US20130017289A1 - Device for cutting plastic products provided in a continuous plastic band for use in the medical sector - Google Patents

Device for cutting plastic products provided in a continuous plastic band for use in the medical sector Download PDF

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Publication number
US20130017289A1
US20130017289A1 US13/583,460 US201113583460A US2013017289A1 US 20130017289 A1 US20130017289 A1 US 20130017289A1 US 201113583460 A US201113583460 A US 201113583460A US 2013017289 A1 US2013017289 A1 US 2013017289A1
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United States
Prior art keywords
laser
plastic products
cutting
plastic
ampoules
Prior art date
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Abandoned
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US13/583,460
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English (en)
Inventor
Heinz Kieburg
Reiner Franzke
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
B Braun Melsungen AG
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B Braun Melsungen AG
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Filing date
Publication date
Application filed by B Braun Melsungen AG filed Critical B Braun Melsungen AG
Assigned to B. BRAUN MELSUNGEN AG reassignment B. BRAUN MELSUNGEN AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FRANZKE, REINER
Publication of US20130017289A1 publication Critical patent/US20130017289A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61J—CONTAINERS SPECIALLY ADAPTED FOR MEDICAL OR PHARMACEUTICAL PURPOSES; DEVICES OR METHODS SPECIALLY ADAPTED FOR BRINGING PHARMACEUTICAL PRODUCTS INTO PARTICULAR PHYSICAL OR ADMINISTERING FORMS; DEVICES FOR ADMINISTERING FOOD OR MEDICINES ORALLY; BABY COMFORTERS; DEVICES FOR RECEIVING SPITTLE
    • A61J1/00—Containers specially adapted for medical or pharmaceutical purposes
    • A61J1/05—Containers specially adapted for medical or pharmaceutical purposes for collecting, storing or administering blood, plasma or medical fluids ; Infusion or perfusion containers
    • A61J1/06—Ampoules or carpules
    • A61J1/067—Flexible ampoules, the contents of which are expelled by squeezing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/40—Removing material taking account of the properties of the material involved
    • B23K26/402—Removing material taking account of the properties of the material involved involving non-metallic material, e.g. isolators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/022—Mechanical pre-treatments, e.g. reshaping
    • B29C66/0224—Mechanical pre-treatments, e.g. reshaping with removal of material
    • B29C66/02241—Cutting, e.g. by using waterjets, or sawing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/024—Thermal pre-treatments
    • B29C66/0246—Cutting or perforating, e.g. burning away by using a laser or using hot air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B29C69/005—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore cutting-off or cutting-out a part of a strip-like or sheet-like material, transferring that part and fixing it to an article
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61J—CONTAINERS SPECIALLY ADAPTED FOR MEDICAL OR PHARMACEUTICAL PURPOSES; DEVICES OR METHODS SPECIALLY ADAPTED FOR BRINGING PHARMACEUTICAL PRODUCTS INTO PARTICULAR PHYSICAL OR ADMINISTERING FORMS; DEVICES FOR ADMINISTERING FOOD OR MEDICINES ORALLY; BABY COMFORTERS; DEVICES FOR RECEIVING SPITTLE
    • A61J1/00—Containers specially adapted for medical or pharmaceutical purposes
    • A61J1/05—Containers specially adapted for medical or pharmaceutical purposes for collecting, storing or administering blood, plasma or medical fluids ; Infusion or perfusion containers
    • A61J1/06—Ampoules or carpules
    • A61J1/065—Rigid ampoules, e.g. glass ampoules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/16—Bands or sheets of indefinite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/30—Organic material
    • B23K2103/42—Plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
    • B26D1/02—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a stationary cutting member
    • B26D1/03—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a stationary cutting member with a plurality of cutting members
    • B26D1/035—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a stationary cutting member with a plurality of cutting members for thin material, e.g. for sheets, strips or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
    • B26D1/04—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member
    • B26D1/045—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member for thin material, e.g. for sheets, strips or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
    • B26D1/04—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member
    • B26D1/06—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member wherein the cutting member reciprocates
    • B26D1/10—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member wherein the cutting member reciprocates in, or substantially in, a direction parallel to the cutting edge
    • B26D1/105—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member wherein the cutting member reciprocates in, or substantially in, a direction parallel to the cutting edge for thin material, e.g. for sheets, strips or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
    • B26D1/04—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member
    • B26D1/06—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member wherein the cutting member reciprocates
    • B26D1/10—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member wherein the cutting member reciprocates in, or substantially in, a direction parallel to the cutting edge
    • B26D1/11—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member wherein the cutting member reciprocates in, or substantially in, a direction parallel to the cutting edge with a plurality of cutting members
    • B26D1/115—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member wherein the cutting member reciprocates in, or substantially in, a direction parallel to the cutting edge with a plurality of cutting members for thin material, e.g. for sheets, strips or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/40—Moulds for making articles of definite length, i.e. discrete articles with means for cutting the article
    • B29C2043/406—Moulds for making articles of definite length, i.e. discrete articles with means for cutting the article laser cutting means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/58—Blowing means
    • B29C2049/5848—Cutting means, e.g. to cut parts of the preform or parison with the blowing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0009—Cutting out
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0027—Cutting off
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0036—Slitting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/40—Moulds for making articles of definite length, i.e. discrete articles with means for cutting the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/03—After-treatments in the joint area
    • B29C66/032—Mechanical after-treatments
    • B29C66/0326—Cutting, e.g. by using waterjets, or perforating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B29C69/001—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts

Definitions

  • the present invention is directed to a device for cutting plastic products provided in a continuous plastic band wherein the single plastic products are connected to each other for use in the medical sector, comprising at least one laser, at least one laser control system, at least one optical acquisition and data processing unit, and a quality control device with an integrated pressure sensor for the detection of incorrect or not sufficient laser cuts. Furthermore, the present invention is directed to a machine for the production of plastic products, especially the production of filled or fillable plastic products for use in the medical sector, comprising the device for cutting plastic products provided in a continuous plastic band connected to each other. Also disclosed is a method to cut the plastic products in the continuous plastic band wherein the single plastic products are connected to each other.
  • the U.S. Pat. No. 5,231,262 A application discloses a laser cutting device, comprising a laser, a position detection system, an image processor and a laser control system in form of mirrors, light-shutters, objective lens and a rotating arm.
  • the U.S. Pat. No. 4,328,411 A application describes a method to cut amorphous metal through crystallization with a laser. Also disclosed is a punching machine in combination with a pressing mould, which punches the pre-cut form out of the amorphous metal.
  • the object of at least one aspect of the present invention is to provide a device, which further improves the prior art and allows an increased efficiency when cutting plastic products provided in a continuous band for use in the medical sector.
  • a device comprising at least one laser, at least one laser control system, at least one optical acquisition and data processing unit, and a quality control device with an integrated pressure sensor for the detection of incorrect laser cuts has an increased efficiency when cutting plastic products provided in a continuous band wherein the single plastic products are connected to each other for use in the medical sector.
  • An optical acquisition unit determines positional data of the plastic products provided in the continuous band and connected to each other.
  • the positional data are used to calculate a cutting pattern, which is transmitted to the laser control system.
  • the position, intensity and focal point of the at least one laser beam is controlled through a focusing optic and a deflection means.
  • gas lasers solid-state lasers and/or dye lasers
  • the lasers belonging to the group of gas lasers comprise excimer laser, noble gas ion laser, metal vapor laser or molecular gas laser.
  • the group of excimer lasers includes but is not restricted to H 2 -laser (116/123 nm), Ar 2 -laser (126 nm), F 2 -laser (157 nm), Xe 2 -laser (172 nm), ArF-laser (193 nm), KrF-laser (248 nm), XeBr-laser (282 nm), XeCl-laser (308 nm) and XeF-laser (351 nm).
  • Noble gas ion lasers include but are not restricted to (Ar) + -laser (including ⁇ 460 nm, 480 nm, 500 nm, 520 nm), (Kr) + -laser (650 nm) and He—Cd-laser (325 nm, 440 nm).
  • the group of metal vapor lasers includes but is not restricted to Cu-laser (500 nm, 545 nm) and Au-laser (310 nm, 605 nm).
  • the group of molecular gas lasers comprises CO-laser (6-8 ⁇ m), CO 2 -laser (9 ⁇ m, 10.6 ⁇ m, 11 ⁇ m) and N 2 -laser (337 nm).
  • Solid-state lasers can be selected from ruby Cr 3+ :Al 2 O 3 -laser (694 nm), Neodymium glass (Nd:Glass) laser (1062 nm), Neodymium-YAG-laser (1064 nm), Alexandrite-laser (755 nm), ALGaN/GaN-laser (400-500 nm), InGaAs/GaAs-laser (700-880 nm), InGaAsP/InP-laser (900-1100 nm) and Pb-Chalkogenide-laser (2,6-30 ⁇ m).
  • the group of dye lasers comprises amongst others stilbenes, coumarins and rhodamines covering the whole spectrum from ⁇ 300 nm to 1300 nm.
  • the cutting process can be performed parallel, synchronous or consecutively by multiple lasers.
  • the cutting process is performed by two lasers, more preferably by three lasers and most preferably by four lasers.
  • the number of lasers can be adapted and depends on the complexity of the cutting pattern and the size and dimension of the plastic products provided in the continuous band. It is also possible to split the laser beam with a beam splitter into multiple beams and control each beam independently from each other for the cutting process. Preferred are CO 2 -laser and UV-laser.
  • CO 2 -laser with a wave length of 9.4 ⁇ m, more preferably with 10.3 ⁇ m or 10.6 ⁇ m with a preferred output power of 200 W or between 180 W and 220 W respectively.
  • Preferred UV-laser comprise solid-state lasers on the basis of Nd:YAG, YLF or Nd:VO4, where by means of frequency conversion with nonlinear crystals, the third harmonic with a wavelength of 355 nm or in the vicinity thereof is generated. These lasers enable an extremely fine focusing of the laser beam, which is suited to cut or separate or perforate the narrow connections between the plastic components completely or partially.
  • a focused laser beam is guided around the contours of the plastic products provided in the continuous band to melt or evaporate the material between the products and/or the continuous band.
  • the Gaussian intensity distribution of the laser beam cross-section ensures that the laser radiation melts the material at the edges and no burr formation occurs. This has the advantage that at the edge of the plastic products no sharp edges form that may damage e.g. sterile gloves used in the medical field or even lead to cuts to the hand of the person working with the cut plastic products.
  • the separation with a laser beam has distinct advantages over mechanical separation devices like e.g. punching devices, because the use of mechanical devices leads inherently to the formation of burrs or sharp edges. The sharpness of the resulting burr and/or the cutting edge is directly dependent form the hardness/rigidity of the plastic material.
  • the plastics are preferably selected from the group consisting of polyamides, polyolefins or copolymers, as well as combinations of such plastics or copolymers in the form of composite materials.
  • the plastic is polyethylene (PE), even more preferred is polypropylene (PP) or any other plastic with at least the hardness/rigidity, tensile strength, torsion module, Young's modulus and/or melting range of polypropylene (PP). Any plastic, that is at least as rigid or hard or even more rigid or harder as PP can be cut preferably according to the present invention.
  • plastics that can be used with the inventive device can be selected from the group consisting of or comprising: polyvalerolactones, poly- ⁇ -decalactones, polylactonic acid, polyglycolic acid, polylactides, polyglycolides, copolymers of the polylactides and polyglycolides, poly- ⁇ -caprolactone, polyhydroxybutanoic acid, polyhydroxybutyrates, polyhydroxyvalerates, polyhydroxybutyrate-co-valerates, poly(1,4-dioxane-2,3-diones), poly(1,3-d ioxane-2-ones), poly-p-dioxanones, polyanhydrides such as polymaleic anhydrides, polyhydroxymethacrylates, fibrin, polycyanoacrylates, polycaprolactonedimethylacrylates, poly-b-maleic acid, polycaprolactonebutyl-acrylates, multiblock polymers such as from oligocaprolactonedioles and oli
  • Plastic products made of polypropylene have the great advantage over plastic products made of polyethylene that they can be autoclaved and sterilized at or above temperatures of 121° C. This is of particular importance in the medical sector, where it is essential to ensure that all germs are killed. Because of the higher temperatures necessary to process polypropylene the plastic products have to be cooled down over a longer distance and/or a longer time before it is possible to cut the plastic products out of the continuous plastic band wherein the single plastic products are connected to each other. Moreover, PP is much harder than PE and mechanical cutting or punching leads naturally to even more sharp burrs and/or cutting edges.
  • plastics With the inventive device it is possible to cut plastics with a high processing temperature directly after processing. It is not necessary to wait for the plastics to cool down nor is it needed to install long conveyer bands to cool the plastic products during transportation down to a temperature at which it is possible to cut the plastic products. Consequently, it is also preferred to cut plastics that have a high Young's modulus and thus tend to form sharp burrs and/or edges when cut or punched mechanically.
  • polypropylene which is regularly specified with a melting range between 160° C. and 170° C. and a Young's modulus of about 1520 N/mm 2 . Thus, such plastics are preferred which have a melting range above 160° C., more preferred above 180° C., further preferred above 200° C.
  • An especially preferred plastic that can be cut with the inventive device is polypropylene and any other plastics, characterised by a melting range, tensile strength, torsion module or hardness/rigidity in the range of polypropylene, wherein “in the range” of is defined as ⁇ 10% to the corresponding value of polypropylene, i.e. a value of ⁇ 10% to +10% of polypropylene.
  • the inventive device uses a laser to cut the plastic products provided in the continuous band of plastic.
  • a cooling line for the hot plastic products is not necessary, because the laser can cut the hot material or the hot material in the process of cooling down respectively, safely and precisely.
  • This is especially advantageous, when cutting plastic products for the medical sector at elevated temperatures directly or shortly after the plastic products leave the molding roll, when they already start to harden. Additionally, it is possible to perforate the narrow connections between the plastic components completely or partially or to induce predetermined breaking points making it easier to separate the plastic products from each other. This is especially advantageous when the plastic products are made of polypropylene, which is extremely tenacious after cooling down making it difficult to separate the plastic products manually without any further mechanical aid e.g. a scissor.
  • the inventive laser cutting device is especially useful for cutting warm or hot polymers and plastics, i.e. cutting polymers or plastics with a temperature of at least 60° C., preferred at least 80° C., further preferred at least 100° C., more preferred at least 115° C., more preferred at least 125° C., even more preferred at least 135° C., further preferred 145° C. and more preferred at least 155° C., whereby plastics and/or polymers can be cut even at temperatures from 200° C. to 250° C.
  • the device according to the invention is preferably used to cut plastic products that are in the process of cooling or heating, wherein the temperature of the segment to be cut is different at the beginning of the cutting process in comparison to the temperature at the end of the cutting process.
  • the word “segment” is to be understood as the section for example in a continuous belt that is recognized in a work cycle by the optical acquisition unit and were the cutting pattern is defined.
  • the laser cutting is very accurate even when a temperature gradient exists, i.e. temperature changes during cutting in the plastic product or the plastic segment respectively.
  • the inventive device acquires and processes the cutting pattern for the plastic products correctly in a temperature range from ⁇ 100° C. to +300° C. Any changes in the temperature of the plastic up to 1° C. per second can be acquired and processed by the inventive device. This includes also changes in consecutive cutting patterns and cutting modes as well as for changing plastic materials during the cutting of a cutting pattern or for consecutive segments and cutting patterns.
  • cutting or “laser cutting” as used herein shall be understood as cutting through plastic material with a laser beam, preferably polypropylene and similar polymers or polyethylene, this also includes perforating, i.e. alternating parts of cut through and uncut parts as well as cutting partially through or thinning parts, in the meaning that the material at the cutting point is not completely cut through but only the thickness is reduced, i.e. the material bonding still exists, but can be separated mechanically with less force.
  • cutting or “laser cutting” describes cutting completely through the plastic material along the whole cutting pattern or only at specific points of the cutting pattern as well as perforating the plastic material along the whole cutting pattern or only at specific points of the cutting pattern, i.e. completely cut through parts alternate with uncut parts.
  • the term “cutting pattern” is to be understood as the totality of all parts to be cut, which are acquired by the optical acquisition unit in one detection step.
  • the cutting pattern can be positioned in a segment of a continuous band of interconnected plastic products.
  • the optical acquisition unit gradually acquires a part (i.e. segment) of the continuous band or belt of interconnected plastic products, which is fed to the inventive device and then is cut according to the cutting pattern.
  • the cutting pattern comprises the plastic products, acquired through the optical acquisition unit, which are usually three-dimensional and lie above and below the plane level and are defined through the continuous band or the continuous belt, which can comprise further user definable and thus predefined information concerning the cutting mode.
  • the optical acquisition unit can detect for example, where the cutting is to be performed.
  • the mode of cutting (completely, partially, perforating, etc.) can be predetermined by the user.
  • the optical acquisition u nit can detect respective markings, which do not only give information where the cuts are to be made but also the mode of cutting can be included as information.
  • a combination of the aforementioned is possible, thus a mix of predefined patterns and automatic detection of the cutting mode and/or cutting pattern is possible.
  • a continuous band or a continuous belt it is also possible that single units or only parts of the continuous band, i.e. isolated segments, are detected by the optical acquisition unit.
  • the cutting pattern and eventually the cutting mode is determined anew by the optical acquisition unit before cutting a specific section, or specific part of the continuous band or the continuous belt, thus it is possible to handle various cutting patterns and cutting modes in random order.
  • the mechanical punching or mechanical cutting tool are determined for a defined cutting pattern or defined cutting mode and cannot adapt to changes in alternating segments with different cutting patterns and cutting modes.
  • the inventive laser cutting device can handle up to ten different cutting patterns with different cutting modes, which is impossible to achieve with a mechanical cutting or punching tool. Even if different punching or cutting tools are used, there are still only a limited number of patterns that can be handled.
  • the inventive device is independent of the exact cutting pattern, i.e. is not restricted to a specific pattern but can detect and handle any cutting pattern.
  • the cutting pattern is determined through suitable markings, which are detected by the optical acquisition unit. This can include colored markings, spatial markings as well as radioactive markings.
  • Colored markings include for example, colored markings in the visible range, infrared range or UV range and can be incorporated or attached to the plastic. This extends also to other materials which can be incorporated or attached to the plastic and are distinguishable from the plastic material such as thin filaments, wires or micro particles. Spatial markings on the other hand can be realized as elavations, dents or holes in the plastic material. Radioactive markers are radioactive substances incorporated or attached to the plastic material, wherein a radioactively labeled substance or solution in the plastic product may serve as a marker.
  • the data processing unit determines which parts of the cutting pattern are to be cut by the laser completely, or are only perforated, thinned and/or are not to be processed.
  • the laser is capable of cutting specific parts completely, perforate them, reduce the thickness of the material to a specific degree and/or ignore specific parts, all within the limits of the detected and/or predetermined cutting pattern by the optical acquisition unit, depending on which mode of cutting was predefined by the user or a marking in the cutting pattern or a segment respectively.
  • the laser is under the control of the data processing unit and is guided according to the cutting pattern detected by the optical acquisition unit and the predefined cutting mode.
  • the use of the laser beam for accurate cutting of the plastic products is dependent from the optical acquisition unit, which determines positional data of the interconnected plastic products provided in the continuous plastic band.
  • the positional data can comprise information about the forms, sizes, shapes, geometric forms, laser markings, shadow projection, color recognition, light/dark zones or reflections which are detected by the optical acquisition unit.
  • the optical acquisition unit comprises a camera.
  • a laser scanner is used together with a detector to determine positional data by measuring the interconnected plastic products provided in the continuous plastic band.
  • the laser can be diverted by a mirror system to depict a complete surface profile of the plastic products.
  • the positional data are transmitted to a data processing unit, e.g. a programmable micro processor, where they are further processed.
  • a data processing unit e.g. a programmable micro processor
  • the term “processed” is to be understood in the way that the actual determined positional data is compared with positional data stored in the data processing unit. For each combination of positional data a cutting pattern is stored in the data processing unit, which is transmitted to the laser control system to control the laser.
  • the positional data are not compared with the stored positional data, but the data processing unit calculates the respective cutting pattern from the acquired positional data and transmits the calculated cutting pattern to the laser control system to control the laser.
  • positional data as well as cutting patterns are stored, which are corrected by the respective actual positional data, leading to an adapted cutting pattern which is transmitted to the laser control system to control the laser.
  • the laser control system consists preferably of a controllable focusing optic, a controllable deflection means and a beam-forming means.
  • controllable is to be understood that the focusing optic and the deflection means can be controlled with the cutting patterns calculated by the data processing unit and further that the data are transmitted in a suitable format.
  • the beam-forming means collimates the laser beam and reduces the divergence of the beam for the purpose of a better focusing.
  • the position of the focus and intensity of the focal point of the at least one laser is controlled by a controllable focusing optic and a controllable deflection means. If more than one laser is used preferably each laser is controlled by another laser control system.
  • the laser control system comprises a beam-forming means, which collimates the laser beam, a telescopic lens system, which reduces the divergence of the beam for the purpose of a better focusing, a mirror deflection system, which guides the laser beam in two- or three-dimensions around the interconnected plastic products according to the predetermined cutting pattern, a focusing optic, which focuses the laser beam such that the plastic material is evaporated during the movement of the laser beam and a software-controlled electronics, which converts the data for the cutting pattern in mirror movements.
  • controllable deflection means is a galvanometer scanner, deflecting the direction of the laser beam with mirrors.
  • the galvanometer scanner deflects the laser beam over two or more mirrors.
  • one or more controllable deflections means can be used.
  • no relative movement takes place between the plastic product and the laser optics, i.e. the laser optics is fixed and immovable, and the laser beam is controlled only by the controllable deflection means.
  • the laser beam is not deflected by a controllable deflection means, but the laser optics or a part of the laser optics is moved relative to the plastic product to perform the cutting process.
  • the term laser optics comprises all the components necessary for forming, focusing, controlling or amplifying the laser beam. For example, only the lens and the mirror system can be moved, or only the lens, or only the mirror system or the entire laser optics relative to the plastic product.
  • the laser beam is controlled by a movable controllable deflection means.
  • the term movable in this context means that the controllable deflection means can be moved in the x, y and z axis. This ensures that the laser beam can also reach and cut areas which are difficult to access.
  • controllable deflection means can also be used to simultaneously label the ampoules, thus cutting and labeling is done in one work process.
  • the focusing optic is preferably a lens or a mirror, more preferably a convex lens or a focusing concave mirror.
  • the concave mirror provides the further advantage that each laser wavelength can be focused on the same point without having to use special optical materials.
  • the device comprises a conveying unit for the interconnected plastic products provided in the continuous band.
  • This conveying unit consists preferably of a feeding-in device that pulls the interconnected plastic products provided in the continuous band under the laser and the optical acquisition unit. This allows a high throughput and a full automatic cutting of the plastic products provided in the continuous band.
  • the conveying unit is a conveyor belt on which the interconnected plastic products are transported.
  • One of the significant advantages of laser separation of plastic products, e.g. ampoules, bags or other cavities is to create a fused edge as opposed to a sharp ridge after mechanical separation. This is especially important when cutting plastic products for use in the medical sector because a sharp ridge may cause damage to sterile gloves or may even injure the hand of the doctor or of the hospital staff when using such ampoules.
  • Mechanically cut plastic products have always sharp ridges due to the fact that at the side where the cutting blade leaves the cut line a sharp ridge will occur.
  • the conventional laser cutting process with a fixed beam and focusing through a nozzle for processing gas may also lead to burrs on the edges. It is better to cut the ampoules with a movable beam, e.g. with a galvo scanner, because this method can be carried out more precisely by fine tuning of laser parameters and beam-forming elements, such as telescopes and lenses and scanner movements so that the edges are fused at the joints. To achieve this, a sensor and a control system are required as provided in the present invention.
  • the ampoules are provided within a pack of ampoules with very narrow connections, the quality of the laser cut can usually only be evaluated with a very complex image recognition system and special cameras. Such a system slows down the whole manufacturing process, is inherently expensive and prone to malfunctions and cannot easily be integrated in existing systems.
  • the inventive device further comprises a quality control device with an integrated pressure sensor for pressing out the cut plastic products.
  • the interconnected plastic products provided in the continuous plastic band are preferably not separated completely by the laser from the residual material, i.e. the framework, so that the cut plastic products can be transported within the surrounding material until the final separation takes place. During the laser cutting, precisely defined narrow connections are left between the plastic products and the surrounding residual material. For the final separation step the plastic products are transported under the quality control device with an integrated pressure sensor.
  • a stamp with the form of the ampoule pack or a stamp with a certain number of pins which hit predefined locations of the single plastic product or of a section of the continuous plastic band, i.e.
  • an adapted stamp presses the plastic products and especially the material between the toggle parts of the ampoules, i.e. the material between the neck regions of neighboring ampoules, out of the residual surrounding material. If the pressure or force necessary to push the ampoules out of the surrounding material and/or the material between the toggle regions exceeds a predefined first adjustable value, this is an indication that the plastic products are not sufficiently separated and are still connected with the surrounding material, i.e. are still connected to the belt or to each other.
  • a gas blow such as an air blow or multiple gas blows generated by one or a plurality of nozzles can be used to put a kind of gas blow pressure on the plastic products or units or bundles of plastic products.
  • the single gas blows are generated with a defined pressure which again indicates the quality of the laser cut by determining if the gas blow or the gas blows were sufficient to separate the single plastic products or units or bundles of plastic products.
  • a gas the skilled person may also use a liquid such as water for the same purpose.
  • the quality control device with an integrated pressure sensor is directed to pressing the laser cut plastic products out of the surrounding residual material of the continuous band thereby generating single plastic products or units of plastic products which are still attached to each other but already perforated preferably by the laser used in the cutting device so that the separation can be done easily without forming sharp ridges.
  • This is usually performed with an adapted mould having the form of the ampoule or ampoule packs.
  • narrow stamps can be included that push out the residual material between the toggle parts, i.e. the area between the neck regions of two adjacent ampoules. If a predefined first adjustable value is exceeded, then the laser cutting was not sufficient and the plastic products are collected separately.
  • the quality control device with an integrated pressure sensor consists of a mould adapted to the form of the ampoules, which presses the plastic products precisely out of the surrounding residual material.
  • the quality control device with an integrated pressure sensor can control the quality of the laser cut, i.e. the quality of the intended separation, by measuring the resistance and/or force that is necessary to press the plastic products out of the surrounding residual material.
  • the quality control is performed at the material between the toggle parts, i.e. the area between the neck regions of two adjacent ampoules.
  • the force required to push the plastic products out of the surrounding residual material provides information on whether the plastic product was cut correctly, i.e. the plastic products can be pushed out of the surrounding material or not. Furthermore, the required force indicates, whether the ridges are safe or if any sharp ridges have formed that may be potentially harmful.
  • first and second values or thresholds for the pressure/force depend on factors such as the kind of plastic to be cut, the thickness of the material, the temperature at which the cut is performed, the output power for the lasers and/or the geometry or size of the plastic products and the like. It is within the scope of the skilled artisan to determine through minimal experimentation, which pressure or force threshold is indicative for the plastic products in the continuous band. Thus, it is not complicated and even not inventive to find the right pressure range which indicates for the given plastic product a faultless cut or an inacceptable cut so that adjustment of the laser has to be performed.
  • the quality control device with an integrated pressure sensor determines the quality of the laser cut by applying an underpressure to the plastic product, such as the ampoule, the ampoule pack and/or the toggle region, i.e. the material between the neck regions of the ampoules.
  • the mode of action is similar to the above described embodiment, however, it is not the force measured that is required to separate the ampoule, the ampoule pack and/or the toggle region from the surrounding residual material. Instead the quality control device with an integrated pressure sensor measures the force required to apply a certain under-pressure such as a certain vacuum.
  • the underpressure or vacuum is applied from below the single plastic products or the pack or bundle of plastic products in order to separate the single plastic products or the pack or bundle of plastic products from the continuous plastic band and from the other single plastic products or the other packs or bundles of plastic products.
  • the quality control device with an integrated pressure sensor applies a pulling force which can be determined in order to assess quality of the laser cut.
  • a pulling force can be applied through means which grip the single plastic products or the pack or bundle of plastic products and separate them from the continuous plastic band and from the other single plastic products or the other packs or bundles of plastic products.
  • the force required to separate the single plastic products or the pack or bundle of plastic products can be measured and is also an indication for the quality of the laser cut in order to assess if the laser cut was faultless or not sufficient.
  • the device comprises a system to compensate for long-term drift effects of the laser beam and the controllable deflection means. This may occur due to changes in temperature, humidity, exposure to vibration, mechanical stress and aging of components and can affect the precision of the laser beam negatively.
  • the system to compensate for long-term drift effects of the laser beam ensures that the precision of the laser is always optimal, reducing production losses, due to maintenance of the device, to an absolute minimum.
  • a thermal imaging camera is used, to register the selective heating on a material surface lying outside of the cutting pattern, but still within the range of deflection of the mirror system of the controllable deflection means.
  • the selective heating results by directing the beam for a short time on this material surface for a specific length of time. These short-term heating can for example be performed while the feeding-in device pulls the next interconnected plastic products provided in the continuous band under the laser and the optical acquisition unit.
  • the thermal imaging camera compares the position on the receiver with previously programmed set/designed positions.
  • the data collected is then transmitted to the laser control system to correct and adjust the cutting pattern.
  • This control mechanism can take place both in or before each cutting process or at certain predefined intervals.
  • the thermal imaging camera can also determine simultaneously the temperature of the heated material surface and conclude from this data on the laser power used for cutting the plastic products. A decrease in laser power can then be adjusted accordingly.
  • a band lying outside of the cutting pattern, but still within the range of deflection of the mirror system of the controllable deflection means, is drawn along within or outside of the plastic band, whereby the laser removes an amount of the material in the band in the form of a point.
  • a camera compares the position of this point with a programmed reference point and any deviations are transmitted as correction data to the laser control system, similar to the process described above.
  • the interconnected plastic products for use in the medical field provided in the continuous plastic band are preferably bottles, bags or containers, and even more preferred ampoules.
  • medical devices or parts of medical devices can be cut according to the invention, such as syringes, vials, hollow fibers for dialysators or parts of powder inhalers.
  • multi-layer plastic products such as those produced via co-extrusion blow molding.
  • These multi-layer plastic products combine the positive properties of different plastics together and are usually characterized by a barrier layer that is arranged between two carrier layers, which are connected together by a bonding agent.
  • these multi-layered plastic products are used in applications where improved barrier properties are needed to gases.
  • Mechanical cutting methods have particularly problems with the joints of the multilayer plastic products. At the joints the barrier layer is naturally not very pronounced and there is an increased risk that the barrier layer is interrupted by the mechanical cutting in those areas.
  • the inventive device has the advantage that the individual layers of the multilayer plastic products are fused together at the joints and along the edges during cutting with the laser. Consequently, the barrier properties of the joints, edges or seams remain intact and are even improved in comparison to mechanical cutting methods.
  • the process for separation of plastic products provided or surrounded by plastic can be applied and performed similar in principle with the described laser-control system with other plastic products such as consumer goods or industrial parts.
  • the inventive device is operated in combination with a device, producing plastic products, under the BFS process (blow-fill-seal process).
  • a device producing plastic products
  • BFS process blow-fill-seal process
  • the inventive device is particularly advantageous for cutting plastic ampoules interconnected, joined together and/or linked together.
  • These ampoules can e.g. be filled by the BFS process (blow-fill-seal process) but also empty ampoules can be processed.
  • BFS process low-fill-seal process
  • the ampoules leave the filling machine as rows of interconnected, joined together and/or linked together ampoules in a continuous band. In this continuous band one row of interconnected, joined together and/or linked together ampoules is followed by the next row of ampoules and all rows are embedded in the continuous band and surrounded by the residual plastic material.
  • the ampoules are arranged very close together and thus the separation of the ampoules is very difficult. This is especially true for the toggle portion at the neck of the ampoules.
  • the toggle portion at the neck of the ampoules is a critical area during mechanical punching as there is only a very small area that has to be cut out precisely and often only a partial separation can be achieved.
  • the inventive device can separate this portion of the ampoules safely without the risk of damaging the opening of the ampoules.
  • Ampoules in the medical field are usually provided as packs, i.e. a certain number of interconnected ampoules are punched out mechanically out of the continuous band.
  • ampoules made of polypropylene tend to develop a sharp ridge when cut out mechanically or when one ampoule is separated manually from the ampoule pack.
  • cutting with the inventive device has the following advantages.
  • the plastic ampoules are not required to cool down and can be cut at higher temperatures. Differences in the size of the ampoules which are inherent and cannot be avoided when manufacturing ampoules at high temperatures and the shrinking process of the ampoules when cooling down are detected by the device and the laser beam is adjusted accordingly.
  • the formation of sharp ridges and/or burr formation are avoided and the ampoules can be provided by the laser with perforations or breaking points between or in the plastic products, making them easier to separate from each other.
  • the present invention also comprises an inventive method for cutting interconnected plastic products for use in the medical sector provided in a continuous band of plastic which comprises the following steps:
  • plastic products or packs of plastic products are cut at temperatures of the plastic products or packs of plastic products of 60° C. to 155° C.
  • the method can further comprise one of the following steps e)-e′′):
  • a pressure or force or underpressure (such as vacuum) below a certain value (e.g. value A) indicates a proper and faultless cut without sharp ridges
  • a pressure or force or underpressure above a certain value e.g. value B
  • a pressure or force or underpressure between the value A and value B indicates an insufficient cut where the plastic products can still be separated but might have sharp ridges.
  • the cut plastic products obtained within the range between value A and value B might be sold as proper medical products or might be discard as unrectifiable rejects.
  • the value A can be identical or almost identical to value B.
  • the force to separate the plastic products from the surrounding material reaches a first predefined adjustable value
  • this first threshold or first value has been reached, no further force is applied to separate the plastic products. This is important, because if the plastic products are still tightly connected to the surrounding residual material, applying an unlimited amount of force could lead to damage to the belt and the following plastic products, e.g. by overstretching the (hot) belt.
  • a second value/threshold which is under or below the first value. If the force required to separate the plastic products from the surrounding residual material exceeds this second value but is still under the first value, the plastic products were separated successfully, but this is an indication for an unsatisfactory and potentially harmful formation of sharp ridges or burrs. If the required force stays under this second value/threshold, then the quality of the laser cut is satisfactory and there is no risk of sharp ridges and/or burrs.
  • first and second values or thresholds for the pressure/force depend on factors such as the kind of plastic to be cut, the thickness of the material, the temperature at which the cut is performed, the output power for the lasers and/or the geometry or size of the plastic products and the like. It is within the scope of the skilled artisan to determine through minimal experimentation, which pressure or force threshold is indicative for the plastic products in the continuous band. Thus, it is not complicated and even not inventive to find the right pressure range which indicates for the given plastic product a faultless cut or an inacceptable cut so that adjustment of the laser has to be performed.
  • an ampoule belt ( 1 ) is pulled and positioned by a feeding-in device ( 2 ) under at least one controllable deflection means ( 5 ) and an optical acquisition unit ( 5 a ).
  • the optical acquisition unit ( 5 a ) acquires the positional data of at least one ampoule strip (II) and the data processing unit calculates from the positional data a cutting pattern for cutting the ampoules (III) individually or in packs of several ampoules out of the at least one ampoule strip (II).
  • the at least one focused laser beam (IV) is modified by the beam-forming means ( 4 ), such that the laser beam is suitable for separating the ampoules (III) through evaporation of the material between and/or around the ampoules.
  • the controllable deflection means ( 5 ) and the controllable focusing optic ( 5 b ) control the at least one focused laser beam (IV) according to the cutting pattern calculated by the data processing unit, to cut the ampoules individually or in packs of several ampoules.
  • the ampoule belt ( 1 ) is pulled further by the feeding-in device ( 2 ) and the next ampoule strip (II) is positioned under the controllable deflection means ( 5 ) and the optical acquisition unit ( 5 a ).
  • the cut ampoules (III) are still located in the ampoule belt ( 1 ) and are now positioned under the quality control device with an integrated pressure sensor ( 7 ) and the knife for separating the strips ( 8 ).
  • the quality control device with an integrated pressure sensor ( 7 ) and the knife for separating the strips ( 8 ) are triggered and the separated material between the toggle parts is collected in a separate container ( 14 ).
  • the ampoules (III) are now separated completely from the ampoule belt ( 1 ) and are transported in an upright position over a slide to an external transport route ( 9 ) for further processing.
  • the knife ( 8 ) separates the residual material ( 10 ) of the stripe from the belt and collects the residual material in the container ( 15 ).
  • the quality control device with an integrated pressure sensor ( 7 ) is triggered to press the ampoules (III) out of the belt it simultaneously measures the required pressure.
  • the required pressure to press the ampoules (III) out of the belt exceeds a previously adjustable threshold value, whereby the flap ( 11 ) is opened and the residual material with the filled ampoules ( 12 ) is dropped in the container ( 16 ). If the laser cutting device falls out completely, then two flaps ( 13 ) are triggered and the feeding-in device ( 2 ) transports the residual ampoule belt ( 1 ) uncut out of the device for later cutting.
  • the inventive device separates container products from a framework and/or among each other and consists of at least one laser with at least one laser control system and at least one optoelectronic system for image recognition and image processing, which determines the position of the container products in the framework and/or among each other and transmits these data to the at least one laser control system, whereby the at least one laser and/or laser beam is controlled such that the container products are separated from the framework and/or among each other.
  • the present invention is furthermore directed to a method for cutting plastic products provided in a continuous band consisting of segments to be cut with one laser cut for use in the medical sector, wherein the method enables cutting of the plastic products provided in the continuous band at varying temperatures.
  • the application WO 2009030311 A1 describes a cutting device, for cutting single containers provided in a plastic band, characterized by a free falling mechanical punching device, which separates by free fall the single containers from the surrounding material.
  • the mechanical punching device is powered by an electro motor, which moves the punching device from the starting position in a punching position.
  • the plastic products When the plastic products leave the forming mould, they usually have to be cooled down, before separation from the surrounding residual material is possible. During the cooling process the plastic products are subject to temperature dependent changes in their size (shrinking).
  • the prior art mechanical punching devices are dependent on a predetermined temperature, at which the plastic products can be separated, because only at this temperature does the size of the plastic products in the continuous band correlate with the shape of the punching tool.
  • the mechanical punching device is positioned in a fixed distance from the plastic products manufacturing device, e.g. a Blow-Fill-Seal apparatus, so that the plastic products have an exact predetermined temperature, when they reach the mechanical punching device.
  • the mechanical cutting devices are not able to follow these changes in geometry and size so that cuts at different temperatures will cause inaccurate or faulty cuts, thereby producing unrectifiable rejects. Therefore a method is needed which is able to cut out plastic products of a segment of interconnected plastic products at any temperature or any temperature range between 30° C. and 155° C.
  • the further objective of the present invention is to provide a method for cutting plastic products or cutting segments of plastic products provided in a continuous band for use in the medical sector, wherein the method enables cutting of the plastic products or segments thereof provided in the continuous band at varying temperatures.
  • the inventive method is useful for cutting warm or hot polymers and plastics, i.e. cutting polymers or plastics with a temperature of at least 30° C., preferred at least 60° C., preferred at least 80° C., further preferred at least 100° C., more preferred at least 115° C., more preferred at least 125° C., even more preferred at least 135° C., further preferred 145° C. and more preferred at least 155° C., whereby plastics and/or polymers can be cut even at temperatures from 200° C. to 250° C.
  • the temperature of the segment has at least one of the above described temperatures.
  • the segment has any temperatures ranging from 30° C. to 155° C., preferably from 35° C. to 125° C., more preferably from 40° C. to 110° C., still more preferably from 45° C. to 100° C., still more preferably from 50° C. to 90° C. and most more preferably from 55° C. to 80° C.
  • the inventive method allows the cutting of plastic products provided in a continuous band or within segments of the continuous band at any temperature and is totally independent from any changes in size of the plastic products due to shrinkage, e.g. while cooling down.
  • the temperature of the plastic products can vary, which makes mechanical punching at a predetermined temperature only possible for very narrow applications, namely only one fixed manufacturing process for one product.
  • Each change in one of these parameters inevitably necessitates a rearrangement of the manufacturing line, which does not only comprise the changing of the punching mould itself but also includes the repositioning of the whole punching device.
  • interconnected plastic products provided in the continuous belt is to be understood as an endless belt with a defined width, wherein the interconnected plastic products are embedded, i.e. are surrounded by the residual material.
  • segment is to be understood as the section for example in a continuous belt that is recognized in one single work cycle by the optical acquisition unit and were the cutting pattern is defined.
  • a “segment” has a defined length and width, with a certain number of interconnect plastic products. Consequently, the proportions of the segments are directly dependent from the settings of the optical acquisition unit.
  • segment is not to be understood in a physical sense in that there are e.g. precut fields or markings in the continuous belt, but is solely defined by the field of acquisition from the optical acquisition unit.
  • a “segment” is preferably this part of the continuous band which is detected or picked by the optical acquisition and data processing unit in one work cycle and which preferably contains a certain number of interconnect plastic products.
  • the subdivision or partition of the continuous band into segments is a more theoretical construct due to the fact that the continuous band does not contain markers indicating the segments and due to the fact that the position of the segments can be selected arbitrarily. Moreover it is possible that two segments overlap or that two subsequent segments are not directly connected to each other.
  • each segment can be cut precisely independent from its temperature and the temperature of the previous or the following segment with plastic products in the continuous band.
  • a mechanical punching device such precise cutting at varying temperatures is not possible.
  • the plastic products would have different sizes due to the different temperatures and thus cannot be punched mechanically.
  • the method according to the invention is preferably used to cut plastic products that are in the process of cooling or heating, wherein the temperature of the segment to be cut is different at the beginning of the cutting process in comparison to the temperature at the end of the cutting process.
  • the laser cutting is very accurate even when a temperature gradient exists, i.e. temperature changes during cutting in the plastic product or the plastic segment respectively.
  • the cutting pattern for the plastic products can be acquired and processed correctly in a temperature range from ⁇ 30° C. to +300° C. and preferably from +30° C. to +300° C. Any changes in the temperature of the plastic up to 1° C. per second can be acquired and processed. This includes also changes in consecutive cutting patterns and cutting modes as well as for changing plastic materials during the cutting of a cutting pattern or for consecutive segments and cutting patterns.
  • At least one segment with interconnected plastic products has a varying temperature than any of the previous segments with the interconnected plastic products.
  • the term “varying temperature” is to be understood to comprise any differences in temperature that exceed at least 0.5° C. This is particularly advantageous, if it comes to delays and/or small inconsistencies during the manufacturing process. In such cases it is still possible to cut the next segment with interconnected plastic products that are provided in the continuous belt, even though the size of the plastic products has changed due to the extra cooling time.
  • it is preferred to cut interconnected plastic products provided in the continuous belt that have a cool-down rate of 0.01° C. to 5° C. per minute.
  • the interconnected plastic products provided in the continuous belt consist of polypropylene and/or polyethylene.
  • the inventive method can be performed with a device comprising at least one laser, at least one laser control system, at least one optical acquisition and data processing unit, and optionally a quality control device with an integrated pressure sensor for the detection of incorrect laser cuts.
  • the optical acquisition unit determines in a segment positional data of the plastic products provided in the continuous band and connected to each other.
  • the positional data in the segment are used to calculate a cutting pattern, which is transmitted to the laser control system.
  • the position, intensity and focal point of the at least one laser beam is controlled through a focusing optic and a deflection means.
  • gas lasers solid-state lasers and/or dye lasers
  • the lasers belonging to the group of gas lasers comprise excimer laser, noble gas ion laser, metal vapor laser or molecular gas laser.
  • the group of excimer lasers includes but is not restricted to H 2 -laser (116/123 nm), Ar 2 -laser (126 nm), F 2 -laser (157 nm), Xe 2 -laser (172 nm), ArF-laser (193 nm), KrF-laser (248 nm), XeBr-laser (282 nm), XeCl-laser (308 nm) and XeF-laser (351 nm).
  • Noble gas ion lasers include but are not restricted to (Ar) + -laser (including ⁇ 460 nm, 480 nm, 500 nm, 520 nm), (Kr) + -laser (650 nm) and He—Cd-laser (325 nm, 440 nm).
  • the group of metal vapor lasers includes but is not restricted to Cu-laser (500 nm, 545 nm) and Au-laser (310 nm, 605 nm).
  • the group of molecular gas lasers comprises CO-laser (6-8 ⁇ m), CO 2 -laser (9 ⁇ m, 10.6 ⁇ m, 11 ⁇ m) and N 2 -laser (337 nm).
  • Solid-state lasers can be selected from ruby Cr 3+ :Al 2 O 3 -laser (694 nm), Neodymium glass (Nd:Glass) laser (1062 nm), Neodymium-YAG-laser (1064 nm), Alexandrite-laser (755 nm), ALGaN/GaN-laser (400-500 nm), InGaAs/GaAs-laser (700-880 nm), InGaAsP/InP-laser (900-1100 nm) and Pb-Chalkogenide-laser (2.6-30 ⁇ m).
  • the group of dye lasers comprises amongst others stilbenes, coumarins and rhodamines covering the whole spectrum from ⁇ 300 nm to 1300 nm.
  • the cutting process or the laser cut can be performed parallel, synchronous or consecutively by multiple lasers.
  • the cutting process or the laser cut is performed by two lasers, more preferably by three lasers and most preferably by four lasers.
  • the number of lasers can be adapted and depends on the complexity of the cutting pattern and the size and dimension of the plastic products provided in the continuous band. It is also possible to split the laser beam with a beam splitter into multiple beams and control each beam independently from each other for the cutting process.
  • CO 2 -laser and UV-laser are CO 2 -laser and UV-laser.
  • CO 2 -laser with a wave length of 9.4 ⁇ m, more preferably with 10.3 ⁇ m or 10.6 ⁇ m with a preferred output power of 200 W or between 180 W and 220 W respectively.
  • Preferred UV-laser comprise solid-state lasers on the basis of Nd:YAG, YLF or Nd:VO4, where by means of frequency conversion with nonlinear crystals, the third harmonic with a wavelength of 355 nm or in the vicinity thereof is generated. These lasers enable an extremely fine focusing of the laser beam, which is suited to cut or separate or perforate the narrow connections between the plastic components completely or partially.
  • a focused laser beam is guided around the contours of the plastic products in the segment provided in the continuous band to melt or evaporate the material between the products and/or the continuous band.
  • the Gaussian intensity distribution of the laser beam cross-section ensures that the laser radiation melts the material at the edges and no burr formation occurs.
  • This has the advantage that at the edge of the plastic products no sharp edges form that may damage e.g. sterile gloves used in the medical field or even lead to cuts to the hand of the person working with the cut plastic products.
  • the separation with a laser beam has distinct advantages over mechanical separation devices like e.g. punching devices, because the use of mechanical devices leads inherently to the formation of burrs or sharp edges. The sharpness of the resulting burr and/or the cutting edge is directly dependent form the hardness/rigidity of the plastic material.
  • the plastics are preferably selected from the group consisting of polyamides, polyolefins or copolymers, as well as combinations of such plastics or copolymers in the form of composite materials.
  • the plastic is polyethylene (PE), even more preferred is polypropylene (PP) or any other plastic with at least the hardness/rigidity, tensile strength, torsion module, Young's modulus and/or melting range of polypropylene (PP).
  • Any plastic, that is at least as rigid or hard or even more rigid or harder as PP can be cut preferably according to the present invention.
  • the laser cut of the segment or the laser cutting of PP is performed at any temperature between 30° C. to 155° C., preferably between 35° C.
  • plastics that can be used can be selected from the group consisting of or comprising: polyvalerolactones, poly- ⁇ -decalactones, polylactonic acid, polyglycolic acid, polylactides, polyglycolides, copolymers of the polylactides and polyglycolides, poly- ⁇ -caprolactone, polyhydroxybutanoic acid, polyhydroxybutyrates, polyhydroxyvalerates, polyhydroxybutyrate-co-valerates, poly(1,4-dioxane-2,3-diones), poly(1,3-dioxane-2-ones), poly-p-dioxanones, polyanhydrides such as polymaleic anhydrides, polyhydroxymethacrylates, fibrin, polycyanoacrylates, polycaprolactonedimethylacrylates, poly-b-maleic acid, polycaprolactonebutyl-acrylates, multiblock polymers such as from oligocaprolactonedioles and oligodiox
  • Plastic products made of polypropylene have the great advantage over plastic products made of polyethylene that they can be autoclaved and sterilized at or above temperatures of 121° C. This is of particular importance in the medical sector, where it is essential to ensure that all germs are killed. Because of the higher temperatures necessary to process polypropylene the plastic products have to be cooled down over a longer distance and/or a longer time before it is possible to cut the plastic products out of the continuous plastic band wherein the single plastic products are connected to each other. Moreover, PP is much harder than PE and mechanical cutting or punching leads naturally to even more sharp burrs and/or cutting edges.
  • plastics especially PP with a high processing temperature directly after processing. It is not necessary to wait for the plastics to cool down nor is it needed to install long conveyer bands to cool the plastic products during transportation down to a temperature at which it is possible to cut the plastic products. Consequently, it is also preferred to cut plastics that have a high Young's modulus and thus tend to form sharp burrs and/or edges when cut or punched mechanically.
  • polypropylene which is regularly specified with a melting range between 160° C. and 170° C. and a Young's modulus of about 1520 N/mm 2 .
  • plastics are preferred which have a melting range above 160° C., more preferred above 180° C., further preferred above 200° C. and especially preferred above 220° C. and can be routinely autoclaved at or above temperatures of 121° C. without getting deformed.
  • plastics are preferred which have an operating temperature above 100° C., more preferred above 110° C. and/or with a Young's modulus above 1500 N/mm 2 , more preferred above 1700 N/mm 2 and further preferred above 1900 N/mm 2 .
  • An especially preferred plastic that can be cut with the inventive device is polypropylene and any other plastics, characterised by a melting range, tensile strength, torsion module or hardness/rigidity in the range of polypropylene, wherein “in the range” of is defined as ⁇ 10% to the corresponding value of polypropylene, i.e. a value of ⁇ 10% to +10% of polypropylene.
  • the inventive method uses a laser to cut the plastic products provided in the continuous band of plastic.
  • a cooling line for the hot plastic products is not necessary, because the laser can cut the hot material or the hot material in the process of cooling down respectively, safely and precisely.
  • This is especially advantageous, when cutting plastic products for the medical sector at elevated temperatures directly or shortly after the plastic products leave the molding roll, when they already start to harden. Additionally, it is possible to perforate the narrow connections between the plastic components completely or partially or to induce predetermined breaking points making it easier to separate the plastic products from each other. This is especially advantageous when the plastic products are made of polypropylene, which is extremely tenacious after cooling down making it difficult to separate the plastic products manually without any further mechanical aid e.g. a scissor.
  • cutting or “laser cutting” as used herein shall be understood as cutting through plastic material with a laser beam, preferably polypropylene and similar polymers or polyethylene, this also includes perforating, i.e. alternating parts of cut through and uncut parts as well as cutting partially through or thinning parts, in the meaning that the material at the cutting point is not completely cut through but only the thickness is reduced, i.e. the material bonding still exists, but can be separated mechanically with less force.
  • cutting or “laser cutting” describes cutting completely through the plastic material along the whole cutting pattern or only at specific points of the cutting pattern as well as perforating the plastic material along the whole cutting pattern or only at specific points of the cutting pattern, i.e.
  • cutting or “cut” or “laser cut” is to be understood as the cutting done in one segment of the continuous belt. After the cutting has been done in one segment, the next cutting in the subsequent segment is performed. Thus, each cutting pertains to one segment, and each segment starts a new cutting process named as the “cut” or the “laser cut”.
  • cutting pattern is to be understood as the totality of all parts to be cut, which are acquired by the optical acquisition unit in one detection step/work cycle.
  • the cutting pattern can be positioned in a segment of a continuous band of interconnected plastic products.
  • cutting pattern refers to the entirety of single cut-lines within one segment.
  • the cutting pattern comprises the plastic products, acquired through the optical acquisition unit, which are usually three-dimensional and lie above and below the plane level and are defined through the continuous band or the continuous belt, which can comprise further user definable and thus predefined information concerning the cutting mode.
  • the optical acquisition unit can detect for example, where the cutting is to be performed.
  • the mode of cutting (completely, partially, perforating, etc.) can be predetermined by the user.
  • the optical acquisition unit can detect respective markings, which do not only give information where the cuts are to be made but also the mode of cutting can be included as information.
  • a combination of the aforementioned is possible, thus a mix of predefined patterns and automatic detection of the cutting mode and/or cutting pattern is possible.
  • a continuous band or a continuous belt it is also possible that single units or only parts of the continuous band, i.e. isolated segments, are detected by the optical acquisition unit.
  • the cutting pattern and eventually the cutting mode is determined anew by the optical acquisition unit for each segment, thus it is possible to handle various cutting patterns and cutting modes in random order. This is a distinct advantage over mechanical cutting and/or punching processes.
  • the mechanical punching or mechanical cutting tool are determined for a defined cutting pattern or defined cutting mode and cannot adapt to changes in alternating segments with different cutting patterns and cutting modes.
  • the laser cutting device can handle up to ten different cutting patterns with different cutting modes, which is impossible to achieve with a mechanical cutting or punching tool. Even if different punching or cutting tools are used, there are still only a limited number of patterns that can be handled.
  • the device is independent of the exact cutting pattern, i.e. is not restricted to a specific pattern but can detect and handle any cutting pattern.
  • the cutting pattern is determined through suitable markings, which are detected by the optical acquisition unit. This can include colored markings, spatial markings as well as radioactive markings.
  • Colored markings include for example, colored markings in the visible range, infrared range or UV range and can be incorporated or attached to the plastic. This extends also to other materials which can be incorporated or attached to the plastic and are distinguishable from the plastic material such as thin filaments, wires or micro particles. Spatial markings on the other hand can be realized as elavations, dents or holes in the plastic material. Radioactive markers are radioactive substances incorporated or attached to the plastic material, wherein a radioactively labeled substance or solution in the plastic product may serve as a marker.
  • the data processing unit determines which parts of the cutting pattern are to be cut by the laser completely, or are only perforated, thinned and/or are not to be processed.
  • the laser is capable of cutting specific parts completely, perforate them, reduce the thickness of the material to a specific degree and/or ignore specific parts, all within the limits of the detected and/or predetermined cutting pattern by the optical acquisition unit, depending on which mode of cutting was predefined by the user or a marking in the cutting pattern or a segment respectively.
  • the laser is under the control of the data processing unit and is guided according to the cutting pattern detected by the optical acquisition unit and the predefined cutting mode.
  • the use of the laser beam for accurate cutting of the plastic products is dependent from the optical acquisition unit, which determines positional data of the interconnected plastic products provided in the continuous plastic band.
  • the positional data can comprise information about the forms, sizes, shapes, geometric forms, laser markings, shadow projection, color recognition, light/dark zones or reflections which are detected by the optical acquisition unit.
  • the optical acquisition unit comprises a camera.
  • a laser scanner is used together with a detector to determine positional data by measuring the interconnected plastic products provided in the continuous plastic band.
  • the laser can be diverted by a mirror system to depict a complete surface profile of the plastic products.
  • the positional data are transmitted to a data processing unit, e.g. a programmable micro processor, where they are further processed.
  • a data processing unit e.g. a programmable micro processor
  • the term “processed” is to be understood in the way that the actual determined positional data is compared with positional data stored in the data processing unit. For each combination of positional data a cutting pattern is stored in the data processing unit, which is transmitted to the laser control system to control the laser.
  • the positional data are not compared with the stored positional data, but the data processing unit calculates the respective cutting pattern from the acquired positional data and transmits the calculated cutting pattern to the laser control system to control the laser.
  • positional data as well as cutting patterns are stored, which are corrected by the respective actual positional data, leading to an adapted cutting pattern which is transmitted to the laser control system to control the laser.
  • the laser control system consists preferably of a controllable focusing optic, a controllable deflection means and a beam-forming means.
  • controllable is to be understood that the focusing optic and the deflection means can be controlled with the cutting patterns calculated by the data processing unit and further that the data are transmitted in a suitable format.
  • the beam-forming means collimates the laser beam and reduces the divergence of the beam for the purpose of a better focusing.
  • the position of the focus and intensity of the focal point of the at least one laser is controlled by a controllable focusing optic and a controllable deflection means. If more than one laser is used preferably each laser is controlled by another laser control system.
  • the laser control system comprises a beam-forming means, which collimates the laser beam, a telescopic lens system, which reduces the divergence of the beam for the purpose of a better focusing, a mirror deflection system, which guides the laser beam in two- or three-dimensions around the interconnected plastic products according to the predetermined cutting pattern, a focusing optic, which focuses the laser beam such that the plastic material is evaporated during the movement of the laser beam and a software-controlled electronics, which converts the data for the cutting pattern in mirror movements.
  • controllable deflection means is a galvanometer scanner, deflecting the direction of the laser beam with mirrors.
  • the galvanometer scanner deflects the laser beam over two or more mirrors.
  • one or more controllable deflections means can be used.
  • no relative movement takes place between the plastic product and the laser optics, i.e. the laser optics is fixed and immovable, and the laser beam is controlled only by the controllable deflection means.
  • the laser beam is not deflected by a controllable deflection means, but the laser optics or a part of the laser optics is moved relative to the plastic product to perform the cutting process.
  • the term laser optics comprises all the components necessary for forming, focusing, controlling or amplifying the laser beam. For example, only the lens and the mirror system can be moved, or only the lens, or only the mirror system or the entire laser optics relative to the plastic product.
  • the laser beam is controlled by a movable controllable deflection means.
  • the term movable in this context means that the controllable deflection means can be moved in the x, y and z axis. This ensures that the laser beam can also reach and cut areas which are difficult to access.
  • controllable deflection means can also be used to simultaneously label the ampoules, thus cutting and labeling is done in one work process.
  • the focusing optic is preferably a lens or a mirror, more preferably a convex lens or a focusing concave mirror.
  • the concave mirror provides the further advantage that each laser wavelength can be focused on the same point without having to use special optical materials.
  • the device comprises a conveying unit for the interconnected plastic products provided in the continuous band.
  • This conveying unit consists preferably of a feeding-in device that pulls the interconnected plastic products provided in the continuous band under the laser and the optical acquisition unit.
  • This allows a high throughput and a full automatic cutting of the plastic products provided in the continuous band.
  • incompletely or faulty cut segments of the continuous band could be introduced into the laser cutting process again in order to complete cutting.
  • the re-introduced segments have further cooled down or cooled down to room temperature before they were re-introduced into the cutting process.
  • the inventive method is able to complete the incorrect or faulty laser cut within these segments even at quite different temperatures in comparison to the temperatures where the original incorrect or faulty laser cut was performed.
  • the rejects are detected anew by the optical acquisition and data processing unit and the laser-cut is repeated without the need to adjust the complete device to the new temperature of the rejects and without the need to warm the rejects up to temperatures where the original laser cut was performed.
  • the conveying unit is a conveyor belt on which the interconnected plastic products are transported.
  • One of the significant advantages of laser separation of plastic products, e.g. ampoules, bags or other cavities is to create a fused edge as opposed to a sharp ridge after mechanical separation. This is especially important when cutting plastic products for use in the medical sector because a sharp ridge may cause damage to sterile gloves or may even injure the hand of the doctor or of the hospital staff when using such ampoules.
  • Mechanically cut plastic products have always sharp ridges due to the fact that at the side where the cutting blade leaves the cut line a sharp ridge will occur.
  • the conventional laser cutting process with a fixed beam and focusing through a nozzle for processing gas may also lead to burrs on the edges. It is better to cut the ampoules with a movable beam, e.g. with a galvo scanner, because this method can be carried out more precisely by fine tuning of laser parameters and beam-forming elements, such as telescopes and lenses and scanner movements so that the edges are fused at the joints. To achieve this, a sensor and a control system are required as.
  • the ampoules are provided within a pack of ampoules with very narrow connections, the quality of the laser cut can usually only be evaluated with a very complex image recognition system and special cameras. Such a system slows down the whole manufacturing process, is inherently expensive and prone to malfunctions and cannot easily be integrated in existing systems.
  • the laser cutting device can optionally comprise a quality control device with an integrated pressure sensor for pressing out the cut plastic products.
  • the interconnected plastic products provided in the continuous plastic band are preferably not separated completely by the laser from the residual material, i.e. the framework, so that the cut plastic products can be transported within the surrounding material until the final separation takes place.
  • precisely defined narrow connections are left between the plastic products and the surrounding residual material.
  • the plastic products are transported under the quality control device with an integrated pressure sensor.
  • an adapted stamp presses the plastic products and especially the material between the toggle parts of the ampoules, i.e. the material between the neck regions of neighboring ampoules, out of the residual surrounding material. If the pressure or force necessary to push the ampoules out of the surrounding material and/or the material between the toggle regions exceeds a predefined first adjustable value, this is an indication that the plastic products are not sufficiently separated and are still connected with the surrounding material, i.e. are still connected to the belt or to each other.
  • a gas blow such as an air blow or multiple gas blows generated by one or a plurality of nozzles can be used to put a kind of gas blow pressure on the plastic products or units or bundles of plastic products.
  • the single gas blows are generated with a defined pressure which again indicates the quality of the laser cut by determining if the gas blow or the gas blows were sufficient to separate the single plastic products or units or bundles of plastic products.
  • a gas the skilled person may also use a liquid such as water for the same purpose.
  • the quality control device with an integrated pressure sensor is directed to pressing the laser cut plastic products out of the surrounding residual material of the continuous band thereby generating single plastic products or units of plastic products which are still attached to each other but already perforated preferably by the laser used in the cutting device so that the separation can be done easily without forming sharp ridges.
  • This is usually performed with an adapted mould having the form of the ampoule or ampoule packs.
  • narrow stamps can be included that push out the residual material between the toggle parts, i.e. the area between the neck regions of two adjacent ampoules. If a predefined first adjustable value is exceeded, then the laser cutting was not sufficient and the plastic products are collected separately.
  • the quality control device with an integrated pressure sensor consists of a mould adapted to the form of the ampoules, which presses the plastic products precisely out of the surrounding residual material.
  • the quality control device with an integrated pressure sensor can control the quality of the laser cut, i.e. the quality of the intended separation, by measuring the resistance and/or force that is necessary to press the plastic products out of the surrounding residual material.
  • the quality control is performed at the material between the toggle parts, i.e. the area between the neck regions of two adjacent ampoules.
  • the force required to push the plastic products out of the surrounding residual material provides information on whether the plastic product was cut correctly, i.e. the plastic products can be pushed out of the surrounding material or not. Furthermore, the required force indicates, whether the ridges are safe or if any sharp ridges have formed that may be potentially harmful.
  • first and second values or thresholds for the pressure/force depend on factors such as the kind of plastic to be cut, the thickness of the material, the temperature at which the cut is performed, the output power for the lasers and/or the geometry or size of the plastic products and the like. It is within the scope of the skilled artisan to determine through minimal experimentation, which pressure or force, threshold is indicative for the plastic products in the continuous band. Thus, it is not complicated and even not inventive to find the right pressure range which indicates for the given plastic product a faultless cut or an inacceptable cut so that adjustment of the laser has to be performed.
  • the quality control device with an integrated pressure sensor determines the quality of the laser cut by applying an underpressure to the plastic product, such as the ampoule, the ampoule pack and/or the toggle region, i.e. the material between the neck regions of the ampoules.
  • the mode of action is similar to the above described embodiment, however, it is not the force measured that is required to separate the ampoule, the ampoule pack and/or the toggle region from the surrounding residual material. Instead the quality control device with an integrated pressure sensor measures the force required to apply a certain under-pressure such as a certain vacuum.
  • the underpressure or vacuum is applied from below the single plastic products or the pack or bundle of plastic products in order to separate the single plastic products or the pack or bundle of plastic products from the continuous plastic band and from the other single plastic products or the other packs or bundles of plastic products.
  • the quality control device with an integrated pressure sensor applies a pulling force which can be determined in order to assess quality of the laser cut.
  • a pulling force can be applied through means which grip the single plastic products or the pack or bundle of plastic products and separate them from the continuous plastic band and from the other single plastic products or the other packs or bundles of plastic products.
  • the force required to separate the single plastic products or the pack or bundle of plastic products can be measured and is also an indication for the quality of the laser cut in order to assess if the laser cut was faultless or not sufficient.
  • the device comprises a system to compensate for long-term drift effects of the laser beam and the controllable deflection means. This may occur due to changes in temperature, humidity, exposure to vibration, mechanical stress and aging of components and can affect the precision of the laser beam negatively.
  • the system to compensate for long-term drift effects of the laser beam ensures that the precision of the laser is always optimal, reducing production losses, due to maintenance of the device, to an absolute minimum.
  • a thermal imaging camera is used, to register the selective heating on a material surface lying outside of the cutting pattern, but still within the range of deflection of the mirror system of the controllable deflection means.
  • the selective heating results by directing the beam for a short time on this material surface for a specific length of time. These short-term heating can for example be performed while the feeding-in device pulls the next interconnected plastic products provided in the continuous band under the laser and the optical acquisition unit.
  • the thermal imaging camera compares the position on the receiver with previously programmed set/designed positions.
  • the data collected is then transmitted to the laser control system to correct and adjust the cutting pattern.
  • This control mechanism can take place both in or before each cutting process or at certain predefined intervals.
  • the thermal imaging camera can also determine simultaneously the temperature of the heated material surface and conclude from this data on the laser power used for cutting the plastic products. A decrease in laser power can then be adjusted accordingly.
  • a band lying outside of the cutting pattern, but still within the range of deflection of the mirror system of the controllable deflection means, is drawn along within or outside of the plastic band, whereby the laser removes an amount of the material in the band in the form of a point.
  • a camera compares the position of this point with a programmed reference point and any deviations are transmitted as correction data to the laser control system, similar to the process described above.
  • the interconnected plastic products for use in the medical field provided in the continuous plastic band are preferably bottles, bags or containers, and even more preferred ampoules.
  • medical devices or parts of medical devices can be cut according to the invention, such as syringes, vials, hollow fibers for dialysators or parts of powder inhalers.
  • multi-layer plastic products such as those produced via co-extrusion blow molding.
  • These multi-layer plastic products combine the positive properties of different plastics together and are usually characterized by a barrier layer that is arranged between two carrier layers, which are connected together by a bonding agent.
  • these multi-layered plastic products are used in applications where improved barrier properties are needed to gases.
  • Mechanical cutting methods have particularly problems with the joints of the multilayer plastic products. At the joints the barrier layer is naturally not very pronounced and there is an increased risk that the barrier layer is interrupted by the mechanical cutting in those areas.
  • the inventive method has the advantage that the individual layers of the multilayer plastic products are fused together at the joints and along the edges during cutting with the laser. Consequently, the barrier properties of the joints, edges or seams remain intact and are even improved in comparison to mechanical cutting methods.
  • the process for separation of plastic products provided or surrounded by plastic can be applied and performed similar in principle with the described laser-control system with other plastic products such as consumer goods or industrial parts.
  • the inventive method is particularly advantageous for cutting plastic ampoules interconnected, joined together and/or linked together.
  • These ampoules can e.g. be filled by the BFS process (blow-fill-seal process) but also empty ampoules can be processed.
  • BFS process low-fill-seal process
  • the ampoules leave the filling machine as rows of interconnected, joined together and/or linked together ampoules in a continuous band. In this continuous band one row of interconnected, joined together and/or linked together ampoules is followed by the next row of ampoules and all rows are embedded in the continuous band and surrounded by the residual plastic material.
  • the ampoules are arranged very close together and thus the separation of the ampoules is very difficult. This is especially true for the toggle portion at the neck of the ampoules.
  • the toggle portion at the neck of the ampoules is a critical area during mechanical punching as there is only a very small area that has to be cut out precisely and often only a partial separation can be achieved.
  • the inventive method can separate this portion of the ampoules safely without the risk of damaging the opening of the ampoules.
  • Ampoules in the medical field are usually provided as packs, i.e. a certain number of interconnected ampoules are punched out mechanically out of the continuous band.
  • ampoules made of polypropylene tend to develop a sharp ridge when cut out mechanically or when one ampoule is separated manually from the ampoule pack.
  • cutting with the inventive device has the following advantages.
  • the plastic ampoules are not required to cool down and can be cut at higher temperatures. Differences in the size of the ampoules which are inherent and cannot be avoided when manufacturing ampoules at high temperatures and the shrinking process of the ampoules when cooling down are detected by the device and the laser beam is adjusted accordingly.
  • the formation of sharp ridges and/or burr formation are avoided and the ampoules can be provided by the laser with perforations or breaking points between or in the plastic products, making them easier to separate from each other.
  • plastic products or packs of plastic products are cut at temperatures of the plastic products or packs of plastic products of 30° C. to 155° C.
  • the method can further comprise one of the following steps e)-e′′):
  • a pressure or force or underpressure (such as vacuum) below a certain value (e.g. value A) indicates a proper and faultless cut without sharp ridges
  • a pressure or force or underpressure above a certain value e.g. value B
  • a pressure or force or underpressure between the value A and value B indicates an insufficient cut where the plastic products can still be separated but might have sharp ridges.
  • the cut plastic products obtained within the range between value A and value B might be sold as proper medical products or might be discard as unrectifiable rejects.
  • the value A can be identical or almost identical to value B.
  • the force to separate the plastic products from the surrounding material reaches a first predefined adjustable value
  • this first threshold or first value has been reached, no further force is applied to separate the plastic products. This is important, because if the plastic products are still tightly connected to the surrounding residual material, applying an unlimited amount of force could lead to damage to the belt and the following plastic products, e.g. by overstretching the (hot) belt.
  • a second value/threshold which is under or below the first value. If the force required to separate the plastic products from the surrounding residual material exceeds this second value but is still under the first value, the plastic products were separated successfully, but this is an indication for an unsatisfactory and potentially harmful formation of sharp ridges or burrs. If the required force stays under this second value/threshold, then the quality of the laser cut is satisfactory and there is no risk of sharp ridges and/or burrs.
  • first and second values or thresholds for the pressure/force depend on factors such as the kind of plastic to be cut, the thickness of the material, the temperature at which the cut is performed, the output power for the lasers and/or the geometry or size of the plastic products and the like. It is within the scope of the skilled artisan to determine through minimal experimentation, which pressure or force threshold is indicative for the plastic products in the continuous band. Thus, it is not complicated and even not inventive to find the right pressure range which indicates for the given plastic product a faultless cut or an inacceptable cut so that adjustment of the laser has to be performed.
  • an ampoule belt ( 1 ) is pulled and positioned by a feeding-in device ( 2 ) under at least one controllable deflection means ( 5 ) and an optical acquisition unit ( 5 a ).
  • the optical acquisition unit ( 5 a ) acquires in a segment the positional data of at least one ampoule strip (II) and the data processing unit calculates from the positional data a cutting pattern for cutting the ampoules (III) individually or in packs of several ampoules out of the at least one ampoule strip (II).
  • the ampoule strip (II) can be named as a segment of the ampoule belt ( 1 ). This segment or ampoule strip (II) has a temperature of 67.5° C. when fed into the cutting device.
  • the temperature of the segment or ampoule strip (II) is 67.1° C.
  • the at least one focused laser beam (IV) is modified by the beam-forming means ( 4 ), such that the laser beam is suitable for separating the ampoules (III) through evaporation of the material between and/or around the ampoules.
  • the controllable deflection means ( 5 ) and the controllable focusing optic ( 5 b ) control the at least one focused laser beam (IV) according to the cutting pattern calculated by the data processing unit, to cut the ampoules individually or in packs of several ampoules.
  • the ampoule belt ( 1 ) is pulled further by the feeding-in device ( 2 ) and the next ampoule strip (II) is positioned under the controllable deflection means ( 5 ) and the optical acquisition unit ( 5 a ).
  • the cut ampoules (III) are still located in the ampoule belt ( 1 ) and are now positioned under the quality control device with an integrated pressure sensor ( 7 ) and the knife for separating the strips ( 8 ).
  • the quality control device with an integrated pressure sensor ( 7 ) and the knife for separating the strips ( 8 ) are triggered and the separated material between the toggle parts is collected in a separate container ( 14 ).
  • the ampoules (III) are now separated completely from the ampoule belt ( 1 ) and are transported in an upright position over a slide to an external transport route ( 9 ) for further processing.
  • the knife ( 8 ) separates the residual material ( 10 ) of the stripe from the belt and collects the residual material in the container ( 15 ).
  • the quality control device with an integrated pressure sensor ( 7 ) is triggered to press the ampoules (III) out of the belt it simultaneously measures the required pressure. If one or more ampoules are not separated as planned, then the required pressure to press the ampoules (III) out of the belt exceeds a previously adjustable threshold value, whereby the flap ( 11 ) is opened and the residual material with the filled ampoules ( 12 ) is dropped in the container ( 16 ).
  • the feeding-in device ( 2 ) transports the residual ampoule belt ( 1 ) uncut out of the device for later cutting.
  • the quality control device with an integrated pressure sensor ( 7 ) detects an insufficient or inaccurate or faulty laser-cut of a segment or of an ampoule strip (II)
  • this segment or ampoule strip (II) when separated from the ampoule belt ( 1 ) which is the continuous band can be re-introduced into the laser cutting process and is fed into the cutting device again.
  • this segment or ampoule strip (II) has meanwhile cooed down to 48° C. and has shrank.
  • the change in size and geometry of the re-fed segment or ampoule strip (II) does not effect the second laser-cut.
  • the cutting pattern are newly detected by the optical acquisition unit ( 5 a ) and the laser-cut is again performed now resulting in a properly and accurate cut segment or ampoule strip (II).
  • the properly and accurate cut segment or ampoule strip (II) is then processed as usual through the quality control device with an integrated pressure sensor ( 7 ) without detection of inaccurate or faulty cuts.
  • the inventive device separates container products from a framework and/or among each other and consists of at least one laser with at least one laser control system and at least one optoelectronic system for image recognition and image processing, which determines the position of the container products in the framework and/or among each other and transmits these data to the at least one laser control system, whereby the at least one laser and/or laser beam is controlled such that the container products are separated from the framework and/or among each other.
  • a camera acquires the positional data for the interconnected plastic ampoules provided in a continuous band of plastic.
  • the positional data is converted by the data processing unit in a cutting pattern for the laser beam.
  • the exact path for separating the ampoules with the laser beams is obtained by conversion of a CAD graphics of the ampoules, which is transmitted in the form of converted commands to the laser beam control system.
  • a beam-forming system consisting of a lens system for improving the beam properties ( 4 ), modifies the laser beam ( 6 ) such that the beam is suitable for ampoule separation by evaporation and is also divided in several beams. Overall four CO 2 -laser with an output power of 200W each are deployed.
  • the diameter of the laser beams is widened and adjusted to the following mirror deflectors.
  • the mirror deflectors are dimensioned in such a way that the beam can move freely within the opening of the focusing optics after deflection over the necessary deflection range.
  • four mirror deflection systems and focusing optics are deployed stationary next to each other.
  • the laser beams cut ampoule packs from an ampoule belt with twenty adjacent ampoules, each pack consisting of five ampoules. As a result of the ampoule geometrics the laser beams cannot reach the ampoule bottoms in the same work step. Consequently, the ampoule bottoms are separated in the previous work step.
  • the remaining sides of the ampoules packs are cut and the bottoms of the next ampoules are cut.
  • the ampoule packs are still connected by narrow connecting pieces to the outer framework, however, the single ampoule packs are separated completely from the adjacent ampoule packs.
  • the material between the ampoules within a pack is perforated with the laser, which makes it easier to separate the ampoules manually.
  • the belt with the ampoule strips ( 1 ) that comes out of the filling machine is pulled by means of a feeding-in device ( 2 ) in a processing position under the mirror deflector ( 5 ).
  • a digital camera takes an image of multiple reference markings and compares the position of these markings with the designed position of previously stored reference markings.
  • the exact path for separating the ampoules with the laser beams is obtained by conversion of a CAD graphics of the ampoules, which is transmitted in the form of converted commands to the laser beam control system.
  • a beam-forming system consisting of a lens system for improving the beam properties ( 4 ), modifies the laser beam ( 6 ) such that the beam is suitable for ampoule separation by evaporation and is also divided in several beams. Overall four CO 2 -lasers with an output power of 200W each are deployed. To improve the focusing properties of the laser beams, the diameter of the laser beams is widened and adjusted to the following mirror deflectors.
  • the mirror deflectors are dimensioned in such way that the beam can move freely within the opening of the focusing optics after deflection over the necessary deflection range.
  • four mirror deflections systems and focusing optics are deployed stationary next to each other.
  • the laser beams cut ampoule packs from an ampoule belt with twenty adjacent ampoules, each pack consisting of five ampoules.
  • the ampoule bottoms are separated in the previous work step.
  • the remaining sides of the ampoules packs are cut and the bottoms of the next ampoules are cut.
  • All components necessary for beam formation are connected with enclosed ( 17 ) granite constructions ( 3 ) ensuring that no vibration or oscillation is transferred to the highly sensitive beam guiding system.
  • a control program for the deflection of the movable mirrors guides the focused laser beams along the contours of the ampoules such that the ampoules are separated from the residual material save for a couple of narrow connections. After this process the feeding-in device ( 2 ) pulls the next ampoule strip in processing position.
  • the completely or nearly completely separated ampoules as well as eventually existing material between the toggle parts is separated from the residual framework by the quality control device with an integrated pressure sensor ( 7 ) and the ampoules are transported in upright position over a slide to an external transport route ( 9 ) for further processing, wherein the residual material between the toggle parts is collected in a container ( 14 ).
  • the quality control device with an integrated pressure sensor ( 7 ) consists of two simultaneously controlled stamps, wherein one stamp pushes the ampoule pack out and the other stamp pushes the residual material between the toggle parts. The stamps are moved pneumatically, wherein the pressure is adjustable.
  • a sensor If the required pressure exceeds a first threshold, a sensor is activated, indicating an incomplete separation of the ampoules, the sensor then transmits a signal to the sorting device, which removes the ampoules. If the required pressure exceeds a second threshold but is still under the first threshold, a sensor is activated, indicating an unsatisfactory and potentially harmful formation of sharp ridges or burrs in the ampoules, the sensor then transmits a signal to the sorting device, which removes the ampoules.
  • the removed ampoules are not unrectifiable rejects but can rather be re-introduced into the inventive cutting device for repeating the laser cut. Since this re-introduction can be done automatically the inventive cutting device or inventive cutting machine produces only a few unrectifiable rejects and thus saves costs and material and reduces waste.
  • a knife ( 8 ) separates the residual material ( 10 ) of the stripe from the belt and the residual material ( 10 ) is collected in a container ( 15 ). If one or more ampoules are not separated as planned and still are connected to the residual material, e.g. when the the quality control device with an integrated pressure sensor transmits a signal to the sorting device, a flap ( 11 ) is opened and the residual material with the filled ampoules ( 12 ) is dropped in the container ( 16 ). If the laser cutting device falls out completely, then two flaps ( 13 ) are triggered and the feeding-in device ( 2 ) transports the uncut belt out of the device for later cutting.
  • FIG. 1 A first figure.
  • Each strip contains twenty ampoules, which are each interconnected to the rest of the surrounding material as well as with the neighboring ampoules on the sides and the toggle region.
  • the laser cuts four ampoule packs with five ampoules each out of the ampoule strip containing twenty ampoules. This means that the two outermost ampoules in the ampoule strip are still connected to the surrounding material via some narrow connections; however, the connections between the ampoule packs, i.e. after every fifth ampoule, are separated completely from each other.
  • the connections between the ampoules within the ampoule packs are perforated, which makes it easier to manually separate the ampoules from the ampoule packs.
  • the material between the toggle regions of the ampoules are cut out completely and the upper edge of the ampoules are separated from the rest of material with the exception of some narrow connections.
  • the bottoms of the ampoules of the next ampoule strip are separated from the surrounding material, again with the exception of a few narrow connections.
  • the reason behind this is the ampoule geometrics, because the laser beams cannot reach the ampoule bottoms in the same work step. Consequently, the ampoule bottoms are separated in the previous work step. In the current work step the remaining sides of the ampoules packs are cut and the bottoms of the next ampoules are cut.
US13/583,460 2010-03-09 2011-03-09 Device for cutting plastic products provided in a continuous plastic band for use in the medical sector Abandoned US20130017289A1 (en)

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RU2013102850A (ru) 2014-07-27
KR101601888B1 (ko) 2016-03-09
CA2790158A1 (en) 2011-09-15
EP2614919A1 (en) 2013-07-17
MX2012010246A (es) 2013-01-18
HK1182357A1 (zh) 2013-11-29
JP2013135856A (ja) 2013-07-11
CN103108723B (zh) 2016-05-18
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RU2012142825A (ru) 2014-04-20
BR112012022480B1 (pt) 2018-06-26
CN103108723A (zh) 2013-05-15
US9421642B2 (en) 2016-08-23
KR101831424B1 (ko) 2018-02-22
KR20130004611A (ko) 2013-01-11
US20130049265A1 (en) 2013-02-28
EP2544850A2 (en) 2013-01-16
BR122012022929B1 (pt) 2018-12-26
HK1180273A1 (zh) 2013-10-18
CN103203553B (zh) 2016-04-13
CN103203553A (zh) 2013-07-17
KR20130018996A (ko) 2013-02-25
BR122012022929A2 (pt) 2018-06-12
MX336894B (es) 2016-02-05
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EP2614919B1 (en) 2016-05-18
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JP2013521080A (ja) 2013-06-10
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WO2011110337A3 (en) 2012-08-30
DE102010011207A1 (de) 2011-09-15

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