Method for pouring a candle wax and obtained candle

Abstract

The current invention relates to a method for making a multi-layered candle wherein at least one candle wick is affixed to a bottom portion of a candle jar, a first layer of the candle wax composition is poured in the candle jar, such that the candle wax composition reaches a vertical wall of the jar, and the first layer of candle wax composition is allowed to solidify for a period of at least 24 hours. This process is repeated for each subsequent layer of candle wax, ensuring a gap of 3 to 5 mm is left between the penultimate candle wax layer and the vertical wall of the jar, before depositing the final layer of wax. The invention also relates to a candle obtained by this method. The method provides versatility in material use, enhances candle burning, increases aesthetic value, allows for customizable candles, and ensures stable candle placement and improved wick alignment.

Description

FIELD OF THE INVENTION

[0001] The field of the invention relates to the production of candles, more specifically to a method for making multi-layered candles using a specific process of affixing wicks, pouring wax layers, and allowing each layer to solidify before the next is poured. The invention also includes specific characteristics of the candle jar, the candle wax composition, and the method of securing the wicks.BACKGROUND

[0002] Candles, especially multi-layered candles, are popular decorative items and are often used to create a warm and inviting atmosphere. However, the manufacturing process of these candles can be quite complex and requires careful attention to several factors. The number of layers in a multi-layered candle can vary, and each layer needs to be poured and allowed to solidify before the next layer can be added. This process can be time-consuming and requires precise control of the wax temperature and the timing of the pouring process. Additionally, the wick, which is an essential part of any candle, needs to be properly positioned and secured in the candle jar. This is typically done by affixing the wick to the bottom of the jar, but the method of affixation and the material used can affect the stability of the wick and the burning properties of the candle. Furthermore, the size and shape of the jar, as well as the number of wicks used, can also influence the burning properties of the candle and its overall aesthetic appeal. Therefore, there is a need for an improved method for manufacturing multi-layered candles that addresses these issues.

[0003] Methods for candles manufacturing are known from US2013 / 084535, however this method does not focus on improving the melt pools of wax during the burning of the candle.

[0004] The present invention aims to resolve at least some of the problems and disadvantages mentioned above.SUMMARY OF THE INVENTION

[0005] The invention pertains to a method for manufacturing multi-layered candles, ensuring a visually appealing and structurally stable end product. The method involves affixing at least one wick to the bottom of a candle jar, pouring a layer of wax into the jar, and allowing each layer to solidify for at least 24 hours before pouring the next layer. The penultimate layer of wax is poured such that a gap of 3 to 5 mm is left from the jar's vertical wall, ensuring a clean and uniform final layer. The wick is secured using a wick-holding device, which can be made of various materials like metal, plastic, or wood, and is affixed using clips. The method allows for the creation of candles with 1 to 7 wicks and 2 to 6 layers of wax, with the wax composition customizable to include a polymer additive, UV stabilizer, fragrance, and pigment. The jar used is preferably made of glass and can have varying dimensions in terms of height and diameter. The invention offers numerous advantages, such as flexibility in design, enhanced aesthetic value, increased burning efficacy, superior structural stability, and improved safety measures.DESCRIPTION OF FIGURES

[0006] Figure 1 shows a schematic representation of the method of making a multilayered candle according to an embodiment of the invention. Figure 2 shows a transversal section of an embodiment of the candle layers obtained using the method of the invention. Figure 3 depicts the arrangement of the wicks on the bottom of the jars according to the embodiments of the invention. Figure 4 depicts a wick tab (Fig. 4A) before the wick insertion and a pinched wick tab (Fig. 4B) after the insertion of the wick according to an embodiment of the invention. Figure 5 depicts wick-holding devices according to embodiments of the invention. Figure 6 depicts the vertical gap between the surface of the solidified wax and the upper edge of the candle jar according to the embodiments of the invention. Figure 7 depicts sinkholes in the first wax layer according to embodiments of the invention. DETAILED DESCRIPTION OF THE INVENTION

[0007] Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included to better appreciate the teaching of the present invention.

[0008] As used herein, the following terms have the following meanings: "A", "an", and "the" as used herein refer to both singular and plural referents unless the context clearly dictates otherwise. By way of example, "a compartment" refers to one or more than one compartment.

[0009] "About" as used herein refers to a measurable value such as a parameter, an amount, a temporal duration, and the like, is meant to encompass variations of + / -20% or less, preferably + / -10% or less, more preferably + / -5% or less, even more preferably + / -1% or less, and still more preferably + / -0.1% or less of and from the specified value, in so far such variations are appropriate to perform in the disclosed invention. However, it is to be understood that the value to which the modifier "about" refers is itself also specifically disclosed.

[0010] "Comprise", "comprising", and "comprises" and "comprised of" as used herein are synonymous with "include", "including", "includes" or "contain", "containing", "contains" and are inclusive or open-ended terms that specify the presence of what follows e.g. component and do not exclude or preclude the presence of additional, non-recited components, features, element, members, steps, known in the art or disclosed therein.

[0011] The term 'wick' as used in this invention pertains to any fibrous material, typically cotton, hemp or linen, that is capable of drawing wax upwards due to capillary action, facilitating its vaporization and subsequent combustion.

[0012] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order, unless specified. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

[0013] The recitation of numerical ranges by endpoints includes all numbers and fractions subsumed within that range, as well as the recited endpoints.

[0014] The expression "% by weight", "weight percent", "%wt" or "wt%", here and throughout the description unless otherwise defined, refers to the relative weight of the respective component based on the overall weight of the formulation.

[0015] Whereas the terms "one or more" or "at least one", such as one or more or at least one member(s) of a group of members, is clear per se, by means of further exemplification, the term encompasses inter alia a reference to any one of said members, or to any two or more of said members, such as, e.g., any ≥3, ≥4, ≥5, ≥6 or ≥7 etc. of said members, and up to all said members.

[0016] Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, definitions for the terms used in the description are included to better appreciate the teaching of the present invention. The terms or definitions used herein are provided solely to aid in the understanding of the invention.

[0017] Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to a person skilled in the art from this disclosure, in one or more embodiments. Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

[0018] In a first aspect, the invention provides a method for making a multi-layered candle, which offers enhanced burning efficacy, wherein the method comprises the steps of: (a) affixing at least one candle wick to a bottom portion of a candle jar; (b) pouring a first layer of the candle wax composition in the candle jar, such that the candle wax composition reaches a vertical wall of the jar; (c) allowing the first layer of candle wax composition to solidify for a period of at least 24 hours; (d) repeating steps (b) and (c) for each subsequent layer of candle wax; and (e) ensuring a gap of 3 to 5 mm is left between the penultimate candle wax layer and the vertical wall of the jar, before depositing the final layer of wax.

[0019] The candle jar comprises a bottom portion, an upper portion opposite to the bottom portion and a vertical wall connecting the upper portion and the bottom portion.

[0020] Preferably, the the method comprises the steps of: (a) affixing at least one candle wick to the bottom portion of a candle jar; (b) pouring a first layer of the candle wax composition in the candle jar, such that the candle wax composition reaches the vertical wall of the jar; (c) allowing the first layer of candle wax composition to solidify for a period of at least 24 hours; (d) pouring subsequent layers of candle wax composition and allowing each subsequent layer to solidify; and (e) ensuring a gap of 3 to 5 mm is left between the penultimate candle wax layer and the vertical wall of the jar, before depositing the final layer of wax.

[0021] The method relates to the creation of a multi-layered candle, wherein the candle comprises between two and six layers of a wax composition. The multi-layering technique significantly contributes to the structural stability of the candle. This is particularly beneficial for candles with larger diameters where maintaining structural integrity can be more challenging. By creating the candle in multiple layers, each allowed to solidify before the next is poured, the candle is endowed with enhanced structural strength. This ensures that the candle retains its shape and appearance even after prolonged use, thereby extending the lifespan of the candle and providing an aesthetically pleasing product for the duration of its use.

[0022] The method as disclosed herein comprises of several steps that contribute to the high quality and performance of the final product. The first step involves affixing at least one candle wick to the bottom portion of a candle jar. The candle wick can be affixed using various adhesive means, but in a preferred embodiment, silicone is used due to its high heat resistance and strong adhesive properties. The use of silicone ensures that the wick remains stable and firmly attached to the jar's bottom portion through the candle's burning process. This stability is crucial in ensuring that the flame burns evenly and consistently, not just in the central part of the candle, but across the entire surface.

[0023] In the next step, a first layer of a candle wax composition is poured into the candle jar. The first layer of wax is then allowed to solidify for a period of at least 24 hours. This specific curing time is essential in ensuring that the wax layer fully hardens before the next layer is added, resulting in a candle with high structural integrity.

[0024] The prolonged solidification period of up to 24 hours for the first candle layer ensures that sinkholes appear in the wax layer. When wax transitions from liquid to solid, it contracts, leading to shrinkage. This shrinkage is more pronounced at the centre and near the wicks where the wax cools and solidifies at different rates, causing sinkholes to form.

[0025] The sinkholes advantageously provide enhanced layer adhesion when the following layers of wax are poured. The wells create a slightly irregular surface on the top of the first layer, increasing the surface area where the next layer of wax will make contact. This can lead to better adhesion between layers, helping to bind the layers together more effectively and reducing the risk of separation as the candle burns. The lack of proper adhesion between layers is a common problem with large multilayer candles.

[0026] Additionally, the sinkholes contribute to the formation of controlled melt pools of wax during the burning of the candle. In large candles with multiple wicks, the sinkholes guide the burn pool inwards as it progresses through the layers. This leads to a more consistent burn pattern and reduces the risk of tunnelling, the phenomenon where the wax melts unevenly and forms a deep cavity around the wick.

[0027] The method disclosed herein is used to make candles with stable melt pools, which is particularly advantageous for large, multi-wick candles that typically experience issues with unstable melt pools. This stability enhances the burn quality, ensures even wax consumption, and reduces the likelihood of tunnelling or uneven burning, common challenges in larger candles with multiple wicks.

[0028] The process of pouring the wax and allowing it to solidify is then repeated for each subsequent layer. In a preferred embodiment, the candle comprises between 2 and 6 layers of wax, more preferably between 3 and 5 layers, and most preferably 4 layers.

[0029] In an embodiment of the method, as disclosed herein, the candle wax composition is poured in 2 to 6 layers and the total number of layers is determined based on the diameter of the upper portion of the jar according to the formula: L = 3 + d / 10 wherein L is the total number of layers and d is the diameter of the upper portion of the jar.

[0030] The number of layers in a candle are proportional to the diameter of the jar, more specifically the upper portion of the jar. In an embodiment, the method is used to make a candle in a jar with a diameter of the upper portion of the jar of between 10 cm and 16 cm, such a candle is formed of 4 layers. In another embodiment, the method is used to make a candle in a jar with a diameter of the upper portion of the jar of between 17 cm and 24 cm, such a candle is formed of 5 layers. In yet another embodiment, the method is used to make a candle in a jar with a diameter of the upper portion of the jar of over 24 cm, such a candle is formed of 6 layers.

[0031] In embodiments of the method, as disclosed herein, the layers have different solidification periods, as follows: the second layer of wax composition is allowed to solidify for a period of between 5 hours and 24 hours; the third layer of wax composition is allowed to solidify for a period of between 1 hour and 5 hours; the fourth layer of wax composition is allowed to solidify for a period of up to 2 hours; and the fifth and sixth layers of wax composition are allowed to solidify for a period of up to an hour.

[0032] Preferably, the first layer is solidified for at least 24 hours irrespective of the diameter of the upper portion of the candle jar.

[0033] The second layer of wax is solidified for at least 5 hours if the diameter of the upper portion of the candle jar is less than or equal to 24 cm. If the diameter of the upper portion of the candle jar is more than 24 cm, the second layer is solidifies for up to 24 hours.

[0034] The third layer of wax is solidified for between 1 hour and 2 hours for candles having a diameter of the upper portion of the candle jar of less than or equal to 24 cm. If the diameter of the upper portion of the candle jar is more than 24 cm, the third layer is solidified for up to 5 hours.

[0035] The fourth layer of wax is solidified for up to 1 hour for candles having a diameter of the upper portion of the candle jar of less than or equal to 24 cm. If the diameter of the upper portion of the candle jar is more than 24 cm, the fourth layer is solidified for up to 2 hours.

[0036] Candles with the upper portion of the candle jar greater than 24 cm also have fifth and sixth layers. These are solidified for up to 1 hour.

[0037] The penultimate candle wax layer which leaves a gap of 3 to 5 mm between the wax layer and the vertical wall of the jar, is solidified for about 1 hour. The final layer is poured into a thin layer and solidified for less than an hour, ensuring an even upper surface of the candle.

[0038] In embodiments of the method, as disclosed herein, a vertical gap of between 2 cm and 4.5 cm is left between the surface of the solidified wax and the upper edge of the candle jar. This gap allows space for safe burning and prevents wax from spilling over the edge. The distance is adjusted based on the diameter of the jar, with larger diameters having a larger gap.

[0039] In preferred embodiments, the vertical gap between the surface of the solidified wax and the upper edge of the candle jar (G) is defined in function of the diameter (d) of the upper portion of the candle jar by the formula: G = 0.1 d + 1

[0040] Before the final layer of wax is poured, a gap of 3 to 5 mm is left between the penultimate layer of wax and the vertical wall of the jar. This gap is essential in ensuring a safer and more uniform burn, preserving the stability of the wick until the final stage of burning. In a more preferred embodiment, the gap is between 3.5 and 4.5 mm, more preferably between 3.8 and 4.2 mm, and most preferably at 4 mm. The final layer of wax is then poured to reach the vertical wall of the jar, creating a uniform and aesthetically pleasing surface. The resulting multi-layered candle provides a consistent and satisfying user experience, burning for a longer duration and in a cleaner manner compared to candles made using traditional methods.

[0041] In a preferred embodiment, the method of making a multi-layered candle includes a final step where the last layer of candle wax is poured such that the candle wax composition extends to the vertical wall of the jar. This specific embodiment ensures that the final appearance of the candle is uniform and smooth, enhancing its visual appeal and cleanliness. The uniformity of the final layer of wax also ensures that the candle burns evenly, providing a consistent light and heat source. The final layer of wax is thus poured such that it forms a level surface with the vertical wall of the jar. This creates a clean and precise edge, enhancing the overall aesthetic appeal of the candle. The level surface also ensures that the wick is fully embedded in the wax, promoting consistent and efficient burning.

[0042] Alternatively, the final layer of wax is poured such that it slightly exceeds the height of the vertical wall of the jar. This creates a slightly domed surface, which further enhances the visual appeal of the candle. The domed surface also promotes even burning, as the wax melts evenly from the centre towards the edges.

[0043] In some embodiments of the method disclosed herein, the final layer of wax composition is poured to a level of between 1.3 cm and 4.5 cm, more preferably between 1.8 cm and 2.8 cm, and most preferably at 2.1 cm from the upper portion of the jar.

[0044] The final layer of wax is poured once all the preceding layers have solidified. The wax is poured carefully to ensure that it reaches the vertical wall of the jar without spilling over. The pouring process may be manual or automated, depending on the volume of production.

[0045] The wax is then left to solidify for a period of at least 24 hours. The solidification period ensures that the wax hardens fully and adheres to the previous layer, creating a seamless and uniform final layer.

[0046] The specific composition of the wax used in the final layer may vary depending on the desired properties of the candle. In a preferred embodiment, the wax composition comprises between 0.1% to 1.5% by weight (wt / wt) of a polymer additive, between 0.1% to 1% by weight (wt / wt) of a UV stabilizer, between 2% to 10% by weight (wt / wt) of a fragrance composition, between 0% to 1.5% by weight (wt / wt) of a pigment composition, and wax up to 100% by weight (wt / wt). The polymer additive improves the hardness and durability of the wax, while the UV stabilizer prevents discolouration from sunlight. The fragrance and pigment compositions provide the candle with a pleasant smell and colour, respectively.

[0047] It should be noted that while the preferred embodiments described herein specify the use of the same wax composition for each layer, the invention is not so limited. In alternative embodiments, different wax compositions may be used for different layers, providing further opportunities for variation in the aesthetic appearance of the candle. For instance, different wax compositions may have different colours or transparencies, allowing for the creation of multi-layered candles with visually striking layered effects. However, even when the same wax composition is used for all layers, the method of the invention still provides significant advantages in terms of structural stability and aesthetic appeal.

[0048] In a preferred embodiment of the invention, the method involves the affixation of at least one wick to the bottom portion of a candle jar. The wick, a critical component in the candle-making process, is attached using a silicone-based adhesive. The use of silicone as an adhesive material provides several advantages in the context of candle making.

[0049] Firstly, silicone adhesives are known for their strong bonding capabilities. This ensures that the wick remains firmly attached to the base of the candle jar, even as the candle wax is poured and solidified around it. The stability of the wick is critical to ensure an even and consistent burn of the candle. If the wick were to shift or become dislodged during the candle-making process, it could result in an uneven burn, or in severe cases, the extinguishing of the candle flame.

[0050] Secondly, silicone adhesives are resistant to both high temperatures and chemical interactions. This makes them suitable for use in candle making, where the wick will be exposed to the high temperatures of the burning candle, and potentially to chemical reactions with the candle wax or any additives contained therein.

[0051] In a more preferred embodiment, the silicone adhesive used to affix the wick to the candle jar comprises between 5 and 20 wt% of the total weight of the silicone adhesive, more preferably between 10 and 15 wt%, and most preferably around 12 wt%. This concentration range ensures an optimal balance between the adhesive strength of the silicone and its resistance to high temperatures and chemical interactions.

[0052] In a further preferred embodiment, the wick is affixed to the bottom portion of the jar using a silicone adhesive that has been cured for a period of between 12 and 24 hours, more preferably between 16 and 20 hours, and most preferably around 18 hours. This curing period allows the silicone adhesive to achieve its full bonding strength, temperature and chemical resistance, ensuring the stability of the wick during the subsequent candle-making process.

[0053] In yet another preferred embodiment, the wick is affixed to the bottom portion of the jar using a silicone adhesive that has been applied in a layer of between 1 and 3 mm in thickness, more preferably between 1.5 and 2.5 mm, and most preferably around 2 mm. This thickness range ensures an optimal balance between the adhesive strength of the silicone and its resistance to high temperatures and chemical interactions, while also ensuring a secure and stable affixation of the wick to the candle jar.

[0054] Preferably, the wick is affixed to a wick tab which is further affixed to the bottom portion of the jar using silicone. A wick tab or wick base as used throughout the disclosure, is a small metal or plastic base attached to the bottom of a candle wick. It stabilizes the wick to prevent it from falling. In a further embodiment, the wick tab is pinched. Pinching the wick tab further enhances the stability of the tab and keeps the wick upright during the candle-pouring process.

[0055] In a preferred embodiment of the method, at least one wick is anchored to an upper portion of the jar using a wick-holding device. This wick-holding device serves a critical role in the process of creating the multi-layered candle, as it ensures the wick remains in a proper position throughout the process. The anchoring of the wick to the upper portion of the jar using the wick-holding device results in a straighter wick in the finished candle, enhancing its aesthetic appeal and ensuring an even burn when the candle is lit.

[0056] The wick-holding device may be designed to accommodate a single wick or multiple wicks, depending on the design and size of the candle being created. Regardless of the number of wicks, the device securely holds each wick in place during the wax pouring process, maintaining the vertical alignment of the wick and preventing any lateral movement that could disrupt the uniformity of the layers of wax.

[0057] The wick-holding device may be constructed from a variety of materials, including but not limited to metal, plastic, or wood. The choice of material may depend on factors such as the thermal properties of the material.

[0058] The wick-holding device may be triangle-shaped, square-shaped, rectangle-shaped, cross-shaped or star-shaped depending on the size of the candle and the number of wicks used.

[0059] In a more preferred embodiment, the wick-holding device is designed with at least one hole through which the wick is threaded. This hole may be centrally located in the device, or it may be positioned off-centre depending on the design of the candle. The hole is typically large enough to allow the wick to pass through easily, but small enough to hold the wick securely in place.

[0060] In preferred embodiments, the wick-holders comprise multiple holes spaced at intervals ranging from 5 cm to 7.7 cm apart.

[0061] In the most preferred embodiment, the wick is affixed to the wick-holding device by at least one clip. This clip securely grips the wick, preventing it from slipping out of the device during the wax pouring process. The clip may be integrated into the design of the wick-holding device, or it may be a separate component that is attached to the device.

[0062] The use of a wick-holding device in this method provides several advantages. Firstly, it ensures the wick remains straight and centred throughout the wax pouring process, resulting in a better quality candle. Secondly, it allows for the creation of candles with multiple wicks, expanding the range of candle designs that can be produced. Finally, it simplifies the wax pouring process, making it easier and more efficient to produce multi-layered candles.

[0063] In a preferred embodiment of the method, the wick-holding device is characterized by comprising at least one hole to thread the at least one wick through. This characteristic feature of the wick-holding device plays a crucial role in ensuring the optimal performance of the candle. The hole in the wick-holding device provides a specific pathway for the wick, thus enabling the user to easily and accurately position the wick within the candle jar.

[0064] The placement and security of the wicks can directly influence how well a candle burns. By using a wick-holding device with at least one hole, consistent proper position and tension of the wicks are assured, resulting in a uniform and efficient burn throughout the life of the candle.

[0065] In a more preferred embodiment, the wick-holding device may comprise a plurality of holes for threading a corresponding number of wicks through. This would be particularly beneficial in the case of large candles that require multiple wicks for optimal burning. The number of holes in the wick-holding device could range from 2 to 7, more preferably from 3 to 6, and most preferably 4 or 5.

[0066] The size of the hole in the wick-holding device is also an important consideration. In a preferred embodiment, the hole has a diameter that allows the wick to pass through with ease but without excessive clearance that could compromise the stability of the wick. The diameter of the hole could range from 1 mm to 5 mm, more preferably from 1.5 mm to 4 mm, and most preferably around 2 mm or 3 mm.

[0067] In a preferred embodiment of the method, the wick is affixed to the wick-holding device utilizing at least one clip. This particular feature of the method provides a significant advantage in terms of the performance of the finished candle. Specifically, the use of a clip to secure the wick to the wick-holding device greatly reduces the likelihood of a crooked burn. It is well known in the art of candle making that a crooked burn can lead to uneven heat distribution and inconsistent lighting. By ensuring that the wick is securely affixed and held in place by a clip, the method of the present invention ensures a uniform burn and consistent light and heat output. This results in a superior quality candle that provides reliable performance for the end user.

[0068] In some embodiments, the clip used to affix the wick to the wick-holding device may be made of a resilient material, such as metal or plastic. The clip may be of any suitable size and shape so long as it is capable of securely holding the wick in place. In more preferred embodiments, the clip may be designed to accommodate a range of wick sizes, providing flexibility in the manufacture of candles of different sizes and shapes. This can be particularly advantageous in commercial settings where a variety of candle sizes may be produced.

[0069] In further embodiments, the clip may be designed to easily attach and detach from the wick-holding device. This can facilitate the process of placing the wick in the candle jar, as the wick can be affixed to the wick-holding device prior to being positioned in the jar. Once the wick and clip are securely in place, the candle wax can be poured into the jar without concern for the wick becoming displaced.

[0070] It should be understood that while the use of a clip to affix the wick to the wick-holding device is a preferred embodiment, other means of securing the wick may also be employed within the scope of the present invention. For instance, in some embodiments, the wick may be tied to the wick-holding device or secured using adhesive. However, the use of a clip as described herein provides a particularly effective and efficient means of securing the wick, contributing to the superior performance of the resulting candle.

[0071] The use of metal as a material for the wick-holding device offers several advantages. Metals, such as steel or aluminium, are known for their high strength and durability. These properties ensure that the wick-holding device can withstand the heat generated by the burning candle without deforming or melting. Moreover, metal wick-holding devices can be easily cleaned and reused, thus extending their lifespan and reducing waste. In a more preferred embodiment, the wick-holding device is made from stainless steel or brass, which are known for their excellent heat resistance properties.

[0072] In another preferred embodiment, the wick-holding device is made from plastic. Plastic wick-holding devices are typically lighter than their metal counterparts, making them easier to handle and install. Furthermore, plastic can be moulded into various shapes and sizes, allowing for a greater degree of customization in the design of the wick-holding device. In a more preferred embodiment, the plastic used is a high-temperature resistant plastic, such as polyphenylene sulfide (PPS) or polyether ether ketone (PEEK), to ensure that the wick-holding device can withstand the heat generated by the burning candle.

[0073] In yet another preferred embodiment, the wick-holding device is made from wood. Wood offers a unique aesthetic appeal that can enhance the overall appearance of the candle. Moreover, wood is a renewable resource, making it a more environmentally friendly choice compared to other materials. In a more preferred embodiment, the wood used is hardwood, such as oak or maple, which are known for their high strength and durability. In a most preferred embodiment, the wood is treated with a heat-resistant coating to improve its heat resistance properties.

[0074] In some embodiments of the method, as disclosed herein, the candle comprises a number of wicks that may vary between 1 and 7. This embodiment provides the flexibility to customize the burning rate of the candle. The number of wicks in the candle can be adjusted according to the desired burn rate. A candle with a single wick would burn at a slower rate, providing a long-lasting source of light and heat. Conversely, a candle with seven wicks would burn at a much faster rate, producing a greater amount of light and heat in a shorter period of time. This flexibility in the number of wicks allows the user to control the burn rate of the candle depending on their specific needs and preferences. Preferably the number of wicks used depends on the size of the candle. Larger candles with high volumes of wax composition have preferably multiple wicks that ensure a uniform burning.

[0075] In an embodiment of the method, as disclosed herein, between 1 and 6 wicks are used and the total number of wicks is determined based on the diameter of the upper portion of the jar according to the formula: W = 3 + d / 10 wherein W is the total number of wicks and d is the diameter of the upper portion of the jar.

[0076] The number of wicks in a candle is proportional to the diameter of the jar, more specifically the upper portion of the jar. In an embodiment, the method is used to make a candle in a jar with a diameter of the upper portion of the jar of between 10 cm and 16 cm, such a candle comprises 4 wicks. In another embodiment, the method is used to make a candle in a jar with a diameter of the upper portion of the jar of between 17 cm and 24 cm, such a candle comprises 5 wicks. In yet another embodiment, the method is used to make a candle in a jar with a diameter of the upper portion of the jar of over 24 cm, such a candle comprises 6 wicks.

[0077] The wicks of the candle are preferably made of a material that burns at a steady rate, such as cotton or hemp. The wicks are preferably coated with a wax composition to ensure a steady burn rate. The wax composition may comprise various additives to improve the burn characteristics of the wicks, such as a polymer additive to increase the burn time, a UV stabilizer to protect the wicks from UV damage, a fragrance composition to add a pleasant scent to the candle, and a pigment composition to add colour to the candle. The composition of the wax and the type of wick material used can also be adjusted to further customize the burn rate of the candle. In some embodiments, the wicks are coated with paraffin.

[0078] In a preferred embodiment of the method, the candle wax composition comprises a range of additives, each contributing to the overall quality and characteristics of the final product. Specifically, the composition includes 0.1% to 1.5% by weight (wt / wt) of a polymer additive. This polymer additive enhances the structural integrity of the candle, ensuring it maintains its shape over extended periods of use. More preferably, the polymer additive is present in an amount of 0.5% to 1.2% by weight, and most preferably, it is present in an amount of 0.8% to 1% by weight.

[0079] In addition to the polymer additive, the candle wax composition also comprises 0.1% to 1% by weight (wt / wt) of a UV stabilizer. This UV stabilizer protects the candle from the harmful effects of ultraviolet radiation, thereby extending the lifespan of the candle and preserving its aesthetic appeal. More preferably, the UV stabilizer is present in an amount of 0.3% to 0.8% by weight, and most preferably, it is present in an amount of 0.5% to 0.7% by weight.

[0080] Further, the candle wax composition includes 2% to 10% by weight (wt / wt) of a fragrance composition. This fragrance composition imparts a pleasant aroma to the candle, enhancing the overall user experience. More preferably, the fragrance composition is present in an amount of 3% to 8% by weight, and most preferably, it is present in an amount of 4% to 6% by weight.

[0081] In addition, the candle wax composition may comprise 0% to 1.5% by weight (wt / wt) of a pigment composition. This pigment composition provides the candle with its distinctive colour, adding to its visual appeal. More preferably, the pigment composition is present in an amount of 0.2% to 1.2% by weight, and most preferably, it is present in an amount of 0.5% to 1% by weight.

[0082] Finally, the balance of the candle wax composition comprises wax, up to 100% by weight (wt / wt). The wax forms the bulk of the candle and serves as the fuel for the flame. More preferably, the wax constitutes 85% to 100% by weight of the composition, and most preferably, it constitutes 90% to 95% by weight of the composition.

[0083] Through the careful selection and combination of these components, the method allows for the creation of candles that are not only aesthetically pleasing but also durable and long-lasting. The wide range of possible compositions also enables the creation of customized candles, tailored to the specific preferences of the user in terms of colour, scent, and UV stability. This results in a superior quality candle, compared to those produced by other traditional methods.

[0084] In a preferred embodiment of the present invention, the jar used for the method of making a multi-layered candle is made of glass. This choice of material for the jar is not arbitrary but serves a specific purpose and brings about distinct advantages.

[0085] Glass, as a material, is known for its heat-resistant properties. This makes it an ideal choice for a candle jar, as it can withstand the heat produced by the burning candle wick and the melting wax without deforming or melting itself. This heat resistance ensures the safety of the user and the durability of the candle, as the jar will not be damaged or deformed by the heat produced during the burning of the candle.

[0086] Moreover, glass is a transparent material, which provides an aesthetic advantage for the multi-layered candle. The transparency of the glass jar allows for the visibility of the multiple layers of wax, creating a visually appealing product. Each layer of wax can be of a different colour, and the user can enjoy the sight of these layers melting one after the other as the candle burns. This visual appeal enhances the overall user experience and adds value to the product.

[0087] In a further preferred embodiment, the glass used for the jar could be clear or coloured. Clear glass would provide the most visibility for the wax layers, but coloured glass could add an additional aesthetic element to the candle. The colour of the glass could be chosen to complement the colours of the wax layers, creating a cohesive and visually pleasing product. However, the colour of the glass should not be so dark as to completely obscure the wax layers, as their visibility is one of the key features of this invention.

[0088] In some embodiments of the method, as disclosed herein, the glass jar has various forms and dimensions. In an embodiment, the jar is cylindrical with a uniform diameter throughout its height or has a conical shape with a smaller diameter at the bottom and a larger diameter at the top.

[0089] In a preferred embodiment of the present invention, the jar used for creating the multi-layered candle has a height that falls between 9 cm and 40 cm. This range of height offers versatility in the application of the method, allowing it to be adapted to different jar sizes. This adaptability makes the method suitable for a broad spectrum of applications, catering to both commercial and personal use.

[0090] More preferably, the height of the jar is between 10 cm and 35 cm. This more restricted range is particularly advantageous as it encompasses the most common jar sizes used in candle making. This allows the method to be efficiently applied in a majority of candle production scenarios, thereby enhancing its practical utility. Moreover, the use of jars within this height range also results in candles that are aesthetically pleasing and of a convenient size for handling and usage.

[0091] In a most preferred embodiment, the jar height is between 15 cm and 30 cm. This even narrower range is especially suitable for creating candles that are ideal for standard household use. Candles made using jars of this height are not only visually appealing but also of an optimal size for providing a long-lasting source of light and fragrance.

[0092] In an embodiment of the present invention, the upper portion of the jar, utilized for the method of creating a multi-layered candle, has a diameter that ranges between 9 cm and 30 cm. The range of diameters serves to accommodate the production of candles of varying sizes, from small to large. This flexibility in size is a distinct advantage of the present invention as it allows for the creation of candles tailored to a variety of aesthetic and functional requirements.

[0093] The term 'upper portion' as used in this invention denotes the area of the candle jar that is opposite to the base, where the wicks are affixed and is typically where the opening of the jar is located. The term 'diameter' as used in this invention refers to the horizontal distance across the top opening of the candle jar, from one inner wall to the opposite inner wall.

[0094] More specifically, the diameter of the upper portion of the jar can be adjusted to any value within the mentioned range, depending on the desired size of the candle to be produced. For instance, a smaller diameter, such as 9 cm, may be selected for the production of a small, compact candle, suitable for intimate settings or as a decorative element on a dining table. On the other hand, a larger diameter, such as 30 cm, may be chosen for the creation of a large, imposing candle, ideal for grand spaces or as a centrepiece in a large room.

[0095] In a more preferred embodiment of the invention, the diameter of the upper portion of the jar ranges between 13 cm and 24 cm. This narrower range of diameters is particularly suited for the production of medium to large candles, which are often sought after for their longer burning times and significant visual impact. By focusing on this specific range of diameters, the method of the present invention is able to efficiently produce candles of a size that is highly desirable in the market.

[0096] Furthermore, the ability to adjust the diameter of the upper portion of the jar within the specified range allows for the production of candles of various sizes using the same method, without requiring any significant changes to the process. This not only increases the versatility of the method but also contributes to its efficiency and cost-effectiveness.

[0097] In addition, the adjustable diameter of the upper portion of the jar enables the control of the thickness of the candle layers. By selecting a larger diameter, the layers of wax can be made thinner, resulting in a faster burning candle. Conversely, a smaller diameter results in thicker layers of wax, producing a slower-burning candle. This control over the burning rate of the candle is another advantage of the present invention, providing further customization options to meet different user preferences.

[0098] In some embodiments of the method, the bottom portion of the jar has a diameter that falls within the range of 7 cm and 20 cm. More preferably, the diameter of the bottom portion of the jar is between 10 cm and 16 cm. This specific range for the lower diameter of the jar has been found to contribute significantly to the stability of the candle. By ensuring that the bottom portion of the jar has a diameter within these specified ranges, the resulting candle is less likely to tip over, thereby reducing the risk of accidental fires. This is of particular importance in situations where the candle may be left unattended, or in environments where there may be vibrations or movements that could potentially cause an unstable candle to tip over.

[0099] In the context of the herein-disclosed invention, the 'bottom portion' of the jar refers to the base of the jar or the part of the jar that is designed to be in contact with the surface on which the jar is placed. The 'diameter' of the bottom portion of the jar refers to the largest straight-line distance that can be measured across the base of the jar.

[0100] In the most preferred embodiment, the bottom portion of the jar has a diameter of exactly 16 cm. However, it is to be understood that the bottom portion of the jar may have a diameter that falls anywhere within the range of 10 cm to 16 cm. For instance, in some embodiments, the bottom portion of the jar may have a diameter of 12 cm, 14 cm, or any other value that falls within this range. Similarly, although the lower limit for the diameter of the bottom portion of the jar is specified as 7 cm, it is to be understood that this is not a strict lower limit, and in some embodiments, the bottom portion of the jar may have a diameter that is slightly less than 7 cm. On the other hand, the upper limit for the diameter of the bottom portion of the jar is specified as 20 cm, but in some embodiments, the bottom portion of the jar may have a diameter that is slightly more than 20 cm.

[0101] In a second aspect, the invention relates to a multi-layered candle obtained through a method as described in any of the previous embodiments. The key characteristic of this embodiment is the creation of a candle with multiple layers of wax, each layer being allowed to solidify before the subsequent layer is poured. The method of preparation contributes significantly to the quality and functionality of the final product.

[0102] In this embodiment, the multi-layered structure of the candle serves to enhance the longevity and evenness of burning. The distinct layers of wax, each allowed to solidify properly before the addition of the next, create a candle that burns longer and more evenly than those produced using conventional methods. This is a significant advantage in terms of consumer satisfaction and product performance.

[0103] In a preferred embodiment, the candle may comprise between two and six layers of wax. However, it should be noted that this is not a limitation and the candle could have more or fewer layers depending on specific requirements or preferences. More preferably, the candle could comprise between three and five layers of wax, and most preferably, it could comprise four layers of wax.

[0104] The method of preparation involves pouring a layer of wax into a jar, allowing it to solidify for a period of at least 24 hours, and then repeating this process for each subsequent layer. In a preferred embodiment, the period of solidification is between 24 and 48 hours, more preferably between 24 and 36 hours, and most preferably exactly 24 hours. This ensures that each layer is fully solidified before the next is added, contributing to the overall quality of the final product.

[0105] Before pouring the last layer of wax, a distance of 3 to 5 mm is left between the preceding layer and the vertical wall of the jar. In a preferred embodiment, the distance is between 3 and 5 mm, more preferably between 3.5 and 4.5 mm, and most preferably 4 mm. This creates a space for the final layer of wax, ensuring that it reaches the vertical wall of the jar and creates a smooth, uniform surface.

[0106] In conclusion, the embodiment of the invention described herein provides a method for producing a multi-layered candle that burns longer and more evenly than those produced using conventional methods. The method involves the careful pouring and solidification of multiple layers of wax, each allowed to solidify before the addition of the next, resulting in a high-quality, functional product.

[0107] The invention is further described by the following non-limiting examples which further illustrate the invention, and are not intended to, nor should they be interpreted to, limit the scope of the invention.EXAMPLES Example 1. Method of manufacturing 24 cm candies

[0108] A candle A with a diameter of the top portion of the jar of 24 cm was manufactured according to an embodiment of the invention in a glass jar.

[0109] Cotton wicks were coated with paraffin and affixed to wick tabs (Fig. 4A) that were pinched (Fig. 4B) and 5 wicks were affixed to the bottom portion of the jar. The wicks were further anchored to an upper portion of said jar using a star-shaped wick-holding device with holes spaced at 7.7 cm (Fig 5C).

[0110] A candle wax composition was prepared by mixing at 65°C 1% polymer additive (Vybar ®< ), 0.2% UV stabilizer (Kaiser ®< ), 7% Feu Crepitant fragrance and the remainder was made up of Paraffin Wax CSP131C.

[0111] The composition was poured into the glass jar in 6 layers and left to solidify each time for a different period as follows: 1 st< layer 24 hours 2 nd< layer 5 hours 3 rd< layer 2 hours 4 th< layer 1 hour 5 th< layer 10 minutes.

[0112] The 5 th< layer was poured so that a gap of 5 mm formed between the 5 th< wax layer and the vertical wall of the jar, before depositing the final layer of wax. Between the 6 th< layer of wax and the upper edge of the candle jar a vertical gap of 4.5 cm was left (Figure 6).

[0113] A second candle B was manufactured using the same method as for candle A, with the difference that the 1 st< layer was solidified for 1 hour.

[0114] Results: During the 24-hour solidification time of the 1 st< layer, a sinkhole appeared in the wax layer of the candle (Fig. 7). No sinkhole appeared in the wax layer of candle B after the 1-hour solidification period of the 1 st< layer.Example 2. Structural stability and burn quality of a candle

[0115] Candles A and B obtained in Example 1 were evaluated for structural stability and burn quality.

[0116] Results: Candle A showed excellent structural stability, with no layer separation and a consistent, even burn pool. Candle B exhibited less structural stability and developed tunnelling during the burning due to uneven wax melting.DESCRIPTION OF FIGURES

[0117] The present invention will now be further exemplified with reference to the following examples. The invention is in no way limited to the given examples or to the embodiments presented in the figures.

[0118] FIG. 1 depicts an embodiment of the method of making a multilayer candle (1) according to the invention. The candle (1) is made in a glass jar (2) that has a bottom portion (3) and an upper portion (4). The bottom portion of the jar (3) has a diameter of 10 cm and the upper portion of the jar (4) has a diameter of 13 cm. Nonetheless it would be obvious that in other embodiments the diameter of the bottom portion may vary between 7 cm and 20 cm, preferably between 10 cm and 16 cm. The upper portion of the jar (4) has a diameter of 13 cm. Nonetheless it would be obvious that in other embodiments the diameter of the bottom portion may vary between 9 cm and 30 cm, preferably between 13 cm and 24 cm. The jar (2) has a height of 10 cm, however in other embodiments the candle may have a height of between 9 cm and 40 cm, preferably between 10 cm and 35 cm.

[0119] As a first step of the method, four wicks (11) are affixed to the bottom portion (3) of the jar by their wick base or tab (12) using silicone drops and anchored to the top portion of the jar (4) using a cross-shaped metal wick-holding device (9). Each of the wicks (11) was threaded through a hole (10) in the wick-holding device (9) and affixed with a clip (16). The wax composition, comprising 1% by weight of a polymer additive, 0.5% by weight of a UV stabilizer, 5% by weight of a fragrance composition, 1% by weight of a pigment composition, and wax up to 100% by weight, is poured in four layers (5, 6, 7 and 8). The first layer is allowed to solidify for 24 hours before the next layer is poured. The prolonged solidification period of up to 24 hours for the first candle layer ensures that sinkholes appear in the wax layer, as shown in FIG. 7. Each subsequent layer is solidified for a period progressively shorter, namely 5 hours, 2 hours, 1 hour and the last layer for under an hours such as 10 minutes. The penultimate layer (7) is poured such that a 4 mm gap is left between the wax layer and the vertical wall of the jar (17). The final layer (8) is poured such that the wax composition reaches the vertical wall of the jar (17). The resulting candle has a uniform upper layer and showed enhanced burning efficacy and aesthetic appeal.

[0120] FIG. 2 shows a transversal section of an embodiment of the candle layers obtained using the method of the invention, wherein the candle is in a glass jar (2) and has a first, a second, a third and a fourth layer of wax. The coverage of the 1 st< , 2 nd< , and 4 th< layers (15) is up to the vertical wall (17) of the jar. The coverage of the 3 rd< layer (14), which is the penultimate layer is smaller when compared with the other layers, and does not reach the vertical wall (17) of the jar but leaves a gap (13) of 3 to 5 mm between the penultimate layer of wax and the vertical wall (17) of the jar.

[0121] The number and arrangement of wicks depend on the size of the diameter of the upper portion of the jar as shown in FIG 3. Candles with a diameter of the upper portion of the jar of less than 10 cm have one wick (Fig. 3A). Candles with a diameter of the upper portion of the jar between 10 cm and 16 cm comprise 4 wicks (Fig. 3B and Fig. 3C). Candles with a diameter of the upper portion of the jar of between 17 cm and 24 cm comprises 5 wicks (Fig. 3D). Candles with a diameter of the upper portion of the jar of over 24 cm comprise 6 wicks or more (Fig. 3E).

[0122] FIG. 4 depicts a wick tab (Fig. 4A) used to insert / affixed the coated wicks. The wick tabs is pinched (Fig. 4B) after the insertion of the wick and is further affixed to the bottom portion of the jar.

[0123] As shown in FIG. 5, the wick-holding devices may be square-shaped (Fig. 5A), cross-shaped (FIG. 5B) or star-shaped (FIG. 5C) depending on the size of the candle and the number of wicks used. The wick-holders comprise multiple holes spaced at distances (18) ranging from 5 cm to 7.7 cm apart.

[0124] As shown in FIG. 6, a vertical gap (19) of between 2 cm and 4.5 cm is left between the surface of the solidified wax (20) and the upper edge of the candle jar (21). This gap allows space for safe burning and prevents wax from spilling over the edge. The distance is adjusted based on the diameter of the jar, with larger diameters having a larger gap.

[0125] The present invention is in no way limited to the embodiments described in the examples and / or shown in the figures. On the contrary, methods according to the present invention may be realized in many different ways without departing from the scope of the invention. 1 - candle 2 - jar 3 - bottom portion of the jar 4 - upper portion of the jar 5 - 1 st< layer of wax 6 - 2 nd< layer of wax 7 - 3 rd< layer of wax (the layer before the last layer) 8 - 4 th< layer of wax 9 - wick support 10 - wick support insertion hole 11 - wick 12 - wick base or tab 13 - distance between the layer before the last layer and the jar 14 - coverage of the layer before the last layer 15 - coverage of the 1 st< , 2 nd< and 4 th< layers 16 - clip 17 - vertical wall of the jar 18 - distance between holes 19 - vertical gap 20 - surface of the solidified wax 21 - upper edge of the candle jar

Claims

1. A method for making a multi-layered candle in a candle jar, wherein said jar comprises a bottom portion, an upper portion opposite to the bottom portion and a vertical wall connecting the upper portion and the bottom portion, wherein the method comprises the steps of: (a) affixing at least one candle wick to the bottom portion of a candle jar; (b) pouring a first layer of the candle wax composition in the candle jar, such that the candle wax composition reaches the vertical wall of the jar; (c) allowing the first layer of candle wax composition to solidify for a period of at least 24 hours; (d) pouring subsequent layers of candle wax composition and allowing each subsequent layer to solidify; and (e) ensuring a gap of 3 to 5 mm is left between the penultimate candle wax layer and the vertical wall of the jar, before depositing the final layer of wax.

2. The method according to claim 1, wherein the candle wax composition is poured in 2 to 6 layers, and wherein the total number of layers is determined based on the diameter of the upper portion of the jar according to the formula: L = 3 + d / 10 wherein L is the toal number of layers and d is the diameter of the upper portion of the jar.

3. The method according to any of the claims 1 or 2, wherein - the second layer of wax composition is allowed to solidify for a period of between 5 hours and 24 hours; - the third layer of wax composition is allowed to solidify for a period of between 1 hour and 5 hours; - the fourth layer of wax composition is allowed to solidify for a period of up to 2 hours; and - the fifth and sixth layers of wax composition are allowed to solidify for a period of up to an hour.

4. The method according to any of the previous claims, wherein the final layer of candle wax is poured such that the candle wax composition reaches the vertical wall of the jar.

5. The method, according to any of the previous claims, wherein the at least one wick is affixed to a wick tab which is further affixed to the bottom portion of the jar using silicone.

6. The method according to claim 5, wherein the wick tab is pinched.

7. The method according to any of the previous claims, wherein the at least one wick is anchored to an upper portion of said jar using a wick-holding device.

8. The method according to claim 7, wherein the wick-holding device comprises at least one hole to thread the at least one wick through.

9. The method according to any of the claims 7 or 8, wherein the at least one wick is affixed to the wick-holding device by at least one clip.

10. The method according to any of the claims 5 to 7, wherein the wick-holding device is made of metal, plastic or wood.

11. The method according to any of the claims 1 to 8, wherein the candle comprises between 1 and 7 wicks.

12. The method according to any of the claims 1 to 11, wherein the jar has a height between 9 cm and 40 cm, preferably between 10 cm and 35 cm.

13. The method according to any of the claims 1 to 12, wherein the upper portion of the jar has a diameter of between 9 cm and 30 cm, preferably between 13 cm and 24 cm.

14. The method according to any of the claims 1 to 13, wherein the bottom portion of the jar has a diameter of 7 cm and 20 cm, preferably between 10 cm and 16 cm.

15. A multi-layered candle obtained by the method described in any of the claims 1 to 14.

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