Systems and methods for conversion processing of glass tubes using millimeter-wavelength microwaves

Abstract

Methods for producing glass articles from glass tubes are provided. The method includes securing a glass tube in a holder of a conversion machine having a plurality of processing stations, including a heating station, a forming station, and a separation station. The method includes forming one or more features of a glass article at a processed end of the glass tube by indexing the glass tube through the heating station and the forming station; separating the glass article from the processed end of the glass tube in the separation station; and indexing the glass tube from the separation station to an auxiliary processing station having a heating station or a forming station. The method includes volumetrically heating the glass tube and a target heating region on the glass article using an electromagnetic heating device in at least one of the processing stations.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 428,774, filed on November 30, 2022, under 35 U.S.C.§119, the content of which is incorporated herein by reference in its entirety and for all purposes. Technical Field

[0003] This specification generally relates to systems and processes for producing glass articles from glass tubes, and more particularly, to glass tube conversion processing systems and processes that include treating glass tubes in a conversion processing system using millimeter - wave radiation. Background Art

[0004] For a long time, glass has been used as the material of choice for pharmaceutical packaging due to its gas - tightness, optical transparency, and excellent chemical durability relative to other materials. Specifically, the glass used for pharmaceutical packaging must have sufficient chemical durability so as not to affect the stability of the pharmaceutical formulations contained therein. Glasses with suitable chemical durability include those within the ASTM standard "Type IA" and "Type IB" glass compositions, which have proven long - term chemical durability.

[0005] Glass tubes can be converted into other glass articles, such as various glass containers for pharmaceutical applications, including but not limited to vials, syringes, ampoules, cartridges, and other glass articles. The glass tubes can be converted, for example, in a "conversion processing machine". Conversion processing machines have been in use for over 75 years and are currently manufactured by various commercial and in - house equipment suppliers. These conversion processing machines typically use steps that include flame processing, rotary and stationary tool forming, thermal separation or scoring and impact severance steps to reform long sections of glass tubes into multiple glass articles. Various burners and forming tools are typically used to shape one or more articles from the glass tube and separate the articles from the glass tube. Summary of the Invention

[0006] According to an embodiment of the present disclosure, a method for producing a plurality of glass articles from a glass tube is provided. The method includes fixing the glass tube in a holder of a conversion processing machine including a plurality of processing stations, the plurality of processing stations including a plurality of heating stations, at least one forming station, and a separation station, wherein the conversion processing machine rotates the holder and the glass tube successively through each of the processing stations. The method includes forming one or more features of a glass article at a processing end of the glass tube by rotating the glass tube through each of the plurality of heating stations and the at least one forming station. The method further includes: separating the glass article from the processing end of the glass tube at the separation station; and rotating the glass tube from the separation station to an auxiliary processing station directly downstream of the separation station, the auxiliary processing station including one of the plurality of heating stations or one of the at least one forming stations. The method also includes volumetric heating of a target heating area on at least one of the glass tube and the glass article using an electromagnetic heating device in at least one of the processing stations.

[0007] According to an embodiment of the present disclosure, a conversion processing machine for producing a plurality of glass articles from a glass tube is provided. The conversion processing machine includes: a plurality of holders, each of the plurality of holders being operable to fix a glass tube and rotate the glass tube about a central axis of the glass tube; a plurality of processing stations including a plurality of heating stations, at least one forming station, and a separation station, wherein: the conversion processing machine is operable to rotate the plurality of holders and the glass tube through each of the plurality of processing stations; the separation station is operable to separate a glass article from a processing end of the glass tube; and the conversion processing machine includes an auxiliary processing station directly downstream of the separation station, wherein the auxiliary processing station includes one of the plurality of heating stations or one of the at least one forming stations; and an electromagnetic heating device configured to heat the glass tube or the glass article in at least one of the plurality of processing stations, the electromagnetic heating device being configured to volumetrically heat the glass tube or the glass article.

[0008] It should be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and characteristics of the claimed subject matter. The drawings are included to provide a further understanding of the various embodiments and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein and, together with the description, serve to explain the principles and operations of the claimed subject matter. Description of the Drawings

[0009] Figure 1A front view schematically depicting an embodiment of a conversion processing machine for producing glass articles from glass tubes according to one or more embodiments shown and described herein;

[0010] Figure 2 Schematically depicting according to one or more embodiments shown and described herein Figure 1 A top view of the main turntable and secondary turntable of a conversion processing machine having an auxiliary processing station directly downstream of a separation station;

[0011] Figure 3A Schematically depicting according to one or more embodiments shown and described herein Figure 1 The heating station of a conversion processing machine;

[0012] Figure 3B A perspective view of a row of glass tubes during a conversion processing step according to one or more embodiments shown and described herein;

[0013] Figure 4 Schematically depicting according to one or more embodiments shown and described herein Figure 1 An embodiment of the forming station of a conversion processing machine;

[0014] Figure 5 Schematically depicting according to one or more embodiments shown and described herein Figure 1 Another embodiment of the forming station of a conversion processing machine;

[0015] Figure 6 Schematically depicting according to one or more embodiments shown and described herein Figure 1 The separation station of a conversion processing machine;

[0016] Figure 7 Schematically depicting according to one or more embodiments shown and described herein during Figure 1 A perspective view of a section of a glass tube before conversion processing in a conversion processing machine;

[0017] Figure 8 A plot of the dielectric loss tangent of borosilicate glass versus microwave frequency according to one or more embodiments shown and described herein;

[0018] Figure 9 A graph of the volumetric loss density of microwave sources with different frequencies through the wall thickness of a glass tube according to one or more embodiments shown and described herein;

[0019] Figure 10Show numerical modeling results of the instantaneous volumetric loss density of a 150 GHz microwave source according to one or more embodiments shown and described herein;

[0020] Figure 11 Show the modeled temperature distribution across the cross-section of a glass tube during heating according to one or more embodiments shown and described herein;

[0021] Figure 12 Show the modeled temperature distribution across three glass tubes when a microwave beam is shaped into a strip according to one or more embodiments shown and described herein; and

[0022] Figure 13 Show the modeled temperature distribution of a microwave beam penetrating three glass tubes according to one or more embodiments shown and described herein. DETAILED DESCRIPTION

[0023] Embodiments of the systems and methods for converting a glass tube into a glass article according to the present disclosure will now be described in detail, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

[0024] During the conversion of a glass tube into a glass article using a conversion machine (i.e., a conversion processor), a heating element such as a burner heats the glass of the glass tube at one or more heating stations to a temperature at which the viscosity of the glass allows the glass to be formed into one or more features of the glass article. The forming station includes forming tools such as pin and wheel assemblies to contact the heated glass tube and form the internal and external dimensions of the features of the finished glass article. After the features are formed at the processing end of the glass tube, the glass article including the formed features is separated from the processing end of the glass tube at a separation station and transferred to a bottom forming machine. To heat the glass tube in the conversion machine, gas burners are typically used at locations that require heating such as preheating, separation, and shaping. In many cases, a large amount of heating is required. For example, in the preheating stage, depending on the glass composition, the temperature of the glass tube may need to be raised by 1000 °C or more, and further heating may be required in subsequent stations of the conversion machine (e.g., to allow the glass article to be separated from the glass tube).

[0025] One of the challenges of existing conversion processing techniques is manufacturing throughput. With the recent worldwide increase in demand for high-volume production of vials for medical applications (such as vials for vaccines), the throughput challenge has been exacerbated, and the productivity of manufacturing equipment, including conversion processing machines, can be a bottleneck in the production of vials and other glass products. All known equipment designed for high-volume production of vials and similar glass products uses gas burners as the heat source for glass processing. The productivity or manufacturing rate (number of parts per minute) of existing equipment depends on many factors, including mechanical design details, equipment size, component reliability, material quality, process control, precision, maintenance frequency, downtime during production, and other factors. One parameter common to all machines of this type and critical to throughput is the maximum glass heating rate, which is determined by the ability of the heat source (such as a gas burner) to heat a glass part to the appropriate processing temperature without damaging the part. The limiting factor is that the heat generated by the burner is first absorbed substantially in the glass surface layer and then transferred through the glass volume via a heat conduction mechanism. All other things being equal, the glass heating rate and heating uniformity are limiting factors in production throughput - factors that are fundamentally difficult to accelerate or improve.

[0026] In view of the above, embodiments of the present disclosure provide conversion processing systems and methods that use alternative heat sources for glass, enabling higher heating rates while also enabling uniform heating. Specifically, embodiments of the present disclosure include heating glass using microwaves in the millimeter wavelength range. Millimeter wavelength radiation enables high-power and efficient volumetric glass heating. Accordingly, the systems and methods of the present disclosure include using a gyrotron microwave heating device to focus the heating on a focal region of the glass and volumetrically heat the glass at a rapid rate.

[0027] A gyrotron is a high-power linear-beam vacuum tube that generates millimeter-wave electromagnetic waves through the cyclotron resonance of electrons in a strong magnetic field. The operating frequency of a gyrotron is from 20 to 527 GHz, and the output power is from dozens of kilowatts to 1 to 2 megawatts. Standard heating methods, such as gas burners or IR heating, have significant limitations in achieving highly controlled and rapid heating. On the other hand, gyrotron microwave heating offers many advantages over these traditional heating methods. Under the electromagnetic radiation of millimeter waves, glass can absorb electrical energy and convert it into its internal energy due to the dipole reorientation effect. Different from infrared heating, millimeter waves can penetrate into the glass material to achieve volumetric heating. Therefore, gyrotron microwaves can generate a high-frequency internal energy source for volumetric heating of glass, so gyrotron microwaves are a more effective way to heat a certain thickness of glass at a higher rate compared to traditional infrared heating or convective heating, thereby improving the heating efficiency, heating uniformity, and production throughput. Although rapid overall heating is possible and may be desirable for some applications, millimeter-wavelength microwaves can also achieve the precision of local and / or targeted profile heating for a desired thermal regime or profile. This ability enables customizing the temperature and / or viscosity profile from the center to the edge of the glass to optimize the physical, mechanical, and / or optical properties of the glass. Additionally, the energy source can be focused only on the glass without overheating surrounding materials such as plastics or metal materials that may be used in production equipment (such as conversion processing machines).

[0028] Since the millimeter-wave beam can be collimated, the heating device can be directly focused on the target area to be heated in the glass tube and the resulting product. Therefore, compared with conventional heating sources (such as gas burners), the embodiments enable reducing energy waste. With precise control of the target heating area, the millimeter-wave source can also help achieve the nominal design shape with high precision to meet strict dimensional specifications. In theory, the provided control can also enhance process repeatability and increase production output. According to the embodiments of the present disclosure, systems and methods are provided that also enable increasing the heating rate of the glass tube compared with gas burners and other conventional methods. An increased heating rate can be achieved via the use of specific microwave frequencies, improved heating uniformity, and the possible use of the same heating device to heat multiple tubes simultaneously. The systems and methods can be applied to various glass compositions and geometries, including tubes and rods, for forming various glass products. The embodiments include using a millimeter-wave generating device to heat the glass tube during separation, melting, and forming operations.

[0029] According to an embodiment of the present disclosure, there is provided a conversion processing machine for producing a plurality of glass articles from a glass tube. The conversion processing machine may include a plurality of holders. Each of the plurality of holders may be operable to hold the glass tube and rotate the glass tube about a central axis of the glass tube. The conversion processing machine may further include a plurality of processing stations, the plurality of processing stations may include a plurality of heating stations, at least one forming station, and a separation station. The conversion processing machine may be operable to index the plurality of holders and the glass tube through each of the plurality of processing stations. The separation station may be operable to separate the glass article from the processed end of the glass tube. The conversion processing machine may further include an auxiliary processing station disposed directly downstream of the separation station, wherein the auxiliary processing station may include one of the plurality of heating stations or one of the at least one forming stations. In aspects of the embodiment, one or more of the plurality of processing stations may include a gyrotron microwave heating device capable of generating a microwave beam including a millimeter wavelength beam. Specifically, at least one of the plurality of heating stations, the at least one forming station, and the separation station may include a heating device capable of generating a millimeter wavelength beam.

[0030] Separating the glass article from the processed end of the glass tube may form a glass meniscus at the processed end of the glass tube. The conversion processing machine may further include a piercing device disposed between the separation station and the auxiliary processing station. The piercing device may be positioned to pierce the meniscus at the processed end of the glass tube. The piercing device may include at least one piercing heating device to heat the meniscus at the processed end of the glass tube. The piercing heating device may include a burner, such as a single-point or multi-point gas burner, or a plurality of such burners. In aspects of the embodiment, the piercing heating device may include a gyrotron microwave heating device capable of generating a microwave beam including a millimeter wavelength wave. In aspects of the embodiment, each of the plurality of processing stations may be fixed, and the conversion processing machine may index the glass tube successively through each of the plurality of processing stations.

[0031] According to a further embodiment of the present disclosure, there is provided a method for producing a plurality of glass articles from a glass tube using a conversion processing machine. The method includes using a conversion processing machine according to an embodiment disclosed herein. The method may include: holding the glass tube in a holder of the conversion processing machine; forming one or more features of the glass article at the processed end of the glass tube by indexing the glass tube through each of the plurality of heating stations and the at least one forming station; separating the glass article from the processed end of the glass tube at the separation station; indexing the glass tube from the separation station to an auxiliary processing station disposed directly downstream of the separation station. The method may further include piercing the meniscus of the glass tube.

[0032] According to additional embodiments of the present disclosure, a method for producing a plurality of glass articles from a glass tube is provided. The method may include securing the glass tube in a holder of a conversion processing machine that includes a plurality of processing stations. The plurality of processing stations may include a plurality of heating stations, at least one forming station, and a separation station, and the conversion processing machine may cause the holder and the glass tube to be sequentially indexed through each of the processing stations. The method may further include forming one or more features of the glass article at a processing end of the glass tube by indexing the glass tube through each of the plurality of heating stations and at least one forming station. The method may include separating the glass article from the processing end of the glass tube at the separation station. Separating the glass article from the processing end of the glass tube may form a glass meniscus at the processing end of the glass tube. The method may further include indexing the glass tube from the separation station to an auxiliary processing station that may be disposed directly downstream of the separation station. The auxiliary processing station may be one of the heating stations of the plurality of heating stations or one of the forming stations of the at least one forming station. The method may further include piercing the meniscus of the glass tube. Piercing the meniscus may open the processing end of the glass tube. In aspects of the embodiments, one or more of the plurality of processing stations may include a gyrotron microwave heating device capable of generating a microwave beam that includes a millimeter wavelength beam. Specifically, at least one of the plurality of heating stations, at least one forming station, the separation station, and the piercing device may include a heating device capable of generating a millimeter wavelength beam.

[0033] Reference Figure 1 and 2, schematically depicts an embodiment of a conversion processing machine 100 for producing a plurality of glass articles from a glass tube 102. The conversion processing machine 100 includes a plurality of holders 130, each of the plurality of holders 130 being operable to hold the glass tube 102 and rotate the glass tube 102 about a central axis of the glass tube 102. The conversion processing machine 100 further includes a plurality of processing stations 106, the plurality of processing stations 106 including a plurality of heating stations 202, at least one forming station 204, and a separation station 206, wherein the conversion processing machine 100 is operable to index the plurality of holders 130 and the glass tube 102 through each of the plurality of processing stations 106. The separation station 206 is operable to separate the glass article 103 from the processed end of the glass tube 102, wherein separating the glass article 103 from the processed end of the glass tube 102 forms a glass meniscus at the processed end of the glass tube 102. The conversion processing machine 100 may further include an auxiliary processing station 203 disposed directly downstream of the separation station 206. The auxiliary processing station 203 may include one of the plurality of heating stations 202 or one of the forming stations 204. The conversion processing machine 100 may further include a piercing station 212, the piercing station 212 being disposed on the main loop 116 downstream of the separation station 206 in the indexing direction 222 of the main turntable 108. At the piercing station 212, the meniscus at the processed end of the glass tube 102 is pierced, thereby reopening the processed end 150 of the glass tube 102.

[0034] The conversion processing machine 100 disclosed herein can be used in a method for producing a plurality of glass articles 103 from a glass tube 102. The method can include fixing the glass tube 102 in a holder 130 of the conversion processing machine 100, the conversion processing machine 100 including a plurality of processing stations 106, the plurality of processing stations 106 including a plurality of heating stations 202, at least one forming station 204, and a separation station 206. The conversion processing machine 100 indexes the holder 130 and the glass tube 102 sequentially through each of the processing stations 106. The method can further include: forming one or more features of the glass article 103 at a processing end 150 of the glass tube 102 by indexing the glass tube 102 through each of the plurality of heating stations 202 and at least one forming station 204; and separating the glass article 103 from the processing end of the glass tube 102 at the separation station 206, wherein separating the glass article 103 from the processing end of the glass tube 102 forms a glass meniscus at the processing end of the glass tube 102. The method can further include indexing the glass tube 102 from the separation station 206 to an auxiliary processing station 203 disposed directly downstream of the separation station 206, wherein the auxiliary processing station 203 includes one of the heating stations 202 or one of the forming stations 204. The method can further include piercing the meniscus at the processing end of the glass tube. Piercing the meniscus opens the processing end of the glass tube 102. The auxiliary processing station 203 can be a heating station 202 or a forming station 204.

[0035] Directional terms used herein - such as up, down, right, left, front, back, top, bottom - are only with reference to the drawn figures and the coordinate axes provided therewith, and are not intended to imply absolute orientation.

[0036] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a particular order, nor that any apparatus require a particular orientation. Accordingly, if a method claim does not actually recite an order to be followed by its steps, or any apparatus claim does not actually recite an order or orientation of individual components, or the steps are not otherwise specifically stated in the claims or specification to be limited to a particular order, or the order or orientation of components of the apparatus is not recited, then it is in no way intended that an order or orientation be inferred in any respect. This applies to any possible basis of non-explicit interpretation, including: logical matters regarding step arrangement, operational flow, component order, or component orientation; plain meaning derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.

[0037] As used herein, unless the context clearly dictates otherwise, the singular forms "a", "an", and "the" include plural referents. Thus, for example, unless the context clearly indicates otherwise, reference to "a" component includes aspects having two or more such components.

[0038] As used herein, the "processing end" of a glass tube is the end of the glass tube that is oriented relative to the retainer towards the processing station of the main turntable of the conversion processing machine, and the "non-processing end" of the glass tube is the end of the glass tube that is oriented away from the processing station of the main turntable.

[0039] As used herein, the "dwell time" of a conversion processing machine refers to the duration that a glass tube spends in a particular processing station before being transferred to the next subsequent processing station. For an indexing conversion processing machine, the dwell time is the time elapsed from the first time the glass tube reaches a fixed position in the processing station and the second time the glass tube begins to move out of the fixed position towards the next processing station.

[0040] As used herein, the term "active time" refers to the duration that a glass tube remains in engagement with at least one heating element or at least one forming tool while in a particular processing station.

[0041] As used herein, the term "indexing time" when used in relation to an indexing conversion processing machine refers to the duration that a glass tube is translated from one processing station to the next processing station immediately downstream of the one processing station. "Dwell time", "active time", and "indexing time" are all measured in units of time.

[0042] When used in relation to a heating station, the "engagement" of the heating device with the glass tube 102 may refer to placing the heating device in a position where the flame and / or electromagnetic radiation from the heating device extends towards or contacts the glass tube 102 to heat the glass tube 102. Conversely, when the heating device is disengaged from the glass tube 102, the heating device is placed in a position where the flame or electromagnetic radiation from the heating device is directed away from the glass tube 102 or moved far enough away from the glass tube 102 such that the flame or electromagnetic radiation does not contact the glass tube 102 or directly heat it.

[0043] When used in relation to the forming tool 324 in the forming station 204, the term "engagement" refers to the forming tool 324 contacting the glass tube 102. When the forming tool 324 is disengaged, the forming tool 324 does not contact the glass tube 102.

[0044] As used herein, the term "part rate" refers to the production rate or throughput rate of a conversion processing machine in units of the number of glass articles per unit time.

[0045] As used herein, the term "circumference" of a glass tube refers to the set of points that are at a constant radius r from the central axis D of the glass tube 102 at a particular Z position (i.e., a position on the + / -Z axis of the figure) throughout 360 degrees. For example, the circumference of the glass tube 102 may coincide with the outer surface 140 of the glass tube 102 at a particular Z position, or may coincide with the inner surface 146 of the glass tube 102 at different Z positions.

[0046] As used herein, the term "run" refers to the normal steady-state operation of a conversion processing machine. Thus, as used herein, a "run setting" refers to the settings of a conversion processing machine for the normal steady-state operation of the conversion processing machine.

[0047] As used herein, the terms "upstream" and "downstream" refer to the relative positioning of the processing stations of a conversion processing machine with respect to each other. If a glass tube experiences a second processing station before it experiences a first processing station, the first processing station is considered to be "downstream" of the second processing station. Similarly, if a glass tube experiences a first processing station before it experiences a second processing station, the first processing station is considered to be "upstream" of the second processing station.

[0048] A glass tube can be converted into glass articles, particularly various glass articles for pharmaceutical applications, which can include but are not limited to vials, syringes, ampoules, cartridges, jars, and other glass articles. A conversion processing machine, such as a conversion processing machine including multiple processing stations, can be used to convert the glass tube into these glass articles. The processing stations can include but are not limited to heating stations, forming stations, separating stations, piercing stations, cooling stations, polishing stations, measuring stations, or other types of processing stations. The conversion processing machine typically uses steps including but not limited to flame processing, rotary and fixed tool forming, separating (such as thermal separation or scribing and impact truncation steps), piercing, cooling, measuring, or other processing steps to reform a long glass tube section into multiple glass articles. Thus, the glass articles produced by the conversion processing process performed on the conversion processing machine are subjected to a series of flame burners or other heating elements and forming tools to shape the glass tube into a particular shape and size and to separate the formed glass article from the processed end of the glass tube.

[0049] Now refer to Figure 1, schematically depicts an embodiment of a conversion processing machine 100 for producing glass articles from a glass tube 102. The conversion processing machine 100 converts the glass tube 102 into a plurality of glass articles. The conversion processing machine 100 may include a base 104 having a plurality of processing stations 106 and a main turntable 108 positioned above the base 104 and rotatable relative to the base 104 about a central axis A. The conversion processing machine 100 may further include a glass tube loading turntable 110 positioned above the main turntable 108 for feeding the glass tube 102 to the main turntable 108. The conversion processing machine 100 may also include a plurality of secondary processing stations 112 on the base 104 and a secondary turntable 114 rotatable relative to the base 104.

[0050] As Figure 1 schematically depicted therein, the base 104 of the conversion processing machine 100 may be fixed, and the processing stations 106 may be coupled to an upper portion 105 of the base 104. The plurality of processing stations 106 may be spaced apart from each other and arranged in a main loop 116. In an embodiment, the main loop 116 may be circular such that the main turntable 108 indexes the glass tube 102 through the plurality of processing stations 106 by rotating the main turntable 108 about the central axis A. Alternatively, in an embodiment, the main loop 116 may be a linear arrangement of the processing stations 106. Although described herein with reference to a circular arrangement of the processing stations 106, it should be understood that the subject matter disclosed herein may be equally well applied to conversion processing machines having other arrangements of the processing stations 106 (such as linear, curved, or irregular shaped arrangements of the processing stations 106).

[0051] The type and / or shape of the glass articles to be manufactured from the glass tube 102 may affect the total number of processing stations 106 of the conversion processing machine 100. The number of processing stations 106 of the main turntable 108 may be from 14 to 32 processing stations 106. Although the conversion processing machine 100 and the conversion processing process are described herein in the context of the conversion processing machine 100 having sixteen processing stations 106 in the main loop 116, it should be understood that the conversion processing machine 100 may have more or fewer than sixteen processing stations 106 in the main loop 116. The processing stations 106 of the conversion processing machine 100 may include, for example but not limited to, one or more heating stations, forming stations, polishing stations, cooling stations, separation stations, measurement stations, tube loading stations, discharge stations, other processing stations, or combinations of these stations for producing glass articles from the glass tube 102. The type and / or shape of the articles to be manufactured from the glass tube 102 may also affect the type of the processing stations 106 of the conversion processing machine 100 and / or the order of the processing stations 106 in the main loop 116.

[0052] The main turntable 108 is generally positioned above the base 104 and is rotatable relative to the base 104 about a central axis A. A drive motor (not shown) can be used to rotate the main turntable 108 relative to the base 104. The main turntable 108 includes a plurality of holders 130 configured to removably secure each glass tube 102 to the main turntable 108 and rotate the glass tube 102. The holders 130 can include, but are not limited to, clamps, chucks, or other holding devices, or combinations of holding devices. The holders 130 can orient each glass tube 102 such that the glass tube 102 is generally parallel to the central axis A of the main turntable 108. Although the converting machine 100 is described in the context of a vertically oriented converting machine 100 in this specification, it should be understood that the converting machine 100 can be horizontally oriented or oriented at an angle such that the glass tube 102 is not vertical during processing. Each holder 130 can extend from the bottom portion 109 of the main turntable 108 in a direction towards the base 104 (i.e., in the -Z direction relative to the coordinate axes in Figure 1 ). As each holder 130 indexes to each successive processing station 106 of the main loop 116, the holder 130 can be oriented to position the processing end 150 of the glass tube 102 in or near each successive processing station 106. The vertical orientation of the glass tube 102 allows the downward projecting portion of each glass tube 102 to gradually index through the processing stations 106.

[0053] The converting machine 100 of the present disclosure can be an indexing converting machine 100, where the converting machine 100 indexes each of a plurality of holders 130 gradually through a plurality of processing stations 106. Indexing refers to the step-by-step process of moving the glass tube 102 into the processing station 106, maintaining the glass tube 102 at a fixed XYZ position in the processing station 106 for a dwell time, and then indexing the glass tube 102 to the next processing station 106. During the dwell time, the glass tube 102 is processed in the processing station 106, such as, but not limited to, heating, forming, cooling, measuring, separating, etc. During the indexing time, the holder 130 and the glass tube 102 are translated between two adjacent processing stations 106.

[0054] Each retainer 130 is rotatable individually relative to the main turntable 108 to rotate the glass tube 102 about a central axis D of the glass tube 102, which central axis D is generally parallel to the central axis A of the main turntable 108. Each retainer 130 is operatively coupled to a motor (not shown), a continuous drive belt, or other drive mechanism for rotating each retainer 130 relative to the main turntable 108. Rotation of the retainer 130 allows the glass tube 102 to rotate about the central axis D of the glass tube 102 relative to a fixed heating element, forming tool, cooling nozzle, or other feature of the processing station 106. In an embodiment, the heating element and / or forming tool in the processing station 106 may be maintained in a fixed position relative to the glass tube 102, and rotation of the glass tube 102 about the central axis D may expose the entire circumference of the glass tube 102 to the heating element or forming tool.

[0055] Reference Figure 1 and 2 , as previously discussed, the conversion processing machine 100 may include a plurality of secondary processing stations 112 spaced apart and arranged in a secondary loop 118 ( Figure 2 ). The conversion processing machine 100 may include a secondary turntable 114 ( Figure 1 ) for indexing or continuously moving an article 103 ( Figure 1 ) that has been separated from the glass tube 102 through the plurality of secondary processing stations 112. The secondary turntable 114 is rotatable relative to the base 104 about a second axis B, where the second axis B is generally parallel to the central axis A of the main turntable 108. The secondary turntable 114 may also include a plurality of retainers 130 for holding the glass article 103 and positioning the glass article 103 to engage each secondary processing station 112 sequentially. The secondary turntable 114 receives the glass article 103 from a separation station 206 ( Figure 2 ) of the main turntable 108, indexes or continuously translates the glass article 103 through the plurality of secondary processing stations 112 by rotation of the secondary turntable 114, and discharges the finished glass article 103 from the conversion processing machine 100. Although shown in a circular pattern, it should be understood that the secondary processing stations 112 may be arranged in a linear, curved, or irregular arrangement. For a conversion processing machine configured to produce glass vials, ampoules, jars, or other single-opening containers, the secondary processing stations 112 are generally collectively referred to as bottom forming machines and are operable to form the bottom of the container.

[0056] The glass tube loading turntable 110 may be positioned adjacent to the main turntable 108 at a location where the glass tube loading turntable 110 is capable of loading a new section of the glass tube 102 into the retainer 130 of the main turntable 108 from that location in at least one processing station 106. In an embodiment, the processing station 106 aligned with the glass tube loading turntable 110 may be a tube loading station 214 ( Figure 2)。When the conversion processor 100 has converted all or at least a portion of the glass tube 102 at the specific retainer position 136 into one or more glass articles, the glass tube loading turntable 110 can be indexed to the retainer position 136 to align with the tube loading station 214 ( Figure 2 ) and deliver a new section of the glass tube 102 to the retainer 130 at the retainer position 136 through the top of the main turntable 108. In an embodiment, the conversion processor 100 can include an arm (not shown) that can move between the main turntable 108 and the glass tube loading turntable 110. When the conversion processor 100 has converted all or a portion of the glass tube 102 at the specific retainer position 136, the arm can grasp a new section of the glass tube 102 from the glass tube loading turntable 110 or other glass tube staging device and deliver the new section of the glass tube 102 to the main turntable 108 at the specific retainer position 136. Other methods and apparatuses for delivering new sections of the glass tube 102 to the main turntable 108 are contemplated.

[0057] Now referring to Figure 2 , an example of an embodiment of the conversion processor 100 of the present disclosure is schematically depicted. As Figure 2 shown, the plurality of processing stations 106 of the conversion processor 100 can include, but are not limited to, one or more heating stations 202, forming stations 204, separation stations 206, polishing stations 108, cooling stations 210, piercing stations 212, tube loading stations 214, discharge stations 216, measurement stations 218, tube section drop stations 220, other stations, and / or combinations of these stations.

[0058] Figure 2 The arrangement of the processing stations 106 is schematically depicted for a conversion processor 100 having a main circuit 116 with sixteen processing stations 106 and a secondary circuit 118 with eight secondary processing stations 112, but more or fewer processing stations 106 and secondary processing stations 112 are contemplated. As previously described, the processing stations 106 of the main circuit 116 can be evenly spaced and evenly distributed around a circular circuit, and the secondary processing stations 112 of the secondary circuit 118 can also be evenly spaced and evenly distributed around a circular circuit.

[0059] Figure 2 The main circuit 116 of the conversion processor schematically depicted in can include one or more heating stations 202, one or more forming stations 204, separation stations 206, piercing stations 212, one or more cooling stations 210, measurement stations 218, tube section drop stations 220, tube loading stations 214, or other processing stations 106. Relative to the indexing direction 222 of the main turntable 108, the heating stations 202 are generally positioned ahead of each of the forming stations 204 and separation stations 206 to preheat the target region of the glass tube 102 to a viscosity at which the glass becomes deformable and can be shaped or stretched and separated.

[0060] Referring again to Figure 2 , the forming station 204 of the main turntable 108 can be positioned downstream of the separation station 106, one or more heating stations 202, or both, in the indexing direction 222. The forming station 204 repeatedly shapes the glass tube 102 to form one or more features of the finished glass article. Specifically, the forming station 204 of the main turntable 108 can be configured to shape the working end 150 of the glass tube 102 ( Figure 4 and 5 ) to form a feature at one end of the glass article 103. After the glass article 103 has been separated from the glass tube 102, the forming station 204 or the polishing station 208 of the secondary turntable 114 can shape the other end of the glass article 103 (e.g., the bottom of a vial). In an embodiment, the conversion processing machine 100 can be used to produce vials from the glass tube 102, and the forming station 204 of the conversion processing machine 100 can include one or more shoulder forming stations, flange forming stations, flange trimming stations, or combinations of these stations, with one or more heating stations 202 positioned before and between each forming station 204.

[0061] The main circuit 116 can further include a measurement station 218 where at least one measuring device can be used to measure one or more properties of the glass tube 102. The properties of the glass tube can include, but are not limited to, one or more dimensions of the glass tube 102, or features of the glass article 103 formed by the forming station 204, one or more appearance properties of the glass tube 102 or the glass article 103, or combinations thereof. The conversion processing machine 100 can further include a cooling station 210, a tube section drop station 220, a tube loading station 214, or combinations of these stations, between the forming station 204 and the separation station 206. At the separation station 206, the partially formed glass article is separated from the glass tube 102 ( Figure 1 ). In the case of glass vials, ampoules, jars, and other single-opening glass containers, the bottom of the container is formed simultaneously during separation. The separation station 206 can also be the processing station 106 where the partially formed glass article is transferred to the secondary turntable 114 ( Figure 1 ) to index through the secondary circuit 118 of the secondary processing station 112.

[0062] Referring again to Figure 2 , the secondary processing station 112 of the secondary circuit 118 can include one or more heating stations 202, forming stations 204, polishing stations 208, piercing stations 212, cooling stations 210, discharge stations 216, other processing stations, or combinations of the secondary processing station 112. The secondary turntable 114 can rotate about axis B in a direction 224 opposite to that of the main turntable 108. In an embodiment, the secondary turntable 114 can rotate in the same direction as the main turntable 108. Although Figure 2The secondary loop is depicted as a circular arrangement having a secondary processing station 112, as previously discussed, but the secondary loop may have the secondary processing station 112 positioned in other non-circular arrangements such as, for example, linear, curved, irregular shapes, or other arrangements. In an embodiment, the secondary processing station 112 of the secondary loop 118 may be used to form one or more features of the glass article 103, such as a vial, ampoule, cartridge, or syringe, for example, at an end of the glass article 103 opposite the end formed by the main turntable 108. For example, in some embodiments, the glass article 103 is a vial, and the forming station 204 of the secondary loop 118 may form the bottom of the vial. Other features are also contemplated, such as those unique to ampoules, cartridges, syringes, etc. The secondary loop 118 may include one or more polishing stations 208 to finish the surface of the glass article. The secondary loop 118 may further include a plurality of cooling stations 210 and an ejection station 216 where the finished glass article 103 is ejected from the conversion processor 100.

[0063] The previous description of the processing stations 106 of the main loop 116 and the secondary processing stations 112 of the secondary loop 118 was in the context of the conversion processor 100 having 16 stations in the main loop 116 and 8 stations in the secondary loop 118. However, it should be understood that more or fewer processing stations 106 and secondary processing stations 112 may be utilized to manufacture vials or other glass articles having different shapes or features, such as cartridges, syringes, ampoules, or other pharmaceutical glass articles. Additionally, it should be understood that the processing stations 106 and secondary processing stations 112 may be arranged in any number of different orders and / or configurations in order to produce glass articles of different shapes or different sizes.

[0064] Now referring Figure 3A to, the heating device 202 of the conversion processor 100 is schematically depicted. Each heating device 202 includes one or more microwave generating devices 301. A heating station 202 is a processing station in which a region of the glass tube 102 is heated by one or more microwave generating devices 301 to increase the temperature of the glass and / or decrease the viscosity of the glass. The heating device 202 may be used in a processing station 202 in which the glass is heated without significantly changing the physical shape of the glass tube 102, or in a processing station 202 in which the shape of the glass tube 102 is changed (e.g., by removing a partially formed glass article from the processing end of the glass tube 102; by piercing the glass meniscus at the processing end 150 of the glass tube to change the shape of the glass tube 102; or by shaping the glass tube 102 to at least partially form the glass article; or by at least partially forming the glass article after separation from the glass tube 102). Thus, the heating device 202 may be used in various processing stations, including heating stations, forming stations, separation stations, piercing stations, cooling stations, polishing stations, measurement stations, or other types of processing stations.

[0065] Referring again to Figure 3A , the heating device 202 includes a beam outlet 302 configured to volumetrically heat the glass tube 102 using electromagnetic radiation. As used herein, "volumetric heating" refers to heating a volume of material (such as the glass tube 102) such that the electromagnetic radiation penetrates uniformly throughout the volume of the material. Thus, volumetric heating delivers energy uniformly into the bulk of the material. In contrast, conventional conduction and convective heat heating rely on heating the surface temperature of the material. Thus, with conventional conduction and convective heating, the surface temperature of the material (such as the glass tube 102) rises much faster than the interior of the material.

[0066] As discussed above, the heating device 202 is an electromagnetic heating device that uses electromagnetic radiation to volumetrically heat the glass tube 102. In an embodiment, the electromagnetic radiation can be microwaves such that the heating device 202 is a gyrotron microwave heating device. It is also contemplated that the electromagnetic radiation is visible light, ultraviolet light, infrared light, or any other radiation configured to heat a volume of the glass tube 102.

[0067] In some embodiments, the heating device 202 includes a high-power linear beam vacuum tube that generates millimeter-wave electromagnetic waves through the cyclotron resonance of electrons in a strong magnetic field. In aspects of the embodiment, the electromagnetic radiation generated by the heating device 202 includes a microwave beam 304, and the heating device 202 directs the microwave beam 304 outward from the beam outlet 302 toward one side of the glass tube 102, such as the first side 306a or the second side 306b of the glass tube 102. As Figure 3A shown, the beam outlet 302 is disposed on the first side of the glass tube 102 such that the beam outlet 302 directs the microwave beam 304 toward the first side 306a, but it should be understood that the beam outlet 302 can be disposed on the second side of the glass tube 102. Also as Figure 3B shown, the microwave beam 304' can be focused by the heating device 202 into a strip shape. In some examples, the cross-section of the microwave beam 304 includes a width equal to or greater than the width of the glass tube 102 or greater than or equal to the width of a plurality of glass tubes positioned side by side.

[0068] As Figure 3BAs shown, in an embodiment, the heating device 202 may be arranged to heat a target region of one or more glass tubes 102a to 102e. This may be achieved using a single microwave generating device 301 in which the microwave beam 304 is shaped to be directed at multiple glass tubes, or by incorporating multiple microwave generating devices 301 in the heating device. Examples of embodiments include multiple microwave generating devices 301 arranged to heat one or more glass tubes from the same side, or arranged to heat one or more glass tubes from opposite sides of the glass tubes. In an embodiment, the heating device 202 may include a mixture of different types of heating devices, including microwave generating devices 301 and one or more gas burners, infrared burners, or other types of heating elements. These other types of burners may be fluidly coupled to a fuel gas supply source, an oxygen supply source, and an optional air supply source. Examples of fuel gases for the burners may include, but are not limited to, hydrogen, hydrocarbon fuel gases such as methane, propane, and butane, other fuel gases, or combinations of these gases.

[0069] The electromagnetic radiation generated by the heating device 202 may include about 1×10 5 W / m 2 or greater, about 1×10 6 W / m 2 or greater, about 2×10 6 W / m 2 or greater, about 3×10 6 W / m 2 or greater, about 4×10 6 W / m 2 or greater, about 5×10 6 W / m 2 or greater, about 6×10 6 W / m 2 or greater, about 7×10 6 W / m 2 or greater, about 8×10 6 W / m 2 or greater, about 9×10 6 W / m 2 or greater, about 1×10 7 W / m 2 or greater, about 1×10 8 W / m 2 or greater or any range of power intensities having any two of these values as endpoints, such as between about 1×10 5 W / m 2 and about 1×10 8 W / m 2 or between about 2×10 6 W / m 2 and about 9×10 6W / m 2 or about 6×10 6 W / m 2 to about 8×10 6 W / m 2 in the range of power intensity. Additionally, the electromagnetic radiation generated by the heating device 202 may include frequencies from about 5 GHz to about 500 GHz, from about 5 GHz to about 400 GHz, from about 5 GHz to about 300 GHz, from about 10 GHz to about 300 GHz, from about 10 GHz to about 200 GHz, from about 25 GHz to about 200 GHz, from about 28 GHz to about 300 GHz, from about 30 GHz to about 150 GHz, from about 50 GHz to about 200 GHz, such as about 5 GHz, about 25 GHz, about 50 GHz, about 75 GHz, about 100 GHz, about 150 GHz, about 200 GHz, about 300 GHz, about 400 GHz, about 500 GHz, or any range with any two of these values as endpoints, or any open-ended range with any one of these values as the lower or upper limit.

[0070] Referring again to Figure 3A , the conversion processor 100 may further include a control structure 356 that includes an absorption device 357, a shielding device 358, or both. For example, in the embodiment depicted in Figure 3A , the control structure 356 includes an absorption device 357 surrounded by a shielding device 358. In some embodiments, the shielding device 358 includes a metallic material, such as stainless steel, to reduce and / or prevent any electromagnetic leakage, such as microwave leakage. The absorption device 357 may include, for example, a carbon-based foam absorber, a water jacket, or a combination thereof, to absorb electromagnetic radiation, thereby reducing and / or preventing any electromagnetic leakage, such as microwave leakage. Additionally, the beam outlet 302 of the heating device 202 may extend into the control structure 356 such that, for example, the microwave beam 304 is contained within the control structure 356, which helps direct the microwave beam 304 towards the target area of the glass tube 102 and minimizes electromagnetic propagation away from the target area and out of the control structure 356. For example, the control structure 356 may include a hole into which (or through which) the beam outlet 302 extends or is otherwise coupled.

[0071] As discussed above, some embodiments of the conversion processing machine 100 include one or more secondary heating devices that can assist the heating step at any of the processing stations. The secondary heating devices can be disposed upstream or downstream of the beam outlet 302 along the path traveled by the glass tube 102. The plurality of secondary heating devices can include one or more conduction heaters, convection heaters, infrared heaters, resistance heaters, induction heaters, flame heaters, and the like. The secondary heating devices can be configured to heat the glass tube 102 simultaneously during the volume heating by the heating device 202. As an aspect of an embodiment of the present disclosure, the heating step performed at one or more processing stations of the conversion processing machine 100 can include volume heating of the glass tube 102 using the heating device 202. In some embodiments, the heating step includes volume heating of the glass tube 102 using the heating device 202 and heating of the glass tube 102 using one or more secondary heaters.

[0072] Because volumetric heating increases the temperature of the glass at a faster rate compared to conventional conduction and convection heating techniques, the volumetric heating disclosed herein may require a reduced heating period to reach the desired temperature and viscosity. For example, during volumetric heating using heating device 202, the temperature of glass tube 102 in the target heating region may increase at an average heating rate of: about 5 °C / second or higher, about 10 °C / second or higher, about 15 °C / second or higher, about 20 °C / second or higher, about 30 °C / second or higher, about 40 °C / second or higher, about 50 °C / second or higher, about 60 °C / second or higher, about 70 °C / second or higher, about 80 °C / second or higher, about 90 °C / second or higher, about 100 °C / second or higher, such as about 5 °C / second to about 100 °C / second, about 10 °C / second to about 90 °C / second, about 20 °C / second to about 80 °C / second, about 30 °C / second to about 80 °C / second, about 40 °C / second to about 80 °C / second, about 50 °C / second to about 80 °C / second, or any range with any two of these values as endpoints. During volumetric heating, the temperature of glass tube 102 in regions other than the target heating region may increase at an average heating rate that is less than the heating rate of the target heating region. For example, the average heating rate may be about 0.3 times, or about 0.4 times, or about 0.5 times, or about 0.6 times, or about 0.7 times, or about 0.8 times, or about 0.9 times less than the average heating rate of the target heating region. Due to the rapid heating provided by the embodiments herein, it is possible to heat the target heating region of the glass tube to the desired temperature within a heating period of: about 0.1 second to about 30 seconds, about 0.1 second to about 20 seconds, about 0.1 second to about 10 seconds, about 0.1 second to about 7.5 seconds, about 0.5 second to about 7.5 seconds, about 1 second to about 7.5 seconds, about 1.5 seconds to about 6 seconds, about 1.5 seconds to about 5 seconds, about 0.5 second to about 5 seconds, or any range with any two of these values as endpoints, or any open-ended range with any one of these values as the lower or upper limit.

[0073] It is also contemplated that the frequency of the electromagnetic radiation generated from the heating device 202 may be related to the thickness and / or shape of the target glass in order to provide an optimal energy absorption rate of the glass. More specifically, the frequency of the electromagnetic radiation may be selected to substantially match and be the same as the thickness of a selected portion of the glass. When the frequency matches the thickness of the selected portion of the glass, the glass absorbs the electromagnetic radiation across the thickness at an optimal absorption rate. When the frequency of the electromagnetic radiation is higher or lower than the thickness of the selected portion of the glass, the glass absorbs the electromagnetic radiation at an absorption rate lower than the optimal absorption rate. For example, if the target heating area of the glass is in a portion of the glass having a thickness of about 2 mm, the frequency of the electromagnetic radiation may be selected to be about 2 mm or less (which is equivalent to about 56 GHz or higher) in order to provide an optimal energy absorption rate for the glass. Additionally, embodiments include selecting the frequency to uniformly heat opposite sides of a hollow glass tube or to uniformly heat the glass tube throughout its entire circumference.

[0074] Embodiments of the present disclosure include steering or shaping millimeter wavelength beams to heat a target area of a glass tube. Since millimeter microwave beams can be collimated, these beams can be directly focused onto the target area to be heated. Compared to, for example, a gas burner, this not only improves the accuracy of heating but also wastes less energy during the process. By precisely controlling the target heating area, the microwave heat source can meet the high-precision requirements of strict dimensional specifications to achieve the nominal design shape of the finished glass product. This precision of the microwave beam can also enhance process repeatability and increase production throughput.

[0075] Embodiments of the systems and methods disclosed herein include heating glass tubes or articles in different arrangements using a microwave generating device. For example, the microwave generating device can heat a single glass tube or article or a group of glass tubes or articles, where the group of glass tubes or articles includes one or more rows of tubes, columns, or clusters of glass tubes. Designing the configuration of the glass tubes involves selecting an optimized frequency, calculating the absorption rate of each tube, and designing beam shaping optics. The ability to heat multiple tubes enables an increase in processing throughput with a higher energy utilization rate.

[0076] Now referring Figure 4 and 5 , an example of the forming station 204 of the conversion processing machine 100 is schematically depicted. The forming station 204 refers to a processing station where one or more features of a glass article are formed in close proximity to the processing end 150 of the glass tube 102 by contacting the glass tube 102 with one or more forming tools 324. The forming station 204 does not include the separating station 206 or the piercing station 212. Each forming station 204 includes one or more forming tools 324, and the one or more forming tools 324 can be relative to the base 104 ( Figure 1)Rotate around the tooling shaft E. When transferred to the forming station 204, the glass tube 102 that has been heated in the previous heating station 202 or in the separation station 206 is rotated by the retainer 130. As the glass tube 102 rotates, the forming tool 324 engages with the glass tube. When engaged, the contact of the forming tool 324 with the heated glass tube 102 can cause the glass tube 102 to be formed into a desired shape. The forming tool 324 can contact the glass tube 102 to achieve the active time of the forming tool 324. At the expiration of the active time, the forming tool actuator 326 can retract the forming tool 324 from the engagement with the glass tube 102. Figure 4 An embodiment of the forming station 204 for forming the shoulder 142 of a glass vial is schematically shown. Figure 5 An exemplary embodiment of the forming station 204' for forming the flange 144 of a glass vial is schematically depicted. The forming station 204' for forming the flange 144 includes three forming tools 324a, 324b, and 324c. Depending on the desired characteristics of the glassware 103, other types of forming tools 324 can be employed in the forming station 204.

[0077] Referring again to Figure 4 , the forming tool actuator 326 is operable to move the forming tool 324 into and out of engagement with the glass tube 102. Moving the forming tool 324 into and out of engagement with the glass tube 102 can control the contact timing of the forming tool 324 with the glass tube 102. The contact timing of the forming tool 324 with the glass tube 102 refers to the timing of each forming tool 324 in the forming station 204 engaging with and disengaging from the glass tube 102. Adjusting the contact timing of the forming tool 324 can adjust the total active time of each forming tool 324 in contact with the glass tube 102, the contact sequence of the forming tool 324 with the glass tube 102, or both. As previously discussed, the active time refers to the duration during which at least one of the forming tools 324 engages or contacts the glass tube 102. The contact sequence of the forming tool 324 with the glass tube 102 refers to the timing of each individual forming tool 324 in the forming station 204 engaging with and disengaging from the glass tube 102. Referring to Figure 5 , in some cases, the contact sequence can be adjusted such that each of the forming tools 324a, 324b, and 324c initially contacts the glass tube 102 at the same moment. In other cases, the contact sequence can be adjusted such that the forming tool 324c (pin) contacts the inner surface of the glass tube 102 before or after the forming tools 324a and 324b (wheels) contact the outer surface of the glass tube 102 at the start of the active time. The contact sequence can also include the order in which each of the forming tools 324a, 324b, 324c disengages from the glass tube 102 at the end of the active time. The term "contact timing" is intended to include both the total active time of the forming tool 324 engaging with the glass tube 102 and / or the contact sequence.

[0078] The forming tool actuator 326 is operable to move the forming tool 324 vertically (e.g., in the + / -Z direction of the coordinate axes in Figure 3A ), horizontally (e.g., in the X-Y plane identified by the coordinate axes in Figure 4 ), or in a combination of these directions relative to the glass tube 102 in the forming station 204. The forming position of the forming tool 324 refers to the position of the forming tool 324 when it engages the glass tube 102. In an embodiment, each forming tool actuator 326 may include one or more servo motors operable to automatically and / or incrementally adjust the position of the forming tool 324 in one or more directions of the coordinate axes in Figure 4 . Any other type of positioner, commercially available or to be made commercially available, may be used as at least a part of the forming tool actuator 326.

[0079] Now referring to Figure 6 , an embodiment of the separation station 206 of the conversion processing machine 100 is schematically depicted. Figure 6 The separation station 206 depicted in Figure 1 is a thermal separation station and may be positioned after one or more heating stations 202 in the indexing direction 222 of the main turntable 108. The heating station 202 positioned before the separation station 206 heats the glass tube 102 at the separation region of the glass tube to make the glass sticky. The separation station 206 may include a separation heating device 340. The separation heating device 340 may have any of the features previously described for the heating device 302, including but not limited to the microwave generating device 301 or a gas burner including associated valves and controls. When the glass tube 102, which has been made viscously deformable by the previous heating station 202, is rotated about the central axis D by the retainer 130, the separation heating device 340 may engage the glass tube 102 at the separation region to heat the glass tube 102 to a temperature at which the viscosity of the glass allows the partially formed glass article to be separated from the glass tube 102. Once separated from the glass tube 102, the partially formed article may be transferred to the secondary turntable 114 ( Figure 1 ) or discharged from the conversion processing machine 100. In an embodiment, the partially formed glass article may be transferred to a secondary retainer 342 for further processing on the secondary loop 118.

[0080] FIGS. 3-6 include schematic diagrams of several different examples of the processing station 106 that may be used in the conversion processing machine 100. However, it should be understood that other processing stations 106 having different structures, combinations of structures, or functions may be utilized, such as but not limited to cooling stations, measurement stations, polishing stations, or other processing stations 106, to effect the desired conversion processing of the glass tube 102 into one or more glass articles.

[0081] Now referring to Figure 7, the glass tube 102 includes an elongated hollow cylindrical tube made of glass. The glass tube 102 has an annular cross-sectional shape and includes an outer surface 140, an inner surface 146, and a thickness t. The thickness t of the glass tube 102 refers to the radial distance between the inner surface 146 and the outer surface 140 of the glass tube 102. The glass tube 102 may have a length L measured in the + / -Z direction of the coordinate axes in Figure 7 . As the glass article 103 is gradually removed from the processing end 150 of the glass tube 102 during the conversion processing operation, the length L of the glass tube 102 decreases. The glass tube 102 has an Figure 7 outer diameter OD as shown in. As previously discussed, throughout the conversion processing operation, the glass tube 102 rotates about the central axis D of the glass tube 102. The processing end 150 of the glass tube 102 is the end of the glass tube 102 that is oriented in the -Z direction of the coordinate axes in Figure 7 when the glass tube 102 is fixed in the holder 130 of the conversion processing machine 100. The non-processing end of the glass tube 102 is the end opposite the processing end 150 (i.e., the end of the glass tube 102 in the +Z direction of the coordinate axes in Figure 2 ). Although the processing end 150 is shown as the lowermost end of the glass tube 102, it should be understood that the conversion processing machine 100 may be configured to orient the processing end 150 of the glass tube 102 in an upward direction, a horizontal direction, or other directions.

[0082] Referring again to Figure 1 and 2 , the conversion processing machine 100 may be an indexing conversion processing machine, where each of the plurality of processing stations 106 is fixed, and the conversion processing machine 100 indexes the glass tube 102 successively through each of the plurality of processing stations 106. In operation, the conversion processing machine 100 indexes the glass tube 102 fixed in the holder 130 into the processing station 106. Specific operations may be performed on the glass tube 102 at each processing station 106, such as heating, forming, separating, cooling, polishing, lowering, loading, measuring, etc. The conversion processing machine 100 may be adjusted such that all processing stations 106 complete their operations within the dwell time. At the end of the dwell time, the conversion processing machine 100 indexes the glass tube 102 to the next processing station 106 in the main loop 116. For an indexing conversion processing machine, the total time per part per station used in the present disclosure is the sum of the dwell time and the indexing time. At the separation station 206, the partially finished glass article 103 is separated from the processing end 150 of the glass tube 102 and transferred to the secondary processing station 112 in the secondary loop 118.

[0083] Examples of a conversion processing machine 100 for converting a glass tube 102 into a glass vial include vial forming machines of model RP16 or RP18 with an automatic tube feeder, manufactured by AMBEG Dr. J. Dichter GmbH, which include sixteen processing stations 106 in the main circuit 116 and eight secondary processing stations 112. Other examples include: a vial forming machine of model RP32, manufactured by AMBEG Dr. J. Dichter GmbH, which has thirty-two processing stations 106 in the main circuit 116 and two secondary circuits 118, each having eight secondary processing stations 112; and a Zeta 098 vial forming machine, manufactured by Euromatic S.R.L., which has 36 processing stations. Another example may include a Zeta 103 cartridge vial forming machine, manufactured by Euromatic S.R.L., which is a conversion processing machine for converting a glass tube into a glass cartridge vial. The cartridge vial conversion processing machine has characteristics similar to those of the previously described vial conversion processing machine 100, but the cartridge vial conversion processing machine is used to produce glass articles having a glass cartridge vial form factor rather than a glass vial.

[0084] Although described in the context of a conversion processing machine 100 for producing glass vials from a glass tube 102, it should be understood that the conversion processing machine 100 described herein may be configured to produce one or more other articles, such as other types of pharmaceutical containers or articles, by changing the order or configuration of the forming tool 324 and / or the processing stations 106 in the main circuit 116 or the secondary processing stations 112 in one or more secondary circuits 118. Pharmaceutical articles may include, but are not limited to, vials, cartridge vials, syringes, ampoules, flasks, or other glass pharmaceutical articles. In an embodiment, the conversion processing machine 100 disclosed herein may be configured to produce single-opening glass containers, such as, but not limited to, vials, ampoules, flasks, or other glass containers, wherein the bottom of the glass container is formed by thermal separation of the glass article from the processing end 150 of the glass tube 102.

[0085] Refer again to Figure 6, during the thermal separation of the partially formed glass article 103 from the processing end 150 of the glass tube 102 at the separation station 206, the glass is heated by the separation heating device 340 until the glass is sufficiently viscous to enable the separation of the glass article from the processing end 150 of the glass tube 102. In an embodiment, the viscosity of the glass can be such that gravity alone is sufficient to separate the partially formed glass article from the processing end 150 of the glass tube 102. In an embodiment, the partially finished glass article 103 can be drawn downward to separate the partially finished glass article 103 from the glass tube 102. The thermal separation in the separation station 206 causes a glass film to form above the upward-facing end of the partially formed glass article 103 and on the new processing end 150 of the glass tube 102. The glass film on the upward-facing end of the partially formed glass article 103 forms the bottom of the glass article including vials, ampoules, jars, and other single-opening containers. On the processing end 150 of the glass tube 102, the glass film seals the processing end 150 of the glass tube 102. As used throughout this disclosure, the term "meniscus" is used to refer to the glass film that forms horizontally (e.g., perpendicular to the central axis D of the glass tube 102) across the processing end 150 of the glass tube 102. Before further heating and shaping the next glass article 103 at the processing end 150 of the glass tube 102, the glass meniscus at the processing end 150 must be pierced to reopen the processing end 150 of the glass tube 102.

[0086] As used herein, a "piercing station" refers to a processing station 106 where the glass meniscus 350 at the processing end 150 of the glass tube 102 is pierced. According to an embodiment, the piercing can be performed at the piercing station during the dwell time of the conversion processing machine 100. According to other embodiments, the piercing can be at least partially performed during the indexing time of the conversion processing machine 100 as the glass tube 102 is indexed from one processing station to the next. The piercing station 212 can include a piercing heating device arranged to heat the glass meniscus at the processing end 150 of the glass tube 102. During operation, the conversion processing machine 100 indexes the glass tube 102 directly from the separation station 206 to the piercing station 212. In the piercing station 212, the meniscus is pierced by heating the meniscus of the glass tube 102 previously formed in the separation station 206, thereby reopening the processing end 150 of the glass tube 102. Alternatively, the piercing of the meniscus can be performed while indexing the glass tube 102 from one processing station to the next.

[0087] According to an embodiment, the piercing can be formed by the heating device 202 disclosed herein. For example, the piercing can be performed by a burner directed to direct a flame into contact with the glass meniscus at the processing end 150 of the glass tube 102. In an embodiment, the microwave generating device 301 is used to heat the processing end 150 of the glass tube 102 and thus pierce the meniscus. The microwave generating device can direct a beam from below the processing end (i.e., in the Figure 3A -Z direction in Figure 3A shown) upward in the +Z direction to the meniscus. In other embodiments, the microwave generating device 301 can be placed on one side of the glass tube (as Figure 3A shown) to direct a beam with an appropriate frequency and energy to pierce the meniscus in the processing end 150 of the glass tube. For example, the microwave generating device 301 can direct the beam substantially horizontally (in the Figure 3A X-Y plane) to heat the center of the meniscus, or the microwave generating device 301 can be oriented at an angle to heat the meniscus of the processing end 150 of the glass tube 102. As described herein, the frequency and energy of the microwave beam 304 can be selected to preferentially heat the meniscus rather than the sidewall of the glass tube, or specifically target the center of the meniscus.

[0088] The piercing device can be any device capable of piercing the meniscus formed at the processing end 150 of the glass tube 102. Piercing devices suitable for piercing the meniscus can include, but are not limited to, a piercing burner, a laser, a suction device, a positive airflow device, a mechanical device, a gyrotron microwave generator, or a combination of these devices.

[0089] In an embodiment, the meniscus may be pierced by directing a gas flow, such as compressed air, nitrogen, argon, or other gases, at or across the meniscus. In an embodiment, a suction device may be used to generate a negative pressure large enough to pierce the meniscus. In an embodiment, mechanical means or other methods may be used to pierce the meniscus instead of using a piercing heating device. Various methods of piercing the meniscus are disclosed in the following documents: U.S. Patent No. 10,968,133, entitled "METHODS FOR MINIMIZING SHR IN GLASS ARTICLES BY PRODUCING A GAS FLOW DURING PHARMACEUTICAL PART CONVERTING," granted on April 6, 2021; co-pending U.S. Application No. 16 / 197,187, entitled "SYSTEMS AND METHODS FOR MINIMIZING SHR FROM PIERCING DURING PHARMACEUTICAL PART CONVERTING USING A GAS FLOW," filed on November 20, 2018; co-pending U.S. Application No. 16 / 197,971, entitled "SYSTEMS AND METHODS FOR MINIMIZING SHR FROM PIERCING DURING PHARMACEUTICAL PART CONVERTING USING NEGATIVE PRESSURE EVACUATION," filed on November 21, 2018; and co-pending U.S. Application No. 16 / 198,041, entitled "SYSTEMS AND METHODS FOR MINIMIZING SHR FROM PIERCING FROM PHARMACEUTICAL PART CONVERTING USING PULSED EJECTION," filed on November 21, 2018, the entire contents of all of which are incorporated herein by reference.

[0090] The conversion processing machine 100 can be used in a method for producing multiple glass products from a glass tube. The method for producing multiple glass products from the glass tube 102 can include fixing the glass tube 102 in the holder 130 of the conversion processing machine 100. The conversion processing machine 100 can include any of the features of the conversion processing machine 100 previously described herein. The conversion processing machine 100 can include a plurality of processing stations 106, where the plurality of processing stations 106 can include a plurality of heating stations 202, at least one forming station 204, and a separation station 206. The conversion processing machine 100 indexes the holder 130 and the glass tube 102 successively through each processing station 106. The method can further include forming one or more features of the glass product at the processing end 150 of the glass tube 102 by indexing the glass tube 102 through each of the plurality of heating stations 202 and at least one forming station 204, and then separating the glass product from the processing end 105 of the glass tube 102 at the separation station 206. Separating the glass product from the processing end 150 of the glass tube 102 forms a glass meniscus at the processing end 150 of the glass tube 102. The method can further include indexing the glass tube 102 from the separation station 206 to an auxiliary processing station 203 disposed directly downstream of the separation station 206, and piercing the meniscus. The auxiliary processing station 203 can be one of the heating stations in the plurality of heating stations 202 or one of the forming stations 204. Piercing the meniscus opens the processing end 150 of the glass tube 102.

[0091] Separating the glass product from the processing end 150 of the glass tube 102 can include thermally separating the partially formed glass product from the processing end 150 of the glass tube 102. Refer to Figure 6 , thermally separating the partially formed glass product from the glass tube 102 can include heating a separation region of the glass tube 102 with a separation heating device 340 in the separation station 206, where the heating increases the viscosity of the glass in the separation region of the glass tube 102 to a degree that gravity will cause the partially formed glass product to separate from the processing end 150 of the glass tube 102. In some embodiments, during heating with the separation heating device 340, the partially formed glass product can be gradually pulled away from the processing end 150 of the glass tube 102. Thermal separation in the separation station 206 forms a glass meniscus above the processing end 150 of the glass tube 102.

[0092] Examples

[0093] The following examples illustrate the operation of the disclosed conversion processing machine and method for producing multiple glass products from a glass tube. The following examples are not intended to limit the scope of the present disclosure.

[0094] The glass tubes in these examples are borosilicate glass manufactured by Corning Incorporated. However, the embodiments are not intended to be limited to borosilicate glass, but may include, for example, aluminosilicate glass tubes, such as those manufactured and sold by Corning Incorporated glass. The aluminosilicate glass tubes can be further processed by annealing and / or ion-exchanging the glass tubes after conversion processing. The effects of the systems and methods disclosed herein do not depend on the type or composition of the glass. Thus, embodiments of the present disclosure can use borosilicate glass, aluminoborosilicate glass, aluminosilicate glass, fluorosilicate glass, phosphosilicate glass, fluorophosphate glass, thiophosphate glass, germanate glass, vanadate glass, borate glass, phosphate glass, titanium-doped silica glass, and the like.

[0095] Microwaves are electromagnetic (EM) waves with a frequency range between 0.3 GHz and 300 GHz. The microwave heating mechanism is the effect of microwave absorption through dielectric loss. In a microwave field, the inherent dipole moment or the induced dipole moment generated in a dielectric material interacts with the alternating EM field and reorients to align with the high-frequency EM field, thereby causing energy conversion from electrical energy to heat. EM waves are composed of an oscillating electric field component (E) and a magnetic field component (H), and the governing equations for the EM field are based on Maxwell's equations, as shown below in Equations (1) and (2):

[0096]

[0097] where E and H are the electric field vector and the magnetic field vector, J is the current density vector, D is the electric flux density vector, and B is the magnetic flux density vector. The relationships between J, D, and B and E and H are:

[0098]

[0099] where σ is the conductivity, ε is the dielectric constant or permittivity, and μ is the permeability.

[0100] Glass is non-magnetic, and its permeability is small enough to be negligible. In a uniform EM field, the power P(r) dissipated per unit volume in the glass is represented by the following equation (Equation (4)):

[0101]

[0102] where p e is the polarization power loss per unit volume (W / m 3 ); p c is the conduction power loss per unit volume (W / m 3); ω is the angular frequency (rad / s), ω = 2πf; f is the frequency (Hz); ε0 is the permittivity of free space (8.854×10 -8 F / m); ε″ is the relative electric loss factor; and δ is the loss angle. The dielectric loss factor is a measure of the energy absorbed in the dielectric as the electromagnetic wave passes through the dielectric.

[0103] The heat transfer equation describes the spatial and temporal behavior of the temperature field of a dielectric exposed to microwave radiation (Equation (5)).

[0104]

[0105] In Equation (5), ρ, c p and k are the material density, specific heat capacity, and thermal conductivity, respectively. The microwave power from the electric field distribution is used as volumetric heat generation. Using approximate boundary conditions, the solution of the above equation gives the transient temperature profile in the object.

[0106] Microwaves travel in a vacuum at the speed of light c v = 3×10 8 m / s. Considering a glass dielectric with a refractive index of n = 2.62, the permittivity can be derived as ε = n 2 = 6.85. The speed of light in the glass is To uniformly heat the glass material, it is important to select the frequency considering both the volumetric loss density profile and the energy attenuation. At higher frequencies, the d / λ g ratio is lower, and higher attenuation through the glass thickness is introduced.

[0107] Since the conductivity of dielectric materials is typically much smaller than the dipole reorientation effect, the relative electric loss factor becomes the main material property for microwave absorption. For most dielectric materials, the dielectric constant (or relative permittivity) is close to a constant in the gyrotron frequency range. The loss tangent (tanδ) of the material will then determine its ability to absorb microwaves. In Figure 8 , the frequency-dependent loss tangent of borosilicate glass is plotted based on experimental data. Data below 60 GHz were measured in the experiments for this disclosure, while data above 100 GHz are from the reference "Miscellaneous data on materials for millimeter and submillimeter optics". The existing measurement data are based on room temperature conditions. Compared with soda-lime glass and Compared with glass, borosilicate has a relatively low microwave absorption rate, but a higher absorption rate compared to silica. It is desirable to use a higher frequency gyrotron (100 GHz to 300 GHz) to achieve higher energy utilization and higher heating efficiency. Generally, glass exhibits a higher absorption rate at high temperatures. It can be seen that the loss tangent increases with increasing frequency. This means that the material has a larger absorption rate at the higher frequency end of 90 to 150 GHz.

[0108] The volume loss density of the entire glass thickness can be calculated based on Maxwell's equations. A sinusoidal energy profile can be formed at a given frequency and wall thickness. Figure 9 Show the volume loss density distribution of different microwave sources across a borosilicate tube with a wall thickness of 1.3 mm for frequencies of 30 GHz, 60 GHz, 90 GHz, and 150 GHz. A higher conversion of microwave energy to the internal energy of the glass can be achieved through a higher frequency microwave source. Figure 9 The plots in also show that the energy penetrates excellently through the glass thickness, enabling volumetric heating of the tube with high thermal uniformity. For example, in the case of a borosilicate tube with a wall thickness of 1.3 mm, for frequencies above 60 GHz, more than one cycle is formed across the wall thickness, but for 30 GHz, less than one cycle is formed, as Figure 9 shown in. Considering the low attenuation, a profile with more oscillations and less attenuation helps to achieve better thermal uniformity. Higher frequencies also result in higher energy absorption rates. In fact, a balance between the absorption rate and uniformity needs to be maintained. A larger absorption rate is not always beneficial because it may cause overheating of the surface layer of the glass tube, which will lead to poor thermal uniformity.

[0109] Borosilicate glass has a dielectric constant of 4.45 and a loss tangent of 0.01 to 0.02 in the range of 30 GHz to 150 GHz, and the corresponding power penetration depth is in the range of 80 mm to 8 mm. Due to the slow power attenuation in this frequency range, when the beam is incident vertically on the sidewall, the microwave energy can be uniformly converted within the glass tube wall thickness (from sub-millimeter to millimeter), and the transmitted energy can also heat the wall on the far side of the glass tube simultaneously. For a wall thickness of about 1 to 2 mm, a higher volume loss density can be achieved by using higher frequency microwaves. Due to the relative loss factor enhancement above 100 GHz, a high conversion percentage from electromagnetic energy to the internal energy of the glass can be achieved.

[0110] Use COMSOL software (from COMSOL Inc.) for modeling. The modeled glass tube has an outer diameter of 29.5 mm and a wall thickness of 1.3 mm. Using a 150 GHz and 40 kW millimeter wave source, more than 1.5E9 W / m can be generated in the two walls3 Volume loss density (VLD). Figure 10 Show the numerical modeling results of the instantaneous volume loss density of this 150 GHz source. The results show that microwaves can penetrate both walls from the near side and the far side and convert heat on both walls. And it only takes 14 s to raise the tube temperature from room conditions to over 1,000 °C. While applying the millimeter wave beam, the tube is kept spinning to ensure that the entire outer circumference is uniformly heated with a temperature gradient of less than 10 °C (see Figure 11 ). Figure 11 Show the tube temperature distribution during heating while keeping the tube spinning. Depending on the gyrotron power, the temperature can be raised from room temperature to over 1,000 °C in seconds to tens of seconds. The thermal uniformity along the glass outer circumference is within 10 °C.

[0111] As discussed herein, alternative configurations can be designed to increase production throughput, such as strip beam heating of a row of tubes, as Figure 12 modeled. Figure 12 Show that the embodiments of the present disclosure can be extended to simultaneously process multiple tubes when the beam is formed into a strip. Figure 12 The results in Figure 13 come from modeling the electric field and the corresponding tube temperature when heating a row of three tubes. Since only 26% of the energy is absorbed when the EM is transmitted to each wall of the 150 GHz gyrotron, a double row configuration can be designed to make full use of the energy. In Figure 13 an example of a 3-row configuration is modeled using the same frequency and power supply. It can be seen from the modeling results in Figure 13 that at least two rows of tubes can be heated simultaneously with high thermal uniformity. In this example, if there are more than three rows, the outer layer tubes will be heated less due to power attenuation. Here,

[0112] Although various embodiments of the conversion processing machine 100 and the system and method for producing multiple glass articles 103 from a glass tube 102 have been described herein, it should be understood that each of these embodiments and techniques is expected to be used alone or in combination with one or more embodiments and techniques.

[0113] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the essence and scope of the claimed subject matter. Accordingly, this specification is intended to cover modifications and variations of the various embodiments described herein, provided that such modifications and variations fall within the scope of the appended claims and their equivalents.

[0114] Exemplary Embodiments

[0115] The following is a description of various aspects of the embodiments of the disclosed subject matter. Each aspect may include one or more of the various features, characteristics, or advantages of the disclosed subject matter. The embodiments are intended to illustrate several aspects of the disclosed subject matter and should not be considered a comprehensive or exhaustive description of all possible embodiments.

[0116] Aspect 1 relates to a method for producing a plurality of glass articles from a glass tube, the method comprising: fixing the glass tube in a holder of a conversion processing machine including a plurality of processing stations, the plurality of processing stations including a plurality of heating stations, at least one forming station, and a separation station, wherein the conversion processing machine successively indexes the holder and the glass tube through each of the processing stations; forming one or more features of the glass article at a processing end of the glass tube by indexing the glass tube through each of the plurality of heating stations and the at least one forming station; separating the glass article from the processing end of the glass tube at the separation station; and indexing the glass tube from the separation station to an auxiliary processing station disposed directly downstream of the separation station, the auxiliary processing station including one of the plurality of heating stations or one of the at least one forming stations; and volumetrically heating a target heating region on at least one of the glass tube and the glass article using an electromagnetic heating device in at least one of the processing stations.

[0117] Aspect 2 relates to the method of Aspect 1, further comprising: heating the glass tube or the glass article during the volumetric heating such that an average temperature of the target heating region increases at a heating rate of about 15 °C / second or greater.

[0118] Aspect 3 relates to the method of Aspect 1 or Aspect 2, wherein the electromagnetic heating device is a gyrotron microwave heating device.

[0119] Aspect 4 relates to the method of Aspect 3, wherein, during the volumetric heating, the gyrotron microwave heating device generates electromagnetic radiation having a frequency of about 28 GHz to about 300 GHz.

[0120] Aspect 5 relates to the method of any one of Aspects 1 to 4, wherein a wall thickness of the glass tube or the glass article is approximately equal to or greater than a wavelength of the electromagnetic radiation generated from the electromagnetic heating device.

[0121] Aspect 6 relates to the method of any one of Aspects 1 to 5, wherein the glass article includes a pharmaceutical packaging container.

[0122] Aspect 7 relates to the method of Aspect 6, wherein the glass article includes a vial, a cartridge, a syringe, an ampoule or a wide-mouth bottle.

[0123] Aspect 8 relates to the method of any one of Aspects 1 to 7, wherein during the volumetric heating, the temperature of the glass tube or the glass article rises from room temperature to above 1000 °C in less than 2 minutes, less than 1 minute, less than 30 seconds or less than 15 seconds.

[0124] Aspect 9 relates to the method of any one of Aspects 1 to 8, wherein during the volumetric heating, the outer periphery of the glass tube or the glass article in the target heating area has a temperature change of about 10 °C or less.

[0125] Aspect 10 relates to the method of any one of Aspects 1 to 9, wherein the volumetric heating includes simultaneously heating a plurality of glass tubes or a plurality of glass articles using a beam from the electromagnetic heating device.

[0126] Aspect 11 relates to the method of Aspect 10, which further includes shaping the beam from the electromagnetic heating device into a strip to simultaneously heat the plurality of glass tubes or the plurality of glass articles.

[0127] Aspect 12 relates to the method of any one of Aspects 1 to 11, wherein separating the glass article from the processing end of the glass tube forms a glass meniscus at the processing end of the glass tube, and the method further includes piercing the meniscus, wherein piercing the meniscus opens the processing end of the glass tube.

[0128] Aspect 13 relates to the method of any one of Aspects 1 to 12, wherein the electromagnetic heating device is used in at least one of a forming station, a separating station, a heating station and a piercing station.

[0129] Aspect 14 relates to a conversion processing machine for producing a plurality of glass articles from a glass tube, the conversion processing machine comprising: a plurality of holders, each of the plurality of holders being operable to hold the glass tube and rotate the glass tube about a central axis of the glass tube; a plurality of processing stations including a plurality of heating stations, at least one forming station, and a separation station, wherein: the conversion processing machine is operable to rotate the plurality of holders and the glass tube through each of the plurality of processing stations; the separation station is operable to separate the glass article from the processed end of the glass tube; and the conversion processing machine includes an auxiliary processing station disposed directly downstream of the separation station, wherein the auxiliary processing station includes one of the plurality of heating stations or one of the at least one forming stations; and an electromagnetic heating device configured to heat the glass tube or the glass article in at least one of the plurality of processing stations, the electromagnetic heating device being configured to volumetrically heat the glass tube or the glass article.

[0130] Aspect 15 relates to the conversion processing machine of aspect 14, further comprising one or more secondary heating devices configured to heat the glass tube or the glass article simultaneously with the electromagnetic heating device.

[0131] Aspect 16 relates to the conversion processing machine of aspect 15, wherein the one or more secondary heating devices include at least one of a conduction heater, a convection heater, an infrared heater, a resistance heater, an induction heater, and a flame heater.

[0132] Aspect 17 relates to the conversion processing machine of any one of aspects 14 to 16, wherein the electromagnetic heating device is configured to generate electromagnetic radiation having a frequency of from about 5 GHz to about 500 GHz.

[0133] Aspect 18 relates to the conversion processing machine of any one of aspects 14 to 17, wherein the electromagnetic heating device is a gyrotron microwave heating device.

[0134] Aspect 19 relates to the conversion processing machine of any one of aspects 14 to 18, wherein the beam from the electromagnetic heating device is configured to heat a plurality of glass tubes or a plurality of glass articles simultaneously.

[0135] Aspect 20 relates to the conversion processing machine of aspect 19, further comprising beam shaping optics to shape the beam from the electromagnetic heating device into a strip for heating the plurality of glass tubes or the plurality of glass articles.

Claims

1. A method for producing a plurality of glass articles from a glass tube, the method comprising: Fixing the glass tube in a holder of a conversion processing machine including a plurality of processing stations, the plurality of processing stations including a plurality of heating stations, at least one forming station, and a separation station, wherein the conversion processing machine causes the holder and the glass tube to be sequentially indexed through each of the processing stations; Forming one or more features of the glass article at a processing end of the glass tube by indexing the glass tube through each of the plurality of heating stations and the at least one forming station; Separating the glass article from the processing end of the glass tube at the separation station; And Indexing the glass tube from the separation station to an auxiliary processing station disposed directly downstream of the separation station, the auxiliary processing station including one of the plurality of heating stations or one of the at least one forming stations; And Performing volumetric heating on a target heating region on at least one of the glass tube and the glass article using an electromagnetic heating device in at least one of the processing stations.

2. The method according to claim 1, further comprising: During the volumetric heating, the glass tube or the glass article is heated such that the average temperature of the target heating region increases at a heating rate of about 15 °C / second or greater.

3. The method according to claim 1 or claim 2, wherein the electromagnetic heating device is a gyrotron microwave heating device.

4. The method according to claim 3, wherein During the volumetric heating, the gyrotron microwave heating device generates electromagnetic radiation having a frequency of about 28 GHz to about 300 GHz.

5. The method according to any one of claims 1 to 4, wherein the wall thickness of the glass tube or the glass article is approximately equal to or greater than the wavelength of the electromagnetic radiation generated from the electromagnetic heating device.

6. The method according to any one of claims 1 to 5, wherein the glass article includes a pharmaceutical packaging container.

7. The method according to claim 6, wherein the glass article includes a vial, a cartridge, a syringe, an ampoule, or a wide-mouth bottle.

8. The method according to any one of claims 1 to 7, wherein, During the volumetric heating, the temperature of the glass tube or the glass article rises from room temperature to above 1000 °C in less than 2 minutes, less than 1 minute, less than 30 seconds, or less than 15 seconds.

9. The method according to any one of claims 1 to 8, wherein During the volumetric heating, the outer periphery of the glass tube or the glass article in the target heating region has a temperature change of about 10 °C or less.

10. The method according to any one of claims 1 to 9, wherein the volumetric heating includes simultaneously heating a plurality of glass tubes or a plurality of glass articles using a beam from the electromagnetic heating device.

11. The method according to claim 10, further comprising shaping the beam from the electromagnetic heating device into a strip to simultaneously heat the plurality of glass tubes or the plurality of glass articles.

12. The method according to any one of claims 1 to 11, wherein separating the glass article from the processed end of the glass tube forms a glass meniscus at the processed end of the glass tube, and the method further comprises piercing the meniscus, wherein piercing the meniscus opens the processed end of the glass tube.

13. The method according to any one of claims 1 to 12, wherein the electromagnetic heating device is used in at least one of a forming station, a separating station, a heating station, and a piercing station.

14. A conversion processing machine for producing a plurality of glass articles from a glass tube, the conversion processing machine comprising: a plurality of holders, each of the plurality of holders being operable to hold the glass tube and rotate the glass tube about a central axis of the glass tube; a plurality of processing stations, including a plurality of heating stations, at least one forming station, and a separating station, wherein: the conversion processing machine is operable to index the plurality of holders and the glass tube through each of the plurality of processing stations; the separating station is operable to separate the glass article from the processed end of the glass tube; and the conversion processing machine includes an auxiliary processing station disposed directly downstream of the separating station, wherein the auxiliary processing station includes one of the plurality of heating stations or one of the at least one forming stations; and an electromagnetic heating device configured to heat the glass tube or the glass article in at least one of the plurality of processing stations, the electromagnetic heating device being configured to volumetrically heat the glass tube or the glass article.

15. The conversion processing machine according to claim 14, further comprising one or more secondary heating devices configured to heat the glass tube or the glass article simultaneously with the electromagnetic heating device.

16. The conversion processing machine according to claim 15, wherein the one or more secondary heating devices include at least one of a conduction heater, a convection heater, an infrared heater, a resistance heater, an induction heater, and a flame heater.

17. The conversion processing machine according to any one of claims 14 to 16, wherein the electromagnetic heating device is configured to generate electromagnetic radiation having a frequency of about 5 GHz to about 500 GHz.

18. The conversion processing machine according to any one of claims 14 to 17, wherein the electromagnetic heating device is a gyrotron microwave heating device.

19. The conversion processing machine according to any one of claims 14 to 18, wherein the beam from the electromagnetic heating device is configured to heat a plurality of glass tubes or a plurality of glass articles simultaneously.

20. The conversion processing machine according to claim 19, further comprising beam shaping optics to shape the beam from the electromagnetic heating device into a strip for heating the plurality of glass tubes or the plurality of glass articles.

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