US3886252A - Method of making a wax candle replica - Google Patents

Abstract

A wax candle shell is molded in the exact replica of a master article. The shell is partially filled with a flame consumable fill wax, and a wick is provided to burn the fill wax. The wax shell is made by a process that includes making a silicone rubber mold, pouring molten wax into the mold, and while the wax cools, rotating the mold in a manner that causes the wax to form a shell having the shape of the mold cavity. The wax shell is removed from the mold and given a decorative organic finish that has a permanent antiquing appearance.

Description

United States Patent Eker et al. 1 May 27, 1975 54} METHOD or MAKING A WAX CANDLE 3,641,228 2/1972 Fleck .1 264/225 REPLICA 3,678,987 7/1972 Kydd 264/225 5.739.051 6/1973 Smith 264/225 Inventors: James E. Eker; Everett Weidner,

both of Woodward, Okla.

Pioneer Arts 81 Crafts, lnc., Woodward, Okla.

Filed: Sept. 7, 1973 Appl. No.: 395,378

Assignee:

US. Cl. 264/225; 264/69; 264/132; 264/152; 264/255; 264/310; 431/288 Int. Cl. B29c 1/02 Field of Search 264/220, 225, 222, 255, 264/130, 310', 431/288 References Cited UNITED STATES PATENTS 10/1936 Gastel 431/288 5/1960 Taccone 264/220 Primary ExaminerRobert F. White Assistant ExaminerT. E. Balhoff Attorney, Agent, or Firm-Dunlap & Codding [57] ABSTRACT A wax candle shell is molded in the exact replica of a master article. The shell is partially filled with a flame consumable fill wax, and a wick is provided to burn the till wax. The wax shell is made by a process that includes making a silicone rubber mold, pouring molten wax into the mold, and while the wax cools, rotating the mold in a manner that causes the wax to form a shell having the shape of the mold cavity. The wax shell is removed from the mold and given a decorative organic finish that has a permanent antiquing appearance.

3 Claims, 20 Drawing Figures PATENTEBHAY 2 7 1915 SHEET PATENTEDHAY 27 I875 FIT-IL:

SHEET PATENTEDHAY 27 ms Jr: a.

1rq !--J SHEET PATENTEUHAY 27 i975 IL-A- l j SHEET 14A F1 III.

1 METHOD OF MAKING A WAX CANDLE REPLICA BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to candles. and specifically to candles having a decorative shell containing a flame supporting fill wax.

2. Description of the Prior Art Candles have long been the object of artistic craftsmanship, evolving from early day utilitarian objects to present day artistry. Early day candles were regarded chiefly as a source of light and to some extent, heat. It was simply that candles were of necessity looked upon as items of consumption. Candles also have long served to vaporize chemicals to give pleasant or medicinal aromas and scents, and today candles are available in a wide range of aromatic flavors.

Beyond the utilitarian role of candles, it was early noted that wax, like clay, can be sculptured by artisan effort into shapes the limit of which is bounded only by the imagination. Perhaps because candles lacked the permanency ofmetal or stone, such sculpture remained relatively rare until techniques of late have developed that reduce the amount of skill required to transfer expressions of art into the form of candles.

Many decorative candle designs have been conceived, such as: candles having the shape of flowers with delicately made petals, bejeweled or sequined candles; multiple part candles having refillable cores or cartridges. designed to preserve the exterior portion of the candle; special waxes and additives for such purposes as controlling the rate of burning and the evenness of consumption; and numerous other developments which have enhanced candles as objects of art. It should be noted that along with making a beautiful candle goes the problem of how to burn it while maintaining its shape.

The molding of candles permits candles to be made in the shape of almost any container, and today one finds a wide variety of shapes and styles of candles commercially available. However, simple wax molding has limitations in that the candle mold itself must be crafted if it is to yield a unique and creative candle embellished with a high quality of engraving or embossment. It is undeniably difficult to create elaborate artwork on the face of a mold cavity, and the making of candle replicas of existing works of art has heretofor not been possible without great expense in engraving the mold cavity. Furthermore, such costs increase greatly if a candle mold is constructed so that the molded candle will have both exterior and interior details of sculpture.

Even when a candlemaker has invested in high quality molds to produce sculptured candles, production methods have often produced less than desired quality. Problems with non-uniform wax distribution in molds lead to stratification or variable density candles. This and other production problems have generally come to mean that a high production line output of candles means low quality; with superior results achievable only by high labor input for highly ornate candles.

Another problem faced by candlemakers is the lack of a means to provide permanent finishes due to the nature of the candle surface. Thus, many finish techniques are unavailable to candlemaking, an example of which is permanent antique finishes. The available an tique finishes have a tendency to just rub off.

SUMMARY or THE INVENTION The present invention relates to the replication of candles having the exact configuration of a sculptured or pattern bearing art master. A mold having a cavity with the exact likeness of the art master is made by the use of silicone rubber mold making materials. The mold has a top that permits the forming of the sculpture details on the interior surfaces as well as on the outside of the candle. Wax at molten temperature is poured into the cavity and the mold is caused to rotate continuously during cooling of the wax so as to form a uniform shell in the outline of the surfaces of the cavity. The wax shell is removed from the cavity and becomes the container for the fill wax or inner core. The surfaces of the wax shell are further decorated as by the application of organic coatings and antiquing.

It is therefore a general object of the present invention to provide a candle having the shape and patterns of an art masterv Another object of the present invention is to provide a method of molding a candle in the exact replica of an art master so as to produce replica candles having highly ornate surfaces.

Another object of the present invention is to provide the replication of art masters in the form of candles on a production basis with higher quality and low unit cost.

Another object of the present invention is to provide a molded, highly ornate candle having a refillable flame consumable core and a relatively high melting point wax shell so as to prolong the life of the ornate wax shell of the candle.

Another object of the present invention is to provide an ornate candle having an organic antique finish.

Other objects, features and advantages of the present invention will be apparent to those skilled in the art from the following detailed description of presently preferred embodiments of the invention given for the purpose of disclosure when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows an art master vase to be replicated in wax by the present invention.

FIG. 2 is a cut-away of the art master of FIG. I with a plug inserted.

FIG. 3a shows the art master vase of FIG. 2 inverted. FIG. 3b views a mother mold placed about the art master and plug. FIG. 3c depicts the pouring of mold forming material. FIG. 3d is a partial cut-away viewing the cured mold.

FIG. 4 shows the mother mold displaced on the mold.

FIG. 5 is a cut-away of vase 10 having another plug inserted.

FIG. 6 depicts the forming of the mold top.

FIG. 7 shows the mold and its top.

FIG. 8 shows a cross-sectional view of the mold and mold top in place, revealing the shape of the cavity.

FIG. 9 depicts molten wax being ladeled into the mold cavity.

FIG. 10 shows a rotating and oscillating apparatus.

FIG. 11 is a view of the plenum apparatus used to expedite wax cooling.

FIG. 12 shows the wax shell molded in the image of the art master of FIG. I.

FIG. 13 depicts the wax shell being given an ornamental organic coating while rotating on a rotary table. FIG. 14a is a cross-sectional view of the wax shell with a fill wax; FIG. 14b shows the insertion of a wire into the semi-cooled fill wax; and FIG. 14:" shows the wick placement and final fill wax pouring into the wax shell.

FIG. 15 is a candle replica of a miniature football.

DESCRIPTION OF PREFERRED EMBODIMENTS Referring to the drawings, and particularly to FIG. I, there is shown an ornamental vase which will serve as an art master to be replicated as a candle by the present invention, the vase generally designated by the numeral 10. It will become apparent from the description that follows, that a great variety of articles may be used as art masters for making replica candles by the application of the present invention. As used herein, the term replicate means to make multiple replicas of art master 10.

It should be noted that the vase 10 in FIG. 1 has ornamental designs 12 embossed into the wall 14, on both exterior surfaces 16 and interior surface 18. The top of vase 10 has scalloped shaped protrusions 20 forming a part of its design. As was stated above, it is an object of the present invention to make candles in the image of vase 10 and other art masters in a manner that will capture every detail of the ornamental designs 12 as well as the shape of vase 10 to include the protrusions 20.

In FIG. 2, a wood plug 21 has been inserted into hollow 22 of vase 10 such that plug 21 has a protruding portion 24, the purpose of which will become clear below. The length of plug 21 may vary and can be adjusted in a manner that will become apparent below. Plug 21 should be made so that it will substantially fill the hollow 22 in such a way as to be firmly inserted but without damaging the art master. It has been found that the protruding portion 24 should extend approximately one inch from the top of the art master 10. Plug 21 is shaped to closely approximate the dimensions of hollow 22, but there is no need for extreme accuracy in shaping plug 21. Many articles which can serve as art masters for the application of the present invention will have sloping interior walls, and it will usually be sufficient to fill the space 26 between interior surface 18 and plug 21 with a sealant such as clay 28, which also serves to secure plug 21 in the hollow 22.

At this point, it should be stated that while hollow vase 10 has been selected for illustration, it will be understood that the present invention does not require that the art master be hollow. If the art master is not hollow, it will be understood by persons skilled in the art that an alternative method of connecting plug 20, or a similar plug, to an art master will be quickly determinable, such as by the use of adhesive material. The fact that an art master is solid places no impediment in the production of candle replicas by the present invention, but of course, only the details of external design will be replicated.

As shown in FIG. 3a, vase 10 is placed upside down and supported by plug 21 on flat plane 30, which is a Smooth surface such as glass. A mother mold 32 is placed over and about vase 10 so that mother mold 32 also rests upon plane 30, as can be seen in FIG. 3b. Mother mold 32 is an open ended cylinder that is to contain the mold forming material 34 that is at this point poured about vase 10, as shown in FIG. 3c, to

form a mold to be used to replicate vase 10. In the present case, mold forming material 34 is silicone rubber material curable at room temperature. This material, obtainable commercially from several manufacturing sources, is of the type represented by RTV-E silastic made by the Dow-Corning Company, Midland, Mich. The uncured silicone rubber material should be allowed to set at room temperatures for approximately 36 hours following mixing and pouring into mother mold 32. It will be understood that the curing of the mold forming substance 34, that is silicone rubber, will form a resilient mold 36 having its external shape corresponding to the internal dimensions of mother mold 32 and a cavity 38 outlining master article or vase l0 and plug 21, as shown by the partial cutaway in FIG. 3d.

Continuing a description of the mold making process, FIG. 4 shows mother mold 32 and its contents, following the curing cycle, turned over so that vase 10 is in an upright position, and plug 21 is removed. Mold 36 is moved axially in relation to mother mold 32 so that the top edge 40 of mother mold 32 is positioned above top surface 42 of mold 36 at an appropriate distance D. It has been found that a value of three fourths of an inch is satisfactory for the distance D. As will become clear below, distance D will determine the thickness of the top of the second portion of the mold in the present invention.

At this point, a second plug 44 is inserted into hollow 22 of vase 10 as depicted in FIG. 5. For purposes of clarity of illustration, the vase 10 is shown in FIG. 5 as being removed from mold 36. It will be understood that vase 10 need not be removed from base 36 for the insertion of wood plug 44. The shape and dimensions of wood plug 44 at ends 46 are as have been discussed for plug 21, and clay 28 again seals the inner wall space 26 between plug 44 and vase 10. End 48 of plug 44 is smaller in diameter such that shoulder 50 is formed between end 46 and end 48. Plug 44 is inserted into hollow 22 to a depth so that shoulder 50 is placed below the lowest portion of wall 14 and all of protrusions 20 will rise above shoulder 50.

Returning now to a description of vase 10 as it is positioned in mold 36, the next and final step of making the mold in the present invention is shown in FIG. 6 where more mold forming substance 34 is poured into the upper part of mother mold 32 so as to enclose end 48 of plug 44. Prior to the step of pouring mold forming substance 32, it is advisable to spray surface 42 of mold 36 with a commercially available mold release material. It has been found that most silicone spray materials available in local hardware stores are sufficient for use as a mold release. As was used to make mold 36, Dow- Corning RTV-E silastic is used for mold forming substance 34 as illustrated in FIG. 6. Again, the mold forming substance 34 is permitted to stand for approximately 36 hours at room temperature to cure. It will be understood that upon setting, a resilient mold top 52 will be formed, as viewed in FIG. 7 which shows the mold 36 and top mold 52 removed from mother mold 32. Also, the vase l0 and plug 44 have been removed. In FIG. 7, mold 36 has been split along its axis to facilitate the removal of vase 10, a step that is necessary when the shape of the art master is too tight to retrieve readily from mold 36.

FIG. 8 shows a cut-away sectional of mold top 52 placed on top of mold 36 as will be the position of the two ends making the replica candle as discussed below. The purpose of FIG. 8 is to show the shape of cavity 38 as is formed and restricted by the molds 36 and mold top 52. It will be noted that the top of cavity 38 are found cavity portion 54 formed between surface 56 of cavity 38 and surface 58 of mold top 52. These cavity portions 54 being the top portion of cavity 38. they outline with specific detail the scalloped protrusions 20 of vase l0, and as will be made clear below. permit the forming of the replica candle made by the present invention to have exact shape and details of the scalloped protrusions 20.

At this point in the description, the mold 36 and mold top 52 have been discussed in detail. The next step is to band these two together so as to prevent leakage. This may be done by using elastic bands 56 around the circumference of mold 36. Mold top 52 is placed on top of mold 36 and secured by the use of elastic bands 56. As shown in FIG. 9, molten wax is poured into mold 36 from a ladle 60 so as to fill cavity 38 approximately half full. Wax 58 will be described in more detail below. It is sufficient to state at this point that wax 58 is heated to a temperature of approximately 250 F. prior to pouring it into cavity 38.

Plug 60 is inserted into the hollow center 53 of mold top 52 for sealing purposes. This is done just as a precaution because of the high temperature of molten wax S8, and as no leakage of wax 58 is usually incurred, plug 60 need be only of approximate dimensions.

Mold 36 is now rotated while wax 58 is molten and during the time of the cooling thereof, so that the wax 58 is caused to fill cavity 38 and cavity portions 54. R tation may be achieved in a number of ways. one such method being by the use of a centrifuge. However, it has been found that a very good and inexpensive method is by the apparatus 70 shown in FIG. I0. The apparatus 70 is comprised of roller sub-assembly 72 and oscillating gear assembly 74. Shaft 76 attaches to base 78 of roller sub-assembly 72 and is drivingly oscillated by oscillating gear assembly 74, the latter being of conventional design and therefore will not be described in detail. Attached to base 78 are frame members 80 which are parallel to each other. Roller subassembly 72 has a general configuration of well-known conveyors, and it will not be necessary to describe it in more than a general terms. It is sufficient to say that roller sub-assembly 72 is comprised of several rollers 82 bearingly journaled and spanned between the frame members 80 so that the rollers 82 are able to rotate in the same manner as do the rollers of a conveyor. Drive sprockets 84 are attached to the arbors 86 of some of the rollers 22 as shown in FIG. 10. As a practical matter, since the object of these sprockets is to rotate rollers 82, it is sufficient to provide sprockets 84 at every fourth roller 82. At one end of sub-assembly 72 is lo cated electric motor 88. Connected to the power shaft 90 of electric motor 88 is power sprocket 92. Connecting power sprocket 92 and the sprockets 84 are a number of endless chains 94.

In operation, apparatus 70 operates as follows. The oscillating gear drive 74 operates on shaft 76 so as to cause the entire roller sub-assembly 72 to pivot and oscillate about centerline 96. At the same time, electric motor 88 through shaft 90 drives power sprocket 92 and thus the endless chains 94 to continuously rotate the rollers 82 that are connected thereto. The molds 36 set nestled by two adjacent rollers 82 as shown in FIG.

l0 and are thereby caused to both rotate and oscillate. Having described an apparatus suitable for rotating and oscillatingly tilting mold 26 with mold top 52, the description herein once again will return to the point of the process where the molten wax 58 has been poured into cavity 38, as shown in FIG. 9 and discussed above. Immediately after molten wax 58 is poured into cavity 38 and plug 60 is placed into the hollow center 53 of top mold 52, the mold is placed onto the roller subassembly as shown in FIG. I0. As apparatus 70 causes the mold and contents to simultaneously rotate and oscillatingly tilt. the wax 58 is cooling. It has been found that sufficient cooling of the wax 58 will occur within two to five minutes so that the mold 36 may be removed from the operation of apparatus 70 after that time. The point is to permit sufficient time for the wax 58 to solidify at the surfaces of cavity 38 so as to com pletely imitate every surface detail.

The mold 36 may then be set upright and allowed to cool. This cooling is expedited by the apparatus shown in FIG. 11. The cooling device generally designated I00, is comprised ofa conventional airblower 102 connected to a box plenum 104. It is sufficient to say that the plenum is a box type structure that receives air at a slightly increased pressure from air blower 102. Pro vided at the bottom of plenum 104 are a series of apertures 106, each of which has a flexible cloth tube 108 hanging therefrom. Shown beneath the plenum in FIG. 11 are several molds 36, placed in position so that a cloth tube 108 is in air communication between the plenum and the cavity 38. This allows a constant air circulation to be effected within cavity 38 for faster cooling. It is recognized that other means of cooling could be effected such as refrigeration. but it is important that wax 58 be cooled naturally without subjection to abrupt cooling in order to minimize the possibility of shock resulting in cracks in the solidified wax 58. It has been found that the cooling device 100 will cool the wax 58 in mold 36 to approximately room temperature in a residence time under the plenum 104 of five to ten minutes. Following this, the wax can be removed from the mold.

Shown in FIG. 12 is the wax shell 110 formed by the cooling of molten wax 58 within the cavity 38 of mold 36 as subjected to the process as described above. The wax shell I is in the exact image and physical size of the art master which in this case is vase l0. Wax shell 110 has a hollow portion 112 and a fill line I14. It has scalloped protrusions exactly corresponding to the scalloped protrusions of vase 10. The exterior wall 118 is shaped exactly like exterior wall 16 of vase 10, bearing every detail of ornamentation of the exterior surface 16. The interior surface I22 of wall 120, above the fill line 114, also bears every ornamental detail of its counterpart, interior surface 18 of vase 10. The fill line I14 corresponds to the depth of which the shoulder 50 of plug 44 was placed in vase 10 during the steps of molding the mold top 52, discussed above. It will be obvious to a person skilled in the art that fill line 114 can be established as desired. As will be made clear below, fill line I14 will not be visible in the finished edition of the replica candle.

Wax shell 110 as it is removed from mold 36 is of the color that wax S8 naturally has, and it will be understood by those skilled in the art of candle making. a color additive may be placed in wax 58 to create virtually any color desired for wax shell I10. In an effort to further enhance the appearance of exterior surface 118 of wax shell H0, it has been found that an antique firiish will improve and beautify wax shell I10 regardless of the selected color. The antique finish will be applied as follows.

The wax shell 110 is placed on a rotary table 130 as diagrammatically depicted in FlG. l3 and rotated about its base. At this point. wax shell receives a series of organic coatings by the conventional spray guns l32 and 134. While the wax shell H0 is rotated at approximately 50 rpm, spray gun l32 first causes to be sprayed upon the exterior surface 116 a clear acrylic lacquer spray 136 in continuous application. After ap proximately four rotations of wax shell 110 in acrylic spray 136. a very fine black spray mist 138 is cornmenced from spray gun 134 while the acrylic lacquer spray 136 continues. Approximately one rotation of wax shelf 110 in the black spray mist 138 is a sufficient application of the black lacquer. At this time, spray gun 134 ceases to spray, and spray gun I32 continues to spray acrylic lacquer spray 136 for an additional four rotations of wax shell 110 on rotary table 130. The number of rotations given here are examples of actual runs for the type of product described in the process above. That is, these values are applicable for a wax shell in the shape of the vase 10. It is within the range of experimentation for a person skilled in the art to establish the number of turns required, and these relative rotations may easily be adjusted according to a number of variables, such as spray gun performance, rotation of the wax shell, room temperature and humidity of the ambient air.

immediately following the rotations of the wax shell described in the preceding paragraph, wax shell 110 is removed from rotary table 130 and gently wiped with a cloth so as to remove excess lacquer and to streak the black lacquer as will be recognized by a person skilled in the art of antique finishing. Wax shell 110 is then allowed to dry at room temperature in a dust free environment. The dried antique-lacquered finish gives an appearance of age and depth to the ornamental design of the wax shell 110, and the finish will be permanent. A further discussion of the lacquers used in the process described for the antiquing of wax shell 110 will be given below.

Among the final steps in making the replica candle of this invention is the filling of wax shell 110 with a flame consumable core such as fill wax 140. FIG. 14a is a cross-sectional view of wax shell 110 having received a first pouring of fill wax 140. Of course, it may be decided to use a flame consumable material which is a room temperature liquid to fill wax shell 110, and the only additional step in that case would be to place a wick or the like in some fashion in communication with the flame consumable liquid to produce a candle. A common method is to place a nonconsumable wick on a floating platform on top of the surface of the flameconsumable liquid. But if. as in illustration FIG. [40, a molten fill wax 140 has been poured into wax shell 110, additional steps will be required to properly provide a wick for the final candle.

Allowing the fill wax 140 to cool for approximately one hour, it has been discovered that a crust 142 will form at the surface uf fill wax 140. At this time, a rod or wire 144 is inserted through the crust to a depth to which the final wick is to be inserted. After wire 144 is inserted, the fill wax 140 is allowed to continue cooling until it solidifies. Following this, wire 144 is withdrawn and a wick 146 is easily inserted into the hole left by wire 144, the size of which was selected to facilitate wick insertion. See FlG. 14c. At this point, additional fill wax 140 at approximately the same molten temperature is poured into wax shell H0 because of the contraction of volume that occurs to wax 140 upon cooling. At this final pouring, fill wax 140 is poured so that its surface will be slightly above fill line 114. The hot fill wax 140 will again shrink. and it is the object to cause the surface of the final pouring of fill wax I40 to cover the till line 114. This allows the interior surface [22 which bears all the detail of ornamental design 112 of interior surface [8 to be displayed. while interior surfaces below fill line 4 are hidden.

The advantage of the two pour method of filling the wax shell 0 with fill wax 140 described above is that the wick 146 is easily positioned and held in place by the solidified wax during the the final pouring of fill wax 140. The hot liquid wax 140 of the final pour will fill around wick 146 so that it is firmly embedded in the fill wax.

Several points in the above discussion were referred to later discussion and it is at this point that these will be described in more detail. The description above has been toward the producing of a replica candle by the use of a two piece mold made from room temperature curable silicone rubber material. It will be obvious to a person skilled in the art in candlemaking, that the mold need not be made in two pieces if no detail of the interior surfaces of the art master are to be copied. The top piece, mold top 52 above, serves the purpose of forming the outline of the scalloped protrusions 20 of vase 10. If the top of the art master is regular and no particular attention is desired as to the interior detail, then the mold top need not be used, and the cavity can be covered in any convenient fashion during the rotation of the mold on rotary table 130. The discussion has also been toward the replication of candles from a hol low art master, such as vase l0. Mention was made that solid articles can be used as well. An example of this might be the replication in a candle wax of a rock. All that is necessary for applying the above process in order to obtain a perfect copy of the rocks shape, is to attach a plug at a point on the rock which is desired as the candle top. Once the mold is made in the manner described above, partially filling the mold with the mo]- ten wax to immediately be followed by rotating on roller apparatus will cause to be formed a perfect replica copy of the rocks shape. Sufficient hollow space will be left in wax shell replica of the rock to permit filling with a fill wax as above described.

The process herein disclosed is adaptable to the pro duction of replica candles in almost any shape. If the art master is not valuable and can be readily modified, other techniques of preparing the art master can be employed, as would be the case for making a replica candle in the image ofa miniature football. The miniature football replica candle is produced simply by obtaining a toy football having sufficient strength to hold its shape when deflated. By drilling a hole in the football at a point which will be the candles top, and placing a wood plug into the hole, a silicone rubber mold can be made by the process above. To add a support base, since the miniature football will be round, it is necessary only to glue :1 block of a suitable shape to the football at an appropriate point on the miniature footballs surface. This brief discussion is given simply to give an example of how easily adaptable is the process disclosed herein for making of replica candles of most shapes. The candle made in accordance with the example for the miniature football.

The replica candle of the present invention has been described as being made of a wax shell 110 having an inner core of fill wax 140 and a wick 146. It will be understood that the outer shell of the replica candle could as well be made of any substance amenable to the molding process described herein. In this case, wax has been used in order to create an all wax candle. Wax shell 110 is made by pouring molten wax 58 into mold cavity 38. While wax 58 may be selected from a large number of commercially available waxes, it has been found that Gulf Wax 55, available from Gulf Oil Corporation, is a very good wax for this purpose. If wax is to comprise both the wax shell and the inner core of the replica candle, it is desirable that the wax shell have a melting point exceeding that of the fill wax. Gulf Wax 55 has a melting point of approximately l55F. By add ing commercially available additives to this basic wax, the desired properties of melting form and consistency can be achieved for the wax shell. The art and science of candle additives is complex, and there are several commercial sources which provide the additives together with technical assistance to achieve the desired attributes of the wax used. It has been found that additives manufactured by the plastics division of Allied Chemical Company, Morristown, N..l., are suitable to provide the melting point and consistency required of the wax shell in the present invention. Referring to additives of Allied Chemical Company: to basic Gulf Wax 55 are added approximately of homopolymer AC-6; approximately 5% of copolymer AC-430; and approximately one-half of copolymer AC-400. The percentages recited are examples only, and the recommended procedure is to send a sample quantity of each batch of basic wax received to the commercial source vending the candle additives. The recommendation of technical tests performed upon the sample will vary the percentages given as well as the recommended additives themselves. It will be understood that this invention is not restricted by the type of wax as additives used, and this discussion has been included as an assist to the potential candlemaker.

The fill wax for the replica candle of the present invention, in this case is also Gulf Wax 55 as described above. As will be understood by those persons skilled in the art of candlemaking, additives are also available for the fill wax for such purposes as creating the aromatic properties such that the candle has a pleasant scent during burning. the addition of additives to cause the candle to glow during its burning; and additives to create desired colors in the wax shell and fill wax.

The antiquing process described above and illustrated in FIG. 13 requires the application of two organic coatings in order to achieve the desired streaking effect of the antiquing process. As was described above, the spraying from spray gun 132 is first initiated with the subsequent operation of spray gun 134 for approximately one rotation of rotary table 130. The purpose of the first spray. that is from spray gun 132, is to give the coating adhesion as well as body. This can be achieved using a number of paints, although it is preferable to use a clear spray so as to not counteract the effect of the dark spray. One product found acceptable is a clear acrylic sold under the trade name Spray Enamel, manufactured by Deshler Products Company. Deshler, Ohio. The content of this product is: 6.3% non-volatile acrylic resin; 32.5% aromatic hydrocarbons; 33.97: ketones and halogenated hydrocarbons: and 27.371 propane isobutane. As for the black spray 138, a product found suitable is also one made by the Deshler Products Company, sold under the trade name of Spray Enamel, and identified as Gloss Black 8036 (I3) comprised of: 1.07: carbon black; 4.0% tall oil alkyd resin; 5.07: soya alkyd resin; 2.071 ester gum phenolic resin; l/07r driers; 9.0% aliphatic hydrocarbons; 4.09? naptha; l.O7r alcohol; l4.0'7( toluene; 30.0% methylene chloride; and 29.0% propane isobutane.

From the above description, it is clear that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned as well as those inherent therein. While presently preferred embodiments in the invention have been described for purposes of this disclosure, numerous changes may be made which will readily suggest themselves to those skilled in the art and which are accomplished within the spirit of the invention disclosed and as defined in the appended claims.

What is claimed is: l. A method of making a wax candle replica ofa hollow art master, comprising the following steps:

making a silicone rubber mold having a cavity and having a bottom portion and a top portion, comprising the following steps: placing a first plug which is fittingly receivable in the hollow of the art master into the hollow so that the first plug protrudes from the hollow; placing a mother mold around the art master; pouring uncured silicone rubber mold-forming materials into the mother mold to cover the art master and a portion of the first plug; allowing the silicone rubber mold-forming material to cure to form the bottom portion of the silicone rubber mold; removing the first plug from the art master; placing a second plug into the hollow. said second plug having a first end fittingly receivable by the hollow of the art master and a second end smaller cross-sectionally than the first end, said first end being submerged in the hollow and the second end protruding therefrom; sliding the mother mold on the cured silicone rubber mold-forming material so that the mother mold is positioned so as to surround a portion of the second plug while continuing to contain a part of the bottom portion of the silicone rubber mold; pouring uncured silicone rubber mold-forming material into the mother mold so as to cover a portion of the second end of the second plug; allowing silicone rubber mold-forming material surrounding the second end of the second plug to cure so as to form the top portion of the mold; and, removing the mother mold from around the bottom portion and the top portion of the silicone rubber mold; attaching the top portion of the silicone rubber mold onto the bottom portion of the silicone rubber mold;

consumable material.

2. The method of claim 1 to include the step of spraying the top of the bottom portion of the silicone rubber mold with a mold release material prior to pouring uncured silicone rubber into the mother mold to cover a portion of the second end of the second plug.

3. The method of claim 1 wherein the flame consumable material is a wax having a melting point lower than the melting point of the wax forming the wax shellv k k k

Claims (3)

1. A METHOD OF MAKING A WAX CANDLE REPLICA OF A HOLLOW ART MASTER, COMPRISING THE FOLLOWING STEPS: MAKING A SILICONE RUBBER MOLD HAVING A CAVITY AND HAVING A BOTTOM PORTION AND A TOP PORTION, COMPRISING THE FOLLOWING STEPS: PLACING A FIRST PLUG WHICH IS FITTINGLY RECEIVABLE IN THE HOLLOW OF THE ART MASTER INTO THE HOLLOW SO THAT THE FIRST PLUG PROTRUDES FROM THE HOLLOW, PLACING A MOTHER MOLD AROUND THE ART MASTER, POURING UNCURED SILICONE RUBBER MOLD-FORMING MATERIALS INTO THE MOTHER MOLD TO COVER THE ART MASTER AND A PORTION OF THE FIRST PLUG, ALLOWING THE SILICONE RUBBER MOLD-FORMING MATERIAL TO CURE TO FORM THE BOTTOM PORTION OF THE SILICONE RUBBER MOLD, REMOVING THE FIRST PLUG FROM THE ART MASTER, PLACING A SECOND PLUG INTO THE HOLLOW, SAID SECOND PLUG HAVING A FIRST END FITTINGLY RECEIVABLE BY THE HOLLOW OF THE ART MASTER AND A SECOND END SMALLER CROSSSECTIONALLY THAN THE FIRST END, SAID FIRST END BEING SUBMERGED IN THE HOLLOW AND THE SECOND END PROTRUDING THEREFROM, SILIDING THE MOTHER MOLD ON THE CURED SILICONE RUBBER MOLD-FORMING MATERIAL SO THAT THE MOTHER MOLD IS POSITONED SO AS TO SURROUND A WHILE CONTINUING TO CONTAIN A PART OF THE BOTTOM PORTION OF THE SILICONE RUBBER MOLD, POURING UNCURED SILICONE RUBBER MOLD-FORMING MATERIAL INTO THE MOTHER MOLD SO AS TO COVER A PORTION OF THE SECOND END OF THE SECOND PLUG; ALLOWING SILICONE RUBBER MOLD-FORMING MATERIAL SURROUNDING THE SECOND END OF THE SECOND PLUG TO CURE SO AS TO FROM THE TOP PORTION OF THE MOLD, AND, REMOVING THE MOTHER MOLD FROM AROUND THE BOTTOM PORTION AND THE TO PORTION OF THE SILICONE RUBBER MOLD, ATTACHING THE TOP PORTION OF THE SILICONE RUBBER MOLD ONTO THE BOTTOM PORTION OF THE SILICONE RUBBER MOLD, PURING A MOLTEN WAX INTO THE MOLD TO PARTIALLY FILL THE SILICONE RUBBER MOLD, ALLOWING THE WAX TO COOL WHILE IMPARTING ROTATORY MOTION TO THE SILICONE RUBBER MOLD TO CAUSE THE WAX TO SOLIDIFY IN THE FROM OF A WAX SHELL AGAINST THE SURFACE OF THE CAVITY, REMOVING THE WAX SHELL FROM THE SILICONE RUBBER MOLD, PURING A FLAME CONSUBABLE MATERIAL INTO THE WAX SHELL, AND, PROVIDING WICK MEANS TO COMMUNICATE WITH THE FLAME COMSUMABLE MATERIAL.

2. The method of claim 1 to include the step of spraying the top of the bottom portion of the silicone rubber mold with a mold release material prior to pouring uncured silicone rubber into the mother mold to cover a portion of the second end of the second plug.

3. The method of claim 1 wherein the flame consumable material is a wax having a melting point lower than the melting point of the wax forming the wax shell.

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