Flexible Plastic Container Forming Without Inserts

The patent combines multiple manufacturing stages into a single integrated process. Two sheets are simultaneously formed and sealed together in one operation using a mold with cavities that define the three-dimensional geometry, eliminating the need for separate forming and superimposition steps while maintaining the required complex shape

The sheets are pre-positioned in direct contact with each other before the forming operation begins. The mold cavities are designed to simultaneously shape both sheets into their final three-dimensional configuration and seal them together, performing multiple actions in advance of the actual forming process

The forming and sealing operations are merged into a single simultaneous process. The sheets remain in direct contact throughout, forming a closed internal space that is never exposed to the external environment, thereby eliminating contamination risks associated with multiple handling stages

The internal storage space is extracted and protected from contamination by forming the two sheets into direct contact and sealing them simultaneously. This creates a closed internal environment that is isolated from external contaminants throughout the manufacturing process

Instead of placing an insert between sheets to define the internal shape, the patent inverts the approach by using the mold cavities themselves to directly form the three-dimensional geometry of both sheets simultaneously. The sheets conform to the mold cavity shapes, defining the internal storage spaces without requiring any inserts

The mold is designed with multiple cavities that can simultaneously form multiple containers or complex multi-chamber structures in a single operation. The same molding process handles both simple single-chamber containers and complex multi-chamber structures with fluid communication elements, providing universal manufacturing capability