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Title:
REFILLABLE CONTAINER WITH A ZERO WASTE DISPENSING SYSTEM
Document Type and Number:
WIPO Patent Application WO/2012/109525
Kind Code:
A2
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 (2:0), a helical track embodiment (100), a helical axle embodiment (240) and an air-bladder embodiment (300) o f refillable containers having common components permit dispensing of products from the containers (20, 100, 240, 300) to achieve virtually zero waste of the products.

Inventors:
DERBY STEPHEN (US)
MCFADDEN JOHN (US)
BROWN DAVID (US)
ECKERT EUGENE (US)
Application Number:
PCT/US2012/024620
Publication Date:
August 16, 2012
Filing Date:
February 10, 2012
Export Citation:
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Assignee:
DERBY STEPHEN (US)
MCFADDEN JOHN (US)
BROWN DAVID (US)
ECKERT EUGENE (US)
International Classes:
B65D8/04; B65D77/04; B65D25/18; B65D30/20; B65D69/00; B65D83/76
Domestic Patent References:
WO2002085749A12002-10-31
WO2004004529A12004-01-15
Foreign References:
US20080093378A12008-04-24
US20040118725A12004-06-24
US5490603A1996-02-13
Attorney, Agent or Firm:
CHISHOLM, Malcolm, J. (220 Main StreetLee, MA, US)
Download PDF:
Claims:
CLAIMS

Wh t is claimed la:

1. A refillable container (20, 100), the container comprising :

a. a semi-rigid outer shell (22, 102) defining an interior void (24, 104) and including one of a detachable pour spout (26) and a discharge cap (106) adjacent a top end «28, 10?) of the shell (22, 102) and a top end (30) of the interior void <24, 104);

b, a collapsible insert. (32, 110) dimensioned to bo selectively secured within the semi-rigid outer shell (22, 102) and cloved from the semi-rigid outer shell (22, 102), the collapsible insert (32, 110) including a securing coupler (34, 112) affixed to a top end (36) of the insert (32, 102} and configured to

mechanically engage one: cf the pour spout (26) and the discharge cap (106) of the semi-rigid outer shell (22, 102) , and the securing coupler (34, 112} also forming a fill fitting (34, 122) configured to mate with an automated tiller (40) before the collapsible insert (32, 110) is positioned within the send.-rig id outer shell (22, 102) .

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 hotter?*, 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) t the secured base fixture (42) thereby providing sero waste while the substance is poured out of the collapsible insert (32) .

3. The refiilahie 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 (75) during transportation of the collapsible inserts (32.) ,

4» The refiilabie container (20) of claim 3, wherein the securing couplers {34} ox the plurality of collapsible inserts {32} are configured to engage and to be selectively secured to a bottom surface (79) of the holding tray {73} .

5, The refillable container (20) of claim 3, wherein the plurality of collapsible inserts {32} are secured adjacent each other in a eide-by-side arrangement (76) , and -wherein the securing couplers (34} of each of the plurality of collapsible inserts (32) are configured to mechanics 11y engage a lift device (84) for lifting the collapsible inserts {3-2} from a collapsed position to an expanded position.

6. The refiilafole container (20) of claim .1, wherein the pour spout (26) is configured to siidabiy 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, he refillable container (100) of claim I, further comprisin :

a. at least one helical track {124 J defined upon an inside surface (122} of the seird-rigi outer shell {192} so that the helical track (124) revolves about the outer shell {102) from adjacen 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 {132} extending into a track follower {134), the track follower {134} being siidably 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 refiilabie container (100) of claim 7, further comprising a ratchet mechanism 0168} mechanically secured to the drive mechanism (ISO) to permit only one-way, incremental rotation of the semi-rigid outer shell (102) relative to the discharge cap (106)„

9. The refiilabie 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 (1025 and the at least one helical track (124) descends from adjacent the too end (107) of the oute shell (102) back to the place of beginning (128) through less than one revolution about the inside surface (122) *

10. The refiilabie container (100) of claim 8, wherein the con ainer (100) further comprises a compression layer (138) secured between the elevator platforrfi {114} and the collapsible insert (110) that applies constant pressure forcing the collapsible insert (110) toward the top end (10?) of the outer shell (102) .

11. The refiilabie 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. he refiliabie container (100) of claim 8, wherein the discharge cap (106) includes a twist spout (182) mechanically linked to the drive mechanism (1¾0) so that rotation of the twist spout (182) rotates one of the outer shell (102) and the elevator platform {114) .

13. The refiliabie container (100) of claim 8, further comprising one of the discharg cap (106) h ving 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 (ISO) and an on/o f valve (152) , a forth discharge cap (156} including a wide-xiiouth outlet (158) .

14. The refiliabie container (1005 of claim 8, wherein the semi-rigid outer shell (102) includes aft integral handle (104) wit a trigger {16 extending from the handle (164) and mechanically linked to the: drive mechanism {ISO)..

15. A refiilabie container (240., 300)., the container comprising :

a. a semi-rigid outer shell (242, 242') defining ah interior void (244, 244' } and including a detachable pour spout (246, 246')

b. a collapsible insert (250, 250' 5 dimensioned to foe 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 adjace t the side-force extraction apparatus (266, 266, 310, 312) .

16'. The refiilahie container (240, 240'} of claim 15, wherein the semi-rigid outer shell (242, 242' ) is secured between a first pivot base (256, 25 ' } 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, 26'B) 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 (166) ao 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 refiliable 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 wail {302} and a first compression piate (306) and a second air bladder {312} secured between a second, side wall {304) and a second compression piate (3083 , and a fluid pump control apparatus and pump c·::'·. ·.;.:.:. i.or (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 piate {306) and a second compression plate (308) toward the collapsible insert (250' } .

10. A method of man factu ing collapsible inserts (32,- 110, 250 and 250' ) of claim 1 and claim IS, the method including ;

a. joining a predetermined umber of securing couplers (34, 112, 251, 251' ) to a same predetermined number of flexible bodies (50) to form a predetermined number of joined collapsible inserts (32, 110, 259 and 250'), wherein the collapsible insert 32, 110, 250 and 250') 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, 250 and 250') within a top surface (77} of a holding tray {78};

c. col lapsing the predetermined number of joined collapsible inserts (32, 110, 250 and 25-0' } unto '■. ho top surface (?7) of the holding tray (78) to form a first set of collapsed collapsible inserts (80); and,

cL transporting the first set of collapsed collapsible inserts (80) on the holding' tray (7.8} frors a place of manufacture of the first set (80) to a place of filling the first set of collapsible inserts { O) .

20. The ethod of manufacturing collapsible inserts (32, 110, 250 and 250' ) 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 ίϋ4] with the -securing couplers (34., 112, 251, 2.511} of the first set of collapsible inserts (BO) to expand the inserts (80) f om a collapsed position to an expanded position, and theft inserting an automated fill device (40) through the securing couplers (34, 112, 251, 251'} to fill the collapsible inserts (32, 110, 250 and 250' ) ¾fith a product whil the collapsible inserts (32, HO, 250 and 250'} remain secured within the holding tray (78) ,

Description:
Description

REFILL&BLE CONTAINER WITH Ά ESRO WASTE

DISPENSING SYSTEM

Cross-Reference to Related Applications {00013 This Application claims the benefit of U.S. Provisional Patent Application Serial Number 61/462,971 that was filed o February 10, 2011 entitled "Flow Bottle Design and Manufacture" and U.S. Provisional Patent Application Serial Number 61/516,804 that was filed on April 8, 2011 entitled vi Fiow Bottle Twist Dispenser Design and Manufacturing",

Technical Field

[0002] This disclosure relates to structures for containing and pouring liquids and f ' lowable substances (such as fruit juice, soda, laundry detergent, kitty litter,- peiletized animal food, etc.), and in particular relates to a retiliable, reusable container that receives and secures a collapsible insert that contain the liquids or flowable substances *

Background Art

[00033 It is well known that traditional containers for dispensing liquids and flo abre substances are generally blow-molded bottles made of varying types of thermoplastics. Every supermarket has literally hundreds of ' different types of such semi- igid bottles to contain all types of common household products - Typically the bottles are manufactured in a first manufacturing facility, and then shipped to second facility for filling and sealing prior to distribution to a third retail sales type of facility *

[0004] Very substantial transportation and handling costs are involved with processing such serai- rigid bottles from a manufacturing plant to a filling plant * For example, and as shown schematically in FIGS, 4 and 5, prior art handling of empty bottles being delivered from manufacturing " to filling facilities may Involve the costs of palletizing and securing th bottles 10 on separate pallets 12, or i is also common to sim ly transport the bottles 10 within a box-like bottle container 14 shown in FIG. 5. Upon arrival at a filling facility the bottles 1G must then be individually processed through filling ' machinery- It is apparent that the costs of transporting large, light empty containers combined with the costs of separating the e t containers for processing during filling is a very substantial component of the overall costs of manufacture and delivery of Such liquids and flowable substances to an end user.

[0005] Moreover, the need to form such containers into semi-rigid bottles 10 is mandated by requirements for retail display of the containers as well as of automated machinery that transfers the delivered . , now bottles into filling and distribution machinery. This gives rise to grave environmental concerns. Because the bottles 10 must have adequate structural integrity to withstand the described processing, including retail display, the bottles 10 invariably pose environmental challenges, While expensive and time-consuming efforts are being undertaken to recycle and reuse the materials of these semi-rigid plastic bottles, it is apparent that recycling will never be completely success ul , and used semi-rigid plastic containers continue to pollute our environment in ever greate quantities.

[0006] Accordingly, there is a need for an improved, more efficient, and more environmentally friendly system for manufacture, filling and distribution of containers for liquids and £lowable substances. bumaiary of the Disclosure

CGO07J "The disclosure includes a refiiia ie container with a zero waste dispensing system. In one embodiment, the refillahle container has a semi-rigid outer shell that, defines an interior void. The container also includes- a detachable pour spout adjacent a top end of the shell and adjacent a top end ox t e interior void, .¾ collapsible insert is dimen ioned to be selectively secured within the interior void of the semi-rigid outer sheil and is also dimensioned to be selectively removed from the semi-rigid outer shell- The: collapsible insert and outer shell are cooperatively formed to permit selective pouring of the substance through th pour spout out of the shell. The collapsible insert includes a securing coupler affixed to a top end of the insert and the coupler is configured to be mechanically engage the pour spout of the semi-rigid outer sheii. The securing coupler also forms a fill fitting configured to mate with an automated filler before the collapsible insert is positioned within the serisi-rigid outer shell.

[0008] A base fixture is secured to a bottom end of the collapsible insert, opposed to the top end of the insert, and the base fixture is constructed to engage and be selectively secured to a bottom end of the semi-rigid outer shell. This prevent the collapsible insert from collapsing or folding during pouring of a ponrabie substance out of the insert through the securing coupler and pour spout of the shell. The secured base fixture thereby provides for zero waste while the substance is poured out of the collapsible insert.

[0009] An end user would acquire one semi-rigid outer shell, and then purchase multiple collapsible inserts that are filled with product to be secured within the void of the shell one at a time, When a first collapsible insert is empty r it would be removed and a second collapsible insert would replace it within the outer shell . Because the collapsible insert does not have to be manufactured with adequate structural integrity to stand on its owfi, such as within a retail displa o ketchup,- juice, milk, or detergent bottles, etc., the collapsible inserts can be readily manufactured of biodegradable materials, or at least will have a smaller amount of traditional packaging materials.

[0010] Additionally,, the present disclosure includes manufacture of the collapsible inserts so that they may be transported from a place of manu acture to a place of filling in a collapsed state. This alone provides for enormous cost savings in the processing of containers for fiowable goods. In another embodiment, collapsible inserts may be manufactured in strips with a pred termined number of inserts secured to each other in a side-by-side arrangement. The inserts may be manufactured so that base fixtures of the collapsible inserts are also joined together side-by-side to fcrai a packet of three or more collapsible inserts. This will facilitate processing of the collapsible inserts through utomated machinery utilized in transporting, separating and filling the inserts, as well as in adding structural integrity for retail display. For example, instead of one collapsible, filled insert standing alone, which would foe difficult, three or more may have tear-separable base fixtures and/or tear-separable securing couplers to facilitate support of, for example, a square of four inserts, or a sis-pack of six inserts, ail of which may be mutually supported within a common retail-display sheathing .

[0011] Alternativel , instead of tear-separafoie base fixtures and/or securing couplers, the base fixtures of the collapsible inserts may be secured within a holding tray configured to selectively secure the base fixtures of a plurality of collapsible inserts. Such holding trays may be utilized to facilitate processing of the collapsible inserts from manufacture, through filling to retail display. The holding trays may also include structures on opposed support surfaces of the holding trays to secure both the ease fixtures of a first set of collapsible inserts and the securing couplers of a second set of collapsible inserts, so that trays of collapsible inserts may be stacked upon each other. Such stacking of layers of collapsible inserts may be utilized when the inserts are empty add collapsed, or filled and expanded. It is anticipated, that stacked trays of a plurality of filled inserts may be efficiently utilised for retail display at large, end-of-aisle displays in '"big-box" types of retail-sales facilities, etc.

100X2} In a further embodiment the present disclosure includes a refiilable container with a zero waste dispensing system for non-pourable liquids, such as lotions f pastes and other highly viscous substances, and ordinary liquids. This thick-liquid embodiment also includes a semi-rigid outer shell defining an interior void and a discharge cap adjacent a top end of the shell. A collapsible insert is also included and is dimensioned to be selectively inserted into and .removed from the interior void of th shell. The collapsible insert includes a securing coupler that is configure to mate with and ssechanicaliy engag the discharge cap of the shell. Instead of relying upon the force of gravity to pour the contents out of the insert upon tipping of the container, as it the above described container for fiowabie substances, the thick-liquid embodiment utilizes varying efficient but com lex extractions mechanisms to move the thick liquid and ordinary liquid within the insert through the discharge cap and out of the container, The thick-liquid embodiments may not just dispense highly viscous liquids, but can also dispense those and ordinary liquids at precisely measured doses through use of a ratchet-based mechanical drive. Each click of a ratchet mechanism can be calibrated to dispense a precise amount , The disclosure includes use of a pointer and a dosing or measured amount indicator linked to the ratchet mechanism for sensitive dispensing of contained products.

10013] A first extraction mechanism includes at least one or two and preferably three helical tracks defined upon an inside surface of the semi-rigid outer shell, {For purposes herein, the phrase "helical track" is intended to include both a groove defined to descend below the inside surface of the shell as well as a ridge defined to extend above the inside surface of the shell. It is expected that most embodiments of the helical track will foe in the f rm a groove.) The helical tracks may define endless loops that ascend from a place of beginning of the tracks adjacent the bottom end of the rigid shell at a modest angle toward the top end of the shell and then descend at a very acute angle back to the bottom of the shell to the place of beginning of the helical tracks _ An elevator platform is configured to fit within the interior void of the shell and the elevator platform includes pins projecting away from the platform and into or onto the helical tracks.

[0014] The collapsible inser is placed upon the elevator platform and the securing coupler is secured to the discharge cap of the re " usabie container.- Rotation of the elevator platform relative to the semi-rigid outer shell, or rotation of the semi-rigid ocitar shell relativ to the elevator platform causes the platform pin to move along the upward ascending helical tracks to thereby force the non-flowafole liquid out of the collapsible insert through the discharge cap, A ratchet mechanism may be included so that each rotation of either the platform relative to the shell or the shell relative to the platform causes a predetermined increment of highly viscous liquid to pass through the discharge cap. The ratchet mechanism also prohibits descent of the elevator platform after an incremental ascent. One embodiment includes only multiple revolutions of the helical track about the rigid shell as the platform ascends upward toward the top of the shell. When the collapsible insert reaches adjacent the top of the shell, it is then empty,, and the insert y be removed from the shell and the elevator platform returned to the bottom of the shell. Another embodiment includes the multiple revolutions of the helical track about the perimeter of the rigid shell,, and also includes about one-hall of one revolution about the shell for the platform to return from the top to the bottom of the inferior void of the shell. This facilitates rapid re-e;¾pansion of the collapsible insert so that the user knows when the insert is e ty and will not damage the rotating mechanism.

ίθθΐδ] This rapid return feature of the helical track also promotes zero waste dispensing because the consumer is clearly informed by the rapid return mechanism when the collapsible insert is emptied. The described refiilafole container for nori-flowable liquids therefore provides an. extremely high efficiency of complete usage of the liquids compared to know: technologies ' for dispensing non-flowabla liquids. For example, traditional hand-lotion dispensers utilize a plunger pump which invariably ends up leaving ten percent or more of the lotion adhered to interior w lls and the bottom of the dispenser after the rd anger pump is incapable of developing suction. Similarly, even rolled up tooth-paste tubes are incapable of dispensing all of their contents, while most are not even roiled up. This thick-liquid embodiment also avails itself of the aforesaid advantages of utilizing replaceable, collapsible inserts: of the non-f lowable or thick liquid.

[0016] A further embodiment ox the thick liquid refiilable container includes use- of the aforesaid elevator platform mechanism for barely flowable substances suet as coffee by rotating the container so that it is upside down. Then the relative rotation of the elevator platform is activated while a user holds and possibly shakes the outer shell while holding a measuring cup under the discharge cap. The thick liquid embodiments using a ratchet mech nism also obtains a very substantial advantage in effectively eliminating any back flow or suction force into their discharge caps. Traditional thick-liquid dispensers, from lotion bottles with plunger pumps to tooth paste tubes, slightly re- expand after usage permi ting atmospher or other contaminants into the discharge caps and containers. Use of the ratchet mechanism in the present disclosure prevents entry of air back into the container and thereby enhances preservation of the quality of the contents of the refillable container,

00173 In an additional embodiment of the refillable container, an alternative extraction mechanism may involve applying force to one or more sides of the collapsible insert. A first side-force extraction mechanism utilizes a semi-rigid outer shell that defines an interior void into which a collapsible insert is positioned and secured by a securing coupler affixed to a discharge cap of the outer shell. In this embodiment one or store compression plates are secured within the interior void and are secured within the interior void by one or preferably sore helical xles that define helical tracks about the exterior surfaces of the axles. The allie extend between and they are supported by side walls of the semi-rigid outer shell . The axles pass through corresponding ' axle slots in the compression plates to support the compression plates in varying positions.

£0018] For example, a gearing echanisn- allows the helical axles to rotate upon rotation of a drive mechanism that extends from the side wail of the outer shell so that rotation of the helical axles forces the compression plates away fr m the side walls of the outer shell toward each other. In use of this etfifoodiment, as the compression plates are adjacent th side wails of the shell, a collapsible insert of a thick liquid, or any liquid, is inserted within the shell between the compression plates so that the securing coupler of the insert engages a discharge cap of the shell . The drive mechanism may also include a one-way ratchet device so that the rotation of the helical axles by the drive mechanism causes compression of the collapsible insert and discharge of a predetermined quantity of the contents of the insert out of the container. By utilizing uniform, Incremental compression of the ns rt by the compression plates, no waste product remains within the insert. As wit the aforesaid embodiments, this thick- liquid,- compression plate embodiment includes the many benefits of a replaceable, collapsible insert, and use of the ratchet mechanism to restrict -entry of air or other contaminants into the container,

[0019] In an additional embodiment the compression plates may be activated to move toward each other and force th contents of a thick liquid, or any liquid out of the compressible insext by one or more air bladders that are secured between the compression plates and the sides of the semi-rigid outer shell. This embodiment may include a pneumatic controller that permits, or pumps in a flow of compressed air into the bladders to measure out predet rmined amounts of the thick liquid through the discharge cap.

[0020] Accordingly, it is a general purpose of the present disclosure to provide a refiliable container with a ze o waste dispensing system that overcomes deficiencies of the prior art,

[0021] It is a more specific purpose to provide a refiiiable container with a zero waste dispensing system that minimizes manufacturing and transportation c sts of packaging and delivering liquids, thick li ids and other flowable substances while substantially reducing environmental burdens associated with manufacture, distribution and use of known containers for .liquids* thick liquids and other flowable substances,

[0022] These and other purposes and advantages of the present refiiiable container with a zero waste dispensing system will become more readily apparent whan the following description is read in conjunction with the accompanying drawings .

Brief Description of the Drawings 10023 ] Figures IA - IF are a sequence of simplified plan drawings {FIG . IA - FIG, IE} and a perspective drawing (FIG. IF) showing steps in using a refiiiable container with a zero waste dispensing system constructed in accordance with the present invention and showing insertion of a collapsible insert within an interior void of a semi-rigid outer shell of the disclosure .

10024] Figure 2 is a perspective view of a collapsible insert of the present disclosure showing a securing coupler and base fixture at opposed ends of the insert .

[0025] Figure 3 is top plan view of three optional arrangements of groups of collapsible Inserts and holding trays for securing the inserts relative to each other. [0026] Figure 4 is a schematic representation of prior art stacked pallets of empty semi-rigid:, plastic bottles,

[0027] Figure 5 is a schematic representation of a prior art bottle container for holding and transporting semi-rigid plastic bottles.

[0028] Figure 6 is a side plan view of a pl rality of collapsible inserts secured in a sid -by- side arrangement by a holding tray.

C0029] Figure 7 is a side plan view of the Figure 6 collapsible inserts in a holding tray and showing additional pluralities of collapsible inserts stacked upon additional holding trays,

[0030] Figure 8 is a simplified, schematic representation of the Figure 6 plurality of collapsible inserts co¾tmencittg engagemen - of fill fittings of the inserts- with a lift device,

[0031] Figure S is a simplified, schematic representation of the Figure 8 lift device engaging all fill fittings of the plurality of collapsible inserts *

[0032] Figure 10 is a si plified,- schematic representation of a fill device positioned ove the Figure 9 plurality of collapsible inserts after the Figure 8 lift device has lifted and expanded the coila si 1e inse t .

[0033] Figure 11 is a simplified, schematic representation of the Figure 10 fill device showing the fill device inserted through fill fittings of the collapsible inserts to fill the expanded inserts.

[0034] Figure 12 is a simplified, schematic representation of the Figure 11 plurality of expanded, filled, collapsible inserts and showing a sinvpiified schematic repr sentation of a sealing device positioned over the fill fittings of the inserts to apply o bl seals to the inserts.

[00353 Figure 13 is a simplified, schematic representation of two groups of filled, sealed collapsible inserts secured to two separate holding " trays with one holding tray stacked upon the fill fittings of the other group of inserts.

[ 00363 Figure I4A is a sectional f perspective view of a prior art thick-iiquid dispensing container showing a thick liquid remaining within the container and unable to be removed.

100373 Figure 14B is a simplified perspective drawing showing aft expanded and filled collapsible insert secured upon an elevator platform within an interior void of a semi-rigid outer " shell..

t 00383 Figure 14C is a simplified perspective drawing of the Figure 14B collapsible insert, showing the insert partially collapsed alter dispensing thick-liquid contents within the insert,

[0039] Figure 14D is a simplified perspective drawing of the Figure 1 B collapsible: insert, showing the elevator platforin adjacent a top end of the interior void of the serai-rigid outer shell after the thick liquid has been dispensed from the collapsed collapsible insert.

[0040] Figure 15 is a schematic, perspective drawing showing two helical tracks defined upon aft interior surface of a shell.,- and showing a portion of the helical tracks defining multiple revolutions of the helical track between a bottom end and a top end of the shell, ana showing portions of the helical tracks defining about one half of a revolution about the perimeter of the shell b twee the top and bottom ends of the shell,

[ 0041 ] Figure 16 is a perspective ie of the Figure IS helical tracks defined upon an interior surface of a shell and showing an elevator platform adjacent a bottom end of th shell .

[0042] Figure 17 is schematic, perspective representation of a track follower showing the track follower positioned within an ascending helical track that intersects a descending helical track wherein the track follo er defines a length greater than a width of the helical track to avoid the: track follower entering the descending helical track,

{ 0043] Figure 18 is a schematic.,- perspective view of the Figure 16 helical tracks and elevator platform and showing platform pins extending from the elevator platform into the Figure 17 track follower within the helical tracks..

10044] Figure Ιθ is a schematic., perspective view of a rigid shell defining helical tracks and an elevator platform having aligning posts passing through the platform to restrict rotation of the elevator platform relative to rotation of the rigid shell,

£ 0045] Figure 20 is schematic, perspective view of the Figure 19 semi-rigid outer shell and showing a collapsible insert within interior void of the shell and mounted upon an elevator platform.

10046] Figure 21 is a schematic.,- perspective view of the Figure 19 rigid shell and showing a collapsible insert, secured upon a compression layer to apply a constant, upward pressure to the collapsible insert. [0047] Figure 22Ά is a schematic, perspective view of a dispensing ' to of a twistafoie refiiiafoie container sho i g an outer-cap as measuring cup.

[0048] Figure 22B is a schematic, perspective view of a dispensing top of a t istable refiiiafoie container showing a reservoir secured to the dispensing top that is filled upon dispensing from the container, and then poured oat of the reservoir.

C00493 Figure 22C is a schematic, perspective view of a dispensing top of a twistable refiiiafoie container in the form of a spray nozzle.

£0050] Figure 22D is a schematic, perspective view of a dispensing top of a twistable refiiiafoie container inverted to a ply dispensed substances to a sponge or paint, pad.

[0051] Figure 23 is a simplified, perspective view of an exemplary semi-rigid outer shell including a trigger-shaped drive mechanism for actuating a ratchet mechanism to rotate a collapsible insert.

10052] Figure 24 is a simplified, perspective view of a refiiiafoie container and showing a discharge cap secured to a serai-rigid outer shell *

[0053] Figure 25 is a simplified, perspective view of the Figure 24 refiliable container and showing the discharge cap removed to expose a collapsible insert within the semi-rigid outer shell,

[0054] Figure 26 is a simplified, perspective view of the Figure 24 discharge cap *

[0055] Figure 2? is a bottom perspective view of the Figure 26 discharge cap and showing exemplary gear mechanism, that provides for rotation of the figure 25 collapsible Insert upon rotation of a dispensing s ou of the discharge ca .

[0056] Figure 28 is a perspective view of a Figure 23 refillabie container a.nd shoeing an alternative discharge cap and measuring cup.

[0057] Figure 2 is a simplified, side plan view of a refi liable container including trigger drive m ch ni e and measuring cup secured to the container.

[0058] Figure 30 is a simplified, side plan view of the Figure 29 refillabie container and showing the container inverted so that a dispensed substance is poured into the measuring cup which is detachable from the container .

[0059] Figure 81 shows the Figure 30 reriilahle container returned to an upright positio without the measurin cup.

[0060] Figure 32 is a top plan view of a multistage sequence for securing a plural ty of Collapsible inserts to a bottom fixture and a top alignment plate.

[006X] Figure 33 is a side plan view of the Figure 32 multistage sequence,

[0062] Figure 34 is a simplified perspective view of a side-force extraction embodiment of a refillabie container of the present disclosure: and showing the container in a dispensing mode.

[0063] Figure 35 is a simplified perspective view of the Figure 34 refillabie container ' and showing the container in a refill mode.

[0064] Figure 36 is a front pe spective,, fragmentary view of the Figure 34 refillabie container having a semi -rigid outer shell removed and showing a collapsible insert positioned, between: opposed compr sion plates secured to a helical axle .

[0065] Figure 37 is a simplified, f agmentary perspective view of the Figure 34 side-force extraction embodiment and showing two helical axles extending between two opposed geared rotation disks of the contai e .

[0066] Figure 38 is a top perspective view of the Figure 36 refillable container showing a collapsible insert secured between opposed compression plates and two helical axles.

[0067] Figure 39 is a front perspective view of the Figure 38 refillable container showing the compression plates completely compressing the collapsible ins rt .

[0088j Figure 40 is a perspective view of an alternative side-force extraction embodiment showing a ref llable container in a dispensing mode and showing a pomp actuator drive mechanism, on a front surface of a semi-rigid outer shell of the container,

ί00693 Figure 41 is front perspective view of the Figure 40 refillable container showing the container in a refill mode,

t 00703 Figure 42 is fragmentary, front perspective view of the Figure 40 refillable container having a front wall of a semi-rigid outer shell removed and showing a collapsible insert secured within the container between opposed compression plates and showing- inflatable bladders secured between side of the senu- rigid outer shell and the compression pl tes,

[0071] Figure 43 is a ragment ry to perspective view of the Figure 42 refillable container. r; [0072] Figure 44 is a frsgmentary, front perspective view of the Figure 42 refiiiabie container and showing the compression plates completely compressing the collapsible insert and showing the air bladders com letely expanded

[0073] Figure 45 is a simplified, plan view o a standard ratchet mechanism.

Preferred Embodiments of the Disclosure

[0074] Referring to the drawings in detail, a simplified schematic drawing of a refiiiabie container with a zero waste dispensing system is shown in simplified font; in FIGS. IK - IF and is generally designated by reference numeral 20. The refiiiabie container 20 includes a semi-rigid outer shell 22 that defines an interior void 24. (For purpose herein, the phrase ^semi-rigid" is to mean that the outer shell is sufficiently pliable to be squeezed, such as with a common,- plastic ketchup or mustard container, and that the outer shell is not as rigid as a glass or steel shell woald be.) The container 20 also includes a detachable pour spout 26 adjacent a top end 28 of the shell 22 and adjacent a top end 30 of the interior void 24. As hown in. FIGS . 1A - IE, the pour spout 26 may be detachable from the semi-rigid outer shell 22,

{00753 A collapsible insert 32 is dimensioned to be selectively secured within the intexior void 24 of the semi-rigid outer shell 22 and is also dimensioned to be selectively removed from he semi-rigid outer shell 22» The collapsible insert 32 and outer shell 22 are cooperatively formed to permit selective pouring of a flowable substance (not shown) through the pour spout 26 out of the shell 22. The collapsible insert 32 includes a securing coupler 34 affixed to a top end 36 of the insert and the coupler 3 is configured to mechanic lly engage the pour spout 26 of the semi-rigid outer shell 22. As shown in FIGS. 1A - IE, the securing coupler 3 may he dimensioned as a lip 34 extending beyond a perimeter of the collapsibl insert 32 so that when the lip 34 extends out of the top end 2-8 of the shell 22, the pour spout 26 slides below the. securing coupler 34 to thereby secure the insert 32 within void 24 of the outer sheil 22. The semi-rigid outer sheil 22 may also include a handle 38 for permitting a user (not shown) to lift and tilt the container 201 This embodiment 20 of the re.filiable container 20 may therefore be referred to for convenience as a tilt-pouring refiliable container 20.

[0076] The securing coupler 34 also serves as a fill fitting 34 that is configured to mate with an automated filler 40, as shown schematically in FIGS. 10 and 11.. As will be described in defail be low mating of the fill fitting 34 with the automated filler 40 is accomplished before the collapsible insert 32 is positioned within the semi-rigid outer shell 22.

10077] A base fixture 42 is secured to a bottom end 44 of the collapsible insert 32 opposed to the top end 36 of the insert 32. The bass fixture 42 is constructed to engage and foe selectively secured to a bottom end 46 of the semi-rigid outer shell 22, This prevents the collapsible insert 32 from collapsing or folding during pouring of a poorable substance (not shown) out of the insert 32 through the securing coupler 34 and pour spout 26 of the shell 22, By securing the base fixture 42 to th bottom end 46 of the shell 22 , all of the pourabie substance within the insert 32 is readily dispensed from the container 20, thereby providing for zero waste of the pourabie substance.

[0078] As is apparent from the sequence of FIGS.

1A - IF, an end us r simply inserts the collapsible insert 32 into the interior void 24 of the semi-rigid outer shell 22, and then slides the detachable pour spout 26 onto the top end 28 of the shell 22 to engage the securing coupler 34 of the collapsible insert 32. The user may simply penetrate the securing coupler 3 , or remove a seal tab 35 {shown in FIG. 12} from the securing coupler 34 prior to or after insertion of the collapsible insert 32 into the shell 2/ . The base fixture 42 prohibits the insert 32 from collapsing in o the void 24 of the sh ll r and the refiilable container 20 is ready for use. After dispensing ail of the contents of the insert 32, the pour spout 26 o ' uld be removed and another collapsible insert secured within the shell 22., It is to be understood, that while the pour spout 26 is shown in the FIG. 1A ~ IF embodiment as detachable, the disclosure includes a pour spout 26 that is not detachable from the outer shell, and simply secures the securing coupler of the insert 32 in another manner that is known for securing a pour opening to a replaceable pourable substance container, FIG. 2 shows a collapsible insert 32 separated from the semi-rigid outer shell 22, and shows the securing coupler 36 having a pe imeter edge 43 that extends beyond a flexible body 50 of the insert 32, The securing coupler 36 is also always in the form of a fill fitting 36 wherein a fill opening 52 is configured to both receive an automated filler 40, as seen in FIGS . 10 arid 11, and to also engage the pour spout 26 of the semi-rigid outer shell 22.

10079] As described above, the present disclosure includes manu cture of collapsible inserts 32 so that they may be transported from a place of manufacture (not shown) to a place of filling (not shown) in a collapsed state. Manufacture of the flexible bodies 50, securing couplers 34 and base fixtures 42 of the collapsible Inserts 32 may he most e ficiently achieved by manufacturing ' the inserts 32 in groups of strips of inserts 32. FIG. 3 shows three optional sequential arrangement 54 , 56 ' , 58 of three groups of three collapsible inserts 32, wherein the inserts 32 are in the form of expandable pouches, in the first arrangement 54, pouch inserts 6QA, 60B, 6QC are arranged parallel to & long axis of a securing ' coupler 62A, 62B, 62C. In the second optional arrangement 56, pouch inserts 64¾, 64B, 64C are arranged in parallel-diagonal arrangement relative to their three securing couplers 66A, 66 ' B, and 66C in the third optional arrangement 58, pouch inserts 68«, 685, 68C are arranged in zig-zag arrangement relative to their three securing couplers 6¾A, 66B, and 66C, In this zig-zag arrangement 58, the pouch inserts 68A, 68B, 68C may be secured to each other at adjacent longitudinal seams 12, 74 fo a longer duration during transport ana filling operations. This provides for enhanced efficiencies in manufacture because such expandable, liquid-Containing pouches are typically manufactured in a side-foy-side arrangement secured to each other along adjacent longitudinal seams,

[0080] FIG . 6 shows that collapsible inserts 32 may be manufactured in strips wi h a predetermined number of inserts 32 secured to each, other in a side~foy-side arrangement . The inserts 32 may -foe manufactured so that base fixtures 42 of the collapsible inserts 32 are also oined together side-by-side to form a packet 76 of three or more collapsible inserts 32. The inserts 32 shown in FIG * 6 are shown in a collapsed state and secured in side-by-side arrangement to a top surfac 77 of a holding fray 76» As described above, such a side-by-side,, or siK~pack" type of grouping of the: inserts will facilitate processing of the collapsible inserts 32 through automated machiner utilised in transporting, separating and filling the inserts, as well as in adding structural integrity for retail display. While FIG. € shows the collapsed insert 32 secured as group fey the holding tray 78 , alternative ei'ibodiifient include the inserts being secured as groups by tsar-separable base fixtures 2 or securing couplings 34.

[00813 The holding trays 78 may be utilised to facilitate processing of the collapsifeie inserts 3d f om manufacture, through filling of the inserts 32 to retail display and ultimately to acquisition by an end user (not shown} . As shown in FIG. 7, the holding trays 73 saa also include structures on opposed bo om surfaces 79 of the trays 78 to secure both the base fixtures 42 of a first set 89 of collapsible inserts 32 and the securing couplers 34 of a second set 82 of collapsible inserts 32, so that trays 78 of collapsible inserts 32 may foe stacked upon, each other. Such stacking of layers SO, 82 of collapsible inserts 32 may foe utilised when the inserts 32 are empty and collapsed, or filled and expanded.

[0082] FIG. 8 shows a simplified, schematic representation of the plurality of collapsible inserts 32 shown in Figure 6, wherein a lif device 4 is coxnmen ing engagement of fill fittings 34 of the packet 76 or plurality of inserts 76. FIG. 9 shows the lift device 84 engaging ail the fill fittings 34 or securin couplers 34 of the packet 76 of collapsible inserts 32 on their holding tray 78. FIG. 10 shows schematically that the lift device 84 has expanded the packet 76 of collapsible inserts 32 above their holding tray 78 and that the fill device 0 has been positioned over the fill fittings 34 o the packet 76 of inserts 32. FIG. 11 simply shows that the fill device 40 has penetrated fill openings 52 of the fill fittings 34 of the packet 6 of collapsible inserts 32 to fill the expanded inserts 32 with a pourable liquid.

10083] FIG, 12 shows a further sequential operation in the autorsiated transport and filling of the packet 76 of collapsible inserts 32 by positioning a seal applicator 86 over the filling openings 52 of the fill fittings 34 after removal or the automated filler 40, The seal applicator 86 applies a seal 35 to each of the ex anded, filled collapsible inserts 32, FIG. 13 sho s that the filled packet 76 of collapsible inserts 32 may then receive a second holding tray 88 applied to the fill fittings 34 of the packet so that a second packet 99 of expanded, filled collapsible inserts 32 inay rest upon the second holding tray 88 which is upon the first packet 76 of collapsible inserts 32, The second holding tray 88 is applied after removal of the lift device 84 f om the first packet 76. The same holding trays 78., 38 may be utilised in enhancing the efficiencies of transporting the packets 76, 90 of collapsible inserts 32 from a .manu acturing- facility {not shown) to a filling facility {not shown) and then for transporting the filled inserts 32 to a warehouse or a point of sale facility (not shown.)- -

10084.3 FIGS. 14B ~ 14D and FIGS. 15 - 31 show further erabodiments of the present disclosure of a refiliable container with a zero waste dispensing system for non-pourafoie or siowiy-pourabie liquids, such as lotions, astes, shampoos and other highly viscous substances. Such, substances will be referred to herein for convenience as thick liquids" . FIG. 14Ά show a traditional prior art container 92 for a thick liquid for a lotion 94 that utilizes a plunger pump 96 to extract the thick liquid 94 or hand lotion. The sectional view of the prior art lotion container 92 shows much thick liquid 94 adhering to interior sides of the container 92 after the plunger u p 96 can no longer extract the thick liquid 94, This traditional dispensing system 92 for dispensing thick liquids S4 therefore leaves a lot of unused,- wasted product *

[0085] The sequence of drawings in FIGS . I B, 14C and 1 D sho a thick liquid embodiment 100 of a refiliable container with a zero waste dispensing system. This thick-liquid embodiment 100 also includes a semirigid outer shell 192 defining an interior void 104 and a discharge cap 106 {shown only in FIGS. 24 - 27) adjacent a top end 10? of the shell 102. A collapsible insert 110 is also included and is dimensioned to foe selectively inserted into- and removed from the interior void 104 of the shell 102. The collapsible insert 110 includes a securing coupler 112 having a fill opening 113 that is configured to mate and. mechanically engage with the detachable discharge cap 106 of the shell 102» In FIG. I4B the collapsible insert 110 is shown fully expanded and resting upon an elevator platform 114. FIG, 14C sho¾rs the collapsible insert 110 partially collapsed having moved u the interior void 104 u the piatforra 114, and F G , 14D shows the collapsible insert 110 fully collapsed so that only the elevator platform 114 is visible adjacent the securing coupler 112 of the container 110. FIGS. 14B, 1 G and 13D also shows alignment posts 116, 11B that pass from a shell bas 120 upward within the void 104 through the elevator platform 11 and into the discharge cap 106. The alignment posts 116, IIS may or may not be ' utilised to align the elevator platform 114 and control its rotation relative to the otter shell 102,

[0086] As described above, instead of relying upon the force of gravity to pour the contents out of the collapsible insert 110 upon tipping of the FIG. 1A container 20, the thick-liquid embodiment 100 utilizes varying efficient but cos-spies extractions mechanisms to move the thick liquid within the insert 110 through the discharge cap 106 and out of the container 100,

[0087] A first extraction mechanism is shown generally in FIGS. 15 - 31. For convenience, this first extraction mechanism will be referred to herein as a helical track extraction mechanism. (As described above,- for purposes herein, the phrase w helical track' * is intended to include both a groove defined to descend below an inside su face 122 of the shell as well as a ridge defined to extend above the inside surface 122 of the shell, It is expected that most helical track extrac ion mecha i e embodiments will be in the form a groove . ) {0088] As shown in FIG, 15 a preferred, eiiihodt ent Includes first helical track 124 and a second helical track 126 defined upon the inside surface 122 of the seiai-rigid outer shell 102. The helical tracks 124, 126 may define endless loops that ascend from a first place of beginning 128 and second place of beginning 130 of each track adjacent the shell base 120 of the rigid shell at modest angle toward the top end 107 of the shell and then descend at very acute angle back to the shell base 120 to the places of beginning 128, 130 of the helical tracks 124, 126.. FIG. 16 shows a perspective view of the FIG. 15 helical tracks 124, 126 defined upon the interior surface 122 of the shell 102 and showing the elevator platform 114 adjacent the shell base 120.

[00893 Fjg, jg shows the elevator platform 114 having a pin 132 extending away from a perimeter of the platform 114 into a track follower 134. The track follower 134 is configured to slide along the helical track 126, as within a groove as shown or upon a ridge {not shownS . FIG < 1? shows the track follower 134 positioned within a groove 136 of the first helical track 124 at a point where the first helical track 124 crosses over the second helical track 126, Track follower 134 is configured to define an axial length greater than a width of the helical tracks 124, 126 to avoid the track follower 134 entering a crossed helical track 124, 126.

[0090] FIG . 19 shows the elevator platform 114 within the rigid shell 102 and including the two alignment posts 116, 118 passing from the shell base 120 through the elevator platform 114, The alignment posts 116, US optionally serve to restrict rotation of the elevator platform 114 relative to rotation or the rigid shell 102,

Ϊ.Ο09Χ1 FIG, 20 shows the FIG. 14B collapsible insert 110 secured upo the elevator platform 114 within the semi-rigid outer shell 102. Use of the alignment posts 116, 118 permits the elevator platform 114 to rise as the outer shell 102 is rotated. This allows for the discharge cap 106 to remain stationary relative to the collapsible insert ilO while the outer shell 102 is rotated, FIG. 21 shows the FIG. 20 collapsible insert 110 secured upon a compression layer 138 tha applies a constant upward pressure to the collapsible insert 110 to further minimize any loss ox waste of contents within the insert 110 rid to virtually eliminate ingr ss ox any atmosphere or foreig material Into the collapsible insert 110 through the discharge cap 106 during usage.

C00921 FIG . Z2 shows a second discharge cap 140 of a helical track extraction embodiment of the refillable container 100, The second discharge- cap 140 includes an outer-cap- 142 as a measuring cup 142 that receives dispensed thick liquids by upward pressure of the elevator platform 114 through a pour nozzle 144. FIG, 22B shows the second discharge cap 140 utilizing the pour nozrie 144 to fill a reservoir 146 secured to the second discharge cap 140. The reservoir 146 is filled upon dispensing thick liquids from the container 100, and then poured out of the reservoir 146, This embodiment of the second discharge cap .140 provides for usage of the helical track embodiment of the container 100 with liquids that may be less viscous than pastes and hence slightly pourable, such as hair shampoos,- conditioners e tc . {0093] Figure 22C shows a third discharge cap 148 that includes a spray o^rl 150 and an on/ f valve 152 that provides for spray of contents 154 of the container 100 upon twisting of the third discharge cap 148 to produce compression of the contents 154 within the collapsible insert 110 *

{0094] Figure 22.D shows a forth discharge cap 156 that includes a wide-mouth outlet 15S that can be dimensioned to mate with or overlie a sponge 160 or other painting apparatus , to deliver a predetermined amount of a paint or other substance into the sponge 160 upon rotation of the discharge cap 156 or outer shell 102 of the container 100, Ose of the forth discharge cap 156 ould typically apply when invert ng the: container 100 to be upside-down during discharge,

[0095] Figure 23 shows an exemplary semi-rigid outer shell 162 including an integral handle 164 having a trigger-shaped drive mechanism 166 extending from the handle 164, The drive mechanist! .166 is mechanicall linked to a standard ratchet mechanism 168 that is shown in FIG. 45 in simplified form * The ratchet mechanism includes a ratchet wheel HO secured to rotate about an axle 172, wherein the ratchet wheel 170 includes a plurality of angled teeth 174 surrounding the periphery of the ratchet wheel 170, A standard pawl 176 is configured to pivot on a pawl axle 17S that bears against the angled teeth 174 to permit only one-way movement of the angled teeth 174 under the pawl 176 upon rotation of the ratchet wheel 170 in a manner that is well known in the art. The ratchet mechanism 1¾8 is secured within or ad cent a discharge cap 106, 140, 143, 156 to apply a one-way rotational force to gears that engage either the collapsible insert 110 or outer shell 102 to thereby Move the elevator platform 114 to force the contents 15 within the insert 110 through a discharge cap 106, 1 0, 148, 156. Use of the ratchet mech nise 168 in the present disclosure prevents entry of air back into the container 100 and thereby enhances preservation of the quality of the contents of the refutable container 100.

[0096] FIGS. 24 ~ 27 show an exem a y usage of a drive mechanise 180 to rotate the first discharge cap 106 relative to a semi- igid ou e shell 102 of the thick- liquid, helical track refilliable container 100. The first discharge cap 106 is secured to the outer shell 102 and includes a twist spout 182 that may be twisted to rotate a first gear 184 on the spout and. below a top surface of the discharge cap 106. The first gear 184 rotates an adjacent second gear 186 that is configured to engage a gear receiving edge 188 of the outer shell 102. FIG 25 shows the outer shell 102 and collapsible insert 110 without the discharg cap 106 exposing ' the gear receiving, or toothed edge 18S of the outer shell 102. Upon rotation b a user of either the twist spout 182 relative to the outer shell 102, or of the oute shell 102 relative to the twist spout 182, the track follower 134 commences movement, up the helical track 124 to raise the elevator platform 114 upward toward the discharge cap 106 to thereby force contents 154 out of the insert 110 through the spout 182. FIG. 26 shows the first discharge cap 106 removed from the outer shell 102, while FIG, 27 shows a bottom view of the removed discharge cap 106.

£0097] Preferably the ratchet mechanism 168, or a practical variation thereof is secured within the discharge cap 106 to permit only one-way motion of outer shell 102 relative to the collapsible insert 110. Alternative embodiments include the helical tracks 124, 126 only ascending upward wit in the outer shell 102 and coming to- a point of ending (not shown) adjacent the discharge cap 106, with a possible pawl release (not shown) to facilitate return of the elevator platform 114 to the shell base 120 by reverse rotation of the outer shell 102 relative to the twist spout 18-2. While the helical track embodiment 100 of the refiiiabie container has described the manual rotation, geared and ratcheted embodiments above, it is to be understood that any other motive force known may also be utilized within the scope of the invention. For example, a sm ll electric motor, battery and hand-actuated on-ofi switch (not shown) may be secured within the discharge cap 106 or other locations- of th -container 100 to achieve controlled, incremental relative rotation between the cap 106 and the outer shell 102 of the refiiiabie container 100 to achieve discharge of predetermined amounts of the contents 154 of the container 100,

[0098] FIG, 28 shows the FI . 23 refiiiabie container 162 having- the integral handle 166 and drive mechanism 164, but with a fifth discharge cap 190 having a curved spout 192 and integral s-easuring cup 194 for convenience in using the helical track -container 100 for dispensing specific amounts of the contents 154. FIGS. 29 ~ 31 show use of an alternative helical track container 19-6 having an outer shell 198 and integral handle 200 with a drive mechanism 202 that is appropriate for dispensing flowable contents, such as ground coffee. A second measuring cup 204 is detachabiy secured to a sixth discharge cap 206. The container 196 of FIGS. 29 - 31 includes the sam§ helical track extraction mechanism described above for helical track container 100. FIG. 30 shows that a user inverts the container 196; activates the drive mechanism 2 ' 02, and predetermined amount of the contents is dispensed into the measuring cup 204. The measuring cup is then slidafoly disengaged from the discharge cap 206 in the direction of arrow 208, The container 196 is then returned to a upright position as shown in FIG. 31 wa.it.irig return of the measuring cup 204.

[0099] An efficient manuf c uring process for manufacturing collapsible inserts is shown in. FIGS. 32 and 33. FIG. 32 is a top plan view of a multistage seq ence for securing a plurality of collapsible inserts 210 to a bottom fixture 212 and a top securing coupler 214, FIG, 33 is a side plan view of the FIG. 32 multistage sequence wherein a "Stage is shown at reference numeral 216, ''Stags 2" at 218, "Stage 3" at 220, and ^St ge 4 is shown at reference numeral 222,

[01003 At Stage 1 in FIG, 32,, I the pouch-like collapsible inserts 2X0 have been formed, inflated with air, and a fill fitment 226 has been attached. The inserts 210 are still empty throughout this Stage 1 - Stage 4 manuf cturing process . The inserts 210 are zigzagged in Stage 2 as shown in FIG, 33, and a roll of bo om fixture plate chip board 212 is attached with a hot melt glue {not shown) . At Stage 3 the. top securing coupler 214 chip board with handles 228 is applied while aligning fill openings 230 in the securing coupler roll 214 to the pouch fitments 226, In Stage 4 the securing coupler 214 is snapped over a looking feature (not shown) of the fill fitment 226, Ά continuous stream of -packs of the completed, collapsible inserts 210 ' aving secured bottom, fixtures 212 and securing; couplers 214 is then secured into holding trays 78, 87 for shipping. The collapsible inserts 210 are then compressed top to bottom while the air is released through the fill fitments 220 for compact shipment, as shown in FIGS. 0 and 7,

{01013 FIGS„ 34 ~ 44 show additional embodiment of the r l liable container that utilize an alternative extractio mechanism. his extraction r&echanisTR involves applying force to one or more sides of a collapsible insert secured within a semi-rigid outer shell. FIGS. 34 - 39 show an exemplary alternative refillable container 240 referred to herein as a helical axle side-force extraction refillable container 240. The container 240 includes a sesisi-rigld outer shell 242 that defines an interior void ' and includes pour spout 246 adjacent a pour end 248 of the outer shell 242 and interior void 244, A collapsible insert 250 (shown in FIGS . 36, 38} is dimensioned to be selectively secured within the interior void 244 of the outer shell 242. The collapsible insert 250 includes a securing coupler 251 (shown in FIG. 38) dimensioned to be housed within a receiver 252 of the pour spout 246 of the outer shell 242. The securing coupler 251 Is affixed to an insert pour end 254 of the insert and the coupler 251 is configured to be selectively secured to and detached from the pour spout 246.

10102] FIG. 34 shows that helical axle refillabie container 242 rssay be ivotally mounted between a fi at pivot base 256 and a second pivot base 258. The semirigid outer shell 242 is pivotally secured between the pivot bases 256, 258 so the shell 242 may be deployed in a dispensing mode as shown in FIG. 34 or in. a refill .mode as shown, in FIG.. 35. The outer shell 242 also .includes a front wall 260, top wall 262, a bottom wall 264 f a first side wail 266 and a second side wall 268 (shovm only In FIG. 36) . In this helical axl embodiment 2 0, the side walls 266, 268 rsay foe rigidly secured to the front, top and bottom wails 260, 262, 264 so that opposed compression plates may be secured within the shell 242.

101031 Alternatively, and as shown i FIGS. 34 - 36, and FIGS. 38, 39, the side wails 260, 262 may be siidably secured to the front, top and bot om walls 260, 262, 264 to thereby serve as compression plates 266, 26S to apply pressure to the collapsible insert 250. As shown best in FIGS . 36, 37, 38, 39 the helical axle container 240 may include a first helical axle 270 and preferably a second helical axle 272 that are secured through the opposed compression plates 266, 263 and are secured to a first support plate 274 and a second support plate 276 as shown in FIGS, 36,- 39. As shown best in FIG. 37, one of the support plates 274, 276 includes a driver gear 278 adjacent a perimeter of, for exam l , a second support plate 276» The driver gear 273 engages a first axle gear 280 that also surrounds an end of the first helical atie 270, and the driver gear 276 also engages a second axle gear 282 tha surrounds an. end of a second helical axle 272,

[0104] Rotation by a user {not shown) of the support plates 274, 276 therefore causes rotation of the helical axles 270, 272 as shown in FIGS . 3 and 39, rotation of the helical axles 270, 272 causes the compression plates 266, 268 to remove from a fully expanded position shown in FIG, 36 to a fully compressed position shown in FIG. 33 which has completely col lapsad an insert 250. While the .mechanical rods extending between the first and second support plates 274, 276 are referred to herein as tt .helical axles" ' , and are described as moving the compressiors plates 266 ? 268 toward or away from each other " upon rotation of the helical a¾les 270, 272, it is to be understood that the phrase "helical axles' *' is to include any kr-ow rods that can achieve the same function,, such as threaded rods, notched, rods using mechanical actuators or electro-mechanical actuators, tc .

[0105] n use of the helical axle container 240,· the container 240 is pivoted about th pivot bases 256., 258 so that the pour spout 246 is upright, as shown in FIG, 35, As shown in. FIG. 38 1 . wherein the pot spout 246 and ottom wall 264 are removed, the collapsible insert 250 is placed within the interior void 244 between the first and second helical a^les 270, 272. The bottom wall 264 is then repositioned and the receiver 252 of the poisr spout 248 is secured in mechanical and fluid communication with the securing couple 251 of the collapsible insert 250. The outer shell 242 is then repositioned from the refill ode (shown in FIGS, 35 and 38} to the dispensing mode (shown in FIGS. 3:4, 36, 37 and 39) . A user (not shown) then rotates o e: of the support plates 274, 276 which in turn rotate the helical axles 270, 272 that forced the sid walls or compression plates 266, 268 to apply a compressive force on the insert 250. Contents of the collapsible insert 250 may then pour out of the pour spout 246,. Preferably, a ratchet n-echanism 166 is secured in association with the driver gear 278, the first axle gear 280 or the second axle gear 282 to restrict reverse motion of the driver gear 278, to thereby restrict entry of air or other contaminants into the container 240.

[0106] It is anticipated that this helical axle embodiment 240 may be " utilized to min mize waste in transportation and di tribution of common beverages such as beer, soda, fruit juices, etc. By utilising the refiliable outer shell 242 with non or slightly pres urised contents within the collapsible insert 250, enormous savings in both cost and volume and mass of liquid containers may be achieved. Additionally, the helical axle embodiment of the refiliable container 240 may be utilized to dispense the same thick liquids described with respect to the helical track embodiment 100 of th refiilabis container of the present disclosure ,

10107] FIGS . 40 - 44 s orn an alternative extraction echanism for an ir-bladder refiilahie container 300. The air-bladder container 300 includes many virtually identical components described above with respect to the helical xle container 240 and those similar components will be identified in FIGS. 40 - 44 as primes of the reference numerals associated with the helical axle container 240, For example, the helical axle container 240 includes a semi-rigid outer shell 242 and in FIGS. 40 - 44 a serai-rigid outer shell is designated by reference numeral 242' . Other features of the air-bladder container 300 will simply be numbered i FIGS. 40 ~ 44 rather than providing a redundant description of those features,

[01083 As shown best in FIG. 42 the air-bladder container 300 includes a outer shell 242 ? that includes a first side wail 302 and a second side wall 304.. 'these side walls 30 , 304 are secured to the bottom wall 264' and top wall 262 f and do not ϊίίο β relative to those wails 264' and 262'. Within the interior void 244' of the air- bladder container 300, a first compression plate 306 and a second compression plate 308 are secured in parallel alignment between the top wall 262' and the bottom wall 2-6 ' ' ' . A first air-bladder 310 is secured between the first side wail 302 and the first compression plate 306 and a second air-bladder 312 is secured between the second side wail 304 and the second compression plate 308. As shown in FIG. 40 a um actuator 314 may be secured to the front wall 260' of the cuter shell 242' to selectively compress a standard fluid pump (not shown) to pxx p fluid into the first and second air Madders 310, 312. FIG. 1 r like FIG. 35 for the helical axle container 240, shows the air-bladder container 300 in a refill mode. FIG; , 43, like FIG . 38 fox the helical axle container 240,- shows the air-bladder container having a collapsible insert 250' inserted ' within the interior void 244' ' of the outer shell 242' and between the compression plates 306, 308.

[01093 As best shown in FIG. 44, the compression plates 306, 308 may be compressed by incremental expansion of the air bladders 310, 312 to a l a compressive force to the insert 250' to thereby expel contents of the insert 250' out of pour spout 246' . Like the helical a¾ie container 240 . , the air-bladder container 300 benefits from use of a plurality of collapsible inserts 250' that can. be utilized to refill the container 300 indefinitely. This again provides for enormous savings and manufacture and transport of the inserts 250' , and in reduction of an overall volume and mass of used product containers. The air-bladder container 300 also includes ordinary fluid pump control apparatus (not shown) known in the art to selectively apply incremental increases in fluid pressure within the air bladders 310, 312 * Such fluid pump control apparatus may include a mechanical pump actuated by the pump actuator 314, electric powered pumps , hydraulic pumps, with known flow controllers that are capable of performing the functions described above. The ptmtp control apparatus also includes an ordinary check valve (not shown) or other one-way valve to ensure that pressurised fluid does not flow back, from the air bladders 310, 312 through the pump apparatus.. This also, like the ratchet mechanism 168 in the helical track 100 and helical axle 240 containers r prohibits entry of atmosphere or airy other contaminants into the container 300,

[0110] While the present disclosure has been presented above with respect, to the described and illustrated embodiments of the refillabl containers 20, 100, 240 and 300 with a zero waste dispensing system, it is to be understood that the disclosure is not to be limited to those illustrations and described embodiments . Accordingly, reference should be iaade primarily to the following claims rather than the forgoing description to de ermine the scope of the disclosure.

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