Systems and processes for rapid coating of glass articles

Abstract

Systems and methods of coating glass articles are disclosed herein. The methods of coating the glass articles include transporting glass articles on a conveyor through a focal point of a coating station, where the coating station comprises a plurality of spray nozzles that spray a plurality of coating sprays including at least one leading spray and at least one trailing spray of droplets of a coating solution toward the focal point of the coating station where the spray droplets contact surfaces of the glass articles forming a coating on the glass articles. The systems include the conveyor, the coating station, and a coating material system coupled to the coating station that supplies the plurality of spray nozzles with droplets of the coating solution. The plurality of spray nozzles are oriented in the coating station with a specific spray angle relative to a traveling direction of glass articles.

Description

SYSTEMS AND PROCESSES FOR RAPID COATING OF GLASS ARTICLESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application Serial No. 63 / 603,835 filed on November 29, 2023, the content of which are relied upon and incorporated herein by reference in their entirety.BACKGROUNDField

[0002] The present specification generally relates to systems and methods for continuously processing glass articles, in particular, systems and methods for applying a coating to surfaces of glass articles.Technical Background

[0003] Historically, glass has been used to produce a variety of articles. In particular, because of its hermeticity, optical clarity, and excellent chemical durability relative to other materials, glass has been a preferred material for pharmaceutical applications, including, without limitation, vials, syringes, ampoules, cartridges, jars, and other glass articles. Production of these articles from glass starts with providing glass tubing that may subsequently be formed and separated into a plurality of the glass articles. Specifically, the glass used in pharmaceutical packaging must have adequate mechanical and chemical durability so as to not affect the stability of the pharmaceutical formulations contained therein. Glasses having suitable chemical durability include those glass compositions within the ASTM standard ‘Type IA’ and ‘Type IB’ glass compositions, which have a proven history of chemical durability.

[0004] Coatings can be added to surfaces of the glass articles for purposes of modifying the properties of the glass articles. In some cases, coatings can be added to the glass articles for purposes of changing the coefficient of friction, improving the strength of the glass articles, reducing incidence of damage into the surfaces of the glass articles, or combinations of these.SUMMARY

[0005] Accordingly, a need exists for systems and methods for continuously and efficiently applying coatings to glass articles. According to a first aspect of the disclosure, a method for coating glass articles may comprise passing a glass article through a focal point of a coating station; and directing a plurality of coating sprays towards the focal point of the coating station as the glass article is passed through the focal point, wherein: each of the plurality of coating sprays may comprise atomized droplets of a coating solution; and directing the plurality of coating sprays at the focal point of the coating station while passing the glass article through the focal point may apply the coating solution to surfaces of the glass article when the glass article passes through the coating station.

[0006] A second aspect may include the first aspect, wherein the plurality of coating sprays may comprise at least one leading spray and at least one trailing spray.

[0007] A third aspect may include the second aspect, wherein the at least one leading spray and the at least one trailing spray may each be oriented at a spray angle of incidence of less than or equal to 67.5 degrees, wherein the spray angle of incidence is defined as an acute angle formed between a primary flow vector representing an average direction of contents of the spray from at least one leading spray or at least one trailing spray and a direction of travel of the glass article through the coating station.

[0008] A fourth aspect may include the second aspect, wherein the at least one leading spray and the at least one trailing spray may each be oriented at a spray angle of incidence of less than 90 degrees and greater than 0 degrees, wherein: a direction of travel of the glass article through the coating station may be a linear direction of travel or a line tangent to a curved path of travel at the focal point of the coating station; a center line of the glass article may be a line that passes through a geometric center of the glass article and the focal point of the coating station and is perpendicular to the direction of travel of the glass article through the coating station; a cross-sectional plane of the glass article is a plane that is parallel to the direction of travel and perpendicular to the center line of the glass article; and the spray angle of incidence is defined as an acute angle formed between the direction of travel of the glass article through the coating station and a primary flow vector of the coating spray comprising an average spray direction of the coating spray in the cross-sectional plane of the glass article.

[0009] A fifth aspect may include any one of the second through fourth aspects, wherein the at least one leading spray and the at least one trailing spray may each be oriented to have a spray angle of less than 45 degrees.

[0010] A sixth aspect may include any one of the first through fifth aspects, comprising directing two coating sprays towards the focal point of the coating station.

[0011] A seventh aspect may include any one of the first through sixth aspects, wherein both of the two coating sprays may be orthogonal to a direction of travel of the glass article through the focal point of the coating station.

[0012] A eighth aspect may include any one of the first through seventh aspects, wherein each of the two coating sprays may be oriented to have a spray angle of less than or equal to 67.5 degrees, wherein: a direction of travel of the glass article through the coating station is a linear direction of travel or a line tangent to a curved path of travel at the focal point of the coating station; a center line of the glass article is a line that passes through a geometric center of the glass article and the focal point of the coating station and is perpendicular to the direction of travel of the glass article through the coating station; a cross-sectional plane of the glass article is a plane that is parallel to the direction of travel and perpendicular to the center line of the glass article; and the spray angle is defined as an acute angle formed between the direction of travel of the glass article through the coating station and a spray direction of the coating spray in the cross-sectional plane of the glass article.

[0013] A ninth aspect may include any one of the first through fifth aspects, comprising directing three or more coating sprays towards the focal point of the coating station.

[0014] A tenth aspect may include the ninth aspect, wherein the three or more coating sprays may be distributed evenly about the focal point of the coating station.

[0015] An eleventh aspect may include any one of the ninth through tenth aspects, comprising at least two leading sprays or at least two trailing sprays.

[0016] A twelfth aspect may include any one of the ninth through tenth aspects, comprising at least one leading spray, at least one trailing spray, and at least one neutral spray, wherein the at least one neutral spray may be oriented to have a spray direction that is perpendicular to the direction of travel of the glass article through the coating station.

[0017] A thirteenth aspect may include any one of the first through twelfth aspects, wherein the directing the plurality of coating sprays towards the focal point of the coating station may comprise: atomizing the coating solution to produce an atomized flow of droplets of the coating spray; and creating a plurality of flow patterns of the droplets with a plurality of gas nozzles to produce the plurality of coating sprays and directing the plurality of coating sprays towards the focal point.

[0018] A fourteen aspect may include any one of the first through twelfth aspects, wherein the directing the plurality of coating sprays towards the focal point of the coating station may comprise generating the plurality of coating sprays with a plurality of spray nozzles oriented so that an average flow direction of each of the spray nozzles may be directed towards the focal point of the coating station.

[0019] A fifteenth aspect may include any one of the first through fourteenth aspects, further comprising re-directing stray droplets of the coating solution back towards the glass article in the coating station, wherein: the stray droplets may comprise overspray or droplets of the coating solution deflected from surfaces of the glass article; and the stray droplets may be redirected by gas flows produced with one or a plurality of gas nozzles.

[0020] A sixteenth aspect may include any one of the first through fifteenth aspects, wherein the glass article comprises a glass container having a bottom, wherein the method may further comprise re-directing stray droplets toward a heel, a bottom, or both of the glass container.

[0021] A seventeenth aspect may include any one of the first through sixteenth aspects, further comprising: measuring a thickness profile of a polymer coating on the glass article downstream of the coating station; changing a distance from a nozzle to the focal point, a flow rate of the polymer solution, a spray angle of one or more of the plurality of coating sprays, or combinations of these based on the thickness profile of the polymer coating.

[0022] An eighteenth aspect may include any one of the first through seventeenth aspects, further comprising passing the glass article through the coating station at a speed of greater than or equal to 300 mm / s, greater than or equal to 500 mm / s, greater than or equal to 1000 mm / s, greater than or equal to 1500 mm / s.

[0023] A nineteenth aspect may include any one of the first through eighteenth aspects, comprising passing a plurality of glass articles through the coating station in succession.

[0024] A twentieth aspect may include the nineteenth aspect, wherein the plurality of glass articles may be pharmaceutical containers.

[0025] A twenty-first aspect may include the nineteenth or twentieth aspect, wherein the plurality of glass articles may be pharmaceutical glass vials.

[0026] A twenty-second aspect may include any one of the first through twenty-first aspects, wherein each of the plurality of coating sprays may have an average spray direction that is parallel to a cross-sectional plane of the glass article when a centerline of the glass article is congruent with the focal point of the coating station, wherein: a direction of travel of the glass article through the coating station is a linear direction of travel or a line tangent to a curved path of travel at the focal point of the coating station; the center line of the glass article is a line that passes through a geometric center of the glass article and the focal point of the coating station and is perpendicular to the direction of travel of the glass article through the coating station; and the cross-sectional plane of the glass article is a plane that is parallel to the direction of travel and perpendicular to the center line of the glass article.

[0027] A twenty-third aspect may include any one of the first through twenty-first aspects, wherein one or more of the plurality of coating sprays may have an average spray direction that forms a non-zero angle with a plane perpendicular to a center line of the glass article when the center line of the glass article is congruent with the focal point of the coating station, wherein: a direction of travel of the glass article through the coating station is a linear direction of travel or a line tangent to a curved path of travel at the focal point of the coating station; the center line of the glass article is a line that passes through a geometric center of the glass article and the focal point of the coating station and is perpendicular to the direction of travel of the glass article through the coating station; and the cross-sectional plane of the glass article is a plane that is parallel to the direction of travel and perpendicular to the center line of the glass article.

[0028] A twenty-fourth aspect may include any one of the first through twenty-third aspects, wherein a rotational speed of the glass article may be equal to zero while passing the glass article through the focal point of the coating station.

[0029] A twenty-fifth aspect may include any one of the first through twenty-fourth aspects, wherein the method does not include rotating the glass articles.

[0030] A twenty-sixth aspect may include any one of the first through twenty-fifth aspects and may be directed to a coated glass article prepared according to a method of any one of the first through twenty-fifth aspects, wherein the coated glass article may comprise a plurality of stitching regions, where a stitching region is defined as a region of increased thickness of the polymer coating caused by overlap of two of the coating sprays.

[0031] A twenty-seventh aspect may include the twenty-sixth aspect, wherein the coated glass article may be a pharmaceutical container.

[0032] A twenty-eighth aspect may include the twenty-sixth or twenty-seventh aspect, wherein the coated glass article is a pharmaceutical glass vial.

[0033] According to a twenty-ninth aspect of the disclosure, a system for coating glass articles with a polymer coating may comprise a coating station and a conveyor operable to convey a plurality of the glass articles through the coating station, wherein: the coating station may comprise a plurality of spray nozzles, each of which may be in a fixed position; the plurality of spray nozzles may be distributed radially about a spray focal point of the coating station; and the plurality of spray nozzles may be configured to direct a spray comprising a polymer coating material at each of the plurality of glass articles as each of the plurality of glass articles pass through the coating station.

[0034] A thirtieth aspect may include the system of the twenty-ninth aspect, wherein the coating station may comprise two spray nozzles.

[0035] A thirty-first aspect may include the thirtieth aspect, wherein two spray nozzles may each be oriented to direct a spray of the polymer coating solution in a direction perpendicular to a direction of travel of the plurality of glass articles through the coating station.

[0036] A thirty-second aspect may include any one of the thirtieth or the thirty-first aspects, wherein the two spray nozzles may comprise a first spray nozzle and a second spray nozzle, wherein: the first spray nozzle may be disposed upstream of the focal point of the coating station and oriented to direct a first spray of the polymer coating solution towards the focal point of the coating station; and the second spray nozzle may be disposed downstream of thefocal point of the coating station and oriented to direct a second spray of the polymer coating solution towards the focal point of the coating station.

[0037] A thirty-third aspect may include the thirty-second aspect, wherein the first spray nozzle and the second spray nozzle may each make a spray angle of from less than or equal to 67.5 degrees, wherein the spray angle may be defined as an acute angle formed between an average direction of a spray vector of the first spray nozzle or the second spray nozzle and a direction of travel of the plurality of glass articles through the coating station.

[0038] A thirty-fourth aspect may include the thirty-second aspect, wherein the first spray nozzle and the second spray nozzle may each have a spray angle of less than 45 degrees, where the spray angle may be defined as an acute angle formed between an average direction of a spray vector of the first spray nozzle or the second spray nozzle and a direction of travel of the plurality of glass articles through the coating station.

[0039] A thirty-fifth aspect may include any one of the twenty-ninth through the thirtyfourth aspects, wherein the coating system may comprise three or more spray nozzles.

[0040] A thirty-sixth aspect may include the thirty-fifth aspect, wherein the three or more spray nozzles may be evenly spaced apart in an angular direction about the focal point of the coating system.

[0041] A thirty-seventh aspect may include any one of the thirty-fifth or the thirty sixth aspects, wherein the three or more spray nozzles may comprise at least two leading spray nozzles or at least two trailing spray nozzles.

[0042] A thirty-eighth aspect may include any one of the thirty-fifth or the thirty-sixth aspects, wherein the three or more spray nozzles may comprise at least one leading spray nozzle, at least one trailing spray nozzle, and at least one neutral spray nozzle, wherein the neutral spray nozzle may be oriented to have a spray direction that is perpendicular to the direction of travel of the glass article through the coating station.

[0043] A thirty-ninth aspect may include any one of the twenty-ninth through the thirtyeighth aspects, further comprising one or more gas jets positioned to direct a gas flow that may redirect droplets of the coating solution back towards the glass article in the coating station.

[0044] A fortieth aspect may include any one of the twenty-ninth through the thirty-ninth aspects, wherein the conveyor may be operable to convey the glass articles through the coating station at a speed of greater than or equal to 300 mm / s, greater than or equal to 500 mm / s, greater than or equal to 1000 mm / s, greater than or equal to 1500 mm / s.

[0045] Additional features and advantages of the systems and methods disclosed herein will be set forth in the detailed description that follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments described herein, including the detailed description, which follows, the claims, as well as the appended drawings.

[0046] 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 character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein, and together with the description serve to explain the principles and operations of the claimed subject matter.Brief Description of the Drawings

[0047] FIG. 1 schematically depicts a side view of a system for applying a coating to glass articles, according to one or more embodiments shown and described herein;

[0048] FIG. 2 schematically depicts a top view of the system of FIG. 1, according to one or more embodiments shown and described herein;

[0049] FIG. 3 depicts a cross sectional view of an example structure of a glass article, according to one or more embodiments shown and described herein;

[0050] FIG. 4 schematically depicts a top view of within a spray zone of a coating station of the system of FIG. 1 comprising a base two spray nozzle configuration, according to one or more embodiments shown and described herein;

[0051] FIG. 5 schematically depicts a top view of within a spray zone of a coating station of the system of FIG. 1 comprising a two spray nozzle configuration with a first off-axis angle, according to one or more embodiments shown and described herein;

[0052] FIG. 6 schematically depicts a top view of within a spray zone of a coating station of the system of FIG. 1 comprising a two spray nozzle configuration with a second off-axis angle, according to one or more embodiments shown and described herein;

[0053] FIG. 7 schematically depicts a top view of within a spray zone of a coating station of the system of FIG. 1 comprising a two spray nozzle configuration with a third off-axis angle, according to one or more embodiments shown and described herein;

[0054] FIG. 8 schematically depicts a top view of within a spray zone of a coating station of the system of FIG. 1 comprising a three spray nozzle configuration, according to one or more embodiments shown and described herein;

[0055] FIG. 9 schematically depicts a first comparison of two nozzles from the top view of within a spray zone of a coating station of the three spray nozzle configuration depicted in FIG.8, according to one or more embodiments shown and described herein;

[0056] FIG. 10 schematically depicts a second comparison of two nozzles from the top view of within a spray zone of a coating station of the three spray nozzle configuration depicted in FIG. 8, according to one or more embodiments shown and described herein;

[0057] FIG. 11 schematically depicts a third comparison of two nozzles from the top view of within a spray zone of a coating station of the three spray nozzle configuration depicted in FIG. 8, according to one or more embodiments shown and described herein;

[0058] FIG. 12 schematically depicts a perspective view of within a spray zone of a coating station comprising N number spray nozzles and a heel turn, according to one or more embodiments shown and described herein;

[0059] FIG. 13 graphically depicts a mean thickness of the coating (y-axis) as a function of height position (x-axis) for applying coating on a vial at a first throughput speed, according to one or more embodiments shown and described herein;

[0060] FIG. 14 graphically depicts a mean thickness of the coating (y-axis) as a function of height position (x-axis) for applying coating on a vial at a second throughput speed greater than the throughput speed for FIG. 13, according to one or more embodiments shown and described herein;

[0061] FIG. 15 is a photograph of a bottom of a glass vial coated by redirecting oversprayed and reflected droplets of a coating composition to the bottom of the glass vial, according to one or more embodiments shown and described herein;

[0062] FIG. 16 graphically depicts a mean thickness of a coating (y-axis) as a function of height position (x-axis) of the heel of a coated glass vial, according to one or more embodiments shown and described herein;

[0063] FIG. 17 graphically depicts a mean thickness of a coating (y-axis) as a function of height position (x-axis) of the footprint of a coated glass vial, according to one or more embodiments shown and described herein;

[0064] FIG. 18 depicts a series of brightfield images of a coated glass article as a result of a three spray nozzle coating process, according to one or more embodiments shown and described herein;

[0065] FIG. 19A graphically depicts linear fdmetrics of a coating of a glass article with mean thickness (y-axis) as a function of height position (x-axis) for applying a coating at a first off-axis angle and a first throughput speed, according to one or more embodiments shown and described herein;

[0066] FIG. 19B graphically depicts linear filmetrics of a coating of a glass article with mean thickness (y-axis) as a function of height position (x-axis) for applying a coating at the first off-axis angle of FIG. 19A and a second throughput speed greater than the throughput speed of FIG. 19A, according to one or more embodiments shown and described herein;

[0067] FIG. 19C graphically depicts linear filmetrics of a coating of a glass article with mean thickness (y-axis) as a function of height position (x-axis) for applying a coating at the first off-axis angle of FIG. 19A and a third throughput speed greater than the throughput speed of FIGS. 19A and 19B, according to one or more embodiments shown and described herein;

[0068] FIG. 20A graphically depicts linear filmetrics of a coating of a glass article with mean thickness (y-axis) as a function of height position (x-axis) for applying a coating at asecond off-axis angle greater than the off-axis angle of FIG. 19A and at the first throughput speed of FIG. 19A, according to one or more embodiments shown and described herein;

[0069] FIG. 20B graphically depicts linear filmetrics of a coating of a glass article with mean thickness (y-axis) as a function of height position (x-axis) for applying a coating at the second off-axis angle of FIG. 20A and the second throughput speed that is greater than the throughput speed of FIG. 20A, according to one or more embodiments shown and described herein;

[0070] FIG. 20C graphically depicts linear filmetrics of a coating of a glass article with mean thickness (y-axis) as a function of height position (x-axis) for applying a coating at the second off-axis angle of FIG. 20A and a third throughput speed greater than the throughput speed of FIGS. 20A and 20B, according to one or more embodiments shown and described herein;

[0071] FIG. 21A graphically depicts linear filmetrics of a coating of a glass article with mean thickness (y-axis) as a function of height position (x-axis) for applying a coating at a third off-axis angle greater than the off-axis angle of FIG. 19A and FIG. 20A, according to one or more embodiments shown and described herein;

[0072] FIG. 2 IB graphically depicts linear filmetrics of a coating of a glass article with mean thickness (y-axis) as a function of height position (x-axis) for applying a coating at the third off-axis angle of FIG. 21A at the second throughput speed greater than the throughput speed of FIGS. 21 A, according to one or more embodiments shown and described herein;

[0073] FIG. 21C graphically depicts linear filmetrics of a coating of a glass article with mean thickness (y-axis) as a function of height position (x-axis) for applying a coating at the third off-axis angle of FIG. 21A and the third throughput speed that is greater than the throughput speed of FIGS. 21 A and 2 IB, according to one or more embodiments shown and described herein;

[0074] FIG. 22 graphically depicts linear filmetrics of coatings of glass vials with mean thickness (y-axis) as a function of velocity (x-axis) for applying a coating at the first off-axis angle and at the first, second, and third throughput speeds, according to one or more embodiments shown and described herein;

[0075] FIG. 23 graphically depicts linear filmetrics of coatings of glass vials with mean thickness (y-axis) as a function of velocity (x-axis) for applying a coating at the second off-axis angle and at the first, second, and third throughput speeds, according to one or more embodiments shown and described herein;

[0076] FIG. 24 graphically depicts linear filmetrics of coatings of glass vials with mean thickness (y-axis) as a function of velocity (x-axis) for applying a coating at the third off-axis angle and at the first, second, and third throughput speeds, according to one or more embodiments shown and described herein;

[0077] FIG. 25 graphically depicts a comparison of linear filmetrics of coatings of glass vials with mean thickness (y-axis) as a function of off-set angle, centerline distance (CLD), and velocity (x-axis) for applying a coating at the first, second, and third off-axis angles and at the first, second, and third throughput speeds, and a first CLD and a second CLD, according to one or more embodiments shown and described herein; and

[0078] FIG. 26 graphically depicts a comprehensive box and whisker plot of linear filmetrics of coatings of glass vials with mean thickness (y-axis) as a function of velocity (x- axis), CLD, and off-set angle for applying a coating at the first, second, and third off-axis angles, various speeds, and various CLD values, according to one or more embodiments shown and described herein.DESCRIPTION

[0079] Reference will now be made in detail to embodiments of the systems and methods disclosed herein, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. Referring now to FIG. 1, one embodiment of a system 100 of the present disclosure for applying a coating 104 to a glass article 102 is schematically depicted. The system 100 comprises a coating station 120 and a conveyor 110 operable to transport a plurality of the glass articles 102 through the coating station in a traveling direction 112. Referring to FIG. 2, the coating station 120 comprises a plurality of spray nozzles 122, each of which is in a fixed position. The plurality of spray nozzles 122 may be distributed radially about a spray focal point of the coating station 120. The plurality of spray nozzles 122 are configured to direct a coating spray 130 comprising a polymer coating material at each of the plurality of glass articles 102 as each of the plurality of glass articles 102 pass through the coating station 120 to produce coated glass articles 105. The coated glass articles 105 exit the coating station 120 comprising a coating 104 on the surfaces of the glass articles 102.

[0080] Referring to FIG. 2, methods for coating glass articles 102 according to one or more embodiments may include passing a glass article 102 through a focal point 103 of a coating station 120; and directing a plurality of coating sprays 130 towards the focal point 103 of the coating station 120 as the glass article 102 is passed through the focal point 103. Each of the plurality of coating sprays 130 may comprise atomized droplets of a coating solution. Directing the plurality of coating sprays 130 at the focal point 103 of the coating station 120 while passing the glass article 102 through the focal point 103 applies the coating solution to surfaces of the glass article 102 when the glass article 102 passes through the coating station 120.

[0081] The present application provides a coating station and a method of coating glass articles that has higher throughput of coated articles with processing speeds upward of 1500 mm / s with no adverse influence on coating thickness or coating morphology.

[0082] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order, nor that specific orientations be required with any apparatus. Accordingly, where a method claim does not actually recite an order to be followed by its steps, or that any apparatus claim does not actually recite an order or orientation to individual components, or it is not otherwise specifically stated in the claims or description that the steps are to be limited to a specific order, or that a specific order or orientation to components of an apparatus is not recited, it is in no way intended that an order or orientation be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps, operational flow, order of components, or orientation of components; plain meaning derived from grammatical organization or punctuation, and; the number or type of embodiments described in the specification.

[0083] Directional terms as used herein - for example up, down, right, left, front, back, top, bottom - are made only with reference to the figures as drawn and the coordinate axis provided therewith 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 indicates otherwise.

[0085] As used herein, "axial" refers to a direction parallel to a center axis A of the glass article.

[0086] As used herein, the terms "upstream" and "downstream" refer to the positions of processes or features of the system relative to a direction of travel of the glass article 102 through the system 100. For instance, a first feature is "upstream" of a second feature if the glass article encounters the first feature before encountering the second feature. Conversely, the first feature is "downstream" of the second feature if the glass article 102 encounters the second feature before encountering the first feature.

[0087] Because of its hermeticity, optical clarity, and excellent chemical durability relative to other materials, glass has been a preferred material for pharmaceutical applications, including, without limitation, vials, syringes, ampoules, cartridges, jars, vacutainers, beakers, or other glass articles. These pharmaceutical glass containers, as well as other types of glass articles, can be produced through a process of converting a length of glass tube to one or more of the glass articles through a plurality of heating and forming operations.

[0088] In embodiments, the glass articles 102 may be glass containers, such as but not limited to vials, syringes, ampoules, cartridges, jars, vacutainers, beakers, or other form factors. In embodiments, the glass articles 102 may be glass vials, such as glass vials with ISO size designation 2R to 50R with average wall thickness of from about 0.5 mm to about 3 mm, or about 1.0 mm. An example structure of a glass article 102 comprising a glass vial is depicted in cross sectional view in FIG. 3. The glass vial 102 comprises atop portion 154 with an interior opening 160, a neck connects the top portion 154 to a cylindrical shaped tubular body 159, the cylindrical shaped body 159 comprising a shoulder 152 proximate the neck, an outer sidewall surface 151 connected to the shoulder, a heel 158 connected to the sidewall surface 151, and an underside / bottom surface 156 connected to the heel. Though a cylindrical shape is depicted in FIG. 3, other body shapes may be considered such as rectangular, or polygonal. The systems and methods disclosed herein are described in the context of glass articles 102 that are glass vials. However, it is understood that the systems 100 and methods disclosed herein can be applied to other form factors, such as but not limited to syringes, ampoules, cartridges, jars, vacutainers, beakers, or other form factors, to similar effect.

[0089] The glass composition of the glass articles is not particularly limited and may comprise any compatible composition suitable for pharmaceutical applications and coating application such as Type IB borosilicate glass such as Coming® VELOCITY® borosilicate glass, ion-exchanged or non-ion exchanged aluminosilicate glass such as Coming® VALOR®aluminosilicate glass or any other glass materials that exhibit similar trends in terms of SHR and CDR and ICP-MS measurements.

[0090] Glass compositions such as VALOR® Glass (Coming Incorporated, Coming, N.Y.) or VELOCITY® Glass (Coming Incorporated, Coming, N.Y.) are preferable glass compositions, though not required. VALOR® Glass is a tubular glass packaging solution with Type I hydrolytic performance that substantially reduces particle contamination and prevents cracks. VALOR® Glass may be formed into glass vials (Coming Incorporated, Coming, N.Y.) designed for pharmaceutical usage and optimized to resist breakage and prevent cracks through ion exchange strengthening and a thermally stable exterior coating. Such an exterior coating on VALOR® Glass vials is applied only to the outside of the vial, so there is no increased risk with respect to extractables and leachables. The external coating reduces the coefficient of friction of the vials, allowing them to process with less resistance on a filling line than conventional borosilicate vials. External coatings can be added to outer surfaces of pharmaceutical glass articles to increase their reliability, resistance to breakage, and chemical resistance during manufacturing and subsequent packaging and / or transport. The composition of such a coating may include any coating that is capable of use as a spray coating as described in one or more embodiments of the disclosure herein. The coating composition can include organic materials and comprise an organic coating such as but not limited to the coatings described in US Patent No. 9,763,852, hereby incorporated by reference in its entirety. In embodiments, a coating can comprise a low friction, thermally stable polymer coating, such as a low friction thermally stable polyimide coating.

[0091] Prior art coating methods typically utilize a single spray nozzle in a spray zone in combination with a spindle apparatus that rotates a respective glass article as it moves through the spray zone of a coating station. However, these coating methods are complicated and expensive to maintain and require synchronizing the single spray nozzle activation with the rotation speed of the spindle apparatus in tandem with the traveling speed of the glass article, thus, necessitating careful calibration of the coating station to effectively coat the glass article. Due to the complicated nature of a single spray coating method with spindle rotation, the average linear speed of a glass article coated with such configuration has been limited to a maximum linear speed of 250 mm / s for conventional coating stations.

[0092] In addition to having a slow speed through the coating station and thus lower throughput of coated articles, traditional systems with coating methods including a single spraynozzle in conjunction with a rotation have defects in surface morphology in the resulting coating formed on the glass articles due to pooling effects. Pooling effects refer to formation of non-uniform thickness areas of the coating solution on the surface of the coated glass article caused from gravity and other forces applied to the uncured coating solution as the coated glass article moves through the coating station. Unless corrected by additional steps, the non-uniform thickness areas resulting from pooling during the coating step are cured and become permanent defects in surface morphology within the coating formed on the glass article. These defects caused by pooling are detrimental to product yield, which, in turn, increases processing costs and further decreases overall throughput. In order to counteract pooling in the traditional single spray nozzle coating processes, process parameters such as linear speed of the glass article (i.e., conveying speed), rotational speed of the glass article, and spray loading (e.g., flux, pressure, viscosity, solids content of the coating spray) have to be adjusted on top of the careful calibration of synchronizing the single spray nozzle with the glass article rotation, thus further increasing the complexity of coating glass articles using traditional coating processes including a single spray nozzle, which in turn increases the probability of error or defects in the product and reducing throughput, and leading to potentially long terms of downtime.

[0093] In the present application, the systems and methods of coating the glass articles are presented that implement two or more spray nozzles that reduce or eliminate coating morphology defects in the coated glass articles while also enabling increasing the linear speed of the glass articles through the coating station, thereby increasing the total throughput. The systems and methods disclosed herein may reduce capital and operating cost by not requiring an expensive spindle apparatus and by improving the efficiency of the coating process, respectively.

[0094] FIG. 4 shows a close up top view of a spray zone of a coating station 120 comprising two spray nozzles arranged in a base configuration with no-rotation of the glass article 102 during the coating process, according to one or more embodiments of the disclosure. In the base configuration, the spray nozzles 122 are oriented 1800apart from each other and point at a common center point within the glass article 102, which may be congruent with a focal point 103 of the spray zone of the coating station 120 when the glass article 102 passed through the coating station 120. The glass articles 102 may pass through the focal point 103 in a traveling direction 112 (i.e., the + / -Y direction of the coordinate axis in FIG. 4) that is perpendicular to a centerline direction 113, such that a tie-line that spans a centerline distance (CLD) betweenthe two spray nozzles 122 extends through the focal point 103 parallel to the centerline direction 113 and perpendicular to the traveling direction 112. This base configuration is considered to be an “on-axis” configuration of the two spray nozzles 122 in the coating station 120. In embodiments, an angle-of-incidence of the coating sprays 130 from the spray nozzles 122 is defined as the angle defined between a primary flow vector representing the average flux of spray contents exiting the spray nozzle 122 in a direction toward the focal point 103 and the traveling direction 112 (Y -direction of the coordinate axis in Fig. 4). Thus, for a two nozzle on-axis configuration, as shown in Fig. 4, the angle of incidence from respective spray nozzles 122 is 0°.

[0095] Other two spray nozzle configurations, such as those of FIGS. 5, 6, and 7 are considered “off-axis” configurations, where the spray nozzles 122 are oriented to have a non- orthogonal angle-of-incidence of the spray contents toward the glass article and the focal point of the coating station. The angle of incidence in an off-axis configuration ranges from greater than 0° (parallel to centerline direction 113, perpendicular to traveling direction 112) to less than 90° (parallel to traveling direction 112, perpendicular to centerline direction 113). Not to be bound by theory, by orienting the two spray nozzles 122 off-axis, the contents / droplets of a coating spray from an off-axis angle of incidence results in a different residence time on the glass article in the spray zone compared to a coating spray directed toward the glass article and the focal point in an on-axis direction. Residence time in this instance refers to the amount of time the droplets of the coating solution emitted by a spray nozzle have to interact with surfaces of a glass article in the proximate area of the focal point of the coating station before the glass article moves out of the coating station. Not to be bound by theory, for a configuration with a 90° angle of incidence, the droplets would reflect parallel to the travel direction, and for a configuration with a 0° angle of incidence (e.g., on-axis), the droplets may miss the glass article due to a short residence time, thus the residence time of a two nozzle configuration having an angle of incidence of less than 90°, such as 67° would be longer than a residence time of the two nozzle configuration having an angle of incidence of 0° (on-axis) or a two nozzle configuration having 22° off-axis angle of incidence.

[0096] Indeed, it was observed that the residence time of the coating sprays could be adjusted by changing the angle of incidence of the coating spray directed toward the focal point thus providing a simple cost effective solution to implement a no-rotation coating process. Initially, in this study, a pooling defect was still observed at low off-axis angles of incidence(i.e. around 22.5°), but unexpectedly, the pooling effects decreased at an angle of incidence of 45°, and altogether disappears at steeper off-axis angles of incidence of 67.5°, without changing any other process parameters. That is, the coating flux and the travel speed of the glass article were maintained constant, yet the angle of incidence alone was able to account for the presence or absence of the pooling defects. As such, the present disclosure is directed to systems and methods of coating a glass article to reduce or eliminate coating morphology defects without influencing product speed or total throughput and at lower cost than no-rotation coating processes.

[0097] Processing vials at high off-axis angle of incidence configurations showed another unexpected phenomena relating to the velocity of the glass article traveling between the spray nozzles. As is shown in FIGS. 22, 23, 24, 25, the average (mean) thickness of the coating on the glass article is nominally stable and invariable at high off-axis angles (i.e. 67.5°), while shallower off-axis angles (i.e. 45°, 22.5°) showed a significant decay in mean thickness (nominally 20% and 30% reductions, respectively) as the velocity of the vial nearly doubles between 500 mm / s and 900 mm / s. However, the decay of the mean thickness of off-axis angle of 67.5° was not statistically resolvable and the mean thickness was stable at a wide range of velocity. It is believed that this is the first demonstration of a coating process that can significantly increase product velocity (glass article traveling speed through a coating station) without significantly perturbing coating cosmetics or morphology. Accordingly, the present disclosure as described herein discloses a coating process that is insensitive to processing speeds under the conditions examined. This phenomena has not been observed by traditional coating processes.

[0098] Referring again to FIGS. 1 and 2, one embodiment of the system 100 disclosed herein for coating glass articles 102 with a polymer coating 104 is schematically depicted. The system 100 comprises a coating station 120 and a conveyor 110 operable to convey a plurality of the glass articles 102 through the coating station 120. The coating station comprises a plurality of spray nozzles 122, each of which may be in a fixed position and oriented relative to a focal point 103. Referring to FIG. 2, the plurality of spray nozzles 122 may be distributed radially about the focal point of a spray zone of the coating station 120, and each of the plurality of spray nozzles 122 may be configured to direct a coating spray 130 comprising a polymer coating solution at each of the plurality of glass articles 102 as each of the plurality of glass articles 102 passes through the focal point 103 of the spray zone of the coating station 120.

[0099] The conveyor 110 is configured to hold a plurality of glass articles 102 and may transport the glass articles 102 in a conveying / traveling direction 112 toward and through the coating station 120. The conveyor 110 holds the glass articles by engaging with surfaces of each of the glass articles 102 that are not receiving a coating in the coating station. In embodiments, the conveyor 110 may be configured to not rotate the glass articles as they move through the focal point 103 of the coating station 120. In embodiments, the conveyor 110 may be configured to translate a glass article 102 through the coating station 120 without rotating the glass article 102.

[0100] The construction of the conveyor 110 may comprise any existing or future developed conveying system that is capable of transporting glass articles such as glass vials including size 2R to 5 OR aluminosilicate vials (such as VALOR® aluminosilicate vials from Coming) or borosilicate vials (such as VELOCITY® borosilicate vials from Coming) or other glass articles suitable for pharmaceutical applications. In embodiments, the conveyor 110 may be a linear conveyor that transports / conveys the glass articles 102 in a straight line through the coating station 120. In embodiments, the conveyor 110 may comprise a curved wheel that conveys a glass article 102 through the focal point 103 along an arcuate travel path.

[0101] The coating station 120 comprises a spray zone (indicated by the dashed line in FIG. 2) with an input side that engages with the conveyor 110 as it transports the glass articles 102 into the coating station 120, a focal point 103 where the glass articles 102 are sprayed with the polymer coating solution by the spray nozzles 122, and an output side that outputs the coated glass articles 105 for further processing downstream such as curing the polymer coating solution to form a polymer coating 104. The spray zone comprises a plurality of spray nozzles 122, where each of the plurality of spray nozzles 122 points toward the focal point 103. The focal point 103 of the coating station is the location where the glass articles 102 are coated. The focal point 103 is a common center point corresponding to a geometric center of a glass article 102 coinciding with the intersection of the centerline 113, the traveling direction 112, and the axial direction 114. In embodiments, the coating station 120 may comprise 2, 3, 4, or more than four spray nozzles 122. In embodiments, the coating station 120 may include 2 spray nozzles 122. In embodiments, the coating station 120 may include 3 spray nozzles 122.

[0102] Each of the plurality of spray nozzles 122 of the coating station 120 may be fluidly coupled to a coating material system 124 that supplies the contents of the polymer coating solution in a suitable liquid form to the spray nozzles 122 located within the spray zone of thecoating station 120. The coating material system 124 can be attached to the coating station in close proximity, or the coating material system 124 can be placed remotely from the coating station 120 and connected to the coating station 120 via a series of pipes / tubes. In embodiments, the coating material system 124 may comprise a tank and an agitator. Although shown in FIG. 2 as including a tank and agitator, it is understood that the coating material system 124 may include any existing or future developed system for preparing the polymer coating solution and delivering the polymer coating solution to the spray nozzles 122.

[0103] The spray nozzles 122 may be fixed inside the spray zone of the coating station 120 and configured to output the polymer coating solution in a coating spray 130 having a primary flow vector oriented in a direction towards the focal point 103 of the coating station 120. The primary flow vector refers to an average flux (magnitude and direction) of the spray contents exiting a spray nozzle 122. The spray nozzles 122 may have any existing or future nozzle construction capable of outputting a polymer coating solution as a plurality of droplets, as described in one or more embodiments herein. The spray nozzles 122 may be oriented relative to the focal point 103 of the coating station 120 so that the spray nozzles form a fixed angle of incidence between the primary flow vector and at least the traveling / conveying direction 112 and one or more directions that are orthogonal to the traveling / conveying direction. That is to say, the spray nozzles 122 may be oriented to have an off-axis angle of incidence (e.g., 90 degrees) inside the spray zone of the coating station 120. The off-axis angle of incidence of the spray nozzles may be defined as an angle formed between the primary flow vector of the spray nozzle 122 and the traveling direction 112 in the X-Y plane, where the off-axis angle of incidence is less than 90° degrees and greater than 0°, where a 90° angle of incidence is defined parallel to the traveling direction 112 and 0° angle of incidence is perpendicular to the traveling direction 112 and parallel to the centerline direction 113. In embodiments, the spray nozzles 122 may be provided on opposite sides of the conveyer line 110 from each other as shown in FIGS. 5-7, or multiple spray nozzles 122 may be provided on one side of the conveyor line, such as shown in FIGS. 8 and 9.

[0104] After entry of the glass articles 102 into the spray zone of the coating station 120, each respective glass article 102 arrives at the focal point 103 of the coating station 120, where the spray nozzles 122 are activated to output the coating spray 130 comprising the composition of a desired polymer coating solution directed towards the focal point 103 of the coating station 120. The droplets of the coating spray 130 make contact with and attach to the surfaces of the glass article 102 so as to cover the surfaces of the glass article 102 with a polymer coatingsolution 104, as the glass article 102 passes through the focal point 103. In embodiments, the coating station 120 may be configured to produce a continuous flow of the coating sprays 130 as the glass articles 102 are translated through the coating station 120 in succession.

[0105] The coating spray 130 output by each of the spray nozzles 122 may comprise a coating composition in the form of an atomized flow / cloud of droplets. In embodiments, the coating composition may be a heat tolerant coating as described in U.S. Patent No. 10,273,049, the entire contents of which are incorporated herein by reference. In embodiments, the coating material may be an organic coating, such as but not limited to a low friction coating, as described in U.S. Patent No. 9,763,852, the entire contents of which are incorporated herein by reference. In embodiments, the coating material may comprise a polymer composition comprising at least one polymer. Polymers may include but are not limited to thermally stable polymer or mixture of polymers, such as but not limited to, polyimides, polybenzimidazoles, polysulfones, polyetheretheketones, polyetherimides, polyamides, polyphenyls, polybenzothiazoles, polybenzoxazoles, polybisthiazoles, and polyaromatic heterocyclic polymers with and without organic or inorganic fillers. Other types of coating materials suitable for coating glass articles such as glass vials for use in pharmaceutical applications such as 2R through 50R sized vials such as defined by ISO 836201:2018, aluminosilicate vials sold under the Coming trademark VAUOR®, borosilicate vials sold under the Coming trademark VEUOCITY®, and other Type I chemical durability vials, or Class B glass ASTM standard E438-92 are contemplated.

[0106] The atomized flow / cloud of droplets of each coating spray 130 may proceed toward the focal point 103 of the coating station spray zone with a primary flow vector corresponding with the majority of the flow of droplets comprising an average vector oriented in line with the direction of orientation of the respective spray nozzle that output the coating spray. The combined flow of droplets from each coating spray 130 arrives at a region in close proximity to the focal point 103 within the spray zone of the coating station 120 and the droplets contact and attach to the surfaces of the glass article 102 and coalesce to form a polymer coating 104 on the surfaces of the glass articles 102 resulting in coated glass articles 105 that exit the coating station 120 for further processing downstream.

[0107] In order to further enhance the efficiency of the flow of droplets within the spray zone of the coating station 120, air flows 142 may be introduced via one or more gas nozzles 140 that are fixed within the spray zone of the coating station. Referring to FIG. 12, dropletsof coating 131 that remain from the coating sprays 130 in the spray zone that did not initially contact surfaces of the glass article 102 as it passed the focal point 103 may be redirected using the air flows 142 so as to contact another area of the glass article 102 before the glass article exits the spray zone. The air flows 142 may be provided by one or more gas nozzles 140 placed within the coating station and can be adjusted in order to create a desired flow profile of droplets that affects the surface morphology of the polymer coating solution 104 on the resulting coated glass article 105 to a desired specification. By using such a configuration that re-directs the coating droplets using the air flows 142, the efficiency of the system may be increased and operating costs reduced by recycling the unused droplets from the coating sprays 130 so that polymer coating solution materials are not wasted. The re-directed flow pattems / profiles of coating droplets can comprise any number or variety of flow patterns as desired. A non-limiting example is shown in FIG. 12, where coating droplets 131 are re-directed toward the heel and / or underside / bottom of the glass article 102 by air flows 142.

[0108] FIG. 4 shows a no-rotation coating process base configuration with two spray nozzles that are oriented on-axis according to embodiments described herein. Though this configuration allows for a no-rotation coating process for glass articles and is improved compared to single spray configurations, the resulting coatings still may have some defects in surface morphology due to pooling, and reflecting droplets. The present application, according to embodiments herein, further improves upon the on-axis two spray nozzle configuration by angling the two spray nozzles so that they are oriented with an off-axis angle of incidence, where one spray nozzle provides a leading spray and another spray nozzle provides a trailing spray as shown in FIGS. 5-7, for example.

[0109] Referring to FIGS. 5-7, the coating station 120 may comprise two spray nozzles 122 according to embodiments of the disclosure. The spray nozzles 122 may be oriented so that the flux of coating material from each of the spray nozzles is directed towards the focal point 103 of the coating station 120. As previously discussed, the focal point 103 of the coating station 120 is located at a common center point of an X-Y -Z coordinate system that coincides with a geometric center of the glass article 102 as it is conveyed through the coating station 120. The X direction coincides with the “on-axis” direction 113 and the center line that extends through the focal point 103 of the coating station 120. The Y-direction coincides with the direction of travel 112 of the conveyor 110. The Z direction coincides with an axial direction 114 that extends through the geometric center of the glass vial perpendicular to both the X and Y-directions.

[0110] In embodiments, two spray nozzles 122 may be spaced apart and oriented 180° with respect to each other, with the openings of the nozzles facing each other across the conveyor 110, such as exemplified by FIGS. 5-7. FIG. 5 shows the nozzles 122 are angled 22.5 ° off-axis, FIG. 6 shows the nozzles 122 oriented 45° off-axis, and FIG. 7 shows the nozzles 122 oriented 67.5° off-axis. Though FIGS. 5-7 depict off-axis angles of incidence of 22.5, 45, and 67.5, embodiments of the present disclosure may comprise other off-axis angles of incidence. In embodiments, the nozzles 122 may be angled with an off-axis angle of incidence of less than 90 degrees and greater than 0 degrees, less than 85 degrees and greater than 20 degrees, less than 80 and greater than 30 degrees, less than 75 degrees and greater than 40 degrees, less than 70 degrees and greater than 45 degrees, less than 70 degrees and greater than 60 degrees, or any subranges therebetween. By placing the spray nozzles with an off-axis angle of incidence, an unexpected phenomenon occurs in which the surface morphology of the coating on the glass article 102 improved with increasing off-axis angles independent of glass article speed through the focal point. Not to be bound by theory, it is believed that placing the spray nozzles off-axis from the traveling / conveying direction creates a leading spray and a trailing spray which increases the residence time of the spray contents of the coating solution at the focal point of the coating station, whereby surface morphology defects of the coated glass articles can be reduced or eliminated without changing any other process parameters. This solution provides a cost effective and simple approach to eliminate pooling defects and other surface morphology defects that are typical in single spray no-rotation coating processes all while increasing throughput speed significantly compared to single spray coating processes.

[0111] Referring now to FIG. 8, in embodiments, the coating station 120 may include three spray nozzles 122. Similar to the two nozzle configurations, the three nozzle configuration employs three nozzles 122 fixed radially about the focal point 103 of the spray zone of the coating station 120. The nozzles may be oriented so that there is still a leading spray and a trailing spray. The two nozzles providing the leading and trailing sprays in FIG. 8 are 122C and 122A, respectively, and nozzles 122C and 122A are oriented about the focal point 103 so as to form an interior angle of about 120 degrees between nozzle 122C and nozzle 122A. That is, in a three nozzle configuration in which the spray nozzles 122 are distributed evenly around the focal point 103 in the angular direction, the coating station 120 still has at least two nozzles that form a leading spray and a trailing spray and have an off-axis angle of incidence from the travel direction 112 and the centerline direction 113 similarly to the two nozzle configuration as described herein. Though the interior angle is depicted at about 120° in FIG. 8, the interiorangle is not limited to 120° and may comprise angles larger or smaller than 120°, such as an angle greater than 110° but less than 180°, 110° to 170°, 120° to 160°, 130° to 140°, and any other angle there between so long as at least two nozzles in the three nozzle configuration remain off-axis with respect to the centerline direction 113 and / or travel direction 112 in order to maintain at least one trailing spray and at least one leading spray.

[0112] The three nozzle embodiment also may comprise a neutral spray nozzle oriented intersecting the interior angle formed between the other two nozzles. For example, in FIG. 8, 122B is a neutral spray nozzle and is oriented on-axis with the center line 113 through the focal point and substantially bisects the interior angle between nozzles 122A and 122C. Though the three nozzles depicted in FIG. 8 show one leading spray 122C, one trailing spray 122A, and one neutral spray 122B, where neutral spray 122B is on-axis, other configurations are contemplated and deemed within the scope of the present disclosure. Other configurations may be achieved by rotating the three or more nozzles axially about the focal point such that a configuration with two leading sprays or two trailing sprays is possible. Providing three nozzles 122 as described in embodiments in the disclosure herein allows for an even higher production speed in a no-rotation coating process compared to a two nozzle configuration. Further, the three nozzle configurations as described in embodiments herein may yield coated glass articles 105 with acceptable vial cosmetics that meet the standard requirements for coated pharmaceutical vials even though the speed of the coating process was increased and the solids content was reduced in each delivered spray.

[0113] In embodiments, the three nozzle configuration may also comprise a heel turn or gas nozzle 140 (refer to FIG. 12) in the spray zone of the coating station to ensure proper coating and product functionality at the heel. A heel turn or gas nozzle included in the spray zone may produce a flow pattern that redirects the overspray (i.e. the droplets of the coating sprays that did not make initial contact with the glass article in the spray zone) towards the heel and bottom / underside of the glass article.

[0114] Though three spray nozzles are depicted in FIG. 8 the present disclosure should not be limited to three nozzles and a coating station spray zone may comprise N number of spray nozzles 122 oriented off-axis about the focal point of the coating station or include additional neutral spray nozzles. Such a configuration is depicted in perspective view FIG. 12 showing N number spray nozzles 122 in a coating station. In embodiments, N may be 2, 3, 4, 5, 6, or more than 6 spray nozzles. In addition to N number spray nozzles, a heel turn or gas nozzle is addedas depicted in FIG. 12 to further ensure proper coating of the heel and underside of the glass article by redirecting overspray.

[0115] A method for coating glass articles using the system 100 according to embodiments is described herein. The method may comprise: passing a glass article 102 through a focal point 103 of a coating station 120; and directing a plurality of coating sprays 130 towards the focal point 103 of the coating station 120 as the glass article is passed through the focal point. Each of the plurality of coating sprays 130 may comprise atomized droplets 131 of the coating solution. The plurality of coating sprays 130 are directed at the focal point 103 of the coating station 120 while passing the glass article 102 through the focal point 103. The contents of the coating sprays 130 contact the surfaces of the glass article 102 and apply the coating solution to the surfaces of the glass article 102 when the glass article passes through the coating station 120. The directing the plurality of coating sprays 130 may comprise directing at least two coating sprays 130 towards the focal point 103 of the coating station 120, wherein one or more coating sprays of the plurality of coating sprays 130 are directed towards the focal point 103 from a different incident direction than another of the one or more coating sprays 130.

[0116] In embodiments, the directing the plurality of coating sprays 130 towards the focal point 103 of the coating station 120 may comprise: atomizing the coating solution to produce an atomized flow of droplets 131 of the coating spray 130; and creating a plurality of flow patterns of the droplets with a plurality of gas nozzles to produce the plurality of coating sprays 130 and directing the plurality of coating sprays 130 towards the focal point 103. In embodiments, the directing the plurality of coating sprays 130 towards the focal point 103 of the coating station 120 may comprise generating the plurality of coating sprays 130 with a plurality of spray nozzles 122 oriented so that an average flow direction of each of the spray nozzles 122 is directed towards the focal point 103 of the coating station 120. The directing the plurality of coating sprays 130 may comprise directing at least two of the coating sprays 130 toward the focal point 103 in a direction that is not orthogonal to a direction of travel of the glass article 102 through the focal point 103 of the coating station 120. The at least two of the coating sprays 130 may comprise at least one leading spray and at least one trailing spray. The at least one leading spray and the at least one trailing spray may each be oriented at a spray angle of less than or equal to 67.5 degrees, wherein the spray angle of incidence is defined as an acute angle formed between an average direction of a primary flow vector of the spray contents of the at least one leading spray or the at least one trailing spray and a direction oftravel of the glass article through the coating station. A direction of travel 112 of the glass article through the coating station may be a linear direction of travel or a line tangent to a curved path of travel at the focal point 103 of the coating station 120. A center line 113 of the glass article 102 is a line that passes through a geometric center of the glass article 102 and the focal point 103 of the coating station 120 and is perpendicular to the direction of travel of the glass article 102 through the coating station 120. A cross-sectional plane of the glass article 102 is a plane that is parallel to the direction of travel and perpendicular to the center line of the glass article 102. The spray angle of incidence is defined as an acute angle formed between the direction of travel of the glass article through the coating station and a spray direction of a primary flow vector of the contents of the coating spray in the cross-sectional plane of the glass article. In embodiments, the plurality of coating sprays comprising the at least one leading spray and the at least one trailing spray may be oriented to have a spray angle of incidence of less than or equal to 45 degrees.

[0117] In embodiments of the methods, each of the plurality of coating sprays 130 may have a primary flow vector defining an average spray direction that is parallel to a cross- sectional plane of the glass article 102 when a centerline of the glass article is congruent with the focal point 103 of the coating station 120.

[0118] In embodiments of the methods, one or more of the plurality of coating sprays 130 may have a primary flow vector defining an average spray direction that forms a non-zero angle with a plane perpendicular to a center line of the glass article 102 when the center line of the glass article 102 is congruent with the focal point 103 of the coating station 120.

[0119] In embodiments of the methods, directing the plurality of coating sprays 130 may also comprise directing three or more coating sprays towards the focal point 103 of the coating station 120. In embodiments, the three or more coating sprays may be distributed evenly about the focal point 103 of the coating station 120. The three or more coating sprays 130 may comprise at least two leading sprays or at least two trailing sprays. The three or more coating sprays 130 may comprise at least one leading spray, at least one trailing spray, and at least one neutral spray, wherein the at least one neutral spray may be oriented to have a spray direction that is perpendicular to the direction of travel of the glass article 102 through the coating station 120. In embodiments, the three or more coating sprays 130 may comprise two sprays that form an interior angle relative to each other, the interior angle being defined between the respective primary flow vectors representing the directions of the average flow of the contents of the twosprays toward the focal point of the coating station. The interior angle may be an angle of less than 180 degrees and greater than or equal to 120 degrees.

[0120] In embodiments, the methods may further comprise re-directing stray droplets of the coating solution back towards the glass article 102 in the coating station 120, where the stray droplets may comprise overspray or droplets of the coating solution deflected from surfaces of the glass article. The stray droplets may be redirected by gas flows produced with one or a plurality of gas nozzles 140 arranged in the coating station 120. The method may further comprise re-directing stray droplets toward a heel, a bottom, or both of the glass article 102 that comprises a glass container having a bottom.

[0121] In embodiments, the methods may further comprise passing the glass article 102 through the coating station 120 at a speed of greater than or equal to 300 mm / s, greater than or equal to 500 mm / s, greater than or equal to 1000 mm / s, greater than or equal to 1500 mm / s, or greater than or equal to 1800 mm / s. The methods may further comprise passing the glass article 102 through the coating station 120 at variable speed that is adjustable between 300 mm / s and 1800 mm / s. In embodiments, a rotational speed of the glass article 102 about the center line of the glass article is equal to zero while passing the glass article 102 through the focal point 103 of the coating station 120. In embodiments, the method does not include rotating the glass articles 102.

[0122] In embodiments, the methods may further include passing a plurality of glass articles 102 through the coating station 120 in succession, wherein the plurality of glass articles 102 are pharmaceutical containers or pharmaceutical glass vials. The pharmaceutical glass vials may comprise aluminosilicate or borosilicate glass vials sized 2Rto 50R.

[0123] The method according to one or more embodiments, as described herein, may further comprise measuring a thickness profde of a polymer coating on the glass article downstream of the coating station; changing a distance from a nozzle to the focal point, a flow rate of the polymer solution, a spray angle of one or more of the plurality of coating sprays, or combinations of these based on the thickness profde of the polymer coating.EXAMPLES

[0124] The various embodiments of coated glass articles disclosed herein will be further clarified by the following examples. The examples are illustrative in nature, and should not be understood to limit the subject matter of the present disclosure.

[0125] Example 1 : Two Spray Nozzles

[0126] A first series of experimental examples were conducted with a two spray nozzle configuration as described in one or more embodiments disclosed herein. The two spray nozzles comprised orientations within the coating station as depicted in FIGS. 5-7. A comparison between the magnitudes of off-axis angles of the spray nozzles to surface morphology of the coating of the glass articles is depicted in FIGS. 19 through 26. For these two spray nozzle examples, 16.75R size glass vials were conveyed by a conveyer line at constant velocities through the spray zone of a coating station which comprised two spray nozzles 122 spaced apart at 180° from each other and oriented off-axis from the centerline direction 113 such that there was a leading spray and a trailing spray. The off-axis angles were set to 22.5°, 45°, and 67° relative to the center line direction 113, the velocities were set to 500, 700, and 900 mm / s, and the spacing between the spray nozzles, which is also known as the Centerline Distance (CLD), was set to 110 mm.

[0127] The coated glass vials of the examples were analyzed using linear filmetrics methods and the results are depicted in FIGS. 19, 20, and 21. FIGS. 19, 20, and 21 show linear filmetrics line scans of the coated 16.75R vials that passed through a coating station with a two spray nozzle configuration as described according to one or more embodiments of the disclosure herein. Linear filmetrics measure the thickness of the coating along the height of the glass vial, from the shoulder (left of plots) to the heel (right of plots). FIGS. 19A, 19B, and 19C show off- axis angle 22.5°, FIGS. 20A, 20B, and 20C show off-axis angle 45°, and FIGS. 21A, 21B, and 21C show off-axis angle 67.5°. FIGS. 19A, 20A, and 21A are at a velocity of 500 mm / s, FIGS. 19B, 20B, and 2 IB are at a velocity of 700 mm / s, and FIGS. 19C, 20C, and 21C are at a velocity of 900 mm / s, where the velocity refers to the velocity of the glass article as it is translated through the focal point of the coating station.

[0128] Referring now to FIGS. 19A-C and 20A-C, the average thickness of the coatings on the glass vials from two sprays with off-axis angles not greater than 45° exhibited some pooling at the heel of the glass vial independent of glass vial travel velocity through the coating station. In particular, FIGS. 19A-19C and 20A-20C each show one or more peaks in average thickness starting at 40 (FIGS. 19A and 20A) or centered around 40 (FIGS. 19B and 20B) which is theheel section of the glass vial, whereas the remainder of the glass vial has a relatively stable average thickness.

[0129] Referring now to FIG. 21, as the off-axis angle was increased to greater than 45°, the two sprays become more leading and trailing than they are intersecting the path of the vial through the focal point and the pooling near the heel is significantly reduced or disappears completely at off-axis angle of 67.5°. In particular, FIG. 21A depicts the average thickness of the coating is stable at around 50 nm and substantially linear over the entire height of the glass vial with no discernable peaks including the heel region near value 40. Thus, by changing the off-axis angle of the two spray nozzles to 67.5°, pooling at the heel of the glass vial was eliminated at a velocity of 500 mm / s through the coating station, which is double the throughput speed of traditional processes of 250 mm / s. As such, providing a two spray nozzle configuration as described in one or more embodiments herein, may improve the surface morphology of coated glass vials compared to traditional coating methods with single spray nozzle methods, may have reduced complexity by not having to rotate the glass vial or synchronize multiple moving parts, and also may provide for significantly higher travel velocity through the coating station and thus higher overall throughput. FIG. 2 IB and FIG. 21 C show that an off-axis angle of 67.5° provides the same effects even at speeds up to 900 mm / s. Thus, it is demonstrated that a two nozzle configuration according to one or more embodiments as described herein can increase the throughput of coated glass vials by a factor of 3-5 times the speed of a traditional coating station having a single spray nozzle with rotation of the glass vial. This increased throughput can be achieved without sacrificing cosmetics and surface morphology of the coating.

[0130] FIGS. 22, 23, and 24 depict the velocity-dependence of the average coating thickness using linear filmetrics of the 16.75R vials from the experimental example series. As shown by FIG. 22 and FIG. 23, off-axis angles of 22.5° and 45° showed average coating thickness of the glass vial changes with changing glass vial velocity through the coating station. Specifically, in FIG. 22, for off-axis angle of 22.5°, the average thickness of the coating on the glass vial decreased by 25 nm as the velocity of the glass vial through the coating station increased from 500 mm / s to 900 mm / s. In FIG. 23, for the off-axis angle of 45°, the average thickness of the coating on the glass vial decreased by 10 nm as the velocity of the glass vial through the coating station increased from 500 mm / s to 900 mm / s.

[0131] For off-axis angle of 67.5°, an unexpected result occurred where the average thickness of the coating on the glass vial did not show any dependence on the velocity of the glass vial. That is, the average thickness of the coating of the glass article remained the same even though the velocity of the glass article through the coating station was almost doubled and increased from 500 mm / s to 900 mm / s. Not to be bound by theory, but this observation shows the effect of orienting the spray nozzles off-axis at an angle of 67.5° from the centerline direction which provides an average coating thickness of a glass article that is independent from glass article speed and has decreased pooling at the heel by providing a leading spray and a trailing spray in the path of the article as it is transported through the spray zone of the coating station.

[0132] FIG. 25 is a comprehensive diagram capturing the results of the off-axis two-gun experimental example series. Average coating thickness is on the coordinate (Y) axis vs off- axis angle, CLD and speed on the abscissa (X) axis. Angle 22.5° is on the left side of the Figure, angle 45° is in the middle, and angle 67.5° is on the right side of the Figure. As depicted by Fig. 25, it was demonstrated that the average thickness of the coating decreased for off-set angles of 22.5° and 45° as glass vial travel velocity increased with a relatively smaller centerline distances (CLD) such as 110 mm. However, this phenomena was not observed for the high angle configuration of off-set angle 67.5° at the same CLD 110 mm and from this plot.

[0133] FIG. 26 is a comprehensive box and whisker plot showing the various conditions tested in the two gun configuration experimental example series. The influence of angle of incidence of sprays on overall coating thickness is clear, as the mean thickness of the coating increases with increasing angle of incidence. More specifically, at zero degrees off-axis (i.e. on-axis), the mean thickness of the coating decreased significantly with increasing velocity. As the off-axis angle of incidence of the sprays increased, the mean thickness of the coating increased compared to the on-axis angle of incidence even with increasing velocity. Moreover, while the apparent dependence of coating thickness on velocity is diminished from run to run. This plot shows, most clearly, that as off-axis angle of incidence increases, the coating thickness is increased while the speed-dependence of thickness is neutralized. The increased presence of a leading and trailing spray gun results in more robust stability across multiple run conditions.

[0134] Example 2: Three Spray Nozzles

[0135] A second series of examples was conducted implementing a three nozzle configuration as described and shown herein. The second example series was conducted using the same sized 16.75R vials similar to the two nozzle examples and the remainder of the processing parameters were the same as the first example series with the exception of including a third nozzle in the spray zone of the coating station. The three nozzles were oriented about the focal point such as depicted in FIG. 7. The resulting coated glass vials that passed through a spray zone of the coating station with the three nozzle configuration were analyzed using similar methods to the two nozzle examples such as COSMOS, brightfield, and linear filmetrics.

[0136] FIG. 13 depicts the linear filmetrics measurements of the coating of the coated glass vials from the three nozzle configuration. Referring to FIG. 13, a first line 1304 represents an average thickness of the coating of the glass vials as measured from the neck to the heel of the glass vials that traveled through a coating station with a travel speed of 900 mm / s. A second line 1302 represents an average thickness of the coating of coated glass vials as measured from the neck to the heel that traveled through a coating station with a speed 1800 mm / s. As shown by FIG. 13, even at speeds of 1800 mm / s, the average coating thickness for the line 1302 remains close to 20 nm from the neck to the heel. As such, this figure represents the high efficacy of no-rotation coating processes according to the one or more embodiments described herein. That is, acceptable vial cosmetics are attainable at higher production rates than previously assumed possible. Moreover, it is demonstrated that suitable coatings on glass vials can be achieved at significantly higher throughput (upward of 1800 mm / s) compared to single spray rotation coating processes (250 mm / s).

[0137] The three gun no rotation coating process can also be adapted to larger vial sizes with minimal adjustments to parameters thus further presenting benefits over the complicated single spray coating processes. FIG 18 shows a brightfield (BF) cosmetics image of a larger size 6R glass vial that was sprayed with a three nozzle configuration using settings that were used for 16.75R vials such as a CLD of 130 mm, and a travel speed of 1300 mm / s. The image shows striations / stitching suggesting irregular coating thickness on the vial such as regions with larger average thickness and regions with thinner thickness (see arrows in FIG. 18) . However, despite the imperfect result, the image confirms the adaptability of the no-rotation coating process as described herein as the three nozzle coating method coated the glass vials that were larger in size without changing the settings from a different size vial. This demonstrates the simplicity and adaptability of a system and method of a no-rotation coating process as described hereinduring a pharmaceutical manufacturing setting where less complex process parameters such as changing the number of nozzles to 4 or more or changing CLD between nozzles, travel velocity, and nozzle pressure can adjust the residence time of the spray before coating occurs thereby providing the ability to make a uniform coating process in a no-rotation coating process for any size vial. Such adaptability is not readily present in traditional single spray coating processes with rotation as the entire process line has to be adjusted for each respective vial size and carefully recalibrated with adjusting the rotation speed of the spindle apparatus and the travel speed.

[0138] In the one or more examples and embodiments disclosed herein, the vials move through the focal point of the coating station at a constant velocity, however, a variable-velocity could also be considered. Further, though the present disclosure discusses no rotation coating processes, a rotation with a respective angular speed could be implemented in order to customize and tune the coating morphology of the coating on the glass article.

[0139] While various embodiments of the systems 100 and methods for coating glass articles 102 using the systems 100 have been described herein, it should be understood that it is contemplated that each of these embodiments and techniques may be used separately or in conjunction with one or more embodiments and techniques.

[0140] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Thus it is intended that the specification cover the modifications and variations of the various embodiments described herein provided such modification and variations come within the scope of the appended claims and their equivalents.

Claims

What is claimed is:

1. A method for coating glass articles, the method comprising: passing a glass article through a focal point of a coating station; and directing a plurality of coating sprays towards the focal point of the coating station as the glass article is passed through the focal point, wherein: each of the plurality of coating sprays comprises atomized droplets of a coating solution; and directing the plurality of coating sprays at the focal point of the coating station while passing the glass article through the focal point applies the coating solution to surfaces of the glass article when the glass article passes through the coating station.

2. The method of claim 1, wherein the plurality of coating sprays comprises at least one leading spray and at least one trailing spray.

3. The method of claim 2, wherein the at least one leading spray and the at least one trailing spray are each oriented at a spray angle of incidence of less than or equal to 67.5 degrees, wherein the spray angle of incidence is defined as an acute angle formed between a primary flow vector representing an average direction of contents of the spray from at least one leading spray or at least one trailing spray and a direction of travel of the glass article through the coating station.

4. The method of claim 2, wherein the at least one leading spray and the at least one trailing spray are each oriented at a spray angle of incidence of less than 90 degrees and greater than 0 degrees, wherein: a direction of travel of the glass article through the coating station is a linear direction of travel or a line tangent to a curved path of travel at the focal point of the coating station; a center line of the glass article is a line that passes through a geometric center of the glass article and the focal point of the coating station and is perpendicular to the direction of travel of the glass article through the coating station; a cross-sectional plane of the glass article is a plane that is parallel to the direction of travel and perpendicular to the center line of the glass article; andthe spray angle of incidence is defined as an acute angle formed between the direction of travel of the glass article through the coating station and a primary flow vector of the coating spray comprising an average spray direction of the coating spray in the cross-sectional plane of the glass article.

5. The method of claim 4, wherein the at least one leading spray and the at least one trailing spray are each oriented to have a spray angle of less than 45 degrees.

6. The method of claim 1, comprising directing two coating sprays towards the focal point of the coating station.

7. The method of claim 6, wherein both of the two coating sprays are orthogonal to a direction of travel of the glass article through the focal point of the coating station.

8. The method of claim 6, wherein each of the two coating sprays are oriented to have a spray angle of less than or equal to 67.5 degrees, wherein: a direction of travel of the glass article through the coating station is a linear direction of travel or a line tangent to a curved path of travel at the focal point of the coating station; a center line of the glass article is a line that passes through a geometric center of the glass article and the focal point of the coating station and is perpendicular to the direction of travel of the glass article through the coating station; a cross-sectional plane of the glass article is a plane that is parallel to the direction of travel and perpendicular to the center line of the glass article; and the spray angle is defined as an acute angle formed between the direction of travel of the glass article through the coating station and a spray direction of the coating spray in the cross-sectional plane of the glass article.

9. The method of claim 1, comprising directing three or more coating sprays towards the focal point of the coating station.

10. The method of claim 9, wherein the three or more coating sprays are distributed evenly about the focal point of the coating station.

11. The method of claim 9, comprising at least two leading sprays or at least two trailing sprays.

12. The method of claim 9, comprising at least one leading spray, at least one trailing spray, and at least one neutral spray, wherein the at least one neutral spray is oriented to have a spray direction that is perpendicular to the direction of travel of the glass article through the coating station.

13. The method of claim 1, wherein the directing the plurality of coating sprays towards the focal point of the coating station comprises: atomizing the coating solution to produce an atomized flow of droplets of the coating spray; and creating a plurality of flow patterns of the droplets with a plurality of gas nozzles to produce the plurality of coating sprays and directing the plurality of coating sprays towards the focal point.

14. The method of claim 1, wherein the directing the plurality of coating sprays towards the focal point of the coating station comprises generating the plurality of coating sprays with a plurality of spray nozzles oriented so that an average flow direction of each of the spray nozzles are directed towards the focal point of the coating station.

15. The method of claim 1, further comprising re-directing stray droplets of the coating solution back towards the glass article in the coating station, wherein: the stray droplets comprise overspray or droplets of the coating solution deflected from surfaces of the glass article; and the stray droplets are redirected by gas flows produced with one or a plurality of gas nozzles.

16. The method of claim 15, wherein the glass article comprises a glass container having a bottom, wherein the method further comprises re-directing stray droplets toward a heel, a bottom, or both of the glass container.

17. The method of claim 1, further comprising: measuring a thickness profile of a polymer coating on the glass article downstream of the coating station; changing a distance from a nozzle to the focal point, a flow rate of the polymer solution, a spray angle of one or more of the plurality of coating sprays, or combinations of these based on the thickness profile of the polymer coating.

18. The method of claim 1, comprising passing the glass article through the coating station at a speed of greater than or equal to 300 mm / s, greater than or equal to 500 mm / s, greater than or equal to 1000 mm / s, greater than or equal to 1500 mm / s.

19. The method of claim 1, comprising passing a plurality of glass articles through the coating station in succession.

20. The method of claim 19, wherein the plurality of glass articles are pharmaceutical containers.

21. The method of claim 19, wherein the plurality of glass articles are pharmaceutical glass vials.

22. The method of claim 1, wherein each of the plurality of coating sprays have an average spray direction that is parallel to a cross-sectional plane of the glass article when a centerline of the glass article is congruent with the focal point of the coating station, wherein: a direction of travel of the glass article through the coating station is a linear direction of travel or a line tangent to a curved path of travel at the focal point of the coating station; the center line of the glass article is a line that passes through a geometric center of the glass article and the focal point of the coating station and is perpendicular to the direction of travel of the glass article through the coating station; and the cross-sectional plane of the glass article is a plane that is parallel to the direction of travel and perpendicular to the center line of the glass article.

23. The method of claim 1, wherein one or more of the plurality of coating sprays has an average spray direction that forms a non-zero angle with a plane perpendicular to a center line of the glass article when the center line of the glass article is congruent with the focal point of the coating station, wherein: a direction of travel of the glass article through the coating station is a linear direction of travel or a line tangent to a curved path of travel at the focal point of the coating station; the center line of the glass article is a line that passes through a geometric center of the glass article and the focal point of the coating station and is perpendicular to the direction of travel of the glass article through the coating station; andthe cross-sectional plane of the glass article is a plane that is parallel to the direction of travel and perpendicular to the center line of the glass article.

24. The method of claim 1, wherein a rotational speed of the glass article is equal to zero while passing the glass article through the focal point of the coating station.

25. The method of claim 1, wherein the method does not include rotating the glass articles.

26. A coated glass article prepared according to the method of claim 1, wherein the coated glass article comprises a plurality of stitching regions, where a stitching region is defined as a region of increased thickness of the polymer coating caused by overlap of two of the coating sprays.

27. The coated glass article of claim 26, wherein the coated glass article is a pharmaceutical container.

28. The coated glass article of claim 26, wherein the coated glass article is a pharmaceutical glass vial.

29. A system for coating glass articles with a polymer coating, the system comprising a coating station and a conveyor operable to convey a plurality of the glass articles through the coating station, wherein: the coating station comprises a plurality of spray nozzles, each of which is in a fixed position; the plurality of spray nozzles are distributed radially about a spray focal point of the coating station; and the plurality of spray nozzles are configured to direct a spray comprising a polymer coating material at each of the plurality of glass articles as each of the plurality of glass articles pass through the coating station.

30. The system of claim 29, wherein the coating station comprises two spray nozzles.31 The system of claim 30, wherein two spray nozzles are each oriented to direct a spray of the polymer coating solution in a direction perpendicular to a direction of travel of the plurality of glass articles through the coating station.

32. The system of claim 30, wherein the two spray nozzles comprise a first spray nozzle and a second spray nozzle, wherein: the first spray nozzle is disposed upstream of the focal point of the coating station and oriented to direct a first spray of the polymer coating solution towards the focal point of the coating station; and the second spray nozzle is disposed downstream of the focal point of the coating station and oriented to direct a second spray of the polymer coating solution towards the focal point of the coating station.

33. The system of claim 30, wherein the first spray nozzle and the second spray nozzle each make a spray angle of from less than or equal to 67.5 degrees, wherein the spray angle is defined as an acute angle formed between an average direction of a spray vector of the first spray nozzle or the second spray nozzle and a direction of travel of the plurality of glass articles through the coating station.

34. The system of claim 30, wherein the first spray nozzle and the second spray nozzle each have a spray angle of less than 45 degrees, where the spray angle is defined as an acute angle formed between an average direction of a spray vector of the first spray nozzle or the second spray nozzle and a direction of travel of the plurality of glass articles through the coating station.

35. The system of claim 29, wherein the coating system comprises three or more spray nozzles.

36. The system of claim 35, wherein the three or more spray nozzles are evenly spaced apart in an angular direction about the focal point of the coating system.

37. The system of claim 35, wherein the three or more spray nozzles comprise at least two leading spray nozzles or at least two trailing spray nozzles.

38. The system of claim 35, wherein the three or more spray nozzles comprises at least one leading spray nozzle, at least one trailing spray nozzle, and at least one neutral spray nozzle, wherein the neutral spray nozzle is oriented to have a spray direction that is perpendicular to the direction of travel of the glass article through the coating station.

39. The system of claim 29, further comprising one or more gas jets positioned to direct a gas flow that redirects droplets of the coating solution back towards the glass article in the coating station.

40. The system of claim 29, wherein the conveyor is operable to convey the glass articles through the coating station at a speed of greater than or equal to 300 mm / s, greater than or equal to 500 mm / s, greater than or equal to 1000 mm / s, greater than or equal to 1500 mm / s.

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