Patent Application
20240409843
Candles made from paraffin or other types of wax are well known and processes used to manufacture candles can vary. However, candles, and the process of producing candles, is an art that continues to see improvements. In their simplest form, candles are composed of a wax or paraffin composition with a fragrance and a wick extending therethrough. Further, a user may ignite the wick, which burns the wick, melts the wax, and emits the fragrance in the wax composition. However, in addition to emitting a fragrance, candles can produce and emit soot and other emissions in the form of volatile organic compounds (VOCs) when the candle burns, which is undesirable.
In one aspect, the present disclosure provides a volatile material dispensing device that includes a container, a wax composition, a wick, and a sleeve having a volatile material. Further, according to this aspect, the sleeve is positioned between the wax composition and the container.
In further embodiments, the volatile material dispensing device includes a wax composition that is essentially free of a fragrance. The sleeve may also be constructed from a permeable material capable of passive emanation of the volatile material. Further, in some embodiments, the wax composition and the container enclose the sleeve and the volatile material. In these embodiments, the volatile material dispensing device may also further include a strip with the volatile material and the strip may be positioned above the wax composition. In other embodiments, a portion of the sleeve extends above the wax composition and is exposed. Further, the volatile material may be selected from the group consisting of a fragrance or a pest control agent, and the volatile material dispensing device may be a candle. In further embodiments, the volatile material dispensing device may include three wicks. In other embodiments, the sleeve may be positioned at least partially between the wax and the container, and the sleeve may include three reservoirs positioned radially outward from the wicks. More so, in some embodiments, the sleeve is constructed from a material selected from the group consisting of a polyethylene (PE), a polyvinyl alcohol (PVOH), a polypropylene (PP), an ethylene-vinyl acetate (EVA), a high-density polyethylene (HDPE), an ethylene vinyl alcohol (EVOH), or a blend thereof.
According to another aspect, the present disclosure provides a volatile material dispensing device that includes a container having a permeable interior surface, a non-permeable exterior surface, and a volatile material between or within the permeable interior surface and the non-permeable exterior surface. In this embodiment, the volatile material dispensing device further includes a wax composition and a wick.
In further embodiments, the wax composition is essentially free of a fragrance and the non-permeable exterior wall includes a sealant layer. In other embodiments, the volatile material is selected from the group consisting of a fragrance or a pest control agent and the volatile dispensing device may be a candle. Additionally, in some embodiments, a portion of the permeable interior surface of the container is exposed and the container is constructed from a material that includes at least one of terracotta and concrete. Here, the candle may also include three wicks.
In other embodiments, the present disclosure provides a candle that includes a wick, a wax composition essentially free of a fragrance, and a container that includes a volatile material.
According to other aspects of the present disclosure, a method of making a candle is provided. According to one embodiment, the method includes the steps of providing a container and a reservoir having a volatile material, positioning the reservoir adjacent an interior surface of the container, positioning a wick in the container, pouring a wax composition in the container, and allowing the wax composition to solidify. According to another embodiment, the method includes the steps of providing a container having a volatile material, positioning a wick in the container, pouring a wax composition in the container, and allowing the wax composition to solidify.
In some aspects, the present disclosure provides a volatile material dispensing device, that includes a container, a disposable tealight candle, and a sleeve having a volatile material. The sleeve is positioned between the disposable tealight candle and the container.
In some embodiments, the sleeve is constructed from a permeable material configured for passive emanation of the volatile material. In some embodiments, the volatile material of the sleeve is functional for up to 6 disposable tealight candles. In some embodiments, the disposable tealight candle and the container enclose the sleeve and the volatile material. In some embodiments, the disposable tealight candle and the container enclose the sleeve and the volatile material. In some embodiments, the volatile material dispensing device further comprises a strip having the volatile material, and the strip is positioned above the disposable tealight candle. In some embodiments, a portion of the sleeve extends above the disposable tealight candle and is exposed. In some embodiments, the volatile material is selected from the group consisting of a fragrance and a pest control agent. In some embodiments, the sleeve is constructed from a material selected from the group consisting of a polyethylene (PE), a polyvinyl alcohol (PVOH), a polypropylene (PP), an ethylene-vinyl acetate (EVA), a high-density polyethylene (HDPE), an ethylene vinyl alcohol (EVOH), or combinations thereof.
In some embodiments, the present disclosure provides for a method of making a volatile material dispensing device that includes providing a container and a reservoir having a volatile material, positioning the reservoir adjacent an interior surface of the container, and positioning a disposable tealight candle in an interior of the container such that the reservoir is positioned between the disposable tealight candle and the container.
In some embodiments, the present disclosure provides a volatile material dispensing device that includes a container, a wax composition, and a wick. The container has a permeable interior surface comprising cement and polymeric beads, a non-permeable exterior surface, and a volatile material within the container. In some embodiments, the wax composition is essentially free of a fragrance. In some embodiments, the wax composition is a disposable tealight candle. Disposable tealight candles used may contain fragrance or be essentially free of a fragrance. In some embodiments, the polymeric beads comprise polyvinyl acetate. In some embodiments, the polymeric beads comprising polyvinyl acetate are whole, crushed, partially crushed, or combinations thereof. In some embodiments, the device comprises a non-permeable exterior wall comprising a sealant layer. In some embodiments, the sealant layer is a polysiloxane. In some embodiments, the volatile material is selected from the group consisting of a fragrance and a pest control agent. In some embodiments, a portion of the permeable interior surface of the container is exposed. In some embodiments, the container is constructed from a material comprising at least one of cement and polymeric beads.
In some embodiments, the present disclosure provides for a method of making a volatile material dispensing device that includes providing a container comprising cement and a reservoir having a volatile material and a non-permeable exterior wall, positioning the reservoir adjacent an interior surface of the container, positioning a wick in the container, pouring a wax composition in the container, and allowing the wax composition to solidify. In some embodiments, the container comprises cement and polymeric beads comprising polyvinyl acetate wherein the polymeric beads are whole, crushed, partially crushed, or combinations thereof. In some embodiments, the non-permeable exterior wall comprises a sealant layer. In some embodiments, the sealant layer is a polysiloxane.
The foregoing and other aspects and advantages of the disclosure will appear from the following description. In the description, reference is made to the accompanying drawings, which form a part hereof, and in which there is shown by way of illustration a preferred configuration of the disclosure. Such configuration does not necessarily represent the full scope of the disclosure, however, and reference is made therefore to the claims herein for interpreting the scope of the disclosure.
The invention will be better understood and features, aspects, and advantages other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such detailed description makes reference to the following drawings.
Before the embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The disclosure is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.
The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans may also recognize that the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.
Referring to the figures generally, an improved candle capable of providing a cleaner, more complete fragrance delivery is depicted. In some aspects, the candles of the present disclosure, unlike typical candles of the prior art, may include a wax or fuel composition devoid, substantially free of, or essentially free of a fragrance, volatile material, or active agent. Rather, the candles of the present disclosure include the fragrance, volatile material, or active agent in another element of the candle. When a disposable tealight candle is used as the wick and wax or fuel composition, the wax or fuel composition may contain a fragrance, volatile material, or active agent, which would be considered a secondary source of fragrance, volatile material, or active agent, and is meant to be used in combination with a primary source of fragrance, volatile material, or active agents in another element of the candle, and not in place of the primary source of fragrance.
In one embodiment, as shown in
In another embodiment, as shown in
Typical candles of the prior art include a wax composition having a fragrance mixed therein, a wick extending through the wax composition, and a jar or vessel that holds the wax composition. Therefore, when a user lights the wick, the wax melts, and a pool of molten wax forms, which allows for evaporation of the fragrance. However, the fragrance in the wax is also burned as the wax is heated and burned, which sometimes causes the formation and emission of soot or particulates, and the emission of volatile organic compounds (VOCs), such as benzene or naphthalene, into the ambient or surrounding environment. This formation and emission of particulates and VOCs by the candle occurs, at least in part, because of an incomplete combustion of the melted wax in the flame of the candle.
The volatile material dispensers of the present disclosure, place a fragrance, volatile material, or active agent in another element of the candle, and the wax or fuel composition may contain a fragrance or be essentially free of, substantially free of, or devoid of a fragrance. In some embodiments, for example, the candle includes a sleeve or reservoir with the fragrance, volatile material, or active agent. In some embodiments, the sleeve or reservoir strip is positioned between the wax or fuel composition and a jar or container that holds the wax or fuel composition. As the wax or fuel composition is configured to burn and melt such that the melting exposes the sleeve or reservoir to the ambient or surrounding environment, which allows emanation of the fragrance, volatile material, or active agent with substantially less particulates and VOC emissions.
In some embodiments, the jar or container of the candle itself includes the fragrance, volatile material, or active agent and the jar or container emanates the fragrance, volatile material, or active agent as the candle burns. For example, in some embodiments, at least a portion of an interior wall of the candle jar or vessel is porous or permeable and an exterior wall of the candle jar or vessel is sealed, non-porous, or non-permeable. As the candle burns and the wax or fuel composition melts, an increased surface area of the interior wall of the candle jar or vessel is exposed, which allows for emanation of the fragrance or volatile material from the candle. This may be referred to as the hot throw of the candle.
Some candles of the present disclosure produce fewer particulates and less VOC emissions compared to a traditional candle because the fragrance, volatile material, and/or active agent is positioned away from the wick and flame of the candle. In addition to lowering particulate and VOC emissions, some candles of the present disclosure provide a more desirable fragrance, since the fragrance, volatile material, or active agent does not have a smoky character, for example. Thus, the smell and delivery of the fragrance, volatile material, and/or active agent is cleaner and stronger than a traditional candle.
Still further, the candles of the present disclosure are more efficient and more cost effective than traditional candles. In particular, when traditional candles are burned, about half of a fragrance or volatile material thereof is never even experienced by a user while burning because about half of the fragrance is burned either as it travels up the wick and into the flame or by being proximate the flame of the candle. The candles of the present disclosure, however, overcome this issue by placing the fragrance, volatile material, and/or active agent away from the wax composition, the wick, and the flame of the candle. As a result, the fragrance, volatile material, and/or active agent of the present disclosure are not burned in the flame of the candle or fragrance device. Thus, in addition to lowering particulate and VOC emissions, the candles of the present disclosure can also use less fragrance and cost less without sacrificing the user experience.
Additionally, a further advantage of the candles of the present disclosure is the relative ease with which the candle can be manufactured and can be manufactured with minimal impact on current production processes and supply chains. As will be described herein, the fragranced or dosed sleeves or reservoir strips disclosed herein can be produced on separate off-line processes and then can be easily added to the manufacturing process, thereby having minimal impact on the current production process and supply chain. Similarly, the vessels or containers having a fragrance or volatile material therein may be produced on separate off-line processes and then inserted into the manufacturing process with minimal impact on the current production process and supply chain.
Even further, as the wax or fuel composition may no longer include a fragrance, volatile material, or active agent, the wax or fuel composition that is free of fragrance, volatile material, or active agents can be consistent across manufacturing lines or product lines. For example, a candle having a first fragrance may include a wax composition identical to a wax composition of a second candle having a second fragrance that is different than the first fragrance. This is advantageous for several reasons. First, the commonality and uniformity between the wax or fuel composition between products and product lines allows for the use of the same wick across products and product lines, which allows for more efficient production lines and material cost savings. Previously, for example, a first wick may be more effective at wicking a first wax composition with a first fragrance and a second wick may be more effective at wicking a second wax composition with a second fragrance; therefore, two different wicks would have to be produced or purchased and inserted into the product lines.
This complexity is not present with the candles of the present disclosure because the fragrance, volatile material, or active agent is present in a portion of the candle other than the wax or fuel composition and the wax or fuel composition is devoid, essentially free, or substantially free of a fragrance, volatile material, or active agent. Thus, a single fuel or wax composition can be used across candles or dispensers with varying fragrances, volatile materials, and/or active agents, and as a result, a single wick can also be used across candles or dispensers without affecting the emanation of the fragrances, volatile materials, or active agents. This also provides a more reliable candle because a candle does not need to be tested each time a new wax composition with a new fragrance is launched. Typically, several different wick sizes and materials are tested to determine the best performing wick when a new fragrance is introduced. This testing aims to ensure that the wick, fragrance, and wax composition perform within a set of criteria for temperature, carbon emissions, blooms, soot emission, and curvature of the wick during use. This testing and optimization are not required for the candles of the present disclosure. Rather, an optimal wick need only be developed once and this optimal wick can be subsequently used, regardless of changes in the fragrance, volatile material, or active agent. In embodiments where a disposable tealight candle is used as the wax or fuel composition and wick, the tealight candle may contain a fragrance to be paired with the fragrance(s) present in another part of the candle. This allows further customization of fragrance and functionality of candle.
Further, some fragrances, active agents, or volatile materials are also incompatible or insoluble with some wax or fuel compositions. As a result, some fragrances, active agents, or volatile materials cannot be used in traditional candles. The candles or dispensers of the present disclosure, however, overcome this issue because the fragrance, active agent, or volatile material is present in a portion of the candle other than the wax or fuel composition. The candles and dispensers of the present disclosure therefore allow for the use of some fragrances, active agents, or volatile materials that were previously incompatible with traditional candles.
Additionally, although this disclosure is primarily focused on fragranced candles, the candles of the present disclosure, and the method of producing the candles, can be used for other chemical ingredients and volatile materials. For example, the embodiments of this disclosure and the method described herein could be a solution for pest control products. With that said, some fragrance materials, pest control actives, and other volatile materials may be less soluble or insoluble in wax compositions. Alternatively, or additionally, some fragrances, pest control actives, and other volatile materials may suppress or inhibit a candle flame, thereby producing a less desirable flame to a user when they are present in the wax composition. Further, some fragrances, volatile materials, or active agents are insoluble or incompatible with wax compositions. The candles of the present disclosure are also advantageous because the placement of the fragrance or volatile material in a permeable sleeve eliminates or greatly reduces these negative effects or drawbacks of standard candles. More particularly, the permeable sleeve or reservoir strip, or the vessel or container, can be constructed from a material that is compatible with a broader range of chemistries or can be customized to work best with various chemistries based on the solubility and chemical characteristics of the fragrance, volatile material, or active agent to be employed in the candle or fragrance device.
As used herein, the term “essentially free of” or “substantially free of” may mean that the indicated material (e.g., a fragrance, volatile material, or active agent) is present in an amount of no more than 0.1 wt. % by weight of a composition (e.g., fuel composition or wax composition), or preferably not present at an analytically detectible level in such compositions. It may also include compositions where the indicated material is present only as an impurity of one or more of the materials deliberately added to such compositions.
As used herein, the term “fragrance” is meant as including any perfume or aroma ingredient or a mixture thereof. A “fragrance” is meant here as a compound which is of current use in the perfumery or aroma industry, i.e., a compound which is used as an active ingredient in perfumed or aroma candles in order to impart a hedonic effect into its ambient or surrounding environment. Put differently, a “fragrance” is an ingredient or mixture that imparts or modifies a surrounding environment with a positive or pleasant odor. More so, this definition is also meant to include compounds that do not necessarily have an odor, but are capable of modulating the odor of a perfuming composition and, as a result, of modifying the perception by a user of the odor of such a composition. In general, these fragrance ingredients belong to chemical classes as varied as alcohols, aldehydes, ketones, esters, ethers, acetates, nitriles, terpene, hydrocarbons, nitrogenous or sulphureous heterocyclic compounds and essential oils, and said perfuming ingredients can be of natural or synthetic origin.
Further, the term “volatile material” used herein encompasses fragrances, as well as any other compounds that emanate or evaporate to provide an effect at normal ambient temperatures (e.g., 15-23°° C.) or elevated temperatures produced by a candle flame. For example, a “volatile material” may be a fragrance that imparts a surrounding environment with a positive or pleasant odor, a pest control agent that acts to repel insects (e.g., mosquitos), or any other compound that emanates to provide an effect to the surrounding environment. Further, “volatile material” may refer to a chemical composition having an active agent, as well as other ingredients. For example, the term “volatile material” may refer to a composition having an active agent—such as a fragrance, an insecticide, a deodorizer, a fungicide, a bacteriocide, a sanitizer, a pet barrier, or other active volatile compound—and a carrier liquid or solvent—such as an oil-based, organic based, and/or water based carrier or solvent, a deodorizing liquid, or the like, and/or combinations thereof. In particular embodiments, the “volatile material” may include an insect control agent, an insect repellent, or an insecticide. Examples of possible insecticides that may be suitable in the “volatile material” include pyrethroids such as metafluthrin, transfluthrin, tefluthrin, and vaporthrin, or natural actives (geraniol, etc.) or a blend of these insecticides. Additional examples of an active agent that may be used in the “volatile material” may include RAID®, Pyrel®, POLIL®, AUTAN®, OUST™ or GLADE®, sold by S. C. Johnson & Son, Inc., of Racine, Wisconsin. The “volatile material” may also comprise other actives, such as sanitizers, air and/or fabric fresheners, cleaners, odor eliminators, mold or mildew inhibitors, insect repellents, and the like, or others that have aromatherapeutic properties. The “volatile material” alternatively comprises any fluid known to those skilled in the art that can be dispensed from a container, such as those suitable for dispersal in the form of particles or droplets suspended within a gas and/or propelled by means of a propellant. In one aspect, the “volatile material” may include one or more solvents, such as an organic or aqueous solution, in which an insect control agent may be dissolved. For example, in certain aspects, the active agent may be in a solid state at room temperature (23° C.), and a solvent may be added to the active agent in order to provide and keep the volatile material in a liquid state, thus allowing the volatile material to spread, be coated on, and positioned within a substrate, such as the sleeve or reservoir strip of the candles of the present disclosure. However, in other embodiments, the “volatile material” may not be mixed with any other components and may consist solely of the active agent.
The term “about,” as used herein, refers to variation in the numerical quantity that may occur, for example, through typical measuring and liquid handling procedures used for making concentrates or use solutions in the real world, through inadvertent error in these procedures, through differences in the manufacture, source, or purity of the ingredients used to make the compositions or carry out the methods, and the like. The term “about” may also encompass amounts that differ due to different equilibrium conditions for a composition resulting from a particular initial mixture. In one embodiment, the term “about” refers to a range of values ±5% of a specified value.
The terms “weight percent,” “wt-%,” “percent by weight,” “% by weight,” and variations thereof, as used herein, refer to the concentration of a substance or component as the weight of that substance or component divided by the total weight, for example, of the composition or of a particular component of the composition, and multiplied by 100. It is understood that, as used herein, “percent,” “%,” and the like may be synonymous with “weight percent” and “wt-%.”
The term “tealight candle,” “disposable tealight candle,” and “replaceable tealight candle,” as used herein, refer to a candle in a thin metal, glass, or plastic cup so that the candle can liquefy completely while lit. It is understood that a “tealight candle” as used herein constitutes a cup containing a wick and a wax composition that may contain fragrance or be substantially or essentially free of fragrance.
With reference to
In particular, when the wick 104 of the candle 100 is lit, the heat of the flame of the candle 100 melts the wax 102 near the wick 104, and then the liquid wax is drawn up the wick 104 by capillary action. The heat of the flame of the candle 100 vaporizes the liquid wax, turning it into a hot gas, and breaks down the hydrocarbons of the wax 102 into molecules of hydrogen and carbon. These vaporized molecules are then drawn up into the flame, where they react with oxygen from the ambient air to create heat, light, water vapor, and carbon dioxide. However, the combustion of the wax 102 and the fragrance therein is sometimes not a complete (e.g., fully stoichiometric or ideal) combustion. As a result, the candle 100 typically produces soot, i.e., a black powdery or flaky substance consisting largely of amorphous carbon produced by the incomplete burning of organic matter, like the hydrocarbon composition of the wax 102. In addition, the candle 100 can emit VOCs. VOCs are compounds that are composed primarily of carbon, oxygen, and hydrogen, which can evaporate into the air as the wax 102 and the fragrance therein burns and evaporates.
Unlike the typical candles depicted in
For example,
As discussed herein, the fragrance or active agent from the sleeve or reservoir 208 is not burned in the flame during use because the fragrance or active agent from the sleeve or reservoir 208 is not in the wax or fuel composition 202. Rather, the fragrance, volatile material, or active agent in the sleeve or reservoir 208 is distinct from the wax composition 202 and is positioned away from the wick 204 and the flame 214 of the candle 200. As a result, the interior wax or fuel composition 202 may contain no fragrance or volatile material, and when the interior wax or fuel composition contains no fragrance, the performance of the flame would be consistent because the fragrance or volatile material is known to affect the burn of the flame, such as the flame 214. When a fragrance or volatile material is included in the wax or fuel composition the fragrance can cause an inconsistent flame and may cause a disturbance in the flame 214 of the candle 200, which leads to the incomplete combustion of the wax or fuel composition 202 and the formation of soot and VOCs. Having a wax or fuel composition 202 devoid, essentially free, or substantially free of a fragrance or volatile material eliminates these disturbances and creates a more consistent flame, such as the flame 214, that more completely burns the wax or fuel composition 202. Even further, when the wax or fuel composition of the candle 200 is devoid, essentially free, or substantially free of a fragrance, the candle 200 provides a more effective and improved fragrance intensity, as the fragrance will not have a smoky character, for example, and will not be burned off prior to release. As such, the smell and delivery of the fragrance or active agent is cleaner and stronger as compared to a traditional candle of the prior art. In addition, when the wax or fuel composition of the candle 200 is devoid, essentially free, or substantially free of a fragrance, the candle 200 provides a more consistent burn than traditional candles because the flame 214 produced by burning a composition of wax that is substantially free of volatile compounds reduces variability in the combustion process taking place on the one or more wicks of the candle 200. A wide variety of fragrances and other active or volatile compounds can be used within the candle 200.
The sleeve or reservoir 208 of the candle 200 may include a permeable material, which allows for air and liquid to freely pass through or otherwise release from the sleeve or reservoir 208. Permeable surfaces and materials are those that contain pores or openings that allow liquids and gases to pass therethrough. For example, in particular embodiments, the sleeve or reservoir 208 may be constructed from a substrate or a material that properly acts as a reservoir for the fragrance, volatile material, or active agent. Specifically, the sleeve or reservoir strip 208 may be constructed from a material that can optimally absorb and store a fragrance, volatile material, or active agent without degrading or decomposing. For example, the sleeve or reservoir 208 may be a fibrous material or fabric, and may be constructed from a cotton, polyester, rayon or nylon-based material, or combinations thereof. In further embodiments, the sleeve or reservoir 208 may include at least one or more materials that act as a barrier layer to the volatile material stored therein. That is, the sleeve or reservoir 208 may include at least one or more materials configured to be rate-limiting for mass-transport of the fragrance, volatile material, or active agent from the dispensing device or candle 200. More particularly, the sleeve or reservoir 208 may be a reservoir layer formed by one or more materials that are permeable to the fragrance, volatile material, or active agent therein, as well as rate-limiting to the volatile material to emit the volatile material at a desired rate of emission. In other words, the sleeve or reservoir 208 may be constructed from a material that is compatible with the volatile material such that the volatile material is readily stored within the sleeve or reservoir 208 when the candle 200 is in a non-active state (i.e., when the candle 200 is not lit), yet allows for emanation of the volatile material or fragrance when the wick 204 is ignited and the flame 214 is present. In some examples, the sleeve or reservoir 208 is formed from a consumable material that releases the fragrance as it is consumed (e.g., melts, evaporates, etc.) As such, the sleeve or reservoir 208 may control the emanation rate or rate of evaporation of the volatile material from the candle 200.
The sleeve or reservoir 208 may also be constructed from a material that is particularly compatible with the fragrance, volatile material, or active agent used in the candle 200. For example, in one specific embodiment, the material of the sleeve or reservoir 208 may be ethylene vinyl acetate and the volatile material may be transfluthrin. Examples of materials that are satisfactory for forming the sleeve or reservoir may also include a nylon or nylon-based film, a polysulfone (PSU), an acrylonitrile butadiene styrene (ABS), a styrene-acrylonitrile (SAN), a polyethylene (PE), a poly(p-phenylen oxide) (PPO), a polybutylene terephthalate (PBT), a polyvinyl chloride (PVC), a polyester film a polycarbonate (PC), a styrene-butadiene (SBR), a polyethylene terephthalate glycol (PETG), a poly(methyl methacrylate) (PMMA), a polyvinyl alcohol (PVOH), a polystyrene (PS), a polypropylene (PP), a polyethylene terephthalate (PET), a polyethylene terephthalate/polyethylene naphthalate copolymer (PET-PEN), an ethylene-vinyl acetate (EVA), a poly(ether sulfones) (PES), a polyvinyl acetate (PVAc), an acrylonitrile-methyl acrylate copolymer (e.g., Barex® 210), a high-density polyethylene (HDPE), an ethylene vinyl alcohol (EVOH), a polyacetal or a polyoxymethylene (POM), a polyethylene glycol (PEO), an ethylene (meth) acrylic acid (EAA, EMAA) (e.g., Surlyn®), cellophane, and/or polyacrylonitrile (PAN), and/or a combination or metalized form thereof.
In one aspect, the sleeve or reservoir 208 may be formed from a polyethylene (PE), a polyvinyl alcohol (PVOH), a polypropylene (PP), an ethylene-vinyl acetate (EVA), such as an ethylene-vinyl acetate resin under the trade name Elvax®, a high-density polyethylene (HDPE), and/or an ethylene vinyl alcohol (EVOH), or blends of these materials. The sleeve or reservoir 208 may also be formed of EZ Peel® EVA or PE co-extruded sealant.
The sleeve or reservoir 208 may also have a thickness and can be a relatively thin layer with a thickness ranging between about 10 μm and about 20 mm, about 10 μm and about 10 mm, about 10 μm and about 1 mm, about 10 μm and about 250 μm, or between about 50 μm and about 100 μm, or between about 75 μm and about 90 μm.
In other embodiments, the sleeve or reservoir 208 may be comprised of terracotta, cement, concrete, or wood. For example, the sleeve or reservoir 208 may include wood, such as a sandalwood, a cedar, a patchouli, a vetiver, a cypress, an oud wood, a guaiac wood, and/or a birch wood. In other embodiments, the sleeve or reservoir 208 may include a terracotta material or a clay-based unglazed or glazed ceramic where the fired body is porous. In further embodiments, the sleeve or reservoir 208 may be constructed from a natural polymer, such as a cellulose nanocrystal (CNC). Additionally, in some embodiments, the sleeve or reservoir 208 is constructed from a material that includes at least cement and may further include polyvinyl acetate beads wherein the beads are mixed with cement in varied forms including, but not limited to, whole beads, crushed beads, or blends of crushed, whole, and partially crushed beads. In further embodiments, the porous jar was coated with a polysiloxane coating.
With specific reference to
The layers 222, 224, 226 of the sleeve or reservoir 208 can provide alternative effects during use. For example, the layers 222, 224, 226 may include different fragrances or volatile materials. As a result, the candle 200 may provide numerous fragrances to a user during its use. More particularly, in one specific embodiment, the upper layer 222 may include a first fragrance, the middle layer 224 may include a second fragrance, and the lower layer 226 may include a third fragrance. Therefore, the candle 200 may emit the first fragrance after a top portion of the wax or fuel composition 202 burns or melts, the second fragrance after a middle portion of the wax or fuel composition 202 burns or melts, and the third fragrance after a lower portion of the wax or fuel composition 202 burns or melts. Alternatively, the layers 222, 224, 226 of the candle 200 can include the same fragrance or volatile material, but the fragrance or volatile material may be included in different concentrations or dosages. For example, the upper layer 222 may include the fragrance or volatile material at a first dosage, the middle layer 224 may include the fragrance or volatile material at a second dosage that is larger than the first dosage, and the lower layer 226 may include the fragrance or volatile material at a third dosage that is larger than the second dosage. This embodiment may be useful when the fragrance or volatile material is known to decrease over time. In these circumstances, the lower layers (such as the middle layer 224 and the lower layer 226) may include a higher dosage of the fragrance or volatile material because these layers are exposed to the ambient environment later than the upper layers of the sleeve or reservoir 208 (such as the upper layer 222). Thus, the lower layers of the sleeve or reservoir 208 include higher concentrations of the fragrance or volatile material, such that the user experience is uniform or relatively constant throughout the lifetime of the candle 200.
According to another embodiment, the upper layers (such as the upper layer 222 and the middle layer 224) may include a higher dosage of the fragrance or volatile material because these layers are exposed to the ambient environment first, and as such, must emanate the fragrance, volatile material, or active agent over a longer period. Therefore, to allow for constant emanation over the life of the candle 200, the upper layers of the sleeve or reservoir 208 may include higher concentrations of the fragrance volatile material, or active agent, such that the user experience is uniform or relatively constant through the lifetime of the candle 200. In addition, as a wax or fuel composition burns and melts, more surface area of the sleeve or reservoir 208 is exposed. Therefore, to allow for a relatively constant emanation rate, the upper layers of the sleeve or reservoir 208 may include higher concentrations, such that when there is less surface area of the sleeve or reservoir 208 exposed to the ambient environment, there is relatively the same emanation rate compared to later when additional surface area of the sleeve or reservoir 208 is exposed as the wax or fuel composition 202 burns or melts. In short, the ability to selectively increase or decrease the fragrance, volatile material, or active agent dosage levels across layers of the sleeve or reservoir 208 allows the candle 200 to be optimized such that habituation does not occur and a user continues to experience the fragrance, volatile material, or active agent over the lifetime of the candle 200.
Further embodiments of the present disclosure provide a candle where the layers 222, 224, 226 may be made from alternative materials. For example, as previously discussed herein, the sleeve or reservoir 208 may be constructed from numerous materials, such as terracotta, cement, concrete, wood, various cloth materials, or plastics. In this embodiment, the upper layer 222 may be constructed from a first material (e.g., terracotta, cement, wood, a cloth, a substrate, etc.), the middle layer 224 may be constructed from a second material, and the lower layer 226 may be constructed from a third material. The materials for the layers 222, 224, 226 may be chosen based on a combination of factors. For example, the layers 222, 224, 226 may include different fragrances or volatile materials or different dosages of fragrances or volatile materials, as previously discussed herein. With that in mind, the materials of the layers 222, 224, 226 may be optimally chosen based on the specific fragrance or dosage or concentration of the fragrance or volatile material for the layer. For example, a first fragrance or volatile material and first dosage therefor may be chosen for the upper layer 222, and then the material for the upper layer 222 may be chosen to optimally store and emanate the first fragrance or volatile material. Further, the second fragrance or volatile material and second dosage therefor may be chosen for the middle layer 224, the material for the middle layer 224 may then be chosen, the third fragrance or volatile material and third dosage therefor may be chosen for the lower layer 226, and the material for the lower layer 226 may then be chosen.
In other embodiments, the sleeve or reservoir 208, as well as the layers 222, 224, 226 thereof, may provide a visible or aesthetic impression to a user. For example, in one embodiment, the upper layer 222 may be a first color, the middle layer 224 may be a second color, and the lower layer 226 may be a third color. According to another embodiment, the sleeve or reservoir 208 may be a first color when the sleeve or reservoir 208 is dosed or primed with the fragrance, volatile material, or active agent, and then transition to a second color once the fragrance, volatile material, or active agent emanates from or leaves the sleeve or reservoir 208. According to yet another aspect, the color or appearance of the sleeve or reservoir 208 may change or transition during use of the candles 200, 300 to provide an aesthetic effect to the candles 200, 300 (such as by providing a visually pleasing appearance or color transition) and/or a function effect to the candles 200, 300 (such as by providing a visual indication that the sleeve or reservoir 208 is devoid of the fragrance, volatile material, or active agent).
Further, in some embodiments, the sleeve or reservoir 208 may include several strips or reservoirs positioned along the interior surface 210 of the container 206. In such embodiments, the wax or fuel composition 202 may also be adjacent to the interior surface 210 where the sleeve or reservoir 208 is not present. For example, in these embodiments, the sleeve or reservoir 208 may include a reservoir positioned every 60 degrees, 90 degrees, 120 degrees, or 180 degrees around a circumference of the interior surface 210 of the container 206. In other embodiments, the reservoirs may be positioned along the interior surface 210 at a location radially outward from the wick 204. Further, in embodiments where the candle 200 includes multiple wicks, the reservoirs may be positioned along the interior surface 210 at a location radially outward from a center of the candle and the wicks of the candle. For example, if a candle includes three wicks in a triangular formation, the candle may include three reservoirs: one reservoir positioned at a location radially outward from a center of the container and a first wick, one reservoir positioned at a location radially outward from the center of the container and a second wick, and one reservoir positioned at a location radially outward from the center of the container and a third wick.
Similar to the other embodiments discussed herein, a user may ignite the wick 304 of the candle 300 during use and cause the wax or fuel composition 302 to burn and melt. Further, as the wax or fuel composition 302 burns and melts, portions of an interior wall 308 of the candle 300 are exposed to the ambient and surrounding environment, which causes emanation or passive evaporation of the fragrance, volatile material, or active agent therefrom (as illustrated by arrows 310 in
In this embodiment, an exterior wall 316 of the vessel or container 306 is also sealed to prevent premature emanation and evaporation of the fragrance or volatile material from the candle 300. More particularly, the vessel or container 306 is constructed from a material that is porous or permeable, but the exterior wall 316 of the vessel or container 306 is sealed by a means to prevent the fragrance from seeping through to the outside of the container 306 and emanating therefrom prior to a user igniting the wick 304 and the wax or fuel composition 302 melting. In one embodiment, the vessel or container 306 is constructed from a terracotta, concrete, clay, or ceramic material and the exterior wall 316 of the candle 300 can be sealed by a glazing process where the exterior wall 316 is glazed with a glass coating, for example. The glaze can take many forms. For example, the glaze can be transparent, may include a metal additive, can be colored, textured, glossy, matte, opaque, etc. In some embodiments, the vessel or container 306 is constructed from a cement mixture which optionally includes PVAc beads in whole, crushed, or partially crushed forms, and the exterior wall 316 of the candle 300 cannot be sealed with a glazing process and is instead coated with a sealant layer. In further embodiments, the sealant layer is a polymer. In some embodiments, the polymer used for the coating of the vessel or container is a polysiloxane.
In another embodiment, the exterior wall 316 may be coated with a solvent resistant coating. For example, the exterior wall 316 may include a sealant layer thereon that is a polyethylene terephthalate (PET), an ethylene-vinyl acetate (EVA), a polyethylene, such as a low-density polyethylene (LDPE), a high molecular weight low-density polyethylene, or a linear low-density polyethylene (LLDPE), a polypropylene (PP), ethylene-butene copolymer, polybutene, butylene copolymers, an ethylene vinyl alcohol copolymer (EVOH), a polyester, a polyethylene terephthalate glycol (PETG), a polylactic acid (PLA), polyvinyl acetate (PVAc) or a nylon. Combinations or blends (e.g., binary or ternary blends) of the aforementioned materials may also be used. For example, blends which may be used for the sealant layer are EVA-LDPE, polybutene-EVA, polybutene-LDPE-EVA, etc. Other materials that may be suitable for use as the sealant layer on the exterior wall 316 include one or more polyethylene terephthalate film structures, such as transparent films under the trade names EZ Peel®, Mylar®, e.g., Mylar® OL, LumiLid®, e.g., Lumilid® XL 7, Lumirror®, e.g., Lumirror® XL 5, or Curlon®, all of which are either provided by DuPont, Toray Industries, Inc. or Bemis Company, Inc. In a further embodiment, the sealant layer may be CURLON® (Grade A9599) and W18-000832 from Bemis Company, Inc. According to another embodiment, the sealant layer may be a polysiloxane coating layer. For example, U.S. Pat. No. 10,472,526, issued on Nov. 12, 2019, and titled “Peelable Surface Coating System Over Multi-Section Substrate” discloses coatings and sealers, including the potential materials that can be used for coatings and sealers. U.S. Pat. No. 10,472,256 is incorporated herein by reference in its entirety.
The interior wall 308 may also be partially glazed or sealed to affect the evaporation and emanation of the fragrance as the candle burns. In these embodiments, the same materials used to glaze or seal the exterior wall 316 may be used to partially seal the interior wall 308 of the vessel or container 308.
In this embodiment, the vessel or container 306 is at least partially constructed from a permeable or porous material, which allows for gas and liquid to freely pass through the vessel or container 306. As discussed previously herein, permeable surfaces and materials are those that contain pores or openings that allow liquids and gases to pass therethrough. For example, in particular embodiments, the vessel or container 306 may be constructed from a material that properly acts as a reservoir for the fragrance, volatile material, or active agent. Specifically, the vessel or container 306 may be constructed from a material that can optimally absorb and store a fragrance, volatile material, or active agent without degrading or decomposing. For example, the vessel or container 306 may be a fibrous material or fabric, and may be constructed from a cotton, polyester, rayon or nylon-based material, or combinations thereof. In further embodiments, the vessel or container 306 may include at least one or more materials that act as a barrier layer to the volatile material stored therein. For example, the vessel or container 306 may be constructed from a material that is compatible with the volatile material such that the volatile material is readily stored within the vessel or container 306 when the candle 300 is in a non-active state (i.e., when the candle 300 is not lit), yet also allows for emanation of the volatile material or fragrance when the wick 302 is ignited and the flame 312 is present. As such, the vessel or container 306 can control the emanation rate or rate of evaporation of the volatile material from the candle 300.
In some embodiments, the vessel or container 306 includes a terracotta, cement, clay, or ceramic material. In other embodiments, the vessel or container 306 includes a concrete material. Still further, in some embodiments, the vessel or container 306 includes wood. For example, the vessel or container 306 may include a sandalwood, a cedar, a patchouli, a vetiver, a cypress, an oud wood, a guaiac wood, and/or a birch wood. In further embodiments, the vessel or container 306 may be constructed from a natural polymer, such as a cellulose nanocystal (CNC).
In some embodiments, the vessel or container 306 may be constructed from ethylene vinyl acetate and the volatile material may be transfluthrin. Further examples of materials that may be used for the vessel or container 306 include a polysulfone (PSU), an acrylonitrile butadiene styrene (ABS), a styrene-acrylonitrile (SAN), a polyethylene (PE), a poly (p-phenylen oxide) (PPO), a polybutylene terephthalate (PBT), a polyvinyl chloride (PVC), a polyester film, a polycarbonate (PC), a styrene-butadiene (SBR), a polyethylene terephthalate glycol (PETG), a poly (methyl methacrylate) (PMMA), a polyvinyl alcohol (PVOH), a polystyrene (PS), a polypropylene (PP), a polyethylene terephthalate (PET), a polyethylene terephthalate/polyethylene naphthalate copolymer (PET-PEN), an ethylene-vinyl acetate (EVA), a poly (ether sulfones) (PES), an acrylonitrile-methyl acrylate copolymer (e.g., Barex® 210), a high-density polyethylene (HDPE), an ethylene vinyl alcohol (EVOH), a polyacetal or a polyoxymethylene (POM), a polyethylene glycol (PEO), an ethylene (meth) acrylic acid (EAA, EMAA) (e.g., Surlyn®), a cellophane, and/or polyacrylonitrile (PAN), and/or a combination or metalized form thereof.
In this embodiment, the second portion 404 of the candle 400 can be constructed from any of the aforementioned materials discussed above in connection with the vessel or container 306 of the candle 300 depicted in
In other embodiments, the vessel or container 306, as well as any portion thereof (including the interior wall 308, the exterior wall 316, the first portion 402, the second portion 404, the first portion 502, the second portion 504), may provide a visible or aesthetic impression to a user. For example, in one embodiment, the first portions 402, 502 may be a first color and the second portions 404, 504 may be a second color. According to another embodiment, the vessel or container 306, or any portion thereof, may be a first color when the vessel or container 306 is dosed or primed with the fragrance, volatile material, or active agent, and then transition to a second color once the fragrance, volatile material, or active agent emanates from or leaves the vessel or container 306. According to yet another aspect, the color or appearance of the vessel or container 306 may change or transition during use of the candles 400, 500 to provide an aesthetic effect to the candles 400, 500 (such as by providing a visually pleasing appearance or color transition) and/or a function effect to the candles 400, 500 (such as by providing a visual indication that the vessel or container 400, 500 is devoid of the fragrance, volatile material, or active agent).
In these aforementioned embodiments, the other elements of the candles 200, 300, 400, 500 can be constructed from materials known in the art. For example, the wax or fuel compositions 202, 302 of the candles 200, 300, 400, 500 can be formed from suitable hydrocarbon or wax compositions, such as soy waxes, paraffin waxes, palm waxes, a beeswax, a hydrogenated natural oil, or a combination thereof. Further, the wicks 204, 304 can be formed of any suitable material, such as cotton, linen, cellulose, plastics or ceramic material, paper, hemp, wood, metal, or any combination thereof.
In addition, for each candle 200, 300, 400, 500, the wicks 204, 304 may be a positioned a predetermined position away from the sleeve or reservoir 208 or the interior wall 210, 308 of the candles 200, 300, 400, 500. As discussed herein, unlike typical candles (such as the candle 100), the fragrance or active agent from the sleeve of the candles of the present disclosure is not burned in the flame during use because the fragrance or active agent from the sleeve is not in the wax or fuel composition. As a result, the candles of the present disclosure emit less soot and/or VOCs as compared to a traditional candle. While in some embodiments, the wax composition is devoid, essentially free, or substantially free of fragrance, in some embodiments a disposable tealight candle is used and the tealight candle has a wick 204, 304 and wax or fuel composition 202, 302, which are contained within a thin metal, glass, or plastic cup or container 228, 318 and may contain fragrance. Therefore, in some embodiments, the wicks 204, 304 are placed a predetermined distance from the sleeve or reservoir 208 or the interior wall 210, 308 of the candles 200, 300, 400, 500 such that sleeve or reservoir 208 or the interior wall 210, 304 of the candles 200, 300, 400, 500, as well as the fragrance, volatile material, or active agent therein, are not burned by the flame 214, 312.
More particularly, the physics of a burning candle, like the candles 200, 300, 400, 500, can be analyzed and the heat transfer and fluid flow behavior of a burning candle can be computed. For example, COMSOL Multiphysics® may be used to compute or graph a temperature profile of a flame of a candle (such as the flame 214, 312 of the candles 200, 300, 400, 500) during the life of the candle, and then an average temperature distribution produced by the candle flame can be illustrated. For example,
For example, some materials, such as glass, may begin to heat and exhibit undesirable effects at temperatures at or above 80° C. Additionally, the sleeve or reservoir 208 of the candle 200 may be constructed from a material that must remain below a specific temperature (e.g., 165° F. or 74° C.) to maintain its integrity. Using a computed temperature profile, such as the exemplary temperature profile illustrated in
Temperature profiles, such as the exemplary temperature profile depicted in
The volatile material dispensing devices of the present disclosure provide embodiments teaching a container containing a disposable tealight candle wherein the wick 204, 304 and wax or fuel composition 202, 302 are contained within a cup 228, 318. The cup 228, 318 may be made of metal, plastic, glass, and combinations thereof. Components of the metal, plastic, and glass of the cups may include but are not limited to aluminum, stainless steel, brass, copper alloy, borosilicate, alumina, silicone dioxide, sodium carbonate, calcium carbonate, silica, cerium oxide, polycarbonate, polymethyl methacrylate, polyethylene, polyacrylate, and polymethacylate. The size of the container will vary depending on the size of the disposable tealight candle. In some embodiments, the diameter (width) of the tealight candle may be from 1.0 to 3.0 inches. In some embodiments, the diameter is at least 1.0 inch, at least 1.5 inches, at least 2 inches, at least 2.5 inches, or at least 3.0 inches. In some embodiments, the height (length) of the tealight candle may be from 0.2 to 4.0 inches. In some embodiments, the height of the tealight candle is at least 0.2 inches, at least 0.4 inches, at least 0.6 inches, at least 0.8 inches, at least 1.0 inches, at least 1.2 inch, at least 1.5 inches, at least 2 inches, at least 2.5 inches, at least 3.0 inches, at least 3.5 inches, or at least 4.0 inches.
The wax or fuel composition 202, 302 contained within the cup 228, 318 of the tealight candle may contain a fragrance, active agent, or volatile material, within the wax or fuel composition that is essentially free, substantially free, or devoid of a fragrance, volatile material, or active agent. A fragrance, volatile material, or active agent is in another element of the candle, such as in a sleeve or reservoir (see
The candles of the present disclosure also alleviate numerous other problems of standard candles of the prior art. For example, about half of a fragrance within a conventional candle is never even experienced by a user when the conventional candle (such as the candle 100) is burned because half of the fragrance is burned as it travels up the wick into the flame of the candle. The present disclosure, however, provides a source of fragrance that is not mixed with the wax or fuel composition. Because a fragrance or volatile material resides in an element of the candle removed or distinct from the wax composition, those fragrances are not at risk of being burned off during the wicking process. As such, the fragrance removed or distinct form the wax or fuel composition is not burned in the flame of the candle and is not wasted, like standard candles of the prior art. This efficiency in emanation of the fragrance has several benefits. First, less fragrance can be used in the candles of the present disclosure without sacrificing a user's experience. In other words, the candles of the present disclosure can use less fragrance, yet the fragrance experienced by the user of the candles can be the same as the fragrance experience by a user for a standard candle (such as the candle 100). As a result, the candles of the present disclosure use less raw materials and can cost less than standard candles.
In addition, the candles of the present disclosure can reduce candle emissions, thereby allowing the candles of the present disclosure to pass more stringent or rigorous candle emission standards. By moving a fragrance source away from the candle flame to the sleeve or reservoir or the jar or vessel, the candles of the present disclosure emit less soot and other emissions, such as VOCs, to a surrounding environment. A further advantage of the candles of the present disclosure is the relative ease in which the candle can be manufactured with minimal impact on current production processes. As described herein, fragranced or dosed sleeves, as well as jars and vessels, can be produced on separate off-line processes that can be easily added to the manufacturing process, thereby having a minimal impact on the current production process and supply chain.
Even further, since the wax or fuel composition may no longer include a fragrance, volatile material, or active agent, the wax or fuel composition can be consistent across manufacturing lines or product lines. For example, a candle having a first fragrance may include a wax composition identical to a wax composition of a second candle having a second fragrance that is different than the first fragrance. This is advantageous for several reasons. First, the commonality and uniformity between the wax or fuel composition between products and product lines allows for the use of the same wick across products and product lines, which allows for more efficient production lines and material cost savings. Previously, for example, a first wick may be more effective at wicking a first wax composition with a first fragrance and a second wick may be more effective at wicking a second wax composition with a second fragrance; therefore, two different wicks would have to be produced or purchased and inserted into the product lines.
This complexity is not present with the candles of the present disclosure where the fragrance, volatile material, or active agent is present in a portion of the candle other than the wax or fuel composition and the wax or fuel composition is devoid, essentially free, or substantially free of a fragrance, volatile material, or active agent. Thus, a single fuel or wax composition can be used across candles or dispensers with varying fragrances, volatile materials, or active agents, and as a result, a single wick can also be used across candles or dispensers without affecting the emanation of the fragrances, volatile materials, or active agents. This also provides a more reliable candle because a candle does not need to be tested each time a new wax composition with a new fragrance is launched. Typically, several different wick sizes and materials are tested to determine the best performing wick when a new fragrance is introduced. This testing aims to ensure the wick, fragrance, and wax composition performs within a set of criteria for temperature, carbon emissions, blooms, soot emission, and curvature of the wick during use. This testing and optimization are not required for the candles of the present disclosure. Rather, an optimal wick need only be developed once and this optimal wick can be subsequently used, regardless of changes in the fragrance, volatile material, or active agent. Further, some fragrances, active agents, or volatile materials are also incompatible or insoluble with some wax or fuel compositions. As a result, some fragrances, active agents, or volatile materials cannot be used in traditional candles.
The candles or dispensers of the present disclosure, however, overcome this issue because the fragrance, active agent, or volatile material is present in a portion of the candle other than the wax or fuel composition, such as a reservoir or sleeve or the container itself. The candles and dispensers of the present disclosure therefore allow the use of some fragrances, active agents, or volatile materials that were previously incompatible with traditional candles. Additionally, although this disclosure is focused on fragranced candles, these candles and the method of producing the candles can be used for other chemical ingredients and volatile materials. For example, the embodiments of this disclosure and the method described herein could be a solution for pest control products. With that said, some fragrance material, pest control actives, and other volatile materials may be less soluble or insoluble in wax compositions. Alternatively, or additionally, some fragrances, pest control actives, and other volatile materials may suppress or inhibit a candle flame, thereby producing a less desirable flame to a user, when they are present in the wax composition. Therefore, the candles of the present disclosure are also advantageous because the placement of the fragrance or volatile material in a permeable sleeve eliminates or greatly reduces these negative effects of standard candles. More particularly, the permeable sleeve or reservoir strip can be constructed from a material that is soluble with a broader range of chemistries or can be customized to work best with various chemistries.
In some embodiments, the containers of the candles 200, 300, 400, 500 are constructed from cement materials. Cement-based jars are sturdy and leak-proof as a candle container. Cement is known to be resistant to heat and fire, making it a safe option while also being quite porous for fragrance release. In some embodiments, the candles are made in cement pots having openings at the top. In some embodiments, the cement containers of the candle are made with a mixture of cement and polymeric materials.
In some aspects, the cement is manufactured through a chemical combination of calcium, silicon, aluminum, iron, and other ingredients. The cement may be selected from one or more general cements that include cemento, hydrostone, hydrocal, masonry cement, Portland cement (OPC), slag cement, alumina cement, and ultrafast cement. The cement mixture used for forming the container or jar may further comprise a polymeric material and/or a filler. In some embodiments, the filler is a sand. Further examples of filler that may mixed with cement to form the jars or containers includes calcium carbonate, talc, wollastonite, mica, kaolin, slica, carbon black, dolomite, barium sulfate, diatomaceous earth, magnetite/hermatite, halloysite, zinc oxide, titanium dioxide, gravel, stone, and rebar.
The polymeric materials used in the cement mixture serve to improve the physical properties of the resulting container by increasing compatibility and adhesion between internal components of the cement. In some embodiments, the polymeric material mixed with cement to make the candle container is a polyvinyl acetate (PVAc). In further embodiments, the PVAc is in the form of PVAc beads. The beads may be mixed with the cement as whole beads, crushed beads, and/or partially crushed beads to form the porous jar. Further examples of polymeric materials that may mixed with cement to form the jars or containers include polystyrene, polyvinyl acetate silane terminated polymer, polyvinyl alcohol, polyvinyl ester, polyvinyl ester silane terminated polymer, methyl methacrylate-butyl acrylate and styrene-butadiene rubber latex, and preferably, polyvinyl acetate, polyvinyl alcohol, methyl methacrylate-butyl acrylate and styrene-butadiene rubber latex and/or any combination thereof.
In some embodiments, the containers of the candles 200, 300, 400, and/or 500 comprise cement mixtures and are coated with a polysiloxane coating because the cement container cannot be sealed with a glazing process and is instead coated with a sealant layer. The sealant layer may comprise polysiloxane, epoxy, acrylic, cementitious, polyurethane, polyurea, and combinations thereof. The sealant layer protects the container of the candle from water damage and improves the lifetime of the device.
In some aspects, the sleeve 208 or reservoir 404, 504 of the candles 200, 300, 400, and 500 comprises the cement mixture. In further embodiments, the sleeve 208 or reservoir 404, 504 comprises cement and PVAc beads wherein the beads are mixed with cement as whole beads, crushed beads, and/or partially crushed beads to form the sleeve or reservoir.
While in some embodiments, the wax composition is devoid, essentially free, or substantially free of fragrance, in some embodiments a disposable tealight candle is used as the wicks 204, 304 and wax or fuel composition 202, 302, and the tealight candle may contain a fragrance (sec
In some embodiments, the sleeve 208 or reservoir 404, 504 contains a complementary fragrance of the fragrance of the disposable tealight candle. Common complementary fragrances of the disposable tealight candle and the fragrance contained in the sleeve 208 or reservoir 404, 504 include but are not limited to, amber and vanilla, apple and honey, apple and pumpkin spice, apple and sage, apple and tobacco, apple and campfire, berry and cinnamon, blue spruce and citrus, cedar and campfire, cedar and neroli, cedarwood and tangerine, citrus and coconut, coconut and clove, coconut and lemon, coconut and mint, coconut and vanilla, cranberry and orange, cucumber and lemon, cucumber and mint, carl grey and apple, carl grey and lavender, eucalyptus and lavender, eucalyptus and lemon, eucalyptus and mint, cucalyptus and vanilla, eucalyptus and white tea, jasmine and sandalwood, lavender and cedarwood, lavender and lemon, lavender and lilac, lavender and mint, lavender and vanilla, lemon and mint, lemon and musk, lily and lilac, mango and mint, mango and pineapple, maple and campfire, maple and mint, maple and pumpkin, pear and white tea, rosemary and mint, sage and cedarwood, sage and rose, sage and sweetgrass, sandalwood and rose, sandalwood and citrus, strawberry and mint, strawberry and vanilla, vanilla and cinnamon, white tea and honey, etc. While this list is not meant to be exhaustive, it is meant to demonstrate the increased versatility of the device when a tealight candle containing fragrance is used.
In some aspects, the design concept of using a fragranced plastic sleeve in conjunction with a disposable tealight candle is used (the wax of the tealight candle may be scented or unscented). The tealight candles have the benefit of a short burn time so they can be used for a single occasion and and/or a user may be comforted with the knowledge that the tealight will burn out in a relatively short period of time if they forget to blow the candle out. The use of a fragranced tealight candle can additionally allow scents to be mixed and matched between the jar and the tealight candle, thereby offering further customization. The disposable tealight candle can be replaced to increase the longevity of the volatile material dispensing device. In the present embodiment, it is anticipated that the device may be used with up to 6 disposable tealight candles, greatly extending the lifetime of the device.
As discussed herein, the candle of the present disclosure produces reduced levels of soot as compared to a control candle that includes a fragrance in its wax or fuel composition. In addition, the candles of the present disclosure produce reduced levels of volatile organic compounds (VOCs) as compared to a control candle that includes a fragrance in its wax or fuel composition. In some embodiments, the reduction in emissions of soot and VOCs is at least 20%, at least 30%, at least 40%, or at least 50% compared to a control candle with the same fragrance, volatile material, or active agent in the wax composition.
The present disclosure also provides a process for producing the candles of the present disclosure. In particular,
With reference to
Step 4 of the method 600 includes the step of positioning the wick 204 in the vessel or container 206 and pouring the wax or fuel composition 202 into the candle vessel or container 206. Then, Step 5 of the method 600 includes the step of allowing the candle 200, which includes the container 206, the sleeve or reservoir 208, the wax or fuel composition 202, and the wick 204, to cool, such that the wax or fuel composition 202 solidifies.
With reference to
With reference to
With reference to
The examples herein are intended to illustrate certain embodiments of the candles and methods of producing the candles to one of ordinary skill in the art and should not be interpreted as limiting in the scope of the disclosure set forth in the claims. The candles, and the methods of making thereof, may comprise the following non-limiting examples.
In one example, the design concept of using a fragranced plastic sleeve in lieu of fragranced wax was studied. First, two different jars having three fragranced plastic pieces (measuring 3″×½″×⅛″) were placed inside a 100-millimeter (mm) diameter glass candle jar and then each jar was filled with wax. One candle (i.e., “Candle No. 1” in Table 1) had the fragranced plastic pieces oriented lengthwise and equidistantly spaced in the jar. The second candle (i.e., “Candle No. 2” in Table 1) had the fragranced plastic pieces oriented horizontally and equidistantly spaced within the jar. The wax levels in both of Candle Nos. 1 and 2 were at a level that covered half of the fragranced pieces. Additionally, the wax in Candle No. 1 and Candle No. 2 were non-fragranced waxes and consisted of a 50/50 blend of soy and paraffin wax with three wicks.
Candle No. 3 and Candle No. 4 were comparative candles where the fragrance was added in the wax composition. First, a 3-wick candle having a fragrance (i.e., “Candle No. 3” in Table 1) was tested in a jar having an approximate size comparable to Candle Nos. 1 and 2. Second, a 1-wick candle with a fragrance, i.e., Candle No. 4, was tested in a jar having an approximate size comparable to Candle Nos. 1 and 2.
After formation, the candles were placed into controlled hedonic chambers and were positioned such that they would be behind a viewing screen, so as not to be observable while being evaluated. The candles were first measured in a cold mode (i.e., without a flame) by evaluators who entered the chambers. During these measurements, the evaluators described the fragrance character and ranked the intensity on a scale of one to five (i.e., five being the strongest intensity). The results of these tests are shown in Table 1 below. As shown in Table 1, Candle No.1, which embodies aspects of the present disclosure, produced increased intensity during a cold mode compared to Candle Nos. 3 and 4. Further, Candle No. 2, which also embodies aspects of the present disclosure, evidenced superior results to Candle No. 3 and similar results to Candle No. 4.
Next, the same candles from Example 1 were tested in a hot mode (i.e., with a lighted flame). Here, the candles were lit and compared in a hot mode using the same method, and the same criteria of intensity and fragrance character as used in Example 1. The results of these measurements are shown in Table 2, below.
As shown in Table 2, a significant jump in fragrance intensity was observed when the candles were lit, even when the exposed surface area was limited. In particular, the candles employing aspects of the present disclosure produced fragrance intensities that either matched or exceeded those of currently produced candles. Further, Candle No. 1 produced a high intensity when lit, which caused the fragrances to fill the room much more quickly compared to both Candle No. 3 and Candle No. 4. Further, Candle No. 2 also produced a high intensity when lit, which was similar to the 3-wick candle of Candle No. 3 and considerably greater than the 1-wick candle of Candle No. 4. Thus, these results showcase the beneficial aspects of candles of the present disclosure.
The benzene emissions of several candles were also tested. In this example, several standard candles (i.e., “Candle No. 5”, “Candle No. 6”, and “Candle No. 7” in Table 3, below) were constructed using 75 grams of wax, about 4.5 grams of which was fragrance. Further, several candles embodying aspects of the present disclosure (i.e., “Candle No. 8”, “Candle No. 9”, “Candle No. 10”, “Candle No. 11”, “Candle No. 12”, and “Candle No. 13” in Table 3, below) were constructed by soaking jars in fragrance to allow the jars to absorb the fragrance therein. In particular, Candle Nos. 8-10 included approximately 4.5 grams of fragrance therein and Candle Nos. 11-13 included approximately 2.25 grams of fragrance therein. Further, Candle Nos. 8-13 were also filled with about 75 grams of non-fragranced wax. Additionally, each candle was burned for approximately 30 minutes before being tested according to EM-001 emission collection methods. The candle emission results are shown in Table 3 below.
As shown in Table 3, the highest levels of benzene emissions occurred in Candle Nos. 5-7, which were the standard or comparable candles. Candle Nos. 8-13, which employed aspects of the present disclosure demonstrated significantly lower benzene or VOC emissions compared to Candle Nos. 5-7, thereby showcasing the improved aspects (i.e., lower VOC emissions) resulting from the candles of the present disclosure.
Variations and modifications of the foregoing are within the scope of the present disclosure. It is understood that the embodiments disclosed and defined herein extend to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present disclosure. The embodiments described herein will enable others skilled in the art to utilize the disclosure. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.
As noted previously, it will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein.
The aspects of the candle and process of making same described herein advantageously create a candle having improved emissions and manufacturing.
Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention. The exclusive rights to all modifications which come within the scope of the appended claims are reserved.
This application is a continuation-in-part of U.S. patent application Ser. No. 18/213,706, filed on Jun. 23, 2023, which claims the benefit of and priority to U.S. Provisional Patent Application 63/355,820, filed on Jun. 27, 2022, which are each incorporated by reference herein in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63355820 | Jun 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18213706 | Jun 2023 | US |
| Child | 18811182 | US |
