Patent Application
20120250336
[Not Applicable]
[Not Applicable]
[Not Applicable]
Generally, the present application relates to flameless candles. Particularly, the present application relates to techniques for screwing an electronics insert into a waxen sidewall of a candle shell.
Flameless candle designs may use candle shells that include wax or a waxen material. As used herein, a waxen material is encompassing of wax, a wax substitute, or similar materials. The waxen material may allow the flameless candle to appear more like a traditional candle. While the waxen material may provide such benefits, it can be relatively expensive.
Because a flameless candle does not typically consume the candle, it may not be necessary to have a candle body that is completely solid. Instead, it may be preferable to have a hollow region within the candle body, such as a candle shell. Such a design requires less material. An electronics insert may then be inserted into the candle shell and at least partially into the hollow region.
One such candle shell is illustrated in
Techniques for inserting the electronics insert into the candle shell may involve one or more intermediate steps. For example, it may be useful to secure the electronics insert to the candle shell. One technique for securing the electronics insert is to place the insert into the candle shell. Subsequently, hot wax or another sealant can be added between the electronics insert and the candle shell.
This process, however, can be relatively expensive and time consuming during the manufacturing process. Of course, the sealant has an associated material. Additionally, the steps of adding the sealant and waiting for drying take time. Furthermore, it may be useful to regulate the insertion depth of the electronics insert into the candle shell before applying the sealant. Moreover, the electronics insert may be damaged by the sealant (for example, hot wax) and, therefore, it may be useful to perform an additional step of protecting the insert before the sealant is applied. These techniques may also require a relatively complex production flow and expensive machine costs.
According to embodiments of the present invention, a flameless candle is claimed, depicted, and described. The candle has a candle shell, which includes a sidewall (such as a waxen sidewall) surrounding a hollow region. There is an opening through the bottom of the candle shell leading into the hollow region.
This flameless candle also has an electronics insert. The insert has a housing. At least one thread (for example, an exterior thread or male thread) is arranged on a lateral portion of the housing. This thread (or threads as used herein) can be rotated in response to a torque force on the electronics insert. The rotation causes the electronics insert to be drawn through the opening and into the hollow region, thereby substantially securing the electronics insert to the candle shell.
In an embodiment, the thread of this candle is a self-tapping thread which cuts into the waxen sidewall. Another option would be to have interior threads (for example, female threads) on the interior of the waxen sidewall. In an embodiment, the electronics insert can be substantially drawn into the hollow region after being rotated approximately one quarter of a turn.
This flameless candle could have a first step, which may or may not be tapered. In another embodiment, the threadform of the threads on the lateral wall of the housing of the electronics insert has a trapezoidal threadform or cross-section.
According to embodiments of the present invention, a method for assembling a flameless candle is claimed, depicted, and described. According to the method an opening in a bottom of a waxen sidewall of a candle shell is aligned with a lateral portion of a housing of an electronics insert. There are exterior threads located on the lateral portion. The threads may be self-tapping. The end portions of the threads are engaged with the waxen sidewall. The electronics insert is then rotated. This causes the threads to rotate as well. The threads then cut into the waxen sidewall. As the threads rotatably cut into the waxen sidewall, the electronics insert is drawn into a hollow region in the candle shell.
The rotation of the electronics insert and the threads may be facilitated through the use of a tool. The tool may be inserted into the battery compartment of the electronics insert. The electronics insert may be rotated while the waxen sidewall is still, or vice versa.
A first step may be formed in the interior of the waxen sidewall. This first step may be tapered. In such embodiment(s), the threads may engage a portion of the first step. As the threads are rotated, they cut into the first step of the waxen sidewall, thereby causing the electronics insert to be drawn into the hollow region.
The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purposes of illustration, certain embodiments are shown in the drawings. It should be understood, however, that the claims are not limited to the arrangements and instrumentality shown in the attached drawings. Furthermore, the appearance shown in the drawings is one of many ornamental appearances that can be employed to achieve the stated functions of the system.
The LED 210 may produce a flickering light when turned on. The light diffusing member 220 may diffuse the light emitted by the LED 210 to promote the illusion of a traditional candle. The battery compartment 250 may be opened from the bottom of the electronics insert 200, for example, with a spring-latched door. The battery compartment 250 may hold the batteries that provide power to the LED 210. The electronics insert 200 may also include a base 260. As shown, the exterior of the lateral portion 230 is tapered (that is, it is shown having an angle that is not perpendicular to the base 260), although other orientations are possible—for example, non-tapered.
One or more threads 240 may be located on the lateral portion 230 of the housing. The threads 240 may be exterior threads. There may be a plurality of threads 240. In an embodiment, there are eight threads 240. One or more threads 240 may have a trapezoidal threadform—that is, cross-sectional profile of the thread 240. Other shapes are possible, such as triangular, square, etc. The threads 240 may have end portions. The end portions may have a different threadform or cross-sectional profile. For example, the end portions may be tapered. As used herein, the term “threads” means one or more threads.
The candle shell 300 may also include a first step 370 and a second step 380. As shown, the first step 370 may be tapered, though it may be non-tapered or have some other orientation. At the first and second steps 370, 380, the waxen sidewall 310 becomes progressively thinner. Other options are also available, such as a waxen sidewall 310 that becomes progressively thicker at the first and second steps 370, 380, or the waxen sidewall 310 could have some other thickness variation. The first step 370 may generally compliment the profile of the exterior of the lateral portion 230 of the electronics insert. The second step 380 may generally compliment the profile of the base 260.
The first step 370 and/or second step 380 may be formed in the waxen sidewall 310 in different ways. For example, the step(s) may be formed after the formation of the waxen sidewall 310. In such an example, the candle shell may be similar to candle shell 300. Portions of the waxen sidewall may then be removed to form the step(s). Other techniques are possible, such as forming the step(s) at the same time the rest of the waxen sidewall 310 is formed (for example, as part of a molding process).
The profile of the opening 330 (see, for example,
Referring to
In order to substantially secure the electronics insert 200 to the candle shell 300, a certain amount of rotation may be required. The number of threads 240 and their corresponding pitch may indicate how much rotation is required. In an embodiment, there is a plurality of threads 240. In one particular example, there are eight threads 240. In this example, the threads 240 have a pitch such that the electronics insert 200 is substantially inserted into the candle shell 300 after one-quarter of a turn. Of course, the process of substantial insertion may be achieved after more or less than one-quarter of a turn.
After engagement, the electronics insert 200 may be rotated with respect to the candle shell 300 so that the threads 240 rotatably cut into the waxen sidewall 310. The electronics insert 200 may be rotated clockwise or counterclockwise with respect to the candle shell 300. As the threads 240 are cutting into the waxen sidewall 310, the electronics insert 200 may be responsively drawn into the hollow region 330 of the candle shell 300. The rotation may be facilitated by one or more tools, such as tool 510. The exemplary tool 510 may be inserted into the battery compartment 250 of the electronics insert 200. The electronics insert 200 may rotate while the position of the candle shell 300 is substantially maintained. Optionally, the position of the electronics insert 200 may be substantially maintained while the candle shell 300 is rotated. As another example, both the electronics insert 200 and the candle shell 300 may be complimentarily rotated. In addition to the torque force used for rotation, an inward force may also be applied to the electronics insert 200 and/or the candle shell 300.
If the candle shell has a first step 370, then the threads 240 may engage in the first step 370 of the waxen sidewall 310. As the electronics insert 200 is drawn into the candle shell 300, the insert 200 may land in a position that is complementary to the first step 370. For example, as shown in
At step 710, the electronics insert 200 is aligned with the opening 330 in the candle shell 300. At step 720, end portions of one or more threads 240 (for example, exterior threads) on the electronics insert 200 are engaged with the waxen sidewall 310 of the candle shell 300. The threads 240 may be self-tapping.
Prior to engagement of the threads 240, the first step 370 (not to be confused with a step of method 700) may be formed in a bottom region of the interior of the waxen sidewall 310. The first step 370 may be formed by removing or routing out waxen material from the waxen sidewall 310. Such removal may be performed by a tool, such as a drill attachment. The first step 370 may be tapered. When performing the engagement step 720, the end portions of the threads 240 may engage with the first step 370.
At step 730, the electronics insert 200 is rotated with respect to the candle shell 300. This causes the threads 240 to rotatably cut into the waxen sidewall 310 (for example, into the first step 370 of the waxen sidewall 310). A position of the electronics insert 200 may be maintained while the candle shell 300 is rotated with respect to the electronics insert 200. As another example, the electronics insert 200 may rotate while the position of the candle shell 300 is substantially maintained. As another example, both the electronics insert 200 and the candle shell 300 may be complimentarily rotated. In addition to the torque force used for rotation, an inward force may also be applied to the electronics insert 200 and/or the candle shell 300.
The rotation of the electronics insert 200 and/or candle shell 300 may be facilitated by one or more tools, such as tool 510 discussed above. A step may be provided during which a tool is inserted into a battery compartment 250 of the electronics insert 200. The battery compartment 250 may provide a useful location for placement of a tool to stabilize and/or control the rotation of the electronics insert 200, especially if there are no batteries in the battery compartment 250. At step 740, in response to the rotation, the electronics insert 200 is drawn into the hollow region 330 in the candle shell 300.
While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. For example, many of the techniques described herein with respect to candle shell 300 may also be applicable to the use of candle shell 100. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
