Method and apparatus for manufacturing glass vials using laser

Abstract

A method for producing a glass article from a glass tube includes rotating a glass tube about a central axis, heating a target region of the glass tube to a forming temperature, forming at least one feature of the glass article at the target region of the glass tube, and separating the glass article from a working end of the glass tube. Heating the target region of the glass tube, separating the glass article from the working end of the glass tube, or both, includes exposing the target region, separation region, or both of the glass tube to a laser beam generated by a laser system, which heats the glass tube at the target region, separation region, or both. A system includes a converter and the laser system for heating the glass tube or separating the glass article from the glass tube.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of priority under 35 U.S.C. §119 to U.S. Provisional Application Serial No. 63 / 441,305, filed on January 26, 2023, and U.S. Provisional Application Serial No. 63 / 523,780, filed on June 28, 2023, the contents of which are relied upon and incorporated herein by reference in their entirety. Technical Field

[0003] The present specification relates generally to methods, apparatus, and systems for glass products, and more particularly to methods, apparatus, and systems for converting glass tubing into glass products in a conversion process. Background Art

[0004] In history, glass has been used to produce various goods. Especially, due to the airtightness, optical transparency and the excellent chemical durability relative to other materials of glass, glass has been the preferred material for pharmaceutical applications, and described pharmaceutical applications include but are not limited to vacuum blood collection tubes, tubes, syringes, syringe barrels, ampoules, bottles, flasks, vials, pipes, beakers, jars and other glass products. Producing these goods from glass starts with providing glass tubing, which is subsequently formable and separated into multiple glass products. Particularly, the glass used in pharmaceutical packaging must have enough mechanical and chemical durability, so as not to affect the stability of pharmaceutical preparations contained therein. Glass with suitable chemical durability comprises those glass compositions in ASTM standard ' type IA ' and ' type IB ' glass compositions, and described glass compositions have confirmed chemical durability history.

[0005] Glass tubing used as the starting material for producing glass products is produced by a continuous process for producing continuous hollow glass cylinders, such as the Danner process or the Vello process. Glass tubing can be converted into other glass products, such as various glass containers for pharmaceutical applications, including but not limited to vacuum blood collection tubes, tubes, syringes, syringe barrels, ampoules, bottles, flasks, vials, tubes, beakers, jars and other glass products. Glass tubing can be converted, for example, in a "converter." Converters have been in use for over 75 years and are currently manufactured by various commercial and in-house equipment suppliers. These converters typically reshape long sections of glass tubing into multiple glass products using a process comprising flame processing, rotating and stationary tool forming, thermal separation or scoring and impact cutting steps. Various burners and forming tools are typically used to shape one or more products from the glass tubing and separate the products from the glass tubing. Summary of the Invention

[0006] Therefore, there is a continuing need for methods, apparatus, and systems for converting a glass tube into a glass article using a laser system to heat the glass tube before forming the glass article from the glass tube, separating the glass article from the glass tube, or both. According to a first aspect of the present disclosure, a method for producing a glass article from a glass tube may include: rotating the glass tube about a central axis of the glass tube; heating a target region of the glass tube to a forming temperature while rotating the glass tube, wherein the target region may be proximate to a working end of the glass tube; after heating the target region of the glass tube, while rotating the glass tube, forming at least one feature of the glass article at the target region of the glass tube; and separating the glass article from the working end of the glass tube at a separation region of the glass tube. Heating the target region of the glass tube, separating the glass article from the working end of the glass tube, or both, may include exposing the target region of the glass tube, the separation region, or both, to a laser beam having a maximum cross-sectional dimension of about 0.5 to about 1.25 times the outer diameter of the glass tube at the point where the laser beam impinges on the glass tube. Exposing the target region, the separation region, or both to the laser beam may heat the glass tube at the target region, the separation region, or both to a temperature greater than or equal to about 1000°C.

[0007] A second aspect of the present disclosure may include the first aspect, wherein heating the target area of ​​the glass tube may include exposing the target area to a laser beam in a heating station of a converter for forming a glass article from the glass tube, wherein the laser beam may be a heating laser beam.

[0008] A third aspect of the present disclosure may include the second aspect, wherein the heating laser beam has a circular cross-section.

[0009] A fourth aspect of the present disclosure may include any one of the first to third aspects, wherein separating the glass article from the working end of the glass tube may include exposing a separation region of the glass tube to a laser beam in a separation station of a converter for forming the glass article from the glass tube, wherein the laser beam may be a separation laser beam.

[0010] A fifth aspect of the present disclosure may include the fourth aspect, comprising exposing a separation region of the glass tube to a preheating laser beam in a heating station prior to translating the glass tube into the separation station.

[0011] A sixth aspect of the present disclosure may include any one of the fourth aspect or the fifth aspect, wherein the separation laser beam may have an elliptical cross-section with a major axis and a minor axis.

[0012] A seventh aspect of the present disclosure may include any one of the fourth to sixth aspects, wherein the separation laser beam may have a beam length of 5 mm to 50 mm at a point where the separation laser beam is incident on the glass tube.

[0013] An eighth aspect of the present disclosure may include any one of the fourth to seventh aspects, wherein separating the glass article from the working end of the glass tube may further include forming an open end on a bottom portion of the glass article, wherein the bottom portion of the glass article is an end portion of the glass article previously connected to the glass tube prior to separation.

[0014] A ninth aspect of the present disclosure may include the eighth aspect, wherein the separation laser beam may have a beam width of about 0.5 mm to about 5 mm at a point where the separation laser beam is incident on the glass tube.

[0015] A tenth aspect of the present disclosure may include any one of the eighth or ninth aspects, wherein the separation laser beam may be an elliptical beam having a major axis to minor axis ratio of about 4 to about 70 at a point where the separation laser beam is incident on the glass tube.

[0016] An eleventh aspect of the present disclosure may include any one of the fourth to seventh aspects, wherein separating the glass article from the working end of the glass tube may further include forming a bottom of the glass article while separating the glass article from the working end of the glass tube.

[0017] A twelfth aspect of the present disclosure may include the eleventh aspect, wherein the separation laser beam may have a beam width of about 3 mm to about 10 mm at a point where the separation laser beam is incident on the glass tube.

[0018] A thirteenth aspect of the present disclosure may include any one of the eleventh or twelfth aspects, wherein the separation laser beam may be an elliptical beam having a major axis to minor axis ratio of about 2 to about 12 at a point where the separation laser beam is incident on the glass tube.

[0019] A fourteenth aspect of the present disclosure may include any one of the eleventh to thirteenth aspects, wherein the separation laser beam may be an elliptical beam with a long axis oriented parallel to or perpendicular to the central axis of the glass tube.

[0020] A fifteenth aspect of the present disclosure may include any one of the eleventh to fourteenth aspects, further comprising reducing the thickness of the bottom of the glass article. The separating laser beam may be an elliptical beam, and reducing the thickness of the bottom of the glass article may include one or more of the following: orienting the separating laser beam such that the long axis of the separating laser beam is perpendicular to the central axis of the glass tube; reducing the beam width of the separating laser beam; or a combination thereof.

[0021] The sixteenth aspect of the present disclosure may include the fifteenth aspect, wherein at a point where the separation laser beam is incident on the glass tube, the separation laser beam may have a beam width of about 5 mm to about 10 mm, or the separation laser beam may have a major axis to minor axis ratio of about 2 to about 7.

[0022] A seventeenth aspect of the present disclosure may include any one of aspects eleven to fourteen, comprising increasing the thickness of a bottom portion of a glass article. The separating laser beam may be an elliptical beam, and increasing the thickness of the bottom portion of the glass article may include one or more of the following: orienting the separating laser beam such that a long axis of the separating laser beam is parallel to a central axis of the glass tube; increasing the beam width of the separating laser beam; or a combination thereof.

[0023] The eighteenth aspect of the present disclosure may include the seventeenth aspect, wherein at a point where the separation laser beam is incident on the glass tube, the separation laser beam may have a beam width of about 3 mm to about 7 mm, or the separation laser beam may have a major axis to minor axis ratio of about 2.5 to about 12.

[0024] A nineteenth aspect of the present disclosure may include any one of aspects eleven to eighteen, wherein separating the glass article from the working end of the glass tube may include: exposing a separation region of the glass tube to a separation laser beam having an elliptical cross-section; and exposing the separation region of the glass tube to a preheating laser beam having a circular cross-section in a separation station.

[0025] The twentieth aspect of the present disclosure may include the nineteenth aspect, which includes superimposing the separation laser beam and the preheating laser beam on the separation region of the glass tube.

[0026] The twenty-first aspect of the present disclosure may include any one of the nineteenth or twentieth aspects, wherein the center of the separation laser beam may be offset relative to the center of the preheating laser beam in an axial direction, wherein the axial direction is a direction parallel to the central axis of the glass tube.

[0027] A twenty-second aspect of the present disclosure may include any one of the nineteenth to twenty-first aspects, further comprising modifying an axial position of the separation laser beam relative to an axial position of the preheating laser beam.

[0028] A twenty-third aspect of the present disclosure may include the twenty-second aspect, further comprising moving the center of the separation laser beam relative to the center of the preheating laser beam toward the working end of the glass tube, wherein moving the center of the separation laser beam closer to the working end of the glass tube relative to the center of the preheating laser beam can increase the flatness of the bottom of the glass article and can reduce the corner radius at the transition between the bottom and the sidewall of the glass article.

[0029] A twenty-fourth aspect of the present disclosure may include any one of the fourth to twenty-third aspects, further comprising exposing the separation region of the glass tube to a burner in the heating station before translating the glass tube into the separation station.

[0030] A twenty-fifth aspect of the present disclosure may include any one of aspects four to twenty-four, wherein separating the glass article from the working end of the glass tube may include: exposing a separation region of the glass tube to a separation laser beam having an elliptical cross-section; and exposing the separation region of the glass tube to a burner in a separation station, wherein the burner preheats the glass tube.

[0031] A twenty-sixth aspect of the present disclosure may include any one of aspects 4 to 25, wherein separating the glass article from the working end of the glass tube may include applying a tensile force to the glass article while exposing a separation region of the glass tube to a laser beam, wherein the tensile force may cause the glass article to move in an axial direction away from the glass tube.

[0032] A twenty-seventh aspect of the present disclosure may include the twenty-sixth aspect, wherein the glass tube may be vertically oriented with a working end of the glass tube facing downward, and the pulling force may include gravity.

[0033] A twenty-eighth aspect of the present disclosure may include any of the twenty-sixth or twenty-seventh aspects, wherein applying the tension may include mechanically pulling the glass article in a direction axially away from the glass tube.

[0034] A twenty-ninth aspect of the present disclosure may include any one of the first to twenty-eighth aspects, wherein heating a target area of ​​the glass tube, separating the glass article from the working end of the glass tube, or both may include: exposing the target area, the separation area, or both of the glass tube with a first laser beam; and simultaneously, exposing the target area, the separation area, or both of the glass tube with a second laser beam, wherein the first laser beam and the second laser beam are incident on the target area or the separation area of ​​the glass tube.

[0035] A thirtieth aspect of the present disclosure may include the twenty-ninth aspect, wherein the first laser beam and the second laser beam may be superimposed on the glass tube.

[0036] A thirty-first aspect of the present disclosure may include any one of the twenty-ninth aspect or the thirtieth aspect, further comprising modifying an axial position of the second laser beam relative to an axial position of the first laser beam.

[0037] A thirty-second aspect of the present disclosure may include any one of aspects twenty-ninth to thirty-first, wherein the first laser beam may have a circular beam cross section, and the second laser beam may have an elliptical beam cross section.

[0038] A thirty-third aspect of the present disclosure may include any one of aspects one to thirty-second, wherein forming may include contacting a surface of the glass tube in the target area with one or more forming tools while rotating the glass tube, wherein the contact between the forming tool and the surface of the glass tube changes the shape of the glass tube in the target area.

[0039] A thirty-fourth aspect of the present disclosure may include any one of aspects 1 to 33, further comprising operating a converter to produce a plurality of glass articles from a plurality of glass tubes, wherein: the converter may include a plurality of processing stations, the plurality of processing stations including at least one heating station, at least one forming station, and a separation station; operating the converter may include translating each of the plurality of glass tubes sequentially through each of the plurality of processing stations; and at least one heating station, at least one separation station, or both may include exposing each of the glass tubes to a laser beam to heat each of the glass tubes at a target region, a separation region, or both.

[0040] A thirty-fifth aspect of the present disclosure may include any one of aspects 1 to 34, further comprising securing the glass tube in a holder of a converter comprising a plurality of processing stations, the plurality of processing stations comprising at least one heating station, at least one forming station, and a separation station, wherein the converter sequentially translates the holder and the glass tube through each of the processing stations. The method may further comprise: forming one or more features of the glass article at a working end of the glass tube by translating the glass tube through the at least one heating station and the at least one forming station; and separating the glass article from the working end of the glass tube in the separation station. Heating the target region of the glass tube may comprise exposing the target region of the glass tube to a laser beam in the at least one heating station, or separating the glass article from the working end of the glass tube may comprise exposing the separation region of the glass tube to a laser beam in the separation station.

[0041] A thirty-sixth aspect of the present disclosure may include any one of the first to thirty-fifth aspects, wherein the glass article may be a pharmaceutical container. A thirty-seventh aspect of the present disclosure may include the thirty-sixth aspect, wherein the pharmaceutical container may include a vacuum blood collection tube, a cartridge, a syringe, a syringe barrel, an ampoule, a bottle, a flask, a vial, a tube, a beaker, or a jar.

[0042] A thirty-seventh aspect of the present disclosure may be directed to a method for removing a glass article from a working end of a glass tube during conversion. The method may include: translating the working end of the glass tube into a separation station of a converter; rotating the glass tube about a central axis of the glass tube; exposing a separation region of the glass tube to a laser beam while rotating the glass tube; and applying an axial force to the glass article in a direction axially away from the glass tube. Exposing the separation region of the glass tube to the laser beam and applying the axial force to the glass article may separate the glass article from the working end of the glass tube.

[0043] A thirty-eighth aspect of the present disclosure may include the thirty-seventh aspect, comprising exposing the separation region of the glass tube to a preheating laser beam in the heating station before translating the glass tube into the separation station.

[0044] A thirty-ninth aspect of the present disclosure may include any one of the thirty-seventh aspect or the thirty-eighth aspect, wherein the separation laser beam may have an elliptical cross-section with a major axis and a minor axis.

[0045] A fortieth aspect of the present disclosure may include any one of the thirty-seventh to thirty-ninth aspects, wherein the separation laser beam may have a beam length of 5 mm to 50 mm at a point where the separation laser beam is incident on the glass tube.

[0046] The forty-first aspect of the present disclosure may include any one of aspects thirty-seven to fortieth, wherein separating the glass article from the working end of the glass tube may further include forming an open end on a bottom portion of the glass article, wherein the bottom portion of the glass article is an end portion of the glass article previously connected to the glass tube prior to separation.

[0047] A forty-second aspect of the present disclosure may include the forty-first aspect, wherein the separation laser beam may have a beam width of about 0.5 mm to about 5 mm at a point where the separation laser beam is incident on the glass tube.

[0048] A forty-third aspect of the present disclosure may include any of the forty-first or forty-second aspect, wherein the separation laser beam may be an elliptical beam having a major axis to minor axis ratio of about 4 to about 70 at a point where the separation laser beam is incident on the glass tube.

[0049] A forty-fourth aspect of the present disclosure may include any one of aspects thirty-seven to forty-third, wherein separating the glass article from the working end of the glass tube may further include forming a bottom of the glass article while separating the glass article from the working end of the glass tube.

[0050] A forty-fifth aspect of the present disclosure may include the forty-fourth aspect, wherein the separation laser beam may have a beam width of about 3 mm to about 10 mm at a point where the separation laser beam is incident on the glass tube.

[0051] The forty-sixth aspect of the present disclosure may include any of the forty-fourth or forty-fifth aspects, wherein the separation laser beam may be an elliptical beam having a major axis to minor axis ratio of about 2 to about 12 at a point where the separation laser beam is incident on the glass tube.

[0052] The forty-seventh aspect of the present disclosure may include any one of the forty-fourth to forty-sixth aspects, wherein the separation laser beam may be an elliptical beam, and the long axis may be parallel to or perpendicular to the central axis of the glass tube.

[0053] A forty-eighth aspect of the present disclosure may include any one of aspects forty-four to forty-seven, further comprising reducing the thickness of the bottom of the glass article, wherein the separation laser beam may be an elliptical beam, and reducing the thickness of the bottom of the glass article may include one or more of the following: orienting the separation laser beam so that the long axis of the separation laser beam is perpendicular to the central axis of the glass tube; reducing the beam width of the separation laser beam; or a combination thereof.

[0054] The forty-ninth aspect of the present disclosure may include the forty-eighth aspect, wherein at the point where the separation laser beam is incident on the glass tube, the separation laser beam may have a beam width of about 5 mm to about 10 mm, or the separation laser beam may have a major axis to minor axis ratio of about 2 to about 7.

[0055] A fiftieth aspect of the present disclosure may include any one of aspects 44 to 49, comprising increasing the thickness of the bottom of the glass article, wherein the separation laser beam may be an elliptical beam, and increasing the thickness of the bottom of the glass article comprises one or more of the following: orienting the separation laser beam so that the long axis of the separation laser beam is parallel to the central axis of the glass tube; increasing the beam width of the separation laser beam; or a combination thereof.

[0056] The fifty-first aspect of the present disclosure may include the fiftieth aspect, wherein at the point where the separation laser beam is incident on the glass tube, the separation laser beam may have a beam width of about 3 mm to about 7 mm, or the separation laser beam may have a major axis to minor axis ratio of about 2.5 to about 12.

[0057] The fifty-second aspect of the present disclosure may include any one of aspects forty-four to fifty-first, wherein separating the glass article from the working end of the glass tube may include: exposing the separation area of ​​the glass tube to a separation laser beam having an elliptical cross-section; and exposing the separation area of ​​the glass tube to a preheating laser beam having a circular cross-section.

[0058] A fifty-third aspect of the present disclosure may include the fifty-second aspect, which includes superimposing the separation laser beam and the preheating laser beam on the separation region of the glass tube.

[0059] The fifty-fourth aspect of the present disclosure may include any one of the fifty-second or fifty-third aspects, wherein the center of the separation laser beam may be offset relative to the center of the preheating laser beam in an axial direction, wherein the axial direction is a direction parallel to the central axis of the glass tube.

[0060] A fifty-fifth aspect of the present disclosure may include any one of the fifty-second to fifty-fourth aspects, further comprising modifying an axial position of the separation laser beam relative to an axial position of the preheating laser beam.

[0061] A fifty-sixth aspect of the present disclosure may include any one of aspects fifty-second to fifty-fifth, further comprising moving the center of the separation laser beam relative to the center of the preheating laser beam toward the working end of the glass tube, wherein moving the center of the separation laser beam relative to the center of the preheating laser beam closer to the working end of the glass tube can increase the flatness of the bottom of the glass article and can reduce the corner radius at the transition between the bottom and the sidewall of the glass article.

[0062] A fifty-seventh aspect of the present disclosure may include any one of the first to fifty-sixth aspects, wherein exposing the target area or separation area of ​​the glass tube to the laser beam may include: generating the laser beam using a laser source; passing the laser beam through an optical device that modifies the shape or power density distribution of the laser beam; and directing the laser beam toward the target area or separation area of ​​the glass tube.

[0063] A fifty-eighth aspect of the present disclosure may include any one of the first to fifty-seventh aspects, wherein the laser beam may be a continuous laser beam or a pulsed laser beam.

[0064] A fifty-ninth aspect of the present disclosure may include any one of the first to fifty-eighth aspects, wherein the laser beam may be a collimated or non-collimated laser beam.

[0065] A sixtieth aspect of the present disclosure may include any one of the first to fifty-ninth aspects, wherein the laser beam may have a laser power of 50W to 2000W.

[0066] The sixty-first aspect of the present disclosure may include any one of the first to sixtieth aspects, wherein the laser beam may be an elliptical beam or a ring-shaped beam.

[0067] A sixty-second aspect of the present disclosure may include any one of the first to sixty-first aspects, wherein the laser beam may have a wavelength in a range of about 1 μm to about 12 μm or about 5 μm to about 11 μm.

[0068] A sixty-third aspect of the present disclosure may include any one of the first to sixty-second aspects, further comprising changing the shape of the laser beam, wherein changing the shape of the laser beam may change the volume of glass heated in a target region or separation region of the glass tube.

[0069] A sixty-fourth aspect of the present disclosure may include any one of the first to sixty-third aspects, further comprising changing a power density of the laser beam, wherein changing the power density may change a heating rate of the laser beam.

[0070] The sixty-fifth aspect of the present disclosure may include any one of the first to sixty-fourth aspects, further comprising controlling the exposure time of the glass tube to the laser beam during heating of a target area of ​​the glass tube by adjusting the time of turning on and off a laser source for generating the laser beam, separating the glass article from the working end of the glass tube, or both.

[0071] A sixty-sixth aspect of the present disclosure may include any one of the first to sixty-fifth aspects, comprising rotating the glass tube at a rotation speed of 60 rpm to 400 rpm.

[0072] A sixty-seventh aspect of the present disclosure may include any one of the first to sixty-sixth aspects, wherein the laser beam may have a heating rate of up to 400° C. / second.

[0073] A sixty-eighth aspect of the present disclosure may include any one of the first to sixty-seventh aspects, wherein the conversion rate of converting the glass tube into the glass article may be greater than or equal to 30 pieces / minute, or wherein the conversion process may not be limited by the rate at which the glass article is separated from the glass tube.

[0074] A sixty-ninth aspect of the present disclosure may relate to a system for producing glass products from glass tubes. The system may include a converter comprising a plurality of processing stations and at least one holder spaced apart in a loop. The plurality of processing stations may include at least one heating station, at least one forming station, and a separation station. The at least one holder may be operable to hold the glass tube and rotate the glass tube about a central axis of the glass tube, wherein the working end of the glass tube is oriented toward the plurality of processing stations. The converter may be operable to successively translate the at least one holder having the glass tube fixed therein through each of the plurality of processing stations. The system may further include a laser system disposed in at least one heating station or separation station. The laser system may include a laser source and a beam delivery system. The laser system may be operable to generate a laser beam, modify one or more properties of the laser beam, and direct the laser beam toward the glass tube while the glass tube is in the at least one heating station or separation station.

[0075] The seventieth aspect of the present disclosure may include the sixty-ninth aspect, wherein the at least one laser system may include a plurality of laser systems, wherein the plurality of laser systems may include at least one heating laser system disposed in at least one heating station and a separation laser system disposed in a separation station.

[0076] The seventy-first aspect of the present disclosure may include any of the sixty-ninth or seventieth aspects, wherein the laser system may include a laser source and a beam delivery system, the laser system may be operable to generate a laser beam having a wavelength of 1 μm to 12 μm and a power density of 50 W to 2000 W, and the beam delivery system may be operable to modify the cross-sectional shape of the laser beam and guide the laser beam to a separation area of ​​the glass tube in the separation station.

[0077] The seventy-second aspect of the present disclosure may include the seventy-first aspect, wherein the laser source may include a CO laser, a CO2 laser, or a quantum cascade laser.

[0078] The seventy-third aspect of the present disclosure may include any of the seventy-first aspect or the seventy-second aspect, wherein the beam delivery system may include at least one optical component selected from a lens, a mirror, a prism, a filter, an aperture, or a combination of these.

[0079] A seventy-fourth aspect of the present disclosure may include any one of aspects seventy-first to seventy-third, wherein the laser system may further include at least one turning mirror.

[0080] The seventy-fifth aspect of the present disclosure may include the seventy-fourth aspect, wherein the laser system may be positioned at a location where the laser beam does not have a straight path to the glass tube in at least one heating station or separation station, and at least one steering mirror may be positioned to change the beam path of the laser beam so that the laser beam is incident on a target area or separation area of ​​the glass tube.

[0081] The seventy-sixth aspect of the present disclosure may include any one of aspects sixty-ninth to seventy-fifth, further comprising a laser system positioner connected to the laser system, wherein the laser system positioner may be operable to position the laser system relative to the glass tube in at least one heating station or separation station.

[0082] A seventy-seventh aspect of the present disclosure may include any one of aspects sixty-ninth to seventy-sixth, wherein the laser system may be disposed in at least one heating station of the converter.

[0083] A seventy-eighth aspect of the present disclosure may include the seventy-seventh aspect, wherein the laser system may be operable to generate a laser beam having a circular cross-section and direct the laser beam at the glass tube in the at least one heating station.

[0084] A seventy-ninth aspect of the present disclosure may include any one of aspects sixty-ninth to seventy-eighth, wherein the laser system may be disposed in the separation station.

[0085] An eightieth aspect of the present disclosure may include the seventy-ninth aspect, wherein the laser system may be operable to generate a laser beam having an elliptical cross-section.

[0086] The eighty-first aspect of the present disclosure may include any one of the seventy-ninth aspect or the eightieth aspect, wherein the laser system may include: a separation laser system that is operable to generate a separation laser beam having an elliptical cross-sectional shape; and a preheating laser system that is operable to generate a preheating laser beam having a circular cross-sectional shape.

[0087] An eighty-second aspect of the present disclosure may include the eighty-first aspect, wherein the laser system may be operable to superimpose the separation laser beam and the preheating laser beam on the separation region of the glass tube.

[0088] The eighty-third aspect of the present disclosure may include any one of aspects seventy-ninth to eighty-second, further comprising a burner in the separation station, wherein the burner may be spaced apart from the laser beam in an angular direction relative to a central axis of the glass tube, and the burner may be operable to preheat the separation region of the glass tube while the laser beam is directed thereto.

[0089] The eighty-fourth aspect of the present disclosure may include any one of aspects seventy-ninth to eighty-third, further comprising a heating station directly upstream of the separation station, wherein the heating station may include a preheating laser system operable to generate a preheating laser beam and direct the preheating laser beam to the separation zone of the glass tube.

[0090] An eighty-fifth aspect of the present disclosure may include the eighty-fourth aspect, wherein the heating station may further comprise a burner operable to further heat the separation region of the glass tube.

[0091] The eighty-sixth aspect of the present disclosure may include any one of aspects seventy-ninth to eighty-fifth, further comprising a heating station directly upstream of the separation station, wherein the heating station may include a burner operable to heat the separation region of the glass tube prior to translating the glass tube to the separation station.

[0092] Additional features and advantages of the systems and methods disclosed herein will be set forth in the detailed description that follows, and in part will be readily apparent to those skilled in the art from that description, or may be learned by practicing the embodiments described herein, including the following detailed description, claims, and accompanying drawings.

[0093] 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 character of the claimed subject matter. The accompanying 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 various embodiments described herein and, together with the detailed description, serve to explain the principles and operation of the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0094] Figure 1 schematically depicts a system including a converter for converting a glass tube into a plurality of glass articles according to one or more embodiments shown and described herein;

[0095] Figure 2 schematically depicts a glass tube according to one or more embodiments shown and described herein;

[0096] Figure 3 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 1 A top view of a converter showing the layout of the processing stations;

[0097] Figure 4 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 1 Heating station for the converter;

[0098] Figure 5 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 1 The forming station of the converter;

[0099] Figure 6 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 1 Another embodiment of the forming station of the converter;

[0100] Figure 7 Schematically depicts a separation station of a converter according to the prior art, said separation station comprising a gas burner;

[0101] Figure 8 schematically depicts a separation station of a converter according to one or more embodiments shown and described herein, wherein the separation station includes a laser system;

[0102] Figure 9 graphically depicting relative beam intensity (y-axis) as a function of beam position (x-axis) for an elongated beam having Gaussian and flat-top power density profiles according to one or more embodiments shown and described herein;

[0103] Figure 10 Schematically depicts a system including a converter and a laser system according to one or more embodiments shown and described herein. Figure 1 A top view of the system;

[0104] Figure 11 schematically depicts a beam shape of an annular heating laser beam incident on a glass tube according to one or more embodiments shown and described herein;

[0105] Figure 12 schematically depicts the beam shape of an elliptical split laser beam incident on a glass tube according to one or more embodiments shown and described herein;

[0106] Figure 13 schematically depicts a beam shape of an elliptical split laser beam with a large major axis to minor axis ratio incident on a glass tube according to one or more embodiments shown and described herein;

[0107] Figure 14 schematically depicts a beam shape of an elliptical split laser beam incident on a glass tube, wherein the long axis of the split laser beam is parallel to the central axis of the glass tube, according to one or more embodiments shown and described herein;

[0108] Figure 15Schematically depicts a beam shape incident on a glass tube resulting from the superposition of an annular heating laser beam and an elliptical separation laser beam according to one or more embodiments shown and described herein;

[0109] Figure 16 schematically depicts a separation station including a preheating laser system and a separation laser system configured to superimpose the preheating laser beam and the separation laser beam on a glass tube according to one or more embodiments shown and described herein;

[0110] Figure 17 schematically depicts a top view of a separation station including a preheat laser system and a separation laser system positioned to direct the preheat laser beam and the separation beam at a separation region of a glass tube without overlapping the two beams according to one or more embodiments shown and described herein;

[0111] Figure 18 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 16 A front view of a separation station, wherein the separation laser beam is axially offset from the preheating laser beam;

[0112] Figure 19A schematically depicts an elevation view of a separation station including a separation laser beam and a gas burner according to one or more embodiments shown and described herein;

[0113] Figure 19B Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 19A A top view of the separation station;

[0114] Figure 20 schematically depicts a front view of a glass article including a glass vial according to one or more embodiments shown and described herein;

[0115] Figure 21 schematically depicts a side view of a heating station including a laser system according to one or more embodiments shown and described herein;

[0116] Figure 22 schematically depicts a top view of a converter of a laser system including a separation station and a heating station upstream of the separation station according to one or more embodiments shown and described herein;

[0117] Figure 23 schematically depicts a top view of a converter including a hybrid preheating system comprising both a burner and a laser heating element upstream of a separation station according to one or more embodiments shown and described herein;

[0118] Figure 24graphically depicts glass temperature (y-axis) versus time (x-axis) for exposure of a glass tube in a processing station of a converter to an elliptical laser beam having different laser powers according to one or more embodiments shown and described herein;

[0119] Figure 25 graphically depicts glass temperature (y-axis) versus time (x-axis) for exposure of a glass tube in a processing station of a converter to a laser beam having the same laser power density but different beam shapes according to one or more embodiments shown and described herein;

[0120] Figure 26 are photographs of an end portion of a glass article separated from a glass tube using a gas burner and an end portion of a glass article separated from a glass tube using laser beam heating according to one or more embodiments shown and described herein;

[0121] Figure 27 a photograph showing a side view of separating a glass article from a glass tube using a laser beam according to one or more embodiments shown and described herein; and

[0122] Figure 28 1 is a photograph of finished ends of glass tubes and glass articles that have been separated by a laser beam to form open ends on the glass tubes and glass articles according to one or more embodiments shown and described herein. DETAILED DESCRIPTION

[0123] Reference will now be made in detail to embodiments of apparatus, systems, and methods for producing glass articles from glass tubes using lasers, 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. Figure 1, schematically depicts one embodiment of a system 400 for forming a glass article from a glass tube 102. The system 400 disclosed herein may include a converter 100, which may include a plurality of processing stations 122 spaced apart in a loop and at least one holder 140. The plurality of processing stations 122 may include at least one heating station, at least one forming station, and a separation station. The at least one holder 140 may be operable to hold the glass tube 102 and rotate the glass tube 102 about its central axis, with the working end 107 of the glass tube 102 oriented toward the plurality of processing stations 122. The converter 100 may be operable to sequentially translate the at least one holder 140, with the glass tube 102 secured therein, through each of the plurality of processing stations 122. The system 400 may further include a laser system 410 disposed in at least one of the heating station and the separation station. The laser system 410 may include a laser source 412 and a beam delivery system 420. Laser system 410 may be operable to generate laser beam 414, modify one or more properties of laser beam 414, and direct laser beam 414 at glass tube 102 while glass tube 102 is in at least one heating station or separation station.

[0124] System 400 may be used in a method of producing a glass article from a glass tube 102. The method may include rotating the glass tube 102 about a central axis A of the glass tube 102; heating a target region of the glass tube 102 to a forming temperature while rotating the glass tube 102, wherein the target region is proximate to a working end of the glass tube 102; after heating the target region of the glass tube 102, forming at least one feature of the glass article at the target region of the glass tube 102 while rotating the glass tube 102; and separating the glass article 103 from the working end of the glass tube 102 at a separation region of the glass tube 102. Heating the target region of the glass tube 102, separating the glass article 103 from the working end of the glass tube 102, or both may include exposing the target region, the separation region, or both of the glass tube 102 to a laser beam 414 having a beam width of about 0.5 mm to about 10 mm. Exposing the target region, the separation region, or both to the laser beam 414 may heat the glass tube at the target region, the separation region, or both to a temperature greater than or equal to about 1000° C.

[0125] Unless otherwise expressly stated, it is not intended that any method described herein be construed as requiring that its steps be performed in a specific order, nor is it intended that any apparatus be required to have a specific orientation. Therefore, in the absence of a method solution that actually recites the order in which its steps are to be followed, or any apparatus solution that actually recites the order or orientation of individual components, or in the absence of other specific statements in the claims or description that the steps are to be limited to a specific order, or in the absence of a specific order or orientation of components of an apparatus, no order or orientation is intended to be inferred in any respect. This applies to any possible non-explicit basis for interpretation, including: matters of logic regarding arrangement of steps, operational flow, order of components, or orientation of components; ordinary meaning derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.

[0126] Directional terms used herein—such as up, down, right, left, front, back, top, bottom—refer only to the drawn figures and the coordinate axes provided therewith, and are not intended to imply absolute orientation.

[0127] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a" element includes aspects having two or more such elements unless the context clearly dictates otherwise.

[0128] As used herein, "axial direction" refers to a direction parallel to the central axis A of a glass tube or glass rod.

[0129] As used herein, the "beam waist" of a laser beam refers to the point along the beam path of the laser beam at which the power density of the laser beam is a maximum.

[0130] As used herein, the term "circumference" of a glass tube refers to the set of points on the glass tube extending 360 degrees from the central axis D of the glass tube at a specific Z position (i.e., a position on the + / - Z axis of the diagram) with a constant radius r. For example, the circumference of the glass tube may coincide with the outer surface of the glass tube at a specific Z position, or may coincide with the inner surface of the glass tube at a specific Z position.

[0131] As used herein, the "residence time" of a converter refers to the duration of time that a glass tube spends in a particular processing station before being passed to the next subsequent processing station.

[0132] As used herein, the term "active time" refers to the duration that a glass tube remains engaged with at least one heating element or at least one forming tool while in a particular processing station.

[0133] As used herein, when used with respect to an indexing converter, the term "index time" refers to the duration of time it takes for a glass tube to be indexed from one processing station to the next. "Dwell time," "active time," and "index time" are all measured in units of time.

[0134] When used with respect to a heating station, "engagement" of the laser beam with the glass tube refers to a condition in which the laser beam is incident on the surface of the glass tube. Conversely, when the laser beam is disengaged from the glass tube, the laser beam is not incident on the glass tube, for example, by turning off the laser beam, moving the laser beam away from the glass tube, or moving the glass tube out of the laser beam's beam path.

[0135] As used herein, the term "component rate" refers to the production rate or throughput rate of a converter in terms of number of glassware per unit time.

[0136] As used herein, the terms "upstream" and "downstream" refer to the location of processing stations and other components of the converter relative to the direction of travel of the glass tube through the conversion process. For example, if the glass tube encounters a first processing station before encountering a second processing station, the first processing station is "upstream" of the second processing station. Conversely, if the glass tube encounters the second processing station before encountering the first processing station, the first processing station is "downstream" of the second processing station.

[0137] As used herein, the terms "upstream" and "downstream" refer to the positioning of two or more features of a system relative to the direction of travel of a laser beam along a beam path through the system. If the laser beam encounters a first component before encountering a second component, the first component can be considered upstream of the second component. Conversely, when the laser beam encounters the second component before encountering the first component, the first component can be considered downstream of the second component.

[0138] As used herein, the "working end" of the glass tube is the end of the glass tube that is oriented toward the processing station of the main turntable of the converter relative to the holder, and the "non-working end" of the glass tube is the end of the glass tube that is oriented away from the processing station of the main turntable.

[0139] Due to its hermeticity, optical clarity, and superior chemical durability relative to other materials, glass has become a preferred material for pharmaceutical applications, including but not limited to vacuum blood collection tubes, barrels, syringes, syringe barrels, ampoules, bottles, flasks, vials, tubes, beakers, jars, and other glass products. These pharmaceutical glass containers, as well as other types of glass products, can be produced by converting a length of glass tubing into one or more of the glass products through multiple heating and forming operations.

[0140] refer to Figure 2, schematically depicts one embodiment of a glass tube 102 that serves as a starting point for manufacturing a plurality of glass articles. The glass tube 102 comprises an elongated hollow glass cylinder having an outer surface 104 and an inner surface 106. The inner surface 106 defines the interior of the glass tube 102. The glass tube 102 has a working end 107 and a non-working end opposite the working end 107. The working end 107 of the glass tube 102 is the end of the glass tube that is heated and formed into a glass article that is then separated from the glass tube 102, as will be described in further detail herein. The working end 107 of the glass tube 102 is the end of the glass tube 102 that is formed into the glass article when the glass tube 102 is secured in the holder of the converter 100. Figure 2 The non-working end 108 of the glass tube 102 is the end opposite to the working end 107 (i.e., the end of the glass tube 102 in the -Z direction). Figure 2 The glass tube 102 may have a circular cross-sectional shape and may be formed by a tube length L, an outer diameter D t The tube length L is the distance from the working end 107 to the non-working end 108, and the thickness t refers to the average radial distance between the outer surface 104 and the inner surface 106 of the glass tube 102. The glass tube 102 further includes a central axis A.

[0141] The glass tube 102 can be converted into glass products, particularly glass products for pharmaceutical applications, which may include, but are not limited to, vacuum blood collection tubes, tubes, syringes, syringe barrels, ampoules, bottles, flasks, vials, tubes, beakers, jars, and other glass products. A converter (i.e., a converter) comprising multiple processing stations can be used to convert the glass tube 102 into these glass products. The processing stations may include, but are not limited to, heating stations, forming stations, separation stations, piercing stations, measuring stations, polishing stations, cooling stations, tube loading stations, or other types of processing stations. Converters typically reshape long glass tube segments into multiple glass products using steps including, but not limited to, flame processing, rotating and stationary tool forming, separation (e.g., thermal separation or scoring and impact cutting steps), piercing, cooling, measuring, or other processing steps. Thus, the glass products produced by the conversion process performed on the converter are subjected to a series of flame burners or other heating elements and forming tools to shape the glass tube into a specific shape and size and to separate the formed glass products from the glass tube.

[0142] Now refer to Figure 1, schematically depicts one embodiment of a system 400 for producing a glass article from a glass tube 102. System 400 includes a converter 100. Converter 100 can be used to convert glass tube 102 into a plurality of glass articles. Converter 100 can include a base 120 having a plurality of processing stations 122, and a primary turntable 124 positioned above and rotatable relative to base 120 about a central axis B. Converter 100 can also include a plurality of secondary processing stations 132 on base 120, and a secondary turntable 134 rotatable relative to base 120.

[0143] like Figure 1 , the base 120 of the converter 100 can be stationary, and the processing stations 122 can be connected to an upper portion 121 of the base 120. The processing stations 120 can be spaced apart from each other and arranged in a main loop 126. In embodiments, the main loop 126 can be circular, so that the main turntable 124 can translate the glass tube 102 through the plurality of processing stations 122 by rotating the main turntable 124. Alternatively, in embodiments, the main loop 126 can be a linear arrangement of processing stations 122. Although described herein with reference to a circular layout of processing stations 122, it should be understood that the subject matter disclosed herein can be equally well applied to converters having other arrangements of processing stations 122 (e.g., linear, curved, or irregularly shaped arrangements of processing stations 122).

[0144] The type and / or shape of the glass article to be made from the glass tube 102 can affect the total number of processing stations 122 of the converter 100. The number of processing stations 122 of the main loop 126 can range from 14 to 50 processing stations 120. Although the converter 100 and the conversion process are described herein in the context of the converter 100 having sixteen processing stations 122 in the main loop 126, it should be understood that the converter 100 can have more or fewer than sixteen processing stations 122 in the main loop 126. The processing stations 122 can include, by way of example and not limitation, one or more heating stations, forming stations, polishing stations, cooling stations, separating stations, piercing stations, measuring stations, feeding stations, discharge stations, other processing stations, or combinations thereof to produce a glass article from the glass tube 102. The type and / or shape of the article to be made from the glass tube 102 can also affect the type of processing stations 122 of the converter 100 and / or the order of the processing stations 122.

[0145] refer to Figure 1 and Figure 3 , the converter 100 may include secondary processing stations 132, which may be spaced apart from each other and arranged in a secondary loop 136 ( Figure 3 In one embodiment, the converter 100 may include a secondary turntable 134 ( Figure 1 ), which is used to separate the product 103 ( Figure 1) is indexed or continuously moved through the plurality of secondary processing stations 132. The secondary turntable 134 is rotatable relative to the base 120 about the second axis C. The secondary turntable 134 can be moved from the separation station 206 ( Figure 3 ) receives a glass product 103, translates (e.g., indexes or continuously moves) the product 103 through a plurality of secondary processing stations 132 via rotation of a secondary turntable 134, and discharges the finished product from the converter 100. Although shown in a circular pattern, it should be understood that the secondary processing stations 132 can be arranged in a linear, curved, or irregular arrangement. In an embodiment, the converter 100 can be configured to produce vials, and the secondary processing stations 132 can be referred to as bottom formers. For vials, the secondary processing stations 132 can be operable to form the bottom of the vial.

[0146] The converter 100 may include a plurality of holders 140 configured to removably secure each glass tube 102 to the main turntable 124. The holders 140 may be clamps, chucks, or other holding devices, or a combination of holding devices. The holders 140 may orient each glass tube 102 so that the glass tube 102 is substantially parallel to the central axis B of the main turntable 124 and substantially perpendicular to the upper portion 121 of the base 120. Although the converter 100 is described herein in the context of a vertically oriented converter 100, it should be understood that the converter 100 may be oriented horizontally or at an angle such that the glass tube 102 is non-vertical during processing. Each holder 140 may be oriented to position the working end 107 of the glass tube 102 in each of the successive processing stations 122 as the main turntable 124 rotates. The vertical orientation of the glass tubes 102 allows the working end 107 of each glass tube 102 to be gradually moved or indexed through the processing station 122 .

[0147] Each holder 140 can be individually rotated relative to the main turntable 124 to rotate the glass tube 102 about the central axis A of the glass tube 102. Each of the holders 140 can be operably connected to a motor (not shown), a continuous drive belt, or other drive mechanism for active rotation of each of the holders 140. Rotation of the holders 140 allows the glass tube 102 to be rotated about the central axis A of the glass tube 102 relative to a stationary heating element, forming tool, cooling nozzle, or other feature of the processing station 122. The heating element or forming tool in the processing station 122 can be maintained in a fixed position relative to the glass tube 102, and rotation of the glass tube 102 about the central axis A can enable the entire circumference of the glass tube 102 to be exposed to the heating element or forming tool.

[0148] The converter 100 is operable to sequentially translate the glass tube 102 through each of the processing stations 122. In an embodiment, the converter 100 may be operable to index each of the plurality of holders 140 through the plurality of processing stations 122. Indexing may refer to a step-by-step process of moving the glass tube 102 into a processing station 122, maintaining the glass tube 102 at a stationary XYZ position in the processing station 122 for a dwell time, and then indexing the glass tube 102 to the next processing station 122. Alternatively, in an embodiment, the converter 100 may be operable to continuously translate the plurality of holders 140 through a conversion process. In an embodiment, the processing station 122 may translate along with the glass tube 102 during the time the glass tube 102 is active in the processing station 122.

[0149] Now refer to Figure 3 As previously described, the plurality of processing stations 122 may include one or more heating stations 202, forming stations 204, separation stations 206, cooling stations 210, piercing stations 212, tube loading stations 214, discharge stations 216, measuring stations 218, tube section lowering stations 220, or other stations, and / or combinations of these stations. Figure 3 One arrangement of the processing stations 122 for a converter 100 is schematically depicted having a primary loop 126 of sixteen processing stations 122 and a secondary loop 136 of eight secondary processing stations 132. As previously described, the processing stations 122 of the primary loop 126 may be evenly spaced and evenly distributed around the circular loop, and the secondary processing stations 132 of the secondary loop 136 may also be evenly spaced and evenly distributed around the circular loop.

[0150] Figure 3 The main circuit 126 of the converter schematically depicted in FIG may include one or more heating stations 202, a separation station 206, a piercing station 212, one or more forming stations 204, one or more cooling stations 210, a measuring station 218, a tube section lowering station 220, and a tube loading station 214. Figure 3 The main loop 126 is depicted as having a circular arrangement of processing stations 122, as previously discussed, but the main loop 126 may have processing stations 122 positioned in other non-circular arrangements, such as linear, curved, irregularly shaped, or other arrangements. Relative to the rotational direction 222 of the main turntable 124, the heating station 202 may be positioned before each of the forming stations 204 and before the separation station 206 to preheat a target area of ​​the glass tube 102 to a viscosity at which the glass becomes deformable and can be effectively shaped or stretched and separated. At the separation station 206, the formed glass article 103 ( Figure 1 ) can be formed simultaneously with the glass tube 102 ( Figure 1) of the working end 107. The separation station 206 may also be a processing station 122 where the partially formed glass article 103, once separated, is transferred to a secondary turntable 134 ( Figure 1 ) to index through the secondary loop 136 of the secondary processing station 132. A piercing station 212 can be positioned on the primary loop 126 downstream of the separation station 206 in the rotational direction 222 of the primary turntable 126. At the piercing station 212, the glass meniscus at the working end 107 of the glass tube 102 formed in the separation station 206 is pierced, thereby reopening the working end 107 of the glass tube 102.

[0151] Reference again Figure 3 , the forming station 204 of the primary turret 108 can be positioned downstream of the piercing station 212 and the one or more heating stations 202 in the direction of rotation 222. The forming station 204 can shape the glass tube 102 to form one or more features of the finished glass article. As noted above, the one or more heating stations 202 can be positioned before each of the forming stations 204 to preheat a target area of ​​the glass tube 102 to a temperature at which the glass tube 102 can be shaped and formed into the desired features. The forming station 204 of the primary turret 124 can shape the working end of the glass tube 102 to form features at one end of the glass article 103, and the forming station 204 of the secondary turret 134 can shape the other end of the glass article 103 after the glass article 103 has been separated from the glass tube 102. In an embodiment, the converter 100 can be used to produce vials from glass tubes 102, and the forming stations 204 of the converter 100 may include one or more shoulder forming stations, flange forming stations, flange processing stations, or a combination of these, with one or more heating stations 202 positioned before and between each of the forming stations 204.

[0152] The main loop 126 may further include a measuring station 218 at which at least one measuring device may be used to measure one or more properties of the glass tube 102, such as diameter and thickness, or one or more dimensions of features of the glass article 103 formed by the forming station 204. One or more appearance properties of the glass tube 102 or glass article 103 may also be evaluated at the measuring station 218. Still referring to Figure 3 , one or more cooling stations 210 may be positioned after the forming station 204 in the rotational direction 222 of the main turret 124. A tube segment lowering station 220 may be positioned after the forming station 204, between the forming station 204 and the separation station 206, to lower the partially formed glass tube 102 downward, thereby positioning the glass tube 102 for separation of the glass article 103 from the glass tube 102 at the separation station 206. The main loop 126 may also include a tube loading station 214 for loading a new section of glass tube 102 stock from a glass tube loading turret (not shown) onto the main turret 124.

[0153] Reference again Figure 3 Once the glass article 103 is separated from the glass tube 102 at the separation station 206, the glass article 103 can be transferred to the secondary processing station 132 of the secondary turret 134. The secondary processing station 132 can include one or more forming stations 204 for forming a second end of the glass article 103, which is opposite the first end of the glass article 103. For example, the forming stations 204 of the secondary processing station 112 can form one or more features at the bottom (second end) of the glass article 103. The secondary turret 134 can rotate about an axis C in a direction 224 that is opposite to the direction of rotation 222 of the primary turret 124. In an embodiment, the secondary turret 134 can rotate in the same direction as the primary turret 124.

[0154] The secondary processing stations 132 of the secondary loop 136 may include one or more heating stations 202, forming stations 204, polishing stations 208, cooling stations 210, discharge stations 216, or other stations, or combinations of secondary processing stations 132. In embodiments, the secondary processing stations 132 of the secondary loop 136 may be used to form one or more features of the glass article 103, such as a vial, ampoule, barrel, or syringe, at an end of the glass article 103 opposite the end formed by the primary turntable 124. For example, in embodiments, the glass article 103 is a vial, and the forming station 204 of the secondary loop 136 may form the bottom of the vial. Other features, such as those characteristic of ampoules, barrels, syringes, evacuated tubes, jars, etc., are also contemplated. The secondary loop 136 may include one or more polishing stations 208 to process the surface of the glass article. The secondary loop 136 may further include a plurality of cooling stations 210 and a discharge station 216 where the finished glass product 103 may be discharged from the converter 100 .

[0155] Reference again Figure 1 and Figure 3 In operation, the main turntable 124 can index or move the glass tube 102 secured in the holder 140 into the processing station 122. Specific operations can be performed at each of the processing stations 122, such as heating, forming, piercing, separating, cooling, lowering, feeding, measuring, etc. The converter 100 can be fine-tuned so that all processing stations 122 complete their operations within the dwell time. At the end of the dwell time, the main turntable 124 can index the glass tube 102 to the next processing station 122 in the main loop 126 during the index time. For the indexing converter, as used in this disclosure, the total time per part at each station is the sum of the dwell time and the index time.

[0156] In an embodiment, the converter 100 can be a continuous converter operable to continuously move the glass tube 102 and the holder 140 through a plurality of processing stations 122. In an embodiment, heating elements, burners, forming tools, measurement devices, and other elements of the conversion process can move with the glass tube 102 as it passes through the processing stations 122. For both indexed and continuous converters, the "active time" of a processing station is the duration that the glass tube 102 remains engaged with at least one heating element, at least one forming tool, at least one cooling nozzle, or other device while in a processing station 122.

[0157] The previous description of the processing stations 122 of the primary loop 126 and the secondary processing stations 132 of the secondary loop 136 may represent a typical converter 100 for producing vials from glass tubes 102. However, it should be understood that more or fewer processing stations 122 and secondary processing stations 132 may be used to produce vials or other glass products having different shapes or features, such as, but not limited to, evacuated blood collection tubes, cartridges, syringes, syringe barrels, ampoules, bottles, flasks, tubes, beakers, jars, and other glass products, or other pharmaceutical glass products. Additionally, it should be understood that the processing stations 122 and secondary processing stations 132 may be arranged in any of many different orders and / or configurations to produce glass products of different shapes.

[0158] Examples of converters 100 for converting glass tubes 102 into glass vials include the RP16 or RP18 vial forming machines with an automatic tube feeder, manufactured by AMBEG Dr. J. Dichter GmbH, which include sixteen processing stations 122 and eight secondary processing stations 132 in a primary loop 126. Other examples include the RP32 vial forming machine, manufactured by AMBEG Dr. J. Dichter GmbH, which includes thirty-two processing stations 122 in a primary loop 126 and two secondary loops 136, each with eight secondary processing stations 132; and the Zeta 098 vial forming machine, manufactured by Euromatic SRL, which includes 36 processing stations. Another example includes the Zeta 103 barrel forming machine, manufactured by Euromatic SRL, which is a converter for converting glass tubes into glass barrels. Barrel converters have similar characteristics to the aforementioned vial converter 100, but are used to produce glass products with barrel dimensions rather than vials. Converters for forming syringes, jars, ampoules, evacuated tubes, or other glass pharmaceutical containers may also be used.

[0159] Now refer to Figure 4 , schematically depicting the heating stations 202 of the converter 100. Each of the heating stations 202 may include one or more heating elements 301. Figure 3As shown in FIG, in a typical converter 100, the heating element 301 may include one or more burners 302, which are used to heat the heat generated by ... Figure 3 ) or perform the forming operation at the separation station 206 ( Figure 3 ) before performing the separation operation. Figure 4 A single burner 302 is depicted, but it should be understood that multiple burners 302 may be employed in a single heating station 202. Each burner 302 may be fluidly connected to a fuel gas supply 304, an oxygen supply 306, and optionally an air supply 308. Examples of fuel gases for the burners 302 may include, but are not limited to, hydrogen, hydrocarbon fuel gases (e.g., methane, propane, and butane), other fuel gases, or combinations of these.

[0160] Each burner 302 may include a fuel control valve 310 for controlling the flow rate of fuel gas to the burner 302. Each burner 302 may also include an oxygen control valve 312 for controlling the mass flow rate of oxygen to the burner 302. Each burner 302 may further include an air control valve 314 for optionally controlling the flow rate of air to the burner 302. The burners 302 combust the fuel gas in the presence of oxygen and / or air to produce a flame that heats at least a target area of ​​the glass tube 102.

[0161] Now refer to Figure 5 and Figure 6 , schematically depicting an example of a forming station 204 of the converter 100. Each forming station 204 may include a Figure 1 ) One or more forming tools 324 that rotate about a tool axis E. When transferred to the forming station 204, the glass tube 102, previously heated in the heating station 202, is rotated by the holder 140. As the glass tube 102 rotates, the forming tools 324 can engage the glass tube. When engaged, the contact of the forming tools 324 with the heated glass tube 102 can form the glass tube 102 into a desired shape. The forming tools 324 can remain in contact with the glass tube 102 for the duration of the forming tool 324's active time. At the end of the active time, the forming tool actuator 326 can retract the forming tools 324 from engagement with the glass tube 102. Figure 5 An embodiment of a forming station 204 for forming the shoulder 142 of a glass vial is schematically shown. Figure 6 An exemplary embodiment of a 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. Other types of forming tools 324 may be employed in the forming station 204 depending on the desired characteristics of the glass article 103.

[0162] Reference again Figure 5 , the forming tool actuator 326 can be 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 engagement and disengagement of each of the forming tools 324 in the forming station 204 with the glass tube 102. Adjusting the contact timing of the forming tools 324 can adjust the total contact time that each of the forming tools 324 is in contact with the glass tube 102. Contact time refers to the duration that the forming tool 324 is engaged or in contact with the glass tube 102. The forming tool actuator 326 can further be operable to move the forming tool 324 vertically relative to the glass tube 102 in the forming station 204 (e.g., Figure 3 in the + / -Z direction of the coordinate axis in ), horizontally (e.g., in the direction defined by Figure 4 The position of the molding tool 324 is changed in the XY plane (indicated by the coordinate axes in the ) or a combination of these directions.

[0163] Now refer to Figure 7 , schematically depicting a conventional separation station 206 of the converter 100 . Figure 7 The conventional separation station 206 depicted in FIG is a hot separation station and is positioned after the one or more heating stations 202 in the direction of rotation 222 of the main turntable 124. The heating station 202 positioned before the separation station 206 preheats the glass tube 102. The conventional separation station 206 has at least one separation burner 348. The separation burner 348 may have any of the features previously described for the burner 302, including but not limited to the fuel gas control valve 310, the oxygen control valve 312, and / or the air control valve 314. As the glass tube 102, which has been made viscous and deformable by the previous heating station 202, is rotated about the central axis A of the glass tube 102 by the holder 140, the separation burner 348 engages the outer surface 140 of the glass tube 102 to heat the glass tube 102 to a temperature at which the viscosity of the glass causes the partially formed glass article to separate from the glass tube 102. Once separated from the glass tube 102, the partially formed article can be transferred to the secondary turntable 134 ( Figure 1 ) or discharged from the converter 100. Similar to the heating station 202, the separation station 206 may also include a burner positioner 318 connected to the separation burner 348. The burner positioner 318 may be operable to vertically (e.g., at the separation station 206) relative to the glass tube 102. Figure 3 in the + / -Z direction of the coordinate axis in ), horizontally (e.g., in the direction defined by Figure 7 The separation burner 348 is positioned in the XY plane (identified by the coordinate axes in the ) or a combination of these directions.

[0164] In conventional converters, gas burners are primarily used for preheating, shaping, and separation steps. In heating station 202, significant heating is required to increase the temperature of the glass tube to a temperature suitable for hot forming or separation, for example, a temperature greater than or equal to 1000°C, depending on the glass composition. Additional heating with different flame configurations is then applied to enable the product to be formed using mechanical glass shaping tools, followed by separation of the components, inspection, annealing, and packaging of the final product. Although existing conversion processes using gas burners for heating and separation are well established and have been used for a considerable period of time, these conventional conversion processes have many challenges and areas for improvement, particularly in view of the increasing demand for pharmaceutical products and the increasing focus on high quality, manufacturing efficiency, and environmental sustainability of the process.

[0165] One of the challenges of existing conventional conversion processes is manufacturing throughput. Typically, the part rate in vial production ranges from approximately 30 to 60 pieces / minute, depending on the wall thickness, nominal diameter, and / or glass composition of the glass tube. The bottleneck in increasing the part rate lies primarily in the efficiency of the gas burner to heat the glass, which is limited by surface heat absorption and thermal conductivity through the glass bulk. Finding a new heat source, as an alternative to the flame from a gas burner, with potentially higher heat transfer through the glass, could enable increasing the part rate of the converter. Furthermore, the gas burners used for heating can be imprecise, sometimes unstable, and more difficult to control due to the time lag between changing the flow rate of air and / or fuel to the gas burner and the change in heating rate. The reduced accuracy, stability, and control of gas burners leads to dimensional inaccuracies in the finished glass products, which can increase the number of rejects and reduce the overall yield of glass products from the glass tubes. Providing a new heat source that is more precise, stable, and better controlled than gas burners could provide better dimensional accuracy of glass products, reduce the number of rejects, and increase the yield.

[0166] Furthermore, the use of gas burners can lead to undesirable contamination of the glass product surface, for example, from contact between the gas burner flame and the glass tube, and chemical reactions and interactions between the glass and the combustion products. Furthermore, the gas burners in conventional converters burn fossil fuels, such as natural gas, and produce combustion products that are emitted during the process. These combustion gases typically require treatment before being discharged. Using fossil fuels to power gas burners can further increase the carbon footprint of the conversion process.

[0167] The present application relates to a converter and conversion process that includes applying high-intensity laser radiation in the far infrared spectrum (i.e., wavelengths of about 4 μm to about 12 μm) to glass that is substantially opaque as an alternative heat source for heating a glass tube, separating the article from a working end of the glass tube, or both. In particular, the present application relates to a system for producing glass articles from a glass tube, wherein the system includes a converter having multiple processing stations and at least one laser system positioned in at least one heating station, a separation station, or a combination thereof. The laser system is operable to generate a laser beam, modify one or more properties of the beam, and direct the laser beam to the glass tube in the heating station, the separation station, or both. The one or more laser beams are generated by the one or more laser systems operating in an IR wavelength range with high absorption in glass that is substantially opaque to the laser radiation.

[0168] The present application also relates to a method for converting a glass tube into a plurality of glass articles using the system disclosed herein. The disclosed method is based on rapidly heating a glass tube using laser beams of varying shapes and spatial power distributions to a temperature at which the glass viscosity permits shaping (forming) by an external mechanical shaping tool through a combination of tensile or compressive forces with internal glass stress, surface tension, and, in some cases, gravity. Heating the glass tube with one or more laser beams can be used to separate the glass article from the working end of the glass tube.

[0169] Due to the clearly defined area affected by the laser beam and the stability of the laser power over an extended period of time, the systems and methods disclosed herein enable a more stable, precise, and controllable method of heat delivery to the glass tube. The precise heating provided by the laser system can reduce dimensional variation in the final part by tightly controlling glass viscosity during the forming and separation steps, reducing scrap and increasing yield. Specifically, the laser power of the laser system herein can be tightly controlled to provide uniform heating to the glass tube without damaging the glass, such as through ablation or evaporation of the glass caused by excessive laser power. The use of a laser beam allows for tight control over the area and / or volume of glass heated by the laser beam. Laser systems providing the laser heat source can be integrated into conventional conversion equipment, which can reduce the number of burners in a hybrid system or allow for the design of an all-laser conversion system. Single or multiple laser systems can be used to achieve tube preheating, bottom forming, and separation with varying beam shapes, orientations, and powers. Laser beam optics enable precise focusing of the beam on the glass without being affected by alignment sensitivities that can arise when burners wear or change over time due to degradation or machining tolerances.

[0170] The laser system in the separation station allows the separation process to be customized to create a bottom for the glass article or to separate the glass article while maintaining the open end of the glass article and the glass tube. When forming the bottom or open end of the glass article, the laser system in the separation station allows both separation of the glass article and processing of the end of the glass article to be achieved in a single processing step using a single processing station. Transitioning from forming the open end to forming the bottom on the glass article can be achieved by quickly and easily modifying the size, shape, orientation, or power density of the laser beam. The size, shape, orientation, and power density of the laser beam can also be adjusted to vary the thickness of the bottom of the glass article.

[0171] The systems and methods disclosed herein do not use gas combustion to heat the glass and do not generate combustion products. The reduction in combustion products can reduce glass contamination through contact between the burner flame and the glass and chemical reactions and interactions with the combustion products. The reduced use of burners can improve the chemical neutrality of the conversion process. Reducing the number of gas burners can also reduce or eliminate process exhaust from combustion products, which can be more environmentally friendly and contribute to greener manufacturing practices, among other features.

[0172] Reference again Figure 1 , graphically depicts one embodiment of a system 400 of the present disclosure for producing a glass article from a glass tube 102. System 400 may include a converter 100 comprising a plurality of processing stations 122 spaced apart in a loop and at least one holder 140. Converter 100 may include any combination of the features previously discussed herein for converter 100. In an embodiment, the plurality of processing stations 122 include at least one heating station, at least one forming station, and a separation station. Each of holders 140 is operable to hold and rotate glass tube 102 about a central axis A of glass tube 102. Converter 100 is operable to sequentially translate holder 140 and the glass tube 102 secured therein through each of processing stations 122. System 400 may further include at least one laser system 410, such as one or more laser systems 410. The at least one laser system 410 may be positioned in at least one heating station, at least one separation station, or both. Laser system 410 may include a laser source 412 and a beam delivery system 420. Laser system 410 may be operable to generate laser beam 414, modify one or more properties of laser beam 414, and direct laser beam 414 at glass tube 102 while glass tube 102 is in a heating station or a separation station.

[0173] Now refer to Figure 8 , the laser system 410 may include a laser source 412 operable to generate a laser beam 414 and a beam delivery system 420 operable to shape and direct the laser beam 414 to the glass tube 102 in a separation station or a heating station. Figure 8 , a laser system 410 is depicted in a laser separation station 440 operable to separate a glass article from the working end 107 of the glass tube 102. Additionally or alternatively, in embodiments, the laser system 410 may be positioned in the heating station 202, e.g. Figure 21 The heating station 202 is depicted in FIG.

[0174] The laser source 412 can be operable to generate a laser beam 414. The laser beam 414 can have a wavelength within a wavelength range that allows the laser beam 414 to be absorbed by the glass of the glass tube 102 to heat the glass without significantly passing through the glass (i.e., very little laser beam 414 passes through the glass). Because silicate-based glass has strong absorption of light having a wavelength greater than or equal to about 4 micrometers (μm), a number of different laser sources can be used to generate the laser beam 414. The laser source 412 can be operable to generate the laser beam 414 having a wavelength in the infrared wavelength region, such as the far infrared region. The laser source 412 can be operable to generate the laser beam 414 having a wavelength greater than or equal to about 1 μm, greater than or equal to about 2 μm, greater than or equal to about 3 μm, greater than or equal to about 4 μm, or even greater than or equal to about 8 μm. The laser source 412 can be operable to generate the laser beam 414 having a wavelength less than or equal to about 12 μm, or even less than or equal to about 11 μm. The laser source 412 can be operable to generate a laser beam 414 having a wavelength of about 1 μm to about 12 μm, about 1 μm to about 11 μm, about 2 μm to about 12 μm, about 2 μm to about 11 μm, about 3 μm to about 12 μm, about 3 μm to about 11 μm, about 4 μm to about 12 μm, about 4 μm to about 11 μm, about 5 μm to about 12 μm, about 5 μm to about 11 μm, about 8 μm to about 12 μm, or about 8 μm to about 11 μm. The specific wavelength range can depend in part on the type of glass composition comprising the glass tube 102.

[0175] The laser source 412 may be operable to generate the laser beam 414 as an infrared laser beam. In embodiments, the laser source 412 may be a CO laser, a CO2 laser, a quantum cascade laser (QCL), or other suitable lasers capable of generating the laser beam 414 having a wavelength within the above-described range. The laser source 412 may be operable to generate a continuous or pulsed laser beam 414. Continuous lasers typically have lower peak power and gradually increase the glass surface temperature, while pulsed lasers typically have higher peak power and increase the glass surface temperature to a greater extent in a shorter period of time than continuous lasers.

[0176] Reference again Figure 1, the beam delivery system 420 can be positioned downstream of the laser source 412. The beam delivery system 420 can be operable to modify characteristics of the laser beam 414, such as shape, power density distribution, other beam characteristics, or combinations thereof. The beam delivery system 420 can be further operable to direct the laser beam 414 to the glass tube 102 while the glass tube 102 is positioned in a processing station 122, such as one of the separation station 206, the heating station 202, or a combination thereof. The beam delivery system 420 can include one or more shaping optics, steering mirrors, beam splitters, or a combination thereof. In an embodiment, the beam delivery system 420 can include at least one shaping optic and at least one steering mirror.

[0177] The shaping optics may include one or more lenses, mirrors, or both operable to modify the shape of the laser beam 414. The laser beam 414 generated by the laser source 412 may be a ring-shaped Gaussian laser beam. The beam delivery system 420 may include optical components that transform the ring-shaped laser beam 414 into an elliptical beam, change the dimensions (e.g., length and width) of the laser beam 414, and / or change the power density distribution along one or two axes of the elliptical laser beam. In embodiments, the beam delivery system 420 may include one or more variable beam expanders (e.g., zoom telescope lenses), cylindrical lenses, aspheric cylindrical lenses, polygonal mirrors, or combinations thereof to modify the beam size, beam shape, beam power density distribution, or combinations thereof. In embodiments, the beam delivery system 420 may include one or more zoom telescope lenses or other variable beam expanders that may be operable to modify the beam size of the laser beam 414, for example, by increasing its beam size. In an embodiment, the beam delivery system 420 may include one or more cylindrical lenses that may be operable to modify the shape of the laser beam 414, such as to modify the beam length, beam width, or both of the laser beam 414. In an embodiment, the beam delivery system 420 may include multiple cylindrical lenses that may be operable to transform the laser beam 414 from having an annular shape to having an elliptical shape. The multiple cylindrical lenses may also expand or compress the laser beam 414 to produce a beam having target dimensions (e.g., length and beam width) at the point where the laser beam 414 contacts the glass tube 102.

[0178] In an embodiment, the beam delivery system 420 may include one or more lenses operable to change the power density distribution of the laser beam 414. In an embodiment, the beam delivery system 420 may include one or more spherical cylindrical lenses operable to produce the laser beam 414 with a Gaussian power density distribution. In an embodiment, the beam delivery system 420 may include one or more aspherical cylindrical lenses operable to produce the laser beam 414 with a flat-top power density distribution. In an embodiment, the beam delivery system 420 may include one or more polygonal mirrors operable to modify the power density distribution of the laser beam 414. In an embodiment, the laser beam 414 is an elliptical beam, and the cylindrical lenses, aspherical cylindrical lenses, or polygonal mirrors may be configured to modify the power density distribution in the direction of the major axis.

[0179] Now refer to Figure 9 , graphically depicts two different power density distributions for a laser beam, with power density (y-axis) varying with beam position (x-axis). Figure 9 The beam position in refers to the position of the laser beam along the long axis of the elliptical beam. Figure 9 , a Gaussian power density profile 902 is characterized by a maximum laser power density at the center 900 of the laser beam and a power density that decreases with increasing distance from the center 900 of the laser beam. In contrast, a flat-top power density profile 904 has a smaller maximum power density, but the power density is more uniform across most of the long axis of the laser beam.

[0180] Reference again Figure 8 , the beam delivery system 420 may include any other optical components, such as, but not limited to, mirrors, lenses, beam splitters, prisms, filters, apertures, etc., that are operable to modify one or more characteristics of the laser beam 414 in an upstream direction at the point where the laser beam 414 is incident on the glass tube 102. The beam delivery system 420 may provide for adjustment of the distances between the various components (e.g., lenses, mirrors, filters, prisms, etc.) within limits. Some adjustment of the distances between the optical components of the beam delivery system 420 may enable fine-tuning of the size and position of the laser beam 414 at the point where the laser beam 414 contacts the glass tube 102 in the processing station. In embodiments, the beam length and beam width of the laser beam 414 may be modified by changing the distances between the lenses and other optical components in the beam delivery system 420.

[0181] like Figure 8 As shown in FIG, in an embodiment, the laser system 410 can be directed so that the laser beam 414 travels directly in a straight line from the laser source 412 through the beam delivery system 420 to the glass tube 102. Referring now to FIG. Figure 10In embodiments, due to space constraints or other considerations, the laser system 410 may not be oriented such that the laser beam 414 may travel in a straight line between the laser source 410 and the glass tube 102. In embodiments, the laser system 410 may include one or more steering mirrors 422 that may be operable to direct the laser beam 414 toward the glass tube 102 in the processing station 122. The steering mirrors 422 may enable the laser source 412 and the beam delivery system 420 to be mounted at a distance away from or above the converter 100 while still being able to deliver the laser beam 414 to a target location on the glass tube 102 in the processing station 122. In embodiments, the laser system 410 may include one or more beam splitters 460 that may be operable to split the laser beam 414 into two or more individual laser beams 414 that may be directed to different processing stations 106 of the converter 100.

[0182] Reference again Figure 8 In an embodiment, the system 400 may further include a laser system positioner 430 operably connected to the laser system 410. The laser system positioner 430 may be operable to change the vertical position of the laser system 410 (i.e., Figure 8 The laser system positioner 430 can also change the vertical position of the laser system 410 relative to the glass tube 102. Figure 8 The direction in the XY plane of the coordinate axis in the laser system positioner 430, one or more steering mirrors 422 ( Figure 10 ) or both may be used to change the beam path so that the laser beam 414 is incident on the outer surface of the glass tube 102 in the processing station 122 (e.g., the heating station and / or the separation station). The laser system positioner 430 may include any device or collection of devices operable to change the position of the laser system 410. In an embodiment, the laser system positioner 430 may include at least one track 432, a laser support 434 connected to the laser system 410, and an actuator 436 that movably secures the laser support 434 to the track 432. The actuator 436 may be operable to Figure 8 The laser support 434 and the laser system 410 are translated along the rails 432 in the + / -Z direction of the coordinate axis in FIG. The actuator 436 can be operable to move the laser support 434 in the + / -Z direction of the coordinate axis in FIG. Figure 8 A stepper motor or other device that moves along the track 432 in the + / -Z direction of the coordinate axis in FIG. Figure 84, and the like. Although depicted as having rails 432, laser support 434, and actuator 436, it should be understood that the laser system positioner 430 may include any other type of equipment, such as a hydraulic or pneumatic positioner, a scissor lift, pulleys, a robot, or other device or combination of devices suitable for moving the laser system 410 relative to the glass tube 102 in the processing station. In an embodiment, the laser system positioner 430 may be manually adjusted to change the position of the laser support 434.

[0183] In an embodiment, laser system positioner 430, steering mirror 422, or both can be operable to position laser system 410 relative to glass tube 102 so that glass tube 102 is centered within the beam waist of laser beam 414. The beam waist refers to the region of the beam path of laser beam 414 where the power density of laser beam 414 is greatest. In an embodiment, laser system positioner 430 can be adjusted to position laser system 410 so that glass tube 102 is positioned within a converging or diverging section of laser beam 414 to reduce the power density of laser beam 414 at the point along the beam path where laser beam 414 impinges on glass tube 102. Changing the position of laser system 410 to move the beam waist closer to glass tube 102 can increase the power density of laser beam 414 at the point where laser beam 414 contacts glass tube 102. Conversely, changing the position of laser system 410 to move the beam waist further away from glass tube 102 can reduce the power density of laser beam 414 at the point where laser beam 414 contacts glass tube 102.

[0184] Additionally, moving the position of the laser system 410 to change the distance between the laser system 410 and the glass tube 102 can also change the beam size. For example, changing the distance between the laser system 410 and the glass tube 102 to move the beam waist farther away from the glass tube 102 (e.g., positioning the glass tube 102 further into the converging or diverging portion of the beam path) can result in the laser beam 414 having a larger beam width and length at the point in the beam path where the laser beam 414 impinges on the outer surface of the glass tube 102. Conversely, changing the distance between the laser system 410 and the glass tube 102 to move the beam waist of the laser beam 414 closer to the glass tube 102 can result in the split laser beam 132 having a reduced beam width and length of the laser beam 414 at the point in the beam path where the laser beam 414 impinges on the outer surface of the glass tube 102.

[0185] Reference again Figure 8 The general operation of the laser system 410 includes generating a laser beam 414 using a laser source 412 and passing the laser beam 414 through a beam delivery system 420, which includes optical devices that modify the shape, power density distribution, or both of the laser beam 414. The laser beam 414 is then directed toward a separation region 424 or target region 426 ( Figure 21) to direct the laser beam 414. The laser system positioner 430, one or more steering mirrors 422, or both may be used and / or adjusted to direct the laser beam toward the separation zone 424 or target zone 426 ( Figure 20 ) guides the laser beam 414.

[0186] Reference again Figure 8 The laser beam 414 may have a wavelength of 1 μm to 12 μm, 1 μm to 11 μm, 1 μm to 10 μm, 2 μm to 12 μm, 2 μm to 11 μm, 2 μm to 10 μm, 3 μm to 12 μm, 3 μm to 11 μm, 3 μm to 10 μm, 4 μm to 12 μm, 4 μm to 11 μm, 4 μm to 10 μm, 5 μm to 12 μm, 5 μm to 11 μm, 5 μm to 10 μm, 8 μm to 12 μm, 8 μm to 11 μm, or 8 μm to 10 μm. In an embodiment, the laser beam 414 may have a wavelength of about 5 μm to about 11 μm. The laser beam 414 may be a continuous laser beam or a pulsed laser beam. The laser beam 414 may be a collimated beam or a non-collimated beam.

[0187] The laser beam 414 may have a total laser power greater than or equal to 50 watts (W), greater than or equal to 100 W, greater than or equal to 200 W, or greater than or equal to 500 W. In embodiments, the laser beam 414 may have a total laser power of 50 W to 2000 W, 50 W to 1500 W, 50 W to 500 W, 50 W to 200 W, 100 W to 2000 W, 100 W to 1500 W, 100 W to 500 W, 100 W to 200 W, 200 W to 2000 W, 200 W to 1500 W, 200 W to 500 W, 500 W to 2000 W, 500 W to 1500 W, 500 W to 1000 W, 1000 W to 2000 W, or even 1000 W to 1500 W. The laser power of the laser beam 414 may be adjusted depending on the beam width of the laser beam 414, wherein the power is increased to increase the beam width of the laser beam 414. In an embodiment, the laser beam 414 may be an elliptical beam with a narrow beam width ( Figure 13 ), and the laser beam 414 may have a laser power of about 50 W to about 500 W, for example, 50 W to 200 W, 100 W to 500 W, 100 W to 200 W, or 200 W to 500 W. In an embodiment, the laser beam 414 may be an elliptical beam with a wide beam width ( Figure 12 ), and the laser beam 414 may have a laser power of about 500 W to about 2000 W, for example, 500 W to 1500 W or 500 W to 1000 W.

[0188] The heating rate of laser beam 414 used to heat glass tube 102 can be increased or decreased by increasing or decreasing the laser power density of laser beam 414. In an embodiment, laser beam 414 can have a laser power density sufficient to produce a heating rate of the glass tube of about 200°C / second to about 400°C / second. Laser beam 414 can be characterized by a power density profile. The heating rate of laser beam 414 can be modified by changing the power density profile of laser beam 414. As previously discussed, in an embodiment, laser beam 414 as modified by beam delivery system 420 can have a Gaussian power density profile along the long axis (e.g., length) of laser beam 414. In an embodiment, laser beam 414 as modified by beam delivery system 420 can have a flat-top power density profile along the long axis (e.g., length) of laser beam 414. The methods disclosed herein can include changing the power density profile of laser beam 414, wherein changing the power density profile changes the heating rate of laser beam 414.

[0189] The laser beam 414, as modified by the beam delivery system 420, can be an annular beam or an elliptical beam. Figure 11 In an embodiment, the laser beam 414 may be an annular beam having a substantially circular cross-sectional shape. When the laser beam 414 is an annular beam, the laser beam 414 may have an outer diameter D that is less than or equal to the outer diameter D of the glass tube 102 at the point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102. t About 1.25 times the beam diameter D b The shape of the beam at the point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102 refers to the cross-sectional shape of the laser beam 414 in a plane perpendicular to the beam path, wherein the plane is located along the beam path at the point where the laser beam 414 first contacts the outer surface of the glass tube 102. In embodiments, the laser beam 414 may have a beam diameter D that is less than or equal to about 1.25 times the outer diameter of the glass tube 102, for example, about 0.5 to about 1.25 times, about 0.5 to about 1.1 times, about 0.5 to about 1 times, about 0.75 to about 1.25 times, about 0.75 to about 1.1 times, about 0.75 to about 1 times, about 0.9 to about 1.25 times, about 0.9 to about 1.1 times, about 0.9 to about 1 times, about 1 to about 1.25 times, or about 1 to about 1.1 times the outer diameter of the glass tube 102. b In an embodiment, the laser beam 414 may have a beam diameter D of about 5 mm to about 50 mm at a point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102. b In an embodiment, the laser beam 414 may have a beam diameter D greater than about 50 mm. b annular beam.

[0190] Now refer to Figures 12 to 14In an embodiment, the laser beam 414 may be an elliptical beam having a major axis and a minor axis. When the laser beam 414 is an elliptical beam, the beam delivery system 420 may be configured to direct the laser beam 414 so that the major axis of the elliptical laser beam 414 is perpendicular to ( Figure 12 and Figure 13 ) or parallel to ( Figure 14 ) The central axis A of the glass tube 102. Figure 12 and Figure 13 In an embodiment, the laser beam 414 may have a major axis to minor axis ratio greater than or equal to 2, greater than or equal to 5, or even greater than or equal to 10 at a point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102. In an embodiment, the laser beam 414 may be an elliptical laser beam having a major axis to minor axis ratio of about 2 to about 100, about 2 to about 70, about 2 to about 40, about 5 to about 100, about 5 to about 70, about 5 to about 40, about 10 to about 100, about 10 to about 70, about 10 to about 40, about 40 to about 100, or about 40 to about 70 at a point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102.

[0191] When the laser system 410 is positioned in the separation station 206, as shown Figure 8 As shown in FIG. 1 , the major axis to minor axis ratio (ie, the beam length L) can be modified. B The laser beam 414 can be heated to a predetermined depth (ratio (W) to the beam width W) to produce an open or closed end of the glass tube 102 at the working end 107 of the glass tube after separating the glass article from the working end 107. During separation, at the separation zone 424, the glass thins and stretches until the glass finally separates to form the glass article 103 separated from the working end 107 of the glass tube 102. Once separated, surface tension within the glass can cause the volume of viscous glass on either side of the separation point to flow back to the new working end of the glass tube 102 and the end of the glass article 103 at the separation point, respectively. In embodiments, the volume of heated glass can be large enough that the viscous glass flowing back to the new end of the glass article 103 can form a meniscus above the end of the glass article 103. The formation of the glass meniscus above the end of the glass article 103 can provide a bottom of the glass article 103. In embodiments, the volume of glass heated by the laser beam 414 may be insufficient to form a meniscus, resulting in the new end of the glass article 103 being open.

[0192] Reference again Figure 12 and Figure 13 , the major axis to minor axis ratio of the laser beam 414 affects the glass volume of the glass tube 102 heated in the separation station 206. Figure 13In order to form an open end at the working end 107 of the glass tube 102 after separation, the laser beam 414 can be an elliptical beam having a large major axis to minor axis ratio, which produces a thin beam that heats a small volume of glass, the volume of which is just enough to separate the glass article from the glass tube 102 but not enough to form a glass meniscus above the ends of the glass tube 102 and the glass article. In embodiments, the separation station can be configured to form an open end on the glass tube and the glass article, and the laser beam 414 can be an elliptical beam having a major axis to minor axis ratio (i.e., beam length L) of about 4 to about 100, e.g., about 4 to about 70, about 5 to about 100, about 5 to about 70, about 10 to about 100, about 10 to about 70, about 12 to about 100, about 12 to about 70, about 15 to about 100, about 15 to about 70, or about 20 to about 100 at the point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102. B The ratio of the major axis to the minor axis of the laser beam 414 used to create the open bottom can depend on the outer diameter, wall thickness, glass composition, or a combination thereof of the glass tube 102 being processed.

[0193] Now refer to Figure 12 In order to form a closed end at the working end 107 of the glass tube 102 and the glass article after separation, the laser beam 414 can be an elliptical beam having a small major axis to minor axis ratio, so that the laser beam 414 heats a larger volume of glass sufficient to form a glass meniscus above the working end of the glass tube 102 and the glass article. In an embodiment, the separation station can be configured to form a closed end on the glass tube 102 and the glass article, and the laser beam 414 can have a major axis to minor axis ratio (i.e., a beam length L) of about 2 to about 12, for example, about 2 to about 10, about 2 to about 8, or about 2 to about 5 at the point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102. B The laser beam 414 may be formed into an elliptical beam having a ratio of the major axis to the minor axis (W) of the beam width. The ratio of the major axis to the minor axis of the laser beam 414 used to produce the closed bottom may depend on the outer diameter, wall thickness, glass composition, or a combination thereof of the glass tube 102 being processed. When a closed end is formed on the working end of the glass tube 102 in the separation station 206, a closed end is also formed on the end of the glass article separated from the glass tube 102. This closed end of the glass article may become the bottom of the glass article, for example, if the glass article is a vial, jar, or other closed-bottom container.

[0194] refer to Figures 12 to 14In an embodiment, the laser beam 414 may be an elliptical beam and may have a beam length L that is less than or equal to about 1.25 times the outer diameter of the glass tube 102, for example, about 0.5 to about 1.25 times, about 0.5 to about 1.1 times, about 0.5 to about 1 times, about 0.75 to about 1.25 times, about 0.75 to about 1.1 times, about 0.75 to about 1 times, about 0.9 to about 1.25 times, about 0.9 to about 1.1 times, about 0.9 to about 1 times, about 1 to about 1.25 times, or about 1 to about 1.1 times the outer diameter of the glass tube 102. B In an embodiment, the laser beam 414 may be an elliptical beam and may have a beam length L of about 5 mm to about 50 mm. B In an embodiment, the beam length L B The beam length L of the laser beam 414 may be greater than about 50 mm. B = refers to the distance along the long axis across the laser beam 414 at the point along the beam path where the laser beam 414 is incident on the outer surface 104 of the glass tube 102. As used herein, the beam length L of the laser beam 414 is B It refers to the maximum distance across the laser beam 414 in a direction parallel to the major axis at that point, rather than the average length taken over the width of the beam. For an elliptical beam, the beam length L B = is equal to the length of the major axis of the elliptical beam at the point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102. In an embodiment, the beam length L of the elliptical laser beam 414 is B The outer diameter D of the glass tube 102 may be based in part on the t And choose.

[0195] The laser beam 414 may have a beam width W of about 0.5 mm to about 20 mm at a point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102. The beam width W refers to the maximum width of the beam in a direction parallel to the minor axis of the laser beam 414 at a point along the beam path where the laser beam 414 is incident on the outer surface 104 of the glass tube 414. For an elliptical beam, the beam width W is equal to the length of the minor axis of the elliptical beam. In embodiments, the laser beam 414 may have a beam width W of 0.5 mm to 10 mm, 0.5 mm to 7 mm, 0.5 mm to 5 mm, 0.5 mm to 3 mm, 0.5 mm to 2 mm, 1 mm to 20 mm, 1 mm to 10 mm, 1 mm to 7 mm, 1 mm to 5 mm, 1 mm to 3 mm, 1 mm to 2 mm, 2 mm to 20 mm, 2 mm to 10 mm, 2 mm to 7 mm, 2 mm to 5 mm, 2 mm to 3 mm, 3 mm to 20 mm, 3 mm to 10 mm, 3 mm to 7 mm, 3 mm to 5 mm, 5 mm to 20 mm, 5 mm to 10 mm, 5 mm to 7 mm, 7 mm to 20 mm, 7 mm to 10 mm, or even 10 mm to 20 mm at a point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102.

[0196] The beam width W of the laser beam 414 can be selected based on the wall thickness, nominal diameter, glass composition, or a combination thereof of the glass tube 102. When the laser system 410 is positioned in the separation station 206, the beam width W of the laser beam 414 can be modified to vary the volume of glass heated during separation of the glass article from the working end 107 of the glass tube 102. Varying the volume of glass heated during separation can enable the formation of an open end or a closed end on the working end of the glass tube 102 and the end of the glass article separated therefrom.

[0197] Now refer to Figure 13 In embodiments, reducing the beam width W of the laser beam 414 to a range of about 0.5 mm to about 5 mm or about 0.5 mm to about 3 mm may result in the formation of open ends of the glass tube 102 and the glass article during separation, depending on the thickness, outer diameter D of the glass tube, and the thickness of the glass tube. t and glass compositions. Reference is now made to Figure 12 , increasing the beam width W of the laser beam 414 to a range of about 3 mm to about 20 mm or about 5 mm to about 10 mm, as Figure 12As shown in FIG. , this can result in the formation of a closed end of the glass tube 102 and the glass article during separation, depending on the thickness, outer diameter, and glass composition of the glass tube. When forming the closed end of the glass tube 102 and the glass article during separation, further increasing the beam width W of the laser beam 414 can further increase the volume of glass heated during separation, which can increase the thickness of the closed end, thereby increasing the thickness of the bottom of the produced glass article. Similarly, decreasing the beam width W of the laser beam 414 can reduce the volume of glass heated during separation, which can result in a thinner closed end and a thinner bottom of the glass article. For example, by changing the beam length L B Changing the shape of the laser beam by adjusting W and / or the beam width W can change the volume of glass heated in the target area or separation area of ​​the glass tube 102.

[0198] Now refer to Figure 14 In an embodiment, the optics of the beam delivery system 420 may be configured to shape the laser beam 414 into an elliptical beam and direct the laser beam 414 so that the major axis of the elliptical cross-section is parallel to the central axis A of the glass tube 102. Directing the laser beam 414 so that the major axis is parallel to the central axis A of the glass tube 102 may enable the laser beam 414 to heat a larger volume of glass during separation of the glass article from the glass tube 102. Figure 14 As shown in FIG. 4 , the laser beam 414 can be directed so that the beam length L B The laser beam 414 is directed so that the long axis is parallel to the central axis A of the glass tube 102, and the beam width W is perpendicular to the central axis A of the glass tube 102. Figure 14 In this way, it is possible to Figure 12 Increasing only the beam width W of the laser beam 414 forms an even thicker bottom on the glass article as shown in FIG.

[0199] Now refer to Figure 15 In an embodiment, the laser system 410 can be configured to generate two laser beams and direct the two laser beams onto the outer surface of the glass tube 102. The two laser beams can be generated by having two individual laser sources, or by having a single laser source and splitting the laser beam one or more times. The two laser beam embodiments will be described herein in terms of two individual laser sources in two individual laser systems, however, it should be understood that a single laser beam can be generated by using a single laser source and then using an optical assembly (e.g., Figure 10 The beam splitter 460 in the embodiment of the present invention splits the laser beam to generate multiple laser beams to generate two or more laser beams.

[0200] Now refer to Figure 16In an embodiment, the laser system 410 may include a separation laser system 440 and a preheating laser system 450. The separation laser system 440 may generate a separation laser beam 444, the preheating laser beam 450 may be operable to generate a preheating laser beam 454, and the separation laser beam 444 and the preheating laser beam 454 may be directed onto the glass tube 102 in the separation station 206. In an embodiment, the separation laser beam 444 and the preheating laser beam 454 may overlap each other at the point where the beams are incident on the outer surface of the glass tube 102. Each of the separation laser system 440 and the preheating laser system 450 may include a laser source 412, as previously described herein.

[0201] The split laser system 440 may include a split beam delivery system 442 positioned downstream of the laser source 412. The split beam delivery system 442 may be operable to modify the shape of the split laser beam 444 to have an elliptical cross-sectional shape having a desired beam length and beam width. The split beam delivery system 442 may have any of the components or features previously described in connection with the beam delivery system 420. The split laser beam 444 may have an elliptical cross-section and may have a wavelength, laser power density, power density distribution, beam shape, or any other characteristics previously described in connection with the laser beam 414.

[0202] The preheating laser system 450 may include a preheating beam delivery system 452 downstream of the laser source 412. The preheating beam delivery system 452 may be operable to generate a preheating laser beam 454 having a desired beam diameter with an annular cross-sectional shape. The preheating beam delivery system 452 may have any of the components or features previously described in connection with the beam delivery system 420. The preheating laser beam 454 may have a wavelength, laser power density, power density distribution, beam shape, or any other characteristics previously described in connection with the laser beam 414. In an embodiment, the preheating laser system 450 may further include one or more steering mirrors 422 operable to direct the preheating laser beam 454 to the glass tube 102. Although Figure 16 Not shown, but in an embodiment, the separation laser system 440 may include one or more steering mirrors 422 operable to direct the separation laser beam 444 to the glass tube 102. The separation laser system 440, the preheating laser system 450, or both may further include a laser system positioner 430 ( Figure 8 ).

[0203] Reference again Figure 15 , schematically depicting the superposition of the preheating laser beam 454 and the separation laser beam 444 on the separation zone 424 of the glass tube 102. Figure 15, the separation laser beam 444 may be an elliptical laser beam having an elliptical cross-section, and the preheating laser beam 454 may be an annular beam having a generally circular cross-section. Figure 8 ) can be operated to change the relative positions of the separation laser beam 444 and the preheating laser beam 454.

[0204] Reference again Figure 8 , the separation station 206 of the converter 100 may include one or more laser systems 410 instead of a separation burner to separate the glass article from the glass tube 102. In an embodiment, the separation station 206 may include a single laser system 410 that may be operable to generate a single laser beam 414 having an elliptical cross-section. Figure 16 In an embodiment, the separation station 206 may include a laser system 410 capable of generating multiple laser beams, such as a laser system 410 including a separation laser system 440 and a preheat laser system 450, as previously discussed herein. The separation station 206 may include one or more laser system positioners 430 operable to change the position of one or more of the laser beams (e.g., laser beam 414, separation laser beam 444, preheat laser beam 454, or a combination thereof) relative to the glass tube 102. In an embodiment, the separation station 206 may further include a chuck 240, rollers, or other devices operable to apply a downward force to the glass article during separation of the glass article from the working end 107 of the glass tube 102.

[0205] Reference again Figure 8 , operation of the separation station 206 including the laser system 410 for separating a glass article from the working end 107 of the glass tube 102 will now be described in greater detail. Separating the glass article from the working end 107 of the glass tube 102 may include translating the holder 140 and the glass tube 102 into the separation station 206. The holder 140 may rotate the glass tube 102 about the central axis A of the glass tube 102. Separating the glass article from the glass tube 102 may further include exposing a separation region 424 of the glass tube 102 to the laser beam 414, which may heat the glass of the glass tube 102 in the separation region 424. Separating the glass article from the glass tube 102 may further include applying a separation force F (e.g., a force applied in an axial direction away from the glass tube 102, such as in the direction of the separation region) to the glass article while exposing the separation region 424 to the laser beam 414. Figure 8 Once the glass in separation zone 424 reaches a temperature at which the glass can be deformed, applying a separation force F to the glass article may separate the glass article from the working end 107 of the glass tube 102 at separation zone 424. Heating the glass tube 102 with the laser beam 414 and applying the separation force F may separate the glass article from the glass tube 102 and process the end of the glass article.

[0206] Exposing the separation region 424 of the glass tube 102 to the laser beam 414 can include generating the laser beam 414 with a laser source 412, modifying the laser beam 414 with a beam delivery system 420, and directing the laser beam 414 to the separation region 424 of the glass tube 102. The laser system 410 can be turned on and off to begin and end exposure of the glass tube 102 to the laser beam 414. In an embodiment, separating the glass article from the glass tube 102 can include exposing the separation region 424 of the glass tube 102 with the laser beam 414, wherein the laser beam has a beam width of about 0.5 mm to about 10 mm at a point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102 in the separation region 424. In an embodiment, the laser beam 414 can have a wavelength in the range of about 1 μm to about 12 μm or about 5 μm to about 11 μm. The laser beam 414 can have any of the characteristics previously described herein for the laser beam 414. Exposing the separation region 424 of the glass tube 102 to the laser beam 414 may heat the glass at the separation region 424 to a separation temperature at which the glass becomes viscous and deformable, such as a separation temperature greater than or equal to about 1000°C.

[0207] The separation region 424 of the glass tube 102 may be exposed to the laser beam 414 for an exposure time sufficient to increase the temperature of the glass to the separation temperature. In one embodiment, the exposure time of the glass tube 102 to the laser beam 414 in the separation station 206 may be less than the dwell time of the converter. Separating the glass article from the glass tube 102 may further include controlling the exposure time of the glass tube 102 to the laser beam 414 by adjusting the time at which the laser source 412 of the laser system 410 used to generate the laser beam 414 is turned on and then off.

[0208] As previously discussed, the laser beam 414 in the separation station 206 can have a heating rate of the glass tube 102 of about 200° C. / second to about 400° C. / second. As previously discussed, the heating rate of the laser beam 414 used to heat the glass tube 102 can be increased or decreased by increasing or decreasing the laser power density of the laser beam 414, changing the power density distribution of the laser beam 414, changing the shape of the laser beam 414, or a combination thereof. In one embodiment, reducing the cross-sectional area of ​​the laser beam 414 (e.g., reducing the diameter of an annular beam or reducing the width of an elliptical beam) at a constant power density can increase the heating rate of the laser beam and reduce the volume of glass heated by the laser beam 414. Conversely, increasing the cross-sectional area of ​​the laser beam 414 can distribute the laser power over a larger area, which can reduce the heating rate and increase the volume of glass heated by the laser beam 414.

[0209] Reference again Figure 8Separating the glass article from the glass tube 102 in the separation station 206 may further include applying a separation force F to the glass article while exposing the separation region 424 of the glass tube 102 to the laser beam 414. Applying the separation force F may cause the glass article to move in an axial direction (i.e., in a Figure 8 The separating station 206 is configured to move the glass article 102 in the -Z direction relative to the coordinate axis in the φ(-Z) direction away from the working end 107 of the glass tube 102. In an embodiment, the glass tube 102 may be oriented vertically in the separation station, with the working end 107 of the glass tube 102 facing downward (i.e., in the -Z direction), and the separating force F may include gravity. In an embodiment, applying the separating force F may include applying a mechanical separating force to the glass article. When the weight of the glass article is insufficient for gravity alone to separate the glass article from the glass tube, or when the glass tube 102 is not oriented vertically in the separation station (e.g., when the converter is oriented horizontally rather than vertically), applying a mechanical force to the glass article in the separation station may facilitate separation of the glass article from the glass tube 102. In an embodiment, the separation station 206 may include a chuck, angled rollers, or other device capable of applying a mechanical separating force to the glass article.

[0210] refer to Figure 8 In an embodiment, the separation station 206 may include a single laser system 410 operable to generate a single laser beam 414. When the separation station 206 includes a single laser system 410, the laser system 410 may be operable to generate the laser beam 414 having an elliptical cross-section, which may have a major axis and a minor axis. The laser beam 414, being an elliptical laser beam, may have a major axis to minor axis ratio of about 2 to about 70, or any range therebetween as previously discussed herein. The laser beam 414 may be oriented such that the major axis is parallel or perpendicular to the central axis A of the glass tube 102. In an embodiment, the laser system 410 may be configured to orient the laser beam 414 such that the major axis is perpendicular to the central axis A of the glass tube 102. In an embodiment, the laser system 410 may be configured to orient the laser beam 414 such that the major axis is parallel to the central axis A of the glass tube 102.

[0211] In an embodiment, separating the glass article from the working end 107 of the glass tube 102 may include forming an open end at the working end 107 of the glass tube 102 and the glass article during separation of the glass article from the glass tube 102. To form the open end at the working end of the glass tube 102 and the glass article, the laser beam 414 may be modified to reduce the volume of glass heated by the laser beam 414. The volume of glass heated by the laser beam 414 may be reduced by orienting the laser beam 414 so that the major axis is perpendicular to the central axis A of the glass tube 102 and reducing the width of the laser beam 414. To produce the open end during separation in the separation station 206, the laser beam 414 may have a beam width of about 0.5 mm to about 5 mm, e.g., about 0.5 mm to about 4 mm, about 0.5 mm to about 3 mm, about 0.5 mm to about 2 mm, about 1 mm to about 5 mm, about 1 mm to about 3 mm, or even about 1 mm to about 2 mm, at a point along the beam path where the laser beam 414 impinges on the outer surface of the glass tube 102 in the separation zone 424. The beam width of the laser beam 414 used to create the open end can be adjusted based on the diameter, thickness, glass composition, or a combination of these of the glass tube 102. For example, for a glass tube 102 having a greater thickness and / or a larger diameter, the beam width of the laser beam 414 can be increased to heat a larger volume of glass, thereby ensuring that separation of the glass article can be achieved during the dwell time of the converter.

[0212] Exposing the separation section 424 of the glass tube 102 to the laser beam 414 having a relatively narrow beam width can remove the glass article from the working end 107 of the glass tube 102 to produce a new end of the glass tube including an opening. The relatively narrow beam width of the laser beam 414, ranging from 0.5 mm to 5 mm, can result in heating a volume of glass in the separation zone that is insufficient to form a glass meniscus above the new working end 107 of the glass tube 102. Separating the glass article from the working end of the glass tube 102 while simultaneously forming an open end at the new working end 107 of the glass tube 102 can enable the downstream piercing station to be removed from the converter or reconfigured as another type of processing station, such as, but not limited to, a heating station 202, a measurement station, a cooling station, a forming station, a loading station, or other type of processing station.

[0213] The laser beam 414 may have a beam length, L, of less than or equal to about 1.25 times the outer diameter of the glass tube 102, such as about 0.5 to about 1.25 times the outer diameter of the glass tube 102, at a point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102 in the separation zone 424. In an embodiment, the laser beam 414 may have a beam length, L, of about 5 mm to about 50 mm, or even greater than about 50 mm, at a point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102 in the separation zone 424. BThe beam length of the laser beam 414 can depend in part on the outer diameter of the glass tube 102. To produce an open end on the glass tube 102 and the glass article, the laser beam 414 can have a major axis to minor axis ratio of about 4 to about 70, e.g., about 5 to about 70, about 8 to about 70, about 10 to about 70, or about 20 to about 70, at the point along the beam path where the laser beam 414 impinges on the outer surface of the glass tube 102 in the separation zone 424.

[0214] In an embodiment, separating the glass article from the working end 107 of the glass tube 102 may include forming a bottom portion of the glass article while separating the glass article from the working end 107 of the glass tube 102. Forming the bottom portion of the glass article may also form a closed end on the working end 107 of the glass tube 102 after separation. The laser system 410 in the separation station 206 may be configured to produce a closed end at the working end 107 of the glass tube 102 and at the end portion of the glass article separated from the glass tube 102. In particular, the laser system 410 may be configured to generate a laser beam 414 capable of heating a volume of glass in a separation zone 424 of the glass tube 102, wherein the volume of heated glass is sufficient to form a glass meniscus above the working end 107 of the glass tube 102 and above the end portion of the glass article during separation of the glass article from the glass tube 102.

[0215] In order to heat a large volume of glass sufficient to form a glass meniscus above the end of both the glass tube 102 and the glass article, the laser system 410 can be configured to generate a laser beam 414 having a larger beam width at a constant beam length than a laser beam used to produce an open end. To form a closed end, the laser beam 414 in the separation station 206 can have a beam width of about 3 mm to 10 mm, e.g., 5 mm to 10 mm or 6 mm to 10 mm, at the point along the beam path where the laser beam 414 impinges on the outer surface of the glass tube 102. The beam width of the laser beam 414 used to produce a closed end can be affected by the diameter, thickness, glass composition, or a combination of these of the glass tube 102. When forming closed ends on the glass tube 102 and the glass article, the beam delivery system 420 can be configured to generate a laser beam 414 having an elliptical cross-section with a major axis to minor axis ratio of about 2 to about 12, e.g., about 2 to about 10, about 2 to about 8, about 2 to about 5, or about 2 to about 4, at the point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102.

[0216] Reference again Figure 8The thickness of the bottom portion of the glass article can be increased or decreased by increasing or decreasing the beam width of the laser beam 414 in the separation station 206, changing the orientation of the long axis of the laser beam 414 relative to the central axis A of the glass tube 102, or a combination thereof. Increasing the beam width of the laser beam 414 can increase the volume of glass heated in the separation zone of the glass tube 102, which can result in a thicker meniscus forming above the end of the glass tube 102 and the end of the glass article separated therefrom. Thus, the thickness of the bottom portion of the glass article can be modified by changing the beam width of the laser beam 414. The beam width of the laser beam 414 can be increased or decreased by changing the distance between two or more lenses of the beam delivery system 420, by changing the distance between the laser system 410 and the glass tube 102 in the separation station 206, or both. Thus, the beam width of the laser beam 414 at the point where the laser beam 414 impinges on the glass tube 102 can be modified without changing the lenses of the beam delivery system 420.

[0217] In addition, refer again Figure 14 Instead of or in addition to changing the beam width of laser beam 414, the volume of glass heated by laser beam 414 in the separation zone can be increased by changing the orientation of laser beam 414 so that the major axis of elliptical laser beam 414 is parallel to central axis A of glass tube 102. Conversely, the volume of glass heated by laser beam 414 can be decreased by changing the orientation of laser beam 414 so that the major axis is perpendicular to central axis A of glass tube 102. The orientation of laser beam 414 relative to glass tube 102 can be modified by changing the orientation of one or more of the optical components of beam delivery system 420 or by changing the optical components of beam delivery system 420.

[0218] In an embodiment, separating the glass article from the working end 107 of the glass tube 102 may include reducing the thickness of the bottom portion of the glass article. In an embodiment, the laser beam 414 may be an elliptical laser beam, and reducing the thickness of the bottom portion of the glass article may include orienting the laser beam 414 such that the long axis of the laser beam 414 is perpendicular to the central axis A of the glass tube 102, reducing the beam width of the laser beam 414, or a combination thereof. In an embodiment, separating the glass article from the working end 107 of the glass tube 102 may further include increasing the thickness of the bottom portion of the glass article. In an embodiment, the laser beam 414 may be an elliptical laser beam, and reducing the thickness of the bottom portion of the glass article may include orienting the laser beam 414 such that the long axis of the laser beam 414 is parallel to the central axis A of the glass tube 102, increasing the beam width of the laser beam 414, or a combination thereof.

[0219] Reference again Figure 16As previously discussed, in embodiments, the separation station 206 may include a laser system 410 comprising two or more laser systems, such as a separation laser system 440 and a preheating laser system 450. In these embodiments, exposing the separation region 424 of the glass tube 102 to a laser beam may include simultaneously exposing the separation region 424 of the glass tube 102 to the two or more laser beams in the separation station 206. In embodiments, the separation station 206 may include a separation laser system 440 operable to generate a separation laser beam 444 and a preheating laser system 450 operable to generate a preheating laser beam 454. Separating the glass article from the working end 107 of the glass tube 102 may include exposing the separation region 424 of the glass tube 102 to the preheating laser beam 454 and simultaneously exposing the separation region 424 of the glass tube 102 to the separation laser beam 444. In embodiments, the separation laser beam 444 and the preheating laser beam 454 may overlap the separation region 424 of the glass tube 102.

[0220] Simultaneously exposing the separation region 424 of the glass tube 102 to the separation laser beam 444 and the preheating laser beam 454 can enable a larger volume of glass to be heated during separation of the glass article from the glass tube 102. The preheating laser beam 454 can further increase the heating rate of the glass in the separation region 424 of the glass tube 102, which can reduce the time required to separate the glass article from the glass tube 102. Furthermore, in embodiments, exposing the separation region 424 of the glass tube to the separation laser beam 444 and the preheating laser beam 454 can achieve a desired effect on the bottom 112 ( Figure 20 ) and the heel 114 of the glass article 103 ( Figure 20 ) for greater control over the geometry. Figure 20 The heel 114 is a portion of the glass article 103 that transitions between the bottom 112 and the sidewall 110 .

[0221] Now refer to Figure 15 In an embodiment, the separation laser beam 444 may be an elliptical beam having a major axis and a minor axis, and the preheating laser beam 454 may be an annular beam having a generally circular cross-section. The separation laser beam 444 and the preheating laser beam 454 may each have any of the other features, shapes, or properties previously discussed herein for the laser beam 414.

[0222] Reference again Figure 16, the separation laser beam 444 may be oriented such that the major axis of the elliptical cross-section of the beam is perpendicular to the central axis A of the glass tube 102. In an embodiment, the separation laser beam 444 and the preheating laser beam 454 may be axially aligned relative to the central axis A of the glass tube 102 such that the major axis of the separation laser beam 444 is aligned with the beam center of the preheating laser beam 454 (i.e., when incident on the outer surface of the glass tube 102, the major axis of the separation laser beam 444 and the beam center of the preheating laser beam 454 are positioned at the same axial position on the glass tube 102). In an embodiment, the separation laser beam 444 may be axially offset relative to the beam center of the preheating laser beam 454. Axial offset refers to the axial displacement in a direction parallel to the central axis A of the glass tube 102 (i.e., in a direction parallel to the central axis A of the glass tube 102). Figure 16 The offset of the coordinate axis in the -Z direction) causes the long axis of the separation laser beam 444 to be not aligned with the center of the preheating laser beam 454 at the point where the two beams are incident on the glass tube 102.

[0223] In an embodiment, the separation laser beam 444 and the preheating laser beam 454 may be aligned horizontally (ie, at Figure 16 ) such that the minor axis of the separation laser beam 444 is aligned with the center of the preheating laser beam 454. In an embodiment, the separation laser beam 444 and the preheating laser beam 454 may be horizontally centered on the glass tube 102 in the separation station 206. Figure 16 , the separation laser beam 444 and the preheating laser beam 454 are shown approaching the glass tube 102 from substantially the same angular direction. Figure 17 In an embodiment, the point at which the separating laser beam 444 is incident on the glass tube 102 can be angularly offset from the point at which the preheating laser beam 454 is incident on the glass tube 102. In other words, in an embodiment, the minor axis of the separating laser beam 444 can be at a different angular position on the glass tube 102 compared to the beam center of the preheating laser beam 454. The separating laser beam 444 and the preheating laser beam 454 can be angularly offset by an angle alpha (α).

[0224] As previously discussed, exposing the separation zone 424 of the glass tube 102 to both the separation laser beam 444 and the preheating laser beam 454 can increase the separation rate in the separation station 206, which can reduce the residence time required to separate the glass article from the glass tube 102. Without wishing to be bound by any particular theory, it is believed that simultaneously exposing the separation zone 424 to both the separation laser beam 444 and the preheating laser beam 454 can increase the heating rate of the glass in the separation zone 424 by increasing the energy density delivered to the glass in the separation zone 424. This increased heating rate can reduce the time required to separate the glass article from the glass tube 102.

[0225] As previously discussed, exposing the separation region 424 of the glass tube 102 simultaneously to the separation laser beam 444 and the preheating laser beam 454 can affect the formation of the bottom of the glass article during separation from the glass tube 102. Specifically, exposing the separation region 424 of the glass tube 102 to the preheating laser beam 454 in addition to the separation laser beam 444 can increase the volume of glass heated during separation, which can increase the volume of glass and the thickness of the meniscus formed on the ends of the glass tube 102 and the glass article during separation. Furthermore, the thickness of the bottom of the glass article separated from the glass tube 102 can be increased by increasing the beam diameter of the preheating laser beam 454, increasing the beam width of the separation laser beam 444, or a combination of both. Conversely, in embodiments, the thickness of the bottom of the glass article separated from the glass tube 102 can be reduced by reducing the beam diameter of the preheating laser beam 454, reducing the beam width of the separation laser beam 444, or a combination of both.

[0226] Now refer to Figure 18 As previously discussed, in embodiments, the separation laser beam 444 may be axially offset from the preheating laser beam 454 such that the major axis 446 of the separation laser beam 444 is in the axial direction (ie, Figure 18 The long axis 446 of the separating laser beam 444 may be axially spaced from the beam center 456 of the preheating laser beam 454 in the + / - Z direction of the coordinate axis in FIG. In an embodiment, the long axis 446 of the separating laser beam 444 may be axially spaced from the beam center 456 of the preheating laser beam 454 by an axial offset G. Changing the axial offset G between the separating laser beam 444 and the preheating laser beam 454 may change the geometry of the bottom and heel of the glass article.

[0227] Reference again Figure 20 , graphically depicting a glass article 103 having a closed bottom (e.g., a vial, a jar, a tray, an ampoule, a beaker, etc.). After separating the glass article 103 from the glass tube 102, the glass article 103 may include a sidewall 110, a bottom 112, and a heel 114 transitioning from the sidewall 110 to the bottom 112. Figure 16 and Figure 18 , the separation laser beam 444 is directed toward the working end 107 of the glass tube 102 relative to the preheating laser beam 454 (i.e., at Figure 18 Shifting the glass tube 102 (in the -Z direction of the coordinate axis in FIG) so that the major axis 446 of the separating laser beam 444 is closer to the working end 107 of the glass tube 102 than the beam center 456 of the preheating laser beam 454 can result in a flatter bottom 112 of the glass article 103 (i.e., having greater flatness and less curvature) and / or a heel 114 having a smaller heel radius than a glass article 103 separated by superimposing the separating laser beam 444 and the preheating laser beam 454 at the same axial position. Increasing the flatness of the bottom 112 and decreasing the heel radius of the heel 114 can make the glass article 103 more stable against rocking and falling.

[0228] In an embodiment, a method of manufacturing a glass article 103 may include modifying an axial position of a separating laser beam 444 relative to an axial position of a preheating laser beam 454. In an embodiment, the method may include moving the separating laser beam 444 relative to a center of the preheating laser beam 454 toward the working end 107 of the glass tube 102, wherein moving the separating laser beam 444 closer to the working end 107 of the glass tube 102 relative to the center of the preheating laser beam 454 may increase the flatness of the bottom 112 of the glass article 103, may reduce the heel radius of the heel 114 of the glass article 103, or both.

[0229] In an embodiment, the preheat laser system 450 may be replaced by a burner in the separation station 206. Referring now to Figure 19A and Figure 19B In an embodiment, the separation station 206 may include a separation laser system 440 and a burner 302. The separation laser system 440 may generate a separation laser beam 444. The burner 302 may be operable to provide additional heat to the separation region 424 of the glass tube 102. In an embodiment, the burner 302 may be spaced apart from the separation laser beam 444 in an angular direction relative to the central axis A of the glass tube 102. In an embodiment, the burner 302 may be oriented to heat the side of the glass tube 102 opposite the side heated by the separation laser beam 444. In an embodiment, the gas burner 302 may be spaced apart from the separation laser beam 444 in an angular direction of about 90 degrees to about 180 degrees, or about 180 degrees, relative to the central axis A of the glass tube 102 in cylindrical coordinates. The burner 302 may have any of the features or characteristics previously disclosed herein for the burner 302.

[0230] When the separation station 206 includes the separation laser system 440 and the gas burner 302, moving the separation laser beam 444 relative to the burner 302 toward the working end 107 of the glass tube 102 so that the major axis 446 of the separation laser beam 444 is closer to the working end 107 of the glass tube 102 than the flame from the gas burner 302 can result in a flatter bottom 112 of the glass article 103 (i.e., having a greater flatness and less curvature) and / or a heel 114 having a smaller heel radius than a glass article 103 separated by superimposing the separation laser beam 444 and the burner 302 at the same axial position. In embodiments, a method of manufacturing a glass article 103 can include modifying the axial position of the separation laser beam 444 relative to the axial position of the burner 302. In an embodiment, the method may include moving the separating laser beam 444 relative to the burner 302 toward the working end 107 of the glass tube 102, wherein moving the separating laser beam 444 relative to the burner 302 closer to the working end 107 of the glass tube 102 may increase the flatness of the bottom 112 of the glass article 103, may reduce the heel radius of the heel 114 of the glass article 103, or both.

[0231] Reference again Figure 3 , the separation station 206 may be preceded by one or more heating stations 202 disposed upstream of the separation station 206. In an embodiment, one or more of the heating stations 202 upstream of the separation station 206 may include a preheat laser system 450 operable to preheat the separation region of the glass tube 102 prior to translating the glass tube 102 into the separation station 206. The preheat laser system 450 may have any of the components or features previously described herein for the preheat laser system 450 associated with the separation station 206.

[0232] Now refer to Figure 21, a preheating laser system 450 in the heating station 202 upstream of the separation station 206 can be operable to generate a preheating laser beam 454, which can be an annular beam having a generally circular cross-section. The preheating laser beam 454 generated by the preheating laser system 450 in the heating station 202 can have any of the characteristics previously discussed herein with respect to the laser beam 414. A method of producing a glass article from a glass tube 102 can include exposing a separation region 424 of the glass tube 102 to the preheating laser beam 454 in the heating station 202 positioned upstream of the separation station 206. In an embodiment, the separation region of the glass tube 102 can be exposed to the preheating laser beam 454 in both the separation station 206 and the heating station 202 upstream of the separation station. In an embodiment, the heating station 202 and the separation station 206 can each have a dedicated preheating laser system 450. In an embodiment, the system 400 may include a single preheat laser system 450, which may include a beam splitter and a plurality of steering mirrors operable to split a preheat laser beam 454 into a plurality of beams and direct one preheat laser beam 454 to the glass tube 102 in the separation station 206 and another preheat laser beam 454 to the glass tube 102 in the heating station 202 upstream of the separation station 206.

[0233] Now refer to Figure 22 In an embodiment, the separation station 206 and the heating station 202 upstream of the separation station 206 may both have laser systems (e.g., the separation laser system 410, the preheating laser system 450, or both) for heating the glass tube 102 in the target zone 424, the separation zone 426, or both. In an embodiment, the separation station 206 and the heating station 202 upstream of the separation station 206 do not include any burners 302 for heating the glass tube 102. Now referring to Figure 23 In an embodiment, the converter 100 can be a hybrid system in which the heating station 202 upstream of the separation station 206 includes a combination of a preheating laser system 450 and a burner 302 for preheating the glass tube 102 prior to separation in the separation station 206. In an embodiment, the heating station 202 immediately preceding the separation station 206 in the direction of rotation 222 can include at least one burner 302.

[0234] Reference again Figure 1 and Figure 8, the system 400 including the laser system 410 disposed in the separation station 206 can increase the total part rate of the converter 100 by reducing the time required to separate the glass article 103 from the glass tube 102 in the separation station 206. In embodiments, the converter 100 of the system 400 can have a total part rate of greater than or equal to about 30 pieces / minute, greater than or equal to about 35 pieces / minute, greater than or equal to about 40 pieces / minute, or even greater than or equal to about 60 pieces / minute. In embodiments, the converter 100 of the system 400 can have a total part rate of from about 30 pieces / minute to about 100 pieces / minute.

[0235] In an embodiment, the system 400 may have a laser system 410 for heating the glass tube 102, disposed in any or all of the heating stations 202 of the converter 100. For example, in an embodiment, the system 400 may include a laser system 410 disposed in more than one of the heating stations 202 upstream of the forming station 204, and the laser system 410 may be operable to heat a target region of the glass tube 102 with a laser beam 414 before contacting the glass tube with a forming tool. Exposing the target region of the glass tube 102 to the laser beam 414 may enable faster and more precise heating of the glass in the target region of the glass tube 102, which may provide greater control over the final geometry and dimensions of features of the glass article formed in the forming station 204. The laser system 410 disposed in the heating station 202 and the laser beam 414 generated thereby may have any of the features or properties previously described herein for the laser system 410 and the laser beam 414, respectively.

[0236] In an embodiment, producing a glass article from a glass tube 102 may include: rotating the glass tube 102 about a central axis A of the glass tube 102; heating a target region of the glass tube 102 to a forming temperature with a laser beam 414 while rotating the glass tube 102; and forming at least one feature of the glass article at the target region of the glass tube 102 after heating the target region of the glass tube 102. Heating the target region of the glass tube 102 may include exposing the target region of the glass tube 102 with a laser beam 414 having a beam width of approximately 0.5 mm to approximately 10 mm and a wavelength in a range of approximately 1 μm to approximately 12 μm. Exposing the target region of the glass tube 102 to the laser beam 414 heats the glass at the target region to a temperature greater than or equal to approximately 1000° C. In an embodiment, the laser beam 414 in the heating station 202 may be an annular beam having a circular cross-sectional shape.

[0237] In an embodiment, the laser system 410 may further be used to polish the glass article after it is separated from the glass tube. In an embodiment, one or more of the processing stations in the secondary loop of the converter 100 may include a laser system 410 that may be directed to one or more areas of the glass article to polish the glass article.

[0238] The system 400 disclosed herein may be used in a method of separating a glass article from a working end of a glass tube during conversion and in a method of forming a glass article from a glass tube during conversion. Figure 8 , a method for removing a glass article from a working end 107 of a glass tube 102 during conversion may include translating the working end 107 of the glass tube 102 to a converter 100 ( Figure 1 ) in the separation station 206. Figure 8 The method may include: rotating the glass tube 102 about the central axis A of the glass tube 102; exposing the separation region 424 of the glass tube 102 to the laser beam 414 while rotating the glass tube 102; and exposing the separation region 424 of the glass tube 102 to the laser beam 414 in an axial direction away from the glass tube 102 (i.e., in a direction away from the glass tube 102). Figure 8 The converter 100 may include any of the components or features previously discussed herein for the converter 100.

[0239] refer to Figure 1 、 Figure 8 and Figure 20 The method disclosed herein for producing a glass article 103 from a glass tube 102 may include: rotating the glass tube 102 about a central axis A of the glass tube 102; while rotating the glass tube 102, moving a target area 426 ( Figure 21 ) to a forming temperature, wherein the target region 426 is proximate to the working end 107 of the glass tube 102; after heating the target region 426 of the glass tube 102, while rotating the glass tube 102, forming at least one feature of the glass article 103 at the target region 426 of the glass tube 102; and Figure 8) at the target zone 426 of the glass tube 102. Heating the target zone 426 of the glass tube 102, separating the glass article 103 from the working end 107 of the glass tube 102, or both, includes exposing the target zone 426, the separation zone 424, or both, of the glass tube 102 with a laser beam 414, which can have a maximum cross-sectional dimension, at a point along the beam path where the laser beam 414 impinges on the outer surface of the glass tube 102 in the target zone 426, that is less than or equal to about 1.25 times the outer diameter of the glass tube 102, such as from about 0.5 to about 1.25 times the outer diameter of the glass tube 102. In an embodiment, the laser beam 414 can have a maximum cross-sectional dimension, at a point along the beam path where the laser beam 414 impinges on the outer surface of the glass tube 102 in the target zone 426, that is from about 5 mm to about 50 mm, or even greater than about 50 mm. Exposing the target region 426, the separation region 424, or both to the laser beam 414 may heat the glass tube 102 at the target region 426, the separation region 424, or both to a temperature greater than or equal to about 1000°C.

[0240] Reference again Figure 21 In embodiments of the methods disclosed herein, heating the target zone 426 of the glass tube 102 may include heating the target zone 426 of the glass tube 102 in the converter 100 ( Figure 1 ) in the heating station 202, the target area 426 is exposed to the laser beam 414. In the heating station 202, the laser beam 414 can be a heating laser beam. Figure 11 In an embodiment, the laser beam 414 in the heating station 202 can have a circular cross-section. In an embodiment, the laser beam 414 in the heating station 202 can have a cross-section having a diameter of up to about 1.25 times the outer diameter of the glass tube 102 at the point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102, such as about 0.5 to about 1.25 times the outer diameter of the glass tube 102. In an embodiment, the laser beam 414 can have a cross-section having a diameter of about 5 mm to about 50 mm, or even greater than about 50 mm, at the point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102.

[0241] Reference again Figure 8In embodiments of the methods disclosed herein, separating the glass article from the working end 107 of the glass tube 102 may include exposing a separation region 424 of the glass tube 102 to a laser beam 414 in the separation station 206 of the converter 100. In the separation station 206, the laser beam 414 may be a separation laser beam. In embodiments, the methods disclosed herein may further include exposing the separation region 424 of the glass tube 102 to a preheating laser beam in the heating station 202 before translating the glass tube 102 into the separation station 206. In embodiments, the heating station 202 including the heating laser beam may be directly upstream of the separation station 206.

[0242] Reference again Figure 8 In the separation station 206, the laser beam 414 may have any of the characteristics or properties previously described herein for the laser beam 414. In an embodiment, the laser beam 414 in the separation station 206 may be a separation laser beam having an elliptical cross-section with a major axis and a minor axis. In an embodiment, the separation laser beam in the separation station 206 may have a beam length, at a point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102, of up to about 1.25 times the outer diameter of the glass tube 102, such as from about 0.5 to about 1.25 times the outer diameter of the glass tube 102. In an embodiment, the laser beam 414 may have a beam length, L, at a point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102, of from about 5 mm to about 50 mm, or even greater than about 50 mm. B The separation laser beam may have any of the features or properties previously disclosed herein for the laser beam 414. In an embodiment, separating the glass article from the working end 107 of the glass tube 102 may include forming an open end on a bottom portion of the glass article, wherein the bottom portion of the glass article is the end portion of the glass article that was previously connected to the glass tube 102 prior to separation. Figure 13 To produce an open end on a glass article, the split laser beam may have a beam width of about 0.5 mm to about 5 mm. In embodiments where an open end is formed on a glass article, the split laser beam may be an elliptical beam having a major axis to minor axis ratio of about 4 to about 70.

[0243] In embodiments of the methods disclosed herein, separating the glass article from the working end 107 of the glass tube 102 may include forming a bottom 112 of the glass article 103 while separating the glass article 103 from the working end 107 of the glass tube 102. Figure 20 ). refer to Figure 12 , forming a bottom on the glass article may include exposing the separation region 424 of the glass tube 102 to a laser beam 414 having a beam width of about 3 mm to about 10 mm, a major axis to minor axis ratio of about 2 to about 12, or both. Figure 12 and Figure 14In an embodiment, the laser beam 414 may be an elliptical beam, and the long axis may be oriented parallel to or perpendicular to the central axis A of the glass tube 102 .

[0244] Reference again Figure 12 In an embodiment, the method disclosed herein may include reducing the thickness of the bottom of the glass article. Reducing the thickness of the bottom of the glass article may include orienting the separating laser beam so that the long axis of the separating laser beam is perpendicular to the central axis A of the glass tube 102, reducing the beam width of the separating laser beam, or a combination thereof. To reduce the thickness of the bottom of the glass article, the separating laser beam may have a beam width of about 5 mm to about 10 mm, or a major axis to minor axis ratio of about 2 to about 7. In an embodiment, the method disclosed herein may include increasing the thickness of the bottom of the glass article. To increase the thickness of the bottom of the glass article, the separating laser beam may be an elliptical beam. Increasing the thickness of the bottom of the glass article may include orienting the separating laser beam so that the long axis of the separating laser beam is parallel to the central axis A of the glass tube 102, increasing the beam width of the separating laser beam, or a combination thereof. To increase the thickness of the bottom of the glass article, the separating laser beam may have a beam width of about 3 mm to about 7 mm, a major axis to minor axis ratio of about 2.5 to about 12, or both.

[0245] Now refer to Figure 16 In an embodiment, separating the glass article from the working end 107 of the glass tube 102 may include exposing the separation region 424 of the glass tube to a separation laser beam 444 having an elliptical cross-section and exposing the separation region 424 of the glass tube to a preheating laser beam 454 having a circular cross-section. The preheating laser beam 454 may be different from the separation laser beam 444. In an embodiment, the method may include superimposing the separation laser beam 444 and the preheating laser beam 454 on the separation region 424 of the glass tube 102. Now referring to Figure 18 In an embodiment, the center of the separation laser beam 444 may be in the axial direction (ie, in Figure 18 The axial position of the separating laser beam 444 may be modified by adjusting the separation beam delivery system 442 ( Figure 16 ) one or more components, one or more steering mirrors 422 or a combination thereof. Figure 18In an embodiment, the method disclosed herein may include moving the vertical center of the separating laser beam 444 (i.e., aligned with the long axis 446) relative to the center 456 of the preheating laser beam 454 toward the working end 107 of the glass tube 102, wherein moving the vertical center of the separating laser beam 444 closer to the working end 107 of the glass tube 102 relative to the center of the preheating laser beam 454 may increase the flatness of the bottom of the glass article 103 and may reduce the transition between the bottom and the sidewall of the glass article 103 (i.e., Figure 20 The corner radius at the heel 114 in the figure.

[0246] In embodiments of the methods disclosed herein, heating a target area of ​​the glass tube 102, separating a glass article from the working end 107 of the glass tube 102, or both, may include: exposing the target area, the separation area, or both of the glass tube 102 with a first laser beam; and simultaneously exposing the target area, the separation area, or both of the glass tube 102 with a second laser beam, wherein the first laser beam and the second laser beam are incident on the target area or the separation area of ​​the glass tube 102. The first laser beam and the second laser beam may each have any of the characteristics or properties previously described herein for laser beam 414. In embodiments, the method may include superimposing the first laser beam and the second laser beam on the glass tube 102. In embodiments, the method may further include modifying the axial position of the second laser beam relative to the axial position of the first laser beam. In embodiments, the first laser beam may have a circular beam cross-section, and the second laser beam may have an elliptical beam cross-section.

[0247] Reference again Figure 8 In an embodiment, separating the glass article from the working end 107 of the glass tube 102 may include applying a tensile force F to the glass article while exposing the separation region 424 of the glass tube 102 to the laser beam 414. The tensile force F may cause the glass article to be pulled in an axial direction (i.e., in a Figure 8 In an embodiment, the glass tube 102 may be oriented vertically with the working end 107 of the glass tube 102 facing downward, and the pulling force may include gravity. In an embodiment, applying the pulling force F may include moving the glass tube 102 in a direction axially away from the glass tube 102 (i.e., in a direction axially away from the glass tube 102). Figure 8 The glass article is mechanically pulled in the -Z direction of the coordinate axis of the glass.

[0248] Reference again Figure 5 and Figure 6 In an embodiment of the method, forming features at the working end of the glass tube 102 may include contacting the surface of the glass tube 102 in the target area with one or more shaping tools 324 while rotating the glass tube 102 about the central axis A of the glass tube. The contact between the shaping tools 324 and the surface of the glass tube 102 may change the shape of the glass tube 102 in the target area. Referring again to Figure 1In embodiments, the methods disclosed herein may further include operating a converter 100 to produce a plurality of glass articles 103 from a glass tube 102. The converter 100 may include a plurality of processing stations 122, including at least one heating station 202, at least one forming station 204, and a separation station 206. Operating the converter 100 may include successively translating each of the glass tubes 102 through each of the plurality of processing stations 122. Heating the glass tubes in the at least one heating station 202, separating the glass articles 103 from the working ends 107 of the glass tubes 102 in the separation stations 206, or both may include exposing each of the glass tubes 102 to a laser beam 414 to heat each of the glass tubes 102 at a target region, a separation region, or both. In embodiments, the methods may further include securing the glass tubes 102 in a holder 140 of the converter 100 including the plurality of processing stations 122. The converter 100 may successively translate the holder 140 and the glass tubes 102 through each of the processing stations. The method may further include forming one or more features of the glass article 103 at the working end 107 of the glass tube 102 by translating the glass tube 102 through at least one heating station 202 and at least one forming station 204, and separating the glass article 103 from the working end 107 of the glass tube 102 in a separation station 206. Heating the target region of the glass tube may include exposing the target region of the glass tube to the laser beam 414 in the at least one heating station 202, or separating the glass article from the working end 107 of the glass tube 102 may include exposing the separation region of the glass tube 102 to the laser beam 414 in the separation station 206.

[0249] In an embodiment, the glass article can be a pharmaceutical container. In an embodiment, the pharmaceutical container can include a vacuum blood collection tube, a cartridge, a syringe, a syringe barrel, an ampoule, a bottle, a flask, a vial, a tube, a beaker, or a jar.

[0250] In an embodiment, exposing the target area or separation area of ​​the glass tube 102 to the laser beam 414 may include: generating the laser beam 414 using a laser source 412; passing the laser beam 414 through an optical device that modifies the shape or power density distribution of the laser beam 414; and directing the laser beam 414 toward the target area or separation area of ​​the glass tube 102. The optical device may include any of the optical components described for the beam delivery system 420. The optical device may also include a steering mirror operable to direct the laser beam 414 toward the glass tube 102. The laser beam 414 may be a continuous laser beam or a pulsed laser beam. In an embodiment, the laser beam 414 may be a collimated beam or a non-collimated beam. In an embodiment, the laser beam 414 may include a laser power of 50 W to 2000 W. In an embodiment, the laser beam 414 may be an elliptical beam or an annular beam. In an embodiment, the laser beam 414 may have a wavelength in the range of about 1 μm to about 12 μm or about 5 μm to about 11 μm.

[0251] In embodiments, methods disclosed herein may include changing the shape of laser beam 414, wherein changing the shape of laser beam 414 may change the volume of glass heated in a target region or separation region of glass tube 102. The shape of laser beam 414 may be changed by changing one or more optical components of beam delivery system 420, by changing the distance between optical components of beam delivery system 420, or both. In embodiments, methods disclosed herein may include changing the power density of laser beam 414, wherein changing the power density may change the heating rate of laser beam 414. Increasing the power density may include increasing the power of laser source 412 of laser system 410. In embodiments, methods may include controlling the exposure time of glass tube 102 to laser beam 414 during heating of a target region of glass tube 102, separation of the glass article from the working end of glass tube 102, or both by adjusting the timing of turning laser source 412 on and off for generating laser beam 414. In embodiments, the laser beam may have a heating rate of 200°C / sec to 400°C / sec. In an embodiment, the method may include rotating the glass tube 102 at a rotational speed of 60 rpm to 400 rpm. The laser system 410 may increase the conversion rate of the converter 100. In an embodiment, the conversion rate of the converter 100 for converting the glass tube 102 into a glass article may be greater than or equal to 30 pieces / minute, greater than or equal to 35 pieces / minute, or even greater than or equal to 40 pieces / minute. In an embodiment, the conversion rate may be less than 30 pieces / minute, for example, but not limited to, when the glass tube 102 has a large outer diameter or a large wall thickness, requiring additional dwell time at each processing station to heat and / or form the glass article.

[0252] Examples

[0253] Various embodiments of the systems and methods disclosed herein will be further illustrated by the following examples, which are illustrative in nature and should not be construed as limiting the subject matter of the present disclosure.

[0254] Examples 1 to 4: Changing the laser power of the laser beam

[0255] In Examples 1-4, the effect of modifying the power of the laser beam on heating a glass tube was evaluated. In Examples 1-4, the glass tube was heated with a laser beam on a benchtop processing station configured as a heating station for an analog converter. The benchtop processing station included a holder (e.g., holder 140) operable to hold the glass tube and rotate the glass tube about its central axis. The benchtop processing station included a laser system comprising a laser source, which was a CO2 laser operable to generate a laser beam having a wavelength of 10.6 nm. The benchtop processing station further included a thermal imaging system operable to obtain thermal images of the glass tube during heating and determine the glass temperature from the thermal images. The operation of a thermal imaging system and a thermal imaging system for measuring glass temperature can be found in U.S. Patent No. 10,773,989, issued on September 15, 2020, and entitled “Systems and Method for Measuring the Temperature of Glass During Tube Conversion,” the entire contents of which are incorporated herein by reference.

[0256] For each of Examples 1 to 4, a glass tube at room temperature was loaded into a holder in a benchtop processing station and rotated. For each of Examples 1 to 4, the glass tube size and composition and the rotation speed were the same. While the glass tube was rotating, the laser system was turned on and the laser beam was directed toward the glass tube at the target location. The laser system and the laser delivery system were configured to generate a laser beam having a wavelength of 10.6 nm and an elliptical cross-sectional shape. For each of Examples 1 to 4, the laser power was different. Table 1 provides the laser power and Figure 24 . The glass tubes were identical for Examples 1 to 4. For each of Examples 1 to 4, the glass tubes were heated using a laser beam from room temperature (i.e., without preheating) to a final temperature at which the laser source was turned off. The glass tubes were then allowed to cool for a period of time. For Examples 1 to 3, the laser exposure time was approximately 6.5 seconds. Due to the greater heating rate, the laser exposure time for Example 4 was reduced to approximately 3.5 seconds at 630 W. The glass temperature was measured using a thermal imaging system during the heating of the glass tubes.

[0257] Table 1

[0258]

[0259] Now refer to Figure 24 As the laser power increases, the heating rate (i.e., the time required to heat the glass to a temperature of 1000°C or greater) also increases. Figure 24As shown in , at a laser power of 630 W (Example 4), the temperature of the glass tube can be increased from room temperature to over 1000° C. in about 3 seconds. Preheating the glass tube upstream of a processing station including a laser system can further enable final heating of the glass tube to be achieved in less than 1 second, which can increase the component rate of the conversion process.

[0260] Examples 5 to 7: Changing the beam shape

[0261] In Examples 5 to 7, the effect of beam shape on the heating rate of a glass tube was evaluated. In Examples 5 to 7, a glass tube was heated with a laser beam using a benchtop processing station and the method previously described in Examples 1 to 4. In Examples 5 to 7, the laser power was maintained constant at 630 W, and the shape of the beam was modified for Examples 5 to 7. The glass tube was identical for each of Examples 5 to 7. The beam shape and Figure 25 's reference numerals.

[0262] Table 2

[0263] Examples 5 6 7 Figure 25 Reference numerals in 2502 2504 2506 Beam shape Ring oval oval Beam diameter (mm) 25 N / A N / A Beam length (mm) N / A 25 28 Beam width (mm) N / A 7 1.5

[0264] Now refer to Figure 25 , showing the heating and cooling curves for Examples 5 to 7. Figure 25 As indicated, changing the shape of the laser beam at a constant power density can also change the heating rate of the glass. For example, for a glass tube with a diameter of 20 to 25 mm and a wall thickness of 0.7 to 1.0 mm, for a more focused beam, such as the narrow elliptical beam (reference numeral 2506) of Example 7, the heating rate can be approximately 200°C / second or even up to 400°C / second. Thus, with the glass tube preheated up to 1000°C to 1100°C at these heating rates, reaching the process temperature for glass forming is expected to take less than or equal to 1 second, which can translate into an increased conversion rate of greater than or equal to about 30 pieces / minute, or even greater than or equal to about 60 pieces / minute. For glass tubes with a thickness of less than about 0.7 mm, the conversion rate can be even greater.

[0265] Comparative Example 8: Separation with a closed bottom using a gas burner

[0266] In Comparative Example 8, a gas burner was used to separate the glass article from the working end of the glass tube according to a prior art separation method. For Comparative Example 8, the benchtop processing station described in conjunction with Examples 1 to 4 was equipped with a bottom chuck operable to apply a pulling force to the glass article in a downward direction (i.e., in an axial direction away from the working end of the glass tube). The laser system was replaced with a gas burner to heat the glass tube for separation. The glass article was separated from the glass tube by heating the separation zone of the glass tube with a gas burner and then applying a pulling force to the glass article. The separation resulted in the formation of a glass meniscus at the end of the glass article, which formed a closed bottom at the end of the glass article.

[0267] Example 9: Separation from closed bottom using laser system

[0268] In Example 9, a laser system is used to separate a glass article from a glass tube and to form a bottom on the end of the glass article separated from the glass tube. For Example 9, the benchtop processing station described in conjunction with Examples 1 to 4 is equipped with a bottom chuck operable to apply a tensile force to the glass article in a downward direction (i.e., in an axial direction away from the working end of the glass tube). The laser system is used to heat the glass tube during separation. The glass article is separated from the glass tube by heating the separation zone of the glass tube with the laser system and then applying a tensile force to the glass article. Separation results in the formation of a glass meniscus at the end of the glass article, which forms a closed bottom on the end of the glass article.

[0269] Now refer to Figure 26 , showing photographs of bottoms formed on glass articles in Comparative Example 8 (left) and Example 9 (right). As shown in the right image, separation using the laser system in Example 9 produced a flatter bottom with less thickness variation than the bottom formed by separation using a gas burner (as in Comparative Example 8 (left)).

[0270] Example 10: Separation to form an open bottom

[0271] In Example 10, a laser system is used to separate a glass article from a working end of a glass tube while forming an open end on the glass article at the end separated from the glass tube. For Example 10, the benchtop processing station described in conjunction with Examples 1 to 4 is equipped with a bottom chuck that is operable to apply a pulling force to the glass article in a downward direction (i.e., in an axial direction away from the working end of the glass tube). The laser system includes a beam delivery system that is operable to produce a narrow elliptical beam that is suitable for heating the glass enough to separate the glass article from the glass tube, but not enough to form a meniscus above the glass article and the end of the glass tube after separation. Reference Figure 27 , the photograph shows an image of separation during application of tension to the glass article just before separation. Figure 28 The results of Example 10 tube separation without bottom formation are shown, combining the tube cutting and edge polishing steps into a single process. Consequently, a clean, nearly defect-free edge is achieved. Tube separation without bottom formation can also be accomplished via glass melting and application of tension, but in this case, the volume of glass heated by laser heating during separation is just sufficient to produce a smooth tube edge, but insufficient to form a bottom on the glass article. Varying the tube area affected by the laser beam and laser power allows for different, well-controlled forming procedures, from clean cutting and processing to forming bottoms of varying thicknesses, using the same laser system configuration.

[0272] While various embodiments of the system 100 and methods of using the system 100 to cut and process the end of the glass tube 102 have been described herein, it should be understood that each of these embodiments and techniques is contemplated for use alone or in combination with one or more embodiments and techniques.

[0273] It will be apparent to those skilled in the art that various modifications and variations may be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Therefore, 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.

Claims

1. A method for producing a glass article from a glass tube, the method comprising: rotating the glass tube around the central axis of the glass tube; While rotating the glass tube, heating the target area of ​​the glass tube to a forming temperature, wherein the target area is proximate to the working end of the glass tube; After heating the target area of ​​the glass tube, forming at least one feature of the glass article at the target area of ​​the glass tube while rotating the glass tube; and separating the glass article from the working end of the glass tube at a separation zone of the glass tube; in: heating the target area of ​​the glass tube, separating the glass article from the working end of the glass tube, or both comprises exposing the target area, the separation area, or both of the glass tube with a laser beam having a maximum cross-sectional dimension of about 0.5 to about 1.25 times the outer diameter of the glass tube at the point where the laser beam is incident on the glass tube; and Exposing the target region, the separation region, or both to the laser beam heats the glass tube at the target region, the separation region, or both to a temperature greater than or equal to about 1000°C.

2. The method of claim 1 , wherein heating the target area of ​​the glass tube comprises exposing the target area to the laser beam in a heating station of a converter for forming the glass article from the glass tube, wherein the laser beam is a heating laser beam. The method according to claim 2 , wherein the heating laser beam has a circular cross-section.

4. The method of claim 1 , wherein separating the glass article from the working end of the glass tube comprises exposing the separation region of the glass tube to the laser beam in a separation station of a converter for forming the glass article from the glass tube, wherein the laser beam is a separation laser beam.

5. The method of claim 4, comprising exposing the separation zone of the glass tube to a preheating laser beam in a heating station before translating the glass tube into the separation station. The method of claim 4 , wherein the split laser beam has an elliptical cross-section with a major axis and a minor axis. 7 . The method according to claim 4 , wherein the separation laser beam has a beam length of 5 mm to 50 mm at a point where the separation laser beam is incident on the glass tube.

8. The method of claim 4, wherein separating the glass article from the working end of the glass tube further comprises forming an open end on a bottom portion of the glass article, wherein the bottom portion of the glass article is the end portion of the glass article that was previously connected to the glass tube prior to separation. 9 . The method of claim 8 , wherein the separation laser beam has a beam width of about 0.5 mm to about 5 mm at a point where the separation laser beam is incident on the glass tube. 10 . The method of claim 8 , wherein the separation laser beam is an elliptical beam having a major axis to minor axis ratio of about 4 to about 70 at a point where the separation laser beam is incident on the glass tube.

11. The method of claim 4, wherein separating the glass article from the working end of the glass tube further comprises forming a bottom portion of the glass article while separating the glass article from the working end of the glass tube. 12 . The method of claim 11 , wherein the separation laser beam has a beam width of about 3 mm to about 10 mm at a point where the separation laser beam is incident on the glass tube. 13 . The method of claim 11 , wherein the separation laser beam is an elliptical beam having a major axis to minor axis ratio of about 2 to about 12 at a point where the separation laser beam is incident on the glass tube.

14. The method of claim 11, wherein the splitting laser beam is an elliptical beam, and the major axis is oriented parallel to or perpendicular to the central axis of the glass tube.

15. The method of claim 11, further comprising reducing a thickness of the bottom portion of the glass article, wherein the split laser beam is an elliptical beam, and reducing the thickness of the bottom portion of the glass article comprises one or more of: orienting the separation laser beam so that the long axis of the separation laser beam is perpendicular to the central axis of the glass tube; reducing the beam width of the split laser beam; or a combination thereof.

16. The method of claim 15, wherein the separation laser beam has a beam width of about 5 mm to about 10 mm at a point where the separation laser beam is incident on the glass tube, or the separation laser beam has a major axis to minor axis ratio of about 2 to about 7.

17. The method of claim 11, comprising increasing a thickness of the bottom portion of the glass article, wherein the split laser beam is an elliptical beam, and increasing the thickness of the bottom portion of the glass article comprises one or more of: orienting the separation laser beam so that the long axis of the separation laser beam is parallel to the central axis of the glass tube; increasing the beam width of the separated laser beam; or a combination thereof.

18. The method of claim 17, wherein the separation laser beam has a beam width of about 3 mm to about 7 mm at a point where the separation laser beam is incident on the glass tube, or the separation laser beam has a major axis to minor axis ratio of about 2.5 to about 12.

19. The method of claim 11, wherein separating the glass article from the working end of the glass tube comprises: exposing the separation region of the glass tube to a separation laser beam having an elliptical cross-section; and The separation zone of the glass tube is exposed to a preheated laser beam having a circular cross section in the separation station.

20. The method according to claim 19, comprising superimposing the separation laser beam and the preheating laser beam on the separation region of the glass tube.

21. The method according to claim 19, wherein a center of the separation laser beam is offset relative to a center of the preheating laser beam in an axial direction, wherein the axial direction is a direction parallel to the central axis of the glass tube.

22. The method of claim 19, further comprising modifying an axial position of the separation laser beam relative to an axial position of the preheating laser beam.

23. The method of claim 22, further comprising moving a center of the separating laser beam relative to a center of the preheating laser beam toward the working end of the glass tube, wherein moving the center of the separating laser beam closer to the working end of the glass tube relative to the center of the preheating laser beam increases the flatness of the bottom of the glass article and reduces the corner radius at the transition between the bottom and sidewall of the glass article.

24. The method of claim 4, further comprising exposing the separation region of the glass tube to a burner in a heating station prior to translating the glass tube into the separation station.

25. The method of claim 4, wherein separating the glass article from the working end of the glass tube comprises: exposing the separation region of the glass tube to the separation laser beam having an elliptical cross-section; and The separation zone of the glass tube is exposed to a burner in the separation station, wherein the burner preheats the glass tube.

26. The method of claim 4, wherein separating the glass article from the working end of the glass tube comprises applying a tensile force to the glass article while exposing the separation region of the glass tube to the laser beam, wherein the tensile force moves the glass article in an axial direction away from the glass tube.

27. The method of claim 26, wherein the glass tube is oriented vertically with the working end of the glass tube facing downward, and the pulling force comprises gravity.

28. The method of claim 26, wherein applying the tensile force comprises mechanically pulling the glass article in a direction axially away from the glass tube.

29. The method of claim 1 , wherein heating the target area of ​​the glass tube, separating the glass article from the working end of the glass tube, or both comprises: exposing the target area, the separation area, or both of the glass tube with a first laser beam; and Simultaneously, the target area, the separation area, or both of the glass tube are exposed with a second laser beam, wherein the first laser beam and the second laser beam are incident on the target area or the separation area of ​​the glass tube.

30. The method of claim 29, wherein the first laser beam and the second laser beam are superimposed on the glass tube.

31. The method of claim 29, further comprising modifying an axial position of the second laser beam relative to an axial position of the first laser beam.

32. The method of claim 29, wherein: The first laser beam has a circular beam cross-section; and The second laser beam has an elliptical beam cross section.

33. The method of claim 1 , wherein forming comprises contacting a surface of the glass tube in the target area with one or more forming tools while rotating the glass tube, wherein contact between the forming tools and the surface of the glass tube changes the shape of the glass tube in the target area.

34. The method of claim 1, further comprising operating a converter to produce a plurality of glass articles from the plurality of glass tubes, wherein: The converter comprises a plurality of processing stations, the plurality of processing stations comprising at least one heating station, at least one forming station and a separation station; Operating the converter includes translating each of the plurality of glass tubes sequentially through each of the plurality of processing stations; and The at least one heating station, the at least one separation station, or both include exposing each of the glass tubes to the laser beam to heat each of the glass tubes at the target region, the separation region, or both.

35. The method of claim 1, further comprising: securing a glass tube in a holder of a converter comprising a plurality of processing stations, the plurality of processing stations including at least one heating station, at least one forming station, and a separation station, wherein the converter successively translates the holder and the glass tube through each of the processing stations; forming one or more features of a glass article at a working end of the glass tube by translating the glass tube through the at least one heating station and the at least one forming station; and The glass article is separated from the working end of the glass tube in the separation station, wherein: heating the target area of ​​the glass tube includes exposing the target area of ​​the glass tube to the laser beam in the at least one heating station; or Separating the glass article from the working end of the glass tube includes exposing the separation region of the glass tube with the laser beam in the separation station.

36. The method of claim 1, wherein the glass article is a pharmaceutical container.

37. The method of claim 36, wherein the pharmaceutical container comprises a vacutainer, cartridge, syringe, syringe barrel, ampoule, bottle, flask, vial, tube, beaker, or jar.

38. The method of claim 1, wherein exposing the target area or the separation area of ​​the glass tube to the laser beam comprises: generating the laser beam using a laser source; passing the laser beam through an optical device that modifies a shape or power density distribution of the laser beam; and The laser beam is directed toward the target or separation zone of the glass tube.

39. The method of claim 1, wherein the laser beam is a continuous laser beam or a pulsed laser beam.

40. The method of claim 1, wherein the laser beam is a collimated or non-collimated laser beam.

41. The method of claim 1, wherein the laser beam comprises a laser power of 50W to 2000W.

42. The method of claim 1, wherein the laser beam is an elliptical beam or an annular beam.

43. The method of claim 1, wherein the laser beam has a wavelength in a range of about 1 μm to about 12 μm or about 5 μm to about 11 μm.

44. The method of claim 1, further comprising changing a shape of the laser beam, wherein changing the shape of the laser beam changes the volume of glass heated in the target zone or the separation zone of the glass tube.

45. The method of claim 1, further comprising varying a power density of the laser beam, wherein varying the power density varies a heating rate of the laser beam.

46. ​​The method of claim 1 , further comprising controlling an exposure time of the glass tube to the laser beam during heating of the target area of ​​the glass tube by adjusting a time at which a laser source used to generate the laser beam is turned on and off, separating the glass article from the working end of the glass tube, or both.

47. The method of claim 1, comprising rotating the glass tube at a rotation speed of 60 rpm to 400 rpm.

48. The method of claim 1, wherein the laser beam has a heating rate of up to 400°C / second.

49. The method of claim 1, wherein the conversion rate of converting a glass tube into the glass article is greater than or equal to 30 pieces / minute, or wherein the conversion process is not limited by the rate at which the glass article can be separated from the glass tube.

50. A method for removing a glass article from a working end of a glass tube during conversion, the method comprising: translating the working end of the glass tube into a separation station of a converter; rotating the glass tube around the central axis of the glass tube; exposing a separation region of the glass tube to a laser beam while rotating the glass tube; and applying an axial force to the glass article in a direction axially away from the glass tube; The separation region of the glass tube is exposed by the laser beam and the axial force is applied to the glass article to separate the glass article from the working end of the glass tube.

51. The method of claim 50, comprising exposing the separation region of the glass tube to a preheating laser beam in a heating station before translating the glass tube into the separation station.

52. The method of claim 50, wherein the split laser beam has an elliptical cross-section with a major axis and a minor axis.

53. The method of claim 50, wherein the separation laser beam has a beam length of 5 mm to 50 mm at a point where the separation laser beam is incident on the glass tube.

54. The method of claim 50, wherein separating the glass article from the working end of the glass tube further comprises forming an open end on a bottom portion of the glass article, wherein the bottom portion of the glass article is the end portion of the glass article that was previously connected to the glass tube prior to separation.

55. The method of claim 54, wherein the separating laser beam has a beam width of about 0.5 mm to about 5 mm at a point where the separating laser beam is incident on the glass tube.

56. The method of claim 54, wherein the split laser beam is an elliptical beam having a major axis to minor axis ratio of about 4 to about 70 at a point where the split laser beam is incident on the glass tube.

57. The method of claim 50, wherein separating the glass article from the working end of the glass tube further comprises forming a bottom portion of the glass article while separating the glass article from the working end of the glass tube.

58. The method of claim 57, wherein the separating laser beam has a beam width of about 3 mm to about 10 mm at a point where the separating laser beam is incident on the glass tube.

59. The method of claim 57, wherein the split laser beam is an elliptical beam having a major axis to minor axis ratio of about 2 to about 12 at a point where the split laser beam is incident on the glass tube.

60. The method of claim 57, wherein the separating laser beam is an elliptical beam with the major axis oriented parallel or perpendicular to the central axis of the glass tube.

61. The method of claim 57, further comprising reducing a thickness of the bottom portion of the glass article, wherein the split laser beam is an elliptical beam, and reducing the thickness of the bottom portion of the glass article comprises one or more of: orienting the separation laser beam so that the long axis of the separation laser beam is perpendicular to the central axis of the glass tube; reducing the beam width of the split laser beam; or a combination thereof.

62. The method of claim 61, wherein at the point where the split laser beam is incident on the glass tube, the split laser beam has a beam width of about 5 mm to about 10 mm, or the split laser beam has a major axis to minor axis ratio of about 2 to about 7.

63. The method of claim 57, comprising increasing a thickness of the bottom portion of the glass article, wherein the split laser beam is an elliptical beam, and increasing the thickness of the bottom portion of the glass article comprises one or more of: orienting the separation laser beam so that the long axis of the separation laser beam is parallel to the central axis of the glass tube; increasing the beam width of the separated laser beam; or a combination thereof.

64. The method of claim 63, wherein at the point where the split laser beam is incident on the glass tube, the split laser beam has a beam width of about 3 mm to about 7 mm, or the split laser beam has a major axis to minor axis ratio of about 2.5 to about 12.

65. The method of claim 57, wherein separating the glass article from the working end of the glass tube comprises: exposing the separation region of the glass tube to a separation laser beam having an elliptical cross-section; and The separation zone of the glass tube is exposed to a preheated laser beam having a circular cross-section.

66. The method of claim 65, comprising superimposing the separation laser beam and the preheating laser beam on the separation region of the glass tube.

67. The method of claim 65, wherein a center of the separation laser beam is offset relative to a center of the preheating laser beam in an axial direction, wherein the axial direction is a direction parallel to the central axis of the glass tube.

68. The method of claim 65, further comprising modifying an axial position of the separation laser beam relative to an axial position of the preheating laser beam.

69. The method of claim 66, further comprising moving a center of the separating laser beam relative to a center of the preheating laser beam toward the working end of the glass tube, wherein moving the center of the separating laser beam closer to the working end of the glass tube relative to the center of the preheating laser beam increases the flatness of the bottom of the glass article and reduces the corner radius at the transition between the bottom and sidewall of the glass article.

70. The method of claim 50, comprising rotating the glass tube at a rotational speed of 60 rpm to 400 rpm.

71. The method of claim 50, wherein the laser beam has a heating rate of up to 400°C / second.

72. A system for producing a glass article from a glass tube, the system comprising: A converter comprising a plurality of processing stations spaced apart in a loop and at least one holder, wherein: The plurality of processing stations include at least one heating station, at least one forming station, and a separation station; The at least one holder is operable to hold a glass tube and rotate the glass tube about a central axis of the glass tube, wherein a working end of the glass tube is oriented toward the plurality of processing stations; and The converter is operable to successively translate the at least one holder having the glass tube secured therein through each of the plurality of processing stations; and a laser system disposed in said at least one heating station or said separation station, wherein: The laser system includes a laser source and a beam delivery system; and The laser system is operable to generate a laser beam, modify one or more properties of the laser beam, and direct the laser beam at the glass tube while the glass tube is in the at least one heating station or the separation station.

73. The system of claim 72, wherein the at least one laser system comprises a plurality of laser systems, wherein the plurality of laser systems comprises at least one heating laser system positioned in the at least one heating station and a separation laser system positioned in the separation station.

74. The system of claim 72, wherein: The laser system includes a laser source and a beam delivery system; The laser system is operable to generate the laser beam having a wavelength of 1 μm to 12 μm and a power density of 50 W to 2000 W; and The beam delivery system is operable to modify a cross-sectional shape of the laser beam and direct the laser beam to the separation region of the glass tube in the separation station.

75. The system of claim 74, wherein the laser source comprises a CO laser, a CO2 laser, or a quantum cascade laser.

76. The system of claim 74, wherein the beam delivery system comprises at least one optical component selected from a lens, a mirror, a prism, a filter, an aperture, or a combination of these.

77. The system of claim 74, wherein the laser system further comprises at least one steering mirror.

78. The system of claim 77, wherein the laser system is positioned at a location where the laser beam does not have a straight path to the glass tube in at least one heating station or the separation station, and the at least one steering mirror is positioned to change the beam path of the laser beam so that the laser beam is incident on the target area or the separation area of ​​the glass tube.

79. The system of claim 72, further comprising a laser system positioner coupled to the laser system, wherein the laser system positioner is operable to position the laser system relative to the glass tube in the at least one heating station or the separation station.

80. The system of claim 72, wherein the laser system is positioned in the at least one heating station of the converter.

81. The system of claim 80, wherein the laser system is operable to generate the laser beam having a circular cross-section and direct the laser beam at the glass tube in the at least one heating station.

82. The system of claim 72, wherein the laser system is positioned in the separation station.

83. The system of claim 82, wherein the laser system is operable to generate the laser beam having an elliptical cross-section.

84. The system of claim 82, wherein the laser system comprises: a split laser system operable to produce a split laser beam having an elliptical cross-sectional shape; and A preheat laser system is operable to generate a preheat laser beam having a circular cross-sectional shape.

85. The system of claim 84, wherein the laser system is operable to superimpose the separation laser beam and the preheating laser beam on a separation region of the glass tube.

86. The system of claim 82, further comprising a burner in the separation station, wherein the burner is spaced apart from the laser beam in an angular direction relative to a central axis of the glass tube, and the burner is operable to preheat the separation region of the glass tube while the laser beam is directed thereto.

87. The system of claim 82, further comprising a heating station directly upstream of the separation station, wherein the heating station comprises a preheating laser system operable to generate a preheating laser beam and direct the preheating laser beam to the separation zone of the glass tube.

88. The system of claim 87, wherein the heating station further comprises a burner operable to further heat the separation zone of the glass tube.

89. The system of claim 82, further comprising a heating station directly upstream of the separation station, wherein the heating station comprises a burner operable to heat the separation zone of the glass tube prior to translating the glass tube to the separation station.

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