Modular Injection Mold for Wax Candle Shells

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Solution Overview

Problem

There is a need for improved systems and methods for forming wax or wax-like shells for electric lighting devices, as existing technologies are inadequate for efficiently producing these components.

Innovation Solution

The use of injection molding to create wax or wax-like shells, which includes a sleeve with a modular top and a core, allowing for different top configurations and eliminating the need for drilling, combined with a cap that allows for wax feeding and excess wax venting, enables efficient production of wax shells for electric candles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional methods are used to form wax shells, then manufacturing flexibility is limited, but production time and cost increase

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidproduction time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The mold is divided into multiple independent components including a sleeve, core, and modular top sections. This segmentation allows each component to be manufactured separately and assembled efficiently, enabling flexible production of different shell designs while maintaining high production speeds through standardized assembly procedures

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention employs a modular top design that can be quickly exchanged between different configurations. This dynamic element allows the manufacturing system to adapt to different product requirements without retooling the entire mold, thereby maintaining both flexibility and high productivity

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If custom top configurations are created for each shell design, then design versatility is improved, but device complexity increases

Engineering Contradiction:

Improvetop configuration optionsVSAvoidmold structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mold is designed with universal components that can serve multiple functions. The sleeve and core are standardized elements that work with different top configurations, while the modular top system allows a single mold structure to produce various shell designs. This multi-functionality reduces overall device complexity while maintaining design versatility

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If manual drilling and assembly methods are used, then alignment precision can be achieved, but manufacturing time increases

Engineering Contradiction:

Improvealignment accuracyVSAvoidmanufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The mold components including the sleeve, core, and top sections are pre-aligned and pre-assembled in the correct positions before the injection molding process begins. This preliminary action ensures that when the wax shell is formed, all components are already in precise alignment, eliminating the need for post-manufacturing drilling and assembly operations

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10647943B2Systems and methods for forming wax or wax-like candles or shells

Publication Date: 2020.05.12 L&L CANDLE CO LLC

AI summary

Systems and methods are described for forming wax shells for use with electric lighting devices. A template can comprise a sleeve that defines an interior space with a removable core at least partially disposed within the interior space. A modular top can be coupled to the sleeve, depending on the desired upper surface of the wax shell.