Method of manufacturing a graveyard candle

Abstract

The method of manufacturing a graveyard candle is characterised in that the ingredients of the flammable mass are heated up to 40°C to 60°C, which causes them to melt and to mix, followed by solidification of the flammable mass mix. The wick (2) guide and the solidified flammable mass mixture are placed inside a mould well and pressure moulded to obtain a solidified candle core (1), next the wick (2) guide is removed, wherein the wick (2) remains fixed in the central part of the core (1) together with a holder (3) stabilising the wick (2) fixed in the core (1) base. Once the candle core (1) is obtained, the side wall of the candle core (1) is wrapped with a film strip (4) 1 to 400µm thick, with width greater than the height of the candle core (1) and additionally increased by at least half of the linear dimension of projection of the candle core (1) base, wherein the length of this film strip (4) is greater than the length of circumference of the side wall of the candle core (1). The candle core (1) is wrapped with the film strip (4) such that the initial section of the film strip (4) is fixed to the candle core (1) and once said strip (4) wraps around the entire circumference of the side wall of the candle core (1), the free end of the film strip (4) is fixed to the initial section of the film strip initially fixed to the candle core (1). Next, the excess film is folded over and below the bottom edge of the candle core (1) onto the candle core bottom surface and these sections of excess film folded onto each other are joined together, forming cover of the candle core bottom. Material based on polyvinyl alcohol PVA or PVOH is used as the film material.

Description

[0001] The subject of the invention is a method of manufacturing a graveyard candle. The graveyard candle market is dominated by candle refills, in which the fuel mass is placed in containers in the form of disposable cups made of plastic based on oil-derived, non-biodegradable polymers. Polymer plastics may be recycled in a closed circuit. In practice, however, such products contaminated with the fuel mass are not suitable for recycling and are directed to a landfill instead of having the plastic cups transferred to recycling. The objective of the invention is to limit the quantity of plastics generated during candle burning, particularly at cemeteries.

[0002] According to the known candle and votive candle manufacturing technologies, generally involving blow moulding of plastics, in the first step a container with thick wall is produced to enable its filling with the fuel mass or placing the candle core inside the container in the subsequent steps. The term of candle core should be understood in this patent disclosure as solidified fuel mass with a wick. Containers with wall thickness below 400µm cannot be used in these industrial technological processes, as they have thin, flexible walls and are thus susceptible to deformation and loss of tightness continuity.

[0003] Using known technologies of container production using injection moulding and blow-moulding, it is thus impossible to obtain a very thin, tight candle core container, up to 400 µm, enabling a highly efficient process of industrial graveyard candle manufacturing. In the known technologies, the process is thus based on an assumption that the candle core container is obtained early on.

[0004] A number of known candle structure solutions, intended to limit the quantity of plastics in the flammable candle structure, is known. In a solution according to the patent document number WO 00 / 56846, a candle is disclosed, in particular a candle for outdoor use, made of a core of flammable material with a wick made of flammable material placed in it and a cover made of biodegradable material, generally surrounding the core, containing: starch, e.g. potato flour at 10%-30 %, gelatine at 10%-60 %, sugar, e.g. gelling sugar at 10%-50 %, water up to 20% and oil, for example olive oil, at 1%-10%.

[0005] According to another solution known from the patent disclosure of the international patent application no. WO 2017 / 202868, the candle is made of flammable material and a wick and a plastic element made at least completely or partially of biopolymer. The biopolymer is gelatine and / or polysaccharide and / or cellulose and / or polylactide. The plastic element is a partial cover, in which the flammable material and the wick are placed. Once the wick is lit, the flammable material present inside the container is slowly burned.

[0006] According another solution known from the disclosure no. DE 4242509, a candle light intended for graves has a container made of a biodegradable material resistant to fire. The core is made of natural fats and / or oils. An inlet duct present in the middle of the container is open at the top and enables the wick to be placed.

[0007] In further disclosure of the international patent application WO 2023 / 199078, a known, environmentally friendly paper votive candle is a radical innovation on the market because of its production method and environment-friendly features, as it does not include plastic parts. The paper votive candle has a paper container made of non-flammable paper shaped as a cylindrical mantle with an inner and an outer side, in which the outer side of the mantle is prevented against moisture by application of a water-borne varnish, while the inner side of the mantle is coated with fire-resistant varnish. The flammable material is made of liquid paraffin and alcohol obtained from plant fats.

[0008] According to the international patent application WO 2020 / 157360, an environmentally friendly candle is formed as a core made of plant wax from refined, hydrogenated fats, with a wick and with a fire-resistant, biodegradable container which delineates the inner space, in which the candle core is placed. The candle contains ingredients which are fully biodegradable, ensuring products sustainable for the environment, which are also economic, easy to transport and safe in use because of the low melting point of the body made of plant wax.

[0009] The known container for the candle product, intended to be filled with flammable material through which the wick is guided, is presented in the international patent publication no. WO 2020 / 148750. The container has a bottom and side walls made of plastic. The plastic is a polymer containing 40% to 99.99% of polylactide PLA and from 0.01% to 60% of ammonium polyphosphate APP. The polylactide PLA may be a mixture of isomers of poly-L-lactide PLLA and poly-D-lactide PDLA, wherein the mixture contains at least 80% of PLLA and no more than 20% of PDLA. Ammonium polyphosphate APP may be microcapsuled, wherein the microcapsules have the diameter between 25 µm and 55 µm and may include a melamin coating.

[0010] According to another solution known from the document PL / EP 2183344, a candle is provided with a body intended to be burned, containing flammable material, such as paraffin, and a wick. The candle is also provided with film which is at least partially supported on the top surface of the body, wherein the film is present on the body, covering the top surface of the core. In the case of a cylindrical candle, the film is formed as a disc floating on the surface of the melting flammable material. The invention also includes a method and a device used to manufacture such a candle.

[0011] According to another solution presented in the international patent application no. WO 00 / 55285, the candle has a metallic layer applied on it. The metallic layer is preferably a metallic foil, which has a metallic layer applied on a carrier film. The metal layer preferably has thickness below 5 µm. The metalling layer may be applied on the side of the candle using a continuous device, separating the metal layer from the carrier film.

[0012] The known solutions focus mainly on the introduction of biodegradable material to the structure of candle elements, such as containers in which the candle core is usually placed. It is also observed, however, that the elements of used candles contaminated with flammable material remaining after the candle has burnt cannot be recycled in many cases. The problem to be solved with these limitations is to find a solution significantly limiting the quantitative consumption of plastics in a production cycle of candles. The container in which the candle wick is placed is the main element of a candle, the production of which requires the use of plastics.

[0013] According to the invention, a method of manufacturing a graveyard candle according to Claim 1 is characterised in that the ingredients of the flammable mass are heated to 40°C to 60°C, causing them to melt and mix, and the flammable mixture mass is solidified, wherein a wick guide and the solidified flammable max mixture is placed in the die socket, with the mass being pressure moulded to obtain the candle core, while once the wick guide is removed, the wick is next fixed in the central part of the core, including the wick stabilising holder fixed in the core base.

[0014] According to the invention, the method of manufacturing a graveyard candle is characterised in that once the candle core is obtained, the side wall of the candle core is wrapped with a film strip 1 µm to 400µm thick, with width greater than the height of the candle core and additionally increased by at least half of the linear dimension of projection of the candle core base, wherein the length of this film strip is greater than the length of circumference of the side wall of the candle core. The candle core is wrapped with the film strip such that the beginning of the film strip is attached to the core cable and once the entire circumference of the side wall of the candle core is covered by said film strip, the free end of the film strip is fixed to the initial section of the film strip fixed on the candle core and the excess film is applied below the bottom edge of the candle core, on the surface of the candle core bottom and these overlapping parts are joined together, forming the bottom cover of the candle core base.

[0015] In a preferable solution according to the invention, plastics based on polyvinyl alcohol designated as PVA or PVOH are used as the film material.

[0016] In another preferable solution according to the invention, plastic based on thermoplastic starch is used as the material of the film.

[0017] The free end of the film strip on the initially fixed on the candle core, initial section of the film strip, is preferably fixed with an overlap.

[0018] The free end of the film strip on the initially fixed on the candle core, initial section of the film strip, is preferably fixed using a layer of glue based on polyvinyl alcohol PVA or PVOH.

[0019] In another preferable embodiment according to the invention, the free end of the film strip on the initially fixed on the candle core, initial section of the film strip, is fixed using a layer of glue based on thermoplastic starch.

[0020] In another preferable embodiment according to the invention, the free end of the film strip on the initially fixed on the candle core, initial section of the film strip, is fixed by heating at a temperature between 145°C and 160°C.

[0021] In another embodiment according to the invention, a method of manufacturing a graveyard candle according to Claim 8 is characterised in that the ingredients of the flammable mass are heated up to 40°C to 60°C, which causes them to melt and mix, followed by solidification of the flammable mass mix, wherein a wick guide and the solidified flammable mass mixture are placed inside the die socket and the mass is formed to obtain the candle core, followed by removal of the wick guide, wherein the wick remains fixed in the central part of the core, including the wick stabilising holder fixed in the core base.

[0022] According to this embodiment of the invention, the method of manufacturing a graveyard candle is characterised in that a sleeve is made of film, µm to 400µm thick, with the length of circumference of the cross-section corresponding to the length of circumference of the cross-section of the candle core and the candle core is placed inside said sleeve, followed by cutting off a part of the sleeve above the top edge of the core candle and below the bottom edge of the core candle, and the excess film is applied below the bottom edge of the core candle, on the candle core bottom surface, and these overlapping parts of excess film are joined together, forming the bottom cover of the candle core base.

[0023] According to a solution according to the invention, material based on polyvinyl alcohol designated as PVA or PVOH, as well as on bio-polyester PHA is preferably used as the film material.

[0024] In another variant of the solution according to the invention, material based on thermoplastic starch is preferably used as the material of the film.

[0025] According to the invention, the overlapping parts of excess film are preferably joined with a layer of glue based on polyvinyl alcohol PVA or PVOH.

[0026] In another preferred variant of the solution according to the invention, the overlapping parts of the film are joined with a layer of glue based on thermoplastic starch.

[0027] The overlapped film parts are joined in another preferred embodiment of the invention by thermal welding at 145°C to 160°C.

[0028] In another preferred variant of the solution according to the invention, before the candle core is inserted, the sleeve is closed on one side by gluing with a layer of glue based on polvwinyl alcohol PVA or PVOH and / or based on potato starch or by thermal welding.

[0029] The objective of the invention is to limit the quantity of plastics polluting the environment and originating from graveyard candles. This also includes refills for candle lights.

[0030] The term graveyard candle should be understood in this patent disclosure as a light source, namely a candle providing light from the flame of a burning wick supplied with melting flammable mass in which the wick is embedded, intended to use mainly, but not exclusively, at graveyards. The structural element of a graveyard candle made of plastics is usually the container, in which the candle core is placed. According to the invention, the problem of limiting the amount of plastics in a graveyard candle was solved by a radical weight decrease of this container. The thickness of the container wall was limited to film thickness and in the solution according to the invention, the container walls are up to 400 µm, and even less than 50µm thick. The problem of container wall rigidity was solved by developing a technology of candle element manufacturing in a reverse order.

[0031] In known technologies, the candle core container is manufactured first, followed by the candle core which is ultimately placed inside the container. On the other hand, in the solution according to the invention, the container is produced at the end of the process by wrapping the candle core with a thin film layer, where biodegradable films are also used. Thanks to the small share of the film in the total weight of the candle, it became possible to use relatively expensive, biodegradable materials, but in very small quantities, to form the candle container. This limited the weight of plastics in the total weight of the candle.

[0032] In the second embodiment of the solution according to the invention, the technology used to apply the film onto the previously manufactured core was changed by forming a film sleeve and then sliding the candle core into said sleeve, followed by gluing or thermal welding of excess film present under the bottom of the candle core. The aforementioned objectives of the invention according to the first embodiment have also been achieved in the second embodiment of the invention, since the same film types have been used in both the first and the second embodiment. In the second embodiment according to the invention, only the film preparation method was changed, and in this embodiment the film is provided as a sleeve ready to receive the candle core. In both embodiments, the solution according to the invention eventually enabled the share of plastics in the total weight of the candle to be decreased, but also enabled the use of relatively expensive, biodegradable films, the share of which in the weight of the candle is small.

[0033] The subject of the invention has been presented in the following embodiments presenting the method of manufacturing a graveyard candle.Example I

[0034] The first variant of the subject of the invention is described in the following embodiment and is presented in the attached drawing, in which individual figures of the drawing represent as follows: Fig. 1 - first step of wrapping the candle core with film. Fig. 2 - second step of wrapping the candle core with film. Fig. 3 - third step of wrapping the candle core with film. Fig. 4 - fourth step of wrapping the candle core with film.

[0035] The method of manufacturing a graveyard candle in this embodiment is characterised in that the ingredients of the flammable mass based on plant or animal fat, plant- or animal-based stearic acid, with the following composition: rapeseed oil, partially hydrogenated, wt 60% technical grade stearic acid as a mixture of palmitic and stearic acid, wt 40% is heated up to 50°C, causing the ingredients to melt and mixed simultaneously, followed by solidification of the flammable mass mixture. In this embodiment, the molten flammable mass is subjected to a known granulation process, yielding the solidified flammable mass in the form of pellets The obtained pellets are used in a known technology to fill the wells of a multi-well mould used in moulding of core candles, wherein a wick guide 2 is previously introduced into each of the wells. The core candles are then formed in the wells using pressure, in a known process, at 100 bar. After pressure moulding of the core 1 of each candle and with the wick guide removed, the wick 2 is then fixed in the central part of the core 1 with the holder 3 stabilising the position of the wick 2, defined in the core 1 base.

[0036] Once the candle core 1 is obtained, the side wall of the candle core is wrapped with a 40µm thick film strip 4, with a width greater than the height of the candle core and additionally increased by at least half of the linear dimension of the projection of the candle core 1 base. Plastic film based on polyvinyl alcohol is used in this embodiment. The first step of candle core wrapping is shown in Fig. 1. It shows the core 1 with the wick 2 placed at its bottom end in the holder 3. A strip of film 4 made of a thermoplastic material is placed around the cylindrical side wall of the core 1, in this embodiment the film is made of biodegradable polyvinyl alcohol PVA also designated as PVOH. The circumference and the height of the candle core 1 are determined in advance. In other embodiments, the candle core 1 may have a different cross-section. In this embodiment, the circumference of the cylindrical wall of candle core 1 is 21 cm. The film strip 4 intended to wrap around the side wall of the core 1, at the length of 25 cm. The initial section of the film strip 1, glued to the cylindrical wall of the candle core 1 in the first wrapping step, after the second wrapping step shown in fig. 2 and after the third wrapping step shown in fig. 3 is covered with the end section of the film strip 4 and glued to said initial section of the film strip 4. In this embodiment, glue based on polyvinyl alcohol PVA, also designated as PVOH, was made.

[0037] Fig. 3 shows the candle core 1 wrapped around with a film strip 4. It shows that the width of the film strip 4 is bigger than the core 1 height. The top edge of the film strip 4 wrapped around the core 1 is located in this embodiment 2 cm above the top edge of the candle core. In other embodiments, the top edge of the film strip 4 may be located at a different level above the top edge of the candle core or may be bent at the top edge of the candle core 1, towards its symmetry axis.

[0038] In the same Fig. 3, it is shown that the width of the film strip 4 is also increased on the other side and the bottom edge of this film strip 4 reaches below the bottom edge of the candle core 1. Fig. 3 shows that in this embodiment, the height of the bottom, free edge of the film strip 4 is equal to the radius of the round candle core 1 base, 4 cm in this embodiment. This allows the film excess to be folded towards the axis of symmetry of the candle core 1 base and the folded sections of the excess film strip 4 glued together using glue based on polyvinyl alcohol PVA, thus obtaining a cover of the candle core 1 base. In other embodiments, this bottom part of the film strip 4 can be wider than the length of the radius of the core candle 1 base projection. These relationships apply to a candle core 1 with circular cross-section. In other embodiments, where the candle core 1 has a different cross-section, for example rectangular, the indicated free, bottom section of the film strip 4 is wider below the bottom edge of the candle core 1 than half of the most narrow linear dimension of the candle core 1 base.

[0039] The term linear dimension of the base should be understood here as the diameter of a round candle core or as the width or length of the projection of a candle core base with shape other than circular. Once the sections of this free, bottom section of the film strip 4 are folded together and the overlapped sections are glued or thermally welded together, a cover of the surface of the candle core 1 base is obtained, protecting the flammable material of the candle core from leaking outside once it melts during the intended use of the candle. Fig. 4 shows a candle according to the . invention in an embodiment. Surface appears on the bottom of the ready candle, onto which information materials, such as a label, can be applied.Example II

[0040] In the second embodiment presenting the second variant of the method of manufacturing candle according to the invention, candle core (1) preparation is identical as in Example 1. However, once the candle core (1) is ready, a 20 µm thick sleeve is made of the film, with the length of circumference of the cross-section corresponding to the length of circumference of the candle cross-section. In this embodiment, the length of the circumference of said sleeve is 25 cm. The candle core (1) is placed inside said sleeve, and then the section of the sleeve above the top edge of the candle core and below the bottom edge of the candle core 1 are cut off. Excess film is folded over and below the bottom edge of the candle core onto the candle core bottom surface and these sections of excess film folded onto each other are joined together, forming cover of the candle core bottom. These activities are described in the description of example I of the embodiment of the invention. In another embodiment, said sleeve may be subjected to gluing or thermal welding of the bottom edge of the sleeve before the candle core 1 is placed inside it. Then, once the candle core 1 is placed in such a closed sleeve, there is no need for further gluing or thermal welding, and in particular, for folding of free bottom sections of the film over the core base.

[0041] Other variants of candle core preparation may be indicated in other embodiments. In a known extrusion process, once the flammable mass mixture is melted and mixed, it is poured into large moulds and cooled to solidify, followed by heating of such a flammable mass block up to its plastification temperature and the flammable mass is extruded through at least one forming duct with cross-section corresponding to the cross-section of the candle core, the flammable mass exits the forming duct and is cooled and cut into pieces corresponding to the length of the candle core, followed by drilling the central part of the core, and a wick provided with a wick holder is introduced into the bore.

[0042] In these embodiments, a film and a glue based on polyvinyl alcohol PVA, otherwise denoted with the symbol PVOH, namely based on polymer decomposed by bacteria, has been proposed. In other embodiments according to the invention, the film and the glue on the basis of potato starch may be produced and then these are also called biodegradable materials. A film and a glue which do not contain biodegradable materials are also predicted in the solution according to the invention, as they solve the task of the solution according to the invention, which is to limit the consumption of plastics.

Claims

1. A method of manufacturing a graveyard candle, in which: - ingredients of the flammable mass are heated up to 40°C to 60°C, which causes them to melt and to mix, followed by - solidification of the flammable mass mixture, wherein - the wick guide (2) and the solidified flammable mass mixture are placed inside the mould well and subjected to pressure moulding - obtaining a solidified candle core (1), - next, the wick (2) guide is removed, wherein the wick (2) remains fixed in the central part of the core (1) with a holder (3) stabilising the wick (2) and fixed in the core (1) base, characterised in that - once the candle core (1) is produced, the side wall of the candle core (1) is wrapped in a film strip (4) 1 / µm to 400µm thick, with thickness bigger than the candle core (1) height and - with the width additionally increased by at least half of the linear dimension of the candle core (1) base projection, wherein - length of this film strip (4) is greater than the length of circumference of the side wall of candle core (1), where - the candle core (1) is wrapped with the film strip (4) such that the beginning of the film strip (4) is fixed to the candle core (1) - and after covering with said film strip (4) the entire circumference of the side wall of the candle core (1), the free end of the film strip (4) is fixed on the initial section of the film strip fixed on the candle core (1), - and next, excess film is folded over and below the bottom edge of the candle core (1) onto the candle core (1) bottom surface and these sections of excess film folded onto each other are joined together, forming cover of the candle core (1) bottom.

2. A method according to claim 1, characterised in that material based on polyvinyl alcohol PVA is used as the film material.

3. A method according to claim 1, characterised in that material based on thermoplastic starch is used as the film material.

4. A method according to claim 1, characterised in that the free end of the film strip (4) is fixed folded over and onto the initial section of the film strip (4) fixed on the candle core.

5. A method according to claim 1 or 2 or 3 or 4, characterised in that the free end of the film strip (4) on the is fixed on the initial section of the film strip (4) fixed on the candle core (1) using a layer of glue based on polyvinyl alcohol PVA.

6. A method according to claim 1 or 2 or 3 or 4, characterised in that the free end of the film strip (4) on the initial section of this film strip (4) initially fixed on the candle core is fixed using a layer of glue based on thermoplastic starch.

7. A method according to claim 1 or 2 or 3 or 4, characterised in that the free end of the film strip (4) is fixed on the initial section of this film strip (4) initially fixed on the candle core (1) by thermal welding at 145°C to 160°C.

8. A method of manufacturing a graveyard candle, in which: - ingredients of the flammable mass are heated up to 40°C to 60°C, which causes them the melt and mix, followed by - solidification of the flammable mass mixture, wherein - the wick guide (2) and the solidified flammable mass mixture are placed inside the mould well and moulded to - obtain the candle core (1), - next, the wick (2) guide is removed, wherein the wick (2) remains fixed in the central part of the candle core (1) with a holder (3) stabilising the wick (2) and fixed in the core (1) base, characterised in that - a 1 to 400µm thick sleeve is made of the film, with the length of circumference of the cross-section corresponding to the length of circumference of the cross-section of the candle core (1), - and the candle core (1) is placed inside said sleeve, - next, the section of the sleeve above the top edge of the candle core (1) and below the bottom edge of the candle core (1) are cut off, - and next, excess film is folded over and below the bottom edge of the candle core (1) onto the candle core (1) bottom surface and these sections of excess film folded onto each other are joined together, forming cover of the candle core (1) bottom.

9. A method according to claim 8, characterised in that polyvinyl alcohol PVA is used as the film material.

10. A method according to claim 8, characterised in that thermoplastic starch is used as the film material.

11. A method according to claim 9 or 10 or 11, characterised in that the sections of the film folded over each other are joined using a layer of glue based on polyvinyl alcohol PVA.

12. A method according to claim 9 or 10 or 11, characterised in that the sections of the film folded over each other are joined using a layer of glue based on thermoplastic starch.

13. A method according to claim 9 or 10 or 11, characterised in that the folded film parts are joined via thermal welding at 145°C to 160°C.

14. A method according to Claim 8, characterised in that the sleeve is closed on one side by gluing with a layer of glue based on polyvinyl alcohol PVA and / or based on potato starch or by thermal welding before the candle core (1) is inserted.

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