Abstract:
The inventor has identified a desire for a customer experience in which the customer constructs their own personalised candle in which the customer can select their desired combination of candle components from a range of different components. Thus there is provided a method of assembling a candle, the method including providing a plurality of n wax layers, wherein n is at least two and wherein each wax layer comprises a hole extending through the centre of the wax layer; providing a wick on which the plurality of n wax layers will be assembled; inserting the wick through the hole of the first wax layer such that the wick extends through the wax layer and the base of the wax layer contacts the base of the wick; for each subsequent wax layer inserting the wick through the hole in that subsequent wax layer such that the wick extends through the wax layer and locating the subsequent wax layer such that it contacts a previously located wax layer.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to a method of manufacturing a candle and specifically to a method of manufacturing a multi-layer candle. 
       BACKGROUND OF THE INVENTION 
       [0002]    Consumer demand for candle products has and continues to increase. Candles are now not only used as a source of light but also more frequently as a source of smell. This can be for hygienic or medical reasons such as alternative medicines or the like. Frequently candles are used in the domestic environment to provide the user with a pleasant smell throughout the home as an example. 
         [0003]    Conventional candles comprise a simple elongate cylindrical wax body with a coaxial wick running through the centre thereof. The wick is lit and the candle wax slowly burns until the wax has been consumed and the flame extinguished. More recent candles are however far more varied in shape and size and this presents a number of challenges to the manufacturer. 
         [0004]    The inventor has established that there is a desire within the market for a consumer experience in which the consumer is able to request and have manufactured their own personalised or bespoke candle. This might, for example, be for a gift or the like. In such an arrangement a consumer would select their desired candle components from a range of different components according to their own taste. This could be in a shop or via a website. The consumer can then construct an individual combination candle which has presented significant challenges to date. 
         [0005]    However, the inventor has also established that there are technical complications and difficulties of manufacturing such a multi-component candle. An invention described herein addresses these technical problems to allow a bespoke multi-layer candle to be manufactured in the commercial environment. 
         [0006]    Technical problems arise in particular if a candle is formed of at least two different parts for example if two or more different wax layers are contemplated. Forming a single candle of two different waxes poses problems with respect to locating the two wax parts with respect to each other and with respect to the wick and ensuring both waxes burn, in particular in the region of transfer from one wax to the other. 
         [0007]    One problem is concerned with the phenomenon of ‘pillaring’ in candles which are formed of two or more layers. 
         [0008]    Candle pillaring occurs when only a portion of the candle wax melts, resulting in an open hole or pillar extending along and within the candle. The pillar follows the path of the wick. This is a particular problem when contemplating a candle formed of a number of waxes since in the region of transfer between wax layers the wick can deviate from the desired location which can lead to pillaring. 
         [0009]    Candle pillaring results in inefficient use of the candle wax since not all of the wax is consumed. It is not then possible to ignite the remaining wax which is of course wasteful and also unattractive. 
         [0010]    Furthermore, pillaring can cause a build-up of molten wax within the hole which can extinguish the flame and requiring the user to repeatedly re-light the candle. Alternatively the build-up of molten wax can flood the wick such that it is not possible to relight the candle as wax covers the wick. 
         [0011]    The present invention provides solutions to these and other issues with the manufacture of multi-layer candles and additionally provides other technical and commercially advantageous features. 
       SUMMARY 
       [0012]    Aspects of the invention are defined in the accompanying claims. 
         [0013]    According to a first aspect there is provided a method of assembling a candle, the method including: providing a plurality of n wax layers; wherein n is at least two; and wherein each wax layer comprises a hole extending through the centre of the wax layer; providing a wick on which the plurality of n wax layers will be assembled; inserting the wick through the hole of the first wax layer such that the wick extends through the wax layer and the base of the wax layer contacts the base of the wick; for each subsequent wax layer inserting the wick through the hole in that subsequent wax layer such that the wick extends through the wax layer and locating the subsequent wax layer such that it contacts a previously located wax layer. 
         [0014]    The method may further include the step of melting a surface of each subsequent wax layer before inserting the wick through the hole in that wax layer such that the melted surface contacts a previously inserted wax layer. 
         [0015]    The wick may be provided on a candle base. The base may include a plurality of locating elements extending away from the base such that when the wick is inserted through the wax layers each wax layer is located between the locating elements. 
         [0016]    The method may further include the step of providing a cover around the wax layers such that the cover locates in the base and extends around the assembled wax layers. The cross sectional area of the candle may correspond substantially with the inner cross sectional area of the cover. The cover may be cylindrically shaped. 
         [0017]    The base may include a recess in which the first wax layer is located. 
         [0018]    Each wax layer may have a different olfactory component. Additionally or alternatively each wax layer may have a different colour. 
         [0019]    Each wax layer may be in the form of a disc. Each wax layer may have a substantially similar thickness. Alternatively at least one wax layer may have a different thickness. 
         [0020]    The method may further include the steps of requesting from a consumer a selection of each individual wax layer and/or requesting from a consumer a selection of the order in which the wax layers are assembled in the container. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    The invention will now be described by way of example only with reference to the following drawings in which: 
           [0022]      FIG. 1  illustrates a four layer candle; 
           [0023]      FIGS. 2 a -2 e    illustrate the manufacture of the four layer candle illustrated in  FIG. 1 ; 
           [0024]      FIG. 3  illustrates an alternative example of a four layer candle manufactured as shown in  FIGS. 2 a   - 2   e;    
           [0025]      FIG. 4  illustrates a further alternative example of a layer candle manufactured as shown in  FIGS. 2 a   - 2   e.    
           [0026]      FIG. 5 a    illustrates an exemplary base on which a candle may be assembled. 
           [0027]      FIG. 5 b    illustrates an alternative example of a base on which a candle may be assembled. 
       
    
    
       [0028]    In the Figures like parts are depicted by like reference numerals. 
         [0029]    While the invention is susceptible to various modifications and alternative forms, specific embodiments are shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the drawings and detailed description of the specific embodiments are not intended to limit the invention to the particular forms disclosed. On the contrary, the invention is covering all modifications, equivalents and alternatives falling within the spirit and the scope of the present invention as defined by the appended claims. For example, various combinations of the features of the dependent claims could be made with the features of the independent claims without departing from the spirit and scope of the present invention. 
       DETAILED DESCRIPTION 
       [0030]    A four layer candle ( 10 ) that can be manufactured according to a customer&#39;s specific requirements is illustrated in  FIG. 1 . In the example shown the candle is a cylindrical shape but may be any other shape, for example a cuboid shape or any other prismatic shape. 
         [0031]    The candle ( 10 ) is formed of four layers of wax ( 1 ,  2 ,  3 ,  4 ). Each layer of wax ( 1 ,  2 ,  3 ,  4 ) is preformed with a hole drilled through the centre of the layer. The cross section of each wax layer ( 1 ,  2 ,  3 ,  4 ) corresponds substantially to the inner cross section of the shape of the final candle ( 10 ). Thus in the example illustrated, since the candle ( 10 ) is a cylindrical shape, each layer of wax ( 1 ,  2 ,  3 ,  4 ) is also of cylindrical shape. Thus each wax layer ( 1 ,  2 ,  3 ,  4 ) is of the same shape as the final candle ( 10 ) but has a shorter length. Each wax layer ( 1 ,  2 ,  3 ,  4 ) is thus in the form of a disc. 
         [0032]    In the present disclosure the term disc is used to refer to any prismatic shape having a short length not just a disc with a circular cross section. Thus, for example triangular, square or octagonal discs are contemplated. The term disc is therefore used to describe a thin or short prismatic shape and is not limited to a thin cylindrical member. 
         [0033]    As discussed above in some examples, other shapes of candle are contemplated and therefore each wax layer may be of any shape. In particular, shapes that have a cross sectional area corresponding to the cross sectional area of the final candle are contemplated. 
         [0034]    In the example shown in  FIGS. 1 , each wax layer ( 1 ,  2 ,  3 ,  4 ) has the same thickness a, typically, 20-35 mm. In particular examples each layer is 25-30 mm thick. Each wax layer has a hole extending through the centre of the layer. The hole is typically between 1 mm and 3.5 mm in diameter. In particular examples the hole is 1.5 mm-3 mm in diameter. 
         [0035]    The hole in each layer of wax is precisely drilled in order to provide accurate location of the wick when the wax layers are assembled together. Thus deviations in the location of the wick ( 12 ) between wax layers ( 1 ,  2 ,  3 ,  4 ) are avoided which in turn helps to prevent pillaring occurring. 
         [0036]    Candle pillaring occurs when only a portion of the candle wax melts, resulting in an open hole or pillar extending along and within the candle. The pillar follows the path of the wick. 
         [0037]    Thus if the wick is not located correctly pillaring can occur. Candle pillaring results in inefficient use of the candle wax since not all of the wax is consumed. It is not then possible to ignite the remaining wax which is of course wasteful and also unattractive. Furthermore, pillaring can cause a build-up of molten wax within the hole which can extinguish the flame and requiring the user to repeatedly re-light the candle. Alternatively the build-up of molten wax can flood the wick such that it is not possible to relight the candle as wax covers the wick. 
         [0038]    Each wax layer ( 1 ,  2 ,  3 ,  4 ) may be different to the other wax layers. For example each wax layer ( 1 ,  2 ,  3 ,  4 ) may have a different scent. Alternatively, or in addition each layer of wax ( 1 ,  2 ,  3 ,  4 ) may have a different colour. 
         [0039]    By supplying the wax in layers or discs of the appropriate dimensions, it is possible for the candle to be assembled at the point of sale, for example in a retail establishment, thereby providing the consumer with greater choice and flexibility. Thus the way the candle is manufactured allows a bespoke candle customised to the user&#39;s particular requirements to be provided. 
         [0040]    A wick ( 12 ) extends through all four wax layers ( 1 ,  2 ,  3 ,  4 ) of the candle and extends out of the top of the top layer of wax ( 4 ) by a few millimetres, typically 5-10 mm, to provide a length of wick ( 12 ) in order to light the candle. The wick ( 12 ) is provided in the centre of the wax layers ( 1 ,  2 ,  3 ,  4 ) in order to promote complete burning of the candle ( 10 ). In other words all of the wax is consumed when the candle ( 10 ) burns. The wick ( 12 ) is located in the hole provided in each wax layer ( 1 ,  2 ,  3 ,  4 ) thus assembling the final candle ( 10 ). Typically the size of the wick is smaller than the diameter of the hole. This facilitates assembly of the wax layers ( 1 ,  2 ,  3 ,  4 ) into the wick ( 12 ) to form the candle ( 12 ). It has been ascertained that when the candle ( 10 ) is first burned the wax immediately adjacent to the hole in which the wick ( 12 ) is located melts to fill the gap between the wax layer ( 1 ,  2 ,  3 ,  4 ) and the wick ( 12 ) thereby securing the wax layer ( 1 ,  2 ,  3 ,  4 ) to the wick ( 12 ). Thus assembly of the candle ( 10 ) is facilitated whilst still securing the wax layers ( 1 ,  2 ,  3 ,  4 ) to the wick ( 12 ). 
         [0041]    A candle ( 10 ) is thus provided such that when the candle ( 10 ) is lit, the top layer of wax ( 4 ) burns first, then the next layer ( 3 ), then the penultimate layer ( 2 ) and finally the last layer ( 1 ). Thus each layer of wax ( 1 ,  2 ,  3 ,  4 ) is consumed as the candle ( 10 ) is burned. The layered form of the candle provides advantages where a particular scent or colour of light is required for a particular length of time for example in an alternative medicine regime or the like. 
         [0042]      FIGS. 2 a -2 e    illustrate the manufacture of the candle illustrated in  FIG. 1 . Advantageously the inventors have arrived at a method of manufacturing candles that can be easily achieved at the point of sale. This provides advantages in terms of providing consumers with the opportunity to create a bespoke product according to their exact specification and leads to a reduction in the amount of stock (in terms of finished candles) that needs to be kept in order to provide the consumer with a wide range of choice. Indeed the number of permutations of end-product candles that may be produced according to the present techniques, in particular when for example 3 or more wax layers are used and there are several choices for the configuration (colour, scent etc) of each layer, will generally greatly exceed the number of different types of finished “off-the-shelf” candles that could otherwise realistically be stocked by the retail establishment. 
         [0043]    The first step in manufacturing a candle is that the individual components of the candle must be selected by the consumer. Each retail outlet provides the consumer with a large choice of ready made wax layers of different types from which to select the four layers they want to use to create the candle. The consumer selects the particular wax layers that they wish to use. For example they may select wax layers of different scents and/or colours. 
         [0044]    The consumer also selects the order in which they would like the different layers to be assembled. Once these decisions have been made the manufacture of the candle can proceed. 
         [0045]      FIG. 2 a    illustrates the first wax layer ( 1 ) being located on the wick ( 12 ). Firstly, a wick ( 12 ) on which the candle is to be assembled is provided. The wick typically has a small metal disc ( 14 ) attached to its base The first bottom wax layer ( 1 ) is selected and threaded onto the wick ( 12 ) via the preformed hole extending through the centre of the wax layer ( 1 ) such that the base of the first wax layer ( 1 ) contacts the metal disc ( 14 ) at the base of the wick ( 12 ). 
         [0046]      FIG. 2 b    illustrates the second wax layer ( 2 ) being provided on top of the first wax layer ( 1 ). The wick ( 12 ) is threaded through the hole in the centre of the second wax layer ( 2 ) such that the base of the second wax layer ( 2 ) contacts the upper surface of the first wax layer ( 1 ). 
         [0047]      FIG. 2 c    illustrates the third wax layer ( 3 ) being provided on top of the second wax layer ( 2 ). The wick ( 12 ) is threaded through the hole in the centre of the third wax layer ( 3 ) such that the base of the third wax layer ( 3 ) contacts the upper surface of the second wax layer ( 2 ). 
         [0048]      FIG. 2 d    illustrates the fourth wax layer ( 4 ) being provided on top of the third wax layer ( 3 ). The wick ( 12 ) is threaded through the hole in the centre of the fourth wax layer ( 4 ) such that the base of the fourth wax layer ( 4 ) contacts the upper surface of the third wax layer ( 3 ). 
         [0049]    Thus a stack of wax layers ( 1 ,  2 ,  3 ,  4 ) are built up on the wick ( 12 ) in the order selected by the consumer. The wax layers ( 1 ,  2 ,  3   4 ) are each located on top of each other on the wick. Gravity assists in keeping the wax layers in place on top of one another. In some examples the base of each wax layer ( 1 ,  2 ,  3 ,  4 ) is melted slightly to assist in securing the wax layers ( 1 ,  2 ,  3 ,  4 ) to each other. In other examples the wax layers are spot welded to each other. Secure location of the wax layers ( 1 ,  2 ,  3   4 ) is important for continuous burning of the candle in particular in the region of transfer from one wax layer to another. Additionally it is important that the layers of wax that make up the candle do not come apart during transportation. 
         [0050]      FIG. 2 e    illustrates the assembled candle as shown in  FIG. 1 . 
         [0051]    Thus a method of assembling a candle from a variety of different candle components that is suitable for assembly at the point of sale has been shown. This method of assembly enables retailers to provide consumers with greater choice and flexibility whilst maintaining low stock levels. 
         [0052]    Although a particular example candle and method has been described above the invention is not limited to these examples. 
         [0053]    For example although it has been described that each wax layer includes a hole through the centre of the layer before the candle is assembled, in an alternative example the wax layers are assembled before a hole is drilled for the wick. The layers of wax can thus be assembled into the final candle form before the wick is inserted. By drilling the hole through the assembled layers of wax the accurate location of the wick can be facilitated. Thus deviations in the location of the wick between wax layers can be reduced. 
         [0054]    The method illustrated in  FIG. 2 a -2 e    could be used to assemble a candle having layers of different thicknesses.  FIG. 3  illustrates one such example candle ( 20 ). The candle ( 20 ) is substantially the same as that illustrated in  FIG. 1  with the exception that two different thicknesses of wax layers are used. The first and third wax layers ( 5 ) have a thickness of x mm where x is approximately 40 mm and the second and fourth wax layers ( 6 ) have a thickness of y mm where y is approximately 15 mm. 
         [0055]    Further examples can also be contemplated for example, a candle in which each wax layer is a different thickness. The method of  FIGS. 2 a -2 e    can therefore be used to assemble a candle having wax layers of any desired thickness. 
         [0056]    Although the method of  FIGS. 2 a -2 e    is described with reference to a four layer wax candle, the method is not limited to a wax candle with this number of layers. The method can be used to assemble a candle with any number of wax layers, for example six wax layers as illustrated in  FIG. 4 . Thus the method described can be used to assemble a candle with n wax layers where n is greater than or equal to 1. 
         [0057]    Whilst in the examples above the candle is assembled without any additional support, the candle may alternatively be assembled on a base designed to facilitate assembly of the candle.  FIG. 5 a    illustrates one example of a base ( 40 ) on which the candle may be assembled. The base ( 40 ) is a circular member having a recess ( 45 ) provided on an upper surface. The area of the recess ( 45 ) corresponds to the cross sectional area of the final candle such that the candle locates in the recess ( 45 ) thereby assisting in securing the candle to the base ( 40 ). A wick ( 12 ) secured to the base ( 40 ) in the centre of the recess ( 45 ) and extends away from the base ( 40 ). Thus when the wax layers are located on the wick ( 12 ) they are located in the recess ( 45 ). The base ( 40 ) is typically formed of metal but may also be formed of glass or any other suitable material. The provision of the base ( 40 ) and recess ( 45 ) assists in holding the wick ( 12 ) in position during assembly of the candle. 
         [0058]      FIG. 5 b    illustrates an alternative example of a base ( 50 ) on which the candle may be assembled. In this example the base ( 50 ) has no recess but includes three locating members ( 55 ) extending away from the base ( 50 ). The locating members ( 55 ) are cylindrically shaped in this example but may be any other suitable shape. The locating members ( 55 ) are provided around the outside of the base ( 50 ) with a wick ( 12 ) extending away from the centre of the base ( 50 ) such that when the candle is assembled the wax layers locate in the middle of the locating members ( 55 ). The locating members ( 55 ) are positioned at regular intervals around the outer surface of the candle thereby assisting in positioning the wax layers in the centre of the base ( 50 ) and in maintaining a straight-sided candle. In the illustrated example three locating members ( 55 ) are shown, however any number of locating members may be used depending on the size and shape of the particular candle being assembled. 
         [0059]    In a further example, a base having both a recess and locating members may be utilised thereby providing two means of locating and securing the wax layers on the base. 
         [0060]    In further examples, the arrangements illustrated in  FIGS. 5 a  and 5 b    may include a cover or guard arranged around the outside of the candle to protect it. Thus the method of assembling such a candle includes a step of locating a cover around the outside of the candle. 
         [0061]    The cover or guard may be made of glass or any other suitable material. In some examples the shape of the cover or guard corresponds substantially to the shape of the candle it protects but with a slightly larger diameter such that the cover or guard does not contact the candle. In the example of  FIG. 5 a    a lip or second recess may be provided around the outer edge of the base to assist with locating the cover or guard in position. In the example of  FIG. 5 b    the cover or guard may be dimensioned such that the locating members and the candle fit within the cover or guard. Thus the locating members are provided between the candle and the cover or guard and assist with securing the cover or guard in place around the candle. 
         [0062]    In an alternative example the shape of the cover or guard may be different to the shape of the candle it protects. For example, the cover or guard may have a cuboid shape and the candle may have a cylindrical shape. Thus many shapes of cover or guard are envisaged in particular those that protect the entire candle from damage or shield the candle from air flow that may snuff the candle out. 
         [0063]    In the examples described above the candle has been described as being formed alone or on a base. However the method of assembling the candle could also be used to assemble a candle in a container. In this example the wick would be provided in the base of the container and the wax layers assembled into the container. In such an example the sides of the container may be slightly heated thereby melting the edge of the wax layer to the container. Thus secure location of the wax layers in the container is provided. 
         [0064]    Thus a method of assembling a variety of different layer candles according to a consumer&#39;s particular requirements has been described. This provides particular advantages in terms of enabling greater consumer choice and customisation of products.