Stress features for crack deflection and protection in glass containers.

Abstract

The glass container comprises a glass body having a first region under compressive stress extending from a surface of the glass body to a compression depth and a second region extending from the compression depth into a thickness of the glass body, the second region being under tensile stress. The glass container also includes a localized compressive stress region having a localized compressive stress extending from the surface to a localized compression depth within the body, the localized compression depth exceeding the compression depth of the first region. The glass container also includes a crack deflection region extending in a predetermined propagation direction, the crack deflection region having a tensile stress greater than the tensile stress of the second region in a subregion of the crack deflection region, the subregion extending substantially perpendicular to the predetermined propagation direction.

Description

Related Applications

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 to U.S. Provisional Application No. 63 / 053,860, filed July 20, 2020, the contents of which are relied upon and incorporated herein by reference in their entirety. [Technical Field]

[0002] FIELD OF THE INVENTION This specification relates generally to glass containers, for example, glass containers for storing pharmaceutical compositions. [Background technology]

[0003] A concern of food and drug manufacturers is maintaining the sterility of package contents against loss during transportation and storage prior to use. While glass containers are superior to many alternative materials, they are not indestructible and occasionally suffer breakage during handling and transportation. Cracks may form through the wall thickness, compromising the sterility of the contents but not resulting in significant package failure. Additional features of glass containers, such as adhesive labels, can make such cracks less noticeable to users, which may lead to continued use despite the compromised sterility. Summary of the Invention

[0004] A first aspect of the present disclosure includes a method of making a glass container having a first surface and a second surface separated by a thickness, the method comprising: forming a first region under compressive stress in the first surface of the glass container, the first region extending from the first surface to a compression depth in the glass container; forming a second region under internal tensile stress, the second region extending from the compression depth into the thickness, the internal tensile stress being sufficient to self-propagate a crack from its initiation point at the first surface; and forming a crack deflection region in the first surface, the crack deflection region extending in a predetermined direction of crack propagation and comprising a higher internal tensile stress in a direction substantially perpendicular to the predetermined propagation direction than the remainder of the glass article, such that when a crack propagates and reaches the crack deflection region, the crack is deflected along the predetermined propagation direction.

[0005] A second aspect of the present disclosure may include the first aspect, wherein the glass container comprises a body having an inner surface and an outer surface, the inner surface defining an interior volume having an axis, and the predetermined direction of propagation is substantially perpendicular to the axis.

[0006] A third aspect of the present disclosure may include the first or second aspect, wherein the thickness of the glass container varies within the crack deflection region, whereby the crack deflection region comprises a thinned region extending substantially parallel to the axis, wherein the thickness in the thinned region is less than the average thickness of the glass container within the crack deflection region.

[0007] A fourth aspect of the present disclosure may include any one of the first through third aspects, wherein the crack redirection region extends around at least a portion of the circumference of the glass container.

[0008] A fifth aspect of the present disclosure may include any one of the first through fourth aspects, wherein the thickness of the glass article in the crack redirection region varies sinusoidally parallel to the axis.

[0009] A sixth aspect of the present disclosure may include any one of the first through fifth aspects, wherein the crack deflection region extends around the entire circumference of the glass container.

[0010] A seventh aspect of the present disclosure may include any one of the first to sixth aspects, wherein the first surface is an exterior surface of a glass container.

[0011] An eighth aspect of the present disclosure may include any one of the first to seventh aspects, wherein the first surface is an inner surface of a glass container.

[0012] A ninth aspect of the present disclosure may include any one of the first through eighth aspects, wherein forming the first region and the second region includes forming a glass container from a glass composition and subjecting a first surface of the glass container to chemical tempering to form the first region and the second region.

[0013] A tenth aspect of the present disclosure may include any one of the first to ninth aspects, wherein the glass composition includes an aluminosilicate glass composition.

[0014] An eleventh aspect of the present disclosure may include any one of the first to tenth aspects, wherein forming the glass article from the glass composition includes forming a glass tube containing the glass composition and converting the glass tube into a glass container, and forming the crack redirection region occurs during conversion of the glass tube into the glass container.

[0015] A twelfth aspect of the present disclosure may include any one of the first through eleventh aspects, wherein forming the crack redirection region includes scanning a pulsed laser beam in a predetermined pattern while heating the glass tube to a softening temperature of the glass composition during conversion of the glass tube into a glass container.

[0016] A thirteenth aspect of the present disclosure may include a method of forming a glass container having a crack diverting region, the method including: providing a feedstock formed from a glass composition; forming the feedstock into a glass article having a body extending between an inner surface and an outer surface and defining an interior volume; forming a compressive stress layer in the glass article, the compressive stress layer extending from at least one of the inner surface and the outer surface to a compressed depth of a thickness of the body; and forming a crack diverting region in the glass article, the crack diverting region comprising a subregion having a higher internal tensile stress than a remainder of the glass article, the subregion extending in a direction substantially perpendicular to a predetermined propagation direction.

[0017] A fourteenth aspect of the present disclosure may include the thirteenth aspect, wherein the raw material includes a glass tubing, and the method further includes converting the glass tubing into a glass article, and wherein forming the crack redirection region includes forming a sub-region of the crack redirection region during conversion of the glass tubing into the glass article, and wherein a thickness of the sub-region is less than an average thickness of the body.

[0018] A fifteenth aspect of the present disclosure may include any one of the thirteenth to fourteenth aspects, wherein forming the subregions includes scanning a pulsed laser beam in a predetermined pattern on the glass article.

[0019] A sixteenth aspect of the present disclosure may include any one of the thirteenth to fifteenth aspects, wherein forming the subregions includes contacting the glass tubing with a shaping element during conversion of the glass tubing into a glass article.

[0020] A seventeenth aspect of the present disclosure may include a glass container comprising: a glass body including a first region under compressive stress extending from a surface of the glass body to a compression depth and a second region extending from the compression depth into a thickness of the glass body, the second region being under tensile stress sufficient to self-propagate a crack from a crack initiation point in a propagation direction; and a crack deflection region on the surface of the glass body, the crack deflection region extending in a predetermined propagation direction of the crack. The crack deflection region includes a tensile stress greater than the tensile stress of the second region in a subregion of the crack deflection region. The subregion extends substantially perpendicular to the predetermined propagation direction, such that when a crack propagates into the crack deflection region, the crack is deflected along the predetermined propagation direction.

[0021] An eighteenth aspect of the present disclosure may include the seventeenth aspect, wherein the glass container includes one of a bottle, a vial, an ampoule, a syringe, or a cartridge.

[0022] A nineteenth aspect of the present disclosure may include any one of the seventeenth to eighteenth aspects, wherein the predetermined propagation direction is a circumferential direction substantially perpendicular to the axis of the glass container.

[0023] A twentieth aspect of the present disclosure may include any one of the seventeenth to nineteenth aspects, wherein the thickness varies within the crack redirection region, whereby subregions of the crack redirection region comprise thinned regions extending substantially parallel to the axis, and in the thinned regions, the thickness is less than the average thickness of the glass article.

[0024] A twenty-first aspect of the present disclosure includes a glass container comprising a body comprising a glass composition, the body having an inner surface, an outer surface, and a wall thickness extending between the inner surface and the outer surface, the body comprising a local compressive stress region having a local compressive stress extending from the outer surface to a localized compressive depth within the body, the localized compressive stress region extending further into the body than any compressive stress region adjacent to the localized compressive stress region.

[0025] A twenty-second aspect of the present disclosure may include the twenty-first aspect, wherein the glass container includes a pharmaceutical container.

[0026] A twenty-third aspect of the present disclosure may include any one of the twenty-first to twenty-second aspects, wherein the localized compression depth extends through at least 2% and at most 25% of the wall thickness.

[0027] A twenty-fourth aspect of the present disclosure may include any one of the twenty-first to twenty-third aspects, wherein the localized compression depth extends through at least 20% and at most 25% of the wall thickness.

[0028] A twenty-fifth aspect of the present disclosure may include any one of the twenty-first to twenty-fourth aspects, wherein the localized compressive stress region includes a compressive stress of 50 MPa or more.

[0029] A 26th aspect of the present disclosure may include any one of the 21st to 25th aspects, wherein the localized compressive stress region includes a surface compressive stress of 75 MPa or greater.

[0030] A twenty-seventh aspect of the present disclosure may include any one of the twenty-first to twenty-sixth aspects, in which the surface compressive stress is 100 MPa or greater.

[0031] A 28th aspect of the present disclosure may include any one of the 21st to 27th aspects, wherein the localized compressive stress region overlaps with a compressive stress layer under compressive stress of the glass container, such that within the localized compressive stress region, the body includes compressive stress of the compressive stress layer to a first compressive depth and a localized stress depth from the first compressive depth to the localized compressive depth.

[0032] A twenty-ninth aspect of the present disclosure may include any one of the twenty-first to twenty-eighth aspects, in which the glass composition includes an aluminosilicate glass composition.

[0033] A 30th aspect of the present disclosure may include any one of the 21st to 29th aspects, wherein the glass container comprises a vial having a base, a barrel connected to the base via a heel, a shoulder extending from the barrel, and a neck extending from the shoulder, and the localized compressive stress area is disposed in at least one of the neck, the heel, and the barrel.

[0034] A thirty-first aspect of the present disclosure may include any one of the twenty-first to thirtieth aspects, wherein the localized compressive stress region is located in the heel.

[0035] A thirty-second aspect of the present disclosure may include any one of the twenty-first to thirty-first aspects, further comprising an additional local compressive stress region having an additional local compressive stress extending from the interior surface to an additional local compressive depth within the body.

[0036] A thirty-third aspect of the present disclosure may include any one of the twenty-first through thirty-second aspects, wherein the localized compressive stress region and the additional localized compressive stress region oppose each other to form an internal tensile stress region between the localized compressive stress region and the additional localized compressive stress region, the internal tensile stress region promoting branching of cracks propagating through the wall thickness and rendering the glass container unusable.

[0037] A thirty-fourth aspect of the present disclosure includes a glass container comprising a glass body comprising a first region under compressive stress extending from a surface of the glass body to a compression depth and a second region extending from the compression depth into a thickness of the glass body, the second region being under tensile stress; and a localized compressive stress region having a localized compressive stress extending from the surface to a localized compression depth within the body, the localized compression depth being greater than or equal to 2% and less than or equal to 25% of a wall thickness of the body, the localized compression depth exceeding the compression depth of the first region.

[0038] A thirty-fifth aspect of the present disclosure may include the thirty-fourth aspect, wherein the localized compressive stress region overlaps with the first region, such that within the localized compressive stress region, the glass body has a compressive stress in the first region to a first compression depth and a localized stress depth from the first compression depth to the localized compression depth.

[0039] A thirty-sixth aspect of the present disclosure may include any one of the thirty-fourth to thirty-fifth aspects, wherein the localized compressive stress region includes a compressive stress of 50 MPa or more.

[0040] A thirty-seventh aspect of the present disclosure may include any one of the thirty-fourth to thirty-sixth aspects, wherein the surface of the glass body is an outer surface of a glass container.

[0041] A thirty-eighth aspect of the present disclosure may include a method of forming a glass container having a localized compressive stress region, the method including: providing a feedstock formed from a glass composition; and forming the feedstock into a glass article having a body having a thickness extending between an inner surface and an outer surface, the body defining an interior volume; and forming a localized compressive stress region in the glass article, the localized compressive stress region having a localized compressive stress extending from the outer surface or the inner surface to a localized compression depth within the body, the localized compression depth being equal to or greater than 2% and equal to or less than 25% of the thickness, wherein forming the localized compressive stress region includes locally applying a refrigerant to a predetermined portion of the glass article when the glass article is heated to an initiation temperature above a softening temperature of the glass composition such that the localized compressive stress region extends further into the body than any compressive stress regions adjacent to the localized compressive stress region.

[0042] A thirty-ninth aspect of the present disclosure may include the thirty-eighth aspect, further including, after the step of forming the localized compressive stress region, subjecting the glass article to ion exchange strengthening to form a first region under compressive stress at the exterior surface, the first region extending from the exterior surface to a compression depth that is less than the localized compression depth.

[0043] A fortieth aspect of the present disclosure may include any one of the thirty-eighth to thirty-ninth aspects, wherein the step of locally applying a refrigerant to a portion of the glass article induces an instantaneous tensile stress in the central thickness portion that induces propagation of any cracks formed in the central portion.

[0044] A forty-first aspect of the present disclosure may include any one of the thirty-eighth to fortieth aspects, further including, prior to forming the localized compressive stress regions, flame cleaning the entire exterior surface to eliminate conversion flaws induced by forming the feedstock into the glass article.

[0045] A forty-second aspect of the present disclosure may include any one of aspects thirty-eight to forty-first, wherein the step of locally applying a refrigerant to a portion of the glass article includes: positioning a collar in proximity to the portion of the glass article as the glass article is heated to a starting temperature, the collar including at least one supply of refrigerant, the collar being shaped to correspond to the portion of the glass article, the collar including contact points that contact the portion of the glass article and control a gap between the fluid manifold of the collar and the portion of the glass article; and providing the refrigerant to the portion of the glass article to form a localized compressive stress region.

[0046] A forty-third aspect of the present disclosure may include any one of the thirty-eighth to forty-second aspects, wherein the glass article is not subjected to an annealing heat treatment after formation of the localized compressive stress regions.

[0047] A forty-fourth aspect of the present disclosure may include any one of the thirty-eighth to forty-third aspects, wherein the glass container comprises a vial having a base, a barrel connected to the base via a heel, a shoulder extending from the barrel, and a neck extending from the shoulder, and the portion of the glass article to which the refrigerant is applied comprises at least one of the neck and the heel.

[0048] A forty-fifth aspect of the present disclosure may include a glass container comprising: a glass body comprising a first region under compressive stress extending from a surface of the glass body to a compression depth and a second region extending from the compression depth into a thickness of the glass body, the second region being under tensile stress; a localized compressive stress region having localized compressive stress extending from the surface to a localized compression depth within the body, the localized compression depth exceeding the compression depth of the first region; and a crack deflection region in the glass body, the crack deflection region extending in a predetermined propagation direction, the crack deflection region having a higher tensile stress than the tensile stress of the second region at a sub-region of the crack deflection region, the sub-region extending substantially perpendicular to the predetermined propagation direction.

[0049] A forty-sixth aspect of the present disclosure may include the forty-fifth aspect, wherein a subregion of the crack deflection region includes a thickness variation at a surface of the glass body.

[0050] A forty-seventh aspect of the present disclosure may include any one of the forty-fifth to forty-sixth aspects, wherein the surface of the glass body includes an outer surface of a glass container.

[0051] A forty-eighth aspect of the present disclosure may include any one of the forty-fifth to forty-seventh aspects, wherein the crack deflection region overlaps the localized compressive stress region at an overlap region.

[0052] A forty-ninth aspect of the present disclosure may include any one of aspects forty-fifth through forty-eighth, wherein the localized compressive stress region overlaps with the first region, such that within the localized compressive stress region, the glass body has a compressive stress in the first region to a first compression depth and a localized stress depth from the first compression depth to the localized compression depth.

[0053] A fiftieth aspect of the present disclosure may include any one of the forty-fifth to forty-ninth aspects, wherein the localized compressive stress region includes a compressive stress of 50 MPa or more.

[0054] A fifty-first aspect of the present disclosure may include any one of the forty-fifth to fiftieth aspects, wherein the glass body is formed from an aluminosilicate glass composition.

[0055] A 52nd aspect of the present disclosure may include any one of the 45th to 51st aspects, wherein the glass container comprises a vial having a base, a barrel connected to the base via a heel, a shoulder extending from the barrel, and a neck extending from the shoulder.

[0056] A 53rd aspect of the present disclosure may include any one of the 45th to 51st aspects, wherein the crack deflection region is positioned within the barrel proximate at least one of the heel and shoulder.

[0057] A 54th aspect of the present disclosure may include any one of the 45th to 53rd aspects, wherein the localized compressive stress region is located in at least one of the neck and the heel.

[0058] A fifty-fifth aspect of the present disclosure may include a method of forming a glass container, the method including: providing a feedstock formed from a glass composition; and forming the feedstock into a glass article having a body extending between an inner surface and an outer surface, the body defining an interior volume; forming a crack redirection region in the glass article, the crack redirection region comprising a subregion having a higher internal tensile stress than a remainder of the glass article, the subregion extending in a direction substantially perpendicular to a predetermined direction of propagation; and forming a localized compressive stress region in the glass article, the localized compressive stress region having a localized compressive stress extending from the inner or outer surface to a localized compressive depth within the body, the localized compressive depth being greater than or equal to 2% and less than or equal to 25% of a thickness of the body, wherein forming the localized compressive stress region includes locally applying a refrigerant to a predetermined portion of the glass article when the glass article is heated to an initiation temperature above the softening temperature of the glass composition.

[0059] A 56th aspect of the present disclosure may include the 55th aspect, further including forming a compressive stress layer in the glass article, the compressive stress layer extending within the thickness of the body from at least one of the inner surface and the outer surface to a compression depth.

[0060] A 57th aspect of the present disclosure may include any one of aspects 55 to 56, wherein the step of forming the compressive stress layer includes, after the step of forming the localized compressive stress region, subjecting the glass article to ion exchange strengthening to form a first region under compressive stress at the outer surface, the first region extending from the outer surface to a compression depth, the compression depth being less than the localized compression depth.

[0061] A fifty-eighth aspect of the present disclosure may include any one of the fifty-fifth to fifty-seventh aspects, wherein the localized compressive stress region overlaps with the first region on the outer surface.

[0062] A fifty-ninth aspect of the present disclosure may include any one of the fifty-fifth to fifty-eighth aspects, wherein the crack deflection region overlaps with a localized compressive stress region on the outer surface.

[0063] A sixtieth aspect of the present disclosure may include any one of the fifty-fifth to fifty-ninth aspects, further including, prior to forming the localized compressive stress regions, flame cleaning the entire exterior surface to eliminate conversion flaws induced by forming the feedstock into the glass article.

[0064] A sixty-first aspect of the present disclosure may include any one of aspects fifty-fifth to sixty-first, wherein the step of locally applying a refrigerant to a portion of the glass article includes: positioning a collar in proximity to the portion of the glass article as the glass article is heated to a starting temperature, the collar including at least one supply of refrigerant, the collar being shaped to correspond to the portion of the glass article; and supplying the refrigerant to the portion of the glass article to form a localized compressive stress region.

[0065] A 62nd aspect of the present disclosure may include any one of the 55th to 61st aspects, wherein the collar includes contact points that contact portions of the glass article to control a gap between the fluid manifold of the collar and the portions of the glass article.

[0066] A 63rd aspect of the present disclosure may include any one of aspects 55 to 62, wherein the glass container comprises a vial having a base, a barrel connected to the base via a heel, a shoulder extending from the barrel, and a neck extending from the shoulder, and the portion of the glass article to which the refrigerant is applied comprises at least one of the neck and the heel.

[0067] A 64th aspect of the present disclosure may include any one of aspects 55 to 63, wherein forming the crack redirection region includes forming a sub-region of the crack redirection region during shaping of the material into the glass article, and the thickness of the sub-region is less than the average thickness of the body.

[0068] A 65th aspect of the present disclosure may include any one of aspects 55 to 64, wherein forming the subregions includes scanning a pulsed laser beam in a predetermined pattern on the glass article.

[0069] A 66th aspect of the present disclosure may include any one of aspects 55 to 65, wherein forming the subregion includes contacting the material with a shaping element having a shape corresponding to the predetermined shape of the subregion during shaping of the material into the glass article.

[0070] A sixty-seventh aspect of the present disclosure may include any one of the fifty-fifth to sixty-sixth aspects, wherein a thickness of a portion of the crack redirection region is greater than an average thickness of the body.

[0071] Additional features and advantages of the processes and systems described herein are set forth in the detailed description that follows, and in part will become readily apparent to those skilled in the art from the detailed description, or may be learned by practicing the embodiments described herein, including the detailed description that follows, the claims, and the accompanying drawings.

[0072] It is to be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and 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 detailed description, serve to explain the principles and operation of the claimed subject matter. [Brief explanation of the drawings]

[0073] The embodiments illustrated in the drawings are schematic and exemplary in nature and are not intended to limit the subject matter defined by the claims. The following detailed description of the schematic embodiments can be understood when read in conjunction with the following drawings, in which like structure is indicated with like reference numerals and in which: [Figure 1] 1 is a schematic cross-sectional view of a glass container including a crack redirection region and a localized compressive stress region according to one or more embodiments described herein. [Figure 2] FIG. 2 is a diagram schematically illustrating a compressive stress layer in a portion of the side wall of the glass container of FIG. [Figure 3] FIG. 1 is a schematic diagram of a portion of a sidewall of a glass container formed from laminated glass. [Figure 4A] 2 is a schematic cross-sectional view of the crack redirection region of FIG. 1 according to one or more embodiments described herein. [Figure 4B] 2 is a schematic cross-sectional view of the crack redirection region of FIG. 1 according to one or more embodiments described herein. [Figure 4C] 2 is a schematic cross-sectional view of the crack redirection region of FIG. 1 according to one or more embodiments described herein. [Figure 5] 2 is a schematic cross-sectional view of an alternative crack redirection region of FIG. 1 according to one or more embodiments described herein. [Figure 6A] 1A-1C are schematic diagrams illustrating glass containers including crack redirection regions according to one or more embodiments described herein. [Figure 6B] FIG. 6B is a schematic diagram of the glass container of FIG. 6A including another crack redirection region according to one or more embodiments described herein. [Figure 6C] FIG. 6B is a schematic diagram of the glass container of FIG. 6A including another crack redirection region according to one or more embodiments described herein. [Figure 6D] FIG. 6B is a schematic diagram of the glass container of FIG. 6A including another crack redirection region according to one or more embodiments described herein. [Figure 6E] FIG. 6B is a schematic diagram of the glass container of FIG. 6A including another crack redirection region according to one or more embodiments described herein. [Figure 6F] FIG. 6B is a schematic diagram of the glass container of FIG. 6A including another crack redirection region according to one or more embodiments described herein. [Figure 6G] FIG. 6B is a schematic diagram of the glass container of FIG. 6A including another crack redirection region according to one or more embodiments described herein. [Figure 6H] FIG. 6B is a schematic diagram of the glass container of FIG. 6A including another crack redirection region according to one or more embodiments described herein. [Figure 7] 1A-1C are schematic diagrams illustrating glass containers including crack redirection regions according to one or more embodiments described herein. [Figure 8A] 1A-1C are schematic diagrams illustrating a glass container including a first crack redirection region extending in a first direction, according to one or more embodiments described herein. [Figure 8B] 8B is a schematic diagram illustrating the glass container of FIG. 8A including a second crack deflection region extending in a first spiral pattern, according to one or more embodiments described herein. [Figure 8C] 8B is a schematic diagram illustrating the glass container of FIG. 8A including a second crack deflection region extending in a second spiral pattern, according to one or more embodiments described herein. [Figure 8D] 8B is a schematic diagram of the glass container of FIG. 8A including a second crack redirection region extending in a second direction perpendicular to the first direction, according to one or more embodiments described herein. [Figure 9] FIG. 1 is a schematic diagram illustrating a converter for converting glass tubing into glass containers, according to one or more embodiments described herein. [Figure 10] 10 is a schematic diagram of a processing station of the converter shown in FIG. 9 according to one or more embodiments described herein. [Figure 11] 2 is a schematic diagram illustrating localized compressive stress regions in the glass container shown in FIG. 1, according to one or more embodiments described herein. [Figure 12A]FIG. 1 is a graphical illustration of compressive stress in a localized compressive stress region as a function of starting temperature and heat transfer coefficient for a glass composition according to one or more embodiments described herein. [Figure 12B] FIG. 12B graphically illustrates internal tensile stress proximate to the localized compressive stress region as a function of starting temperature and heat transfer coefficient for the glass composition of FIG. 12A, according to one or more embodiments described herein. [Figure 12C] FIG. 12B graphically illustrates instantaneous tensile stress in a localized compressive stress region as a function of starting temperature and heat transfer coefficient for the glass composition of FIG. 12A, according to one or more embodiments described herein. [Figure 12D] FIG. 12B graphically illustrates compressive stress in the localized compressive stress region as a function of starting temperature and thickness for the glass composition of FIG. 12A, according to one or more embodiments described herein. [Figure 12E] FIG. 12B graphically illustrates tensile stress proximate to a localized compressive stress region as a function of starting temperature and thickness for the glass composition of FIG. 12A, according to one or more embodiments described herein. [Figure 13A] FIG. 1 is a schematic diagram of a cooling apparatus for performing a localized thermal strengthening treatment on a glass container, according to one or more embodiments described herein. [Figure 13B] FIG. 1 is a schematic diagram of a cooling apparatus for performing a localized thermal strengthening treatment on a glass container, according to one or more embodiments described herein. [Figure 14] 1 illustrates a method of converting a raw material glass composition into a glass container comprising at least one of a crack redirection region and a localized compressive stress region, according to one or more embodiments described herein. DETAILED DESCRIPTION OF THE INVENTION

[0074] Reference is now made in detail to embodiments of glass containers having features that prevent cracks from initiating and propagating through the glass container in a manner that could compromise the sterility of an article (e.g., a pharmaceutical product) placed therein. For example, the glass container features described herein can prevent initial surface flaws from forming or propagating through the glass container in an inconspicuous or unobservable manner, preventing inconspicuous damage to an article placed therein. Such surface flaws can occur in glass containers through contact with other surfaces during formation, shipping, filling, and handling. Cracks under tension can propagate from a point of initiation. For example, cracks formed in glass containers with residual internal tensile stresses can propagate in a direction that is dependent on the stress field within the glass container. For example, if a glass container has higher circumferential stresses than axial stresses, cracks can propagate axially rather than circumferentially. If such an axial crack propagates through the body of a glass container having an adhesive label or other covering, it may be hidden by the adhesive label and generally be less noticeable to a person handling the glass container. Various embodiments of the present disclosure introduce an internal tensile stress distribution into the glass container that facilitates diverting a potential crack in the glass container to a more prominent and / or observable portion of the glass container, or that renders the glass container unusable as a result of the crack deflection. For example, the glass container may include a crack deflection region having an internal axial tensile stress greater than an internal circumferential tensile stress, thereby facilitating the propagation of a circumferential crack in a desired region of the glass container (e.g., a portion of the glass container that is typically not hidden by an adhesive label).

[0075] In embodiments, the glass containers described herein can also include localized compressive stress regions that internally enhance the durability of the glass container. The localized compressive stress regions can be particularly positioned in areas of the glass container that frequently come into contact with external elements (e.g., molding equipment, other glass containers during transport, capping equipment, etc.). Beneficially, the localized compressive stress regions described herein have compression depths that exceed those found in prior art glass containers. Such deeper compression depths advantageously prevent surface flaws from reaching internal tensile stress regions that may exist in the core region of the glass container, thereby preventing surface flaws from propagating through the glass container and compromising the integrity of the container. According to the present disclosure, such localized compressive stress regions can be formed by subjecting selected regions of the glass container to a localized thermal tempering treatment. Such thermal tempering treatment can have additional benefits, such as inducing instantaneous tensile stresses in the glass container, helping to identify glass containers with relatively deep surface flaws resulting from the glass container forming process. Localized thermal tempering can identify and eliminate defective glass containers from a population of glass containers.

[0076] In embodiments, the glass containers described herein can include both a crack deflection region and a localized compressive stress region to provide a synergistic effect. For example, embodiments can include a crack deflection region of increased internal tensile stress that overlaps the localized compressive stress region at the exterior surface of the glass container, providing both improved damage resistance (e.g., resistance to surface scratches reaching the internal tensile stress region within the thickness of the glass container) and crack deflection in the overlapping region. In embodiments, the crack deflection region can be positioned based on the localized compressive stress region included in the glass container, such that the crack deflection region deflects cracks that initiate at specific locations in the glass container that are located between the crack deflection region and the localized compressive stress region.

[0077] In the glass container embodiments described herein, concentrations of components of the glass composition forming the glass container (e.g., SiO, AlO, BO, etc.) are specified in mole percent (mol%) on an oxide basis unless otherwise specified.

[0078] The term "substantially free," when used to describe the concentration and / or absence of a particular component in a glass composition, means that the component is not intentionally added to the glass composition. However, the glass composition may contain trace amounts of the component as tramp or suspended matter in amounts less than 0.05 mole percent.

[0079] As used herein, the term "chemical durability" refers to the ability of a glass composition to resist degradation when exposed to specific chemical conditions. Specifically, the chemical durability of the glass compositions described herein was evaluated in accordance with four established materials testing standards: DIN 12116, dated March 2001, entitled "Testing of glass - Resistance to attack by a boiling aqueous solution of hydrochloric acid - Method of test and classification," ISO 695:1991, entitled "Glass -- Resistance to attack by a boiling aqueous solution of mixed alkali -- Method of test and classification," ISO 720:1985, entitled "Glass -- Hydrolytic resistance of glass grains at 121 degrees C -- Method of test and classification," and ISO 719:1985, entitled "Glass -- Hydrolytic resistance of glass grains at 98 degrees C -- Method of test and classification." Each standard and its classification are described in further detail herein. Alternatively, the chemical durability of glass compositions can be determined using a USP Surface Glass Test entitled "Surface Glass Test." <660> and / or can be evaluated in accordance with European Pharmacopeia 3.2.1 entitled "Glass Containers For Pharmaceutical Use," which evaluates the durability of the glass surface.

[0080] As used herein, the term "softening point" refers to the temperature at which the viscosity of a glass composition reaches 1×10 7.6 Poise (0.1 x 10 7.6 This refers to the temperature at which the temperature is constant (Pa·s).

[0081] As used herein, the term "CTE" refers to the coefficient of thermal expansion of a glass composition over a temperature range from about room temperature (RT) to about 300°C.

[0082] As used herein, the term "about" means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and / or larger or smaller, as appropriate, reflecting tolerances, conversion factors, rounding, measurement error, and other factors known to those skilled in the art. When the term "about" is used in describing a value or the endpoint of a range, the specific value or endpoint referred to is included. Regardless of whether the endpoint of a numerical value or range in the specification indicates "about," two embodiments are described: those modified by "about" and those not modified by "about." It should be further understood that each endpoint of a range is significant both in relation to the other endpoint and independently of the other endpoint.

[0083] Directional terms used herein, such as up, down, right, left, front, back, top, bottom, etc., are with reference to the illustrated figures only and are not intended to imply absolute orientation.

[0084] 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.

[0085] Referring now to FIG. 1 , one embodiment of a glass container 100 for storing a pharmaceutical formulation is shown schematically in cross section. The glass container 100 generally comprises a body 102. The body 102 extends between an inner surface 104 and an outer surface 106, includes a central axis A, and generally encloses an interior volume 108. In the embodiment of the glass container 100 shown in FIG. 1 , the body 102 generally comprises a wall portion 110 and a bottom portion 112. The wall portion 110 transitions to the bottom portion 112 via a heel portion 114. In the illustrated embodiment, the glass container 100 includes a flange 126, a neck region 124 extending from the flange 126, a barrel 118, and a shoulder region 116 extending between the neck region 124 and the barrel 118. The bottom portion 112 is coupled to the barrel 118 via the heel portion 114. In an embodiment, the glass container 100 is symmetrical about a central axis A, with the barrel 118, neck region 124, and flange 126 each being substantially cylindrical. The body 102 has a wall thickness T extending between the inner surface 104 and the outer surface 106, as shown in FIG. W It has.

[0086] In an embodiment, the glass container 100 is a U.S.P. <660> and borosilicate glass compositions such as Type 1B borosilicate glass compositions under U.S.P. <660> The glass container 100 may be formed from a Type I, Type II, or Type III glass as defined in U.S. Pat. Alternatively, the glass container 100 may be formed from an alkali aluminosilicate glass composition such as that disclosed in U.S. Pat. No. 8,551,898, the entire contents of which are incorporated herein by reference, or an alkaline earth aluminosilicate glass such as that described in U.S. Pat. No. 9,145,329, the entire contents of which are incorporated herein by reference. In an embodiment, the glass container 100 may be composed of a soda-lime glass composition.

[0087] 1 as having a particular form factor (i.e., a vial), it is understood that the glass container 100 may have other form factors, including, but not limited to, Vacutainers®, cartridges, syringes, ampoules, bottles, flasks, vials, tubes, beakers, etc. Furthermore, it is understood that the glass containers described herein can be used in a variety of applications, including, but not limited to, pharmaceutical packaging, beverage containers, etc.

[0088] Wall thickness T of the glass container 100 W may vary depending on the implementation. In an embodiment, the wall thickness T of the glass container 100 W may be 6 millimeters (mm) or less, e.g., 4 mm or less, 2 mm or less, 1.5 mm or less, or 1 mm or less. In some embodiments, the wall thickness T W may be 0.1 mm to 6 mm, 0.3 mm to 4 mm, 0.5 mm to 4 mm, 0.5 mm to 2 mm, or 0.5 mm to 1.5 mm. W may be 0.9 mm or more and 1.8 mm or less.

[0089] Various portions of the glass container 100 may be susceptible to surface scratches or cracks during the formation, transportation, and use of the glass container 100. During formation, for example, glass tubing may be subjected to a conversion process that shapes, cuts, and strengthens the glass tube to form the glass container 100. The conversion process may include various processing stations where various equipment (e.g., forming equipment, punching equipment, etc.) may contact the inner surface 104 and outer surface 106, potentially creating defects. In another example, in embodiments where the glass container 100 is a pharmaceutical container, metal filling equipment may contact the neck region 124 (e.g., a rotating metal disc crimp) or the heel region 114, creating a surface scratch 120 on the outer surface 106. In another example, during transportation of the glass container 100, the outer surface 106 of the barrel 118 may contact another glass container, creating a surface scratch 122.

[0090] Various aspects of the glass container 100 can be designed to prevent or reduce the effect of flaws, such as surface flaws 120, 122, on the functionality of the glass container 100. For example, with reference to FIG. 2, in an embodiment, the body 102 extends from at least the outer surface 106 of the body 102 to a wall thickness T W The glass container 100 includes a compressive stress layer 202 extending from the exterior surface 106 of the body 102 to a compression depth DOC. The compressive stress layer 202 generally increases the strength of the glass container 100 and also improves the damage resistance of the glass container 100. Specifically, a glass container having a compressive stress layer 202 is generally able to withstand a greater degree of surface damage, such as scratches, chips, etc., without failure than an unstrengthened glass container because the compressive stress layer 202 mitigates crack propagation from surface damage in the compressive stress layer 202.

[0091] The compressive stress layer 202 can be formed in the body 102 of the glass container 100 using several different techniques. For example, in embodiments in which the body 102 is formed from an ion-exchangeable glass, the compressive stress layer 202 can be formed in the body 102 by ion exchange. In these embodiments, the compressive stress layer 202 is formed by placing the glass container in a bath of molten salt to facilitate the exchange of relatively large ions in the molten salt with relatively small ions in the glass. Several different exchange reactions can be used to achieve the compressive stress layer 202. In one embodiment, the bath can include molten KNO salt, while the glass forming the glass container 100 contains lithium and / or sodium ions. In this embodiment, potassium ions in the bath are exchanged for relatively small lithium and / or sodium ions in the glass, thereby forming the compressive stress layer 202. In another embodiment, the bath can include NaNO salt, while the glass forming the glass container 100 contains lithium ions. In this embodiment, sodium ions in the bath are exchanged for relatively small lithium ions in the glass, thereby forming the compressive stress layer 202.

[0092] In one particular embodiment, the compressive stress layer 202 can be formed by immersing the glass container in a molten salt bath of 100% KNO, or alternatively, a mixture of KNO and NaNO. For example, in one embodiment, the molten salt bath can include KNO with up to about 10% NaNO. In this embodiment, the glass forming the container can include sodium and / or lithium ions. The temperature of the molten salt bath can be between 350°C and 500°C. In some embodiments, the temperature of the molten salt bath can be between 400°C and 500°C. In yet other embodiments, the temperature of the molten salt bath can be between 450°C and 475°C. The glass container can be maintained in the molten salt bath for a time sufficient to facilitate the exchange of relatively large ions in the salt bath with relatively small ions in the glass, thereby achieving the desired surface compressive stress and depth of layer. For example, the glass can be maintained in the molten salt bath for between 0.05 hours and about 20 hours to achieve the desired depth of layer and surface compressive stress. In some embodiments, the glass container may be maintained in the molten salt bath for a period of at least 4 hours and not more than about 12 hours. In other embodiments, the glass container may be maintained in the molten salt bath for a period of at least about 5 hours and not more than about 8 hours. In one embodiment, the glass container may be ion-exchanged in a molten salt bath containing 100% KNO at a temperature of at least about 400°C and not more than about 500°C for a period of at least about 5 hours and not more than about 8 hours.

[0093] Typically, the ion exchange process is carried out at a temperature above the strain point (T strain), to minimize high-temperature stress relaxation. However, in some embodiments, the compressive stress layer 202 is formed in a molten salt bath at a temperature above the strain point of the glass. This type of ion exchange strengthening is referred to herein as "high-temperature ion exchange strengthening." In high-temperature ion exchange strengthening, relatively small ions in the glass are exchanged with relatively larger ions from a molten salt bath, as described herein. When the relatively small ions are exchanged for relatively larger ions at temperatures above the strain point, the resulting stress is released or "relaxed." However, exchanging the smaller ions in the glass for larger ions creates a surface layer in the glass that has a lower coefficient of thermal expansion (CTE) than the rest of the glass. As the glass cools, the difference in CTE between the surface of the glass and the rest of the glass creates a compressive stress layer 202. This high-temperature ion exchange technique is particularly well-suited for strengthening glass articles, such as glass containers, that have complex geometries, and typically shortens the strengthening process time and allows for greater layer depths compared to typical ion exchange processes.

[0094] Referring to FIG. 3 , in embodiments, the glass container 100 can be formed from laminated glass that promotes the formation of a compressive stress layer 202 on at least the exterior surface 106 of the body 102. Laminated glass generally comprises a glass core layer 204 and at least one glass cladding layer 206 a. In the embodiment of the glass container 100 shown in FIG. 3 , the laminated glass includes a pair of glass cladding layers 206 a, 206 b. In this embodiment, the glass core layer 204 generally comprises a first surface 205 a and a second surface 205 b opposite the first surface 205 a. The first glass cladding layer 206 a is fused to the first surface 205 a of the glass core layer 204, and the second glass cladding layer 206 b is fused to the second surface 205 b of the glass core layer 204. The glass cladding layers 206a, 206b are fused to the glass core layer 204 without the use of any additional materials, such as adhesives, coating layers, etc., disposed between the glass core layer 204 and the glass cladding layers 206a, 206b.

[0095] In the embodiment shown in FIG. 3, the glass core layer 204 has an average core coefficient of thermal expansion (CTE) core and the glass cladding layers 206a, 206b are formed from a first glass composition having an average coefficient of thermal expansion CTE clad In the embodiments described herein, the glass is formed from a second, different glass composition having a CTE core is a CTE clad , so that a compressive stress layer exists in at least one of the core layer or the cladding layer. core is a CTE clad Because the CTE is larger, the glass cladding layers 206a, 206b are subjected to compressive stress without ion-exchanging or thermally tempering. In such embodiments, one of the cladding layers 206a, 206b may comprise the compressive stress layer 202 shown in Figure 2. In some other embodiments, such as when the laminated glass comprises a single core layer and a single cladding layer, the CTE clad is a CTE core , whereby the glass core layer is subjected to compressive stress without ion exchange or thermal tempering. Laminated glass can be formed by processes such as the fusion lamination process described in U.S. Pat. No. 1,045,021, which is incorporated herein by reference. When laminated glass is used to form a container, these compressive stress layers extend from the outer surface 106 of the glass container 100 to the wall thickness T W and from the inner surface 104 of the glass container to the wall thickness T W Extends within.

[0096] Referring to FIG. 2, the compressive stress layer 202 has a wall thickness T W The DOC extending into the glass container body can depend on the method used to form the compressive stress layer 202. Depending on the implementation, the compressive stress layer 202 may extend from the outer surface 106 of the glass container body to the wall thickness T W Within the thickness of about 1 μm or more, the wall thickness T WIn embodiments where the compressive stress layer 202 is formed as a sub-layer of the laminated glass, the compressive stress layer 202 may extend from the outer surface 106 of the body 102 of the glass container to a wall thickness T W Within the thickness of about 1 μm or more, the wall thickness T W In embodiments where the compressive stress layer 202 is formed by subjecting the glass container 100 to an ion exchange process, the compressive stress layer 202 may extend from the outer surface 106 of the body 102 of the glass container 100 to a wall thickness T W Within the thickness of about 1 μm or more, the wall thickness T W The DOC can extend to a value that is about 10% or less of the DOC.

[0097] In embodiments, the compressive stress layer 202 (e.g., both outer cladding layers 206a, 206b) may be under a compressive stress of 50 megapascals (MPa) or more, 75 MPa or more, 100 MPa or more, or even 150 MPa or more. For example, in embodiments, the compressive stress layer 202 may be under a compressive stress of 50 MPa to 700 MPa, 50 MPa to 500 MPa, 50 MPa to 400 MPa, 75 MPa to 750 MPa, 75 MPa to 500 MPa, 75 MPa to 400 MPa, 100 MPa to 700 MPa, 100 MPa to 500 MPa, or even 100 MPa to 400 MPa.

[0098] In embodiments, the remainder of the glass container 100 outside the compressive stress layer 202 (e.g., the core layer 204 described with respect to FIG. 3) is under an internal tensile stress that balances the compressive stress of the compressive stress layer 202. For example, in embodiments, as a result of the CTE mismatch between the outer cladding layers 206a, 206b, the core layer 204 can exhibit an internal tensile stress or stress of 10 MPa to 50 MPa, 10 MPa to 40 MPa, 10 MPa to 30 MPa, 15 MPa to 50 MPa, 15 MPa to 40 MPa, or 15 MPa to 30 MPa. In embodiments (e.g., when the compressive stress layer 202 is formed by subjecting the glass container 100 to ion exchange), the core layer 204 can exhibit an internal tensile stress of 10-15 MPa.

[0099] 1, where the internal tensile stress stored in the glass container 100 exceeds a threshold amount (e.g., 10 MPa), surface flaws 120, 122 in the glass container 100 that extend into the internal tensile stress may form cracks that propagate from their point of initiation. The propagation direction of cracks originating from the surface flaws 120, 122 may depend on the orientation of the residual stress field within the glass container 100. For example, in one embodiment, the wall thickness T W is substantially constant (e.g., about 1.5 mm) throughout the barrel 118, and the residual tensile stress in the axial direction (e.g., parallel to axis A) in the barrel 118 is less than the residual tensile stress in the circumferential direction (e.g., extending within the barrel 118 perpendicular to the central axis A and the outer surface 106). In such a case, the surface flaw 122 may propagate in a direction perpendicular to the direction of the higher residual tensile stress. In this example, the surface flaw 122 may propagate axially. The glass container 100 may have the strength necessary to maintain the overall structure of the glass container (e.g., remain intact) even if a crack caused by the surface flaw 122 extends axially through the entire glass container 100.

[0100] Under these circumstances, a user of the glass container 100 may not notice such a crack propagating in the axial direction. Furthermore, during use, the glass container 100 may include any number of labels (e.g., adhesive labels) disposed on the exterior surface 106. Such adhesive labels may conceal cracks arising from surface flaws, such as the surface flaws 120 and 122. A crack propagating through the glass container 100 may also branch into multiple cracks, generally extending perpendicular to the direction of the greatest residual tensile stress. Such cracks may compromise the sterility of items contained within the glass container 100. In light of this, it is advantageous to prevent cracks from propagating from the surface flaws 120 and 122. Furthermore, if such a crack enters an area of ​​the glass container 100 under tensile stress, it is beneficial to ensure that such cracks propagate conspicuously, enabling the defective glass container 100 to be quickly identified and discarded.

[0101] In view of the above, in embodiments, the glass container 100 includes a crack redirection region 130 and a localized compressive stress region 140. The localized compressive stress region 140 is a region of the glass container 100 under compressive stress extending from at least one of the exterior surface 106 and the interior surface 104. In the illustrated embodiment, the localized compressive stress region 140 extends from the exterior surface 106 through the wall thickness T by an amount greater than the region of compressive stress of the glass container 100 adjacent the compressive stress region 140. W For example, in embodiments in which the glass container includes a compressive stress layer 202, as described with respect to FIG. 2, the local compressive stress region 140 has a local compression depth DOC that exceeds the DOC of the compressive stress layer. L The greater compressive depth of compressive stress in the localized compressive stress region 140 beneficially prevents surface flaws from reaching the residual tensile stresses in the glass container 100 and propagating within the glass container 100.

[0102] 1 includes a single localized compressive stress region 140 in the heel region 114, it should be understood that embodiments including a greater number of localized compressive stress regions and / or localized compressive stress regions in alternative locations on the glass container 100 (e.g., in the neck region 124, the barrel 118, the shoulder region 116, or any other location on the glass container 100) are contemplated. In embodiments, the localized compressive stress region 140 is formed by applying a localized thermal strengthening process to the glass container 100 that includes heating the glass container to a particular temperature (e.g., heating the glass composition forming the glass container 100 to its softening point), followed by a rapid cooling step in which at least one of the inner surface 104 and the outer surface 106 is cooled by applying a refrigerant to at least one of the inner surface 104 and the outer surface 106. Various methods of forming the localized compressive stress region 140 are described in more detail herein.

[0103] 1 , the crack redirection region 130 includes a modified residual stress field relative to the remainder of the glass container 100 (e.g., the portion of the glass container other than the crack redirection region 130). The stress field may be modified such that the residual tensile stress within the crack redirection region 130 is greater in a direction substantially perpendicular to the desired propagation direction of the crack. For example, in embodiments, it may be desirable to redirect a crack that initially propagates axially (e.g., substantially parallel to axis A) from the surface flaw 122 toward the bottom portion 112 to instead propagate circumferentially toward a prominent portion of the glass container 100 (e.g., an area of ​​the glass container 100 not covered by the adhesive label). In such embodiments, the crack redirection region 130 may include a residual tensile stress region with higher tensile stress extending axially than circumferentially, diverting the crack in the desired direction.

[0104] The residual stress field within the crack redirection region 130 can be directionally modified in a variety of different ways compared to the remainder of the glass container 100. In the embodiment shown in FIG. 1, for example, the crack redirection region 130 is WThe crack redirection region 130 is a thinned region where the wall thickness T is reduced. This reduction in thickness can increase the internal tensile stresses within the crack redirection region 130 when the glass container is strengthened. For example, the compressive stress layer 202 (formed, for example, through an ion exchange process) may have a wall thickness T W , so that the area of ​​the glass container 100 outside the compressive stress layer 202 has greater internal tensile stress to balance the compressive stress. The crack redirection region 130 can include any number of such thinned regions arranged in any manner to create a desired directionality in the residual tensile stress field within the crack redirection region 130.

[0105] The glass container 100 can include any number of crack deflection regions having a variety of different configurations. In embodiments, the crack deflection regions are positioned to deflect cracks through portions of the glass container 100 that are typically not covered by adhesive labels or the like, increasing the visibility of cracks propagating through the glass container 100 from relatively common initiation points. The various different crack deflection regions and methods of forming them are described in more detail herein.

[0106] 1 , while both the crack redirection region 130 and the localized compressive stress region 140 are shown extending on the exterior surface 106, it should be understood that in alternative embodiments, at least one of the crack redirection region 130 and the localized compressive stress region 140 may be located on the interior surface 104. Furthermore, certain embodiments may include multiple crack redirection regions or localized compressive stress regions. In embodiments, both the exterior surface 106 and the interior surface 104 include at least one localized compressive stress region and crack redirection region.

[0107] In embodiments, the crack redirection region 130 may overlap with the localized compressive stress region 140. Such a configuration may advantageously reduce the extent to which the glass container 100 must be modified to create the crack redirection region 130 that redirects the crack in a desired manner. Within the localized compressive stress region 140, the wall thickness TW In addition to having a layer under compressive stress that extends deeper within the glass container 100, the glass container 100 can also have a larger internal tensile stress region overlapping the deeper layer of compressive stress. For example, the embodiment shown in FIG. 1 illustrates an overlap region 150 between the localized compressive stress region 140 and the crack redirection region 130. That is, the overlap region 150 includes both the crack redirection region 130 and the localized compressive stress region 140 (i.e., the overlap region 150 has been subjected to a process described herein to form both the crack redirection region 130 and the compressive stress region 140). The increased internal tensile stress proximate the overlap region 150, resulting from the localized thermal strengthening treatment used to form the localized compressive stress region 140, can, for example, reduce the need to modify the thickness of the glass container within the crack redirection region 130 to achieve the desired modification of the residual stress field. In other words, a larger wall thickness T within the overlap region 150 W to achieve the same crack redirection effect, resulting in a stronger glass article than if the crack redirection regions 130 did not overlap with the localized compressive stress regions 140, while providing the same crack redirection capabilities.

[0108] 4A, there is shown a cross-sectional view of one embodiment of the crack deflection region 130 taken along line II of FIG. 1. FIG. 4A shows a peripheral portion of the glass container 100 at the crack deflection region 130. The crack deflection region 130 includes a recess 400, and the thickness of the glass container 100 within the recess 400 is less than the wall thickness T throughout the remainder of the barrel 118. W In an embodiment, the glass container 100 has a minimum wall thickness T min The minimum wall thickness T min can be determined based on the overall size and composition of the glass container 100. In an embodiment, the crack deflection region 130 includes a plurality of recesses 400 at the top and bottom (e.g., axially A into the page of FIG. 4A ) that create a stress field that is greater axially than circumferentially to deflect a crack propagating through the glass container 100.

[0109] For example, Figures 4B and 4C show cross-sectional views of an embodiment of the crack deflection region 130 taken along line II-II of Figure 1. As shown, the crack deflection region 130 includes a plurality of recesses 400 extending in an axial direction 402. The recesses 400 are separated by peaks 404, causing the thickness of the glass container 100 to vary sinusoidally within the crack deflection region 130. Within the crack deflection region 130, the glass container 100 reaches a minimum thickness T at a trough 406 within each recess 400. min and a maximum thickness T max In an embodiment, T max is the remaining wall thickness T of the glass container 100 W In an embodiment, T min is the remaining wall thickness T of the glass container 100 W In an embodiment, the average thickness of the glass container 100 in the crack redirection region 130 is equal to the remaining wall thickness T W is equal to.

[0110] FIG. 4B shows the axial (e.g., extending axially) stress profile of the glass container 100 within the crack redirection region 130. FIG. 4C shows the circumferential (e.g., extending circumferentially) stress profile of the glass container 100 within the crack redirection region 130. As shown in FIG. 4B, within the crack redirection region 130, the axial stress profile is min 4C, within the crack redirection region 130, the circumferential stress profile is such that in the illustrated example, the thickness is equal to T max 404 (corresponding to a local maximum in the thickness of the glass container 100) and includes an area of ​​greatest hoop stress. In an embodiment, the substantially constant wall thickness T WUnlike the remainder of the glass container 100 having a trough 406, the axial stress at the troughs 406 can be greater than the circumferential stress at the peaks 404 in the crack deflection region 130. Thus, the points of greatest axial stress in each of the troughs 406 exert axial tensile stresses such that a crack propagating through the crack deflection region 130 is deflected circumferentially.

[0111] Various aspects of the crack redirection region 130 may be varied according to the embodiments shown in Figures 4A, 4B, and 4C to vary the stress field for a particular crack redirection effect. For example, the amplitude of the sinusoid (e.g., T max and T min Varying the period P of the sinusoid (the difference between P and P) or the period P of the sinusoid can affect the difference in the direction of the stresses, thereby altering the propagation path of cracks propagating from various initiation points on the glass container 100 (e.g., decreasing the period P can increase the axial tensile stress). It should be understood that the thickness variation within the crack redirection region 130 may not vary sinusoidally in certain embodiments, but may include any distribution of thickness variation having different minimum and maximum thicknesses.

[0112] Referring to Figure 5, in embodiments, the crack deflection region 130 may also extend circumferentially around the circumference of the glass container 100 (e.g., extending tangentially to the inner surface 104), such that a crack originating from any circumferential portion of the glass container 100 may be diverted through the crack deflection region 130. As shown in Figure 5, the crack deflection region 130 includes a plurality of recesses 400 similar to those described herein with respect to Figures 4A, 4B, and 4C that extend sinusoidally in the circumferential direction. In embodiments, the crack deflection region 130 extends circumferentially around the entire circumference of the glass container 100. An axial crack that encounters such a crack deflection region 130 (e.g., extending axially or into or out of the page of Figure 5) may be diverted to separate the glass container 100, rendering the glass container 100 unusable for its intended purpose. In an embodiment, rather than a single crack deflection region 130 extending around the entire glass container 100, the glass container 100 may include multiple separate crack deflection regions, each of which may extend around only a portion of the glass container 100.

[0113] Crack redirection regions having different locations on the glass container and different structures than the crack redirection region 130 described herein are contemplated and possible. For example, Figures 6A-6H show cross-sectional views of a glass container 600 having a neck region 602 and multiple different crack redirection regions in the neck region 602. For example, Figure 6A shows an embodiment of a glass container 600 including a crack redirection region 608 that includes a notch in the neck region 602. The glass container 600 has a reduced thickness in the crack redirection region 608, which creates an axial internal tensile stress differential and redirects an axial crack circumferentially.

[0114] 6B shows an embodiment of a glass container 600 that includes a crack deflection region 610 that includes multiple grooves on both the inner surface 606 and the outer surface 604 of the neck region 602. The inclusion of grooves on both the inner surface 606 and the outer surface 604 creates additional peaks in axial stress, increasing the likelihood that a crack propagating through the crack deflection region 610 will be diverted circumferentially. The inclusion of grooves on both the inner surface 606 and the outer surface 604 also reduces the overall thickness of the glass container 600 within the crack deflection region 610, thereby increasing the difference in axial and circumferential residual tensile stresses.

[0115] Figure 6C shows an embodiment of a glass container 600 including a crack deflection region 612 comprising a groove in the inner surface 606 and the outer surface 604 at the transition region between the neck region 602 and the shoulder region 614 of the glass container 600. Such positioning of the groove allows for a segment of minimum thickness to be positioned at the base of the neck region 602, so that in the event of a crack propagating through the neck region 602, the neck region 602 can separate from the remainder of the glass container 600. Figure 6D shows an embodiment of a glass container 600 including a crack deflection region 616 comprising a groove in the inner surface 606 and the outer surface 604 at the transition region between the neck region 602 and the flange 618. Such positioning of the groove allows for a segment of minimum thickness to be positioned at the base of the flange 618, so that in the event of a crack propagating through the neck region 602 or the flange 618, the flange 618 can separate from the remainder of the glass container 600.

[0116] Figure 6E shows an embodiment of a glass container 600 that includes a crack redirection region 620 that includes rims protruding from both the inner surface 606 and the outer surface 604. The incorporation of such rims can concentrate stresses during the ion exchange process of the glass container, thereby inducing an axial differential in tensile stress. Such an implementation can be beneficial in that it can maintain the structural strength of the neck region 602 by eliminating the need for a reduced thickness region. Figure 6F shows an embodiment of a glass container 600 that includes a crack redirection region 622 that includes a gradual concavity on both the inner surface 606 and the outer surface 604 of the neck region 602.

[0117] FIG. 6G illustrates an embodiment of a glass container 600 that includes a crack deflection region 624 that includes a concave surface on the outer surface 604 within the shoulder region 614. Such positioning of the crack deflection region 624 can cause separation of the glass container 600 at the shoulder region 614 in the event of a crack that propagates axially through the barrel portion 626 of the glass container. FIG. 6H illustrates an embodiment of a glass container 600 that includes a crack deflection region 628 that includes an opening in the neck region 602. The opening creates two regions of minimum thickness within the crack deflection region 628 (e.g., a first region between the inner surface 606 and the opening, and a second region between the outer surface 604 and the opening), creating multiple axial peaks in the residual tensile stress in those regions. In an embodiment, the opening can include a material with a lower CTE than the glass composition in contact with the opening, further enhancing the tensile stress.

[0118] It should be understood that any of the crack diverting regions described with respect to Figures 6G-6H can include features on the inner surface 606, the outer surface 604, or both the inner surface 606 and the outer surface 604. Additionally, any of the crack diverting regions described with respect to Figures 6G-6H can be positioned at any location on the glass container 600 (e.g., the barrel portion 626, the heel portion, etc.).

[0119] In embodiments, the crack redirection zones described herein may not include a change in the thickness of the glass container, but may include other features that alter the residual stress field within the glass container. For example, in embodiments, the crack redirection zones may be formed by surface blocking of ions (e.g., potassium ions) during ion exchange strengthening, creating a change in axial residual tensile stress and inducing crack redirection. In another example, density changes within the glass container may be used to form the crack redirection zones. Regions of reduced density within the glass container may result in an increased depth of the compressive layer as a result of ion exchange strengthening, creating regions of increased tensile stress. In embodiments, the crack redirection zones may be formed by subjecting selected regions of the glass container to differential annealing or cooling. For example, in certain embodiments, the crack redirection zones may be formed by shielding regions of the glass container during an annealing heat treatment (e.g., after the initial formation of the glass container), by contacting desired regions of the glass container with a cooling tool during conversion of a raw material (e.g., a tube) into a glass container, or during a post-heating / cooling treatment after bulk annealing of the glass container. The crack redirection zones described herein may be formed using any technique capable of creating directional residual tensile stresses in desired regions of a glass container. In embodiments, the crack redirection zones may be formed by locally modifying fictive temperature via flame or laser treatment. In embodiments, energy from an energy source (e.g., flame, laser, etc.) may be incident on the desired location of the crack redirection zone to locally heat it. Subsequent cooling of the desired location can result in a local density change in the glass container, resulting in a different stress profile in the glass container at the crack redirection zone. This difference in stress profile between the crack redirection zone and other regions of the glass container can be increased by subsequent chemical strengthening (e.g., by ion exchange) to provide the desired crack redirection effect.

[0120] The foregoing discussion of crack redirection regions described herein primarily describes localized features within a glass container that are used to create regions of higher residual tensile stress that extend axially through the glass container. Such localized features can extend in any direction and have any desired crack redirection effect.

[0121] For example, FIG. 7 shows a perspective view of a glass container 700 including a crack 702 propagating axially through the glass container 700. The glass container 700 includes a crack deflection region 704 that generally extends circumferentially around a neck region 706 of the glass container 700. The crack deflection region 704 can include any feature (e.g., a recess, a groove, a reduced density region). However, in the illustrated embodiment, the crack deflection region 704 does not extend directly circumferentially, but rather extends along a zigzag path. For example, the crack deflection region 704 can include multiple grooves arranged in a zigzag pattern (e.g., such that the thickness of the glass container 700 varies according to a sinusoidal curve along the zigzag pattern). Such a pattern is beneficial in that the axially extending crack 702 does not intersect the crack deflection feature at a 90° angle. Therefore, the angular amount that the crack 702 must be diverted to extend along the crack redirection region 704 is smaller than in embodiments where the crack redirection region extends in a straight line along the circumferential direction. This reduction in the amount of necessary diverting can better facilitate crack diversion.

[0122] 8A-8D illustrate an embodiment of a glass container 800 including a first crack deflection feature 802. The first crack deflection feature 802 may include a plurality of features (e.g., recesses) as described herein that extend circumferentially around the neck region of the glass container 800 to deflect axial cracks circumferentially. In embodiments, additional crack deflection features may be added to the crack deflection region 802 to deflect cracks extending in a variety of different directions.

[0123] For example, Figure 8B shows an embodiment of a glass container 800 including a crack deflection region 804 that extends in a first spiral pattern. In an embodiment, the crack deflection region 804 includes a plurality of features (e.g., grooves, depressions, concavities) extending along the crack deflection region 804. The first spiral pattern can be relatively tight, such that the crack deflection region 804 extends at least once around the entire circumference of the glass container between the bottom portion 810 of the glass container and the crack deflection region 802. Such a pattern facilitates a crack initiated at any axial location within the glass container 800 to encounter the crack deflection region 804 at an angle less than 90°, thereby facilitating crack deflection in a significant manner and allowing the glass container 800 to be discarded if the glass container 800 is defective.

[0124] Figure 8C shows an embodiment of a glass container 800 that includes a crack deflection region 806 extending in a second spiral pattern. Compared to the first spiral pattern described with respect to Figure 8B, the second spiral pattern extends at a smaller angle relative to the axial direction and generally promotes the redirection of axially propagating cracks. Figure 8D shows an embodiment of a glass container 800 that includes an axially extending crack deflection region 808, which promotes the axial redirection of circumferentially propagating cracks around the glass container. The crack deflection region 808 can expose cracks that would otherwise be hidden by an adhesive label disposed on the exterior surface of the glass container 800.

[0125] In embodiments, the crack deflection regions described herein can be formed during a process for converting a feedstock (e.g., a glass tubing) into a glass container. Such a converting process is described in more detail herein with respect to FIG. 9. FIG. 9 illustrates a converter 900 that can be used to produce a glass article from a glass tubing, such as the glass container 100 described herein with respect to FIG. 1. It should be understood that the illustrated converter 900 is merely exemplary and is not intended to be limiting. The glass containers described herein can be formed by any type of converting process. The converter 900 includes a base 902 having multiple processing stations 904, a main turret 906 positioned above the base 902 and rotatable relative to the base 902 about a central axis A, and a glass tube loading turret 908 positioned above the main turret 906 and supplying a glass tubing 910 to the main turret 906. Converter 900 may also include a plurality of secondary processing stations 912 mounted on base 902 and a secondary turret 914 rotatably mounted relative to base 902 .

[0126] The multiple processing stations 904 are spaced apart from one another and arranged on a main circuit 916. In one or more embodiments, the main circuit 916 may be circular, and the main turret 906 may index the glass tubing 910 through the multiple processing stations 904 by rotation of the main turret 906 about a central axis A. Alternatively, in other embodiments, the main circuit 916 may be linear. While described herein with reference to a circular layout of the processing stations 904, it is understood that the subject matter disclosed herein is equally applicable to converters having other arrangements of the processing stations 904. The multiple processing stations 904 may include any number of processing stations depending on the implementation. The processing stations 904 may include, by way of example and not limitation, one or more heating, shaping, polishing, cooling, separating, perforating, re-coating, trimming, measuring, feeding, or ejecting stations, or other processing stations for producing a glass article from the glass tubing 910. The type and / or shape of the article to be produced from the glass tubing 910 can also influence the type and / or sequence of processing stations 904 of the converter 900 .

[0127] The main turret 906 includes a plurality of holders 918 configured to removably secure each glass tubing 910 to the main turret 906. The holders 918 may be clamps, chucks, or other holding devices, or a combination of holding devices. The holders 918 may orient each piece of glass tubing 910 so that the glass tubing 910 is approximately parallel to a central axis A of the main turret 906. The glass tube loading turret 908 may include a plurality of loading channels 920 arranged in a circular circuit, the plurality of loading channels 920 configured to hold lengths of glass tubing 910. The glass tube loading turret 908 can be positioned to align and orient one of the loading channels 920 vertically (i.e., parallel to the central axis A of the main turret 906 and / or parallel to the Z axis in FIG. 9 ) with the processing station 904 of the main circuit 916 of the converter 900 and a corresponding holder 918 on the main turret 906 that is indexed through the processing station 904 of the main circuit 916.

[0128] 10 , a processing station 1000 is shown schematically. In an embodiment, the processing station 1000 is one of the processing stations 904 of the converter 900 described herein with respect to FIG. 9 . For example, in an embodiment, the processing station 1000 may be positioned in the main circuit 916 after a first processing station that is a heating station among the processing stations 904 and a second processing station that is a forming station among the processing stations 904. As shown in FIG. 10 , a partially formed glass container 1002 is secured in a holder 1004 (e.g., corresponding to one of the holders 918 described herein with respect to FIG. 9 ). In an embodiment, the first processing station that is a heating station among the processing stations 904 may initially preheat the glass tubing to a target temperature (e.g., a softening point or working point) at which the glass tubing becomes plastically deformable and can be effectively formed without cracking or shattering the glass. After the glass tubing is preheated, a second processing station, which may be a forming station (or multiple forming stations in addition to a separation station) among processing stations 904, may form the glass tubing into a partially formed glass container 1002.

[0129] After the glass tubing is formed into the partially formed glass container 1002, the partially formed glass container 1002 may be subjected to an additional processing station 904 where the container is reheated. In an embodiment, after the glass tubing is formed into the partially formed glass container 1002, the partially formed glass container 1002 may be transferred to processing station 1000 where a crack deflection region is formed.

[0130] 10, processing station 1000 includes a first laser beam source 1006 emitting a first laser beam 1008 and a second laser beam source 1010 emitting a second laser beam 1012. Processing station 1000 can be advantageously positioned within converter 900 so that the partially formed glass container 1002 is at an elevated temperature (e.g., above the softening point of the glass composition comprising the partially formed glass container 1002) when it reaches processing station 1000. Such an elevated temperature facilitates the use of relatively low-power laser beam sources for first laser beam source 1006 and second laser beam source 1010. In an embodiment, first laser beam source 1006 and second laser beam source 1010 are CO laser sources emitting pulsed laser beams 1008, 1012. The pulsed laser beams 1008, 1012 can have a variety of different pulse lengths and spot sizes depending on the characteristics of the crack redirection region desired to be formed. For example, the pulse length and / or power of the first laser beam source 1006 and the second laser beam source 1010 can be adjusted to a desired minimum thickness of the glass container within the crack redirection region (e.g., T as described with respect to Figures 4A, 4B, and 4C). min The spot size of the pulsed laser beams 1008, 1012 can be adjusted (e.g., using optics, not shown, positioned between the laser beam sources 1006, 1010) based on the desired size of the thickness change in the crack redirection region (e.g., the period P described with respect to FIG. 4C).

[0131] A second laser beam 1012 is directed toward the exterior surface 1014 of the partially formed glass container 1002. Thus, the second laser beam source 1010 may be used to form recesses (e.g., recesses 400 described herein with respect to FIGS. 4A, 4B, and 4C) on the exterior surface 1014. In embodiments, the partially formed glass container 1002 and the second laser beam 1012 may be moved relative to one another (e.g., via a scanning element, not shown, positioned between the second laser beam source 1010 and the partially formed glass container 1002) to form a desired pattern of recesses on the exterior surface 1014. In embodiments, the holder 1004 rotates while the partially formed glass container 1002 is in the processing station 1000, such that any desired pattern of recesses may be formed around the entire circumference of the partially formed glass container 1002. In embodiments, the relative positioning between the partially formed glass container 1002 and the second laser beam 1012 can be adjusted axially (e.g., via a scanning element, via an axially translating holder 1004) so ​​that crack redirection features are formed at any axial location on the exterior surface 1014. Recesses can be formed in the interior surface 1016 of the partially formed glass container 1002 via the first laser beam 1008 in a similar manner.

[0132] 10 , it should be understood that processing station 1000 may include any number of laser beam sources depending on the implementation. For example, in an embodiment, processing station 1000 may include multiple laser beam sources positioned at various axial locations on partially formed glass container 1002 to simultaneously form multiple crack redirection regions on exterior surface 1014 and interior surface 1016. In an embodiment, a single laser beam source may be used to form crack redirection regions on both interior surface 1016 and exterior surface 1014.

[0133] Alternative processing stations for forming the crack redirection regions described herein during the conversion process are also contemplated. For example, one processing station can include a molding or forming element that mechanically contacts the surface (e.g., exterior surface 1014 and interior surface 1016) of the partially formed glass container 1002 while the partially formed glass container 1002 is at an elevated temperature. The forming element can have a surface including a first portion that conforms to the surface (e.g., exterior surface 1014) of the partially formed glass container 1002 and a second portion shaped to correspond to the desired profile of the crack redirection region feature (e.g., recess, rim). The forming element can be press-fit into various locations on the partially formed glass container 1002 to form the crack redirection region described herein. Another alternative processing station can include a localized heat source (e.g., laser beam, flame) that locally alters the fictive temperature within a region of the partially formed glass container 1002 to form the crack redirection region.

[0134] While the foregoing examples describe forming the crack redirecting regions herein during a conversion process for converting a glass tubing into a glass container, it should be understood that the crack redirecting features described herein may be formed at different times. For example, any of the crack redirecting features may be formed during a step in which the finished glass container is heated after the conversion process.

[0135] 11A, region 1100 of glass container 100 described with respect to FIG. 1 is shown schematically in accordance with an exemplary embodiment. Region 1100 includes a localized compressive stress region 140. In the illustrated embodiment, glass container 100 includes a compressive stress layer 1104 extending across region 1100. In embodiments, compressive stress layer 1104 can be formed by any of the methods described herein with respect to compressive stress layer 202 shown in FIG. 2. In embodiments, glass container 100 may not include compressive stress layer 1104. For example, in embodiments where the glass container is relatively large (e.g., defining an internal volume of 20 ml or greater but not greater than 50 ml), glass container 100 may not be chemically strengthened by ion exchange and may not include compressive stress layer 1104, provided that the localized compressive stress region is located in a high-contact region of the glass container (e.g., heel region 114, neck region 124, shoulder region 116). That is, the localized compressive stress regions described herein can eliminate the need to ion-exchange certain glass containers, reducing processing costs.

[0136] 11A, the compressive stress layer 1104 extends from the outer surface 106 into the wall thickness of the glass container 100 to a first compression depth DOC1. In the embodiment, the glass container 100 has a maximum compressive stress CS max Below is the maximum compressive stress CS max The value of can vary depending on how the compressive stress layer 1104 is formed and the composition of the glass container 100. For example, in an embodiment, the maximum compressive stress CS max may be in the range of 50 MPa to 750 MPa (eg, 750 MPa, 700 MPa, 500 MPa, 400 MPa, 300 MPa, 200 MPa, 100 MPa, 50 MPa, or any value therebetween).

[0137] At line A shown in Figure 11A, the residual stress profile of the glass container 100 changes to tension at a first compression depth DOC1. That is, the compressive stress layer 1104 extends from the outer surface 106 to the wall thickness T WThe compressive stress layer 1104 extends to a first compressed depth DOC1 within the laminated glass. The first compressed depth DOC1 may vary depending on the implementation. For example, in embodiments where the compressive stress layer 1104 is formed by ion exchange, the first compressed depth DOC1 may be about 3 μm or greater. In some embodiments, the layer depth may be about 25 μm or greater, or even about 30 μm or greater. For example, in some embodiments, the first compressed depth DOC1 may be about 10 μm or greater and about 200 μm or greater. In some other embodiments, the first compressed depth DOC1 may be about 30 μm or greater and about 150 μm or less. In still other embodiments, the first compressed depth DOC1 may be about 30 μm or greater and about 80 μm or less. In some other embodiments, the first compressed depth DOC1 may be about 35 μm or greater and about 50 μm or less. In embodiments, the compressive stress layer 1104 may be formed within the cladding layer of the laminated glass. In such an embodiment, the cladding layer may also be subjected to ion exchange strengthening, creating a superimposed compressive stress profile in the compressive stress layer 1104 .

[0138] In an embodiment, the first compression depth DOC1 is the distance from the outer surface 106 to the wall thickness T of the glass container 100. W In an embodiment, the first compression depth DOC1 may extend no more than 25% into the wall thickness T W 2% or less of the wall thickness T W 3% or less of the wall thickness T W 5% or less of the wall thickness T W 10% or less of the wall thickness T W 15% or less of the wall thickness T W 20% or less of the wall thickness T W or any value therebetween.

[0139] 11A, within the localized compressive stress region 140, the glass container 100 is under compressive stress to a second compressive depth DOC2 that exceeds the first compressive depth DOC1 of the compressive stress layer 1104. Thus, within the localized compressive stress region 140, the residual compressive stress is greater than in regions of the glass container 100 outside of (or adjacent to) the localized compressive stress region 140, the wall thickness T WThe compressive stress in the localized compressive stress region 140 extends deeper into the glass container 100. Considering that surface flaws imparted to the exterior surface 106 can branch and propagate under tensile stress, such a greater depth of compressive stress in the localized compressive stress region 140 can increase the glass container 100's resistance to fracture. That is, the greater compressive stress depth in the localized compressive stress region 140 effectively increases the threshold amount of damage required to cause fracture of the glass container 100. In this manner, because the localized compressive stress region 140 is positioned proximate to the heel region 114 of the glass container 100 (see FIG. 1 ), the glass container 100 is effectively made more resistant to contact with external objects (e.g., holders, other glass containers, etc.) within the heel region 114.

[0140] In embodiments, the localized compressive stress region 140 is formed by applying a localized heat strengthening treatment to a portion of the glass container 100. For example, the glass container 100 may be heated to a target temperature (e.g., to its softening point) and then rapidly cooled in a controlled manner (e.g., by exposing the exterior surface 106 to a coolant, such as a gas or liquid). Such rapid cooling hardens the surface layer of the glass container 100 exposed to the coolant, leaving the interior of the glass container 100 in a softer state. The cooled surface layer forms a rigid structure that prevents the interior of the glass container 100 from contracting upon cooling, creating a tension region that opposes the compressive state of the surface layer exposed to the coolant. Such a localized heat strengthening treatment can result in a compressive stress depth that exceeds that achievable by chemical strengthening techniques, such as ion exchange.

[0141] In an embodiment, the stress profile of the compressive stress within the localized compressive stress region 140 can be different from the stress profile of the compressive stress outside the localized compressive stress region 140 as a result of a localized thermal strengthening treatment applied to the localized compressive stress region 140. In an embodiment, the compressive stress within the localized compressive stress region 140 is substantially parabolic in shape and extends through the wall thickness T W1. In an embodiment, the second compression depth DOC2 exceeds the first compression depth DOC1 outside the localized compressive stress region 140. In the example shown, the compressive stress layer 1104 overlaps (or extends through) the localized compressive stress region 140. Such a structure may result from a process in which the glass container 100 is subjected to a localized thermal strengthening treatment (e.g., in the cooling processing station of the converter 900 described with reference to FIG. 9 ) to form the localized compressive stress region 140, followed by chemical strengthening by ion exchange. As a result, the exterior surface 106 at the localized compressive stress region 140 may be subjected to both the thermal strengthening treatment and the ion exchange. In an embodiment, by exposing the exterior surface 106 to both the ion exchange and the thermal strengthening treatment, the maximum compressive stress at the exterior surface 106 may be greater within the localized compressive stress region 140 than outside the localized compressive stress region 140.

[0142] While the foregoing examples include a compressive stress layer 1104 and a localized compressive stress region 140, it should be understood that various alternative embodiments are contemplated. For example, certain embodiments may not include a compressive stress layer 1104 extending throughout the entire glass container 100. The localized compressive stress region 140 may also be formed by localized chemical strengthening, and in certain embodiments, the second compression depth DOC2 may be less than the compression depth shown in FIG. 11B. For example, in embodiments in which the localized compressive stress region 140 is formed using a localized ion exchange process, the second compression depth DOC2 may be less than the wall thickness T W The second compression depth DOC2 depends on the method used to form the localized compressive stress region 140 and may be less than 3% (e.g., 1%, 2%, 2.5%) of the wall thickness T W The change may be between 2% and 25% of the

[0143] Additionally, it should be understood that the glass containers described herein can include multiple different localized compressive stress regions in various different locations. Particular embodiments of the glass container 100 can include localized compressive stress regions on the interior surface 104. Additionally, the crack redirection regions described herein can overlap with localized compressive stress regions. Such structures are beneficial in that the localized thermal strengthening treatment used to create the localized compressive stress regions can work in concert with the structural changes in the crack redirection regions to create tensile stress differentials perpendicular to the desired propagation direction. This tensile stress differential, resulting from the overlapping crack redirection regions and localized compressive stress regions, can reduce the amount of structural (e.g., thickness) modification within the crack redirection regions, maintaining the structural strength of the glass container 100 while providing a similar crack redirection effect.

[0144] As described herein, the localized compressive stress regions described herein can be formed by locally applying a thermal strengthening process to the glass container 100. Such processes are not typically applied to glass containers because uniform cooling of glass with complex shapes is generally difficult. Thermal strengthening processes may rely on the application of a gaseous refrigerant to the heated glass surface to achieve uniform cooling of the glass. Referring to FIG. 1, the glass container 100 includes a complex shape (e.g., flange 126, shoulder region 116, heel region 114) that makes it difficult to apply such a refrigerant to the glass container 100. Therefore, it is difficult to achieve the required heat transfer coefficient when thermally strengthening the entire glass container 100. Additionally, thermal strengthening processes can be more effective in glass compositions with a high coefficient of thermal expansion (CTE). Prior art glass containers may be constructed from compositions (e.g., alkali borosilicate glasses) that are incompatible with thermal strengthening techniques. Certain glass containers also require a wall thickness T of 0.6 mm or greater and 3 mm or less. W Also, conventional thermal strengthening techniques are not compatible with such thicknesses due to reduced heat transfer coefficients.

[0145] With this in mind, the glass containers described herein may be constructed from glass compositions that are more amenable to heat strengthening processes than prior art glass container compositions. In embodiments, the glass containers described herein may be constructed from glass compositions that are more amenable to heat strengthening processes than prior art glass container compositions. -6 °C -1 The glass container 100 is constructed from a glass composition having a CTE equal to or greater than 10 ...

[0146] 12A, 12B, 12C, and 12D graphically illustrate various aspects that affect the effectiveness of thermal strengthening for glass containers described herein. FIG. 12A graphically illustrates surface compressive stress (e.g., at the exterior surface 106) versus the starting temperature to which the glass container is heated during thermal strengthening. Each curve represents the transfer coefficient (cal / (cm)) during cooling of the glass. 2 In the illustrated embodiment, the glass container 100 is generally constructed from an alkali aluminosilicate glass composition including a combination of SiO and one or more alkali oxides, such as NaO and / or KO. The glass composition may also include AlO and at least one alkaline earth oxide. The glass container 100 has a wall thickness T of 1.1 mm in the illustrated example. W In the illustrated example, the glass container 100 is not ion-exchange strengthened.

[0147] As shown in FIG. 12A, the higher the heat transfer coefficient and onset temperature, the higher the level of compressive stress at the exterior surface 106 within the localized compressive stress region 140. 2 A heat transfer coefficient of 0.001 cal / (cm s K) provides a compressive stress of approximately 225 MPa at the outer surface 106. In contrast, a 211B described above, provides a compressive stress of approximately 30 MPa at the outer surface 106 to achieve a desired amount of damage tolerance within the localized compressive stress region 140. max ) can be 50 MPa or greater (e.g., 75 MPa or greater, 100 MPa or greater, 125 MPa or greater, 150 MPa or greater, or 200 MPa or greater). Thus, for the illustrated alkali aluminosilicate compositions, an onset temperature of about 750°C or greater can be used. Additionally, 0.01 cal / (cm 2 A heat transfer coefficient of at least 1000 K (s·k) or greater may be used to cool the glass container after it has been heated to a starting temperature of at least about 750°C.

[0148] FIG. 12B graphically illustrates various curves of internal tensile stress (e.g., in the adjacent region 1110 described with reference to FIG. 11A) resulting from the thermal tempering process described with reference to FIG. 12A for the glass container 100. As shown, thermal tempering to achieve the desired amount of compressive stress at the exterior surface 106 also provides an internal tensile stress of approximately 30 MPa or greater. Such internal tensile stress can promote crack branching and propagation if a surface flaw somehow penetrates the localized compressive stress region 140. FIG. 12C graphically illustrates various curves of maximum surface tensile stress resulting from the thermal tempering process described with reference to FIG. 12A. That is, the thermal tempering process described herein results in an instantaneous tensile stress at the exterior surface 106. Such instantaneous tensile stress can isolate surface flaws imparted to the glass container during the conversion process, resulting in the rejection of the defective container. As shown, thermal tempering to achieve the desired amount of compressive stress at the exterior surface 106 also results in a surface tensile stress of approximately 40 MPa or more, which is sufficient to render the glass container 100 unsuitable for use if a surface flaw is imparted to the glass container 100 during conversion.

[0149] Figure 12D shows the 0.06 cal / (cm 212A illustrates the compressive stress at the exterior surface 106 within the localized compressive stress region 140 of a glass container 100 having various thicknesses, assuming a heat transfer coefficient of 100 / 200 kJ / cm² (≈1.5 s≈K). As shown, a thicker glass container 100 generally results in a higher compressive stress at the exterior surface 106. FIG. 12E illustrates the internal tensile stress within the localized compressive stress region 140 of a glass container having the thickness described in FIG. 12D. As shown, the greater the thickness (e.g., in the adjacent region 1110 described with respect to FIG. 11A), the greater the internal tensile stress.

[0150] Various coolants may be applied to the glass container 100 at the localized compressive stress region 140 to achieve a desired amount and depth of compressive stress within the glass container 100 in the localized compressive stress region 140. In embodiments, helium, air, engine oil, and evaporated steam have relatively high heat transfer coefficients, making them suitable for potential use in the thermal strengthening processes described herein. In embodiments, the coolant may be delivered to the localized compressive stress region 140 at a specific temperature via a tool specifically designed for the area on the glass container 100 where the localized compressive stress region 140 is located.

[0151] 13A and 13B schematically illustrate a cooling device 1400 for performing the localized thermal strengthening process described herein. In embodiments, the cooling device 1400 can be incorporated into a processing station of a converter (e.g., the converter 900 described herein with respect to FIG. 9 ) to thermally strengthen the glass container 100 during the process of converting the glass tubing into the glass container 100. As described herein, the converter 900 can include a heating station that heats the glass tubing to a temperature suitable for forming (e.g., a temperature of 870°C or higher). Such a temperature is higher than the starting temperature (e.g., 750°C or higher) to achieve the desired level of compressive stress in the alkali aluminosilicate glass container. Therefore, it should be understood that positioning the cooling device 1400 within the converter 900 can provide efficiencies; because the glass composition has already been heated to the required starting temperature, the cooling device 1400 can be separated from the converter 900 and used after the subsequent heating step of the fully converted glass container 100.

[0152] In the illustrated embodiment, the cooling device 1400 is designed to apply a coolant to specifically cool a neck region 1404 of a glass container 1402. The cooling device 1400 includes a coolant manifold 1408 sized to contact an outer surface 1410 of the neck region 1404. The coolant manifold 1408 extends from a body 1412. The coolant manifold 1408 can have a size (e.g., axially and circumferentially of the glass container 1402) that corresponds to the desired size of the localized compressive stress region to be placed on the glass container 1402.

[0153] 13B, the body 1412 includes a first portion 1414 and a second portion 1416. In FIG. 13B, the first portion 1414 and the second portion 1416 are separated from one another (e.g., in a processing station on the converter 900) to provide clearance for inserting the glass container 1402 (or glass tubing or partially formed glass container) therebetween. The first portion 1414 and the second portion 1416 can each be coupled to an actuator that facilitates translation along an axis 1418 that extends perpendicular to the axis of the glass container 1402. For example, once the glass container 1402 is positioned in a desired axial position (such that the cooling device 1400 axially overlaps the area of ​​the glass container 1402 where it is desired to incorporate a localized compressive stress region), the first portion 1414 and the second portion 1416 can be translated toward one another, after which the inner surfaces 1420, 1422 of the cooling device 1400 are separated from the outer surface 1410 by a desired minimum separation distance. In the embodiment shown in FIG. 13B , the cooling device 1400 can surround the glass container 1402, imparting a localized compressive stress region extending around the entire glass container 1402 within the neck region 1404.

[0154] 13A , the cooling device includes contact points 1424 and 1426 that precisely control the minimum separation distance between the cooling device 1400 and the exterior surface 1410. In an embodiment, the contact points 1424 and 1426 may include points of pressurized gas (e.g., refrigerant, other gases, coming from a refrigerant supply 1430). In an embodiment, the contact points 1424 and 1426 may comprise wheels or other rotatable members to facilitate positioning the cooling device 1400 on the glass container 1402. In an embodiment, the contact points 1424 and 1426 may include rims (e.g., constructed of the same material as the body 1412 or a different material from the body 1412) extending from the refrigerant manifold 1408 to provide a controlled minimum separation distance. As the first portion 1414 and the second portion 1416 translate toward one another, the contact points 1424 and 1426 can contact the exterior surface 1410, creating a refrigerant cavity 1428 disposed between the refrigerant manifold 1408 and the exterior surface 1410. The body 1412 includes a refrigerant supply 1430 extending therethrough. In an embodiment, the refrigerant supply 1430 fluidly couples the refrigerant cavity 1428 to a refrigerant source (not shown). Refrigerant (e.g., water vapor, helium, air, oil) from the refrigerant source can be provided through the refrigerant supply 1430 into the refrigerant cavity 1428, allowing the refrigerant to contact the glass vessel 1402 and increasing the heat transfer coefficient achieved through the cooling device 1400.

[0155] The body 1412 also includes fluid channels 1432 extending therethrough. The fluid channels 1432 can receive cooling fluid from a fluid source (not shown) to reduce the temperature of the cooling device 1400. By sizing the various components of the cooling device 1400 (e.g., the coolant manifold 1408, the body 1412) in a manner that corresponds to a particular region on the glass vessel 1402, intimate contact between the glass vessel 1402 and the cooling device 1400 can be achieved, providing a sufficiently high heat transfer coefficient to induce compressive stress within the glass vessel 1402. That is, by specifically designing the thermal strengthening treatment process for a sub-region of the vessel, the intimate contact and application of coolant to the sub-region provides a relatively high heat transfer coefficient for effective thermal strengthening in the localized compressive stress region.

[0156] The above example described with respect to FIGS. 13A and 13B is tailored to the neck region of a glass container 1402. It should be understood that similar sizing and configuration are possible for various other locations depending on the type of glass container being strengthened. Some other areas where it may be desirable to incorporate localized compressive stress regions include, but are not limited to, the heel region of a vial (e.g., heel region 114 described herein with respect to FIG. 1), the foot region of a cartridge, the neck region of a syringe, the flange of a syringe, or any other location within a glass container. In embodiments, a glass container can include multiple localized compressive stress regions. In such embodiments, the multiple localized compressive stress regions can be formed in a single processing step (e.g., a single cooling device may include multiple axial sections, each designed to intimately contact a sub-region of the container) or in separate processing steps. For example, each processing step can include a cooling device similar to cooling device 1400 described with respect to FIGS. 13A and 13B designed to intimately contact a separate region of the glass container. In embodiments, the separate processing steps to form each localized compressive stress region may be separated by a heating step to reheat the glass container to a desired starting temperature for the thermal strengthening process.

[0157] Alternative methods beyond the cooling devices shown in FIGS. 13A and 13B can be used for the localized thermal strengthening process described herein. For example, targeted application of a refrigerant to specific regions of the glass container can be used to create localized compressive stress regions. Such embodiments can include a refrigerant applicator that does not contact the glass container, but applies the refrigerant to the glass container in a desired pattern to create a desired cooling effect. For example, the refrigerant can include a condensed refrigerant (e.g., snow) that can be controllably applied to various regions (e.g., both the interior and exterior surfaces of the glass container). In such embodiments, water, steam, air, oil, and a variety of other potential refrigerants can be used. In embodiments, the rate of heat transfer can be controlled by the amount of refrigerant circulated to contact the glass container (e.g., an amount determined by controlling the refrigerant supply) and / or the amount of evaporation of the refrigerant upon contact with the glass container (e.g., an amount determined by the type of refrigerant used). In embodiments, the controlled cooling of the glass container for thermal strengthening can be combined with other aspects of the conversion process to provide additional processing efficiencies. For example, in embodiments, a forming device (e.g., configured to contact a glass container at a forming temperature to form the glass container) can have an integrated coolant supply such that coolant is supplied to the formed region while the formed region is being formed to thermally strengthen the formed region. In such embodiments, oil can be used to establish an interface between the forming device and the glass container such that the contact surface of the glass container is simultaneously forming and cooling.

[0158] It should also be understood that the localized compressive stress regions described herein can also be located on the inner surface of the outer container. For example, while a glass container is subjected to thermal strengthening via the cooling device 1400 described with respect to Figures 13A and 13B, the inner surface 1434 of the glass container 1402 (see Figure 13B) may be convectively cooled by air flowing through a processing station incorporating the cooling device 1400, resulting in some degree of thermal tempering. In embodiments, the inner surface 1434 may be cooled via a different method than the outer surface 1410. For example, in embodiments, a region of the outer surface 1410 is thermally strengthened via the cooling device 1400, while a region of the inner surface 1434 is thermally strengthened via the application of a controllable coolant (e.g., snow). In embodiments, the reinforced regions of the exterior surface 1410 and the interior surface 1434 can overlap (e.g., face each other) to provide a balanced compressive stress profile and increased internal tensile stress to promote crack branching if a surface flaw exceeds a threshold and damages the glass container 1402. For example, the bottom of the container can be cooled externally and internally to provide such a balanced stress profile to ensure separation if a surface flaw occurs at the bottom.

[0159] Referring now to Figure 15, a flow diagram of a method 1500 for forming a glass container including at least one of a crack redirection region or a localized compressive stress region is shown. Method 1500 may be used to form the glass container 100 described herein with respect to Figure 1. By performing method 1500, the glass container may be locally strengthened in desired areas of the glass container that are susceptible to flaws that may propagate via the localized thermal strengthening treatment described herein. Additionally, the glass container resulting from the performance of method 1500 may be able to redirect cracks that propagate through portions of the container that are difficult for a user to notice, allowing the user to notice such cracks and discard the cracked container.

[0160] In step 1502, a feedstock formed from a glass composition is provided. The composition of the glass article may vary depending on the implementation. As described herein, glass containers incorporating crack redirection regions can provide regions of increased internal tensile stress resulting from mismatched CTEs due to ion exchange strengthening. Accordingly, embodiments incorporating crack redirection regions can be formed from glass compositions that are capable of chemical strengthening via ion exchange. In embodiments, the glass composition is generally an alkali aluminosilicate glass composition comprising a combination of SiO and one or more alkali oxides, such as NaO and / or KO. The glass composition may also include AlO and at least one alkaline earth oxide. In embodiments, borosilicate glass compositions or other aluminosilicate compositions may be used. In embodiments, the feedstock formed from the glass composition can include a glass tubing formed from the glass composition. The glass tubing can be manufactured using a Vero process, such as the process described in U.S. Pat. No. 4,023,953. Other processes, such as the Danner process, can also be used to manufacture the glass tubing.

[0161] In step 1504, the feedstock is formed into a glass container having a body. As can be appreciated, the processing steps performed to form the glass container can depend on the feedstock and the shape of the glass container from which it is formed. For example, in embodiments, the feedstock can be converted into glass containers having a number of different shapes, such as bottles, vials, syringes, ampoules, cartridges, and other glass articles for pharmaceutical applications. The feedstock can also be converted into glass containers for non-pharmaceutical uses, such as food packaging. In embodiments, the forming step can be performed in a converter, such as converter 900 described herein with respect to FIG. 9. As described herein, converter 900 includes a number of processing stations 904, including, for example, one or more heating, shaping, polishing, cooling, separating, perforating, re-coating, trimming, measuring, feeding, or ejecting stations or other processing stations for producing a glass article from a glass tubing. In embodiments, the feedstock is heated to a forming temperature above the softening point of the glass composition via a heating station in the number of processing stations 904. After heating, the feedstock can be subjected to a number of different forming stations to form the feedstock into the desired glass container. For example, if the glass container is a vial as shown in Figure 1, various forming stations may be used to form the flange 126, neck region 124, shoulder region 116, barrel 118, and heel region 114 of the glass container 100. After the forming step and any subsequent additional steps (e.g., measuring, polishing, coating), the formed glass container can be separated from the blank via a separation (e.g., notching) station.

[0162] At step 1506, a crack redirection region is formed in the glass container. As described herein, the crack redirection region can be formed at various points in the process of converting the feedstock into a glass container, or alternatively, after the conversion process is completed. For example, in an embodiment, the converter 900 includes a forming station that forms at least one crack redirection region in the glass container while the feedstock is heated above the forming temperature of the glass composition. For example, in an embodiment, the converter 900 can include a processing station 1000 described herein with respect to FIG. 10. At least one of the first laser beam source 1006 and the second laser beam source 1010 can scan a laser beam (e.g., a pulsed CO laser beam) across a surface of the feedstock, forming a plurality of depressions in the surface of the feedstock, such that the glass container resulting from the conversion process has a wall thickness T of the glass container outside of the crack redirection region. W The minimum thickness T is less than min The recess includes a plurality of recesses having a

[0163] In embodiments, the crack redirection region can be formed simultaneously with or after the formation of the localized compressive stress region. For example, as described herein, the crack redirection region can be formed by exposing the crack redirection region to a different heat treatment than the remainder of the glass container to form a low-density region within the glass container. Thus, in embodiments, the crack redirection region can be formed by a thermal strengthening step similar to that described herein with respect to FIGS. 11A-14B. For example, a cooling device can contact the material in a predetermined pattern to create a tensile stress differential extending substantially perpendicular to any desired propagation direction (e.g., axially, circumferentially, or any combination thereof). In another example, the low-density region can be formed by shielding the glass container during an annealing step after formation of the glass container (e.g., during step 1510).

[0164] In embodiments, the crack redirection region may be formed during chemical strengthening of the glass container (e.g., during step 1512 described herein). For example, during the conversion process, in addition to creating one or more features at the surface of the material, the ion exchange process may be arrested at various locations within the crack redirection region, creating complex internal tensile stress profiles for redirecting the crack. In embodiments, any combination of features and methods of forming the features may be used, and any number of crack redirection regions may be formed on the glass container.

[0165] In step 1508, a localized compressive stress region is formed in the glass container. In embodiments, the localized compressive stress region is formed during the process of converting the raw material into a glass container. For example, in embodiments, after being subjected to the heating station of the converter 900 and heated to a starting temperature, the raw material can be inserted into a thermal tempering station including a cooling device 1400 described herein with reference to FIGS. 13A and 13B. The cooling device 1400 can be specially designed to have a surface corresponding to the outer surface of the raw material, providing intimate contact with the outer surface at the desired location of the localized compressive stress region and enhancing heat transfer. Additionally, the cooling device 1400 can provide a coolant via a coolant supply 1430 to a coolant cavity 1428 on the surface of the raw material, causing the raw material to cool at a rapid and controlled rate, forming a localized compressive stress region having a compression depth greater than any area of ​​the raw material adjacent to the localized compressive stress region. Alternative methods for cooling the raw material can be used. For example, a different coolant (e.g., oil, snow, etc.) can be applied to a portion of the raw material, forming a localized compressive stress region at the desired location on the glass container. In embodiments, the localized compressive stress regions can be formed after the formation of the glass container, where the as-formed glass container is subsequently heated to a desired starting temperature and rapidly cooled by any of the methods described herein.

[0166] In embodiments, the crack redirection region and the localized compressive stress region can overlap one another. For example, a crack redirection region comprising multiple recesses may subsequently be subjected to a localized thermal strengthening treatment as described herein. Such an implementation may increase the internal tensile stress within the crack redirection region relative to embodiments in which the localized compressive stress region does not overlap with the crack redirection region, thereby enhancing the crack redirection capability of the crack redirection region. Additionally, the glass container may include any number of crack redirection regions and localized compressive stress regions on the interior surface, the exterior surface, or both the interior and exterior surfaces.

[0167] In step 1510, additional heat treatments are formed in the glass container. For example, after the glass container is formed, the glass container may be subjected to an annealing step. Such an annealing step can remove residual stresses in the glass container resulting from thermal tempering induced during the conversion process. In embodiments incorporating localized compressive stress regions in regions of the glass container containing such residual stresses, such an annealing step may not be necessary for the glass container because the regions of the glass container most susceptible to damage may have improved protection from damage. Additionally, as described herein with respect to FIG. 12C , the thermal strengthening process described herein can induce momentary tensile stresses in the localized compressive stress regions during the formation of the localized compressive stress regions. Such momentary tensile stresses can cause breakage of the defective glass container. That is, only intact and relatively strong glass containers can withstand the thermal strengthening process, reducing the need for the annealing step.

[0168] In embodiments, the glass container may be subjected to a flame cleaning after the conversion process. Such a flame cleaning step may remove or reduce surface flaws on the glass container resulting from the conversion process. In embodiments, such a flame cleaning step may be performed prior to forming the localized compressive stress regions in step 1508 to remove defects that may propagate as a result of the instantaneous tensile stresses created by the thermal strengthening treatment used to form the localized compressive stress regions.

[0169] In step 1512, the glass container may be subjected to a chemical strengthening treatment. In embodiments, the glass container may be subjected to ion exchange strengthening while immersed in the molten salt bath. Such ion exchange strengthening may form a compressive stress layer (e.g., compressive stress layer 202 described herein with respect to FIG. 2) throughout the glass container. The crack redirection region described herein may have a tensile stress distribution after the chemical strengthening step that balances the compressive stress induced by the chemical strengthening step, with the tensile stress distribution having a stress difference in a direction perpendicular to the desired propagation direction. In embodiments incorporating a localized compressive stress region, the chemical strengthening step may be eliminated because, as a result of the localized compressive stress region, the glass container may be durable enough for use.

[0170] In view of the foregoing, it should be appreciated that incorporating at least one of a crack deflection region and a localized compressive stress region into a glass container advantageously improves the durability of the glass container and / or improves the visibility of cracks propagating through the glass container. The crack deflection region redirects cracks that initiate from common locations of surface flaws on the container to areas of the glass container that do not contain visual obstructions (e.g., adhesive labels, etc.), allowing users of the glass container to notice the crack and discard the defective glass container before the product contained therein is contaminated. The localized compressive stress region beneficially increases the damage threshold of surface flaws propagating through the glass container in areas that are in constant contact with external elements (e.g., filling equipment, other glass containers, carriers), and beneficially increases the durability of the glass container. Thus, the glass containers described herein have improved durability compared to existing glass containers, and if a crack propagates through the glass container, such a crack is diverted to a portion of the container where it can be noticed more quickly than a crack propagating through an existing glass container.

[0171] Unless expressly stated otherwise, it is in no way 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, where a method claim does not actually recite the order in which its steps are to be followed, or an apparatus claim does not actually recite an order or orientation for individual components, or where it is not otherwise clearly stated in the claim or detailed description that the steps are limited to a particular order, or where no particular order or orientation for the apparatus components is recited, no order or orientation is intended to be implied in any way. This applies to all possible non-expressive bases of interpretation, including questions of logic regarding the arrangement of steps, flow of operations, order of components, or orientation of components, the apparent meaning derived from grammatical construction or punctuation, and the number or type of embodiments set forth in the specification.

[0172] 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. Accordingly, it is intended that this specification cover modifications and variations of the various embodiments described herein, provided such modifications and variations come within the scope of the appended claims and their equivalents.

[0173] Preferred embodiments of the present invention will be described below in detail.

[0174] Embodiment 1 1. A method of making a glass container having a first surface and a second surface separated by a thickness, comprising: forming a first region under compressive stress on the first surface of the glass container, the first region extending from the first surface to a compression depth in the glass container; forming a second region under internal tensile stress, the second region extending from the compression depth into the thickness, the internal tensile stress being sufficient to self-propagate the crack from its initiation point at the first surface; forming a crack redirection region on the first surface, the crack deflection region extends in a predetermined direction of propagation of the crack; the crack deflection region comprises a higher internal tensile stress in a direction substantially perpendicular to the predetermined propagation direction than the remainder of the glass article, such that when the crack propagates and reaches the crack deflection region, the crack is deflected along the predetermined propagation direction. forming a crack redirection region; A method comprising:

[0175] Embodiment 2 2. The method of claim 1, wherein the glass container comprises a body having an inner surface and an outer surface, the inner surface defining an interior volume having an axis, and the predetermined direction of propagation is substantially perpendicular to the axis.

[0176] Embodiment 3 The method of embodiment 2, wherein the thickness of the glass container varies within the crack deflection region, whereby the crack deflection region comprises a thinned region extending substantially parallel to the axis, and in the thinned region, the thickness is less than the average thickness of the glass container within the crack deflection region.

[0177] Embodiment 4 4. The method of claim 3, wherein the crack redirection region extends around at least a portion of the circumference of the glass container.

[0178] Embodiment 5 5. The method of claim 4, wherein the thickness of the glass article in the crack redirection region varies sinusoidally parallel to the axis.

[0179] Embodiment 6 5. The method of claim 4, wherein the crack redirection region extends around the entire circumference of the glass container.

[0180] Embodiment 7 3. The method of claim 2, wherein the first surface is the exterior surface of the glass container.

[0181] Embodiment 8 3. The method of claim 2, wherein the first surface is the interior surface of the glass container.

[0182] Embodiment 9 The step of forming the first region and the second region includes: forming the glass container from a glass composition; forming the first region and the second region by subjecting the first surface of the glass container to chemical tempering; 2. The method of embodiment 1, comprising:

[0183] Embodiment 10 10. The method of claim 9, wherein the glass composition comprises an aluminosilicate glass composition.

[0184] Embodiment 11 forming the glass article from the glass composition, forming a glass tube containing the glass composition; converting the glass tube into the glass container; Including, forming the crack redirection region occurs during conversion of the glass tube into the glass container; The method of embodiment 9.

[0185] Embodiment 12 12. The method of claim 11, wherein forming the crack redirection region comprises scanning a pulsed laser beam in a predetermined pattern while heating the glass tube to the softening temperature of the glass composition during conversion of the glass tube into the glass container.

[0186] Embodiment 13 1. A method of forming a glass container having a crack redirection region, comprising: providing a blank formed from a glass composition; forming the blank into a glass article having a body extending between an inner surface and an outer surface and defining an interior volume; forming a compressive stress layer on the glass article, the compressive stress layer extending from at least one of the interior surface and the exterior surface to a compressed depth of the thickness of the body; forming the crack redirection region in the glass article, the crack redirection region comprising a subregion having a higher internal tensile stress than the remainder of the glass article, the subregion extending in a direction substantially perpendicular to a predetermined propagation direction; A method comprising:

[0187] Embodiment 14 the material comprises a glass tubing; The method further includes converting the glass tubing into the glass article; forming the crack redirection region includes forming a sub-region of the crack redirection region during conversion of the glass tubing into the glass article, wherein a thickness of the sub-region is less than an average thickness of the body. The method of embodiment 13.

[0188] Embodiment 15 15. The method of claim 14, wherein forming the subregions comprises scanning a pulsed laser beam in a predetermined pattern on the glass article.

[0189] Embodiment 16 15. The method of claim 14, wherein forming the subregions comprises contacting the glass tubing with a shaping element during conversion of the glass tubing into the glass article.

[0190] Embodiment 17 A glass container, a glass body comprising: a first region under compressive stress extending from a surface of the glass body to a compression depth; and a second region extending from the compression depth into a thickness of the glass body, the second region being under tensile stress sufficient to cause the crack to self-propagate from its initiation point in a propagation direction; a crack diverting region on the surface of the glass body, the crack diverting region extending in a predetermined direction of propagation of the crack, the crack diverting region comprising a tensile stress in a sub-region of the crack diverting region that is greater than a tensile stress in the second region, the sub-regions extending substantially perpendicular to the predetermined propagation direction, whereby when the crack propagates into the crack diverting region, the crack is diverted along the predetermined propagation direction; A glass container comprising:

[0191] Embodiment 18 18. The glass container of embodiment 17, wherein the glass container comprises one of a bottle, a vial, an ampoule, a syringe, or a cartridge.

[0192] Embodiment 19 18. The glass container of claim 17, wherein the predetermined propagation direction is a circumferential direction substantially perpendicular to the axis of the glass container.

[0193] Embodiment 20 20. The glass container of claim 19, wherein the thickness varies within the crack redirection region, such that the subregions of the crack redirection region comprise thinned regions extending substantially parallel to the axis, and in the thinned regions, the thickness is less than the average thickness of the glass article.

[0194] Embodiment 21 A glass container, a body comprising a glass composition, the body having an inner surface, an outer surface, and a wall thickness extending between the inner surface and the outer surface, the body comprising a local compressive stress region having a local compressive stress extending from the outer surface to a local compressive depth within the body; the localized compressive stress region extends further into the body than any compressive stress region adjacent to the localized compressive stress region; Glass container.

[0195] Embodiment 22 22. The glass container of embodiment 21, wherein the glass container comprises a pharmaceutical container.

[0196] Embodiment 23 22. The glass container of claim 21, wherein the localized compression depth extends through at least 2% and at most 25% of the wall thickness.

[0197] Embodiment 24 24. The glass container of claim 23, wherein the localized compression depth extends through 20% to 25% of the wall thickness.

[0198] Embodiment 25 22. The glass container of claim 21, wherein the localized compressive stress region comprises a compressive stress of 50 MPa or more.

[0199] Embodiment 26 23. The glass container of claim 22, wherein the localized compressive stress region comprises a surface compressive stress of 75 MPa or greater.

[0200] Embodiment 27 24. The glass container of embodiment 23, wherein the surface compressive stress is 100 MPa or more.

[0201] Embodiment 28 22. The glass container of claim 21, wherein the localized compressive stress region overlaps with a compressive stress layer of the glass container under compressive stress, such that within the localized compressive stress region, the body includes a compressive stress of the compressive stress layer up to a first compressive depth and a localized stress depth from the first compressive depth to the localized compressive depth.

[0202] Embodiment 29 22. The glass container of claim 21, wherein the glass composition comprises an aluminosilicate glass composition.

[0203] Embodiment 30 22. The glass container of claim 21, wherein the glass container comprises a vial having a base, a barrel connected to the base via a heel, a shoulder extending from the barrel, and a neck extending from the shoulder, and the localized compressive stress area is located in at least one of the neck, the heel, and the barrel.

[0204] Embodiment 31 31. The glass container of claim 30, wherein the localized compressive stress area is located in the heel.

[0205] Embodiment 32 22. The glass container of claim 21, further comprising an additional localized compressive stress region having an additional localized compressive stress extending from the interior surface to an additional localized compressive depth within the body.

[0206] Embodiment 33 33. The glass container of claim 32, wherein the localized compressive stress region and the additional localized compressive stress region oppose each other to form an internal tensile stress region between the localized compressive stress region and the additional localized compressive stress region, the internal tensile stress region promoting branching of a crack propagating through the wall thickness and rendering the glass container unusable.

[0207] Embodiment 34 A glass container, a glass body comprising a first region under compressive stress extending from a surface of the glass body to a compression depth, and a second region extending from the compression depth into a thickness of the glass body, the second region being under tensile stress; a localized compressive stress region having a localized compressive stress extending from the surface to a localized compressive depth within the body; Equipped with the local compression depth is greater than or equal to 2% and less than or equal to 25% of the wall thickness of the body; the local compression depth exceeds the compression depth of the first region; Glass container.

[0208] Embodiment 35 35. The glass container of claim 34, wherein the localized compressive stress region overlaps with the first region, such that within the localized compressive stress region, the glass body has a compressive stress of the first region to a first compression depth and a localized stress depth from the first compression depth to the localized compression depth.

[0209] Embodiment 36 35. The glass container of claim 34, wherein the localized compressive stress region comprises a compressive stress of 50 MPa or more.

[0210] Embodiment 37 35. The glass container of claim 34, wherein the surface of the glass body is an exterior surface of the glass container.

[0211] Embodiment 38 1. A method of forming a glass container having localized compressive stress regions, comprising: providing a blank formed from a glass composition; forming the feedstock into a glass article having a body with a thickness extending between an inner surface and an outer surface, the body defining an interior volume; forming a localized compressive stress region in the glass article, the localized compressive stress region having a localized compressive stress extending from the exterior surface or the interior surface to a localized compression depth within the body, the localized compression depth being between 2% and 25% of the thickness, wherein forming the localized compressive stress region comprises locally applying a refrigerant to a predetermined portion of the glass article when the glass article is heated to an initiation temperature above a softening temperature of the glass composition such that the localized compressive stress region extends further into the body than any compressive stress region adjacent to the localized compressive stress region; A method comprising:

[0212] Embodiment 39 39. The method of claim 38, further comprising, after the step of forming the localized compressive stress region, subjecting the glass article to ion exchange strengthening to form a first region under compressive stress at the exterior surface, the first region extending from the exterior surface to a compression depth that is less than the localized compression depth.

[0213] Embodiment 40 39. The method of claim 38, wherein locally applying the refrigerant to the portion of the glass article induces an instantaneous tensile stress in the central thickness portion that induces propagation of any cracks formed in the central portion.

[0214] Embodiment 41 39. The method of claim 38, further comprising flame cleaning the entire exterior surface to eliminate conversion flaws induced by forming the material into the glass article prior to forming the localized compressive stress regions.

[0215] Embodiment 42 topically applying the refrigerant to the portion of the glass article includes: positioning a collar proximate to the portion of the glass article as the glass article is heated to the starting temperature, the collar including at least one supply of the coolant, the collar being shaped to correspond to the portion of the glass article, the collar including contact points that contact the portion of the glass article to control a gap between a fluid manifold of the collar and the portion of the glass article; providing the refrigerant to the portion of the glass article to form the localized compressive stress region; 39. The method of embodiment 38, comprising:

[0216] Embodiment 43 39. The method of claim 38, wherein the glass article is not subjected to an annealing heat treatment after forming the localized compressive stress regions.

[0217] Embodiment 44 39. The method of claim 38, wherein the glass container comprises a vial having a base, a barrel connected to the base via a heel, a shoulder extending from the barrel, and a neck extending from the shoulder, and the portion of the glass article to which the refrigerant is applied comprises at least one of the neck and the heel.

[0218] Embodiment 45 A glass container, a glass body comprising a first region under compressive stress extending from a surface of the glass body to a compression depth, and a second region extending from the compression depth into a thickness of the glass body, the second region being under tensile stress; a localized compressive stress region having a localized compressive stress extending from the surface to a localized compressive depth within the body, the local compression depth exceeds the compression depth of the first region; localized compressive stress regions; a crack diverting region in the glass body, the crack diverting region extending in a predetermined propagation direction, the crack diverting region having a higher tensile stress in a sub-region of the crack diverting region than the tensile stress of the second region, the sub-region extending substantially perpendicular to the predetermined propagation direction; A glass container comprising:

[0219] Embodiment 46 46. ​​The glass container of claim 45, wherein the subregion of the crack redirection region comprises a change in thickness at the surface of the glass body.

[0220] Embodiment 47 47. The glass container of claim 46, wherein the surface of the glass body comprises an exterior surface of the glass container.

[0221] Embodiment 48 47. The glass container of claim 46, wherein the crack redirection region overlaps the localized compressive stress region at an overlap region.

[0222] Embodiment 49 46. ​​The glass container of claim 45, wherein the localized compressive stress region overlaps with the first region, such that within the localized compressive stress region, the glass body has a compressive stress of the first region to a first compression depth and a localized stress depth from the first compression depth to the localized compression depth.

[0223] Embodiment 50 46. ​​The glass container of embodiment 45, wherein the localized compressive stress region comprises a compressive stress of 50 MPa or more.

[0224] Embodiment 51 46. ​​The glass container of claim 45, wherein the glass body is formed from an aluminosilicate glass composition.

[0225] Embodiment 52 46. ​​The glass container of embodiment 45, wherein the glass container comprises a vial having a base, a barrel connected to the base via a heel, a shoulder extending from the barrel, and a neck extending from the shoulder.

[0226] Embodiment 53 53. The glass container of claim 52, wherein the crack redirection region is located within the barrel proximate at least one of the heel and the shoulder.

[0227] EMBODIMENT 54 54. The glass container of claim 53, wherein the localized compressive stress region is located in at least one of the neck and the heel.

[0228] Embodiment 55 1. A method of forming a glass container, comprising: providing a blank formed from a glass composition; forming the feedstock into a glass article having a body extending between an inner surface and an outer surface, the body defining an interior volume; forming a crack redirection region in the glass article, the crack redirection region comprising a subregion having a higher internal tensile stress than the remainder of the glass article, the subregion extending in a direction substantially perpendicular to a predetermined propagation direction; forming a localized compressive stress region in the glass article, the localized compressive stress region having a localized compressive stress extending from the interior surface or the exterior surface to a localized compression depth within the body, the localized compression depth being between 2% and 25% of a thickness of the body, the forming the localized compressive stress region comprising locally applying a refrigerant to a predetermined portion of the glass article when the glass article is heated to an initiation temperature above a softening temperature of the glass composition; A method comprising:

[0229] Embodiment 56 56. The method of claim 55, further comprising forming a compressive stress layer in the glass article, the compressive stress layer extending within a thickness of the body from at least one of the inner surface and the outer surface to the compression depth.

[0230] Embodiment 57 57. The method of claim 56, wherein forming the compressive stress layer comprises, after forming the localized compressive stress region, subjecting the glass article to ion exchange strengthening to form a first region under compressive stress at the outer surface, the first region extending from the outer surface to the compression depth, the compression depth being less than the localized compression depth.

[0231] Embodiment 58 58. The method of embodiment 57, wherein the localized compressive stress region overlaps with the first region on the exterior surface.

[0232] Embodiment 59 59. The method of claim 58, wherein the crack redirection region overlaps with the localized compressive stress region on the exterior surface.

[0233] Embodiment 60 56. The method of claim 55, further comprising flame cleaning the entire exterior surface to eliminate conversion flaws induced by forming the material into the glass article prior to forming the localized compressive stress regions.

[0234] Embodiment 61 topically applying the refrigerant to the portion of the glass article includes: positioning a collar adjacent to the portion of the glass article as the glass article is heated to the initiation temperature, the collar including at least one supply of the coolant, the collar being shaped to correspond to the portion of the glass article; supplying the refrigerant to the portion of the glass article to form the localized compressive stress region; The method of implementation 55 includes:

[0235] Embodiment 62 62. The method of claim 61, wherein the collar includes contact points that contact the portion of the glass article to control the gap between the fluid manifold of the collar and the portion of the glass article.

[0236] Embodiment 63 63. The method of claim 62, wherein the glass container comprises a vial having a base, a barrel connected to the base via a heel, a shoulder extending from the barrel, and a neck extending from the shoulder, and the portion of the glass article to which the refrigerant is applied comprises at least one of the neck and the heel.

[0237] EMBODIMENT 64 56. The method of claim 55, wherein forming the crack redirection region comprises forming the subregion of the crack redirection region during shaping of the material into the glass article, and the thickness of the subregion is less than the average thickness of the body.

[0238] Embodiment 65 65. The method of embodiment 64, wherein forming the subregions comprises scanning a pulsed laser beam in a predetermined pattern on the glass article.

[0239] Embodiment 66 65. The method of claim 64, wherein forming the subregion comprises contacting the material with a molding element having a shape corresponding to the predetermined shape of the subregion during forming of the material into the glass article.

[0240] Embodiment 67 56. The method of embodiment 55, wherein a thickness of the portion of the crack redirection region is greater than an average thickness of the body.

Claims

1. 1. A method of making a glass container having a first surface and a second surface separated by a thickness, comprising: forming a first region under compressive stress on the first surface of the glass container, the first region extending from the first surface to a compression depth in the glass container; forming a second region under internal tensile stress, the second region extending from the compression depth into the thickness, the internal tensile stress being sufficient to self-propagate the crack from its initiation point at the first surface; forming a crack redirection region in the first surface, the crack deflection region extends in a predetermined direction of propagation of the crack; the crack deflection region contains a higher internal tensile stress in a direction substantially perpendicular to the predetermined propagation direction than the remainder of the glass container, such that when the crack propagates and reaches the crack deflection region, the crack is deflected along the predetermined propagation direction. forming a crack redirection region; Including, the glass container comprises a body having an inner surface and an outer surface, the inner surface defining an interior volume having an axis, the predetermined direction of propagation being substantially perpendicular to the axis; The method, wherein the thickness of the glass container varies within the crack deflection region, whereby the crack deflection region comprises a thinned region extending substantially parallel to the axis, and in the thinned region, the thickness is less than the average thickness of the glass container within the crack deflection region.

2. A method of making a glass container having a first surface and a second surface separated by a thickness, comprising: forming a first region under compressive stress on the first surface of the glass container, the first region extending from the first surface to a compression depth in the glass container; forming a second region under internal tensile stress, the second region extending from the compression depth into the thickness, the internal tensile stress being sufficient to self-propagate the crack from its initiation point at the first surface; forming a crack redirection region in the first surface, the crack deflection region extends in a predetermined direction of propagation of the crack; the crack deflection region contains a higher internal tensile stress in a direction substantially perpendicular to the predetermined propagation direction than the remainder of the glass container, such that when the crack propagates and reaches the crack deflection region, the crack is deflected along the predetermined propagation direction. forming a crack redirection region; Including, The step of forming the first region and the second region includes: forming the glass container from a glass composition; forming the first region and the second region by subjecting the first surface of the glass container to chemical tempering; Including, forming the glass container from the glass composition, forming a glass tube containing the glass composition; converting the glass tube into the glass container; Including, The method, wherein forming the crack redirection region occurs during conversion of the glass tube into the glass container.

3. 3. The method of claim 2, wherein forming the crack redirection region comprises scanning a pulsed laser beam in a predetermined pattern while heating the glass tube to a softening temperature of the glass composition during conversion of the glass tube into the glass container.

4. A glass container, a glass body comprising: a first region under compressive stress extending from a surface of the glass body to a compression depth; and a second region extending from the compression depth into a thickness of the glass body, the second region being under tensile stress sufficient to cause a crack to self-propagate from its initiation point in a propagation direction; a crack diverting region on the surface of the glass body, the crack diverting region extending in a predetermined direction of propagation of the crack, the crack diverting region comprising a tensile stress in a sub-region of the crack diverting region that is greater than a tensile stress in the second region, the sub-regions extending substantially perpendicular to the predetermined propagation direction, whereby when the crack propagates into the crack diverting region, the crack is diverted along the predetermined propagation direction; Equipped with the predetermined propagation direction is a circumferential direction substantially perpendicular to the axis of the glass container; the thickness varies within the crack deflection region, whereby the sub-regions of the crack deflection region comprise thinned regions extending substantially parallel to the axis, and in the thinned regions the thickness is less than an average thickness of the glass container. Glass container.

5. The glass container of claim 4 , wherein the glass container comprises one of a bottle, a vial, an ampoule, a syringe, or a cartridge.

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