EP1461407A1 - Candle with controlled wick placement - Google Patents

Abstract

The wick of a candle is anchored above the bottom of the candle a flame extinguishing distance so that the wick is extinguished by the candle's molten solid fuel when the wick is consumed. Placement of the wick in this manner helps to eliminate bum through. Additionally, a bottom cavity may be formed in the candle. The cavity may be used for the purpose of helping to anchor the wick a desired flame extinguishing distance above the bottom surface of the candle. The cavity may be advantageously filled with scrap wax material since it will not be consumed by the burning wick.

Description

CANDLE WITH CONTROLLED WICK PLACEMENT

CROSS REFERENCES TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S . Provisional Application No.

60/345,072 filed January 4, 2002.

TECHNICAL FIELD

[0002] This invention relates to the controlled placement of wicks in a candle product.

The invention specifically relates to the placement of a candle wick a sufficient distance

f om the bottom of a candle product in order to create a product in which a burning wick

will be extinguished by the molten solid fuel pool when the wick is expended. By

quenching the burning wick with molten solid fuel, burn through of freestanding candles

placed on a combustible surface is minimized. In a preferred embodiment of the

invention, this invention relates to a process for manufacturing a compression molded

candle product having a contour in the bottom of the candle form that allows for the

controlled placement and sealing of wicks in free-standing candles.

BACKGROUND OF THE INVENTION

[0003] Candles have become a very popular form of air freshening for the home in

recent years. Candles are offered that appeal to the olfactory as well as the visual sense,

and come in a variety of forms and shapes and combination of both decorative and

fragrances. A popular form of candles offered are in the form of freestanding, or pillar

candles. [0004] A common manufacturing practice for insertion of wicks on freestanding

candles is during the formation of the candle. Specifically, wicks are place into die molds,

then a fuel source, such as paraffin wax is poured into the mold and allowed to cool, or

prilled wax is poured into a mold and compressed to form a candle shape and a wick is

then inserted. It is common practice that the bottom of the wick be in contact with the

bottom of the candle shape. The result is a wick that extends the full length of the candle.

[0005] The recent increase in candle sales also resulted in an increase of accidents by

candle fires in consumer's home. A closer study of the cause of fires can be attributed to

candles that are allowed to burn until the flames burn through bottom and cause surface

damage from heat or worse combustion of near by flammables. More commonly,

freestanding candles can present fire issues when left unattended and allowed to burn to

the bottom of the candle and thus cause surface damage or worse ignition of near-by

combustibles, or become tipped over allowing the flame to extend beyond the sidewall or

bottom of the candle resulting the same effect of ignition of near-by combustibles.

[0006] Another manufacturing practice is to form a freestanding candles in molds and

insert the wicks afterwards. The practice is to insert the wick and secure to the candle

from the bottom, but has drawbacks and limitations. Wicks are inserted into the candles

for positioning away from the bottom, there is no assurance of controlled placement. To

be accurate, and to control the problems mentioned above, careful wick placement is

required. If the bottom of the wick is placed too high in a candle, this will limit the

enjoyment obtained by the consumer in burning the candle, and a large portion of the

candle will be wasted. Conversely, if the bottom of the wick is placed too close to the bottom of the candle burn through, and combustion of the surface on which the candle is

placed can occur.

[0007] For purposes of commercial-scale manufacture, there can be an economic

advantage in utilizing a design to the bottom of a freestanding candle that allows for the

controlled placement and securing of wicks by means of forming the candles in molds.

[0008] The description of the present invention includes the advantages of inserting

wicks to a specified depth from the bottom of the candle as a way to address any issues of

burn through, as well as economic advantages to manufacturing by providing a contour to

the candle which allows for the reclamation of scrap materials.

[0009] A further advantage, with respect to the production of multilayer, multicolored

candles is the ability to dispose of place scrap wax in the bottom cavity.

THE INVENTION

[00010] Wright et al, U.S, patent application no 0010030195 describes the dangers of

flash-over from candles allowed to burn to a shallow pool which can ignite if the

temperature of the wax reaches its ignition points. Moreover, this invention describes the

phenomenon associated with candles in metal containers.

[00011] Candle compositions comprised of mineral oil and various polymeric additives

are known to develop the phenomenon of flashover due to the inherent nature of these

compositions to build up heat in the melt pools which can reach the ignition point.

Flashover can occur any time during the combustion of these compositions, so placement

of the wicks away from the bottom can offer only limited benefits.

[00012] Candle compositions comprised of wax and respective additives and molded

into the form of freestanding candles can only exhibit flashover when the pools are

contaminated with objects intentionally, and when contained in some form of a container.

A more common observation associated with freestanding candles is the loss of sidewalls

from other means such as improper selection of wicks, or contamination of pools.

BRIEF DESCRIPTION OF THE DRAWINGS

[00013] Fig. 1 shows a freestanding candle;

[00014] Fig. 2 is a bottom perspective view of the freestanding candle of this invention

showing the bottom cavity;

[00015] Fig. 3 is a cutaway view of a freestanding candle showing the cavity and wick

placement; [00016] Fig. 4 is a bottom perspective view of the free standing candle of this invention

showing the bottom cavity filled with a fuel source, optionally scrap wax.

DETAILED DESCRIPTION OF THE DRAWINGS

[00017] Fig. 1 shows a freestanding candle 2 having horizontal top 4, sides 6 and

bottom 8. Axially disposed wick 10 runs the length of candle 2 from the top 4 to the

bottom 8. The top 4, sides 6, and bottom 8 define a candle shape which can be prepared

by a variety of methods. Among the methods that can be used are the pouring of molten

solid fuel, generally a paraffin or vegetable wax into a mold defining the desired candle

shape, such mold optionally containing, placed therein a wick material of suitable

construction which will burn with the desired properties. Optionally, the wick 10 may be

placed into the candle shape after it has been removed from the mold by forming a wick

channel or cavity, and then inserting the wick. The wick should extend a flame sustaining

distance, generally ^lA to 1 inch above the top 4 of candle 2 and more preferably generally

at least Vi inch above the top of the bottom cavity.. Wicks longer than 1 inch may bend

over and create undesirable wax pools when the candle is burnt. Wicks shorter than ^lA

inch are difficult to light, and are sometimes difficult to sustain a flame since they can be

quenched by the capillary action of the solid fuel source, generally a vegetable or paraffin

wax.

[00018] Another method of forming candles is by compression. In this method prill or

powder is formed from the wax, inserted into the mold, and then the wax is compressed in

the mold to form the candle shape. The shape is removed from the mold, a wick cavity

created, and a wick inserted. The fuel for either poured or compression molded candles

may contain colorants, volatile active ingredients such as fragrances, insect control chemicals, sanitizers, deodorants, or the like. In addition the fuel may contain

microcrystalline wax to provide improved candle properties, and C₁₄-C₂₀ fatty acids to also

enhance the properties of the particular wax fuel employed. Sometimes synthetic wax

crystal modifiers such as emylene-alpha-olefin copolymers such as those sold under the

trademark Nybar may be added to the mixture as well. It is not within the scope of this

specification, or this invention to specify particular wax or fuel formulations used for

candles, and the method of this invention will perform with any candle made in

accordance with the teachings herein. Likewise, it is not within the scope of this

specification to discuss the choice of proper candle wicks, and those skilled in the art of

candlemaking will readily appreciate the various wick materials that are available for

particular uses. It is not important in the function of this invention that the candle contain

a volatile active material, this invention having applicability to candles providing light

only. Likewise, the invention is applicable to any candle shape, for example the common

cylindrical shape, square shapes, parallelogram shapes, triangles, etc. so long as the candle

2 has a relatively flat surface for balancing on a surface without falling over.

[00019] With specific reference to the drawings, this invention is directed to a meltable

solid fuel candle 2 having a substantially horizontal top surface 4, a substantially

horizontal bottom surface 8, one or more side surfaces 6 communicating with the top 4 and

bottom 8 surfaces to define a shape, and one or more vertical wick cavities 40 running

substantially vertically from the top surface 4 to the bottom surface 8 of said shape, each

vertical wick cavity 40 having disposed therein a combustible wick 10 having an upper

wick end 11 and a lower wick end 9 to form the shaped candle 2, the upper wick end 11

extending above the candle top surface a flame sustaining distance, and which upper wick end when ignited can sustain a flame with the solid fuel, the flame generating sufficient

heat to melt at least a portion of the solid fuel below the upper wick end to form a pool of

the molten solid fuel immediately below the upper wick end, and to cause the molten solid

fuel to move up a portion of the wick 10 by capillary action to the upper wick end 11 to be

consumed by the flame, the lower wick end 9 of each wick 10 being located substantially

near the bottom horizontal surface of the candle 8, the improvement comprising placing

the lower wick end 9 a flame extinguishing distance 22 above the bottom horizontal

surface of the candle whereby the pool of molten solid fuel formed by the flame heating

the solid fuel extinguishes the flame upon the consumption of each wick 10 and prior to

any contact of the flame or the molten solid fuel with a surface communicating with the

bottom surface.

[00020] With further reference to the drawings, Fig 2 shows a bottom perspective view

of a candle 2 of this invention showing bottom cavity 20 of the invention. Bottom cavity

20 has sides 22 and top 24 which define the cavity. Wick hole 26 extends through top 24

into the cavity 20. Cavity 20 can be prepared by various means. It can be molded into the

candle as it is poured, drilled out of a candle after pouring, or in compression

manufacturing techniques, can be incorporated into either the bottom of the compression

mold, or the ram which is utilized to compress the fuel source in the mold. Bottom cavity

20 does not extend the entire width of the candle, leaving sides 6 and shoulder 30 to

support the candle. The sides 22 of cavity 20 can extend from the bottom of the candle

shoulder 30 to as high in the candle as it is desired to eventually extinguish the flame on

wick 10. Normally, sides 22 should extend a minimum of about inch above the bottom

of the candle. [00021] Fig. 3 shows a cross section view of candle 2. In this view the bottom cavity

20 is shown along with sides 6, shoulder 30, cavity sides 22, and bottom cavity top 24. In

this view, the wick cavity 40 is also shown. Wick cavity 40 shows a axially disposed

vertically placed wick cavity adapted to receive an appropriate wick 10. In practice, wick

10 would be placed within wick cavity 40 and extend about ^lA to about 1 inch above the

top 4 of candle 2. Likewise wick 10 would end at the top 24 of bottom cavity 20, or

slightly above top 24 where in practice it would be anchored with a molten wax material.

The placement of wick 10 slightly above the top 24 of bottom cavity 20 helps insure that

the flame when wick 10 is ignited will be extinguished with the wax pool formed, and will

not be in a sufficient downward location to ignite a flammable surface onto which free

standing candle 2 may be inadvertently placed. Wick 10 may be held in place by a small

amount of molten fuel poured of the same or different composition as candle 2 provided

that the material used to anchor wick 10 should be compatible and adhere to the material

used for candle 2. In a preferred practice, wick 10 is placed 1/8 th inch below the surface

of the top 24 of cavity 20 which is 3/8 inch to give a total flame extinguishing distance of

approximately Vz inch. In other words, the wick is slightly recessed into the candle body

and does not extend into the cavity 20. This feature does not detract from the utility of the

invention when the wick is flush with top 24 or even extends into cavity 20 so long as the

wick is a flame extinguishing distance above the horizontal bottom 8 of the candle. .When

a cavity is utilized, the wick should preferably extend substantially no further than the top

surface of the bottom cavity.

[00022] Fig. 4 shows a bottom view of candle 2 showing bottom cavity 20, bottom

cavity sides 22, bottom cavity top 24 and wick cavity 40. Also shown in dotted line is wax fill 44 which is added to hold wick 10 in place and to provide a better foundation

upon which candle 2 may rest, hopefully on a non-combustible surface. One of the

surprising benefits of the flame extinguishing feature of this invention, is that it provides

both economic and safety benefits.

[00023] Many times in the manufacture of candles different waxes are employed.

These waxes may contain different colorants or pigments, and thus, must be carefully

sorted if they are to be reused, or the material, if commingled must be disposed of as a

chemical waste. This is of special concern when the solid fuel being used contains

different fragrance materials that may or may not be compatible to the olfactory sense.

Previously, waste wax from broken or scrap candles was disposed of at great economic

cost. If the solid fuel being commingled contained different colorants, often a gray or dark

unpl easing color would result if the scrap was melted down and reused. This melted down

scrap was unsatisfactory for candle production since it did not provide proper esthetics for

a commercially saleable product. We have found that when wax scrap is collected and

melted, it may be used to fill the bottom cavity 20 to provide additional support for candle

2 since the wax contained in bottom cavity 20 is not consumed in the combustion of the

candle. This scrap wax is thus contained in the candle and provides stability and support

to the sides 4 and shoulder 30 of candle 2. The scrap wax may also help maintain the wick

at a satisfactory location, preventing it from sliding down. In the absence of scrap wax of

course, new wax can be utilized, and this invention is not meant to be limited to the use of

scrap wax alone. Alternatively, and assuming that shoulder 30 and sides 6 remain intact

and are strong enough to maintain the weight of the candle, the bottom cavity may be left

open. The scrap wax does not prevent the wick from sliding down when a sealing wax is utilized, thus explaining why the cavity can remain unfilled and the wick will extinguish.

As long as the melt point of the sealing wax, the wax that anchors the wick, is not

substantially higher than the melt point of the formula, the wick will fall over and will not

slide down. When no sealing wax is utilized the wax placed into the cavity will help to

maintain the wick in its proper location. We prefer to use sealing wax however to

maintain the placement of the wick at a desired location.

[00024] In the manufacture of candles by compression techniques, such as that

disclosed in my commonly assigned application filed of even date, the compression candle

is molded upside down with a compression ram, having the desired shape to impart the

bottom cavity 20 incorporated into the ram. After compression, the candle shape is

removed from the mold, and still upside down, a wick of suitable material is inserted.

This wick 10 is in the wick cavity 40, placed about 1/8 th inch beneath the top 24 of candle

bottom 8. The wicks utilized may be of any conventional wick material including but not

limited to cotton, cotton/paper, cotton/linen, or synthetic such as rayon. A preferred wick

material is cotton with or without paper braid or a paper core.

[00025] In practice, we prefer not to use metallic wick clips as are commonly used for

the support of wicks, in for instance votive candles because free standing candles are often

placed upon stands having protrusions which engage the candle and steady the candle.

Such protrusions would damage a wick clip, and hence, while this invention will function,

we prefer not to use such devices. Another disadvantage of a conventional metallic wick

clip in the practice of our invention is that the metal will conduct heat, melting additional

wax, and perhaps causing the fuel around the wick clip to melt. This additional melted wax may cause breakthrough of the wax to the bottom of the candle, exposing molten wax

to the surface upon which the candle is to be placed.

[00026] The example presented below illustrates the preparation of a multiple layered

compression molded candle product having the wick shut off feature, and the scrap

disposal feature of the subject invention. As will be seen, while this invention is

illustrated with a compression candle making technique, those skilled in the art will readily

appreciate that the subject wick shut off invention will have applicability with regard to

candles that are poured as well.

[00027] For each composition of a layer, a refined paraffin wax ( IGI Paraflex 1239 MP

60° C); is pre blended with an ethylene derived polymer (Nybar 103, MP 76° C) until the

polymer is fully integrated into the refined paraffin wax. A fragrance/dye/UN inhibitor

concentrate of IFF Stargazer 18 (available from International Flavors & Fragrances),

Sandoplast Yellow 3G, Sandoplast Red 2G (both available from Clariant Gmbh, Pigments

and Additives Division, Frankfurt) and Cyasorb UN 531 (available from Cytec Industries,

Inc., West Patterson, New Jersey) is mixed until all components are dissolved.

[00028] The following four streams: wax/ polymer pre-blend and the fragrance/dye/UN

inhibitor concentrate, stearic acid (Emersol 150 MP 65.5 ° C available from Henkel Corp.),

and microcrystalline wax (Bareco's Victory Lite Wax MP 80° C.) are metered

simultaneously to the formula (using a four stream metering system) and are blended .

through an in-line blending process.

[00029] Separately and simultaneously, additional compositions are prepared using the

same method of mixing process. For the second layer, a refined paraffin wax (IGI Paraflex

1239 MP 60° C); is pre blended with Nybar 103 until the polymer is fully integrated into the refined paraffin wax. A fragrance/dye/UN inhibitor concentrate of IFF 1814 HBA,

Clariant Sandoplast yellow 3G and Cyasorb UV 531 is mixed until all components are

dissolved. The wax/ polymer pre-blend and the fragrance/dye/UN inhibitor concentrate are

further blended through an in-line blending process with the same stearic acid and

microcrystalline wax used in layer mixture 1. A third layer using identical ingredients,

except the fragrance/dye/UN inhibitor concentrate was IFF Moonblossom 47, Clariant

Sandoplast Green 3G, Νitro Fast Blue 2B and Cyasorb UN 531 is mixed until all

components are dissolved. The wax/ polymer pre-blend and the fragrance/dye/UN

inhibitor concentrate are further blended through an in-line blending process as with the

other two layers.

[00030] The separate layer mixture-candle wax compositions are held at a temperature

of approximately 65 to 80° C. usually 75-80° C, and preferably about 77° C and pumped

separately to respective surge tanks until the ingredient mixtures are homogenous. The

candle wax compositions are then pumped to their respective separate wax reservoirs in

Kurschner wax spray drum system and the compositions are held at a temperature of 65 to

80° C. The spray drums are set to a speed of approximately 42 meters/min. The spray

room temperature is held to about 15° C. and the relative humidity of approximately 50%.

although this temperature parameter may vary depending on the composition being dried,

the humidity, the rate of spraying, and the temperature of the material-being sprayed. The

candle wax composition for each layer is pumped through a spray manifold system from

the spray drum reservoir and sprayed to 15 centimeters above the drum from nozzles. The

wax is sprayed into the air and semi-solidifies before contacting the drum surface. The

spray drum is held to a temperature between about 7 and 24 ° C. The prilled wax is collected on the spray drum and them scraped from the drum and transferred into a

vibrating conveyer that leads inside the drum for each of the compositions for further

cooling. The prilled wax is collected at the end of the drum and vacuum fed into holding

separate hoppers. For consistent cavity mold filling and compression for multiple layers in

a single mold, the prilled waxes are maintained at temperatures between about 17 and 32°

C.

[00031] The target dimension for the candle directly from the press is 7.60 cm by

10.16 centimeters in dimension. For a pillar candle of this dimension, the total weight is

about 366 grams and the weight for each layer is about 122 grams. It should be noted that

the candles are made on the basis of volume and weights are given for the purpose of

illustration only.

[00032] The prilled candle waxes above are transferred from the spray drum to three

separate stationary hoppers and maintained at a temperature between 20 and 32° C. The

prilled waxes are transferred from the stationary hoppers to feed tube matrix of the

Progressive Automation compression mold pillar candle press.

[00033] The feed tube matrix consists of 3 rows each containing 6 cavities which are

filled with prilled wax for each layer. The feed tube matrix passes over the a stationary

table of the press and fills one of the two sets of 6 cavity head units with a volume of 122

grams from the feed tube matrix for a layer per candle, until the cavity Is filled with a total

of 366 grams of prilled wax, thus representing three distinct layers of prilled wax

composition in a single candle. The table then rotates one of the 6 head cavity units filled

with the three prilled wax compositions, 180 degrees to a compression station, where the

prilled wax is compressed in the cavity from the top down, forming a contour pocket of approximately 40 millimeters by 9.5 millimeters in dimension to the bottom of the candle.

The prilled waxes are compressed to a force between 2400 and 2800 pounds, for a dwell

time of approximately 1-5 seconds to produce a candle that is of a density of between 0.83

and 0.92 grams/ cubic centimeter, at which time, the cavity molds are heated through the

use of a water jacket, to a temperature of between 10 and 40° C.

[00034] The compressed candles are then extracted from the cavity molds, then placed

onto a pocketed indexing conveyer system, bottom side up to allow for a clearance space

for the top of the candle, and transferred to a Progressive Automation wicking machine

where cotton wicks, with or without paper braids or paper cores having a length of from

about 9 to about 11.5 cm. from Technical Braiding Gmbh are inserted into the candles

from the bottom to allow the wicks to be placed flush to the upper portion of the pocket

and to a total depth of Vz inch from the bottom of the candle. While the candles are

inverted with the bottom up, the wicked candles are dosed with approximately 0.2 to 0.5

grams of paraffin wax at a temperature between 65 and 85 ° C. to seal the wicks in place.

While microcrystalline wax can be advantageously used in this step, it is preferred to

utilize a material having the same properties employed in the bottom layer so that the wax

material is compatible with, and has the same melting point as the main structure. The

candle is then transferred onto a second station where the cavity is filled with between 8

and 10 grams of candle wax that has been reclaimed from scrap candles, and at a

temperature between about 60 and about 80°C. and generally about 60-70°C. This

temperature range is not critical, and molten paraffin of a higher or lower temperature can

be used so long as the temperature is not high enough to damage the structure, or dislodge

the wick. The candles that have been filled with wax into the bottom cavity are then passed through cooling tunnel at a temperature of from about 13 to about 25° C for a

period of approximately 12 to 20 minutes. In the practice of this invention it is necessary

that the selected wick extend out of the top of the candle a flame sustaining distance. In

practice this distance ranges from about A inch to about 1 inch.

[00035] The resultant candles were esthetically pleasing, had satisfactory burn

characteristics and emitted fragrance as they burned. When the candles of the subject

invention were utilized the wick was extinguished by the molten wax pool. Over a series

of candles that were tested, burn though was virtually eliminated.

Claims

1. A meltable solid fuel candle having a substantially horizontal top surface, a

substantially horizontal bottom surface, one or more side surfaces communicating with

the top and bottom surfaces to define a shape, and one or more vertical wick cavities

running substantially vertically from the top surface to the bottom surface of said

shape, each vertical wick cavity having disposed therein a combustible wick having an

upper wick end and a lower wick end to form a shaped candle, the upper wick end

extending above the candle top surface a flame sustaining distance, and which upper

wick end when ignited can sustain a flame with the solid fuel, the flame generating

sufficient heat to melt at least a portion of the solid fuel below the upper wick end to

form a pool of the molten solid fuel immediately below the upper wick end, and to

cause the molten solid fuel to move up a portion of the wick by capillary action to the

upper wick end to be consumed by the flame, the lower wick end of each wick being

located substantially near the bottom horizontal surface of the candle, the improvement

comprising placing the lower wick end a flame extinguishing distance above the

bottom horizontal surface of the candle whereby the pool of molten solid fuel formed

by the flame heating the solid fuel extinguishes the flame upon the consumption of

each wick and prior to any contact of the flame or the molten solid fuel with a surface

communicating with the bottom surface.

2. The improvement of claim 1 wherein the solid fuel is paraffin.

3. The improvement of claim 1 wherein the candle shape is prepared by compressing

solid fuel particles to form a candle shape, wherein the candle shape is compressed

with a bottom cavity defined by an upper surface a flame extinguish distance from the

bottom horizontal surface, and one or more side surfaces extending from the horizontal

bottom surface of the candle shape to the top surface, the top of such bottom cavity

communicating with the bottom of each wick cavity, inserting the combustible wick

into each of said wick cavities, the lower wick end of each wick extending downward

substantially no further than the top surface of said bottom cavity.

4. The Improvement of claim 1 wherein the wick is anchored using molten paraffin wax.

5. The improvement of claim 3 wherein the flame extinguishing distance is greater or

equal to about one-half inch.

6. The improvement of claim 3 wherein and the bottom cavity is filled with additional

solid fuel after the wick is anchored.

7. The improvement of claim 3 wherein a microcrystalline wax is used to anchor the wick

in the wick cavity substantially no further down than the top surface of the bottom

cavity prior to the bottom cavity being filled with additional solid fuel.

8. The improvement of claim 4 wherein the solid fuel is paraffin wax.

9. The improvement of claim 6 wherein the additional solid fuel is wax scrap.

10. The improvement of claim 9 wherein the bottom cavity is filled with waste paraffin

wax

11. The improvement of claim 1 wherein the candle shape is prepared by pouring molten

wax to form a candle shape, wherein the candle shape is molded with a bottom cavity

defined by an upper surface a flame extinguish distance from the bottom horizontal

surface, and one or more side surfaces extending from the horizontal bottom surface of

the candle shape to the top surface, the top of such bottom cavity communicating with

the bottom of each wick cavity, inserting the combustible wick into each of said wick

cavities, the lower wick end of each wick extending downward substantially no further

than the top surface of said bottom cavity.

12. The improvement of claim 11 wherein the bottom cavity is filled with additional solid

fuel after wick placement.

13. The improvement of claim 11 wherein the flame extinguishing distance is greater or

equal to about one-half inch.

14. The improvement of claim 11 wherein the wick is anchored in place using a

microcrystalline wax prior to the bottom cavity being filled with additional solid fuel.

15. . The improvement of claim 1 wherein the candle shape is prepared by pouring molten

wax to form a candle shape, wherein the candle shape after formation is machined to

form a bottom cavity defined by an upper surface a flame extinguish distance from the

bottom horizontal surface, and one or more side surfaces extending from the horizontal

bottom surface of the candle shape to the top surface, the top of such bottom cavity

communicating with the bottom of each wick cavity, inserting the combustible wick

into each of said wick cavities, the lower wick end of each wick extending downward

substantially no further than the top surface of said bottom cavity.

16. The improvement of claim 16 wherein the bottom cavity is filled with additional solid

fuel after wick placement.

17. The improvement of claim 16 wherein the flame extinguishing distance is greater or

equal to about one-half inch.

18. The improvement of claim 16 wherein the wick is anchored in place using a

microcrystalline wax prior to the bottom cavity being filled with additional solid fuel.

19. The improvement of claim 16 wherein the wick is anchored in place using a molten

microcrystalline wax, and the bottom cavity is not filled.

20. A meltable solid fuel candle having a substantially horizontal top surface, a

substantially horizontal bottom surface and one or more side surfaces communicating with the top and bottom surfaces to define a shape, a wick cavity running substantially

vertically from the top surface to the bottom surface of said shape the wick cavity

having disposed therein a combustible wick having an upper wick end and a lower

wick end to form a shaped candle, the upper wick end extending above the candle top

surface a flame sustaining distance, and which upper wick end when ignited can

sustain a flame with the solid fuel, the flame generating sufficient heat to melt at least a

portion of the solid fuel below the upper wick end to form a pool of the molten solid

fuel immediately below the upper wick end, and to cause the molten solid fuel to move

up a portion of the wick by capillary action to the upper wick end to be consumed by

the flame, the lower wick end being located substantially near the bottom horizontal

surface of the candle, the improvement comprising anchoring the lower wick end a

flame extinguishing distance above the bottom horizontal surface of the candle

whereby the pool of molten solid fuel formed by the flame heating the solid fuel

extinguishes the flame upon the consumption of the wick and prior to any contact of

the flame or the molten solid fuel with a surface communicating with the bottom

surface.

21. The improvement of claim 21 wherein the candle shape is made by pouring molten

wax into a mold.

22. The improvement of claim 21 wherein the candle shape is made by compressing wax

prill in a mold.

3. The improvement of claim 21 wherein the flame extinguishing distance is greater or

equal to about one-half inch.