a desired height. The top of the mold  106  may be designed to create a flat top on the molded sidewalls  112 . To position the LED  108  within the central opening of the sidewalls  112 , the sidewalls  112  are molded to extend above the LED  108  of the electronic insert  102 . The candle shell sidewalls  112 , when molded against the walls of the jar  100 , further fills any gap between the electronic insert  102  and the walls of the jar  100  to seal the electronic insert  102  in the bottom of the jar  100 . 
       FIG. 10  is a cross-section section of the flameless candle of the present invention illustrating the candle shell sides  112  and the center depressed wax portion  114  molded in the jar  100 . As illustrated in  FIG. 9 , once the sidewalls  112  are formed, additional waxen or wax material  114  is poured in the center of the jar  110  to create a depression and to cover the electronic insert  102 . In the illustrated example, the central wax portion  114  is poured with a top wax line just below the illumination member  110  and LED  108 . In other implementation, the wax line may be just above the illumination member  110 , especially when an ornamental wick is used above the LED. As illustrated, the illumination member  110  is positioned below the top of the candle shell sidewalls  112  to create a depression in the candle design and lower the LED  108  below the candle shell sidewalls  112 . 
     While  FIGS. 9 and 10  illustrate the LED elevate above the electronic insert  102 , the LED  108  may rest just above the top surface  612  of the electronic insert  102 , as illustrated in  FIGS. 6, 7, and 8 . In this case, the electronic insert  102  may be larger than illustrated in  FIGS. 9 and 10  and only a small amount of wax or waxen material  114  is required to cover the top of the electronic insert  102 . 
     In operation, a jar  100  is tooled with an open bottom having a ring hole  104  for receiving and engaging an electronic insert  102 . The electronic insert  102  is then positioned within the opening at the bottom of the jar  100  and engages with the ring hole of the jar  100  through an engagement mechanism. A silicone mold  106  is then inserted in the jar  100  to create wax sidewalls  112  within the jar  100  such that the sidewalls  112  are molded to a point above the LED light  108 . The mold  106  may provide for the sidewalls  112  to have a flat top. Liquid wax is then poured into the mold  106  to a point above the LED light  108 . The liquid wax helps to further secure and seal the electronic insert  102  within the jar  100  when the wax dries by filling any gap between the electronic insert  102  and the glass walls of the jar  100 . 
     The wax  112  is then allowed to cool at room temperature. The jar  100  can optionally be placed in water to cool the wax further. The silicone mold  106  is then removed from the jar  100  and the jar  100  is removed from any water (if placed in water to cool). As needed, the top of the wax line on the candle shell sidewalls  112  is smoothed flat (with a knife, for example) to remove any imperfections. Additional wax  114  is then poured on top of the electronic insert  102  to a point below the candle shell sidewalls  112 . The wax  114  is then allowed to cool in the same manner as the wax is cooled for the sidewalls  112 . 
     Alternatively, the electronic insert  102  may not be positioned within the opening at the bottom of the jar  100  until after the sidewalls  112  are poured. In this case, a silicone mold  106  is inserted in the jar  100  to create wax sidewalls  112  within the jar  100  such that the sidewalls  112  are molded to a point that will be above the LED light  108  when the electronic insert  102  is positioned in the jar  100 . The mold  106  may provide for the sidewalls  112  to have a flat top. Liquid wax is then poured into the mold  106 . 
     The wax  112  is then allowed to cool at room temperature. The jar  100  can optionally be placed in water to cool the wax further. The silicone mold  106  is then removed from the jar  100  and the jar  100  is removed from any water (if placed in water to cool). The electronic insert  102  is then placed in the jar  100  through the bottom opening in the jar  100  and positioned between the sidewalls  112  of the candle shell  105 . Additional wax  114  is then poured on top of the electronic insert  102  to a point below the candle shell sidewalls  112 . The wax  114  is then allowed to cool in the same manner as the wax is cooled for the sidewalls  112 . 
       FIG. 11  is a cross-section of another implementation a flameless candle of the present invention that illustrates the sidewalls  114  being molded in the jar  100  without the electronic insert positioned within the jar  100  before the sidewalls  114  are molded. As illustrated, the silicone mold  106  has a top for preventing and stopping the flow of wax beyond a desired height. The top of the mold  106  may be designed to create a flat top on the molded sidewalls  112 . To position the LED  108  within the central opening of the sidewalls  112 , the sidewalls  112  are molded to extend above the LED  108  of the electronic insert  102  when inserted in the jar  100 . 
       FIG. 12  is a cross-section of the flameless candle of  FIG. 11  illustrating the sidewalls and a center depressed wax portion molded in the jar after the placement of the electronic insert in the jar. As illustrated in  FIG. 12 , once the sidewalls  112  are molded, the electronic insert  102  is fitted within the jar  100  and additional wax  114  may be poured over the top of the electronic insert  102 . 
     While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention include all embodiments falling within the scope of the appended claims. 
     The foregoing description of implementations has been presented for purposes of illustration and description. It is not exhaustive and does not limit the claimed inventions to the precise form disclosed. Modifications and variations are possible in light of the above description or may be acquired from practicing the invention. The claims and their equivalents define the scope of the invention.