Patent Application
20160298055
The field of the invention is electric lights and candles.
The following background discussion includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
Various electric lights are known in the art. See, e.g., U.S. Pat. No. 8,132,936 to Patton et al., U.S. Pat. No. 8,070,319 to Schnuckle et al., U.S. Pat. No. 7,837,355 to Schnuckle et al., U.S. Pat. No. 7,261,455 to Schnuckle et al., U.S. Pat. No. 7,159,994 to Schnuckle et al., US 2011/0127914 to Patton et al., U.S. Pat. No. 7,350,720 to Jaworski et al.; US 2005/0285538 to Jaworski et al. (publ. December 2005); U.S. Pat. No. 7,481,571 to Bistritzky et al.; US 2008/0031784 to Bistritzky et al. (publ. February 2008); US 2006/0125420 to Boone et al. (publ. June 2006); US 2007/0127249 to Medley et al. (publ. June 2007); US 2008/0150453 to Medley et al. (publ. June 2008); US 2005/0169666 to Porchia, et al. (publ. August 2005); U.S. Pat. No. 7,503,668 to Porchia, et al.; U.S. Pat. No. 7,824,627 to Michaels, et al.; US 2006/0039835 to Nottingham et al. (publ. February 2006); US 2008/0038156 to Jaramillo (publ. February 2008); US 2008/0130266 to DeWitt et al. (publ. June 2008); US 2012/0024837 to Thompson (publ. February 2012); US 2011/0134628 to Pestl et al. (publ. June 2011); US 2011/0027124 to Albee et al. (publ February 2011); US 2012/0020052 to McCavit et al. (publ. January 2012); and US 2012/0093491 to Browder et al. (publ. April 2012).
These and all other extrinsic materials discussed herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.
However, there is still a need for improved systems and methods for forming wax or wax-like candles or shells for use in electric lighting devices, for example.
The inventive subject matter provides apparatus, systems and methods for forming wax or wax-like shells or housings for use with electric candles or other lighting devices, preferable via injection molding.
In one aspect, devices for forming a wax or wax-like shell for use with an electric lighting device, preferably via injection molding, can include a sleeve that defines an interior space. A core can be sized and dimensioned to be inserted within the sleeve's interior space, such that the core may be disposed within the sleeve. A modular top can be configured to couple to the sleeve, such that different tops can be used with the sleeve depending on the desired upper surface of the shell. For example, a shell having a flat top could use a different top that a shell having an indented top surface.
Method for forming wax or wax-like shells using injection molding are also contemplated. Such methods can include providing a device having a sleeve that defines an interior space, a core disposed within the interior space, a modular top configured to be coupled to the sleeve, and a cap having a gate. Wax can then be fed into the interior space via the gate.
It is contemplated that the cap can further include a vent through which excess wax can exit the interior space.
Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
A basic process for manufacturing wax shells includes pouring wax liquid, pre-heated paraffin, into a cooking container and heating it to a desired temperature. Various additives can be added to the mixture including a wax softener, antioxidants, color pigments, and fragrance oil.
As one such example, 50 kg of wax pre-heated, wax liquid can be poured into a container and heated to 120° C. Next, the following substances can be added to the wax liquid: 1) wax softener based on specifications (note: extremely cold weather will require more softener to prevent cracking (approx. 5-20%); 2) antioxidants, up to 2%; 3) color pigment, up to 2%; and 4) fragrance oil, up to 2.5%.
Once heated, the paraffin can be poured into molds. The molds preferably comprise aluminum or other metal tubes that define an outer perimeter of the wax shell, and can include a milled top scallop shape that defines an exterior top surface of the wax shell when formed. Cold water can be used to cool the molds by allowing the cold water to fill or flow through a container processing pool where the wax molds reside. During this time, wax from each mold that is still in liquid form can be poured into a wax heater for later reuse. Once hardened, the wax shells can be removed from the molds.
A drilling machine is used to make a hole in the top of the wax shell that is the correct diameter to fit with an injection molded plastic shell. The shell can then be inserted into the wax shell. Prior to inserting the plastic shell within the wax shell, glue or other adhesive can be applied to an outer portion of the plastic shell and/or an inner portion of the wax shell to adhere the two together.
In some contemplated embodiments shown in
The device 100 can further include a core 110 that can be disposed within the interior space 104. The core 110 advantageously at least partially defines an interior of the wax shell and provides a hollow space in the shell once formed. The core 110 thereby eliminates the need to later drill and remove an interior portion of the shell, saving time and cost in the manufacturing process. The core 110 can advantageously include at least one keyway 112, which creates an indentation in a side of the wax shell when formed at the location of the keyway 112. This is important as it allows for a plastic core to be properly inserted by aligning a projection of the plastic core with the indentation formed in the wax shell to thereby ensure that a flame element coupled to the plastic core is properly aligned with respect to an upper surface of the shell. Exemplary flame elements and electric lighting devices are discussed in U.S. utility patent application Ser. No. 13/850,011 filed on Mar. 25, 2013.
The device 100 can further include a block 114 between the core 110 and the modular top 106 to thereby create an aperture in an upper surface of the wax shell through which a flame element can protrude, for example. The use of the block 114 eliminates the need to later drill to create a hole in the surface of the shell, saving time and money while ensuring that the holes are consistently and properly located relative to the shell's surface.
As shown in
Thus, for example, wax conduits 334 can be used to insert wax into each of the three devices shown. Through the use of the manifold 330, it is contemplated that the number of shells made simultaneously can be scaled up and down as needed, and could be used to create 6 packs, 10 packs and other number of wax shells simultaneously. In such embodiments, it is contemplated that the wax or other material could be pressurized to be quickly inserted into the interior area of each device. With respect to the remaining numerals in
As shown in
As shown in
It is further contemplated that a rubber insert 618 could be used having a flat surface where debossing is not desired. In such embodiment, the tool can be the same for different types of surfaces, which can reduce the overall manufacturing cost. Thus, for example, after a run of shells are made having a flat outer wall, the insert 618 can be swapped out for an insert 618A with indentations to thereby create shells having a debossed outer surface.
In other aspects, methods for injection molding of the housing are contemplated. Preferred methods utilize a wax material or a combination of a wax material and a plastic material to mold the housing.
Where multiple compositions are used, preferably a mixing head can be used prior to injection of the materials. As but one example, a mixture could include a 9:1 ratio of wax to plastic. Preferably, both the wax and plastic materials are heated to their respective melting points and then mixed together prior to injection. It is especially preferred that the mixture comprises at least 25% wax or a 3:1 ratio of plastic to wax.
In still further embodiments, the housing could be molded using a 100% wax material. In such embodiments, a spring-loaded mixing head is required to prevent run out of the wax material in between molds. Once molded, a large injector pin head can be used to separate the wax housing from the mold. Preferred injector pin heads are at least 50% of the surface area of one side of the housing, and sizes of 0.5 in, 1.0 in, and 2.0 inches are contemplated depending on the specific size of the candle housing.
As mentioned above in reference to
As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.
As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously.
It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the scope of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.
As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously.
This application claims priority to U.S. Provisional Application No. 62/145545, filed Apr. 10, 2015. All extrinsic materials identified herein are incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62145545 | Apr 2015 | US |
