CN104094055A - 制造复合烛芯的系统和方法 - Google Patents

制造复合烛芯的系统和方法 Download PDF

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CN104094055A
CN104094055A CN201280066246.8A CN201280066246A CN104094055A CN 104094055 A CN104094055 A CN 104094055A CN 201280066246 A CN201280066246 A CN 201280066246A CN 104094055 A CN104094055 A CN 104094055A
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约翰·E·卡格尔
罗伯特·W·布朗
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Abstract

用于制造复合烛芯的系统和方法包含用于以大体上相同的速度馈送棉芯和木芯的机构。对所述木芯加热以使所述棉芯上的蜡涂层熔化，且经由压缩轮以及载运芯材料的传动带向所述芯材料施加压力。一旦施加所述压力以形成所述复合芯，便接着将所述芯传送通过切割管，在所述切割管中切割刀片将会把所述芯切割到其所要长度。

Description

制造复合烛芯的系统和方法
相关申请
本申请要求2011年11月8日提交的美国申请序号61/556,998的优先权，所述美国申请以引用方式并入本文中。
技术领域
本发明涉及制造复合烛芯的方法，借此两种材料(优选为棉花和木材)借助层压而结合在一起。复合芯使蜡烛的火焰高度一致性得到改善。
背景领域
具有木芯，尤其是平面木芯的蜡烛在正常使用期间火焰高度会不一致。不管使用哪种木材，所述不一致性看起来要归于木材自身的自然变化。无论是由于地形、海拔高度、气候、树龄还是加工，木芯蜡烛中火焰高度的不一致性是蜡烛产业里的一个重大缺点。
火焰高度的不一致性可被认为是使用美感和香味释放性能方面低质量的标记。除非另外设计，否则期望蜡烛维持合理的火焰高度一致性。观察到火焰高度的不一致性为一支蜡烛在其使用期间会出现低火焰和高火焰或在蜡烛与蜡烛之间出现低火焰和高火焰。
具有低火焰的蜡烛产生不良的使用美感且减少香味释放和冲击。举例来说，传统的蜡烛火焰赋予令人愉悦的气氛，如以“烛光晚餐”这个众所周知的概念为例。低火焰的发光将明显降低，从而产生非所要的蜡烛火焰气氛。对于香味蜡烛，此项技术中众所周知的是火焰使蜡熔化，从而导致香味释放。香味蜡的快速熔化和宽熔池(meltpool)的产生有助于最大化香味释放和冲击两者。低火焰缺少易于使蜡熔化的能力且可能不会形成宽熔池，因此抑制香味释放和冲击。具有高火焰的蜡烛很可能产生过多的烟且产生高热量。
为了解决这些问题，已开发出一种复合木/棉芯，其中棉芯粘附到木芯上。此类芯描述于美国专利申请序号13/274,630中，所述美国专利申请的教示以引用方式并入本文中。在层压之后，包括棉芯和木芯的复合芯应具有相同长度，且实际长度将取决于使用所述芯的蜡烛的高度。
本发明的一个重要方面是棉芯3与木芯3被粘附到一起，使得最终经层压的复合芯可耐受额外制造程序而不会分层。额外制造程序包含芯夹应用以形成完整的芯夹总成、容器放置和随后粘附、例如热液体填充等蜡烛成形，以及复合芯修剪以获得最佳的首次蜡烛燃烧用户体验。本发明的另一个重要方面是平面棉芯3不超出木芯的边缘。
发明内容
用于制造复合烛芯的系统和方法包含用于以大体上相同的速度馈送棉芯和木芯的机构。对所述木芯加热以使棉芯上的蜡涂层熔化，且经由压缩轮以及载运芯材料的传动带向芯材料施加压力。一旦施加压力以形成复合芯，便接着将所述芯传送通过切割管，在所述切割管中切割刀片将会把所述芯切割到其所要长度。
从以下详细描述中将能更充分地理解本发明的这些和其他的特征和功能，所述详细描述应依照附图来进行阅读，在附图中对应元件符号在几个视图中指代对应部件。
附图说明
图1是示出了本发明的用于制造复合芯的系统的透视图的示意图。
图2是图1中所示的系统的棉芯和木板馈送部分的示意图。
图3是图1中所示的系统的棉芯和木芯馈送部分的近视示意图。
图4是图1中所示的系统的木板加热管的剖切示意图。
图5是图1中所示的系统的层压部分的示意图。
图6是图1中所示的系统的定尺寸和切割部分的示意图。
具体实施方式
在本发明中，借助层压将布芯3与木板2组合起来以形成各种长度的复合芯15。优选的是，布芯3材料的几何形状是平面的，但布芯3的形状可以是棒状、矩形或某其他几何形状。优选地，本发明中所用的布芯是使用以下材料中的一者或一者以上制造的具有扁平几何形状的(平面的)编结芯：棉花(短纤维和较长的纤维)、纸、人造丝和纤维素。布芯3可包含通过含有具有一个或一个以上多纤维端的人造丝套管的多个饰带而编结到一起的多个棉芯。由于棉花是布芯3的优选材料，因此所述芯在下文中将被称作棉芯。棉芯3的优选厚度是在0.025英寸与0.065英寸之间且优选宽度是在0.25英寸与0.75英寸之间。棉芯3涂有蜡且以10到1000英尺的长度在棉芯线轴上供应。此类芯可购自Atkins and Pearce,1Braidway,Covington,Kentucky41017。
优选的是，木芯2由樱桃硬木制成，但也可使用其他木材类型，例如枫树和橡树硬木。除了硬木之外，也可使用软木，例如松木或杉木。木芯2形成为平面形状，被称作木板，其优选厚度是在0.015英寸与0.04英寸之间，优选宽度是在0.25英寸与1英寸之间，且长度是在3英寸与36英寸之间，其中优选长度是28英寸。此类木芯可购自Candle Art,LLC,10084North1950th Street,Dieterich,IL62424。
作为芯3的后加工的部分，对棉芯3涂上蜡。蜡涂层包含具有粘附性质的材料，例如微晶蜡、高熔点石蜡、聚乙烯蜡、聚α-烯烃或用于传统的芯蜡涂层的某其他材料。此蜡涂层充当下述层压工艺中的粘合剂。在层压之后，包括棉芯和木芯的复合芯将具有相同长度，且实际长度将取决于使用所述芯的蜡烛的高度。
棉芯3是在以十到一千英尺等长度的连续棉芯3长度被缠绕的棉芯线轴1上供应。木板2是以28”的长度来供应且人工馈送到木板加热管4的开口中。
参看图1到图4，通过棉芯线轴1供应的棉芯3以等于木板2馈送速率的馈送速率由棉芯引导轮16引导通过铝框架20。木板加热管4通过辐射加热器19将木板2加热到120℉到190℉之间的温度，所述辐射加热器19位于木板2上方1/4”处以与木板2充分接触。木板2的加热是本发明的一个重要方面，因为它导致棉芯3上的层压蜡的随后些许熔化。
参看图5，棉芯3经由棉芯引导件16引导到压缩轮6，且木板2通过传动带8经木板加热管4引导到压缩轮6。传动带8通过可调带张紧总成5而保持绷紧。传动带8通过使传动带滑轮17转动的DC电动机而运动。压缩轮6由肖氏A型硬度至少是硬度值95(durometer95)的硬聚氨酯制成。传动带8搁置在传动带支撑板7上。将棉芯3引导到木板2的中心上，棉芯3与木板2两者是以相同速率馈送到压缩轮6中。可通过转动张紧螺杆18来调整压缩轮6的压缩力。张紧螺杆18作为带支撑张紧系统10的一部分增加或减小带支撑弹簧11上的压力，这又增加或减小带支撑板7上的压力。复合芯15的层压根据施加到两种芯材料上的在压缩轮6与带支撑板7之间的压力而发生。如上所述，对木板2加热，致使棉芯上的蜡涂层熔化，从而在向两个芯2、3施加压力时使棉芯3粘附到木芯2。对张紧螺杆18进行手动调整使得可以对棉芯3和木板2施与最佳压力。最佳压力是通过对分离经层压片所需的力的离线定性测量来确定。
参看图6，棉芯3和木板2两者具有通过同步步进电动机12控制的相等馈送速率。棉芯3上的蜡涂层是将棉芯3与木板2结合到一起的层压媒介。现在经层压的棉芯3和木板2作为复合芯15而进入到切割管14中。接合切割总成9且切割刀片13根据复合芯15的馈送速率而切割复合芯15。切割总成9的接合可经编程以调整切割长度以配合各种蜡烛高度。复合芯15从切割管离开，其中它随后被芯组装和放置系统接手。
虽然已参考优选实施方案来描述了前述发明，但本领域的技术人员将能想到各种更改和修改。所有此类更改和修改既定属于所附权利要求书的范围内。

Claims (11)

1.一种用于制造复合烛芯的系统，其包括：
第一馈送机构，其用于将布芯馈送到所述系统中；
第二馈送机构，其用于将木芯馈送到所述系统中；以及
压缩装置，其用于向所述布芯和所述木芯施加压力以使所述布芯与所述木芯彼此粘附。
2.如权利要求1所述的用于制造复合烛芯的系统，其中所述第一馈送机构包括线轴，所述布芯缠绕到所述线轴上。
3.如权利要求1所述的用于制造复合烛芯的系统，其还包括木材加热管，所述木芯被馈送到所述木材加热管中。
4.如权利要求3所述的用于制造复合烛芯的系统，其中所述木材加热管包括辐射加热器，在所述木芯经过所述加热器时，所述加热器位于距所述木芯不超过0.25英寸处。
5.如权利要求1所述的用于制造复合烛芯的系统，其还包括卷绕在传动带滑轮上的传动带，所述传动带滑轮通过直流电动机控制。
6.如权利要求1所述的用于制造复合烛芯的系统，其还包括用于将所述复合芯切割到所要长度的切割管。
7.如权利要求5所述的用于制造复合烛芯的系统，其中所述压缩装置与所述传动带相互作用以将压力施加给所述布芯和所述木芯。
8.如权利要求1所述的用于制造复合烛芯的系统，其中所述布芯涂布有可熔化材料，所述可熔化材料在熔化时便于所述布芯粘附到所述木芯。
9.一种用于制造复合烛芯的方法，其包括以下步骤：
加热平面木芯；
将涂布有可熔化材料的布芯放置到邻近于所述平面芯的平面；
向所述平面木芯和所述布芯施加压力以使所述布芯粘附到所述平面木芯构造。
10.如权利要求9所述的用于制造复合烛芯的方法，其中所述施加压力的步骤包括：
将所述平面芯定位在传动带上且以平行方式将所述棉芯搁在所述木芯上；
使所述木芯和所述布芯从压缩轮与所述传动带之间通过以使所述布芯粘附到所述平面木芯。
11.如权利要求9所述的用于制造复合烛芯的方法，其还包括将由所述木芯和所述布芯制成的所述复合芯切割到所要长度。
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