Method of making an improved jar container

Abstract

An improved jar and method of making the same. The double walled jar comprises a single piece double walled container, bottom plug, and lid. The container comprises an inner wall structure with open top and a closed bottom. A shoulder portion extends from the outer surface of the inner structure. Sets of threads are located above the shoulder portion about the outer surface of the inner structure. An outer wall structure extends from the shoulder portion, forming a gap between the structures. The terminal end of the outer structure extends past the closed bottom and has a notched channel within the inner surface of the outer structure below the closed bottom. A bottom plug having a portion shaped for a snap fit into the notched channel is used to cover the bottom of the container. A lid is used to complete the container as a jar.

I claim:  
     
         1 . A double walled jar, the jar comprising: 
 a single piece double walled container, the container comprising: 
 an inner wall structure having an open top end and a closed bottom end;  
 an outer wall structure having a proximal end and a terminal end encircling the inner wall structure forming a gap between the inner wall structure and the outer wall structure, the gap between the inner wall structure and the outer wall structure being greater near the terminal end of the outer wall structure than near the proximal end of the outer wall structure, the terminal end extending past the closed bottom of the inner wall structure and having a notched channel within the inner surface of the outer wall structure located below the closed bottom of the inner wall structure;  
 a shoulder portion linking the inner wall structure with the outer wall structure extending continuously from and about the outer surface of the inner wall structure to the proximal end of the outer wall structure, the shoulder portion being the sole means of linking the inner wall structure and the outer wall structure;  
 a set of threads located above the shoulder portion and about the outer surface of the inner wall structure;  
 a bottom plug sized and shaped to fit within the area encircled by the outer wall structure having a portion sized and shaped for a snap fit into the notched channel within the inner surface of the outer wall structure; and  
 a lid sized and shaped to cover the open top end of the inner wall structure, the lid having a set of threads formed to fit in mating relationship with the set of threads located about the outer surface of the inner wall structure.  
   
     
     
         2 . The jar of  claim 1  wherein the notched channel is located within the inner surface of the outer wall structure such that a face of the bottom plug comes into contact with the closed bottom end when the bottom plug is snapped into the notched channel, the closed bottom providing support to the bottom plug.  
     
     
         3 . The jar of  claim 2  wherein the thickness of the outer wall structure and the thickness of the bottom plug have a relationship such that the bottom plug deflects along the long axis of the bottom plug as the bottom plug is pushed into the area encircled by the outer wall structure and returns to is original shape when the bottom plug snaps into the notched channel.  
     
     
         4 . The jar of  claim 3  further comprising a label placed in the gap between the inner wall structure and outer wall structure, the label held in place by the inner wall structure, outer wall structure and bottom plug.  
     
     
         5 . The jar of  claim 4  wherein the shoulder portion is a fluid tight seat for the lid when the lid is secured to the container.  
     
     
         6 . The jar of  claim 5  wherein the bottom plug is symmetrical about the long axis of the bottom plug.  
     
     
         7 . The jar of  claim 6  wherein the thickness of the inner wall structure is from about 0.035 inches to about 0.047 inches and the thickness of the outer wall structure is less than the thickness of the inner wall structure.  
     
     
         8 . The jar of  claim 7  wherein the bottom plug has at least one indexing lug providing a common point of reference for performing manufacturing processes on the bottom plug.  
     
     
         9 . A single piece double walled container in combination with a symmetrical bottom plug, the combination comprising: 
 a single piece double walled container having an inner wall structure with an open top end and a closed bottom end;    an outer wall structure having a proximal end and a terminal end encircling the inner wall structure forming a gap between the inner wall structure and the outer wall structure, the terminal end of the outer wall structure extending past the closed bottom of the inner wall structure and having a notched channel within the inner surface of the outer wall structure located below the closed bottom of the inner wall structure;    a shoulder portion linking the inner wall structure with the outer wall structure extending continuously from and about the outer surface of the inner wall structure to the proximal end of the outer wall structure, the shoulder portion being the sole means of linking the inner wall structure and the outer wall structure; and    a symmetrical bottom plug having a portion sized and shaped for insertion into the notched channel within the inner surface of the outer wall structure.    
     
     
         10 . The combination of  claim 9  wherein the notched channel is located within the inner surface of the outer wall structure such that a face of the bottom plug comes into contact with the closed bottom end when the bottom plug is inserted into the notched channel, the closed bottom end providing support to the bottom plug.  
     
     
         11 . The combination of  claim 10  wherein the gap between the inner wall structure and the outer wall structure being greater near the terminal end of the outer wall structure than near the proximal end of the outer wall structure  
     
     
         12 . The combination of  claim 11  further comprising a label placed in the gap between the inner wall structure and outer wall structure, the label held in place by the inner wall structure, outer wall structure and bottom plug.  
     
     
         13 . The combination of  claim 12  further comprising a set of threads located above the shoulder portion and about the outer surface of the inner wall structure.  
     
     
         14 . The combination of  claim 13  further comprising a lid sized and shaped to cover the open top end of the inner wall structure, the lid having a set threads formed to fit in mating relationship with the set of threads located about the outer surface of the inner wall structure.  
     
     
         15 . The combination of  claim 14  wherein the shoulder portion is a fluid tight seat for the lid when the lid is secured to the container.  
     
     
         16 . In a double walled injection molded plastic container having a gap between the inner wall and the outer wall, the improvement comprising: 
 forming the inner wall and outer wall out of one continuous piece of injection molded plastic;    extending the outer wall past the bottom of the container;    forming a notched channel within the inner surface of the outer wall located below the bottom of the container; and    inserting a bottom plug having a portion sized and shaped for a snap fit into the notched channel.    
     
     
         17 . The improved container of  claim 16  wherein the thickness of the inner wall is from about 0.035 inches to about 0.047 inches and the thickness of the outer wall is less than the thickness of the inner wall.  
     
     
         18 . The improved container of  claim 17  wherein the bottom plug is symmetrical about the long axis of the bottom plug.  
     
     
         19 . The improved container of  claim 18  further comprising at least one indexing lug providing a common point of reference for performing manufacturing process on the bottom plug.  
     
     
         20 . A method of manufacturing a single piece double walled container, the method comprising: 
 molding a single piece double walled container using a translucent synthetic plastic by forming a translucent inner wall structure with a closed bottom end and a translucent outer wall structure while forming the outer wall structure with a terminal end extending past the inner wall structure and a notched channel within the inner surface of the outer wall structure, the inner and outer translucent wall structure being left free of any interior obstructions there between enabling contents of the container to be clearly visible through the translucent inner and outer wall structures;    molding a bottom plug and sizing and shaping the bottom plug to fit within the area enclosed by the outer wall structure and forming a portion that is sized and shaped for insertion into the notched channel; and    inserting the bottom plug into the notched channel, the bottom plug deflecting along the long axis of the bottom plug as the bottom plug is pushed into the area encircled by the outer wall structure and returning to original shape upon seating into the notched channel.    
     
     
         21 . The method of manufacturing of  claim 20  wherein the molding of the bottom plug further comprises symmetrically forming the bottom plug about the long axis of the bottom plug.  
     
     
         22 . A single piece double walled container of translucent plastic providing unobstructed view of the contents of the container, the container comprising: 
 an inner wall structure having an open top end and a closed bottom end;    an outer wall structure having a proximal end and a terminal end encircling the inner wall structure forming a gap between the inner wall structure and the outer wall structure; and    a shoulder portion linking the inner wall structure with the outer wall structure extending continuously from and about the outer surface of the inner wall structure to the proximal end of the outer wall structure such that the viewing of the contents through the outer wall structure and the inner wall structure of the container is unobstructed.    
     
     
         23 . The single piece double walled container of  claim 22  wherein the shoulder portion is the sole means of linking the inner wall structure and the outer wall structure.  
     
     
         24 . The single piece double walled container of  claim 23  wherein the shoulder portion is a fluid tight seat for a lid when the lid is placed on the container.  
     
     
         25 . The single piece double walled container of  claim 24  wherein the outer wall structure extends past the closed bottom of the inner wall structure and further comprises a notched channel within the inner surface of the outer wall structure located below the closed bottom of the inner wall structure.  
     
     
         26 . The single piece double walled container of  claim 25  further comprising a bottom plug sized and shaped to fit within the area encircled by the outer wall structure having a portion sized and shaped for a snap fit into the notched channel within the inner surface of the outer wall structure.  
     
     
         27 . The single piece double walled container of  claim 26  further comprising a set of threads located above the shoulder portion and about the outer surface of the inner wall structure.  
     
     
         28 . The single piece double walled container of  claim 27  further comprising a label placed in the gap between the inner wall structure and outer wall structure, the label held in place by the inner wall structure, outer wall structure and bottom plug.  
     
     
         29 . A labeled double walled jar of translucent plastic, the jar comprising: 
 an inner wall structure having an open top end and a closed bottom end;    an outer wall structure having a proximal end and a terminal end encircling the inner wall structure forming a gap between the inner wall structure and the outer wall structure the terminal end extending past the closed bottom of the inner wall structure and having a notched channel within the inner surface of the outer wall structure located below the closed bottom of the inner wall structure;    a shoulder portion linking the inner wall structure with the outer wall structure extending continuously from and about the outer surface of the inner wall structure to the proximal end of the outer wall structure;    a bottom plug sized and shaped to fit within the area encircled by the outer wall structure having a portion sized and shaped for a snap fit into the notched channel within the inner surface of the outer wall structure; and    a label placed in the gap between the inner wall structure and outer wall structure, the label held in place by the inner wall structure, outer wall structure and bottom plug.    
     
     
         30 . The labeled double walled jar of  claim 29  wherein the notched channel is located within the inner surface of the outer wall structure such that a face of the bottom plug comes into contact with the closed bottom end when the bottom plug is snapped into the notched channel, the closed bottom providing support to the bottom plug.  
     
     
         31 . The labeled double walled jar of  claim 30  wherein the thickness of the outer wall structure and the thickness of the bottom plug have a relationship such that the bottom plug deflects along the long axis of the bottom plug as the bottom plug is pushed into the area encircled by the outer wall structure and returns to is original shape when the bottom plug snaps into the notched channel.  
     
     
         32 . The labeled double walled jar of  claim 31  wherein the shoulder portion is a fluid tight seat for the lid when the lid is secured to the container.  
     
     
         33 . The labeled double walled jar of  claim 32  wherein the bottom plug is symmetrical about the long axis of the bottom plug.  
     
     
         34 . The labeled double walled jar of  claim 33  wherein the thickness of the inner wall structure is from about 0.035 inches to about 0.047 inches and the thickness of the outer wall structure is less than the thickness of the inner wall structure.  
     
     
         35 . The labeled double walled jar of  claim 34  wherein the bottom plug has at least one indexing lug providing a common point of reference for performing manufacturing processes on the bottom plug.