Production process of a candle

Abstract

Production process of a candle (100) comprising: - providing a sheet (10) in a first wax comprising a weight content of microcrystalline wax greater than or equal to 50% and a weight content of paraffin wax, recomprising the weight content of microcrystalline wax, greater than or equal to 70%; - providing a candle core (11 ) in a second wax having a surface; - applying in a distributed manner a third wax in a molten state on a first face (12) of the sheet (10) and / or on the surface of the candle core (11 ); - at least partially coating a surface of the candle core (11) with the sheet (10), wherein the third wax in the molten state is interposed between the sheet (10) and the surface, and cooling the third wax until solidification to firmly couple the sheet (10) to the candle core (11 ) and produce said candle (100).

Description

[0001] DESCRIPTION

[0002] Title: PRODUCTION PROCESS OF A CANDLE

[0003] Technical field of the invention

[0004] The present invention concerns a production process of a candle, in particular a candle whose outer surface is provided with a desired aesthetic appearance.

[0005] State of the Art

[0006] It is known to produce candles having a surface provided with the most diverse aesthetic appearances, for example a uniform coloration in a color different from the natural color of the wax of which they are made, a design (realistic, fantasy, or abstract), a photograph, a pattern, and / or physical finishes such as embossing, or optical finishes such as a glitter decoration, all realized in the most diverse colors and / or optical effects (matte, metallic, satin, reflective, glossy, etc.) and variously combined.

[0007] Summary of the invention

[0008] In such context, the Applicant has addressed the problem of producing a candle having a desired aesthetic appearance in a versatile manner with respect to the aesthetic appearance, with a high quality of the aesthetic result, while at the same time ensuring structural robustness of the candle even during use, and keeping the process overall economical (in terms of investment in the plant and / or operating and / or maintenance costs).

[0009] According to the Applicant, the aforesaid problem is solved by a production process of a candle in accordance with the attached claims and / or having one or more of the following features.

[0010] According to one aspect the invention relates to a production process of a candle. Preferably the process comprises providing a sheet in a first wax.

[0011] Preferably said first wax comprises a weight content of microcrystalline wax greater than or equal to 50%.

[0012] Preferably said first wax comprises a weight content of paraffin wax greater than or equal to 70%, said weight content of paraffin wax comprising said weight content of microcrystalline wax.

[0013] Preferably the process comprises providing a candle core in a second wax, said candle core having a surface.

[0014] Preferably the process comprises applying in a distributed manner a third wax in a molten state on a first face of said sheet and / or on said surface of said candle core. Preferably the process comprises (subsequently to said providing the sheet in fist wax) at least partially coating a surface of said candle core with said sheet (preferably in a solid state, more preferably flexible), wherein said third wax in the molten state is interposed between said sheet and said surface, and cooling said third wax until solidification to firmly couple the sheet to the candle core and produce said candle.

[0015] The Applicant has discovered that the use of a sheet of (first) wax, in a solid state and flexible, to coat a core of a candle makes it possible to produce candles with a wide flexibility with regard to their decoration and / or surface aesthetic appearance, even in the presence of curved surfaces of the final candle, as typically occurs for cylindrical candles, with a production process that is simple and / or economical and / or fast. In fact, it is possible to produce and / or process the sheet with the desired aesthetic effects (color, decorations, finishes, embossing, etc.) in a simpler, faster, and / or less constrained manner compared to the direct processing of the candle surface, and only subsequently produce the candle by coating the core with the aesthetically processed sheet. For example, it is possible to process only the wax sheet, advantageously under planar conditions, before the joining with the candle core.

[0016] Moreover, the composition of the first wax contains at least 70% paraffin wax (e.g. any mixture of solid hydrocarbons, mainly alkanes, whose molecules have chains with more than 20 carbon atoms, typically obtained from petroleum oils) and at least 50% microcrystalline wax (e.g. a type of paraffin wax obtained from petrolatum, such as isoparaffins, and containing a high percentage of branched alkanes and cycloalkanes, and typically characterized by crystals of smaller size compared to other paraffin waxes, such as n-paraffins). Such composition gives the wax sheet the desired physical and / or mechanical properties, for example in terms of material softness (understood as a mechanical property opposite to hardness, that is, the ability to plastically deform under low mechanical stresses) and / or material malleability, that is, the ability to plastically deform without breaking. In this way, the sheet can be perfectly adapted to the shape of the candle core, easily and without undergoing fractures or cracks.

[0017] The use of the third wax allows a stable and durable welding between the core and the sheet in a simple, fast and / or economical manner, and possibly leaving on the candle minimal aesthetic evidence of the production process (such as, for example, visible interfaces between the sheet and the core).

[0018] The present invention, in one or more of its aspects, may comprise the following preferred features. Preferably said weight content of paraffin wax in said first wax is greater than or equal to

[0019] 75%, even more preferably greater than or equal to 80%.

[0020] Preferably said weight content of paraffin wax in said first wax is less than or equal to 95%, even more preferably less than or equal to 90%.

[0021] Preferably said first wax comprises additives (e.g. resins, etc.), wherein a sum of said weight content of paraffin wax and of a weight content of said additives is equal to 100%. Preferably said weight content of additives is greater than or equal to 10% and / or less than or equal to 20%. Such additives may confer to the first wax suitable properties, for example in terms of melting temperature, viscosity, etc.

[0022] Preferably said weight content of microcrystalline wax in said first wax is greater than or equal to 55%, even more preferably greater than or equal to 60%.

[0023] Preferably said weight content of microcrystalline wax in said first wax is less than or equal to 80%, even more preferably less than or equal to 70%.

[0024] The above weight content values confer to the first wax optimal physical and / or mechanical properties for the purpose of the present production process and / or the quality of the candle produced therein.

[0025] Preferably said first, second and / or third wax is solid at room temperature, for example has a melting temperature greater than or equal to 50°C, more preferably greater than or equal to 55°C, and / or less than 90°C. In this way the process is facilitated.

[0026] The melting temperature can for example be determined according to ISO standard 6244. Preferably said third wax is a strong adhesive wax (e.g. paraffin wax), more preferably without addition of solvents. Preferably said third wax has a melting temperature less than or equal to 70°C, even more preferably less than or equal to 65°C. Preferably said third wax has a melting temperature lower than a respective melting temperature of said first and / or second wax, more preferably at least 10°C, or 15°C, less than said melting temperature of said first wax. In this way, advantageously, it is avoided or limited that the third wax, in the molten state at the beginning of the coating operation, melts by thermal exchange the first wax and / or second wax, thereby improving the quality of the final result, in particular of the thin wax sheet.

[0027] Preferably said third wax in said molten state has a temperature, during said applying and / or in an initial phase of said coating, greater than or equal to 50°C and / or less than or equal to 70°C. In this way, the third wax is sufficiently fluid and flowable to allow its application. Preferably said first, second and / or third wax is water-repellent and / or insoluble in water. Exemplarily said second wax contains, or consists of, natural wax (e.g. beeswax), vegetable wax (e.g. carnauba wax), or paraffin wax, or mixtures thereof. Preferably said candle core has a cylindrical shape (typically with a circular base, but cylindrical shapes with oval or elliptical base are also contemplated).

[0028] Preferably it is provided coating with said sheet an entire lateral surface of said core, and / or an upper surface, more preferably entirely. In this way, the present invention is fully exploited, as the final candle presents the entire visible surface (e.g. with the exception of the bottom support surface) coated, the core not being visible.

[0029] Preferably said providing said sheet comprises spreading (e.g. by casting or spraying), more preferably continuously, said first wax in a molten state over a support, more preferably continuously moving (e.g. by means of a moving member such as a conveyor belt), cooling, more preferably continuously, said first wax until solidification and separating, more preferably continuously, at least partially said support from said first wax to produce said sheet, optionally after cutting said sheet from a continuous sheet. This technique for producing the sheet has proven to be particularly effective and efficient in terms of automation, repeatability, and large-scale operability.

[0030] Preferably said support comprises a film, more preferably in polymeric material, even more preferably in polyester. Preferably said separating at least partially said support comprises or consists of separating said film.

[0031] In one embodiment said support comprises a pigmented layer arranged on a face of said film facing said first wax, wherein said pigmented layer is transferred from said support to said sheet during said cooling of said first wax so as to become an integral part of said first wax sheet (preferably on a second face of the wax sheet). In this way, it is possible to impart a desired colour to the surface of the finished candle (e.g. a metallic colour, which may also serve as the background for the final aesthetic appearance of the candle), while the core of the candle retains the natural colour of the wax, with advantages in terms of cost and / or flexibility in colour selection.

[0032] Preferably it is provided continuously unrolling said support during said spreading said first wax. In this way the production of the sheet is continuous, reducing production costs. Preferably said sheet has a thickness greater than or equal to 0.5 mm, more preferably greater than or equal to 0.7 mm, and / or less than or equal to 3 mm, more preferably less than or equal to 2.5 mm. The Applicant has verified that such values of the sheet thickness, together with the above-mentioned weight content values of the components of the first wax, confer optimal properties to the sheet for the purposes of the process and the qualities of the final product.

[0033] Preferably said spreading said first wax comprises, prior to said solidification, calendering said first wax, more preferably by means of one or more specific calendering rollers arranged above said moving member. In this way, a wax sheet with uniform thickness is effectively obtained.

[0034] Preferably said cooling said first wax until solidification is performed by means of a cooling system acting on said support, more preferably integrated into said moving member. In this way, structural continuity and uniform thickness of the sheet are obtained, and optionally a firm adhesion between the first wax and the pigmented layer.

[0035] Preferably the process comprises, prior to said applying in a distributed manner said third wax, spreading said sheet (preferably in a solid state) on a plane with a second face of said sheet opposite to the first face (possibly said second face comprising said transferred pigmented layer) facing upwards, more preferably fixing said sheet in a fixed position on said plane, and creating an aesthetic appearance on said second face.

[0036] Preferably creating said aesthetic appearance comprises printing an image on said second face (possibly on said transferred pigmented layer), more preferably by means of screen printing.

[0037] Preferably said screen printing comprises placing one or more screen printing frames above said second face of the sheet (in temporal sequence in the case of multiple frames, one for each color or finish, more preferably with the correct relative positioning by means of registers), pouring over each frame a respective solution containing a respective pigment and / or optical finish (e.g. glitter, etc) and spreading (e.g. by means of a screenprinting squeegee) said respective solution over the frame. In this way, the solution passes through the screen mesh of the frame only at the areas suitably shaped to reproduce the part of the final image in the corresponding color or optical finish, depositing onto the second face of the sheet. The Applicant has found that the combination of the wax sheet, which is soft and malleable, and the subsequent layers of color and / or finish applied via the screens confers to the overall structure a high degree of elasticity, which prevents the formation of cracks and defects in the colored areas.

[0038] Preferably said respective solution is water-based or solvent-based, so as not to generate fumes or harmful substances during combustion.

[0039] In one embodiment, at least one of said respective solutions contains solid micro-particles (preferably glittering to produce a glitter effect) dispersed in a water-based resin matrix containing water in a percentage ranging between 10% and 50% by total weight of the solution. The Applicant has discovered that screen printing using a stencil frame allows the realization of a compact and homogeneous glitter-effect layer, which does not detach from the wax when in contact with hands and therefore does not disperse into the environment (as instead occurs when such glitter layer is applied manually). Preferably each screen printing frame comprises a respective screen with microperforated areas according to a pattern. In this way, the solutions selectively pass through the mesh reproducing the desired design corresponding to the respective pattern. Preferably said creating said aesthetic appearance comprises imprinting a debossing (i.e., a three-dimensional relief having a desired design) on said second face of the sheet, more preferably by pressing a die (preferably provided with appropriate registration marks) against said second face of the sheet to imprint a design.

[0040] Brief description of the figures

[0041] Figure 1 schematically shows a plant suitable for implementing a phase of the process of the present invention;

[0042] Figure 2 schematically shows a phase of the process according to the present invention. Detailed description of some embodiments of the invention

[0043] The features and advantages of the present invention will be further clarified by the following detailed description of some embodiments, presented by way of example and not limitation of the present invention, with reference to the attached figure.

[0044] In the figure, the number 1 indicates a plant for producing sheets of first wax according to the present invention.

[0045] The plant 1 comprises a movement element 2 (e.g. a conveyor belt) having a circular movement (indicated by arrows in the clockwise direction) and a dispenser 3 structured to dispense the first wax (e.g. the dispenser comprises, not shown, a reservoir of first wax, heating means for melting the first wax, and optionally means for pushing the first wax). Preferably the conveyor belt 2 comprises a cooling system 5, for example a refrigeration-cycle system comprising suitable piping (not shown) arranged near the conveyor belt 2, e.g. beneath the upper section of the conveyor belt 2, and in which a cooling liquid circulates.

[0046] The plant 1 comprises one or more calendering rollers 4 arranged above the conveyor belt 2.

[0047] In use, the plant 1 implements the process phase of producing the sheet of first wax according to the present invention. To this end, a support 6 is unrolled continuously (e.g. from a roll, not shown) and set in motion resting atop the conveyor belt 2 (e.g. in Figure 1 from left to right, as indicated by the arrow).

[0048] Exemplarily the support 6 comprises a thin film 7 of polyester, e.g. transparent, and a layer 8 containing a pigment, for example a metallic color, spread on the upper face of the film 7.

[0049] The process provides, while the support 6 moves beneath the nozzle of the dispenser 3, to continuously spray the first wax in a molten state onto the support 6, specifically onto the layer 8 with the pigment.

[0050] Downstream of the dispenser 3, the calender 4 acts on the first wax by distributing it on the surface so as to obtain a uniform thickness over the entire desired width. At the same time, the first wax 9 is rapidly cooled by the cooling system 5 along a short cooling section immediately downstream of the dispensing point, where heat is actively removed from the first wax until complete solidification at the end of the cooling section. During this phase, the first wax adheres firmly to the pigmented layer 8, if present. Once solidification has occurred, the film 7 is separated from the assembly of the first wax 9 and the pigmented layer 8, in order to obtain, at the output of the system 1 , the continuous sheet 20, which may for example be wound (not shown). The pigmented layer 8, if present, is transferred from the support 6 to the sheet 20 and may provide the final coloration of the candle or may constitute the background for subsequent aesthetic processes as described below.

[0051] Exemplarily the first wax comprises a weight content of paraffin wax equal to 85% and a weight content of microcrystalline wax (or isoparaffin) equal to 65%, wherein the remaining part of the aforesaid weight content of paraffin wax is substantially constituted by n-paraffins. Exemplarily the first wax has a melting temperature equal to 80°C. Exemplarily the wax sheet has a thickness equal to 1 mm.

[0052] At this point, it is provided to cut from the continuous sheet 20 the sheet 10 of first wax according to appropriate dimensions.

[0053] In an alternative embodiment, the aforementioned process for producing the sheet is carried out in batches in a mold (rather than on a continuously moving support), optionally followed by a step of cutting the sheet 10 to the desired dimensions.

[0054] The process then proceeds to the step of creating the desired aesthetic appearance on the second face 13 of the sheet 10 belonging to the pigmented layer 8. To this end, the sheet is laid on a platen of a screen printing machine (not shown since it is, for example, of a known type per se) with the second face 13 of the sheet facing upwards, securing the sheet by means of appropriate fixed pins that protrude from the platen and pass through the sheet 10.

[0055] For the screen printing, a number of screen printing frames are prepared equal to the number of colors and any optical finishes (glitter, etc.) that make up the final aesthetic appearance, for example starting from an electronic file containing the design to be produced. Each frame comprises a screen with through micro-apertures arranged in a desired pattern.

[0056] The design is then printed on the second face of the wax sheet, optionally bearing the pigmented layer, by sequentially positioning the frames, suitably aligned with each other by means of registration systems, in contact with or at a predetermined distance from the second face 13 of the sheet 10, pouring over each screen a respective solution containing the corresponding pigment and / or optical finish (e.g. glitter, etc.), and spreading the respective solution over the screen by means of a screen printing squeegee, that, thanks to the regulated pressure exerted by the squeegee, it causes the solution to pass through the screen only in correspondence with the micro-perforated areas appropriately arranged to reproduce the part of the final image in the corresponding color or optical finish, depositing on and adhering to the second face 13 of the sheet.

[0057] In the case where a three-dimensional effect is also foreseen in the aesthetic appearance, an embossing step is also carried out, wherein a die (also provided with suitable registration means for correct alignment relative to the frames) is mechanically pressed against the second face 13 of the sheet to plastically deform said face according to the desired pattern.

[0058] The process then proceeds to the step of coupling the sheet 10 with a pre-formed candle core 11 (exemplarily a right circular cylinder) made of a second wax, for example n- paraffin wax at 90% with a melting temperature of 70°C.

[0059] To this end, a third wax (not shown) in a molten state is distributedly applied to a first face 12 of the sheet 10 and, alternatively or additionally, to the surface of the core 11. The third wax may be applied as a uniform and continuous layer, or discontinuously according to a dotted and / or linear pattern.

[0060] Exemplarily, the third wax is a paraffin wax without added solvents and has a melting temperature of about 55°C, advantageously lower than that of the first and second wax. With the third wax in a molten state (e.g. at a temperature of 60°C), it is provided (fig. 2) to coat the entire lateral surface of the candle core 11 with the sheet 10, with the first face 12 of the sheet 10 facing the core 11 (so that the third wax is interposed between the sheet and the surface), and to allow the third wax to cool down, through contact with the core 11 and / or the wax sheet, to ambient temperature until solidification, in order to firmly bond the sheet to the candle core and thereby obtain the candle 100.

[0061] Preferably, it is also provided (not shown) to coat the upper surface of the core 11 with an additional sheet (not shown), according to the process of the present invention.

Claims

CLAIMS1 . Production process of a candle (100) comprising:- providing a sheet (10) in a first wax comprising a weight content of microcrystalline wax greater than or equal to 50% and a weight content of paraffin wax greater than or equal to 70%, said weight content of paraffin wax comprising said weight content of microcrystalline wax;- providing a candle core (11 ) in a second wax, said candle core (11 ) having a surface;- applying in a distributed manner a third wax in a molten state on a first face (12) of said sheet (10) and / or on said surface of said candle core (11 );- at least partially coating a surface of said candle core (11 ) with said sheet (10), wherein said third wax in the molten state is interposed between said sheet (10) and said surface, and cooling said third wax until solidification to firmly couple the sheet (10) to the candle core (11 ) and produce said candle (100).

2. Production process according to claim 1 , wherein said weight content of paraffin wax in said first wax is greater than or equal to 75% and less than or equal to 95%, wherein said weight content of microcrystalline wax in said first wax is greater than or equal to 55% and less than or equal to 80% and wherein the process further comprises coating with said sheet (10) an entire lateral surface and / or an upper surface of said core (11 ).

3. Production process according to any one of the previous claims, wherein said first, second and / or third wax is solid at room temperature and has a melting temperature greater than or equal to 50°C, wherein said third wax has a melting temperature less than or equal to 70°C and at least 10°C less than a respective melting temperature of said first wax, and wherein said third wax in said molten state has a temperature, during said applying and / or in an initial phase of said coating, greater than or equal to 50°C and less than or equal to 70°C.

4. Production process according to any one of the previous claims, wherein said providing said sheet (10) comprises continuously spreading said first wax in a molten state over a continuously moving support (6) by means of a moving member (2), continuously cooling said first wax until solidification and continuously separating, at least partially, said support (6) from said first wax to produce said sheet (10) and wherein said sheet (10) has a thickness greater than or equal to 0.5 mm and / or less than or equal to 3 mm.

5. Production process according to claim 4, wherein said support (6) comprises a film (7) in polymeric material, wherein said separating at least partially said support (6) comprises or consists of separating said film (7).

6. Production process according to claim 4 or 5, comprising continuously unrolling said support (6) during said spreading said first wax, wherein said spreading said first wax comprises, prior to said solidification, calendering said first wax by means of one or more specific calendering rollers (4) arranged above said moving member (2).

7. Production process according to any one of claims 4-6, wherein said cooling said first wax until solidification is performed by means of a cooling system (5) acting on said support (6) integrated into said moving member (2).

8. Production process according to any one of the previous claims, comprising, prior to said applying in a distributed manner said third wax, spreading said sheet (10) on a plane with a second face (13) of said sheet (10), opposite to the first face (12), facing upwards, fixing said sheet in a fixed position on said plane and creating an aesthetic appearance on said second face (13).

9. Production process according to claim 8, wherein said creating said aesthetic appearance comprises printing an image on said second face (13) by means of screen printing, wherein said screen printing comprises placing one or more screen printing frames above said second face (13) of the sheet (10) in a sequential manner, pouring over each frame a respective solution containing a respective pigment and / or optical finish and spreading said respective solution over the frame, wherein said respective solution is water-based or solvent-based, and wherein each screen printing frame comprises a respective screen with micro-perforated areas according to a pattern.

10. Production process according to claim 9, wherein said creating said aesthetic appearance comprises imprinting a debossing on said second face (13) of the sheet by pressing a die against said second face (13) of the sheet (10) to imprint a design.

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