Multilayered compressed candle and method for manufacture

A method for the manufacture of a multilayer compression candle which comprises the steps of:

• a. Preparing x+1 where x is a whole number equal to or greater than 1, paraffin wax prill layer mixtures, each layer mixture containing particles of a compatible paraffin solid fuel having a particle size of from about 500 to about 2000 microns and an effective amount of a colorant;
• b. Adding such layer mixtures to a candle mold in such a manner that no two immediately adjacent layer mixtures contain the same colorant;
• c. Compressing such layer mixtures to form a candle shape within the mold;
• d. Forming either during compression or thereafter a wick cavity within such candle shape;
• e. Placing a combustible wick within such wick cavity;
• such wick being placed to extend a flame sustaining distance above the top of such candle;
• and then,
• Recovering a multilayer compression candle.

A multilayered compression candle having been prepared by the steps of:

• a. Preparing x+1, where x is a whole number equal to or greater than 1, solid-fuel prill or powder layer mixtures, each layer mixture containing a compatible solid fuel having a particle size of from about 600 microns to about 1190 microns, and each layer mixture containing one or more colorants and optionally, a volatile active ingredient from the group consisting of fragrances, insect control agents, sanitization agents and deodorants;
• b. Adding the x+1 layer mixtures of step a to a candle mold in a sequential manner so that no adjacent layer mixture within the mold contains the same colorant each layer mixture being added in a quantity to produce a substantially horizontal layer of a desired thickness;
• c. Subjecting such layer mixtures in the mold to a compressive force of from about 2400 to about 2800 pounds force to form a candle shape within the mold, said candle shape having a substantially horizontal top surface, a substantially horizontal bottom surface, and one or more vertical surfaces communicating with said top and bottom surfaces defining the candle shape, said candle shape having x+1 substantially horizontal layers, each layer having a desired vertical thickness;
• d. Forming either during step “c” or thereafter one or more axially disposed vertical wick cavities within such candle shape;
• e. Placing a combustible wick within each such axially disposed vertical wick cavity;
• such wick being placed to extend a flame sustaining distance above the substantially horizontal top of such candle to at or near the horizontal bottom surface of such candle shape;
• and
• f. Recovering a multilayer compression candle, wherein each solid-fuel prill or powder layer mixture contains:
• i. between about 60 and 95% weight percent of refined paraffin wax having a melting point in the range of about 130 and 150° F. and a maximum oil content of about 1.0%;
• ii. between about 0 and 20 percent of microcrystalline wax having a melt point in the range on 150 to 180° F.;
• iii. between about 2 and 20 weight percent of a C14 to C20 fatty acid ingredient;
• iv. between 0 and 5 weight percent of a polymeric wax crystal modifier ingredient;
• v. between about 0 to 10 weight percent of a volatile active ingredient;
• and,
• vi. between about 0 and 2 weight percent of colorant ingredient;
• wherein the prilled wax composition has a powder density between about 0.50 and 0.65 grams per cubic centimeter.

A multilayered compression candle comprising x+1 layers wherein x is a whole number equal to or greater than 1, each layer containing:

• i. between about 70 and about 93% weight percent of refined paraffin wax having a melting point in the range of about 130 and 150° F. and a maximum oil content of about 1.0%;
• ii. between about 1 and about 3.5 weight percent of microcrystalline wax having a melt point in the range on 150 to 180° F.;
• iii. between about 3 and about 8 weight percent of a C14 to C20 fatty acid ingredient;
• iv. between about 1 and about 5 weight percent of a polymeric wax crystal modifier ingredient;
• v. between about 1 to about 10 weight percent of a volatile active ingredient;
• and,
• vi. between about 0.0001 and about 2 weight percent of colorant ingredient;
• wherein the prilled wax composition has a density between about 0.50 and 0.65 grams per cubic centimeter, and wherein no two adjacent layers contain the same colorant wherein said candle contains at least one axially disposed vertical combustible wick.

A method of making a multilayered compression candle, which process comprises the steps of:

• A. Preparing x+1, where x is a whole number equal to or greater than 1, solid-fuel prill layer mixtures, each layer mixture containing a compatible solid fuel having a particle size of from about 500 to about 2000 microns, and each layer mixture containing an effective amount of a colorant and optionally, one or more different volatile active ingredients from the group consisting of fragrances, insect control agents, sanitization agents and deodorants;
• B. Adding the x+1 layer mixtures of step a to a candle mold in a sequential manner so that no immediately adjacent layer mixture within the mold contains the same colorant, each layer mixture being added in a quantity to produce a substantially horizontal layer of a desired thickness, such mold having placed therein one or more axially disposed wicks;
• C. Subjecting such layer mixtures in the mold to a compressive force to form a candle within the mold, said candle having a substantially horizontal top surface, a substantially horizontal bottom surface, and one or more vertical surfaces communicating with said top and bottom surfaces defining the candle, said candle shape having x+1 layers, each layer having a desired thickness, and said wick extends a flame sustaining distance above the substantially horizontal top of such candle;
• and,
• D. Removing said candle from the mold to recover a multilayer compression candle.