Refillable container with a zero waste dispensing system

Abstract

The refillable container ( 20 ) includes a semi-rigid outer shell ( 22 ) that defines an interior void ( 24 ) and includes a detachable pour spout ( 26 ). The container ( 20 ) may be refilled with a plurality of collapsible inserts ( 32 ). Instead of rigid beverage bottles and other flowable substance containers, the collapsible inserts ( 32 ) may be transported from a manufacturing to a filling facility in a collapsed state ( 76 ), and do not have to include semi-rigid materials thereby minimizing disposal requirements. A tilt-pouring embodiment ( 20 ), a helical track embodiment ( 100 ), a helical axle embodiment ( 240 ) and an air-bladder embodiment ( 300 ) of refillable containers having common components permit dispensing of products from the containers ( 20, 100, 240, 300 ) to achieve virtually zero waste of the products.

1 : A refillable container with a zero waste dispensing system, the container comprising:
 a. a semi-rigid outer shell defining an interior void and including a pour spout adjacent a top end of the shell and a top end of the interior void;   b. a collapsible insert dimensioned to be selectively secured within the semi-rigid outer shell and removed from the semi-rigid outer shell, the collapsible insert including a securing coupler affixed to a top end of the insert and configured to be secured to the pour spout of the semi-rigid outer shell, and the securing coupler also forming a fill fitting configured to mate with an automated filler before the collapsible insert is positioned within the semi-rigid outer shell; and,   c. a base fixture secured to a bottom end of the collapsible insert opposed to the top end of the insert, the base fixture configured to engage and be selectively secured to a bottom end of the shell to prevent the collapsible insert from collapsing during pouring of a substance within the collapsible insert out of the insert through the securing coupler and pour spout of the shell, the secured base fixture thereby providing zero waste while the substance is poured out of the collapsible insert.   
     
     
         2 : The refillable container ( 20 ) of  claim 1 , further comprising a base fixture ( 42 ) secured to a bottom end ( 44 ) of the collapsible insert ( 32 ) opposed to the top end ( 36 ) of the insert ( 32 ), the base fixture ( 42 ) configured to engage and be selectively secured to a bottom end ( 46 ) of the shell ( 22 ) to prevent the collapsible insert ( 32 ) from collapsing during pouring of a substance within the collapsible insert ( 32 ) out of the insert ( 32 ) through the securing coupler ( 34 ) and pour spout ( 26 ) of the shell ( 22 ), the secured base fixture ( 42 ) thereby providing zero waste while the substance is poured out of the collapsible insert ( 32 ). 
     
     
         3 : The refillable container ( 20 ) of  claim 2 , wherein the base fixture ( 42 ) is configured to engage and be selectively secured to a top surface ( 77 ) of a holding tray ( 78 ) for securing a plurality of collapsible inserts ( 32 ) during transportation and filling of the collapsible inserts ( 32 ), and wherein the collapsible inserts ( 32 ) are configured to be secured to the holding tray ( 78 ) in a collapsed mode ( 76 ) during transportation of the collapsible inserts ( 32 ). 
     
     
         4 : The refillable container ( 20 ) of  claim 3 , wherein the securing couplers ( 34 ) of the plurality of collapsible inserts ( 32 ) are configured to engage and to be selectively secured to a bottom surface ( 79 ) of the holding tray ( 78 ). 
     
     
         5 : The refillable container ( 20 ) of  claim 3 , wherein the plurality of collapsible inserts ( 32 ) are secured adjacent each other in a side-by-side arrangement ( 76 ), and wherein the securing couplers ( 34 ) of each of the plurality of collapsible inserts ( 32 ) are configured to mechanically engage a lift device ( 84 ) for lifting the collapsible inserts ( 32 ) from a collapsed position to an expanded position. 
     
     
         6 : The refillable container ( 20 ) of  claim 1 , wherein the pour spout ( 26 ) is configured to slidably engage the securing coupler ( 34 ) of the collapsible insert ( 32 ) to secure the collapsible insert ( 32 ) within the interior void ( 24 ) of the semi-rigid outer shell ( 22 ). 
     
     
         7 : The refillable container ( 100 ) of  claim 1 , further comprising:
 a. at least one helical track ( 124 ) defined upon an inside surface ( 122 ) of the semi-rigid outer shell ( 102 ) so that the helical track ( 124 ) revolves about the outer shell ( 102 ) from adjacent a shell base ( 102 ) upward to pass adjacent the top end ( 107 ) of the shell;   b. an elevator platform ( 114 ) secured within the outer shell ( 102 ), the elevator platform including at least one pin ( 1 . 32 ) extending into a track follower ( 134 ), the track follower ( 134 ) being slidably secured to the helical track ( 124 ); and,   c. a drive mechanism ( 180 ) secured within the detachable discharge cap ( 106 ) and mechanically engaged with the semi-rigid outer shell ( 102 ) whenever the discharge cap ( 106 ) is attached to the outer shell ( 102 ) for rotating the outer shell ( 102 ) relative to the discharge cap ( 106 ) to move the pin ( 132 ) of the elevator platform ( 114 ) and the track follower ( 134 ) along the helical track ( 124 ).   
     
     
         8 : The refillable container ( 100 ) of  claim 7 , further comprising a ratchet mechanism ( 168 ) mechanically secured to the drive mechanism ( 180 ) to permit only one-way, incremental rotation of the semi-rigid outer shell ( 102 ) relative to the discharge cap ( 106 ). 
     
     
         9 : The refillable container ( 100 ) of  claim 8 , wherein the at least one helical track ( 124 ) forms an endless loop from a place of beginning ( 128 ) adjacent the shell base ( 120 ) and ascends toward the top end ( 107 ) of the outer shell ( 102 ) through multiple revolutions about the inside surface ( 122 ) of the outer shell ( 102 ) and the at least one helical track ( 124 ) descends from adjacent the top end ( 107 ) of the outer shell ( 102 ) back to the place of beginning ( 128 ) through less than one revolution about the inside surface ( 122 ). 
     
     
         10 : The refillable container ( 100 ) of  claim 8 , wherein the container ( 100 ) further comprises a compression layer ( 138 ) secured between the elevator platform ( 114 ) and the collapsible insert ( 110 ) that applies constant pressure forcing the collapsible insert ( 110 ) toward the top end ( 107 ) of the outer shell ( 102 ). 
     
     
         11 : The refillable container ( 100 ) of  claim 8 , further comprising at least one alignment post ( 116 ) extending from the shell base ( 120 ) through the elevator platform ( 114 ) to the discharge cap ( 106 ) to prohibit rotation of the elevator platform ( 114 ) relative to the discharge cap ( 106 ). 
     
     
         12 : The refillable container ( 100 ) of  claim 8 , wherein the discharge cap ( 106 ) includes a twist spout ( 182 ) mechanically linked to the drive mechanism ( 180 ) so that rotation of the twist spout ( 182 ) rotates one of the outer shell ( 102 ) and the elevator platform ( 114 ). 
     
     
         13 : The refillable container ( 100 ) of  claim 8 , further comprising one of the discharge cap ( 106 ) having a twist spout ( 182 ), a second discharge cap ( 140 ) having an outer cap measuring cup ( 142 ), a third discharge cap ( 148 ) having a spray nozzle ( 150 ) and an on/off valve ( 152 ), a forth discharge cap ( 156 ) including a wide-mouth outlet ( 158 ). 
     
     
         14 : The refillable container ( 100 ) of  claim 8 , wherein the semi-rigid outer shell ( 102 ) includes an integral handle ( 1 . 64 ) with a trigger ( 166 ) extending from the handle ( 164 ) and mechanically linked to the drive mechanism ( 180 ). 
     
     
         15 : A refillable container ( 240 ,  300 ), the container comprising:
 a. a semi-rigid outer shell ( 242 ,  242 ′) defining an interior void ( 244 ,  244 ′) and including a detachable pour spout ( 246 ,  246 ′);   b. a collapsible insert ( 250 ,  250 ′) dimensioned to be selectively secured within the semi-rigid outer shell ( 242 ,  242 ′) and removed from the semi-rigid outer shell ( 242 ,  242 ′), the collapsible insert ( 250 ,  250 ′) including a securing coupler ( 251 ,  251 ′) affixed to the insert ( 250 ,  250 ′) and configured to mechanically engage the pour spout ( 246 ,  246 ′) of the semi-rigid outer shell ( 242 ,  242 ′); and,   c. side-force extraction apparatus ( 266 ,  268 ,  310 ,  312 ) secured within the interior void ( 244 ,  244 ′) and configured to selectively assert compressive force upon the collapsible insert ( 250 ,  250 ′) secured adjacent the side-force extraction apparatus ( 266 ,  268 ,  310 ,  312 ).   
     
     
         16 : The refillable container ( 240 ,  240 ′) of  claim 15 , wherein the semi-rigid outer shell ( 242 ,  242 ′) is secured between a first pivot base ( 256 ,  256 ′) and a second pivot base ( 258 ,  258 ′) to permit pivoting of the outer shell. ( 242 ,  242 ′) between a dispensing mode and a refill mode. 
     
     
         17 : The refillable container ( 240 ) of  claim 15 , wherein the side-force extraction apparatus ( 266 ,  268 ) include at least one of a first compression plate ( 266 ) and a second compression plate ( 268 ) adjustably secured to at least one of a first helical axle ( 270 ) and a second helical axle ( 272 ), wherein the at least one of the first helical axle ( 270 ) and the second helical axle ( 272 ), is secured between a first cover plate ( 274 ) and an opposed second cover plate ( 276 ) and is mechanically engaged with a driver gear ( 278 ) and a ratchet mechanism ( 168 ) so that rotation of the driver gear ( 278 ) rotates the at least one of the first helical axle ( 270 ) and the second helical axle ( 272 ) to move the at least one of the first compression plate ( 266 ) and the second compression plate ( 268 ) toward the collapsible insert ( 250 ). 
     
     
         18 : The refillable container ( 240 ′) of  claim 15 , wherein the side-force extraction apparatus ( 310 ,  312 ) includes at least one of a first air bladder ( 310 ) secured between a first side wall ( 302 ) and a first compression plate ( 306 ) and a second air bladder ( 312 ) secured between a second side wall ( 304 ) and a second compression plate ( 308 ), and a fluid pump control apparatus and pump actuator ( 314 ) configured for selectively admitting a fluid into the at least one of the first air bladder ( 310 ) and the second air bladder ( 312 ) to move the at least one of a first compression plate ( 306 ) and a second compression plate ( 308 ) toward the collapsible insert ( 250 ′). 
     
     
         19 : A method of manufacturing collapsible inserts ( 32 ,  110 ) of  claim 1 , the method including:
 a. joining a predetermined number of securing couplers ( 34 ,  112 ) to a same predetermined number of flexible bodies ( 50 ) to form a predetermined number of joined collapsible inserts ( 32 ,  110 ), wherein the collapsible inserts  32 ,  110 ) are configured to contain a product, and are configured to be secured to each other in a side-by-side arrangement;   b. securing the predetermined number of joined collapsible inserts ( 32 ,  110 ) within a top surface ( 77 ) of a holding tray ( 78 );   c. collapsing the predetermined number of joined collapsible inserts ( 32 ,  110 ) unto the top surface ( 77 ) of the holding tray ( 78 ) to form a first set of collapsed collapsible inserts ( 80 ); and,   d. transporting the first set of collapsed collapsible inserts ( 80 ) on the holding tray ( 78 ) from a place of manufacture of the first set ( 80 ) to a place of filling the first set of collapsible inserts ( 80 ).   
     
     
         20 : The method of manufacturing collapsible inserts ( 32 ,  110 ) of  claim 19 , further comprising, after the transporting the first set of collapsed collapsible inserts ( 80 ) to the place of filling step, engaging a lift device ( 84 ) with the securing couplers ( 34 ,  112 ) of the first set of collapsible inserts ( 80 ) to expand the inserts ( 80 ) from a collapsed position to an expanded position, and then inserting an automated fill device ( 40 ) through the securing couplers ( 34 ,  112 ) to fill the collapsible inserts ( 32 ,  110 ) with a product while the collapsible inserts ( 32 ,  110 ) remain secured within the holding tray ( 78 ).