Patent Publication Number: US-2023141203-A1

Title: Biodegradable candle designs and methods of manufacture

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to candle design and manufacture. 
     BACKGROUND 
     Candles are commonly used for decorative purposes when unlit as well as for providing illumination and in many formulations pleasing aromas when lit. Typical candle design uses a wax body which may or may not be contained within a vessel and at least one wick embedded in the wax body. The wax body may be scented or unscented. The materials used in the production of many candles, however, may be environmentally problematic. Wax bodies made from petroleum-based paraffin both use an unsustainable source material in addition to producing potentially toxic byproducts when burned. Many of the substances used to provide scents in modern candles are also made from unsustainable and/or synthetic materials which produce potentially toxic byproducts during combustion. Even the non-combustible components of many candles may be environmentally problematic. Wicks are typically secured to a candle body using a metal ring which is commonly thrown away when the candle is fully consumed. Even if a vessel which holds the wax body is made from a recyclable material it is also frequently simply thrown away. These shortcomings of modern candle design and manufacture result in candles which use unsustainable resources to manufacture, produce potentially toxic air pollution when used, and leave behind waste once consumed that must be landfilled. It is evident that there is a continuing need for candle designs which use only sustainably sourced, biodegradable materials. 
     SUMMARY OF THE INVENTION 
     In one aspect, a candle design having a vessel with an upper body wall portion and a base portion defining a candle body volume, a wick fixably mounted to the vessel within the candle body volume by a securing plug, and a wax disposed within the candle body volume and surrounding at least a portion of the wick, where the vessel, wick, securing plug, and wax are all made from biodegradable and/or compostable materials. In one example the vessel is made from bamboo and the wax or combination of waxes used to make the candle are selected at least in part for their ability to adhere to bamboo. Such waxes include, but are not limited to, those made at least in part from coconut oils and include one or more of coco apricot crème, hemp coco soy, and combinations thereof. Optionally the waxes may include one or more fragrance compounds. The wicks may be made from cotton or wood and the securing plug from naturally occurring clays. In still other aspects, the bamboo vessel is coated with one or more layers of a flame retardant compound such as flame retardant compounds containing melamine. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a partial cross sectional view of a candle according to one embodiment; 
         FIG.  2    is perspective view of candle body vessels according to one embodiment; 
         FIG.  3    is a perspective view of a candle according to one embodiment; 
         FIG.  4    is a perspective view of a candle according to one embodiment; and 
         FIG.  5    is a partial cross sectional view of a candle according to another embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     A partial cross sectional view of a candle  10  according to one embodiment is shown in  FIG.  1   . In this particular example candle body vessel  12  having a cylindrical upper portion  28  and a substantially flat base portion  14  define a candle body volume  16 . In one embodiment, the flat base portion  14  may be a node structure which occurs in bamboo such as shown in greater detail in  FIG.  5   . The upper edge  26  of the cylindrical upper portion  28  of the candle body vessel  12  has been worked to produce a rounded edge. In other examples the upper edge may be worked to produce other profiles such as chamfers, bullnoses, bevels, and the like. The candle body vessel  12  is made from a material which is sustainably produced as well as fully biodegradable and/or compostable. In one example the candle body is made from bamboo which typically composts within 6 months. Within the candle body volume  16  a wick  22  is secured to the candle vessel  12  using a securing plug  20  and the volume  16  filled with wax  18  to the desired level until a tip  24  of the wick  22  remains above the wax level  18 . 
     Candles such as those described herein may be manufactured by first selecting and preparing a candle body vessel  30  such as those shown in  FIG.  2   . In this example, bamboo chutes are selected according to the desired diameter of the finished candle then cut to a desired length. The upper  32  and lower  40  ends are then shaped and finished to produce a desired edge profile. For example, the lower end  40  may be cut flat and then sanded whereas the upper end  32  may be given a more decorative finish such as a bevel and then sanded or polished to remove any rough portions. Once the bamboo vessel is cut and shaped to the desired length and profile decorative features  38  may be added to the exterior surface  36 . The exact nature and scope of the decorative features may vary as desired. In this particular example, the profile of a large cat has been branded to the exterior surface  36  using a heated branding iron. In other examples other patterns, words, images, and the like may be added. 
     After any desired decorations are added to the vessel they are treated with one or more applications of a suitable flame retardant substance. In one example, the flame retardant substance is non-toxic, eco-friendly, and/or is sustainably produced. Such flame retardant substances include melamine compounds (one example of which is sold under the name Flamecheck M-111 by Flamecheck® International, LLC of Tucson, Ariz., USA) which typically work by insulating a coated substance from heat as well as evolving nitrogen gas when burned or charred which inhibits further combustion. One or more coats of a suitable fire retardant substance are applied evenly to all surfaces of the candle body vessel  30  including the upper edge  32 , lower edge  40 , exterior surface  36 , and interior surface  34 . Suitable application methods may include spray, brushing, dipping, and the like. 
     Once one or more applications of the flame retardant material have been applied and have dried or cured the candle may be constructed within the prepared candle vessel. First, a wick is set within the candle vessel body. The wick may be made from a variety of different sustainable, natural, and/or biodegradable materials including cotton or raw wood. Optionally raw wood wicks may be fabricated such that they produce an audible “crackling” sound when burned or they may be silent when burned. The amount and intensity of wick “crackle” may be controlled by the species of wood used, the moisture level in the wood, and the wax used in the candle. The wick is set by attaching it to the candle vessel within the vessel body using natural clay (which is fully compostable) rather than the traditional metal plate (which is not biodegradable or compostable). Once the wick is set the candle vessel body may be filled with wax. A variety of sustainably produced and biodegradable and/or compostable waxes may be used. In one example, the wax is selected at least in part for its ability to adhere to the bamboo of the candle vessel body. Natural waxes such as pure beeswax and palm oil wax which might be sustainably produced and biodegradable and/or compostable adhere to bamboo poorly which results in an unstable candle. Suitable waxes include, but are not limited to, coconut apricot crème (coco apricot crème), hemp coconut soy (hemp coco soy), and combinations thereof. Optionally one or more fragrance compounds may be added to the wax prior to casting a candle. In one particular example fragrance compounds are made from sustainably sourced materials and may be all natural, non-toxic, and/or fully biodegradable/compostable. The exact ratio of fragrance compound to wax may vary as desired. Typically fragrance is added up to 12% by weight, but more or less fragrance compound may be added depending on the characteristics of the wax used in a particular candle. Once any fragrance compounds have been added to the melted wax, the wax may be poured into the prepared candle vessel body to the desired level and allowed to cool. Once cooled the candle is finished and ready for use. Candles produced using these techniques are clean burning, producing minimal toxic byproducts when burned, and contain only biodegradable and/or compostable materials. Once the candle has reached the end of its useful life the remaining components (the vessel body, securing plug, and residual portions of the wick and/or wax) may be composted or recycled using normal means. 
     The previously described method may be used to produce variations of the candle shown in  FIG.  1   , which has a candle  42  having a wooden wick  44  as shown in  FIG.  3   . Optionally, a candle  46  having more than one wick  50  may also be produced as seen in  FIG.  4   . In this particular example the candle  46  also includes a decorative pattern  48  on the outer surface. Other patterns, symbols, lettering, and the like may also be burned, etched, carved, or otherwise produced on the outer surface of candles. 
     A partial cross sectional view of a candle  60  according to another embodiment is shown in  FIG.  5   . In this particular example candle body vessel  62  having a cylindrical upper portion  84 , a cylindrical lower portion  66 , and a substantially flat base portion  64  define a candle body volume  78 . In this particular example, the flat base portion  64  is a node structure  68  which occurs in bamboo and divides the cylindrical upper portion  84  and the cylindrical lower portion  66 . The upper edge  80  of the cylindrical upper portion  84  of the candle body vessel  62  has been worked to produce a rounded edge. The lower edge  82  of the lower cylindrical portion  66  has been worked to produce a flat edge which acts as a stable base for the candle  60 . In other examples the edges may be worked to produce other profiles such as chamfers, bullnoses, bevels, and the like. The candle body vessel  62  in this example is made from a bamboo material which is sustainably produced as well as fully biodegradable and/or compostable. Within the candle body volume  78  a wick  72  is secured to the candle vessel  62  using a securing plug  70  and the volume  78  filled with wax  76  to the desired level until a tip  74  of the wick  72  remains above the wax level  76 . 
     The exact length of the cylindrical upper portion and a cylindrical lower portion may vary as desired. Bamboo canes or stems are generally hollow, but are solid at nodes as shown in  FIG.  5   . By selecting a bamboo cane having a particular diameter and cutting the selected cane at particular locations along the internode length of the cane, a candle vessel having a desired length of cylindrical upper portion length and cylindrical lower portion length may be produced. Optionally, the cylindrical lower portion may be eliminated by cutting the bamboo at or near the node and machining or working the piece until the base portion is substantially flat leaving no cylindrical lower portion. 
     The present description is for illustrative purposes only and should not be construed to narrow the breadth of the present disclosure in any way. Thus, those skilled in the art will appreciate that nigh-infinite modifications might be made to the presently disclosed embodiments without departing from the full and fair scope and spirit of the present disclosure. Other aspects, features, and advantages may be apparent upon an examination of the attached drawings and appended claims. As used herein, the articles “a” and “an” are intended to include one or more items, and may be used interchangeably with “one or more.” Where only one item is intended, the term “one” or similar language is used. Also, as used herein, the terms “has,” “have,” “having,” or the like are intended to be open-ended terms. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.