Extruded Wax Melt Blank Production
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Solution Overview
Problem
The production of wax melts is energy and effort intensive due to the multi-step processes involved in compression molding and pour processes, leading to high production costs and consumer dissatisfaction with the need for large quantities of small wax beads for desired fragrancing benefits.
Innovation Solution
A wax melt blank is produced using an extrusion process, combining at least 50% wax with fragrance and up to 30% filler, which is then cut into individual melts, reducing production steps and energy consumption while maintaining homogenous dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If compression molding or pour process is used to produce wax melts, then the wax melts can be produced with reasonable shelf life, but the production process becomes energy and effort intensive with high production costs
Solution Approach 1:
The patent changes the production method from batch processing (compression molding/pour process) to continuous extrusion processing. This parameter change in the manufacturing process reduces energy consumption and production time while maintaining product quality and shelf life through consistent homogenous dispersion of fragrance and filler materials.
2Duration of action of stationary object
If compression molding or pour process is used to produce wax melts, then the wax melts can be produced with reasonable shelf life, but the number of production steps increases leading to high production costs
Solution Approach 1:
The patent combines multiple production steps into a single continuous extrusion process. The extruder integrates mixing, heating, and forming operations that were previously separate steps in compression molding or pour processes, thereby reducing the number of production steps and associated costs while maintaining product quality.
3Ease of operation
If small wax beads are used in warmers, then the warmer can be filled easily, but consumers must purchase significant quantities to provide desired fragrancing benefits
Solution Approach 1:
The patent transitions from small bead-shaped wax products to larger block-shaped wax melts. This dimensional change allows consumers to use smaller quantities to achieve the same fragrancing benefits, reducing the total quantity of wax needed while maintaining ease of use by simply placing the block in the warmer.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The extrusion process simplifies production, reduces costs, and allows for a more cost-effective and efficient method of producing wax melts, addressing the high production costs and consumer dissatisfaction with existing methods.
Implementation Method 1
mixing the filler and the fragrance oil in the first stage
Implementation Method 2
mixing the filler, the fragrance oil, and the wax in a third stage of the twin screw extrusion system to form a mixture
Implementation Method 3
forcing the mixture through a die to form the wax melt blank
Data Source
AI summary
A wax melt blank is produced with an extrusion process and intended to later be cut to length into individual wax melts. The wax melt blank includes at least about fifty percent by weight of wax, a fragrance, and up to about fifty percent by weight of a filler. The wax, the fragrance, and the filler are homogeneously dispersed within the wax melt blank.