Method and apparatus for making glass vials using a laser

Abstract

A method for producing a glass article from a glass tube includes rotating the 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 the 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, the separation region, or both of the glass tube to a laser beam generated by a laser system, thereby heating the glass tube at the target region, the separation region, or both. The system includes a transducer and a laser system for heating the glass article or separating the glass article from the glass tube.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application No. 63 / 441,305, filed January 26, 2023, and U.S. Provisional Application No. 63 / 523,780, filed June 28, 2023, the contents of which are incorporated herein by reference in their entirety.

[0002] FIELD OF THE INVENTION The present disclosure relates generally to methods, apparatus, and systems for glass articles, and more particularly to methods, apparatus, and systems for converting glass tubing into glass articles in a conversion process. [Background technology]

[0003] Historically, glass has been used to produce a variety of articles. In particular, its airtightness, optical clarity, and superior chemical durability compared to other materials have made it a preferred material for pharmaceutical applications, including, but not limited to, vacutainers, cartridges, syringes, syringe barrels, ampoules, bottles, flasks, vials, tubing, beakers, jars, and other glass articles. The production of these articles from glass begins with providing a glass tube that can be subsequently shaped and separated into multiple glass articles. Specifically, glass used in pharmaceutical packaging must have adequate mechanical and chemical durability so as not to affect the stability of the pharmaceutical formulations contained therein. Glasses with suitable chemical durability include those glass compositions within the ASTM standard "Type IA" and "Type IB" glass compositions, which have a proven track record of chemical durability.

[0004] Glass tubing, used as a starting material for producing glass articles, is produced from continuous processes such as the Danner process or the Bellow process, which produce continuous hollow glass cylinders. Glass tubing can be converted into other glass articles, such as various glass containers for use in pharmaceutical applications, including, without limitation, vacutainers, cartridges, syringes, syringe barrels, ampoules, bottles, flasks, vials, tubing, beakers, jars, and other glass articles. Glass tubing can be converted, for example, in a "converting machine." Converting machines have been in use for over 75 years and are now made by various commercial and internal equipment suppliers. These converting machines typically use steps including flame processing, rotary and stationary tool forming, heat separation, or scoring and impact cutting to reshape long lengths of glass tubing into multiple glass articles. Various burners and forming tools are often used to shape one or more articles from the glass tubing and to separate the articles from the glass tubing. Summary of the Invention

[0005] Therefore, there is a continuing need for methods, apparatus, and systems for converting glass tubing into a glass article using a laser system to heat the glass tubing prior to forming, separating the glass article from the glass tubing, or both. According to a first aspect of the present disclosure, a method for producing a glass article from a glass tubing may include rotating the glass tubing about a central axis of the glass tubing; heating a target region of the glass tubing to a forming temperature while rotating the glass tubing, where the target region may be proximate a working end of the glass tubing; forming at least one feature of the glass article in the target region of the glass tubing while rotating the glass tubing after heating the target region of the glass tubing; and separating the glass article from the working end of the glass tubing at a separation region of the glass tubing. Heating the target region of the glass tubing, separating the glass article from the working end of the glass tubing, or both, may include exposing the target region of the glass tubing, the separation region, or both, to a laser beam having a maximum cross-sectional dimension at a point of incidence on the glass tubing that is about 0.5 to about 1.25 times the outer diameter of the glass tubing. Exposing the target area, the separation area, or both to a laser beam can heat the glass tube to a temperature of about 1000° C. or greater at the target area, the separation area, or both.

[0006] 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 at a heating station of a converter for forming a glass article from the glass tube, and the laser beam may be a heating laser beam.

[0007] A third aspect of the present disclosure may include the second aspect, wherein the heating laser beam has a circular cross section.

[0008] 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 the separated region of the glass tube to a laser beam at a separation station of a converter for forming the glass article from the glass tube, and the laser beam may be a separation laser beam.

[0009] A fifth aspect of the present disclosure may include the fourth aspect, including exposing a separation region of the glass tube to a preheating laser beam at a heating station before translating the glass tube into the separation station.

[0010] A sixth aspect of the present disclosure may include either the fourth or fifth aspect, wherein the separated laser beam may have an elliptical cross section having a major axis and a minor axis.

[0011] A seventh aspect of the present disclosure may include any one of the fourth to sixth aspects, wherein the separated laser beam may have a beam length of 5 mm to 50 mm at a point where the separated laser beam enters the glass tube.

[0012] An eighth aspect of the present disclosure may include any one of the fourth to seventh aspects, wherein separating the glass article from the worked end of the glass tube may further include forming an open end at a bottom of the glass article, the bottom of the glass article being the end of the glass article that was pre-bonded to the glass tube before separation.

[0013] A ninth aspect of the present disclosure may include the eighth aspect, wherein the separated laser beam may have a beam width of about 0.5 mm to about 5 mm at the point where the separated laser beam enters the glass tube.

[0014] A tenth aspect of the present disclosure may include either the eighth or ninth aspect, wherein at the point where the separated laser beam enters the glass tube, the separated laser beam may be an elliptical beam having a ratio of major axis to minor axis of about 4 to about 70.

[0015] An eleventh aspect of the present disclosure may include any one of the fourth to seventh aspects, and separating the glass article from the working end of the glass tube may further include shaping a bottom portion of the glass article while separating the glass article from the working end of the glass tube.

[0016] A twelfth aspect of the present disclosure may include the eleventh aspect, wherein the separated laser beam may have a beam width of about 3 mm to about 10 mm at the point where the separated laser beam enters the glass tube.

[0017] A thirteenth aspect of the present disclosure may include either the eleventh or twelfth aspect, wherein at the point where the separated laser beam enters the glass tube, the separated laser beam may be an elliptical beam having a ratio of major axis to minor axis of about 2 to about 12.

[0018] A fourteenth aspect of the present disclosure may include any one of the eleventh to thirteenth aspects, wherein the separated laser beam may be an elliptical beam, the major axis of which is oriented parallel or perpendicular to the central axis of the glass tube.

[0019] A fifteenth aspect of the present disclosure may include any one of the eleventh to fourteenth aspects, further including reducing a thickness of a bottom portion of the glass article. The separate laser beam may be an elliptical beam, and reducing the thickness of the bottom portion of the glass article may include one or more of orienting the separate laser beam with a major axis of the separate laser beam perpendicular to a central axis of the glass tube, reducing a beam width of the separate laser beam, or a combination thereof.

[0020] A sixteenth aspect of the present disclosure may include the fifteenth aspect, wherein the separated laser beam may have a beam width of about 5 mm to about 10 mm, or the separated laser beam may have a ratio of major axis to minor axis of about 2 to about 7 at the point where the separated laser beam enters the glass tube.

[0021] A seventeenth aspect of the present disclosure may include any one of the eleventh to fourteenth aspects, including increasing the thickness of the bottom of the glass article. The separate laser beam may be an elliptical beam, and increasing the thickness of the bottom of the glass article may include one or more of orienting the separate laser beam with a major axis of the separate laser beam parallel to a central axis of the glass tube, increasing a beam width of the separate laser beam, or a combination thereof.

[0022] An eighteenth aspect of the present disclosure may include the seventeenth aspect, wherein the separated laser beam may have a beam width of about 3 mm to about 7 mm, or the separated laser beam may have a ratio of major axis to minor axis of about 2.5 to about 12 at the point where the separated laser beam enters the glass tube.

[0023] A 19th aspect of the present disclosure may include any one of the 11th to 18th aspects, wherein separating the glass article from the working end of the glass tube may include exposing the separated region of the glass tube to a separation laser beam having an elliptical cross-section, and exposing the separated region of the glass tube to a preheating laser beam having a circular cross-section at the separation station.

[0024] A twentieth aspect of the present disclosure may include the nineteenth aspect, including superimposing the separation laser beam and the preheating laser beam on the separation region of the glass tube.

[0025] A twenty-first aspect of the present disclosure may include either the nineteenth or twentieth aspects, wherein the center of the separation laser beam may be axially offset relative to the center of the preheating laser beam, the axial direction being parallel to the central axis of the glass tube.

[0026] A twenty-second aspect of the present disclosure may include any one of the nineteenth to twenty-first aspects, further including modifying an axial position of the separation laser beam relative to an axial position of the preheating laser beam.

[0027] A twenty-third aspect of the present disclosure may include the twenty-second aspect, further including moving the center of the separation laser beam toward the working end of the glass tube relative to the center of the preheating laser beam, 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 may increase the flatness of the bottom of the glass article and may decrease the corner radius at the transition between the bottom and the sidewall of the glass article.

[0028] A 24th aspect of the present disclosure may include any one of the 4th to 23rd aspects, further including exposing a separation region of the glass tube to a burner at the heating station before translating the glass tube into the separation station.

[0029] A 25th aspect of the present disclosure may include any one of the 4th to 24th aspects, and separating the glass article from the working end of the glass tube may include exposing the separated region of the glass tube to a separation laser beam having an elliptical cross-section and exposing the separated region of the glass tube to a burner at the separation station, wherein the burner preheats the glass tube.

[0030] A 26th aspect of the present disclosure may include any one of the 4th to 25th aspects, wherein separating the glass article from the working end of the glass tube may include applying a pulling force to the glass article while exposing the separated region of the glass tube to the laser beam, and the pulling force may move the glass article axially away from the glass tube.

[0031] A twenty-seventh aspect of the present disclosure may include the twenty-sixth aspect, wherein the glass tube may be oriented vertically with a processed end of the glass tube facing downward, and the pulling force may include gravity.

[0032] A twenty-eighth aspect of the present disclosure may include either the twenty-sixth or twenty-seventh aspect, wherein applying a pulling force may include mechanically pulling the glass article axially away from the glass tube.

[0033] A 29th aspect of the present disclosure may include any one of the first to twenty-eighth aspects, and may include heating a target area of ​​the glass tube, separating a glass article from a working end of the glass tube, or both, by exposing the target area, the separation area, or both of the glass tube to a first laser beam and simultaneously exposing the target area, the separation area, or both of the glass tube to 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.

[0034] 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.

[0035] A thirty-first aspect of the present disclosure may include either the twenty-ninth or thirtieth aspects, further including modifying the axial position of the second laser beam relative to the axial position of the first laser beam.

[0036] A thirty-second aspect of the present disclosure may include any one of the twenty-ninth to thirty-first aspects, wherein the first laser beam may have a circular beam cross-section, and the second laser beam may have an elliptical beam cross-section.

[0037] A thirty-third aspect of the present disclosure may include any one of the first to thirty-second aspects, wherein the shaping may include contacting a surface of the glass tube in the target area with one or more shaping tools while rotating the glass tube, wherein the contact between the shaping tools and the surface of the glass tube changes the shape of the glass tube in the target area.

[0038] A thirty-fourth aspect of the present disclosure may include any one of the first through thirty-third aspects, further including 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 including at least one heating station, at least one forming station, and a separation station, wherein operating the converter may include sequentially translating each of the plurality of glass tubes through each of the plurality of processing stations, and wherein the at least one heating station, the 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 area, a separation area, or both.

[0039] A thirty-fifth aspect of the present disclosure may include any one of aspects 1 through 34, further comprising securing the glass tube in a holder of a converter having a plurality of processing stations, the plurality of processing stations including at least one heating station, at least one shaping station, and a separation station, and the converter sequentially translating the holder and the glass tube through each of the processing stations. The method may further include forming one or more features of a glass article on a working end of the glass tube by translating the glass tube through the at least one heating station and the at least one shaping station, and separating the glass article from the working end of the glass tube at a separation station. Heating a target area of ​​the glass tube may include exposing a target area of ​​the glass tube to a laser beam at the at least one heating station, or separating the glass article from the working end of the glass tube may include exposing a separation area of ​​the glass tube to a laser beam at a separation station.

[0040] A 36th aspect of the present disclosure may include any one of the first to 35th aspects, wherein the glass article may be a pharmaceutical container. A 37th aspect of the present disclosure may include the 36th aspect, wherein the pharmaceutical container may include a vacutainer, a cartridge, a syringe, a syringe barrel, an ampoule, a bottle, a flask, a vial, a tube, a beaker, or a bottle.

[0041] A thirty-seventh aspect of the present disclosure may be directed to a method for detaching 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 an axial direction away from the glass tube. Exposing the separation region of the glass tube to the laser beam and applying an axial force to the glass article may separate the glass article from the working end of the glass tube.

[0042] A thirty-eighth aspect of the present disclosure may include the thirty-seventh aspect, including exposing a separation region of the glass tube to a preheating laser beam at a heating station before translating the glass tube into the separation station.

[0043] A thirty-ninth aspect of the present disclosure may include either the thirty-seventh or thirty-eighth aspects, wherein the separated laser beam may have an elliptical cross-section having a major axis and a minor axis.

[0044] A fortieth aspect of the present disclosure may include any one of the thirty-seventh to thirty-ninth aspects, wherein the separated laser beam may have a beam length of 5 mm to 50 mm at the point where the separated laser beam enters the glass tube.

[0045] A forty-first aspect of the present disclosure may include any one of the thirty-seventh to fortieth aspects, wherein separating the glass article from the processed end of the glass tube may further include forming an open end at the bottom of the glass article, the bottom of the glass article being the end of the glass article that was pre-bonded to the glass tube before separation.

[0046] A forty-second aspect of the present disclosure may include the forty-first aspect, wherein the separated laser beam may have a beam width of about 0.5 mm to about 5 mm at the point where the separated laser beam enters the glass tube.

[0047] A forty-third aspect of the present disclosure may include either the forty-first or forty-second aspect, wherein at the point where the separated laser beam enters the glass tube, the separated laser beam may be an elliptical beam having a ratio of the major axis to the minor axis of about 4 to about 70.

[0048] A 44th aspect of the present disclosure may include any one of the 37th to 43rd aspects, and separating the glass article from the processed end of the glass tube may further include shaping a bottom portion of the glass article while separating the glass article from the processed end of the glass tube.

[0049] A forty-fifth aspect of the present disclosure may include the forty-fourth aspect, wherein the separated laser beam may have a beam width of about 3 mm to about 10 mm at the point where the separated laser beam enters the glass tube.

[0050] A forty-sixth aspect of the present disclosure may include either the forty-fourth or forty-fifth aspect, wherein at the point where the separated laser beam enters the glass tube, the separated laser beam may be an elliptical beam having a ratio of major axis to minor axis of about 2 to about 12.

[0051] A forty-seventh aspect of the present disclosure may include any one of the forty-fourth to forty-sixth aspects, wherein the separated laser beam may be an elliptical beam, and the major axis may be parallel or perpendicular to the central axis of the glass tube.

[0052] A forty-eighth aspect of the present disclosure may include any one of aspects forty-four to forty-seventh, further including reducing a thickness of a bottom portion of the glass article, wherein the separation laser beam may be an elliptical beam, and reducing the thickness of the bottom portion of the glass article may include one or more of orienting the separation laser beam with a major axis of the separation laser beam perpendicular to a central axis of the glass tube, reducing a beam width of the separation laser beam, or a combination thereof.

[0053] A forty-ninth aspect of the present disclosure may include the forty-eighth aspect, wherein the separated laser beam may have a beam width of about 5 mm to about 10 mm, or the separated laser beam may have a ratio of major axis to minor axis of about 2 to about 7 at the point where the separated laser beam enters the glass tube.

[0054] A 50th aspect of the present disclosure may include any one of aspects 44 to 49, including increasing the thickness of the bottom of the glass article, wherein the separate laser beam may be an elliptical beam, and increasing the thickness of the bottom of the glass article may include one or more of orienting the separate laser beam with a major axis of the separate laser beam parallel to the central axis of the glass tube, increasing the beam width of the separate laser beam, or a combination thereof.

[0055] A fifty-first aspect of the present disclosure may include the fiftieth aspect, wherein the separated laser beam may have a beam width of about 3 mm to about 7 mm, or where the separated laser beam enters the glass tube, the separated laser beam may have a ratio of major axis to minor axis of about 2.5 to about 12.

[0056] A 52nd aspect of the present disclosure may include any one of the 44th to 51st aspects, and separating the glass article from the working end of the glass tube may include exposing the 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.

[0057] A fifty-third aspect of the present disclosure may include the fifty-second aspect, including overlapping the separation laser beam and the preheating laser beam on the separation region of the glass tube.

[0058] A 54th aspect of the present disclosure may include either the 52nd or 53rd aspects, wherein the center of the separation laser beam may be axially offset relative to the center of the preheating laser beam, the axial direction being parallel to the central axis of the glass tube.

[0059] A fifty-fifth aspect of the present disclosure may include any one of the fifty-second to fifty-fourth aspects, further including modifying an axial position of the separation laser beam relative to an axial position of the preheating laser beam.

[0060] A 56th aspect of the present disclosure may include any one of aspects 52 to 55, further including moving the center of the separation laser beam toward the processing end of the glass tube relative to the center of the preheating laser beam, wherein moving the center of the separation laser beam closer to the processing end of the glass tube relative to the center of the preheating laser beam may increase the flatness of the bottom of the glass article and may reduce the corner radius at the transition between the bottom and sidewall of the glass article.

[0061] A 57th aspect of the present disclosure may include any one of the first to 56th aspects, and wherein exposing the target area or separation area of ​​the glass tube to a laser beam may include generating a laser beam using a laser light source, passing the laser beam through an optical system 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.

[0062] A 58th aspect of the present disclosure may include any one of the first to 57th aspects, wherein the laser beam may be a continuous laser beam or a pulsed laser beam.

[0063] 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 laser beam or a non-collimated laser beam.

[0064] 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 output of 50 W to 2000 W.

[0065] A 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 round beam.

[0066] 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 the range of about 1 μm to about 12 μm, or about 5 μm to about 11 μm.

[0067] A 63rd aspect of the present disclosure may include any one of aspects 1 to 62, further including changing the shape of the laser beam, wherein changing the shape of the laser beam may change the volume of glass heated in the target region or separation region of the glass tube.

[0068] A 64th aspect of the present disclosure may include any one of aspects 1 to 63, further including changing the power density of the laser beam, wherein changing the power density may change the heating rate of the laser beam.

[0069] A 65th aspect of the present disclosure may include any one of the 1st to 64th aspects, further including controlling the exposure time of the glass tube to the laser beam while heating the target area of ​​the glass tube by adjusting the time that a laser light source for generating the laser beam is turned on and off, separating the glass article from the working end of the glass tube, or both.

[0070] A 66th aspect of the present disclosure may include any one of the 1st to 65th aspects, including rotating the glass tube at a rotation speed of 60 rpm to 400 rpm.

[0071] A 67th aspect of the present disclosure may include any one of the first to 66th aspects, wherein the laser beam may have a heating rate of up to 400° C. / sec.

[0072] A 68th aspect of the present disclosure may include any one of the first to sixty-seventh aspects, wherein the conversion rate of converting the glass tubing into glass articles is 30 parts per minute or greater, or the conversion process may not be rate-limited by separation of the glass articles from the glass tubing.

[0073] A sixty-ninth aspect of the present disclosure may be directed to a system for producing glass articles from glass tubes. The system may include a converter including a plurality of processing stations spaced apart in a circulation path and at least one holder. The plurality of heating 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 with a working end of the glass tube oriented toward the plurality of processing stations and to rotate the glass tube about a central axis of the glass tube. The converter may be operable to continuously translate the at least one holder, with the glass tube secured to the at least one holder, 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 characteristics of the laser beam, and direct the laser beam toward the glass tube when the glass tube is in the at least one heating station or separation station.

[0074] A 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, and the plurality of laser systems may include at least one heating laser system disposed in the at least one heating station and a separation laser system disposed in the separation station.

[0075] A 71st aspect of the present disclosure may include either the 69th or 70th aspect, wherein the laser system may include a laser source and a beam delivery system, wherein 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 wherein the beam delivery system may be operable to modify a cross-sectional shape of the laser beam and direct the laser beam to a separation region of the glass tube at the separation station.

[0076] A seventy-second aspect of the present disclosure may include the seventy-first aspect, wherein the laser light source may include a CO laser, a CO laser, or a quantum cascade laser.

[0077] A 73rd aspect of the present disclosure may include either the 71st or 72nd aspects, wherein the beam delivery system may comprise at least one optical component selected from a lens, a mirror, a prism, a filter, an aperture, or a combination thereof.

[0078] A 74th aspect of the present disclosure may include any one of the 71st to 73rd aspects, wherein the laser system may further include at least one turning mirror.

[0079] A 75th aspect of the present disclosure may include the 74th aspect, wherein the laser system may be disposed in a position where the laser beam does not have a straight path to the glass tube at at least one heating station or separation station, and at least one turning 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.

[0080] A 76th aspect of the present disclosure may include any one of aspects 69 to 75, further comprising a laser system positioner coupled to the laser system, wherein the laser system positioner may be operable to position the laser system relative to the glass tube at at least one heating station or separation station.

[0081] A 77th aspect of the present disclosure may include any one of the 69th to 76th aspects, wherein the laser system may be disposed in at least one heating station of the converter.

[0082] A 78th aspect of the present disclosure may include the 77th aspect, wherein the laser system may be operable to generate a laser beam having a circular cross-section and to direct the laser beam to the glass tube at the at least one heating station.

[0083] A seventy-ninth aspect of the present disclosure may include any one of the sixty-ninth to seventy-eighth aspects, wherein the laser system may be disposed in the separation station.

[0084] 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.

[0085] An 81st aspect of the present disclosure may include either the 79th or 80th aspects, wherein the laser system may include a separation laser system operable to generate a separation laser beam having an elliptical cross-sectional shape, and a preheating laser system operable to generate a preheating laser beam having a circular cross-sectional shape.

[0086] An eighty-second aspect of the present disclosure may include the eighty-first aspect, wherein the laser system may be operable to overlap the separation laser beam and the preheating laser beam on the separation region of the glass tube.

[0087] An 83rd aspect of the present disclosure may include any one of aspects 79 to 82, further comprising a burner in the separation station, wherein the burner may be positioned at an angle relative to the central axis of the glass tube and spaced apart from the laser beam, and wherein the burner may be operable to preheat the separation region of the glass tube while the laser beam is directed at the separation region of the glass tube.

[0088] An 84th aspect of the present disclosure may include any one of aspects 79 to 83, further comprising a heating station immediately upstream of the separation station, the heating station operable to generate a preheating laser beam and may comprise a preheating laser system that directs the preheating laser beam toward the separation region of the glass tube.

[0089] 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.

[0090] An 86th aspect of the present disclosure may include any one of aspects 79 to 85, further comprising a heating station immediately upstream of the separation station, wherein the heating station may comprise a burner operable to heat a separation region of the glass tube before translating the glass tube into the separation station.

[0091] Additional features and advantages of the systems and methods disclosed herein will be set forth in the following detailed description, and in part will become 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, the claims, and the accompanying drawings.

[0092] It is to be understood that both the foregoing general description and the following detailed description are intended to describe various embodiments and provide an overview or framework for understanding the nature and features 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 description, serve to explain the principles and operation of the claimed subject matter. [Brief explanation of the drawings]

[0093] [Figure 1] 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. [Figure 2] 1 schematically depicts a glass tube according to one or more embodiments shown and described herein. [Figure 3] 2A and 2B schematically depict a top view of the converter of FIG. 1 illustrating a layout of processing stations according to one or more embodiments shown and described herein; [Figure 4] 2 schematically depicts a heating station of the converter of FIG. 1 according to one or more embodiments shown and described herein. [Figure 5]2 schematically depicts a forming station of the conversion machine of FIG. 1 according to one or more embodiments shown and described herein. [Figure 6] 2A and 2B schematically depict another embodiment of a forming station of the converter of FIG. 1 according to one or more embodiments shown and described herein. [Figure 7] 1 shows a schematic representation of a separation station for a converter according to the prior art, the separation station comprising a gas burner; [Figure 8] 1 schematically depicts a separation station for a conversion machine according to one or more embodiments shown and described herein, the separation station comprising a laser system; [Figure 9] 1 graphically depicts relative beam intensity (y-axis) as a function of beam position (x-axis) for elongated beams having Gaussian and flat-top power density profiles in accordance with one or more embodiments shown and described herein. [Figure 10] 2 schematically depicts a top view of the system of FIG. 1 including a transducer and a laser system according to one or more embodiments shown and described herein. [Figure 11] 10A and 10B schematically depict the beam shape of a round-shaped heating laser beam incident on a glass tube according to one or more embodiments shown and described herein. [Figure 12] 10A and 10B schematically depict the beam shape of an elliptically shaped separated laser beam incident on a glass tube according to one or more embodiments shown and described herein. [Figure 13] 10A and 10B schematically depict the beam shape of an elliptical separated laser beam having a larger ratio of the major axis to the minor axis incident on a glass tube according to one or more embodiments shown and described herein. [Figure 14] 10A and 10B are schematic illustrations of the beam shape of an elliptical separated laser beam incident on a glass tube, with the major axis of the separated laser beam parallel to the central axis of the glass tube, according to one or more embodiments shown and described herein. [Figure 15]10A-10C schematically depict the beam shape incident on a glass tube resulting from the superposition of a round-shaped heating laser beam and an elliptical-shaped separating laser beam according to one or more embodiments shown and described herein. [Figure 16] 10A and 10B schematically illustrate a separation station including a preheating laser system and a separation laser system configured to overlap the preheating laser system and the separation laser beam on a glass tube, according to one or more embodiments shown and described herein. [Figure 17] Schematically depicts a top view of a separation station comprising a preheating laser system and a separation laser system positioned to direct a preheating laser beam and a separation beam to a separation region of a glass tube without overlapping the two beams, according to one or more embodiments shown and described herein. [Figure 18] 17 schematically depicts a front view of the separation station of FIG. 16, where the separation laser beam is axially offset from the preheating laser beam, according to one or more embodiments shown and described herein. [Figure 19A] 1A and 1B schematically depict a front view of a separation station with a separation laser beam and a gas burner according to one or more embodiments shown and described herein. [Figure 19B] 19B schematically depicts a top view of the separation station of FIG. 19A according to one or more embodiments shown and described herein. [Figure 20] 1A and 1B schematically depict a front view of a glass article including a glass vial according to one or more embodiments shown and described herein. [Figure 21] 1 schematically depicts a side view of a heating station including a laser system according to one or more embodiments shown and described herein. [Figure 22] 10A and 10B schematically depict a top view of a converter including a laser system for a separation station and for a heating station upstream of the separation station according to one or more embodiments shown and described herein. [Figure 23] FIG. 10 schematically depicts a top view of a converter with a hybrid preheating system including both burner and laser heating elements upstream of a separation station according to one or more embodiments shown and described herein. [Figure 24] 10 is a graph depicting glass temperature (y-axis) as a function of time (x-axis) for exposing a glass tube in a processing station of a converter to an elliptical shaped laser beam having different laser powers according to one or more embodiments shown and described herein. [Figure 25] 10 is a graph depicting glass temperature (y-axis) as a function of time (x-axis) for exposing glass tubes in a processing station of a converter to laser beams having the same laser power density but different beam shapes, according to one or more embodiments shown and described herein. [Figure 26] 1 is a photograph of an end of a glass article separated from a glass tube using a gas burner and an end of a glass article separated from a glass tube using a laser beam for heating, according to one or more embodiments shown and described herein. [Figure 27] FIG. 1 is a photograph of 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. [Figure 28] Photographs of finished ends of glass tubing and glass articles separated by a laser beam to form open ends of the glass tubing and glass articles according to one or more embodiments shown and described herein. DETAILED DESCRIPTION OF THE INVENTION

[0094] Reference will now be made in detail to embodiments of apparatus, systems, and methods for producing glass articles from glass tubes using a laser, 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. Referring now to FIG. 1 , one embodiment of a system 400 for producing glass articles from glass tubes 102 is schematically depicted. The system 400 disclosed herein may include a converter 100 including a plurality of spaced-apart processing stations 122 arranged in a circular path 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 with a working end 107 of the glass tube 102 oriented toward the plurality of processing stations 122 and to rotate the glass tube 102 about a central axis of the glass tube 102. The converter 100 may be operable to sequentially translate at least one holder 140, with the glass tube 102 secured to the at least one holder 140, through each of the plurality of processing stations 122. The system 400 may further include a laser system 410 disposed in at least one heating station or separation station. The laser system 410 may include a laser source 412 and a beam delivery system 420. The laser system 410 may be operable to generate a laser beam 414, modify one or more characteristics of the laser beam 414, and direct the laser beam 414 to the glass tube 102 while the glass tube 102 is in the at least one heating station or separation station.

[0095] The system 400 may be employed in a method for 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, the target region being proximate a working end of the glass tube 102; forming at least one feature of a glass article in the target region of the glass tube 102 while rotating the glass tube 102 after heating the target region of 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 of the glass tube 102, the separation region, or both, to a laser beam 414 having a beam width of about 0.5 mm to about 10 mm. Exposing the target area, the separation area, or both to the laser beam 414 may heat the glass in the target area, the separation area, or both to a temperature of about 1000° C. or greater.

[0096] Unless otherwise expressly stated, it is never intended that any method described herein be construed as requiring its steps to be performed in a particular order, or that any apparatus require a particular orientation. Thus, if a method claim does not actually recite the order in which its steps are to be followed, or if any apparatus claim does not actually recite an order or orientation for individual components, or if the claim or specification does not specifically state that the steps are to be limited to a particular order or that no particular order or orientation for the apparatus components is recited, then no order or orientation is intended to be inferred in any respect. This holds for any possible implicit basis for interpretation, including logical matters regarding the arrangement of steps, workflow, component order, or component orientation, the apparent meaning derived from grammatical construction or punctuation, and the number or type of embodiments described in the specification.

[0097] Directional terms used herein, e.g., up, down, right, left, front, back, top, bottom, are used only with reference to the depicted figure and the coordinate axes provided with that figure, and are not intended to imply absolute orientation.

[0098] 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" component includes aspects having two or more such components unless the context clearly dictates otherwise.

[0099] As used herein, "axial" refers to a direction parallel to the central axis A of the glass tube or rod.

[0100] As used herein, the "beam waist" of a laser beam refers to the point along the beam path of the laser beam where the power density of the laser beam is greatest.

[0101] As used herein, the term "circumference" of a glass tube refers to the set of points on the glass tube at a certain radius r from the central axis D of the glass tube up to 360 degrees from a particular Z position (i.e., a position on the + / -Z axis of the diagram). The circumference of the glass tube may coincide, for example, with the outer surface of the glass tube at a particular Z position or the inner surface of the glass tube at a particular Z position.

[0102] As used herein, converter "dwell time" refers to the duration that a glass tube spends at a particular processing station before proceeding to the next subsequent processing station.

[0103] As used herein, the term "active time" refers to the duration that a glass tube is maintained engaged with at least one heating element or at least one forming tool while in a particular processing station.

[0104] As used herein, the term "index time," when used in reference to an indexing converter, refers to the duration it takes to index a glass tube from one processing station to the next. "Dwell time," "active time," and "index time" are all measured in units of time.

[0105] When used with respect to the heating station, the term "engagement" of the laser beam with the glass tube refers to the state in which the laser beam is incident on the surface of the glass tube. Conversely, when the laser beam is out of engagement with the glass tube, the laser beam is not incident on the glass tube, such as by turning the laser beam off, moving the laser beam away from the glass tube, or moving the glass tube out of the beam path of the laser beam.

[0106] As used herein, the term "part rate" refers to the production or throughput rate of a converter in units of number of glass articles per unit time.

[0107] As used herein, the terms "upstream" and "downstream" refer to the location of processing stations and other components of a converter relative to the direction of travel of the glass tube through the converting 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 a second processing station before encountering the first processing station, the first processing station is "downstream" of the second processing station.

[0108] As used herein, the terms "upbeam" and "downbeam" 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 may be considered to be beam-upstream of the second component. Conversely, if the laser beam encounters a second component before encountering the first component, the first component may be considered to be beam-downstream of the second component.

[0109] As used herein, the "working end" of the glass tube is the end of the glass tube oriented relative to the holder toward the processing station of the main turret of the converter, and the "non-working end" of the glass tube is the end of the glass tube oriented away from the processing station of the main turret.

[0110] Glass's hermeticity, optical clarity, and superior chemical durability compared to other materials have made it a preferred material for pharmaceutical applications, including, without limitation, vacutainers, cartridges, syringes, syringe barrels, ampoules, bottles, flasks, vials, tubing, beakers, jars, and other glass articles. These pharmaceutical glass containers and other types of glass articles can be produced through a process that converts lengths of glass tubing into one or more of the glass articles through multiple heating and forming operations.

[0111] Referring to FIG. 2 , one embodiment of a glass tube 102 for use as a starting point for fabricating multiple glass articles is schematically depicted. The glass tube 102 comprises an elongated, hollow cylinder of glass 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 an unworked 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, which is then separated from the glass tube 102, as described in further detail herein. The working end 107 of the glass tube 102 is the end of the glass tube 102 that is oriented in the −Z direction of the coordinate axes in FIG. 2 when the glass tube 102 is secured in the holder of the converter 100. The non-processed end 108 of the glass tube 102 is the end opposite to the processed end 107 (i.e., the end of the glass tube 102 in the +Z direction of the coordinate axis in FIG. 2 ). The glass tube 102 may have a circular cross-sectional shape and may have a tube length L and an outer diameter D t , and a thickness t. The tube length L is the distance from the worked end 107 to the unworked 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 comprises a central axis A.

[0112] The glass tubing 102 can be converted into glass articles, particularly glass articles for use in pharmaceutical applications, which may include, without limitation, vacutainers, cartridges, syringes, syringe barrels, ampoules, bottles, flasks, vials, tubing, beakers, jars, and other glass articles. The glass tubing 102 can be converted into these glass articles using a converting machine (i.e., converting machine) that includes multiple processing stations. The processing stations may include, but are not limited to, heating stations, forming stations, separating stations, punching stations, measuring stations, polishing stations, cooling stations, tube loading stations, or other types of processing stations. The converting machine typically reshapes long lengths of glass tubing into multiple glass articles using steps that include, but are not limited to, flame processing, rotary and stationary tool forming, separating (e.g., thermal separating or scoring and impact cutting steps), punching, cooling, measuring, or other processing steps. Therefore, the glass article produced through the converting process carried out on the converting machine is subjected to a series of flame burners, other heating elements and forming tools to shape the glass tube into a particular shape and size and to separate the formed glass article from the glass tube.

[0113] 1 , one embodiment of a converter 400 for producing glass articles from glass tubes 102 is schematically depicted. The system 400 includes a converter 100. The converter 100 may use the glass tubes 102 to convert into a plurality of glass articles. The converter 100 may include a base 120 having a plurality of processing stations 122 and a main turret 124 positioned on the base 120 and rotatable about a central axis B relative to the base 120. The converter 100 may also include a plurality of secondary processing stations 132 on the base 120 and a secondary turret 134 that may be rotatable relative to the base 120.

[0114] As depicted generally in FIG. 1 , the base 120 of the converter 100 may be stationary, and the processing stations 122 may be coupled to an upper portion 121 of the base 120. The processing stations 120 may be spaced apart from one another and arranged in a main circuit 126. In embodiments, the main circuit 126 may be circular, such that the main turret 124 translates the glass tubes 102 through the multiple processing stations 122 by rotation of the main turret 124. Alternatively, in embodiments, the main circuit 126 may be a linear arrangement of processing stations 122. While described herein with reference to a circular layout of the processing stations 122, it is understood that the subject matter disclosed herein may be equally well applied to converters having other arrangements of processing stations 122, such as linear, curved, or irregularly shaped arrangements of the processing stations 122.

[0115] The type and / or shape of the glass article to be produced from the glass tube 102 may affect the total number of processing stations 122 in the converter 100. The number of processing stations 122 in the main circuit 126 may be between 14 and 50 processing stations 120. While the converter 100 and converting process are described herein in the context of a converter 100 having 16 processing stations 122 in the main circuit 126, it is understood that the converter 100 may have more or fewer than 16 processing stations 122 in the main circuit 126. The processing stations 122 may include, by way of example and without limitation, one or more heating, forming, polishing, cooling, separating, punching, measuring, feeding, ejection stations, other processing stations, or combinations thereof, for producing a glass article from the glass tube 102. The type and / or shape of the article to be produced from the glass tube 102 may also affect the type and / or sequence of processing stations 122 in the converter 100.

[0116] 1 and 3, the converter 100 may include secondary processing stations 132, which may be spaced apart from one another and arranged in a secondary circuit 136 (FIG. 3). In embodiments, the converter 100 may include a secondary turret 134 (FIG. 1) for indexing or continuously moving articles 103 (FIG. 1) separated from the glass tube 102 through the multiple secondary processing stations 132. The secondary turret 134 may be rotatable about a second axis C relative to the base 120. The secondary turret 134 may receive the glass articles 103 from the separation station 206 (FIG. 3) of the main turret 124, translate (e.g., index or continuously move) the glass articles 103 through the multiple secondary processing stations 132 through rotation of the secondary turret 134, and discharge the finished glass articles 103 from the converter 100. Although shown in a circular pattern, it is understood that secondary processing stations 132 may be arranged in a linear, curvilinear, or irregular arrangement. In an embodiment, converter 100 may be configured to produce vials, and secondary processing stations 132 may be referred to as bottom formers. For vials, secondary processing stations 132 may be operable to form the bottom of the vial.

[0117] The converter 100 may include multiple holders 140 configured to removably secure each glass tube 102 to the main turret 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 generally parallel to the central axis B of the main turret 124 and generally perpendicular to the upper portion 121 of the base 120. While 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 so 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 at each of successive processing stations 122 as the main turret 124 rotates. The vertical orientation of the glass tubes 102 allows the working end 107 of each glass tube 102 to be moved or indexed sequentially through the processing stations 122 .

[0118] Each holder 140 may be individually rotatable relative to the main turret 124 to rotate the glass tube 102 about its central axis A. Each of the holders 140 may be operably coupled to a motor (not shown), continuous drive belt, or other drive mechanism for active rotation of each of the holders 140. Rotation of the holders 140 allows rotation of the glass tube 102 about its central axis A relative to a stationary heating element, forming tool, cooling nozzle, or other feature of the processing station 122. The heating element or forming tool within the processing station 122 may be maintained in a fixed position relative to the glass tube 102, and rotation of the glass tube 102 about its central axis A may allow the entire circumference of the glass tube 102 to be exposed to the heating element or forming tool.

[0119] The converter 100 is operable to sequentially translate the glass tube 102 through each of the processing stations 122. In embodiments, the converter 100 may be operable to index each of the multiple holders 140 through the multiple processing stations 122. Indexing may refer to a stepwise process of moving the glass tube 102 into a processing station 122, maintaining the glass tube 102 in a resting XYZ position at the processing station 122 for a dwell time, and then indexing the glass tube 102 to the next processing station 122. Alternatively, in embodiments, the converter 100 may be operable to sequentially translate the multiple holders 140 through the conversion process. In embodiments, the processing stations 122 may translate with the glass tube 102 during the glass tube 102's active time at the processing station 122.

[0120] Referring now to Figure 3, as previously described, the plurality of processing stations 122 may include one or more of the heating station 202, forming station 204, separating station 206, cooling station 210, piercing station 212, tube loading station 214, ejection station 216, measuring station 218, tube length drop station 220, other stations, and / or combinations of these stations. Figure 3 schematically depicts one arrangement of processing stations 122 in a converter 100 having a main circuit 126 of 16 processing stations 122 and a secondary circuit 136 of eight secondary processing stations 132. As previously described, the processing stations 122 in the main circuit 126 may be evenly spaced and distributed evenly around the circular circuit, and the secondary processing stations 132 in the secondary circuit 136 may also be evenly spaced and distributed evenly around the circular circuit.

[0121] The converter's main circuit 126, depicted schematically in FIG. 3, 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 length drop station 220, and a tube loading station 214. While FIG. 3 depicts the main circuit 126 as having a circular arrangement of processing stations 122, as previously discussed, the main circuit 126 may have processing stations 122 positioned in other non-circular arrangements, such as linear, curved, irregularly shaped, or other arrangements. With respect to the direction of rotation 222 of the main turret 124, heating stations 202 may generally be positioned before each of the forming stations 204 and before the separation station 206 to preheat target areas of the glass tube 102 to a viscosity at which the glass is deformable and can be shaped or drawn and separated. At the separation station 206, the formed glass article 103 ( FIG. 1 ) may be separated from the working end 107 of the glass tube 102 ( FIG. 1 ) as the bottom of the glass article 103 is simultaneously formed. 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 turret 134 ( FIG. 1 ) that indexes through a secondary circuit 136 of a secondary processing station 132. A piercing station 212 may be located on the main circuit 126 downstream from the separation station 206 in the direction of rotation 222 of the main turret 126. At the piercing station 212, the meniscus of the glass at the working end 107 of the glass tube 102 formed at the separation station 206 is pierced, thereby reopening the working end 107 of the glass tube 102.

[0122] Referring again to FIG. 3 , the forming station 204 of the main turret 108 may be positioned downstream of the punch station 212 and the one or more heating stations 202 in the direction of rotation 222. The forming station 204 may shape the glass tube 102 to form one or more features of the finished glass article. As described above, one or more heating stations 202 may 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 may be shaped and formed into desired features. The forming station 204 of the main turret 124 may shape the working end of the glass tube 102 to form features on one end of the glass article 103, and the forming station 204 of the secondary turret 134 may shape the other end of the glass article 103 after the glass article 103 is separated from the glass tube 102. In an embodiment, the converter 100 may 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 finishing stations, or combinations thereof, with one or more heating stations 202 positioned before and between each of the forming stations 204.

[0123] The main circuit 126 may further include a measurement station 218, which may use at least one measuring device to measure one or more attributes of the glass tube 102 or one or more dimensions of a feature of the glass article 103 formed by the forming station 204, such as diameter and thickness. One or more appearance attributes of the glass tube 102 or glass article 103 may also be evaluated at the measurement station 218. Still referring to FIG. 3 , one or more cooling stations 210 may be positioned behind the forming station 204 in the direction of rotation 222 of the main turret 124. A tube length drop station 220 may be positioned behind the forming station 204 between the forming station 204 and the separation station 206 to drop the partially formed glass tube 102 and thereby position the glass tube 102 for separation of the glass article 103 from the glass tube 102 at the separation station 206. The main circuit 126 may also include a tube loading station 214 for loading new lengths of glass tube 102 raw material into the main turret 124 from a glass tube loading turret (not shown).

[0124] Referring again to FIG. 3 , once the glass article 103 is separated from the glass tube 102 at the separation station 206, the glass article 103 may be transferred to a secondary processing station 132 of the secondary turret 134. The secondary processing station 132 may include one or more shaping stations 204 for shaping a second end of the glass article 103 opposite the first end of the glass article 103. For example, the shaping stations 204 of the secondary processing station 112 may form one or more features on the bottom (second end) of the glass article 103. The secondary turret 134 may rotate about an axis C in a direction 224 opposite to the rotational direction 222 of the main turret 124. In an embodiment, the secondary turret 134 may rotate in the same direction as the main turret 124.

[0125] The secondary processing stations 132 of the secondary circuit 136 may include one or more heating stations 202, forming stations 204, polishing stations 208, cooling stations 210, discharge stations 216, or other processing stations or combinations of secondary processing stations 132. In embodiments, the secondary processing stations 132 of the secondary circuit 136 may be used to form one or more features of the glass article 103, such as a vial, an ampoule, a cartridge, or a syringe, for example, on the end of the glass article 103 opposite the end formed by the main turret 124. For example, in embodiments, the glass article 103 is a vial and the forming station 204 of the secondary circuit 136 may form the bottom of the vial. Features such as those characteristic of ampoules, cartridges, syringes, vacutainers, bottles, and the like are also contemplated. The secondary circuit 136 may include one or more polishing stations 208 for finishing the surface of the glass article. The secondary circuit 136 may further include a plurality of cooling stations 210 and a discharge station 216 at which the finished glass articles 103 may be discharged from the converter 100 .

[0126] 1 and 3, during operation, the main turret 124 may index or move the glass tube 102 secured in the holder 140 into the processing stations 122. A specific operation may be performed at each of the processing stations 122, such as heating, forming, piercing, separating, cooling, lowering, feeding, measuring, etc. The converter 100 may be coordinated so that all of the processing stations 122 complete their operations within the dwell time. At the end of the dwell time, the main turret 124 may index the glass tube 102 to the next processing station 122 in the main circuit 126 during the index time. For an indexing converter, the total time per part per station, as used in this disclosure, is the sum of the dwell time and the index time.

[0127] In embodiments, the converter 100 may be a continuous converter operable to continuously move the glass tube 102 and holder 140 through a plurality of processing stations 122. In embodiments, heating elements, burners, forming tools, measuring devices, and other elements of the conversion process may 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 the processing station 122.

[0128] The foregoing description of the processing stations 122 in the main circuit 126 and the secondary processing stations 132 in the secondary circuit 136 may represent a typical converter 100 for producing vials from glass tubes 102. However, it is understood that more or fewer processing stations 122 and secondary processing stations 132 may be utilized to create vials having different shapes or characteristics, or other glass articles, such as, but not limited to, vacutainers, cartridges, syringes, syringe barrels, ampoules, bottles, flasks, tubing, beakers, jars, and glass articles or other pharmaceutical glass articles. Additionally, it is understood that the processing stations 122 and secondary processing stations 132 may be arranged in any of several different orders and / or configurations to produce differently shaped glass articles.

[0129] An example of a converter 100 for converting glass tubes 102 into glass vials may include a Vial Forming Machine Models RP16 or RP18 with an Automatic Tube Feeder manufactured by AMBEG Dr. J. Dichter GmbH, which includes 16 processing stations 122 in a main circuit 126 and eight secondary processing stations 132. Other examples include a Vial Forming Machine Model RP32 manufactured by AMBEG Dr. J. Dichter GmbH, which includes 32 processing stations 122 in a main circuit 126 and two secondary circuits 136 with eight secondary processing stations 132 in each secondary circuit 136, and a Zeta 098 Vial Forming Machine manufactured by Euromatic SRL, which includes 36 processing stations. Another example may include a Zeta 103 Cartridge Forming Machine manufactured by Euromatic SRL, which is a converter for converting glass tubes into glass cartridges. A cartridge converter has similar characteristics to the previously described vial converter 100, but is utilized to produce glass articles having the form factor of a cartridge rather than a vial. Converters for forming syringes, bottles, ampoules, vacutainers, or other glass pharmaceutical containers may also be used.

[0130] Referring now to FIG. 4, the heating stations 202 of the converter 100 are schematically depicted. Each of the heating stations 202 may include one or more heating elements 301. As illustrated in FIG. 3, typically in the converter 100, the heating elements 301 may include one or more burners 302 used to heat a target area of ​​the glass tube 102 prior to a forming operation performed in the forming station 204 (FIG. 3) or a separating operation performed in the separating station 206 (FIG. 3). While FIG. 4 depicts a single burner 302, it is understood that multiple burners 302 may be employed in a single heating station 202. Each burner 302 may be fluidly coupled to a fuel gas source 304, an oxygen source 306, and optionally an air source 308. Examples of fuel gases for the burners 302 may include, but are not limited to, hydrogen, hydrocarbon fuel gases such as methane, propane, and butane, other fuel gases, or combinations thereof.

[0131] 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 generate a flame that heats at least a target region of the glass tube 102.

[0132] 5 and 6, examples of forming stations 204 of the converter 100 are schematically depicted. Each forming station 204 may include one or more forming tools 324 rotatable about a tool axis E relative to the base 120 (FIG. 1). As the glass tube 102, heated in the previous heating station 202, is rotated by the holder 140 as it passes through the forming station 204. The forming tools 324 may engage with the glass tube 102 as it rotates. Once engaged, contact between the forming tools 324 and the heated glass tube 102 may form the glass tube 102 into a desired shape. The forming tools 324 may contact the glass tube 102 during an active time of the forming tools 324. At the end of the active time, a forming tool actuator 326 may remove the forming tool 324 from engagement with the glass tube 102. FIG. 5 schematically illustrates one embodiment of a forming station 204 for forming the shoulder 142 of a glass vial. 6 schematically depicts an exemplary embodiment of a forming station 204' for forming the flange 144 of a glass vial. The forming station 204' for forming the flange 144 comprises three forming tools 324a, 324b, and 324c. Other types of forming tools 324 may be employed within the forming station 204 depending on the desired features of the glass article 103.

[0133] 5 , the forming tool actuator 326 may 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 may control the timing of contact between the forming tool 324 and the glass tube 102. The timing of contact between the forming tool 324 and 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 may adjust the total contact time each of the forming tools 324 contacts the glass tube 102. The 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 may further be operable to change the position of the forming tool 324 vertically (e.g., in the + / -Z direction of the coordinate axes in FIG. 3), horizontally (e.g., in the XY plane identified by the coordinate axes in FIG. 4), or a combination of these directions relative to the glass tube 102 at the forming station 204.

[0134] Referring now to Figure 7, a conventional separation station 206 of the converter 100 is schematically depicted. The conventional separation station 206 depicted in Figure 7 is a thermal separation station and is positioned behind one or more heating stations 202 in the direction of rotation 222 of the main turret 124. The heating stations 202 positioned before the separation station 206 preheat the glass tubes 102. The conventional separation station 206 has at least one separation burner 348. The separation burner 348 can have any of the features previously described for the burner 302, including, but not limited to, a fuel gas control valve 310, an oxygen control valve 312, and / or an air control valve 314. While the glass tube 102, rendered viscous and deformable by the previous heating station 202, is rotated by the holder 140 about the central axis A of the glass tube 102, a separation burner 348 engages the outer surface 140 of the glass tube 102 and heats 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 turret 134 (FIG. 1) or ejected from the converter 100. Similar to the heating station 202, the separation station 206 may also include a burner positioner 318 coupled to the separation burner 348. The burner positioner 318 may be operable to change the orientation of the separation burner 348 vertically (e.g., in the + / -Z direction of the coordinate axes in FIG. 3), horizontally (e.g., in the XY plane identified by the coordinate axes in FIG. 7), or a combination of these orientations relative to the glass tube 102 at the separation station 206.

[0135] In conventional converting machines, gas burners are primarily used in the preheating, shaping, and separation steps. In heating station 202, extensive heating is required to raise the temperature of the glass tube to a temperature suitable for thermoforming or thermoseparation, such as temperatures of 1000°C or higher, depending on the glass composition. Additional heating using different flame configurations is then applied to enable product shaping using mechanical glass shaping tools, followed by part separation, inspection, annealing, and packaging of the final product. While existing converting processes using gas burners for heating and separation are well established and have been in use for quite some time, these conventional converting processes present many challenges and areas for improvement, particularly in light of the increasing demand for pharmaceutical products and the increased focus on process high quality, manufacturing efficiency, and environmental sustainability.

[0136] One of the challenges with existing conventional converting processes is production throughput. Typically, part speeds in vial production range from approximately 30 to 60 parts per minute, depending on the wall thickness, nominal diameter of the glass tube, and / or the glass composition of the glass tube. The bottleneck in increasing part speed is primarily the glass heating efficiency of the gas burner, which is limited by the surface absorption of heat and by the thermal conductivity through the glass body. Finding a new heat source with potentially higher heat transfer through the glass as an alternative to the flame from a gas burner could potentially increase part speeds in converters. Furthermore, heating gas burners can be inaccurate, 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 changing the heating rate. Reduced precision, stability, and control of the gas burner can lead to dimensional inaccuracies in the finished glass articles, which can increase the number of rejects and reduce the overall yield of glass articles from glass tubes. Providing a new heat source that is more accurate, stable, and better controlled compared to gas burners can provide better dimensional accuracy of glass articles, reduced number of rejects, and higher yields.

[0137] Furthermore, the use of gas burners can result in undesirable contamination of the surface of the glass article, such as contamination resulting from contact of the gas burner flame with 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, to produce combustion products that are exhausted from the process. These combustion gases often need to be treated before being discharged. The use of fossil fuels to power the gas burners can further increase the carbon footprint of the conversion process.

[0138] The present application is directed to a converter and conversion process that involves the application of high-intensity laser radiation in the far-infrared spectrum (i.e., wavelengths from about 4 μm to about 12 μm), to which glass is essentially opaque, as an alternative heat source for heating glass tubing, separating articles from the working end of the glass tubing, or both. In particular, the present application is directed to a system for producing glass articles from glass tubing, the system comprising a converter having multiple processing stations and at least one laser system located in at least one heating station, separating station, or a combination thereof. The laser system is operable to generate a laser beam, modify one or more characteristics of the beam, and direct the laser beam to the glass tubing at the heating station, separating station, or both. The laser beam(s) is generated by a laser system or multiple laser systems operating in the IR wavelength range, which has high absorption in glass, which is essentially opaque to laser radiation.

[0139] The present application is also directed to a method for converting a glass tube into multiple glass articles using the system disclosed herein. The disclosed method is based on rapid heating of the glass tube with laser beams of different shapes and spatial power distributions to a temperature where the glass viscosity allows shaping by an external mechanical shaping tool through internal glass stresses, surface tension, and possibly expansion or compression forces in combination with gravity. Heating the glass tube with laser beam(s) can be used to separate the glass article from the working end of the glass tube.

[0140] The systems and methods disclosed herein may enable more stable, precise, and controllable heat delivery to the glass tube due to the well-defined region affected by the laser beam and the stability of the laser power over time. Precise heating by the laser system can reduce dimensional variations in the final part, reduce the number of rejects, and increase yields by tightly controlling the glass viscosity during the forming and separating steps. In particular, the laser power of the laser system herein can be tightly controlled to provide uniform heating to the glass tube without causing glass damage, such as glass ablation or vaporization caused by excessive laser power. The use of a laser beam can enable tight control of the area and / or volume of glass heated by the laser beam. The laser system providing the laser heat source can be integrated into conventional converting equipment, which may reduce the number of burners in a hybrid system or enable the design of an all-laser converting system. Single or multiple laser systems can be used to enable tube preheating, bottom forming, and separation with different beam shapes, orientations, and powers. The laser beam optics allow for precise beam focusing on the glass and are not subject to alignment sensitivity that burners can be susceptible to as they wear or change over time due to degradation or machining tolerances.

[0141] The laser system at the separation station can allow the separation process to be adjusted to create a bottom portion of the glass article or to separate the glass article while maintaining the open ends of the glass article and glass tube. When forming a bottom or open end on the glass article, the laser system at the separation station can allow separation of the glass article and finishing of the end of the glass article to be achieved in a single processing step using a single processing station. The transition from forming an open end to forming a bottom portion on the glass article can be achieved by quick and easy modifications to 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 change the thickness of the bottom portion of the glass article.

[0142] The systems and methods disclosed herein do not use combustion of gases to heat the glass and do not produce combustion products. Reducing combustion products can reduce contamination of the glass due to contact between the burner flame and the glass and chemical reactions and interactions with the combustion products. Reducing the use of burners can improve the chemical neutrality of the conversion process. Reducing the number of gas burners can also reduce or eliminate process emissions of combustion products, which can contribute to greener and more environmentally friendly manufacturing practices, among other features.

[0143] Referring again to FIG. 1 , one embodiment of a system 400 of the present disclosure for producing glass articles from glass tubes 102 is graphically depicted. The system 400 may include a converter 100 comprising a plurality of spaced-apart processing stations 122 arranged in a circular path and at least one holder 140. The converter 100 may have any combination of the features previously discussed herein for the converter 100. In an embodiment, the plurality of heating stations 122 comprises at least one heating station, at least one forming station, and a separation station. Each of the holders 140 is operable to hold a glass tube 102 and rotate the glass tube 102 about a central axis A of the glass tube 102. The converter 100 is operable to continuously translate the holder 140 and the glass tube 102 secured therein through each of the processing stations 122. The system 400 may further include at least one laser system 410, such as one or more laser systems 410. At least one laser system 410 may be disposed in at least one heating station, at least one separation station, or both. The laser system 410 may include a laser source 412 and a beam delivery system 420. The laser system 410 may be operable to generate a laser beam 414, modify one or more characteristics of the laser beam 414, and direct the laser beam 414 to the glass tube 102 when the glass tube 102 is in the heating station or the separation station.

[0144] 8, a 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 the laser beam 414 and direct the laser beam 414 to the glass tube 102 at a separation station or heating station. In FIG. 8, the laser system 410 is depicted in a laser separation station 440 operable to separate the glass article from the working end 107 of the glass tube 102. Additionally or alternatively, in embodiments, the laser system 410 may be disposed in a heating station 202, such as the heating station 202 depicted in FIG.

[0145] The laser source 412 may be operable to generate a laser beam 414. The laser beam 414 may have a wavelength in a wavelength range that allows the laser beam 414 to be absorbed by the glass of the glass tube 102, heating the glass, and not pass through the glass in significant amounts (i.e., very little of the laser beam 414 passes through the glass). Because silicate-based glass has strong absorption of light having wavelengths of about 4 micrometers (μm) or greater, many different laser sources can be used to generate the laser beam 414. The laser source 412 may be operable to generate a laser beam 414 having a wavelength in the infrared wavelength range, such as the far-infrared range. The laser source 412 may be operable to generate a laser beam 414 having a wavelength of about 1 μm or greater, about 2 μm or greater, about 3 μm or greater, about 4 μm or greater, or even about 8 μm or greater. The laser source 412 may be operable to generate a laser beam 414 having a wavelength of about 12 μm or less, or even about 11 μm or less. The laser source 412 may 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 particular wavelength range may depend in part on the type of glass composition comprising the glass tube 102.

[0146] The laser source 412 may be operable to generate a laser beam 414 that is an infrared laser beam. In embodiments, the laser source 412 may be a CO laser, a CO laser, a quantum cascade laser (QCL), or any other type of suitable laser capable of generating a laser beam 414 having a wavelength in the above range. The laser source 412 may be operable to generate a continuous or pulsed laser beam 414. A continuous laser generally has a lower peak power and increases the glass surface temperature gradually, while a pulsed laser generally has a higher peak power for a shorter period of time and increases the glass surface temperature to a greater extent compared to a continuous laser.

[0147] Referring again to FIG. 1 , the beam delivery system 420 may be positioned downstream from the laser source 412. The beam delivery system 420 may be operable to modify characteristics of the laser beam 414, such as the shape, power density distribution, other beam characteristics, or a combination thereof. The beam delivery system 420 may further be operable to direct the laser beam 414 to the glass tube 102 when the glass tube 102 is disposed in a processing station 122, such as the separation station 206, one of the heating stations 202, or a combination thereof. The beam delivery system 420 may comprise one or more shaping optics, turning mirrors, beam splitters, or a combination thereof. In an embodiment, the beam delivery system 420 may comprise at least one shaping optic and at least one turning mirror.

[0148] 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 round, Gaussian laser beam. The beam delivery system 420 may include optical components that convert the round shape of the 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 both 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, polygon mirrors, or combinations thereof to change 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, which may be operable to modify the beam size, such as by increasing the beam size of the laser beam 414. In embodiments, the beam delivery system 420 may comprise one or more cylindrical lenses that may be operable to modify the shape of the laser beam 414, such as modifying the beam length, beam width, or both of the laser beam 414. In embodiments, the beam delivery system 420 may comprise multiple cylindrical lenses that are operable to transition the laser beam 414 from having a round 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.

[0149] In embodiments, the beam delivery system 420 may include one or more lenses operable to modify the power density distribution of the laser beam 414. In embodiments, the beam delivery system 420 may include one or more spherical cylindrical lenses operable to generate a laser beam 414 having a Gaussian power density distribution. In embodiments, the beam delivery system 420 may comprise one or more aspherical cylindrical lenses operable to generate a laser beam 414 having a flat-top power density distribution. In embodiments, the beam delivery system 420 may include one or more polygon mirrors operable to modify the power density distribution of the laser beam 414. In embodiments, the laser beam 414 is an elliptical beam, and the cylindrical lens, aspherical cylindrical lens, or polygon mirror may be configured to modify the power density distribution in the direction of the major axis.

[0150] Referring now to FIG. 9, a graph depicts power density (y-axis) as a function of position within the beam (x-axis) for two different power density distributions of a laser beam. The position within the beam in FIG. 9 refers to the position within the laser beam in a direction along the major axis of the elliptical beam. As shown in FIG. 9, the Gaussian power density distribution 902 is characterized by a maximum laser power density at the center 900 of the laser beam and a decrease in power density as the distance from the center 900 of the laser beam increases. In contrast, the flat-top power density distribution 904 has a smaller maximum power density, but the power density is more uniform across most of the major axis of the laser beam.

[0151] 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., operable to modify one or more characteristics of the laser beam 414 upstream of where the laser beam 414 enters the glass tube 102. The beam delivery system 420 may, within limits, provide for adjustment of the distance between various components (e.g., lenses, mirrors, filters, prisms, etc.). Some adjustment of the distance between the optical components of the beam delivery system 420 may allow for fine adjustment of the size and position of the laser beam 414 where it contacts the glass tube 102 at the processing station. In embodiments, the beam length and beam width of the laser beam 414 may be modified by changing the distance between lenses and other optical components in the beam delivery system 420.

[0152] As shown in FIG. 8 , in embodiments, the laser system 410 may be oriented so that the laser beam 414 travels in a straight line directly from the laser source 412 through the beam delivery system 420 to the glass tube 102. Referring now to FIG. 10 , in embodiments, the laser system 410 may not be oriented so that the laser beam 414 can travel in a straight line between the laser source 410 and the glass tube 102 due to space constraints or other considerations. In embodiments, the laser system 410 may include one or more turning mirrors 422 that may be operable to direct the laser beam 414 toward the glass tube 102 at the processing station 122. The turning mirrors 422 may allow the laser source 412 and beam delivery system 420 to be mounted at a distance 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 at the processing station 122. In an embodiment, the laser system 410 may include one or more beam splitters 460, which may be operable to split the laser beam 414 into two or more separate laser beams 414, which may be directed to different processing stations 106 of the converter 100.

[0153] Referring again to FIG. 8 , in an embodiment, the system 400 may further include a laser system positioner 430 operably coupled 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., the position in the + / −Z direction of the coordinate axes in FIG. 8 ), which may change the vertical position of the laser beam 414 relative to the glass tube 102. The laser system positioner 430 may also be capable of changing the orientation of the laser system 410 in the horizontal plane (i.e., the XY plane of the coordinate axes in FIG. 8 ). The laser system positioner 430, one or more turning mirrors 422 ( FIG. 10 ), or both may be used to change the beam path of the laser beam 414 so that it 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 rail 432, a laser support 434 coupled to the laser system 410, and an actuator 436 that movably secures the laser support 434 to the rail 432. The actuator 436 may be operable to translate the laser support 434 and the laser system 410 along the rail 432 in the + / -Z direction of the coordinate axes in FIG. 8. The actuator 436 may be a stepper motor or other device operable to move the laser support 434 along the rail 432 in the + / -Z direction of the coordinate axes in FIG. 8. Although depicted in FIG. 8 as having a rail 432, laser support 434, and actuator 436, it is understood that the laser system positioner 430 may include other types of apparatus, such as a hydraulic or pneumatic positioner, a scissor lift, pulleys, robotics, or other devices, or combinations of devices suitable for moving the laser system 410 relative to the glass tube 102 in a processing station. In an embodiment, the laser system positioner 430 may be manually adjusted to change the position of the laser support 434 .

[0154] In embodiments, the laser system positioner 430, the turning mirror 422, or both may be operable to position the laser system 410 relative to the glass tube 102 so that the glass tube 102 is located at the center of the beam waist of the laser beam 414. The beam waist refers to the region of the beam path of the laser beam 414 where the power density of the laser beam 414 is greatest. In embodiments, the laser system positioner 430 may be adjusted to position the laser system 410 so that the glass tube 102 is disposed at a converging or diverging section of the laser beam 414 to reduce the power density of the laser beam 414 at the point along the beam path where the laser beam 414 enters the glass tube 102. Changing the position of the laser system 410 to move the beam waist closer to the glass tube 102 may increase the power density of the laser beam 414 at the point where the laser beam 414 contacts the glass tube 102. Conversely, changing the position of the laser system 410 to move the beam waist further away from the glass tube 102 may decrease the power density of the laser beam 414 where it contacts the glass tube 102 .

[0155] In addition, 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 in a more converging or diverging portion of the beam path) can cause the laser beam 414 to have a larger beam width and length at the point in the beam path where the laser beam 414 is incident 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 cause the separated laser beam 132 to have a reduced beam width and length of the laser beam 414 at the point in the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102.

[0156] 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 that includes optics 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 a target region 426 (FIG. 21) of the glass tube 102. A laser system positioner 430, one or more turning mirrors 422, or both, can be used and / or adjusted to direct the laser beam 414 toward the separation region 424 or the target region 426 (FIG. 20) of the glass tube 102.

[0157] Referring again to FIG. 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 embodiments, 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.

[0158] Laser beam 414 may have an overall laser power of 50 watts (W) or more, 100 W or more, 200 W or more, or 500 W or more. In embodiments, laser beam 414 may have an overall 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 laser beam 414 may be adjusted depending on the beam width of laser beam 414, increasing the power to increase the beam width of laser beam 414. In embodiments, laser beam 414 may be an elliptical beam having a narrow beam width (FIG. 13), and laser beam 414 may have a laser power of about 50 W to about 500 W, such as 50 W to 200 W, 100 W to 500 W, 100 W to 200 W, or 200 W to 500 W. In embodiments, laser beam 414 may be an elliptical beam having a wide beam width (FIG. 12), and laser beam 414 may have a laser power of about 500 W to about 2000 W, such as 500 W to 1500 W, or 500 W to 1000 W.

[0159] The heating rate of the laser beam 414 for heating the glass tube 102 can be increased or decreased by increasing or decreasing the laser power density of the laser beam 414. In embodiments, the laser beam 414 can have a laser power density sufficient to produce a glass tube heating rate of about 200° C. per second to about 400° C. per second. The laser beam 414 can be characterized by a power density distribution. The heating rate of the laser beam 414 can be modified by changing the power density distribution of the laser beam 414. As previously discussed, in embodiments, the laser beam 414 modified by the beam delivery system 420 can have a Gaussian power density distribution along the major axis (e.g., length) of the laser beam 414. In embodiments, the laser beam 414 modified by the beam delivery system 420 can have a flat-top power density distribution along the major axis (e.g., length) of the laser beam 414. The methods disclosed herein can include modifying the power density distribution of the laser beam 414, where modifying the power density distribution changes the heating rate of the laser beam 414.

[0160] The laser beam 414, as modified by the beam delivery system 420, may be a round beam or an elliptical beam. Referring now to Figure 11, in an embodiment, the laser beam 414 may be a round beam having a cross-sectional shape that is generally circular. When the laser beam 414 is a round beam, the laser beam 414 is shaped such that it is elliptical at the point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102. t The beam diameter D is approximately 1.25 times or less bThe beam shape 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, the plane being located along the beam path where the laser beam 414 first contacts the outer surface of the glass tube 102. In embodiments, the laser beam 414 has a beam diameter D that is less than about 1.25 times the outer diameter of the glass tube 102, such as about 0.5 to about 1.25, about 0.5 to about 1.1, about 0.5 to about 1, about 0.75 to about 1.25, about 0.75 to about 1.1, about 0.75 to about 1, about 0.9 to about 1.25, about 0.9 to about 1.1, about 0.9 to about 1, about 1 to about 1.25, 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 the point along the beam path where the laser beam 414 is incident on the exterior surface of the glass tube 102. b In an embodiment, the laser beam 414 may be a round beam having a beam diameter D greater than about 50 mm. b It may be a round beam having

[0161] 12-14, in embodiments, 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 orient the laser beam 414 so that the major axis of the elliptical laser beam 414 is perpendicular (FIGS. 12 and 13) or parallel (FIG. 14) to the central axis A of the glass tube 102. Referring to FIGS. 12 and 13, in embodiments, the laser beam 414 may have a ratio of the major axis to the minor axis of 2 or greater, 5 or greater, or even 10 or greater at the point along the beam path where the laser beam 414 is incident on the outer surface of the glass tube 102. In embodiments, the laser beam 414 may be an elliptical laser beam having a ratio of the major axis to the minor axis 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 the point along the beam path where the laser beam 414 is incident on the exterior surface of the glass tube 102.

[0162] As shown in FIG. 8, when the laser system 410 is disposed in the separation station 206, the ratio of the major axis to the minor axis (i.e., the beam length L to the beam width W) is BThe ratio of the heating rate (°C) to the working end 107 of the glass tube 102 may be modified to create 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, in the separation region 424, the glass thins and stretches until the glass eventually separates and forms the glass article 103, which is separated from the working end 107 of the glass tube 102. Upon separation, surface tension within the glass may cause a volume of viscous glass on either side of the separation point to flow back into 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 may be large enough that the viscous glass flowing back into the new end of the glass article 103 may form a meniscus across the end of the glass article 103. Forming a meniscus of glass across the end of the glass article 103 may provide the bottom of the glass article 103. In embodiments, the volume of glass heated by laser beam 414 may not be sufficient to form a meniscus such that the new end of glass article 103 is open.

[0163] 12 and 13, the ratio of the major axis to the minor axis of the laser beam 414 affects the volume of glass in the glass tube 102 heated at the separation station 206. Referring to FIG. 13, to form an open end at the working end 107 of the glass tube 102 after separation, the laser beam 414 may be an elliptical beam with a large ratio of the major axis to the minor axis, which results in a narrow beam that heats a small volume of glass that is just enough to separate the glass article from the glass tube 102, but not enough to form a meniscus of glass across the end of the glass tube 102 and the glass article. In embodiments, the separation station may be configured to form open ends on the glass tubes and glass articles, and the laser beam 414 has a ratio of major axis to minor axis (i.e., beam length L to beam width W) of about 4 to about 100, such as 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 exterior surface of the glass tube 102.B The ratio of the major axis to the minor axis of the laser beam 414 to produce an open bottom may depend on the outer diameter, wall thickness, glass composition, or a combination thereof, of the glass tube 102 being processed.

[0164] 12 , to form closed ends on the glass tube 102 and the worked end 107 of the glass article after separation, the laser beam 414 may be an elliptical beam having a ratio of major axis to minor axis such that the laser beam 414 heats more glass than is sufficient to form a meniscus of glass across the worked end of the glass tube 102 and the glass article. In an embodiment, the separation station may be configured to form closed ends on the glass tube 102 and the glass article, and the laser beam 414 has a ratio of major axis to minor axis (i.e., beam length L to beam width W) of about 2 to about 12, such as 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 ratio of the major axis to the minor axis of the laser beam 414 to produce a closed bottom may depend on the outer diameter, wall thickness, glass composition, or a combination thereof, of the glass tube 102 being processed. When forming a closed end on the working end of the glass tube 102 at 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, such as when the glass article is a vial, bottle, or other closed-bottom container.

[0165] 12-14 , in an embodiment, the laser beam 414 may be an elliptical beam and have a beam length L that is 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, about 0.5 to about 1.1, about 0.5 to about 1, about 0.75 to about 1.25, about 0.75 to about 1.1, about 0.75 to about 1, about 0.9 to about 1.25, about 0.9 to about 1.1, about 0.9 to about 1, about 1 to 1.25, or about 1 to about 1.1 times the outer diameter of the glass tube 102. BIn 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 also be greater than about 50 mm. B refers to the distance across the laser beam 414 along its major axis at the point along the beam path where the laser beam 414 is incident on the exterior surface 104 of the glass tube 102. As used herein, the beam length L of the laser beam 414 B refers to the maximum distance across the laser beam 414 in a direction parallel to the major axis at this point, rather than the average length taken across the beam width. 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 shaped laser beam 414 B is the outer diameter D of the glass tube 102 t The selected value may be based in part on the

[0166] The laser beam 414 may have a beam width W of about 0.5 mm to about 20 mm at the point along the beam path where the laser beam 414 is incident on the exterior surface 104 of the glass tube 102. The beam width W refers to the maximum width of the beam along a direction parallel to the minor axis of the laser beam 414 at the point along the beam path where the laser beam 414 is incident on the exterior 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 the point along the beam path where the laser beam 414 is incident on the exterior surface of the glass tube 102.

[0167] The beam width W of the laser beam 414 may 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 disposed in the separation station 206, the beam width W of the laser beam 414 may be modified to change the volume of glass heated during separation of the glass article from the working end 107 of the glass tube 102. Changing the volume of glass heated during separation may allow for the formation of open or closed ends on both the working end of the glass tube 102 and the end of the glass article separated from the working end.

[0168] Referring now to FIG. 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, is achieved by reducing the thickness of the glass tube, the outer diameter D tDepending on the thickness, outer diameter, and glass composition of the glass tube, this may result in forming an open end of the glass tube 102 and the glass article during separation. Referring now to FIG. 12, as shown in FIG. 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, may result in forming 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 a closed end on the glass tube 102 and the glass article during separation, further increasing the beam width W of the laser beam 414 may further increase the volume of glass heated during separation, thereby increasing the thickness of the closed end and thereby increasing the thickness of the bottom of the resulting glass article. Similarly, decreasing the beam width W of the laser beam 414 may reduce the volume of glass heated during separation, thereby resulting in a thinner closed end and a thinner bottom of the glass article. B Varying the shape of the laser beam, such as by changing the beam width W, may change the volume of glass heated in the target or isolated region of the glass tube 102.

[0169] 14 , in embodiments, the optics of the beam delivery system 420 may be configured to shape the laser beam 414 into an elliptical shaped beam and to orient 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. Orienting the laser beam 414 so that the major axis is parallel to the central axis A of the glass tube 102 may allow the laser beam 414 to heat a larger volume of glass while separating the glass article from the glass tube 102. As shown in FIG. 14 , the laser beam 414 may be shaped into an elliptical beam having a beam length L B12, the laser beam 414 may be oriented such 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. Orienting the laser beam 414 so that the long axis is parallel to the central axis A of the glass tube 102, as in Figure 14, may allow for forming an even thicker bottom portion on the glass article compared to simply increasing the beam width W of the laser beam 414, as shown in Figure 12.

[0170] 15, in embodiments, a laser system 410 may be configured to generate two laser beams and direct the two laser beams onto the exterior surface of the glass tube 102. The two laser beams may be generated by having two separate laser light sources or by having a single laser light source and splitting the laser beam one or more times. While the two laser beam embodiments are described herein with reference to two separate laser light sources in two separate laser systems, it will be understood that two or more laser beams may be generated by using a single laser light source to generate a single laser beam and then splitting the laser beam using optics (e.g., beam splitter 460 in FIG. 10) to generate multiple laser beams.

[0171] 16 , in 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, and the preheating laser beam 450 may be operable to generate a preheating laser beam 454, which may be directed onto the glass tube 102 at the separation station 206. In an embodiment, the separation laser beam 444 and the preheating laser beam 454 may be overlapped with each other 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.

[0172] Separate laser system 440 may include a separate beam delivery system 442 disposed beam downstream from laser source 412. Separate beam delivery system 442 may be operable to modify the shape of separate laser beam 444 to have an elliptical cross-sectional shape with a desired beam length and beam width. Separate beam delivery system 442 may have any of the components or features previously described in conjunction with beam delivery system 420. Separate 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 characteristic previously described in conjunction with laser beam 414.

[0173] The preheating laser system 450 may include a preheating beam delivery system 452 downstream from the laser source 412. The preheating beam delivery system 452 may be operable to generate a preheating laser beam 454 having a round cross-sectional shape with a desired beam diameter. The preheating beam delivery system 452 may have any of the components or features previously described in conjunction with the beam delivery system 420. The preheating laser beam 454 may have the wavelength, laser power density, power density distribution, beam shape, or any other characteristic previously described in conjunction with the laser beam 414. In embodiments, the preheating laser system 450 may further include one or more turning mirrors 422 operable to direct the preheating laser beam 454 toward the glass tube 102. Although not shown in FIG. 16 , in embodiments, the separation laser system 440 may include one or more turning mirrors 422 operable to direct the separation laser beam 444 toward the glass tube 102. The separation laser system 440, the preheat laser system 450, or both may further include a laser system positioner 430 (FIG. 8).

[0174] Referring again to Figure 15, there is shown a schematic depiction of the superposition of the preheating laser beam 454 and the separation laser beam 444 on the separation region 424 of the glass tube 102. As shown in 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 a round beam having a generally circular cross-section. The laser system positioner 430 (Figure 8) may operate to change the relative positions of the separation laser beam 444 and the preheating laser beam 454.

[0175] Referring again to FIG. 8 , the separation station 206 of the converting machine 100 may include one or more laser systems 410 instead of a separation burner for separating the glass article from the glass tube 102. In embodiments, 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. Referring to FIG. 16 , in embodiments, the separation station 206 may include a laser system 410 that can generate multiple laser beams, such as a laser system 410 that includes a separation laser system 440 and a preheating laser system 450, as previously discussed herein. The separation station 206 may include one or more laser system positioners 430 that are operable to change the position of one or more of the laser beams (e.g., laser beam 414, separation laser beam 444, preheating laser beam 454, or a combination thereof) relative to the glass tube 102. In embodiments, the separation station 206 may further include a chuck 240, roller, or other device 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.

[0176] 8 , the operation of the separation station 206, which includes the laser system 410, to separate the glass article from the working end 107 of the glass tube 102 will now be described in further 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 a 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 a laser beam 414, which may heat the glass of the glass tube 102 at the separation region 424. Separating the glass article from the glass tube 102 may further include applying a separation force F to the glass article (e.g., a force applied axially away from the glass tube 102, such as a force applied in the −Z direction of the coordinate axes in FIG. 8 ) while exposing the separation region 424 to the laser beam 414. Applying the separation force F to the glass article may cause the glass article to separate from the working end 107 of the glass tube 102 at the separation region 424 when the glass in the separation region 424 reaches a temperature at which the glass is deformable. 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 finish the end of the glass article.

[0177] Exposing the separation region 424 of the glass tube 102 to the laser beam 414 may include generating the laser beam 414 using a laser source 412, modifying the laser beam 414 using 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 may be turned on and off to begin and end the exposure of the glass tube 102 to the laser beam 414. In embodiments, separating the glass article from the glass tube 102 may include exposing the separation region 424 of the glass tube 102 to the laser beam 414 having 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 exterior surface of the glass tube 102 at the separation region 424. In embodiments, the laser beam 414 may have a wavelength in a range of about 1 μm to about 12 μm, or about 5 μm to about 11 μm. The laser beam 414 may 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 in the separation region 424 to a separation temperature at which the glass becomes viscous and deformable, such as a separation temperature of about 1000° C. or greater.

[0178] The separation region 424 of the glass tube 102 may be exposed to the laser beam 414 for an exposure time sufficient to raise the temperature of the glass to a separation temperature. In embodiments, the exposure time of the glass tube 102 to the laser beam 414 at the separation station 206 may be shorter 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 times that the laser source 412 of the laser system 410 for generating the laser beam 414 is turned on and then turned off.

[0179] As previously discussed, the laser beam 414 in the separation station 206 may have a heating rate of the glass tube 102 of about 200° C. per second to about 400° C. per second. As previously discussed, the heating rate of the laser beam 414 for heating the glass tube 102 may 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 embodiments, decreasing the cross-sectional area of ​​the laser beam 414 at a constant power density (e.g., decreasing the diameter of a round beam or decreasing the width of an elliptical beam) may increase the heating rate of the laser beam and decrease the volume of glass heated by the laser beam 414. Conversely, increasing the cross-sectional area of ​​the laser beam 414 may distribute the laser power over a larger area, which may decrease the heating rate and increase the volume of glass heated by the laser beam 414.

[0180] 8 , separating the glass articles from the glass tube 102 in the separation station 206 may further include applying a separation force F to the glass articles while exposing the separation region 424 of the glass tube 102 to the laser beam 414. Applying the separation force F may move the glass articles axially away from the working end 107 of the glass tube 102 (i.e., in the −Z direction of the coordinate axes in FIG. 8 ). In embodiments, the glass tube 102 may be oriented vertically at the separation station with the working end 107 of the glass tube 102 facing downward (i.e., in the −Z direction), and the separation force F may include gravity. In embodiments, applying the separation force F may include applying a mechanical separation force to the glass articles. Applying a mechanical force to the glass articles at the separation station may assist in separating the glass articles from the glass tube 102 if the weight of the glass articles is insufficient to separate them from the glass tube by gravity alone, or if the glass tube 102 is not vertically oriented at the separation station (e.g., if the converter is oriented horizontally rather than vertically). In an embodiment, the separation station 206 may comprise a chuck, angled roller, or other device capable of applying a mechanical separation force to the glass articles.

[0181] Referring to FIG. 8 , in embodiments, 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 a laser beam 414 having an elliptical cross-section, which may have a major axis and a minor axis. The laser beam 414, which is an elliptical laser beam, may have a ratio of the major axis to the minor axis ranging from 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 embodiments, the laser system 410 may be configured to orient the laser beam 414 with its major axis perpendicular to the central axis A of the glass tube 102. In embodiments, the laser system 410 may be configured to orient the laser beam 414 with its major axis parallel to the central axis A of the glass tube 102.

[0182] In embodiments, separating the glass article from the working end 107 of the glass tube 102 may include forming an open end on 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 an open end on 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 with its long axis perpendicular to the central axis A of the glass tube 102, thereby reducing the width of the laser beam 414. To generate an open end during separation at the separation station 206, the laser beam 414 may have a beam width of about 0.5 mm to about 5 mm, such as 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 the point along the beam path where the laser beam 414 is incident on the exterior surface of the glass tube 102 in the separation region 424. The beam width of the laser beam 414 for generating the open end may be adjusted based on the diameter, thickness, glass composition, or a combination thereof, 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 may be increased to heat a larger volume of glass, ensuring that separation of the glass article can be achieved during the converter dwell time.

[0183] Exposing the separated section 424 of the glass tube 102 to a laser beam 414 having a narrower beam width may detach the glass article from the working end 107 of the glass tube 102 and create a new end of the glass tube with an opening. The narrower beam width of the laser beam 414, in the range of 0.5 mm to 5 mm, may result in heating a volume of glass in the separated region that is not sufficient to form a glass meniscus across the new working end 107 of the glass tube 102. Separating the glass article from the working end of the glass tube 102 while forming an open end at the new working end 107 of the glass tube 102 may allow the downstream drilling station to be removed from the converter or reconfigured to another type of processing station, such as, but not limited to, a heating station 202, a measuring station, a cooling station, a forming station, a loading station, or another type of processing station.

[0184] The laser beam 414 may have a beam length that is 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 the 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 embodiments, 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 the 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. B The beam length of the laser beam 414 may depend in part on the outer diameter of the glass tube 102. To create an open end on the glass tube 102 and the glass article, the laser beam 414 may have a ratio of its major axis to its minor axis that is about 4 to about 70, such as 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 is incident on the outer surface of the glass tube 102 in the separation region 424.

[0185] In embodiments, separating the glass article from the working end 107 of the glass tube 102 may include shaping a bottom of the glass article while separating the glass article from the working end 107 of the glass tube 102. Shaping the bottom of the glass article may also form a closed end at the working end 107 of the glass tube 102 after separation. The laser system 410 in the separation station 206 may be configured to generate a closed end at the working end 107 of the glass tube 102 and an end 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 region 424 of the glass tube 102, the heated volume of glass being sufficient to form a meniscus of glass throughout the working end 107 of the glass tube 102 and across the end of the glass article during separation of the glass article from the glass tube 102.

[0186] To heat a larger volume of glass sufficient to form a glass meniscus across the entire 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 given beam length compared to a laser beam for creating an open end. To form a closed end, the laser beam 414 at the separation station 206 can have a beam width of approximately 3 mm to 10 mm, such as 5 mm to 10 mm, or 6 mm to 10 mm, at the point along the beam path where the laser beam 414 is incident on the exterior surface of the glass tube 102. The beam width of the laser beam 414 for creating a closed end can be affected by the diameter, thickness, glass composition, or a combination thereof, of the glass tube 102. When forming closed ends on the glass tube 102 and glass article, the beam delivery system 420 can be configured to produce a laser beam 414 having an elliptical cross-section with a major axis to minor axis ratio of about 2 to about 12, such as 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 exterior surface of the glass tube 102.

[0187] Referring again to FIG. 8 , the thickness of the bottom of the glass article can be increased or decreased by increasing or decreasing the beam width of the laser beam 414 at the separation station 206, by 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 region of the glass tube 102, which can result in a thicker meniscus being formed throughout the end of the glass tube 102 and the end of the glass article separated therefrom. Therefore, by changing the beam width of the laser beam 414, the thickness of the bottom of the glass article can be changed. 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 at the separation station 206, or both. Therefore, the beam width of the laser beam 414 at the point where it enters the glass tube 102 can be modified without changing the lenses of the beam delivery system 420 .

[0188] 14 , instead of or in addition to changing the beam width of the laser beam 414, the volume of glass in the separation region heated by the laser beam 414 can be increased by changing the orientation of the elliptical laser beam 414 so that the major axis of the elliptical laser beam 414 is parallel to the central axis A of the glass tube 102. Conversely, the volume of glass heated by the laser beam 414 can be decreased by changing the orientation of the laser beam 414 so that the major axis is perpendicular to the central axis A of the glass tube 102. The orientation of the laser beam 414 relative to the glass tube 102 can be modified by changing the orientation of one or more optical components of the beam delivery system 420 or by changing the optical components of the beam delivery system 420.

[0189] In embodiments, separating the glass article from the working end 107 of the glass tube 102 may include reducing the thickness of the bottom of the glass article. In embodiments, the laser beam 414 may be an elliptical laser beam, and reducing the thickness of the bottom of the glass article may include orienting the laser beam 414 with a major axis of the laser beam 414 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 embodiments, separating the glass article from the working end 107 of the glass tube 102 may further include increasing the thickness of the bottom of the glass article. In embodiments, the laser beam 414 may be an elliptical beam, and reducing the thickness of the bottom of the glass article may include orienting the laser beam 414 with a major axis of the laser beam 414 parallel to the central axis A of the glass tube 102, increasing the beam width of the laser beam 414, or a combination thereof.

[0190] 16 , as 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 two or more laser beams at 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 with the separation laser beam 444. In an embodiment, the separation laser beam 444 and the preheating laser beam 454 may be superimposed on the separation region 424 of the glass tube 102 .

[0191] Simultaneously exposing the separation region 424 of the glass tube 102 to the separation laser beam 444 and the preheating laser beam 454 may allow for a larger volume of glass to be heated during separation of the glass article from the glass tube 102. The preheating laser beam 454 may further increase the heating rate of the glass in the separation region 424 of the glass tube 102, thereby reducing 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 102 to the separation laser beam 444 and the preheating laser beam 454 may allow for greater control over the geometry of the bottom 112 of the glass article 103 ( FIG. 20 ) and the heel 114 of the glass article 103 ( FIG. 20 ) that are formed during separation. With reference to FIG. 20 , the heel 114 is the portion of the glass article 103 that transitions between the bottom 112 and the sidewall 110.

[0192] 15, in an embodiment, separation laser beam 444 may be an elliptical beam having a major axis and a minor axis, and preheating laser beam 454 may be a round beam having a generally circular cross-section. Separation laser beam 444 and preheating laser beam 454 may each have any of the other features, shapes, or characteristics previously discussed herein for laser beam 414.

[0193] 16 , the separated laser beam 444 may be oriented such that the major axis of the beam's elliptical cross section is perpendicular to the central axis A of the glass tube 102. In embodiments, the separated laser beam 444 and the preheating laser beam 454 may be axially aligned with the central axis A of the glass tube 102 such that the major axis of the separated laser beam 444 is aligned with the beam center of the preheating laser beam 454 (i.e., the major axis of the separated laser beam 444 and the beam center of the preheating laser beam 454 are disposed at the same axial position on the glass tube 102 when incident on the outer surface of the glass tube 102). In embodiments, the separated laser beam 444 may be axially offset with respect to the beam center of the preheating laser beam 454. By axially offset, we mean that the long axis of the separated laser beam 444 is offset in a direction parallel to the central axis A of the glass tube 102 (i.e., in the -Z direction of the coordinate axis in Figure 16) so that it is not aligned with the center of the preheating laser beam 454 at the point where the two beams enter the glass tube 102.

[0194] In embodiments, the separation laser beam 444 and the preheating laser beam 454 may be horizontally aligned (i.e., in the XY plane of FIG. 16 ) such that the minor axis of the separation laser beam 444 is aligned with the center of the preheating laser beam 454. In embodiments, the separation laser beam 444 and the preheating laser beam 454 may be horizontally centered on the glass tube 102 at the separation station 206. In FIG. 16 , the separation laser beam 444 and the preheating laser beam 454 are shown approaching the glass tube 102 from generally the same angular direction. Referring now to FIG. 17 , in embodiments, the point at which the separation laser beam 444 enters the glass tube 102 may be angularly offset from the point at which the preheating laser beam 454 enters the glass tube 102. In other words, in embodiments, the minor axis of the separation laser beam 444 may be at a different angular position on the glass tube 102 compared to the beam center of the preheating laser beam 454. The separation laser beam 444 and the preheat laser beam 454 may be angularly offset by an angle alpha (α).

[0195] As previously discussed, exposing the separation region 424 of the glass tube 102 to both the separation laser beam 444 and the preheating laser beam 454 may increase the separation rate at the separation station 206, which may reduce the dwell time required to separate the glass articles from the glass tube 102. While not intending to be bound by any particular theory, it is believed that simultaneously exposing the separation region 424 to both the separation laser beam 444 and the preheating laser beam 454 may increase the heating rate of the glass in the separation region 424 by increasing the energy density delivered to the glass in the separation region 424. This increased heating rate may reduce the time required to separate the glass articles from the glass tube 102.

[0196] As previously discussed, simultaneously exposing the separation region 424 of the glass tube 102 to the separation laser beam 444 and the preheating laser beam 454 may affect the shaping of the bottom of the glass article during separation of the glass article from the glass tube 102. In particular, exposing the separation region 424 of the glass tube 102 to the preheating laser beam 454 in addition to the separation laser beam 444 may increase the volume of glass heated during separation, thereby increasing the volume of glass formed across the ends of the glass tube 102 and the glass article during separation and the thickness of the meniscus. Furthermore, 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 can increase the thickness of the bottom of the glass article separated from the glass tube 102. Conversely, in embodiments, decreasing the beam diameter of the preheating laser beam 454, decreasing the beam width of the separation laser beam 444, or a combination of both can decrease the thickness of the bottom of the glass article separated from the glass tube 102.

[0197] 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 spaced axially (i.e., in the + / −Z direction of the coordinate axes in FIG. 18 ) from the beam center 456 of the preheating laser beam 454. In embodiments, the major axis 446 of the separation laser beam 444 may be spaced axially from the beam center 456 of the preheating laser beam 454 by an axial offset G. Varying the axial offset G between the separation laser beam 444 and the preheating laser beam 454 may change the geometry of the bottom and heel of the glass article.

[0198] 20 , a glass article 103 having a closed bottom (e.g., a vial, bottle, dish, ampoule, beaker, etc.) is graphically depicted. After separation of the glass article 103 from the glass tube 102, the glass article 103 may comprise a sidewall 110, a bottom 112, and a heel 114, which is the transition from the sidewall 110 to the bottom 112. 16 and 18 , moving the separation laser beam 444 toward the working end 107 of the glass tube 102 relative to the preheating laser beam 454 (i.e., in the −Z direction of the coordinate axes in FIG. 18 ) so that the major axis 446 of the separation laser beam 444 is closer to the working end 107 of the glass tube 102 compared to the beam center 456 of the preheating laser beam 454, by overlapping the separation laser beam 444 and the preheating laser beam 454 in the same axial location, may result in a base 112 of the glass article 103 that is flatter (i.e., has greater flatness and less curvature) and / or a heel 114 with a smaller heel radius compared to the separated glass article 103. Increasing the flatness of the base 112 and reducing the heel radius of the heel 114 may make the glass article 103 more stable against shaking and tipping.

[0199] In embodiments, the method of making the glass article 103 may include modifying the axial position of the separate laser beam 444 relative to the axial position of the preheating laser beam 454. In embodiments, the method may include moving the separate laser beam 444 toward the working end 107 of the glass tube 102 relative to the center of the preheating laser beam 454, where moving the separate laser beam 444 closer to the working end 107 of the glass tube 102 relative to the center of the preheating laser beam 154 may increase the flatness of the bottom 112 of the glass article 103, reduce the heel radius of the heel 114 of the glass article 103, or both.

[0200] In an embodiment, the preheating laser system 450 may be replaced with a burner in the separation station 206. Referring now to FIGS. 19A and 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 a 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 by about 90 degrees to about 180 degrees, or about 180 degrees, in this angular direction relative to the central axis A of the glass tube 102 in cylindrical coordinates. Burner 302 may have any of the features or characteristics previously disclosed herein for burner 302.

[0201] Where the separation station 206 comprises a separation laser system 440 and a 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 compared to the flame from the gas burner 302 may result in a flatter bottom 112 of the glass article 103 (i.e., having greater flatness and less curvature) and / or a heel 114 with a smaller heel radius compared to a glass article 103 separated by overlapping the separation laser beam 444 and the burner 302 at the same axial position. In an embodiment, a method of making a glass article 103 may 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 separation laser beam 444 toward the working end 107 of the glass tube 102 relative to the burner 302, and moving the separation laser beam 444 closer to the working end 107 of the glass tube 102 relative to the burner 302 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.

[0202] 3 , the separation station 206 may be preceded by one or more heating stations 202 disposed upstream from the separation station 206. In an embodiment, one or more of the heating stations 202 upstream of the separation station 206 may include a preheating laser system 450 operable to preheat a separation region of the glass tube 102 prior to translating the glass tube 102 into the separation station 206. The preheating laser system 450 may have any of the components or features described earlier herein for the preheating laser system 450 associated with the separation station 206.

[0203] 21 , a preheating laser system 450 in the heating station 202 upstream of the separation station 206 may be operable to generate a preheating laser beam 454, which may be a round beam having a generally circular cross-section. The preheating laser beam 454 generated by the preheating laser system 450, the heating station 202, may have any of the characteristics previously discussed herein for the laser beam 414. A method of producing glass articles from a glass tube 102 may include exposing a separation region 424 of the glass tube 102 to the preheating laser beam 454 in the heating station 202 disposed upstream of the separation station 206. In embodiments, the separation region of the glass tube 102 may be exposed to the preheating laser beam 454 in the separation station 206 and in the heating station 202 upstream of the separation station. In embodiments, the heating station 202 and the separation station 206 may each have a dedicated preheating laser system 450. In an embodiment, the system 400 may include a single preheating laser system 450 that may include a beam splitter and multiple turning mirrors operable to split the preheating laser beam 454 into multiple beams and direct one preheating laser beam 454 to the glass tube 102 at the separation station 206 and another preheating laser beam 454 to the glass tube 102 at the heating station 202 upstream of the separation station 206.

[0204] 22 , in an embodiment, the separation station 206 and the heating station 202 upstream of the separation station 206 may all have a laser system (e.g., a separation laser system 410, a preheating laser system 450, or both) for heating the glass tube 102 in the target area 424, the separation area 426, or both. In an embodiment, the separation station 206 and the heating station 202 upstream of the separation station 206 do not include a burner 302 for heating the glass tube 102. Referring now to FIG. 23 , in an embodiment, the converter 100 may 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 at the separation station 206. In an embodiment, the heating station 202 immediately preceding the separation station 206 in the rotation direction 222 may include at least one burner 302.

[0205] 1 and 8 , the system 400, including the laser system 410 disposed at the separation station 206, can increase the overall part rate of the converter 100 by reducing the time required to separate the glass articles 103 from the glass tubes 102 at the separation station 206. In embodiments, the converter 100 of the system 400 can have an overall part rate of about 30 parts per minute or more, about 35 parts per minute or more, about 40 parts per minute or more, or even about 60 parts per minute or more. In embodiments, the converter 100 of the system 400 can have an overall part rate of about 30 parts per minute to about 100 parts per minute.

[0206] In embodiments, the system 400 may have a laser system 410 for heating the glass tube 102 disposed in any one or all of the heating stations 202 of the converter 100. For example, in embodiments, the system 400 may include a laser system 410 in one or more of the heating stations 202 disposed upstream of the forming station 204, which may be operable to heat a target area of ​​the glass tube 102 with a laser beam 414 before contacting the glass tube with a forming tool. Exposing the target area of ​​the glass tube 102 to the laser beam 414 may enable faster and more precise heating of the glass in the target area of ​​the glass tube 102, which may provide greater control over the final geometry and dimensions of the 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 from the laser system 410 may have any of the features or characteristics previously described herein for the laser system 410 and the laser beam 414, respectively.

[0207] In embodiments, producing a glass article from the glass tube 102 may include rotating the glass tube 102 about a central axis A of the glass tube 102; heating a target area 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 in the target area of ​​the glass tube 102 after heating the target area of ​​the glass tube 102. Heating the target area of ​​the glass tube 102 may include exposing the target area of ​​the glass tube 102 to a laser beam 414 having a beam width of about 0.5 mm to about 10 mm and a wavelength in a range of about 1 μm to about 12 μm. Exposing the target area of ​​the glass tube 102 to the laser beam 414 heats the glass in the target area to a temperature of about 1000° C. or greater. In embodiments, the laser beam 414 in the heating station 202 may be a round beam having a circular cross-sectional shape.

[0208] In embodiments, the laser system 410 may further be used to polish the glass article after separation of the glass article from the glass tube. In embodiments, one or more of the processing stations in the secondary circuit of the converter 100 may include a laser system 410, which may be directed at one or more regions of the glass article to polish the glass article.

[0209] The system 400 disclosed herein may be utilized in methods for separating a glass article from a working end of a glass tube during conversion and in methods for forming a glass article from a glass tube during a conversion process. Referring now to FIG. 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 into a separation station 206 of a converter 100 ( FIG. 1 ). Referring to FIG. 8 , the method may include rotating the glass tube 102 about a central axis A of the glass tube 102, exposing a separation region 424 of the glass tube 102 to a laser beam 414 while rotating the glass tube 102, and applying an axial force F to the glass article in a direction axially away from the glass tube 102 (i.e., in the −Z direction of the coordinate axes in FIG. 8 ). The laser beam 414 may have any of the characteristics previously discussed for the laser beam 414 or the separation laser beam 440. Exposing the separation region 424 of the glass tube 102 with the laser beam and applying an axial force F to the glass article separates the glass article from the working end 107 of the glass tube 102. The converter 100 may have any of the components or features previously discussed herein for the converter 100.

[0210] 1, 8, and 20, a 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; heating a target region 426 (FIG. 21) of the glass tube 102 to a forming temperature while rotating the glass tube 102, the target region 426 being proximate to a working end 107 of the glass tube 102; forming at least one feature of the glass article 103 at the target region 426 of the glass tube 102 while rotating the glass tube 102 after heating the target region 426 of the glass tube 102; and separating the glass article 103 from the working end 107 of the glass tube 102 at a separation region 424 (FIG. 8) of the glass tube 102. Heating the target area 426 of the glass tube 102, separating the glass article 103 from the work end 107 of the glass tube 102, or both, includes exposing the target area 426 of the glass tube 102, the separation area 424, or both, to a laser beam 414, which may have a maximum cross-sectional dimension of 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, 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 target area 426. In embodiments, the laser beam 414 may have a maximum cross-sectional dimension of from 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 target area 426. Exposing the target area 426, the separation area 424, or both to the laser beam 414 may heat the glass tube 102 in the target area 426, the separation area 424, or both to a temperature of about 1000° C. or greater.

[0211] Referring again to FIG. 21 , in embodiments of the methods disclosed herein, heating the target area 426 of the glass tube 102 may include exposing the target area 426 to a laser beam 414 at a heating station 202 of a converter 100 ( FIG. 1 ) for forming a glass article from the glass tube 102. At the heating station 202, the laser beam 414 may be a heating laser beam. Referring again to FIG. 11 , in embodiments, the laser beam 414 at the heating station 202 may have a circular cross-section. In embodiments, the laser beam 414 at the heating station 202 may have a cross-section having a diameter of up 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 embodiments, the laser beam 414 may have a cross-section with 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.

[0212] 8 , in embodiments of the method disclosed herein, 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 a laser beam 414 at a separation station 206 of the converter 100. At the separation station 206, the laser beam 414 may be a separation laser beam. In embodiments, the method disclosed herein may further include exposing the separation region 424 of the glass tube 102 to a preheating laser beam at a heating station 202 before translating the glass tube 102 into the separation station 206. In embodiments, the heating station 202 comprising the heating laser beam may be immediately upstream of the separation station 206.

[0213] Referring again to FIG. 8 , at separation station 206, laser beam 414 may have any of the features or characteristics previously described herein for laser beam 414. In embodiments, laser beam 414 at separation station 206 may be a separated laser beam having an elliptical cross-section having a major axis and a minor axis. In embodiments, laser beam 414 at separation station 206 may have a beam length of up to about 1.25 times the outer diameter of glass tube 102, such as about 0.5 to about 1.25 times the outer diameter of glass tube 102, at the point along the beam path where laser beam 414 is incident on the outer surface of glass tube 102. In embodiments, 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 the point along the beam path where laser beam 414 is incident on the outer surface of glass tube 102. B The separating laser beam may have any of the features or characteristics previously disclosed herein for laser beam 414. In embodiments, separating the glass article from the working end 107 of the glass tube 102 may include forming an open end at the bottom of the glass article, the bottom of the glass article being the end of the glass article that was pre-bonded to the glass tube 102 prior to separation. With reference to FIG. 13 , to generate an open end of the glass article, the separating laser beam may have a beam width of about 0.5 mm to about 5 mm. In embodiments forming an open end on the glass article, the separating laser beam may be an elliptical beam having a ratio of the major axis to the minor axis of about 4 to about 70.

[0214] In embodiments of the methods disclosed herein, separating the glass article from the working end 107 of the glass tube 102 may include shaping the bottom 112 ( FIG. 20 ) of the glass article 103 while separating the glass article 103 from the working end 107 of the glass tube 102. With reference to FIG. 12 , shaping the 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 ratio of the major axis to the minor axis of about 2 to about 12, or both. With reference to FIGS. 12 and 14 , in embodiments, the laser beam 414 may be an elliptical beam, and the major axis may be oriented parallel or perpendicular to the central axis A of the glass tube 102.

[0215] Referring again to FIG. 12 , in embodiments, the methods disclosed herein may include reducing the thickness of the bottom portion of the glass article. Reducing the thickness of the bottom portion of the glass article may include orienting the separation laser beam to align the major axis of the separation laser beam perpendicular to the central axis A of the glass tube 102, reducing the beam width of the separation laser beam, or a combination thereof. To reduce the thickness of the bottom portion of the glass article, the separation laser beam may have a beam width of about 5 mm to about 10 mm, or a ratio of the major axis to the minor axis of about 2 to about 7. In embodiments, the methods disclosed herein may include increasing the thickness of the bottom portion of the glass article. To increase the thickness of the bottom portion of the glass article, the separation laser beam may be an elliptical beam. Increasing the thickness of the bottom portion of the glass article may include orienting the separation laser beam to align the major axis of the separation laser beam parallel to the central axis A of the glass tube 102, increasing the beam width of the separation laser beam, or a combination thereof. To increase the thickness of the bottom of the glass article, the separating laser beam can have a beam width of about 3 mm to about 7 mm, a ratio of the major axis to the minor axis of about 2.5 to about 12, or both.

[0216] 16 , in embodiments, 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 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 embodiments, 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. Referring now to FIG. 18 , in embodiments, the center of the separation laser beam 444 may be offset axially (i.e., in the + / −Z direction of the coordinate axes in FIG. 18 ) relative to the center 456 of the preheating laser beam 454, the axial direction being a direction parallel to the central axis A of the glass tube 102. In embodiments, the methods disclosed herein may include modifying the axial position of the separation laser beam 444 relative to the axial position of the preheating laser beam 454. Modifying the axial position of the separated laser beam 444 may be achieved by adjusting one or more components of the separated beam delivery system 442 ( FIG. 16 ), one or more turning mirrors 422, or a combination thereof. Referring again to FIG. 18 , in embodiments, the methods disclosed herein may include moving the vertical center of the separated laser beam 444 (i.e., coincident with the major axis 446) toward the working end 107 of the glass tube 102 relative to the center 456 of the preheating laser beam 454; moving the vertical center of the separated 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 decrease the corner radius at the transition between the bottom and sidewall of the glass article 103 (i.e., heel 114 in FIG. 20 ).

[0217] 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 with a second laser beam, where 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 features or characteristics previously described herein for the laser beam 414. In embodiments, the method may include overlapping 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.

[0218] Referring again to FIG. 8 , in embodiments, separating the glass article from the working end 107 of the glass tube 102 may include applying a pulling force F to the glass article while exposing the separation region 424 of the glass tube 102 to the laser beam 414. The pulling force F may move the glass article axially (i.e., in the −Z direction of the coordinate axes in FIG. 8 ) away from the glass tube 102. In embodiments, 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 embodiments, applying the pulling force F may include mechanically pulling the glass article axially away from the glass tube 102 (i.e., in the −Z direction of the coordinate axes in FIG. 8 ).

[0219] 5 and 6 , in method embodiments, forming features on the working end of the glass tube 102 may include contacting a surface of the glass tube 102 in the target area with one or more forming tools 324 while rotating the glass tube 102 about a central axis A of the glass tube. Contact between the forming tools 324 and the surface of the glass tube 102 may alter the shape of the glass tube 102 in the target area. Referring again to FIG. 1 , in embodiments, the method disclosed herein may further include operating the converting machine 100 to produce a plurality of glass articles 103 from the glass tube 102. The converting machine 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 converting machine 100 may include sequentially translating each of the glass tubes 102 through each of the plurality of processing stations 122. Heating the glass tubes at at least one heating station 202, separating the glass articles 103 from the working ends 107 of the glass tubes 102 at a separation station 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 area, a separation area, or both. In an embodiment, the method may further include securing the glass tubes 102 to a holder 140 of a converter 100 that includes multiple processing stations 122. The converter 100 may continuously 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 on 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 at a separation station 206. Heating the target area of ​​the glass tube may include exposing the target area of ​​the glass tube to a laser beam 414 at 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 separated area of ​​the glass tube 102 to the laser beam 414 at the separation station 206.

[0220] In embodiments, the glass article may be a pharmaceutical container, which may include a vacutainer, a cartridge, a syringe, a syringe barrel, an ampoule, a bottle, a flask, a vial, a tube, a beaker, or a bottle.

[0221] In embodiments, exposing the target or separated 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 system that modifies the shape or power density distribution of the laser beam 414, and directing the laser beam 414 toward the target or separated area of ​​the glass tube 102. The optical system may include any of the optical components described for the beam delivery system 420. The optical system may also include a turning 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 embodiments, the laser beam 414 may be a collimated beam or a non-collimated beam. In embodiments, the laser beam 414 may have a laser power of 50 W to 2000 W. In embodiments, the laser beam 414 may be an elliptical beam or a round beam. In embodiments, 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.

[0222] In embodiments, the methods disclosed herein may include changing the shape of the laser beam 414, which may change the volume of glass heated at the target area or separation area of ​​the glass tube 102. The shape of the laser beam 414 may be changed by modifying one or more optical components of the beam delivery system 420, by modifying the distance between optical components of the beam delivery system 420, or both. In embodiments, the methods disclosed herein may include changing the power density of the laser beam 414, which may change the heating rate of the laser beam 414. Increasing the power density may include increasing the output of the laser source 412 of the laser system 410. In embodiments, the methods may include controlling the exposure time of the glass tube 102 to the laser beam 414 during heating of the target area of ​​the glass tube 102, during separation of the glass article from the working end of the glass tube 102, or both, by adjusting the times that the laser source 412 to generate the laser beam 414 is turned on and off. In embodiments, the laser beam may have a heating rate of 200°C / sec to 400°C / sec. In embodiments, 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 embodiments, the conversion rate of the converter 100 for converting the glass tube 102 into a glass article may be 30 parts per minute or more, 35 parts per minute or more, or 40 parts per minute or more. In embodiments, the conversion rate may be less than 30 parts per minute, such as, but not limited to, when the glass tube 102 has a large outer diameter or a larger wall thickness that requires additional dwell time between processing stations to heat and / or form the glass article. [Example]

[0223] Various embodiments of the systems and methods disclosed herein will be further clarified by the following examples, which are illustrative in nature and should not be construed as limiting the subject matter of the present disclosure.

[0224] Examples 1 to 4: Changing the laser output of the laser beam In Examples 1-4, the effect of modifying the power of the laser beam on heating of the glass tube was evaluated. In Examples 1-4, the glass tube was heated with a laser beam on a benchtop processing station configured to simulate the heating station of a 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 with a laser light source, a CO 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 acquire thermal images of the glass tube during heating and determine the glass temperature from the thermal images. The thermal imaging system for measuring the temperature of glass and its operation can be found in U.S. Patent No. 10,773,989, issued 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.

[0225] For each of Examples 1-4, a room-temperature glass tube was loaded into a holder in a benchtop processing station and rotated. The size and composition of the glass tube, as well as the rotation speed, were the same for each of Examples 1-4. While the glass tube was rotating, the laser system was turned on and a laser beam was directed at a target location on the glass tube. The laser system and laser delivery system were configured to generate a laser beam having a wavelength of 10.6 nm and an elliptical cross-sectional shape. The laser power was different for each of Examples 1-4. Table 1 provides the laser power and reference numbers in Figure 24 for Examples 1-4. The glass tube was the same for Examples 1-4. For each of Examples 1-4, the glass tube was heated with the laser beam from room temperature (i.e., without preheating) to a final temperature at which point the laser source was turned off. The glass tube was then allowed to cool for a period of time. For Examples 1-3, the laser exposure time was approximately 6.5 seconds. Due to the faster heating rate, the laser exposure time at 630 W in Example 4 was reduced to about 3.5 seconds. During heating of the glass tube, the glass temperature was measured with a thermal imaging system. [Table 1]

[0226] Referring now 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. As shown in Figure 24, with 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. Pre-heating the glass tube upstream of the processing station with the laser system can further enable the final heating of the glass tube to be achieved in less than 1 second, thereby increasing the part speed of the conversion process.

[0227] Examples 5 to 7: Changing the beam shape In Examples 5-7, the effect of beam shape on the heating rate of a glass tube is evaluated. In Examples 5-7, the glass tube was heated with a laser beam using a benchtop processing station and the method previously described in Examples 1-4. In Examples 5-7, the laser power was kept constant at 630 W, and the beam shape was modified for Examples 5-7. The glass tube was the same for each of Examples 5-7. The beam shapes and reference numbers for Figure 25 are provided in Table 2 below. [Table 2]

[0228] Referring now to FIG. 25, heating and cooling curves for Examples 5-7 are shown. As shown by FIG. 25, 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 having a diameter of 20-25 mm and a wall thickness of 0.7-1.0 mm, the heating rate can be about 200°C / sec, or even 400°C / sec, for a more focused beam such as the narrow elliptical beam of Example 7 (reference number 2506). As a result, with these heating rates and a preheating of the glass tube up to 1000°C-1100°C, it would be expected to take less than a second to reach the process temperature for glass forming. This time can translate into an increased conversion rate of about 30 parts per minute or more, or even about 60 parts per minute or more. For glass tubes having a thickness less than about 0.7 mm, the conversion rate can be even greater.

[0229] Comparative Example 8: Separation with a closed bottom using a gas burner In Comparative Example 8, a glass article was separated from the working end of the glass tube using a gas burner in accordance with a prior art separation method. For Comparative Example 8, the benchtop processing station described in conjunction with Examples 1-4 was equipped with a bottom chuck operable to apply a pulling force downward (i.e., axially away from the working end of the glass tube) to the glass article. 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 region of the glass tube with the gas burner and then applying a pulling force to the glass article. Separation caused the formation of a glass meniscus at the end of the glass article, thereby forming a closed bottom at the end of the glass article.

[0230] Example 9: Separation with a Closed Bottom Using a Laser System In Example 9, a laser system was used to separate a glass article from a glass tube and form a bottom at the end of the glass article separated from the glass tube. For Example 9, the benchtop processing station described in conjunction with Examples 1-4 was equipped with a bottom chuck operable to apply a pulling force downward (i.e., axially away from the working end of the glass tube) to the glass article. A laser system was used to heat the glass tube during separation. The glass article was separated from the glass tube by heating the separation region of the glass tube with the laser system and then applying a pulling force to the glass article. Separation caused the formation of a glass meniscus at the end of the glass article, thereby forming a closed bottom at the end of the glass article.

[0231] 26, photographs of the bases formed on the glass articles in Comparative Example 8 (left) and Example 9 (right) are shown. As shown in the image on the right, separation using a laser system in Example 9 produces a flatter base with less thickness variation compared to the base formed by separation using a gas burner, as in Comparative Example 8 (left).

[0232] Example 10: Separation to form an open bottom In Example 10, a laser system was used to separate a glass article from the 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 1-4 was equipped with a bottom chuck operable to apply a pulling force downward (i.e., axially away from the working end of the glass tube) to the glass article. The laser system included a beam delivery system operable to generate a thin, elliptical beam suitable for heating the glass sufficiently to separate the glass article from the glass tube, but not enough to form a meniscus across the glass article and the end of the glass tube after separation. Referring to Figure 27, a photograph shows an image of separation during application of a pulling force to the glass article, just moments before separation. Figure 28 shows the results of tube separation in Example 10 without bottom forming, which combines the tube cutting and edge polishing steps into a single process. The result is a clean and virtually defect-free edge. Tube separation without bottom forming can also be achieved by applying glass melting and pulling forces, but in this case the volume of glass heated by the laser during separation is barely enough to produce a smooth tube edge, but not enough to form a bottom on the glass article. Varying the tube area affected by the laser beam and laser power can enable a variety of well-controlled forming procedures, from clean cutting and finishing to forming bottoms of different thicknesses, using the same configuration of the laser system.

[0233] While various embodiments of the system 100 and methods for using the system 100 to cut and finish the end of the glass tube 102 are described herein, it is understood that it is contemplated that each of these embodiments and techniques may be used separately or in conjunction with one or more other embodiments and techniques.

[0234] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Thus, it is intended that the present specification cover the modifications and variations of the various embodiments described herein, provided that such modifications and variations come within the scope of the appended claims and their equivalents.

Claims

1. 1. A method for producing a glass article from a glass tube, the method comprising: rotating the glass tube around a central axis of the glass tube; heating a target area of ​​the glass tube to a forming temperature while rotating the glass tube, the target area being adjacent to a working end of the glass tube; After heating the target area of ​​the glass tube, forming at least one feature of the glass article in 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 region of the glass tube; heating the target area of ​​the glass tube, separating the glass article from the work end of the glass tube, or both, comprises exposing the target area of ​​the glass tube, the separation area, or both, to a laser beam having a maximum cross-sectional dimension of about 0.5 to about 1.25 times an outer diameter of the glass tube at the point where the laser beam enters the glass tube; The method, wherein exposing the target area, the separation area, or both to the laser beam heats the glass tube to a temperature of about 1000° C. or greater at the target area, the separation area, or both.

2. 2. The method of claim 1, wherein heating the target area of ​​the glass tube comprises exposing the target area to the laser beam at a heating station of a converter for forming the glass article from the glass tube, the laser beam being a heating laser beam.

3. The method of claim 2 , wherein the heating laser beam has a circular cross section.

4. 2. 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 at a separation station of a converter for forming the glass article from the glass tube, the laser beam being a separation laser beam.

5. 5. The method of claim 4, including exposing the separation region of the glass tube to a preheating laser beam at a heating station before translating the glass tube into the separation station.

6. The method of claim 4 , wherein the separated laser beam has an elliptical cross section having a major axis and a minor axis.

7. 5. The method of claim 4, wherein the separated laser beam has a beam length of 5 mm to 50 mm where the separated laser beam is incident on the glass tube.

8. 5. The method of claim 4, wherein separating the glass article from the working end of the glass tube further comprises forming an open end at a bottom of the glass article, the bottom of the glass article being the end of the glass article that was pre-bonded to the glass tube prior to separation.

9. 9. The method of claim 8, wherein the separated laser beam has a beam width of about 0.5 mm to about 5 mm where the separated laser beam is incident on the glass tube.

10. 9. The method of claim 8, wherein the separated laser beam is an elliptical beam having a ratio of major axis to minor axis of about 4 to about 70 where the separated laser beam is incident on the glass tube.

11. 5. The method of claim 4, wherein separating the glass article from the working end of the glass tube further comprises shaping a bottom of the glass article while separating the glass article from the working end of the glass tube.

12. 12. The method of claim 11, wherein the separated laser beam has a beam width of about 3 mm to about 10 mm where the separated laser beam is incident on the glass tube.

13. 12. The method of claim 11, wherein the separated laser beam is an elliptical beam having a ratio of major axis to minor axis of about 2 to about 12 where the separated laser beam is incident on the glass tube.

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

15. further comprising reducing a thickness of the bottom portion of the glass article, wherein the separated laser beam is an elliptical beam, and reducing the thickness of the bottom portion of the glass article comprises: orienting the separated laser beam with a long axis of the separated laser beam perpendicular to the central axis of the glass tube; reducing the beam width of the split laser beam; or a combination thereof.

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

17. increasing a thickness of the bottom portion of the glass article, wherein the separated laser beam is an elliptical beam, and increasing the thickness of the bottom portion of the glass article comprises: orienting the separated laser beam with a long axis of the separated laser beam parallel to the central axis of the glass tube; increasing the beam width of the separated laser beam; or a combination thereof.

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

19. separating the glass article from the working end of the glass tube; exposing the separation region of the glass tube to a separation laser beam having an elliptical cross section; and exposing the separated region of the glass tube at the separation station to a preheating laser beam having a circular cross section.

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

21. 20. The method of claim 19, wherein the center of the separation laser beam is axially offset relative to the center of the preheating laser beam, the axial direction being parallel to the central axis of the glass tube.

22. 20. 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. 23. The method of claim 22, further comprising: moving a center of the separation laser beam toward the working end of the glass tube relative to a center of the preheating laser beam, 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 increases flatness of the bottom of the glass article and decreases a corner radius at a transition between the bottom and a sidewall of the glass article.

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

25. separating the glass article from the working end of the glass tube; exposing the separation region of the glass tube to the separation laser beam having an elliptical cross section; 5. The method of claim 4, further comprising: exposing the separation region of the glass tube to a burner at the separation station, the burner preheating the glass tube.

26. 5. The method of claim 4, wherein separating the glass article from the work end of the glass tube comprises applying a pulling force to the glass article while exposing the separation region of the glass tube to the laser beam, the pulling force moving the glass article axially away from the glass tube.

27. 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. 27. The method of claim 26, wherein applying the pulling force comprises mechanically pulling the glass article axially away from the glass tube.

29. heating the target area of ​​the glass tube, separating the glass article from the working end of the glass tube, or both; exposing the target area, the separation area, or both of the glass tube with a first laser beam; 2. The method of claim 1, comprising 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.

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

31. 30. 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 first laser beam has a circular beam cross section; 30. The method of claim 29, wherein the second laser beam has an elliptical beam cross section.

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

34. further comprising operating the converter to produce a plurality of glass articles from the plurality of glass tubes; the converter comprises a plurality of processing stations, including at least one heating station, at least one forming station, and a separation station; operating the converter includes sequentially translating each of the plurality of glass tubes through each of the plurality of processing stations; 2. The method of claim 1, wherein the at least one heating station, the at least one separation station, or both, includes exposing each of the glass tubes to the laser beam to heat each of the glass tubes at the target area, the separation area, or both.

35. securing the glass tube in a holder of a converter having 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, the converter sequentially translating 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; separating the glass article from the working end of the glass tube at the separation station; heating the target area of ​​the glass tube includes exposing the target area of ​​the glass tube to the laser beam at the at least one heating station; or 2. The method of claim 1, wherein separating the glass article from the working end of the glass tube comprises exposing the separation area of ​​the glass tube with the laser beam at the separation station.

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

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

38. exposing the target area or the separation area of ​​the glass tube to the laser beam; generating the laser beam using a laser light source; passing the laser beam through an optical system that modifies the shape or power density distribution of the laser beam; and directing the laser beam toward the target or separation area 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 50 W to 2000 W.

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

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

44. 10. The method of claim 1, further comprising: modifying a shape of the laser beam, wherein modifying the shape of the laser beam changes a volume of glass heated in the target area or the separation area 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. 10. The method of claim 1, further comprising: controlling the exposure time of the glass tube to the laser beam while heating the target area of ​​the glass tube by adjusting the times a laser light source for generating the laser beam is turned on and off; separating the glass article from the working end of the glass tube; or both.

47. 10. The method of claim 1, comprising rotating the glass tube at a rotational speed of between 60 rpm and 400 rpm.

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

49. 10. The method of claim 1, wherein the conversion rate of the glass tube to the glass article is 30 parts per minute or greater, or the conversion process is not rate-limited by the separation of the glass article from the glass tube.

50. 1. A method for removing a glass article from a working end of a glass tube during conversion, said method comprising: translating the worked end of the glass tube into a separation station of a converter; rotating the glass tube around a central axis of the glass tube; exposing a separated region of the glass tube to a laser beam while rotating the glass tube; 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 with the laser beam and applying the axial force to the glass article separates the glass article from the working end of the glass tube.

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

52. 51. The method of claim 50, wherein the separated laser beam has an elliptical cross section having a major axis and a minor axis.

53. 51. The method of claim 50, wherein the separated laser beam has a beam length of between 5 mm and 50 mm where the separated laser beam is incident on the glass tube.

54. 51. The method of claim 50, wherein separating the glass article from the working end of the glass tube further comprises forming an open end at a bottom of the glass article, the bottom of the glass article being the end of the glass article that was pre-bonded to the glass tube prior to separation.

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

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

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

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

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

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

61. further comprising reducing a thickness of the bottom portion of the glass article, wherein the separated laser beam is an elliptical beam, and reducing the thickness of the bottom portion of the glass article comprises: orienting the separated laser beam with a long axis of the separated laser beam perpendicular to the central axis of the glass tube; reducing the beam width of the split laser beam; or a combination thereof.

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

63. increasing a thickness of the bottom portion of the glass article, wherein the separated laser beam is an elliptical beam, and increasing the thickness of the bottom portion of the glass article comprises: orienting the separated laser beam with a long axis of the separated laser beam parallel to the central axis of the glass tube; increasing the beam width of the separated laser beam; or a combination thereof.

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

65. separating the glass article from the working end of the glass tube; exposing the separation region of the glass tube to a separation laser beam having an elliptical cross section; and exposing the separated region of the glass tube to a preheating laser beam having a circular cross section.

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

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

68. 66. 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. 67. The method of claim 66, further comprising: moving a center of the separation laser beam toward the processing end of the glass tube relative to a center of the preheating laser beam, wherein moving the center of the separation laser beam closer to the processing of the glass tube relative to the center of the preheating laser beam increases flatness of the bottom of the glass article and reduces a corner radius at a transition between the bottom and a sidewall of the glass article.

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

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

72. 1. A system for producing glass articles from glass tubing, the system comprising: A conversion machine comprising a plurality of processing stations spaced apart along a circulation path and at least one holder, the plurality of processing stations including 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 with a working end of the glass tube oriented toward the plurality of processing stations and to rotate the glass tube about a central axis of the glass tube; a translator operable to sequentially translate the at least one holder, with the glass tube secured to the at least one holder, through each of the plurality of processing stations; a laser system disposed in the at least one heating station or the separation station; the laser system comprises a laser source and a beam delivery system; The system, wherein the laser system is operable to generate a laser beam, modify one or more characteristics of the laser beam, and direct the laser beam to the glass tube when the glass tube is in the at least one heating station or the separation station.

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

74. the laser system comprises a laser source and a beam delivery system; the laser system is operable to generate the laser beam having a wavelength between 1 μm and 12 μm and a power density between 50 W and 2000 W; 73. The system of claim 72, wherein the beam delivery system is operable to modify a cross-sectional shape of the laser beam and direct the laser beam to the separation area of ​​the glass tube at the separation station.

75. The laser light source is a CO laser, a CO ２ 75. The system of claim 74, comprising a laser or a quantum cascade laser.

76. 75. 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 thereof.

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

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

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

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

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

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

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

84. the laser system: a separation laser system operable to generate a separation laser beam having an elliptical cross-sectional shape; a preheating laser system operable to generate a preheating laser beam having a circular cross-sectional shape.

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

86. 83. The system of claim 82, further comprising a burner at the separation station, the burner being spaced apart from the laser beam at an angle relative to the central axis of the glass tube, the burner being operable to preheat the separation area of ​​the glass tube while the laser beam is directed at the separation area of ​​the glass tube.

87. 83. The system of claim 82, further comprising a heating station immediately upstream of the separation station, the heating station comprising a preheating laser system operable to generate a preheating laser beam and direct the preheating laser beam to the separation region of the glass tube.

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

89. 83. The system of claim 82, further comprising a heating station immediately upstream of the separation station, the heating station comprising a burner operable to heat the separation region of the glass tube prior to translating the glass tube into the separation station.

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