Patent Publication Number: US-9885007-B2

Title: Wax forms with permanent hardware

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This patent application claims the benefit of U.S. Provisional Patent Application No. 61/628,169, entitled “Method of making wax forms with permanent hardware for Attaching Ornamentation,” filed Oct. 24, 2011, which application is incorporated in its entirety here by this reference. 
     BACKGROUND OF THE INVENTION 
     Technical Field 
     This invention relates to making of wax forms, including but not limited to candles, with permanent hardware. 
     Background Art 
     Currently, there are candles and wax forms that have ornamentation affixed to their sides, most often with adhesives or by tying some type of material around the candle, such as string or raffia, or pinned into the wax. Some ornaments are molded into candles and wax forms, but these are permanently embedded, and have no provisions by which to attach other ornamentation. Thus, there is a need for a method and apparatus for embedding permanent hardware into the surface of a wax form or candle, wherein the hardware acts as an ornament itself, and may further serve as an attachment device for other ornamentation. 
     BRIEF SUMMARY OF INVENTION 
     The present invention is directed to wax forms, including candles, and hardware embedded therein. The hardware allows wax forms and candles to be adorned with ornamentation. To that effect, a connector portion of the hardware may be flush with the outer surface of the wax form or candle. The connector comprises a fastener to attach to the ornamentation. The ornamentation has a reciprocal fastener to attach to the connector. 
     In some embodiments, the hardware may have a stabilizer to facilitate securing the hardware in the wax form or candle. In some embodiments, multiple hardware may be utilized to hold multiple ornamentation. In some embodiments, the hardware may have multiple connectors, each connector flush with an outer surface region of the wax form for candle. 
     The hardware can be used in wax forms or candles of any shapes and sizes to provide a discreet way of adorning the wax forms or candles with ornamentation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an embodiment of the present invention. 
         FIG. 2  is a perspective view of another embodiment of the present invention. 
         FIG. 3  is an embodiment of a hardware of the present invention. 
         FIG. 4  is an exploded view of the hardware shown in  FIG. 1 . 
         FIG. 5  is a perspective view of another embodiment of a hardware of the present invention. 
         FIG. 6  is a perspective view of another embodiment of a hardware of the present invention. 
         FIG. 7  is a side view of a cross section of an embodiment of a mold with the hardware in place. 
         FIG. 8  is another embodiment of a mold filled with wax with the hardware in place. 
         FIG. 9  is a cross-section through line  9 - 9  of  FIG. 8 . 
         FIG. 10  is a perspective view from the top of another embodiment of a mold with the hardware in place, prior to filling with wax. 
         FIG. 11  is a close-up of a cross-section of an embodiment of the hardware in place with an ornamentation attached. 
         FIG. 12  is a close-up of a cross section of another embodiment of the hardware in place with an ornamentation attached. 
         FIG. 13  is a close-up of a cross-section of another embodiment of the hardware in place with an ornamentation attached. 
         FIG. 14  is a perspective view of a hurricane embodiment of the invention with an ornamentation attached. 
         FIG. 15  is a perspective view of an embodiment of a hurricane mold with the hardware in place, prior to filling with wax. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. However, it is to be understood that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention. 
     The present invention is directed towards a decorable wax form or candle  100 . In this description, decorable means capable of being decorated or adorned, for example, with ornamentation, including two or three dimensional shapes, letters, or numbers, music boxes, broaches, and other articles or accessories used to beautify an object. The decorable candle  100  typically comprises a wax core  102  having an outer surface  104 , an optional wick  106  embedded in the core, and a hardware  300  permanently embedded in the core  102 . Alternatively, the decorable wax form or candle  100  may be in the form of a hurricane, which comprises a wax shell with at least one open end and a hollow interior, as shown in  FIG. 14 . A hurricane may a variety of shapes, including but not limited to round (see  FIG. 14 ), square, rectangular, polygonal, oval, etc. (not shown). A hurricane is typically used to contain another illumination source, such as a candle, an LED lamp, or other illumination source that can highlight the design of the wax shell. The “core”  102  in a hurricane refers to the wax between the outer surface  104  and the interior surface  103 , which interior surface  103  defines the hollow interior, as depicted in  FIG. 14 . 
     The hardware  300  provides a means for adorning the candle with ornamentation  108 . In general, the hardware  300  can be any device capable of allowing ornamentation  108  to be attached to it while the hardware  300  is embedded inside the wax core  102 . As such, the hardware  300  has a connector portion  302  and an anchor portion  304  as shown in  FIGS. 3-6 . The connector portion  302  is configured to attach to the ornamentation  108 . The anchor  304  is configured to embed inside the wax core  102  so as to hold the ornamentation  108  in place on the wax core  102  as shown in  FIGS. 8 and 9 . 
     The connector  302  has a first side  306  and a second side  308  opposite the first side  306 . The first side  306  is generally a surface that can be positioned flush with the outer surface  104  of the candle. The first side  306  also comprises a fastener or fastening mechanism. The fastener may be a resistance fit system  1100  as shown in  FIG. 11 , an adhering system  1200  as shown in  FIG. 12 , a screw system  1300  as shown in  FIG. 13  or other types of fastening systems, including but not limited to, a hook-n-loop system, a button system, or any other type of reversible fastening system, and any combination thereof, preferably with quick-release capabilities, meaning the fastening system can be fastened and unfastened quickly without the need of any additional tools as in the examples above. The second side  308  is configured to connect to the anchor  304 . 
     In the resistance fit system shown in  FIG. 11 , the resistance fit fastener  1100  has a hole aligned flush against the outer surface  104  of the candle through the connector  1102  through which a reciprocal connector of the ornamentation  108  can be inserted. The reciprocal connector  1102  may have substantially the same dimensions as the hole of the resistance fit fastener  1100  so as to create a tight resistance fit. In the screw system as shown in  FIG. 13 , the reciprocal connector  1102  and the hole may be threaded so that the reciprocal connector  1102  can be screwed into the hole instead of relying on resistance fit. In the adhering system shown in  FIG. 12 , the ornamentation  108  and adhering fastener have mating surfaces so as to stick together. 
     In the preferred embodiment, the anchor  304  is an elongated structure having a first end  310  and a second end  312  opposite the first end  310 , the elongated structure defining a longitudinal axis L from the first end  310  to the second end  312 . The second end  312  connects to the second side  308  of the connector  302  by various means. For example, the anchor  304  may be integrally formed with the connector  302 . In some embodiments, the anchor  304  may be fastened to the connector  302 , for example, by welding or by screwing, clipping, adhering, and the like with an appropriate fastening system. With the anchor  304  embedded within the wax core  102 , the connector  302  is provided with the proper stability to maintain the ornamentation  108  on the wax candle. 
     In some embodiments, to counter any force on the anchor  304  created by the ornamentation  108 , the hardware  300  may also comprise a stabilizer  320  at the first end  310  of the anchor  304 . The stabilizer  320  defines a surface  322  that is non-parallel to the longitudinal axis L of the anchor  304 . Preferably, the stabilizer  320  defines a surface  322  that is generally perpendicular to the longitudinal axis L of the anchor  304 . The stabilizer  320  may be removably or irremovably connected to the anchor  304 . Any fastening system described above connecting the anchor  304  to the connector  302  may be used here as well. Preferably, the fastening system is reversible. This permits interchangeability of an anchor  304  with different stabilizers  320 . For example, for a large candle with a heavy ornament  108 , the stabilizer  320  should have a large surface area to keep the anchor  304  in place when the ornament  108  is attached. For smaller candles, space in the candle may not be available so a stabilizer  320  with a smaller surface area would be used. In other embodiments, the anchor  304 , stabilizer  320 , and connector  302  may all be a single unit, which may be cast, stamped, or otherwise formed as a unitary piece. The hardware  300  may be of any size or shape, but in a preferred embodiment it is approximately ½ inch in length, sufficiently long to be permanently embedded in the wax form, but short enough not to interfere with the burning of any wick  106 . 
     In some embodiments, the decorable candle  100  may be provided with a plurality of hardware  300   a ,  300   b  each having its own connector  302   a ,  302   b , anchor  304   a ,  304   b , and stabilizer  320   a ,  320   b  as shown in  FIG. 7 . This would allow a single candle to be decorated with a plurality of ornamentations  108   a ,  108   b ,  108   c  (shown where the ornamentation would be located after removal of the mold). 
     In some embodiments, the length of the anchor  304  may be shorter than the thickness or diameter of the wax core  102 . In some embodiments, the length of the anchor  304  may be approximately the thickness of the wax core  102  as shown in  FIGS. 8-10 . In other words, the first end  310  of the anchor  304  may extend to a first surface region  104   a  of the candle and the second end  312  may extend to a second surface region  104   b  as shown in  FIGS. 8-10 : For example, for a cylindrical wax core, the length of the anchor  304  may be approximately the diameter of the wax core  102  so that the first end  310  of the anchor  304  and the second end  312  of the anchor  304  are at diametrically opposite ends of the wax core. Each end may comprise its own connector  302   a ,  302   b  with the first connector  302   a  flush with a first surface region  104   a  of the wax core  102  and the second connector  302   b  is flush with the second surface region  104   b  of the wax core  102 . In such an embodiment, a stabilizer  320  would not be required as the connectors  302   a ,  302   b  would function as stabilizers for each other. 
     In some embodiments, the anchor  304  may comprise a hole  500  through which the wick  106  may be inserted as shown in  FIGS. 5, 8, 9, and 10 . This would be particularly important in embodiments in which the anchor  304  passes through the center of the wax core  102 . Although the hole  500  is shown as a hole in a rod in  FIGS. 5 and 10 , the hole  500  may be an entirely different structure, such as a large ring (not shown). Such a ring may be made of spring material that may assist holding the connectors  302   a ,  302   b , against the sides of the mold  700 . 
     In some embodiments, the first side  306  of the connector  302  may comprise an ornamental feature, thereby, functioning as the ornamentation  108 , such as a company logo, tradename, or other decorative design as shown in  FIG. 4 . In some embodiments, an ornamentation  108  may be provided that can be connected to the first side  306  of the connector  302 . For example, the ornamentation  108  may be two or three-dimensional letters that are removably attachable to the first side  306  of the connector  302 . Various other removably attachable ornamentations may be employed, including by not limited to two-dimensional or three-dimensional designs and shapes, music boxes, broaches, etc. In some embodiments, the decorable candle  100  may be provided with a plurality of ornamentations  108   a ,  108   b ,  108   c  each ornamentation removably attachable to the first side  306  of the connector  302  so that each ornamentation is interchangeable with another ornamentation. A single connection  302  may comprise multiple fastening mechanisms so that ornamentation  108   a ,  108   b  having different fastening mechanisms can still be used on a given connector  302 . In other words, the connector  302  may be a type of “universal” connector. 
     To make a decorable candle  100  of the present invention a mold  700  having a bottom  702  attached to at least one side wall  704  defining an open top  706  is provided to create the wax core  102 . For example, if a cylindrical wax core is needed, then the mold  700  would have a circular bottom  702  attached to a cylindrical side wall  704  having an open top  706 . If a rectangular wax core  102  is made, then the mold  700  would have a rectangular bottom  702  with four sidewalls  704   a ,  704   b ,  704   c ,  704   d , and an open top  706 . In any case, the sidewall(s)  704 ,  704   a - d  would have an outer surface  707  and an inner surface  708  defining a cavity. The connector  302  of the hardware  300  can be fixed on the inner surface  708  of the mold  700 . Liquid wax can then be poured into the mold  700  allowing the liquid wax to solidify into a solid candle or wax form having a perimeter surface  104  defined by the inner surface  708  of the sidewall  704 ,  704   a - d  of the mold  700 , with the hardware  300  embedded within the solid candle and the connector  302 ,  302   a ,  302   b  flush with the perimeter surface  104  of the candle. The solid candle containing the embedded hardware  300  may be removed from the mold  700 . With the connector  302 ,  302   a ,  302   b  flush with the perimeter surface  104  of the candle, ornamentation  108   a ,  108   b ,  108   c  can now be attached to the connector  302 ,  302   a ,  302   b.    
     Making a hurricane uses a similar process, but a closed-end insert  1500  may be used inside of the mold  700  to create the cavity of the hollow interior, as depicted in  FIG. 15 . The insert  1500  is smaller than the mold  700 , and may be placed inside the mold  700  prior to pouring the wax. Then the melted wax may be poured between the mold  700  and the insert  1500  to form a hollow interior. Alternatively, an open-end insert may be used, but it may have to be held tightly against the bottom of the mold  700  so that the wax does not get underneath the insert bottom. 
     Fixing the hardware  300  against the inner walls  708  of the mold  700  can be achieved by a variety of methods. In some embodiments, the fixing step comprises the connector  302  being adhered to the inner surface  708  of the mold  700  with a removable adhesive (not shown) between the connector  302  and the inner surface  708  of the mold  700 . The removable adhesive may be pressure sensitive, air cured, heat cured, RF cured, or any other suitable removable adhesive. After the wax is poured into the mold, the removable nature of the adhesive will allow the candle to be removed with the hardware  300  still embedded. Once the candle is removed from the mold  700 , the adhesive is then removed. 
     Alternatively, the fixing step comprises the connector  302  being adhered to the inner surface  708  of the mold  700  with wax (not shown). The wax may be placed between the connector  302  and the inner surface  708  of the mold  700 , or it may be placed so that the adhering wax surrounds the connector  302  and adheres to the inner surface  708  of the mold  700  by surrounding the connector  302 . During the wax pouring phase, the adhering wax should stay solid long enough for the hardware  300  to stay in place on the inner surface  708  of the mold  700  while the poured wax hardens around it. 
     When making a hurricane, the fixing step may comprise the first end  310  of the anchor  304  or the stabilizer  320  being adhered to the outer surface of the insert  1500  with a removable adhesive (not shown) between the first end  310  of the anchor  304  or the stabilizer  320 , and the outer surface of the insert  1500 . In such an embodiment, the finished wax form  100  may have a connector  302  that is flush with the outer surface  104  of the wax form  100 , or beneath the outer surface  104 . Alternatively, hardware  300  may be physically held in place inside the mold  700  while the insert  1500  is placed into the mold, with the hardware  300  creating a resistance fit between the inner surface  708  of the mold  700  and the outer surface of the insert  1500 , as depicted in  FIG. 15 . Then the wax may be poured between the mold  700  and the insert  1500  to from the hurricane and embed the hardware  300  in the wax shell. In such embodiments, a connector  302  may be located on the inside of the hollow interior  103  in lieu of, or in addition to, a stabilizer  320 . Such an interior connector may be utilized in a similar manner as described for the exterior connector  302 . 
     In some embodiments, the fixing step comprises creating a biasing force against the inner surface  708  of the mold  700  with the connector  302 . 
     In some embodiments, the biasing force may be created by inserting the hardware  300  into the mold  700 , wherein the hardware  300  extends substantially from one region of the mold to a diametrically opposite region of the mold so as to create a resistance fit between the mold and the hardware. The anchor  304  may be extendable or telescoping so that the anchor  304  can be lengthened until the first and second ends  310 ,  312  of the anchor  304  abut and press against the sidewall(s)  704  of the mold  700 . In some embodiments, the biasing force created by anchor extensions may be achieved by a plurality of anchor extensions that may not necessarily be diametrically opposed, such as a spoke-type configuration with a plurality of anchors projecting radially outwardly from a central hub. For example, a structure similar to the Mercedes-Benz hood ornament, with three “anchors” pressing against the cylindrical sidewall could result in a resistance fit. Such anchors need not be symmetrical, even for two contact points, if appropriately designed. Such anchors could also be on one or more planes relative to the axis of the candle. 
     In some embodiments, the mold  700  may have cutouts configured in the shape of the connector  302 . The connector  302  essentially plugs the hole created by the cutout so as to prevent the liquid wax from leaking out through the hole. 
     The hardware  300  may be comprised of any suitable material that will withstand the temperatures of melted wax and have sufficient strength to remain permanently attached to the wax form, but in a preferred embodiment the hardware  300  is made of metal. In some embodiments, the hardware  300 , or any of its constituent parts (connector portion  302 , anchor portion  304 , and stabilizer  320 ), may be made of blended metals, including but not limited to iron, nickel, cobalt, or their alloys. In such an embodiment, ornamentation  108  may be removably attached by using a magnet, such as shown in  FIGS. 7 and 12  (with  FIG. 7  depicting the placement of the ornamentation  108  after the mold is removed). 
     All of the above-described methods and apparatus may be used with any wax form, which may or may not have a wick. Such wax forms may include, but are not limited to, candles, electric-powered or oil-powered “candles,” sculptures, art forms, wax hurricane, or any other object made from wax. 
     The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention not be limited by this detailed description, but by the claims and the equivalents to the claims appended hereto.