U.S. patent application number 10/060603 was filed with the patent office on 2003-03-13 for pharmaceutical formulation.
Invention is credited to Brown, Adrian, Clarke, Allan J., McAllister, Stephen Mark, Raby, Ronald K. JR..
Application Number | 20030049311 10/060603 |
Document ID | / |
Family ID | 9907781 |
Filed Date | 2003-03-13 |
United States Patent
Application |
20030049311 |
Kind Code |
A1 |
McAllister, Stephen Mark ;
et al. |
March 13, 2003 |
Pharmaceutical formulation
Abstract
The present invention is directed to pharmaceutically acceptable
polymeric compositions suitable for injection molding of single or
multi-component pharmaceutical dosage forms comprising a plurality
of drug substance containing sub-units, being capsule compartments
and/or solid sub-units comprising a solid matrix of a polymer which
contains a drug substance, the sub-units being connected together
in the assembled dosage form by a weld between parts of the
assembled dosage form.
Inventors: |
McAllister, Stephen Mark;
(Harlow, GB) ; Raby, Ronald K. JR.; (Collegeville,
PA) ; Brown, Adrian; (Harlow, GB) ; Clarke,
Allan J.; (Collegeville, PA) |
Correspondence
Address: |
GLAXOSMITHKLINE
Corporate Intellectual Property - UW2220
P.O. Box 1539
King of Prussia
PA
19406-0939
US
|
Family ID: |
9907781 |
Appl. No.: |
10/060603 |
Filed: |
January 30, 2002 |
Current U.S.
Class: |
424/452 |
Current CPC
Class: |
A61K 9/4816 20130101;
A61P 43/00 20180101; A61K 9/4808 20130101; Y02A 50/30 20180101 |
Class at
Publication: |
424/452 |
International
Class: |
A61K 009/48 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 30, 2001 |
GB |
0102342.3 |
Claims
What is claimed is:
1. A pharmaceutical composition for moulded capsules comprising
Eudragit E100 present in an amount of 30 to 90% w/w, a lubricant
from 0 to about 30% w/w, a dissolution modifying excipient from
about 5 to 70% w/w, and optionally a plasticizer from about 0 to 5%
w/w and/or a processing agent from about 0 to about 10% w/w.
2. The composition according to claim 1 wherein the Eudragit E100
is present in an amount of 50 to 90% w/w.
3. The composition according to claim 1 wherein the lubricant is
the lubricant is stearyl alcohol, glycerol monosterate (GMS), talc,
magnesium stearate, silicon dioxide, amorphous silicic acid, or
fumed silica; and combinations or mixtures thereof.
4. The composition according to claim 3 wherein the lubricant is
stearyl alcohol or glycerol monosterate.
5. The composition according to claim 4 wherein the lubricant is
present in an amount of about 5 to 15% w/w.
6. The composition according to claim 5 the lubricant is stearyl
alcohol and is present in an amount of about 10 to 12% w/w.
7. The composition according to claim 1 wherein the dissolution
modifying excipient is poly(ethylene) oxide, stearic acid, ethyl
cellulose, cellulose acetate phthalate, hydroxypropylmethyl
cellulose (HPMC), lactose, Starch 1500, croscarmellose sodium,
copovidone, or crospovidone (cross-linked polyvinyl pyrrolidone);
and combinations or mixtures thereof.
8. The composition according to claim 7 wherein the dissolution
modifying excipient is polyethylene oxide, lactose, HPMC or
copovidone; or combinations or mixtures thereof.
9. The composition according to claim 8 wherein the dissolution
modifying agent is polyethylene oxide present in an amount of about
5 to 30% w/w.
10. The composition according to claim 9 wherein the polyethylene
oxide present in an amount of about 10 to 20% w/w.
11. The composition according to claim 8 which is a combination of
polyethylene oxide, and at least one of lactose, HPMC, or
copovidone.
12. The composition according to claim 11 which is a combination of
polyethylene oxide and copovidone.
13. The composition according to claim 12 wherein the
polyethyleneoxide is present in an amount of about 10 to 20% w/w,
and the copovidone is present in an amount of 5 to 35% w/w.
14. The composition according to claim 1 wherein the plasticizer is
triethyl citrate (TEC), tributyl citrate, acetyl triethyl citrate
(ATEC), acetyl tributyl citrate (ATBC), dibutyl phthalate, dibutyl
sebacate (DBS), diethyl phthalate, vinyl pyrrolidone glycol
triacetate, polyethylene glycol, polyoxyethylene sorbitan
monolaurate, propylene glycol, or castor oil; and combinations or
mixtures thereof.
15. The composition according to claim 1 wherein the processing
agent is talc.
16. The composition according to claim 15 wherein the talc is
present in an amount of 5 to 10% w/w.
17. The composition according to claim 7 wherein the processing
agent is talc present in an amount of 5 to 10% w/w, and the
lubricant is stearyl alcohol present in an amount of 10 to 12%
w/w.
18. The composition according to claim 1 which further comprises a
surfactant.
19. The composition according to claim 18 wherein the surfactant is
a block copolymers of ethylene oxide and propylene oxide, lecithin,
sodium dioctyl sulfosuccinate, sodium lauryl sulfate, hydrogenated
castor oil, polyoxyethylene sorbitan fatty acid esters, the
sorbitan fatty acid esters, polyethylene glycol, glyceryl
monostearate, d-alpha-tocopheryl polyethylene glycol 1000
succinate, sucrose fatty acid esters; and combinations and mixtures
thereof.
20. The composition according to claim 19 wherein the surfactant is
a block copolymer of ethylene oxide and propylene oxide.
21. The composition according to claim 19 wherein the surfactant is
present in an amount of about 0.25 to 5% w/w.
22. The composition according to claim 1 which is:
6 Eudragit E100 75.0 Stearyl alcohol 5.0 Polyethylene oxide 20.0
Eudragit E100 60.0 Hydroxypropyl cellulose 10.0 Polyethylene oxide
20.0 Stearyl alcohol 10.0 Eudragit E100 60.0 Hydroxypropylmethyl
cellulose 20.0 Polyethylene oxide 10.0 Stearyl alcohol 10.0
Eudragit E100 60.0 Starch 1500 20.0 Polyethylene oxide 10.0 Stearyl
alcohol 10.0 Eudragit E100 65.0 Glyceryl monostearate 5.0
Hydroxypropylmethyl cellulose 20.0 Stearyl alcohol 10.0 Eudragit
E100 65.0 Glyceryl monostearate 5.0 Starch 1500 20.0 Stearyl
alcohol 10.0 Eudragit E100 55.0 Hydroxypropylmethyl cellulose 20.0
Polyethylene oxide 10.0 Lactose (regular) 5.0 Stearyl alcohol 10.0
Eudragit E100 55.0 Hydroxypropylmethyl cellulose 15.0 Polyethylene
oxide 10.0 Lactose (regular) 5.0 Starch 1500 5.0 Stearyl alcohol
10.0 Eudragit E100 57.5 Hydroxypropylmethyl cellulose 15.0
Polyethylene oxide 10.0 Lactose (regular) 5.0 Starch 1500 2.5
Stearyl alcohol 10.0 Eudragit E100 80.0 Sucrose ester 10.0
Polyethylene oxide 10.0 Eudragit E100 70.0 Sucrose ester 10.0
Polyethylene oxide 10.0 Stearyl alcohol 10.0
23. The pharmaceutical composition according to claim 1 which
is:
7 Eudragit E100 75.0 55.0 70.0 62.5 67.5 80.0 30.0 90.0 45.0 42.5
Copovidone 35.0 17.5 17.5 35.0 35.0 17.5 Polyethylene 10.0 20.0
10.0 20.0 20.0 oxide Talc 5.0 5.0 10.0 5.0 10.0 10.0 Stearyl
alcohol 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 Eudragit
E100 48.75 60.0 52.5 40.0 63.75 60.0 55.0 50.0 Kollidon VA64 26.25
17.5 35.0 8.75 20.0 5.0 16.5 PolyOx WSR N-80 10.0 20.0 20.0 10.0
10.0 5.0 20.0 20.0 Talc 5.0 10.0 5.0 7.5 5.0 10.0 3.5 Stearyl
alcohol 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0.
24. The pharmaceutical composition according to claim 1 which
further comprises a second co-polymer which is Eudragit RL 100 or
Eudragit RS 100.
25. The pharmaceutical composition according to claim 24 which
is:
8 Eudragit E100 70.0 Eudragit RL 20.0 Steryl alcohol 10.0 Eudragit
E100 60.0 Eudragit RL 20.0 PolyOx WSR N-80 10.0 Steryl alcohol
10.0
26. An injection molded capsule shell, linker or spacer having a
composition according to claim 1.
27. A multicomponent injection molded capsule shell, linker or
spacer having a composition according to claim 1.
28. A welded multicomponent injection molded capsule shell, linker
or spacer having a composition according to claim 1.
29. A multi-component pharmaceutical dosage form which comprises a
plurality of sub-units, each sub-unit being selected from a) a drug
substance-containing capsule compartment which is soluble or
disintegrable in a patient's gastrointestinal environment for
release of the drug substance contained in the capsule compartment,
and b) a solid matrix comprising a polymer and containing a drug
substance, the polymer being soluble, dispersible or disintegrable
in a patient's gastro-intestinal environment for release of the
drug substance contained in the solid matrix, and in which, at
least prior to administration to a patient, the sub-units are
welded together in an assembled dosage form.
30. A multi-component pharmaceutical dosage form according to claim
29, in which at least one of the sub-units is a solid matrix
comprising Eudragit E100 present in an amount of about 50 to 90%
w/w, and a dissolution-modifying excipient present in an amount of
about 10 to about 30% w/w.
31. A multi-component pharmaceutical dosage form according to claim
30, in which the solid matrix also comprises a lubricant present in
an amount up to about 15% w/w.
32. A multi-component pharmaceutical dosage form according to claim
31, in which the lubricant is stearyl alcohol and/or glyceryl
monosterate.
33. A multi-component pharmaceutical dosage form according to claim
30 in which the solid matrix also comprises a processing agent
present in an amount up to about 10% w/w.
34. A multi-component pharmaceutical dosage form according to claim
33 in which the processing agent is talc.
35. A multi-component pharmaceutical dosage form according to claim
30, in which the dissolution-modifying excipient is
polyethyleneoxide.
36. A multi-component pharmaceutical dosage form according to claim
30, in which the dissolution-modifying excipient is a combination
of polyethyleneoxide and talc, Starch 1500, lactose,
hydroxypropylmethylcell- ulose, and/or co-povidone.
37. A multi-component pharmaceutical dosage form according to claim
36, in which the lubricant is stearyl alcohol.
38. A dosage form according to claim 29, comprising plurality of
drug substance-containing capsule compartments, each compartment
being physically separated from at least one adjacent compartment
by a wall made of a pharmaceutically acceptable polymer
material.
39. A multi-component pharmaceutical dosage form according to claim
38, in which the wall comprises Eudragit 4135F present in an amount
of about 30 to 90% w/w, and a disolution-modifying excipient
present in an amount of about 10 to about 30% w/w.
40. A multi-component pharmaceutical dosage form according to claim
39, in which the wall also comprises a lubricant present in an
amount up to about 15% w/w.
41. A multi-component pharmaceutical dosage form according to claim
39, in which the wall also comprises a plasticizer present in an
amount up to about 10% w/w.
42. A multi-component pharmaceutical dosage form according to claim
39, in which the wall also comprises a processing agent present in
an amount up to about 10% w/w.
43. A dosage form according to claim 29, in which at least one of
the sub-units is a drug substance-containing capsule compartment
having a wall with a thickness in the range of about 0.3-0.8
mm.
44. A dosage form according to claim 29, in which at least one of
the sub-units is a substantially immediate release sub-unit.
45. A dosage form according to claim 29, in which at least one of
the sub-units is a sustained release or pulsed release
sub-unit.
46. A set of multi-component dosage forms, each comprising a
plurality of sub-units each sub-unit being selected from: a) a drug
substance-containing capsule compartment which is soluble or
disintegrable in a patient's gastro-intestinal environment for
release of the drug substance contained in the capsule compartment,
and b) a solid matrix comprising a polymer and containing a drug
substance, the polymer being soluble, dispersible or disintegrable
in a patient's gastro-intestinal environment for release of the
drug substance contained in the solid matrix, in which at least one
of the dosage forms of the set comprises at least one said drug
substance-containing capsule compartment and at least one other
dosage form of the set comprises at least one said solid matrix,
and in which the drug substance-containing capsule compartment of
said at least one of the dosage forms is interchangeable with said
solid matrix of said at least one other dosage form, and in which
at least prior to administration to a patient, the sub-units of
each dosage form are welded together to provide an assembled dosage
form.
47. A process for making a pharmaceutical dosage form comprising
the steps of: a) introducing Eudragit E100 and an excipient
composition simultaneously, and at substantially the same location,
into an elongated hot melt extruder; b) mixing said Eudragit E100
and said excipient composition in the hot melt extruder to form a
homogeneous composition therein and ejecting the homogeneous
composition in the form of a strand from the hot melt extruder
though a die at a location remote from said same location at which
the Eudragit E100 and said excipient composition are introduced; c)
cutting the strand into pellets; d) introducing said pellets into
an injection molder and forming thin-walled capsule compartments
from said pellets by injection molding.
48. The process according to claim 47, in which the excipient
composition comprises a dissolution modifying excipient.
49. The process according to claim 47, in which the excipient
composition comprises polyethylene oxide.
50. The process according to claim 47, in which the excipient
composition comprises a lubricant.
51. The process according to claim 47, in which the hot melt
extruder is maintained at a temperature not exceeding approximately
125.degree. C.
52. The process according to claim 47, in which the hot melt
extruder is maintained at a temperature not lower than the Eudragit
E100 and said excipient composition melting points.
53. The process according to claim 47, in which the temperature in
the hot melt extruder gradually increases along the length of the
hot melt extruder, from said same location at which the Eudragit
E100 and an excipient composition are introduced, to the die, the
maximum temperature not exceeding approximately 125.degree. C.
54. The process according to claim 47, in which the hot melt
extruder comprises an elongated barrel having first and second
opposite ends, and twin screws within the barrel for propelling
Eudragit E100 and said excipient composition along the length of
the interior of the barrel, said substantially same location at
which the Eudragit E100 and said excipient composition are
introduced is located adjacent the first end of the barrel, and
said die is located adjacent the second end of the barrel.
55. The process according to claim 47, in which the injection
molding of the thin-walled capsule compartments is carried using an
injection molder having a barrel and a nozzle, while maintaining
the injection molder barrel at a temperature in the range of about
110.degree. C. to 130.degree. C.
56. The process according to claim 47, in which the injection
molding of the thin-walled capsule compartments is carried using an
injection molder having a barrel and a nozzle, while maintaining
the injection molder nozzle at a temperature in the range of about
130.degree. C. to 150.degree. C.
57. The process according to claim 47, in which the injection
molding of the thin-walled capsule compartments is carried using an
injection molder having a barrel and a nozzle, while maintaining
the injection molder nozzle at a temperature of about 140.degree.
C.
58. The process according to claim 47, in which the injection
molding of the thin-walled capsule compartments is carried using an
injection molder having a barrel and a nozzle, while maintaining
the injection molder barrel at a temperature in the range of about
110.degree. C. to 130.degree. C. and maintaining the injection
molder nozzle at a temperature in the range of about 130.degree. C.
to 150.degree. C.
59. The process according to claim 47 wherein the pharmaceutical
dosage forms are assembled using said capsule compartments as
components of said dosage forms.
60. The process according to claim 59 wherein the said capsule
compartments of the assembled dosage form are connected together by
at least one weld where adjacent parts of said components are in
contact.
61. The process according to claim 60 wherein the weld is produced
by a thermal weld, an ultrasonic weld, an inductive weld, or an
adhesive weld.
62. A molded pharmaceutical capsule component defined by a
generally frusto-conical side wall, a dome-shaped end wall situated
at, and connected to, one end of the side wall, and an annular rim
portion disposed at an opposite end of the side wall, the side
wall, the dome, and the annular rim portion together forming a
hollow receptacle having an interior and an exterior, and an open
end opposite said dome-shaped end wall, the side wall being
composed of a plurality of panels each having a thickness in the
range of about 0.2 to 0.3 mm, and reinforcing ribs integrally
molded with the panels, each panel being situated between a pair of
said reinforcing ribs.
63. A molded pharmaceutical capsule component in accordance with
claim 62, in which the reinforcing ribs are formed on the exterior
of the hollow receptacle.
64. A molded pharmaceutical capsule component in accordance with
claim 62, in which the reinforcing ribs extend over at least a part
of the dome-shaped end wall.
65. A molded pharmaceutical capsule component in accordance with
claim 62, in which dome-shaped end wall has a centrally located
peak, and in which the reinforcing ribs extend toward said peak
over at least a part of the dome-shaped end wall, and gradually
decrease in thickness as they approach the peak.
66. A molded pharmaceutical capsule component in accordance with
claim 62, in which the annular rim portion extends radially
outwardly beyond the panels, and in which the reinforcing ribs have
ends which meet, and are connected to, the annular rim portion.
67. A molded pharmaceutical capsule component in accordance with
claim 62, in which the annular rim portion extends radially
outwardly beyond the panels, and in which the reinforcing ribs have
ends which meet, and are connected to, the annular rim portion, the
thickness of the ribs at said ends being substantially equal to the
distance through which the annular rim portion extends outwardly
beyond the panels, whereby the ribs merge smoothly with the rim
portion.
68. A molded pharmaceutical capsule component in accordance with
claim 62, in which the annular rim portion extends radially
outwardly beyond the panels and comprises a tapered frusto-conical
exterior surface, and in which the reinforcing ribs have ends which
meet, and are connected to, the tapered frusto-conical surface of
the annular rim portion, the thickness of the ribs at said ends
being substantially equal to the distance through which the annular
rim portion extends outwardly beyond the panels, whereby the ribs
merge smoothly with the rim portion.
Description
FIELD OF THE INVENTION
[0001] This invention relates to the preparation of an injection
molded single or multi-component dosage forms using
pharmaceutically acceptable polymeric blends.
BACKGROUND OF THE INVENTION
[0002] Various types of pharmaceutical dosage forms are known for
oral dosing. Pharmaceutical capsules are well known, generally
being intended for oral dosing. Such capsules generally comprise an
envelope wall of a pharmaceutically acceptable, e.g. orally
ingestible, polymer material such as gelatin, although other
materials for capsule walls, e.g. starch and cellulose based
polymers are also known. Such capsules generally have soft walls
made by making a film on a capsule former, which is then allowed to
dry. Rigid walled capsules made by injection molding are also
known, see for example U.S. Pat. Nos. 4,576,284; 4,591,475;
4,655,840; 4,738,724; 4,738,817 and 4,790,881 (all to Warner
Lambert). These disclose specific constructions of capsules made of
gelatin, starch and other polymers, and methods of making them by
injection molding of hydrophilic polymer --water mixtures. U.S.
Pat. No. 4,576,284 specifically discloses such capsules provided
with a cap which closes the capsule, and which is formed in situ on
the filled capsule by molding. U.S. Pat. No. 4,738,724 discloses a
wide range of rigid capsule shapes and parts.
[0003] Multi-compartment capsules, including those of the type
where each compartment has different drug release characteristics,
or for example, contains a different drug substance or formulation
are also known, for example in U.S. Pat. No. 4,738,724
(Warner-Lambert); U.S. Pat. No. 5,672,359 (University of Kentucky);
U.S. Pat. No. 30 5,443,461 (Alza Corp.); WO 95/16438 (Cortecs
Ltd.); WO 90/12567 (Helminthology Inst.); DE-A-3727894, and BE
900950 (Warner Lambert); FR 2524311, and NL 7610038 (Tapanhony NV);
FR 1,454,013 (Pluripharm); U.S. Pat. No. 3,228,789 (Glassman); and
U.S. Pat. No.3,186,910 (Glassman) among others. U.S. Pat. No.
4,738,817 discloses a multicompartment capsule with a similar
construction to those of U.S. Pat. Nos. 3,228,789 and 3,186,910,
made of a water-plasticized gelatin. U.S. Pat. No. 4,738,817 ('817)
Witter et al., U.S. Pat. No. 4,790,881 ('881), Witter et al., and
EP 0 092 908, Wittwer, F., all discloses injection molded capsules
prepared with gelatin and other excipients. Wittwer et al. '817 and
'881 also prepare capsules with other hydrophilic polymers, such as
hydroxypropylmethylcell- ulose phthalate (HPMCP), methylcellulose,
microcrystalline cellulose, polyethylene glycol, cellulose acetate
phthalate (CAP) and with polyvinylpyrrolidone. Both U.S. Pat. No.
4,790,881 and EP 0 091 908 propose other polymers having enteric
properties suitable for use, including generally acrylates and
methacrylates (Eudragits) although none are demonstrated and no
specific details are provided.
[0004] Pharmaceutical dosage forms are also known which comprise a
matrix of a solid polymer, in which a drug substance is dispersed,
embedded or dissolved as a solid solution. Such matrixes may be
formed by an injection molding process. This technology is
discussed in Cuff G, and Raouf F, Pharmaceutical Technology, June
(1998) pages 96-106. Some specific formulations for such dosage
forms are disclosed in U.S. Pat. Nos. 4,678,516; 4,806,337;
4,764,378; 5,004,601; 5,135,752; 5,244,668; 5,139,790; 5,082,655;
5,552,159; 5,939,099; 5,741,519; 4,801,460; 6,063,821; WO 99/27909;
CA 2,227,272; CA 2,188,185; CA 2,211,671; CA 2,311,308; CA
2,298,659; CA 2,264,287; CA 2,253,695; CA 2,253,700; and CA
2,257,547 among others.
[0005] U.S. Pat. No. 5,705,189, is directed to a group of
co-polymers of methacrylic acid, methyl methacrylate and methyl
acrylate, for use as thermoplastic agents in the production of
drugs coatings, and capsules. No information is presented on the
quality of the capsule formation with respect to warping or other
distortions produced by the injection molding process. Nor is shear
rate data presented for the viscosity/temperature figures of the
emulsions presented therein.
[0006] It would also be desirable to prepare a pharmaceutical
dosage form in which a pharmaceutically acceptable polymeric blend
is extruded by hot melt, or injection molded into a suitable dosage
form, which may be multicompartmental, such as a capsule. This
pharmaceutical polymeric composition as the dosage form, may
provide differing physio-chemical characteristics for each segment
containing an active agent, such that a convenient dosage form can
be optioned which may include a rapid dissolve, immediate, delayed,
pulsatile, or modified release which can be produced by simply
selecting the appropriate polymer(s) to be molded for each
section.
SUMMARY OF THE INVENTION
[0007] The present invention provides for pharmaceutical
compositions, injection molded capsule shells, linkers, spacers,
multicomponent injection molded capsule shells, linkers or spacers,
multicomponent pharmaceutical dosage forms, and other aspects as
defined in the claims and description of this application.
[0008] It is an object of this invention to provide an alternative
and improved pharmaceutical dosage form which provides, inter alia,
greater flexibility in the dosage form adapted to a patient's
specific administration requirement, and ease of manufacture.
[0009] Another object of this invention is to provide a process of
producing a multicomponent dosage form comprising a
pharmaceutically acceptable polymeric blend by injection molding.
These multi-component dosage forms are suitable for containing a
pharmaceutically acceptable active agent, or agents, for release
thereby.
[0010] The present invention is also directed to the novel
formulation or composition of a pharmaceutically acceptable polymer
and suitable excipients to be used for injection molding of the
capsules or multi-component dosage forms.
[0011] Another embodiment of the present invention is directed to
the solid dosage form comprising a capsule compartment bounded by a
wall made of a pharmaceutically acceptable polymeric
formulation/composition, and optionally containing a drug
substance.
[0012] In accordance with the invention, a multi-component,
injection molded capsule shell is provided for, having at least one
shell, linker or spacer with a composition, preferably including
Eudragit E100, and further, preferably having it's components
welded together.
[0013] More particularly, a preferred embodiment of the invention
is a multi-component pharmaceutical dosage form, comprising a
plurality of sub-units, each sub-unit being either a drug
substance-containing capsule compartment which is soluble or
disintegrable in a patient's gastro-intestinal environment for
release of the drug substance contained in the capsule compartment,
or a solid matrix comprising a polymer and containing a drug
substance, the polymer being soluble, dispersible or disintegrable
in a patient's gastro-intestinal environment for release of the
drug substance contained in the solid matrix. At least prior to
administration to a patient, the sub-units are welded together in
an assembled dosage form.
[0014] If a solid matrix is used as one of the sub-units, it
preferably comprises comprises Eudragit 100 present in an amount of
about 30 to 90% w/w, and a dissolution-modifying excipient present
in an amount of 5 to about 70% w/w. The solid matrix also
preferably comprises a lubricant present in an amount up to about
30% w/w, optionally, a plasticizer present in an amount up to about
5% w/w, and a processing agent present in an amount up to about 10%
w/w.
[0015] In an alternative preferred embodiment, the pharmaceutical
dosage form comprises a plurality of sub-units, each being a drug
substance-containing capsule compartment. In this case, each
compartment is physically separated from at least one adjacent
compartment, preferably by a wall made of a pharmaceutically
acceptable polymer material. In a preferred embodiment, the wall
comprises Eudragit 100, present in an amount of about 30 to 90%
w/w, and a dissolution-modifying excipient present in an amount of
about 5 to about 70% w/w. As in the case of the solid matrix, the
wall preferably comprises a lubricant present in an amount up to
about 30% w/w, optionally a plasticizer present in an amount up to
about 5% w/w, and a processing agent present in an amount up to
about 10% w/w.
[0016] In another alternative embodiment, the pharmaceutical dosage
form comprises a plurality of sub-units, wherein the wall comprises
a second acceptable polymeric material, such as Eudragit 4135F in a
blended formulation.
[0017] In the case in which at least one of the sub-units is a drug
substance-containing capsule compartments its wall thickness is
preferably in the range of about 0.3-0.8 mm.
[0018] The multi-component dosage form of the invention affords a
high degree of versatility in that it can be composed of various
combinations of different dosage forms having different release
characteristics. For example at least one of the sub-units can be a
substantially immediate release sub-unit, a sustained release
sub-unit, or a pulsed release sub-unit.
[0019] Another advantage afforded by a preferred embodiment of the
invention is interchangeability of components. Thus, a set of
multi-component dosage forms may be provided each comprising a
plurality of sub-units. Each sub-unit may be either a drug
substance-containing capsule compartment which is soluble or
disintegrable in a patient's gastro-intestinal environment for
release of the drug substance contained in the capsule compartment,
or a solid matrix comprising a polymer and containing a drug
substance, the polymer being soluble, dispersible or disintegrable
in a patient's gastro-intestinal environment for release of the
drug substance contained in the solid matrix. At least one of the
dosage forms of the set comprises at least one such drug
substance-containing capsule compartment and at least one other
dosage form of the set comprises at least one such solid matrix,
and the drug substance-containing capsule compartment the one
dosage form is interchangeable with the solid matrix of the other
dosage form. Thus, in the manufacturing process, selected
components can be welded together in various combinations to
provide an assembled dosage form for administration to a
patient.
[0020] Another important advantage of the invention resides in the
process by which the constituents of the capsule compartments are
prepared for injection molding. Especially in the case of an
injection-molded, thin-walled capsule compartment composed of an
aminoalkylmethacrylate copolymer and excipients such as dissolution
modifiers, lubricants, release agents and strengtheners, it is
important that the material forming the capsule compartment be
homogeneous. It is also important that the material be processed at
a sufficiently low temperature to avoid degradation of the polymer
and the excipients. In accordance with the invention, a high degree
of homogeneity is achieved by introducing the copolymer and an
excipient composition simultaneously, and at substantially the same
location, into an elongated hot melt extruder. The polymer and the
excipient composition are mixed in the hot melt extruder to form
the homogeneous composition therein and the composition is ejected
from the hot melt extruder in the form of a strand though a die at
a location remote from the location at which the polymer and
excipient composition are introduced. The strand is cut into
pellets, and the pellets are then introduced into an injection
molder which forms thin-walled capsule compartments. Pharmaceutical
dosage forms are assembled using the capsule compartments as
components.
[0021] In order to avoid degradation of the polymer and the
excipient composition, the hot melt extruder should be maintained
at a temperature not exceeding approximately 125.degree. C., and
preferably at a temperature not exceeding approximately 110.degree.
C. In a preferred embodiment, the temperature gradually increases
along the length of the hot melt extruder, from the location at
which the polymer and excipient composition are introduced, to the
die, the maximum temperature not exceeding approximately
125.degree. C.
[0022] The process injection molding of the thin-walled capsule
compartments is preferably carried out while maintaining the
injection molder barrel at a temperature in the range of about
110.degree. C. to 130.degree. C., and maintaining the injection
molder nozzle at a temperature in the range of about 130.degree. C.
to 150.degree. C. Preferably the nozzle temperature is about
140.degree. C.
[0023] A thin-walled capsule compartment is advantageous especially
where quick dissolution of the capsule is desired. However, the
wall thickness of conventional capsule shells is generally uniform,
and in the range of about 0.3 mm to 0.5 mm., in order to achieve
adequate strength, allowing the capsule shells to be formed and
handled without breakage or distortion.
[0024] In accordance with another aspect of the invention, a
preferred, molded pharmaceutical capsule component is defined by a
generally frusto-conical side wall, a dome-shaped end wall situated
at, and connected to, one end of the side wall, and an annular rim
portion disposed at an opposite end of the side wall, the side
wall, the dome, and the annular rim portion together forming a
hollow receptacle having an interior and an exterior, and an open
end opposite the dome-shaped end wall. The side wall is composed of
a plurality of panels, each having a thickness in the range of
about 0.2 to 0.3 mm, and reinforcing ribs integrally molded with
the panels, each panel being situated between a pair of the
reinforcing ribs.
[0025] The reinforcing ribs are preferably formed on the exterior
of the hollow receptacle, and extend over at least a part of the
dome-shaped end wall toward a centrally located peak, and gradually
decrease in thickness as they approach the peak. In a preferred
embodiment, the annular rim portion extends radially outwardly
beyond the panels and comprises a tapered frusto-conical exterior
surface. The reinforcing ribs have ends which meet, and are
connected to, the tapered frusto-conical surface of the annular rim
portion. The thickness of the ribs, at their ends which meet the
rim portion, is preferably substantially equal to the distance
through which the annular rim portion extends outwardly beyond the
panels, so that the ribs merge smoothly with the rim portion.
[0026] Other objects and advantages of the invention will be
apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 shows injection-molded components comprising Eudragit
E100 75%, PolyOx N-80 WSR 20%, stearyl alcohol 5%.
[0028] FIG. 2 demonstrates a dissolution profile of the polymeric
composition of Eudragit E100 75%, PolyOx N-80 WSR 20%, stearyl
alcohol 5%, welded to Eudragit 4135F linkers, the dissolution media
used was pH 1.2 Simulated Gastric Fluid.
[0029] FIG. 3 is a longitudinal sectional view of a dosage form of
the invention assembled together.
[0030] FIG. 4 is a longitudinal sectional view of another dosage
form of the invention, partially assembled.
[0031] FIG. 5A is a longitudinal, exploded, sectional view of
another dosage form of the invention.
[0032] FIG. 5B is a longitudinal sectional view of an alternative
sub-unit for use in the dosage form of FIG. 5A.
[0033] FIG. 6 is a longitudinal sectional view of a dosage form of
the invention assembled together.
[0034] FIG. 7 is a longitudinal sectional view of another dosage
form of the invention assembled together.
[0035] FIG. 8A is longitudinal sectional view of still another
dosage form of the invention in partially assembled condition.
[0036] FIG. 8B is a cross section taken on plane B-B of FIG.
8A.
[0037] FIG. 8C is an enlarged, exploded view of a portion of the
dosage form of FIG. 8A.
[0038] FIG. 9 is an assembly sequence of a dosage form of FIG.
8A.
[0039] FIG. 10 is an elevational view of an injection-molded
paneled shell in accordance with the invention.
[0040] FIG. 11 is a schematic diagram illustrating the hot-melt
extrusion and pelletizing apparatus for producing pellets for
injection molding.
[0041] FIG. 12 is rheology plot comparing Eudragit E100 base
polymer to Example 1 blended polymeric formulation.
DETAILED DESCRIPTION OF THE INVENTION
[0042] The present invention is directed to novel compositions of a
pharmaceutically acceptable polymer and excipients, which polymeric
composition may be injection molded into one or more components
which can be utilized together, such as in a stacked or
multi-component dosage form. It is recognized that the polymeric
blends may be injection molded into a single component that may
also contain an active agent for oral administration.
[0043] The pharmaceutically acceptable polymeric blends as a final
dosage form may be designed to provide rapid dissolution,
immediate, delayed, or modified dissolution, such as sustained
and/or pulsatile release characteristics.
[0044] It is one object of the present invention to provide a final
dosage form which can contain a pharmaceutically acceptable
drug/active agent in a pharmaceutically acceptable polymeric
blended multicomponent dosage form.
[0045] The parts of the dosage form of this invention, e.g. a
capsule compartment wall, a solid sub-unit, or a closure or linker,
may comprise a pharmaceutically acceptable polymeric blend (and
adhesive material if adhesive welds are formed) which is generally
regarded as safe, e.g. for oral ingestion and is capable of being
formed into the required shape of a capsule compartment wall, a
solid sub-unit, or a closure or linker as described above. A
preferred method of forming the polymer material into the desired
shape is injection molding, which may be a hot or cold runner
injection molding process. Suitable injection molding machines for
such a process are known.
[0046] The pharmaceutical dosage form may comprises a plurality of
capsule compartments each bounded and physically separated from at
least one adjacent compartment by a wall made of a pharmaceutically
acceptable polymer material, adjacent compartments being connected
together in the assembled dosage form, and being retained together
by the connection at least prior to administration to a patient,
one or more of the compartments containing a drug substance.
Suitably in the assembled dosage form of this first embodiment
there are at least two, for example, capsule compartments. Three or
more such compartments may be linearly disposed in the assembled
dosage form, e.g. in an arrangement comprising two end compartments
at opposite ends of the line, and one or more intermediate
compartments. Suitably there may be two such capsule compartments.
Suitably one of such two capsule compartments may be made of a
material which is a sustained release component, i.e. so that the
capsule compartment wall dissolves, bursts, erodes, or is otherwise
breached to release its contents after a time delay, e.g. when the
compartment has reached the intestine. Suitably the other of such
two capsule compartments may be made of a material which is an
immediate release component, i.e. so that the capsule compartment
wall dissolves, bursts or is otherwise breached to release its
contents immediately or effectively immediately, e.g. when the
compartment is in the mouth or stomach.
[0047] One or more, e.g. all, of the capsule compartments may for
example be substantially cylindrical, which term includes shapes
which have a circular, oval or oblate circular cross section across
the longitudinal axis, and shapes which have parallel or tapering
e.g. with side walls which taper conically over at least part of
their extent. Such substantially cylindrical capsule compartments
may be provided with connectable parts at one or both of their
longitudinally disposed ends so that the assembled dosage form may
also be overall of a substantially cylindrical shape.
[0048] A preferred form of the multi-component dosage form of this
invention comprises two capsule compartments.
[0049] The invention also provides individual sub-units, e.g.
individual capsule compartments or solid sub-units adapted for use
in the assembled dosage form.
[0050] In the assembled dosage form, the adjacent capsule
compartments may be connected together by means of a weld at the
area where two adjacent parts of the dosage form, e.g. sub-units,
are in contact, e.g. a thermal weld, an ultrasonic or inductive
weld, or an adhesive weld (e.g. curable adhesives such as UV
curable adhesive). A thermal weld may for example be achieved by
bringing sub-units into adjacent contact and applying localised
heating for example produced by directing a laser beam or a fine
jet of hot gas e.g. nitrogen at the area where two adjacent
sub-units are in contact. In thermal, inductive and ultrasonic
welding normally localised fusion together of the materials of
adjacent parts of the dosage form which are in contact occurs, and
on subsequent solidification of the materials a bond is formed
between the adjacent parts. An adhesive weld may be achieved by
applying an adhesive (e.g. curable adhesives such as UV curable
adhesive) to parts of the dosage form which when the dosage form is
assembled are in contact, and then causing or allowing the adhesive
to set.
[0051] The multi-component dosage form of the present invention is
particularly suited to fabrication using ultrasonic welding.
Ultrasonic welding is a known technique involving the use of high
frequency sound energy to soften or melt a thermoplastic material
at the site where a joint with the material is required. A general
description of ultrasonic welding is for example to be found in the
publication "Ultrasonic Welding of Thermoplastics" (TWI Ltd.,
Abington, Cambridgeshire GB, (1997)). Parts to be joined are held
together under pressure and then subjected to ultrasonic vibrations
usually at a frequency of 20-40 kHz. The actual mechanism
responsible for the generation of heat at the joint site is not
well understood. An ultrasonic welding machine comprises five main
components, being a power supply, a control system, a welding head,
fixturing to hold the parts to be welded, and a system to apply the
required pressure. The power supply converts electricity into high
frequency electric power which drives a transducer, e.g. a
piezoelectric transducer, which converts electrical energy, e.g.
from the mains supply, into mechanical, i.e. ultrasonic, energy.
Between the transducer and the parts to be welded is located a
booster and horn system, being a usually metallic component which
serves to amplify the ultrasonic waves (the booster horn), transmit
the clamping pressure, and deliver the sound energy to the part to
be welded (the sonotrode or welding horn). For successful
ultrasonic welding careful design of the parts to be welded and set
up of the welding equipment is important.
[0052] Preferably, additionally or alternatively adjacent sub-units
may be provided with respectively interconnectible first and second
connectible parts such that the first connectible part on one
sub-unit may connect with the second connectible part on an
adjacent part of the dosage form, e.g. an adjacent sub-unit in a
suitable configuration, e.g. in the above-mentioned linear
configuration. This interconnection may contribute to the strength
of bond achieved by the weld, or additionally or alternatively may
help to hold adjacent parts of the dosage form together prior to
and in readiness for the weld to be formed and contributes to the
retention of the adjacent sub-units together, e.g. via a retaining
friction, snap, screw or other kind of fit between the connectible
parts. The connectible parts may be such as to facilitate the
assembly together of the sub-units in preferred configurations,
e.g. the connectible part(s) on one or more one sub-unit may be
such as to only connect with a corresponding connectible part on
other selected sub-units but not with non-corresponding connectible
parts on other sub-units. Alternatively the connectible parts on
the sub-units may be common and interchangeable so that the
sub-units may be connected together in a wide range of
combinations. This means inter alia that otherwise different
capsule compartments or solid sub-units may have mutually
connectible parts so that the different capsule compartments or
solid sub-units may be connected together in different combinations
of solid sub-units or solid sub-units and capsule compartments.
[0053] For example in one embodiment the respective first and
second connectible parts may be respectively interlocking parts.
For example, the first or second part may be a socket part, and the
corresponding second or first connectible part may be a
corresponding plug part which fits into the socket with a retaining
friction, snap, screw or other kind of interlocking fit. If for
example these plug and socket parts are common, then any plug part
on any solid sub-unit or capsule compartment may interconnect with
any socket part on another solid sub-unit or capsule
compartment.
[0054] In a friction fit for example the plug part may be slightly
larger than the socket such that force needs to be applied against
the natural resilience and contact friction of the plug and socket
parts to cause the plug part to enter the socket, and similar force
needs to be applied to separate them. In a snap fit for example the
plug and socket parts may be respectively provided with a concavity
and a corresponding convexity, such as a ridge and groove, which
lock together as the parts are forced together against the natural
resilience of the parts. Such a ridge and groove may for example
comprise a co-operating circumferential or part circumferential
bead and groove, for example located about the circumference of a
connectible plug and socket part.
[0055] The above-described first and second connectible parts
facilitate assembly of sub-units together in various ways.
[0056] For example in a dosage form of the invention comprising a
linear disposition of three or more e.g. four, sub-units, an
intermediate sub-unit may be provided with one or more connectible
parts for example one at each end, which may connect with one or
more connectible part on an adjacent intermediate sub-unit. An end
sub-unit may be provided with one or more connectible part which
may connect with a connectible part on an adjacent intermediate
sub-unit and/or with one or more connectible part on another end
sub-unit. By means of this two end sub-units may connect together
in a dosage form comprising two sub-units, or two end sub-units may
be connected to one or more intermediate sub-units. By using common
first and second connectible parts on the sub-units the various end
and intermediate sub-units may be made such that they may be
connected together in various combinations of assembled dosage
forms.
[0057] One or more sub-unit which is a capsule compartments may for
example be substantially tub-shaped, i.e. having a base closed by a
base wall, and side walls extending from the base wall (herein
referred to as an "upward" direction), and an upper open mouth.
With such a construction capsule compartments may connect together
by the base of a first compartment fitting into the open mouth of
an adjacent second capsule compartment, so as to close the mouth of
the adjacent capsule compartment, and such that the base wall of
the first compartment physically separates the compartments. In
such a construction the base of the first compartment comprises a
plug connectible part, and the mouth opening of the second
compartment comprises a socket connectible part.
[0058] For example the dosage form may include one or more linker
unit positioned between adjacent pairs of capsule compartments,
preferably with at least one weld in the dosage form may be between
a capsule compartment and such a linker unit. Such a linker unit
may for example have connectible parts which are connectible to the
above-mentioned first and/or second connectible parts on the
adjacent capsule compartments. Suitably to facilitate a linear
assembly of capsule compartments in the dosage form a linker unit
may have its connectible parts in opposite linear facing
directions. Suitably such a linker unit may comprise a closure for
the mouth opening of a capsule compartment, e.g. connecting with
the capsule compartment in the manner of a plug or a cap for its
mouth opening, and having a connectible part enabling connection to
an adjacent sub-unit, e.g. another capsule compartment. If a
capsule compartment is made of a sustained release component, then
preferably such a linker/closure is also made of a sustained
release component, so that the entire capsule compartment envelope
of compartment and closure is a sustained release envelope.
[0059] In a specific form the linker may have one or two
connectible parts which connect with the mouth opening of a capsule
compartment. For example such a linker may have two connectible
parts which are opposite facing plug parts and which can connect in
a plug and socket manner with the mouth opening of two
oppositely-facing capsule compartments to thereby form a
capsule-linker-capsule assembly. Suitably welds, e.g. ultrasonic
welds, may be formed between both of the capsule compartments and
the linker between them in such a dosage form.
[0060] For example a linker may comprise a closure for the mouth
opening of a capsule compartment, and this linker may have one or
more first and/or second connectible parts such that the first or
second part on the closure may connect with respectively the second
or first part on an adjacent capsule compartments in a suitable
configuration.
[0061] For example in one form such a linker/closure may be provide
with two oppositely-facing plug connectible parts which can connect
with the mouth openings of opposite-facing capsule compartments.
Such a closure can thereby act as a linker between two capsule
compartments with their mouth openings oppositely facing, in a
capsule compartment--linker--capsu- le compartment linear
arrangement. For example this arrangement may be an end
compartment--linker--end compartment arrangement.
[0062] Other ways in which such a linker may be used in a dosage
form of the invention will be apparent. For example an intermediate
capsule compartment may be in the form of a generally cylindrical
shape with two oppositely facing open ends, and two linkers may
connect via respectively one each of their connectible parts with
an open end of the cylinder, leaving the other connectible part
available for connection to respectively another sub-unit.
[0063] Preferably at least one, or both, of the connectible parts
of the linker is a plug part which fits in a plug-and-socket manner
into the open end of a capsule compartment. Therefore such a plug
part is typically a cylindrical shape, corresponding closely to the
internal shape of the open end of a capsule compartment adjacent to
the open end.
[0064] Preferably the linker is in the form of a solid wall part
with oppositely facing plug connectible parts, oppositely facing
end surfaces of the plug parts extending generally transverse to
the longitudinal direction of the linker. Preferably each plug part
is a snug friction fit into the open end of a capsule compartment.
Preferably each plug part is provided with an abutment surface to
define and limit the extent to which each plug part can extend into
the open end of a capsule compartment by abutting against the rim
of the open end of a capsule compartment when the plug part extends
to a suitable extent into the capsule mouth.
[0065] In a preferred construction, the linker comprises a
generally cylindrical solid body, its opposite facing ends being
plug parts, with two oppositely facing abutment surfaces each being
a surface of a ledge formed around the circumference of the
cylindrical body and generally planar in a plane perpendicular to
the length direction. Such a ledge may typically be ring shaped
with its plane perpendicular to the longitudinal direction of the
capsule. With such a linker the assembled dosage form may comprise
two capsule compartments each in the shape of a cylinder having one
open end and one closed end (e.g. the above-described tub or bucket
shapes), with their open ends in an opposite facing relationship,
with a linker between them with each of the opposite facing plug
parts of the linker fitting in a plug-and-socket manner into the
open end of a capsule compartment, with an ultrasonic weld formed
between a plug part and/or an abutment surface of the linker and
the compartment wall in the vicinity of the open end, e.g. the rim
of the open end.
[0066] A preferred construction of multicompartment capsule
assembly comprises a capsule compartment made of a sustained
release component, capsule compartment made of an immediate release
component, and a linker between them made of a sustained release
component. In such a construction the immediate release compartment
may breach and release its content, leaving the envelope of
compartment and closure as a sustained release envelope to release
its contents in e.g. the intestine.
[0067] In the process of injection molding a fluid polymer is
injected under pressure into a precisely made die cavity in a mold
block. Injection molding processes can enable the sub-units to be
made with the precision necessary to achieve connection by tight
friction-fit or snap-fit interlocking and to maintain suitable
contact between adjacent parts to facilitate a weld. Suitable
techniques of injection molding are known from for example the art
of manufacture of small plastic components e.g. small parts of
LEGO.RTM. toys. Processes such as those described in Cuff. G and
Raouf. F, supra, may be used to manufacture such solid sub-units
and capsule compartments via injection molding.
[0068] Consequently the invention also provides for a molding
process, for example an injection molding or powder compression
process, wherein sub-units, including the solid sub-units and
capsule compartments of the dosage form are made in respective mold
cavities of the pharmaceutically acceptable polymeric blends.
[0069] Details of the multi-component dosage forms referred to
above will now be described with reference to FIGS. 3-10.
[0070] Referring to FIG. 3, a dosage form 11 is shown comprising
three sub-units 12, 13, 14 linearly disposed in the assembled
dosage form, in an arrangement comprising two end compartments, 12
and 14, at opposite ends of the line, and one intermediate solid
sub-unit 13. The compartments 12 and 14 and the solid sub-unit 13
are substantially cylindrical. The compartments 12 and 14 are
substantially tub shaped; i.e. each has a base closed by a base
wall 12A, 14A, and each has side walls 12B, 14B extending upward
from the base wall 12A, 14A, and an upper mouth. Each of the
compartments 12 and 14 is made of polyvinyl alcohol polymer by
injection molding.
[0071] The solid sub-unit 13 is also substantially cylindrical, and
has its base end 13A formed into a plug shape capable of engaging
with and thereby closing the mouth of either compartment 12 or 14.
As shown in FIG. 3, the base end 13A of solid sub-unit 13 fits into
and is in engagement with the mouth opening of compartment 14. The
upper end of solid sub-unit 13 has its upper end 13B formed into a
socket connector capable of engagement with the shape of the base
12A or 14A of capsule compartment 12 or 14. As shown in FIG. 3, the
socket at the upper end 13B of the solid sub-unit 13 is in
engagement with the base of compartment 12.
[0072] The compartments 12, 14 and solid sub-unit 13 connect
together by fitting the base 12A of compartment 12 into the upper
socket 13B of adjacent solid sub-unit 13, and fitting the base 12A
of the solid sub-unit 13 into the mouth of adjacent compartment 14
so as to close its mouth. In this assembly of sub-units 12, 13, 14,
the base part of an upper sub-unit 12, 13 comprises a plug part and
the mouth opening or upper socket of a lower sub-unit respectively
13, 14 comprises a socket.
[0073] Compartment 14 is an end compartment, and has its mouth
opening closed by the base end 13A of solid sub-unit 13. The other
upper end compartment 12 is closed by a closure 15, having a plug
part 16 which is dimensioned to fit into the mouth opening of the
compartment 12.
[0074] The plug part 16, and the base parts 12A and 13A, fit
respectively into the mouth opening of compartment 12, the socket
of solid sub-unit 13, and the mouth opening of compartment 14.
Thermal welds are formed between the plug part 16, base parts 12A
and 13A, and the respective mouth openings and upper socket of the
compartments 12, 14 and the solid sub-unit 13 at the regions where
these parts are in contact. Each of the base parts 12A, 13A, and
the plug part 16, and the corresponding respective mouth openings
and upper socket of the compartments 12, 13 and 14 may additionally
or alternatively be provided with features (not shown) such as a
convex circumferential bead and a corresponding circumferential
groove into which the bead may fit, such that the base part 12A,
13A, the mouth openings of the compartments 12 and 14, the upper
socket 13B and the plug part 16 and mouth opening of compartment 12
may connect together by snap fit interlocking engagement,
overcoming the natural resilience of the polymer material of the
base part and mouth opening.
[0075] The thermal welds may be formed between the plug part 16,
the base parts 12A and 13A, and the mouth openings and upper socket
of the compartments 12, 14 and the solid sub-unit 13, by directing
a laser beam to the region where these parts are in contact.
[0076] The base parts 12A, 13A, 14A of the compartments 12, 13, 14,
the mouth openings of the compartments 12 and 14, the upper socket
3B and the plug part 16 are preferably all of common dimensions so
that the compartments 12 and 14 and the solid sub-unit may be
fitted together in other linear combinations, and so that the plug
15 may be used to close the mouth opening of the other compartments
14.
[0077] Similarly, two or more than the three sub-units 12, 13 or
14, may be connected together in a manner analogous to that shown
in FIG. 1.
[0078] FIG. 4 shows another dosage form assembly 21. This assembly
21 also comprises three sub-units 22, 23. 24 in a linear assembly
consisting of an end compartment 22, an intermediate compartment 23
and a solid end sub-unit 24. The intermediate compartment 23 is
composed of part compartment shells 23A and 23B, the part shells
23A, 23B comprising respectively a closed end 23C and 23D and side
walls 23E and 23F with a mouth opening opposite each closed end 23C
and 23D. The mouth openings of the two part shells 23A and 23B are
each provided respectively with connectible plug and socket parts
25 and 26. By engagement of their respective plug and socket parts
25 and 26, these part shells 23A, 23B are connected together to
form the capsule compartment 23. The closed ends 23C, 23D are
provided with external connectible parts 27, 28.
[0079] The end compartment 22 is in the form of a tub-shaped
compartment and has a mouth opening 29, which comprises a socket
part that corresponds in shape with connectible part 27 on the
intermediate compartment 23 to connect the assembly 21
together.
[0080] The end solid sub-unit 24 is formed as a substantially
cylindrical body, having a connectible part 210 in the form of a
socket engageable with either of the connectible parts 27 or 28 on
intermediate capsule compartment 23. As shown in FIG. 3 the
connectible part 210 on solid sub-unit 24 is connected to the part
28 on capsule compartment 23.
[0081] As with the dosage form of FIG. 3, a thermal weld is formed
between the parts 25,26, 27, 29, 28 and 210 at the region where
these parts are in contact. Each of these parts 25, 26, 27, 29, 28
and 210 may additionally or alternatively be provided with features
(not shown) such as respectively a convex circumferential bead and
a circumferential groove into which the bead may fit, such that
these interlocking parts may connect together by a snap fit
engagement.
[0082] FIG. 5A shows another dosage form assembly 31. This assembly
31 comprises four sub-units 32, 33, 34, 35 in a linear assembly
consisting of an end solid sub-unit 32, an intermediate solid
sub-unit 33, a tub-shaped, intermediate capsule compartment 34 and
an end solid sub-unit 35. The intermediate capsule compartment
sub-unit 34 has a mouth opening 36, and the immediately adjacent
rim 37 of this mouth opening 36 is formed as a plug connectible
part. The end solid sub-unit 35 is substantially hemispherical and
is formed as a closure cap for the tub-shaped intermediate capsule
compartment 34, being formed at its lower end as a socket
connectible part 38 which fits in a sealing engagement with the
part 37. The closed lower end of compartment 34 is externally
provided with a socket connectible part 39.
[0083] The intermediate solid sub-unit 33 has its upper end formed
as a plug connectible part 310 engageable with the part 39 of the
compartment 34, and a lower end formed as a socket connectible part
311.
[0084] The end solid sub-unit 32 has a flat bottom and a truncated
spherical exterior, with a plug connectible part 312 that
corresponds in shape with connectible part 311 on the intermediate
compartment 33. Each of these parts 37, 38, 39, 310, 311, 312 may
additionally or alternatively be provided with features (not shown)
such as respectively a convex circumferential bead and a
circumferential groove into which the bead may fit, such that these
interlocking parts may connect together by a snap fit
engagement.
[0085] In FIG. 5B, an alternative construction of the intermediate
solid sub-unit 33 is designated by reference number 313, parts
common with the sub-unit 33 being numbered correspondingly. The
sub-unit 313 has a cylindrical internal bore 314 so that the
sub-unit 313 is of a generally hollow, cylindrical shape. The bore
314 may alternatively be of a longitudinally tapering, e.g.
generally cylindrical, shape.
[0086] By connection of the various connectible parts 37, 38, 39,
310, 311, 312 the assembly 31 may be connected together along the
axis shown.
[0087] FIG. 9 shows a dosage form 41 comprising three capsule
compartments 42, 43, 44, linearly disposed in the assembled dosage
form, in an arrangement comprising two end compartments 42, 44 at
opposite ends of the line, and one intermediate compartment 43. All
of the compartments 42, 43, 44 are substantially cylindrical, and
have an oval cross section across the longitudinal axis. The
compartments 42, 43, 44 are substantially tub-shaped, i.e. each
having a base closed by a base wall 42A, 43A, 44A, a side wall 42B,
43B, 44B extending upward from the base wall 42A, 43A, 44A, and an
upper mouth. Each of the compartments 42, 43 and 44 is made of a
polymer such as Eudragit E100 by injection molding.
[0088] The compartments connect together by the base 42A, 43A of a
first compartment 42, 43 fitting into the open mouth of an adjacent
second compartment respectively 43, 44 so as to close the mouth,
and such that the base wall 42A, 43A of the first compartment 42,
43 physically separates the first and second compartments 42, 43
and 44. In this assembly of compartments 42, 43, 44 the base part
of an upper compartment 42, 43 comprises a plug part and the mouth
opening of a lower compartment respectively 43, 44 comprises a
socket.
[0089] Compartment 44 is an end compartment and has its mouth
opening closed by the base wall 43A of compartment 43. The other
end compartment 42 is closed by a closure 45 having a plug part 46
which is dimensioned to fit into the mouth opening of the
compartment 42.
[0090] The base parts 42A and 43A, and the plug part 46, fit into
the respective mouth openings of the compartments 43, 44 and 42. A
weld is formed between the base parts 42A and 43A, the plug part
46, and the respective mouth openings of the compartments 43, 44
and 42, for example by the application of local heating or an
ultrasonic horn (not shown) to the region where these parts are in
contact. Each of the base parts 42A, 43A, and the plug part 46, and
the corresponding mouth openings of the compartments 43, 44 and 42
may additionally or alternatively be provided with features (not
shown) such as a convex circumferential bead and a corresponding
circumferential groove into which the bead may fit, such that the
base part 42A, 43A and mouth openings of the compartments 43 and
44, and the plug part 46 and mouth opening of compartment 42 may
connect together by a snap fit interlocking engagement overcoming
the natural resilience of the polymer material of the base part and
mouth opening.
[0091] The base parts 42A, 43A, 44A of the compartments and the
mouth openings of the compartments 42, 43, 44, and the plug part 46
are all of common dimensions so that the compartments 42, 43 and 44
may be fitted together in other linear combinations, and so that
the plug 45 may be used to close the mouth opening of any of the
other compartments 42, 43 or 44.
[0092] Similarly, two or more than the three compartments 42, 43 or
44, may be connected together in a manner analogous to that shown
in FIG. 4.
[0093] FIG. 7 shows another dosage form assembly 51. This assembly
51 also comprises three compartments 52, 53, 54 in a linear
assembly of two end compartments 52, 54 and an intermediate
compartment 53. The intermediate compartment 53 is composed of two
shells parts 53A and 53B, the shell part 53A comprising a closed
end 53C and side walls 53E, and the shell part 53B comprising a
closed end 53D and a side wall 53F. Each shell part has a mouth
opening opposite its closed end. The mouth openings of the two
shells part 53A and 53B are provided respectively with a plug
connectible part 55 and a socket connectible part 56. The
respective plug and socket parts 55 and 56 of these shell parts
connect together to form the capsule compartment 53. Both of the
closed ends 53C, 53D are externally provided with connectible plug
parts 57, 58.
[0094] Each end compartment 52, 54 is in the form of a tub-shaped
compartment and has a mouth opening, e.g. opening 59 of compartment
52, which comprises a socket part that corresponds in shape with
the connectible plug parts 57, 58 on the intermediate compartment
53 to connect the assembly 51 together.
[0095] As with the dosage form of FIG. 6, a weld is formed between
the parts 55, 56, 57, 58 and the respective mouth openings of the
compartments 52, 54, by the application of local heating or an
ultrasonic horn (not shown) to the region where these parts are in
contact. Each of these parts 55, 56, 57, 58 and the respective
mouth openings of the compartments 52, 54 may additionally or
alternatively be provided with features (not shown) such as
respectively a convex circumferential bead and a circumferential
groove into which the bead may fit, such that these interlocking
parts may connect together by a snap fit engagement.
[0096] Each of the compartments 42, 43, 44, 52, 54 in FIGS. 6 and 7
may be made of the same or different polymer and may have the same
or different drug release characteristics. The intermediate
compartments respectively of FIGS. 3 and 4 are more suitable for a
modified release compartment, as dissolution or disruption of the
end compartments can occur without disturbance of the intermediate
compartments, and before dissolution or disruption of the
intermediate compartments.
[0097] The compartments 42, 43, 44, 53, 54 and 55 in FIGS. 6 and 7
may contain the same or different drug substances and/or
formulations. The drug substance or formulation may be, for
example, in the form of powder, granulates, or other solid forms.
Alternatively the compartments may contain liquid, gel or similar
formulations (not shown).
[0098] FIGS. 8A, 8B and 8C show another dosage form assembly 61. As
shown in longitudinal section in FIG. 8A and in cross section in
FIG. 8B, this dosage form is an assembly composed of an end capsule
compartment 62, a linker 63, and another end capsule compartment 64
in a linear arrangement. Each end compartment 62, 64 has one open
end and one closed end, and is generally in the shape of a
cylinder, the compartments shown in FIG. 8A, having a slight
conical taper, the cross section being greatest at the open end.
The closed end is in the form of an end wall having a rounded
periphery, giving the compartment forming an open ended "bucket" or
"tub" shape. The central part of the rounded end of each
compartment (designated 65 in the case of compartment 62) is
flattened over at least 5% of the end surface area to facilitate
the application of ultrasonic energy during a welding operation.
The wall of each capsule compartment 62, 64 is ca. 0.4.+-.0.05 mm
thick in the side walls of the compartment.
[0099] The linker 63 is provided in the form of a solid wall with
oppositely facing surfaces 66, 67 extending generally transverse to
the longitudinal direction of the linker. These oppositely facing
surfaces are the end surfaces of oppositely facing plug connectible
parts 68, 69 formed at each of the longitudinal ends of the linker.
The linker 63 is a generally cylindrical body flattened in the
direction of its length, with a diameter: length ratio ca. 3:1. In
a specific embodiment, the diameter of the linker 63 is ca 7.5 mm,
and its length is ca. 3.0 mm. The end surfaces 66, 67 are
substantially planar over at least 50% of their extent to
facilitate application of ultrasonic energy thereto in the welding
operation. The surface 67 is a planar ring-shaped surface
surrounding a central concavity 610. The surface 66 is similar,
except that, within the central cavity there is the residue 611 of
an injection molding runner. The planar surfaces 66, 67 extend
continuously over a dimension of at least 2 mm, i.e. having a
surface area of at least 4 mm.sup.2. Each plug part 68, 69 fits
snugly with a friction fit into the open end of a capsule
compartment 62, 64. Each plug part 68, 69 is provided with an
abutment surface 612 constituted by a ledge formed around the
circumference of the cylindrical body 63. The abutment surface 612
is ring shaped with its plane perpendicular to the longitudinal
direction of the capsule. The abutment surface 612 defines and
limits the extent to which each plug part 68, 69 can extend into
the open end of a capsule compartment 62, 64 by abutting against
the rim of the open end of a capsule compartment 62, 64. In the
specific embodiment shown, the abutment surface 612 is ca 0.3 mm
wide measuring across the length direction.
[0100] An ultrasonic weld is formed between each plug part 68, 69
and/or an abutment surface 612 of the linker 63 and the compartment
wall 62, 64 in the vicinity of the open end, e.g. the rim of the
open end. The lower compartment 64 is shown formed in this way, the
upper compartment 62 being shown disassembled.
[0101] For forming an ultrasonic weld between adjacent contacting
parts of the capsule compartments 62, 64 and the linker 63, these
parts are profiled and dimensioned to facilitate an ultrasonic
shear joint, as shown enlarged in FIG. 8C. The connectible plug 68
and socket 613 comprise interlocking tenon parts 614, 615, where
the length of one tenon 614 (D1 ca. 0.2-0.3 mm) is less than the
length (D2 ca. 0.5-0.6 mm) of the other tenon part 615, and under
the ultrasonic welding operation the material of the capsule
compartment 62 in the region 616 can collapse until the tenon parts
engage longitudinally to form the ultrasonic weld between the
capsule compartment 62 and the linker 63. The weld between the
linker 63 and the compartment 64 has been formed in a similar
manner.
[0102] The length D2 of the plug part, being ca. 0.55 mm, is ca.
20% of the overall length of the linker 63 between the end surfaces
66 and 67.
[0103] FIG. 9 shows a typical assembly procedure for a dosage form
of FIG. 8A. The procedure comprises the following steps:
[0104] (1) A first capsule compartment 64 is positioned and
supported in a suitable holding means with its mouth opening
pointing upwards, and the capsule compartment 64 is filled with a
suitable quantity of a drug substance.
[0105] (2) A first plug part 69 (see FIG. 8A) of a linker 63 is
inserted into the open end of the first capsule compartment 64. In
this manner, the linker 63 forms a closure for the mouth opening of
the capsule compartment 64.
[0106] (3) A downwardly pointing ultrasonic horn (not shown) is
applied to the surface 66 of the linker, i.e. to the surface on the
end of the linker opposite the f first plug part 69, and an
ultrasonic weld between the linker 63 and the first capsule
compartment 64 is formed.
[0107] (4) The formed assembly of first capsule compartment 64 and
linker 63 is inverted so that the plug part 68 (see FIG. 8A) is
pointing downwards.
[0108] (5) A second capsule compartment 62 is positioned and
supported in a suitable holding means (not shown) with its mouth
opening pointing upwards, in a manner analogous to step 1, and the
second compartment 62 is filled with a suitable quantity of drug
substance.
[0109] (6) The plug part 68 of the linker 63 is inserted into the
open end of the second capsule compartment 62.
[0110] (7) An ultrasonic horn (not shown) is applied to the outer
surface of the second compartment 62 from underneath. An ultrasonic
weld is formed between the linker 63 and the second capsule
compartment 62.
[0111] In an alternative welding mode shown as step (8), an
ultrasonic horn (not shown) is applied laterally, as shown by the
arrow, to the side of the region of contact between the capsule
compartment 64 and the linker 63.
[0112] In other alternative modes, (not shown) thermal, laser or
adhesive welds may be formed between the capsule compartments 62
and 64 and the linker 63.
[0113] Each of the compartments and sub-units in FIGS. 1 and 10 may
be made of the same or different polymer and may have the same or
different drug release characteristics. The intermediate capsule
compartments are more suitable for a modified release compartment,
as dissolution or disruption of the end compartments can occur,
without disturbance of these intermediate compartments, before the
intermediate compartments are disrupted or dissolved.
[0114] The solid sub-units are more suitable as sustained release
sub-units, because the dissolution of the matrix polymer is likely
to occur more slowly than the disruption of the thin wall of a
capsule compartment. The hollow bore of unit 313 (FIG. 5B) gives
the solid unit 313 a dissolution rate tending toward first-order
dissolution kinetics.
[0115] Each of the sub-units 12, 13, 14, 22, 23, 24, 32, 33, 34, 35
may contain the same or different drug substance and/or
formulation. This may for example be in the form of powder,
granulates, or other solid forms. Alternatively the capsule
compartments 12, 14, 22, 34 may contain liquid, gel etc.
formulations (not shown). The end sub-unit 35 may contain a drug
substance or alternately may simply comprise a solid polymer cap
devoid of drug substance.
[0116] As shown in FIG. 10, a preferred capsule shell, having the
advantages of thin walls for quick dissolution, but avoiding the
deficiencies of excessively thin walls, is composed of a plurality
of thin panels separated by reinforcing ribs. As seen in FIG. 10,
the capsule is composed of three principal sections, a side wall
106, which is generally frusto-conical in shape, a generally
hemispherical dome 108 and an annular rim 110. (The term
"frusto-conical," as used herein, unless otherwise qualified,
includes a cylindrical shape, i.e., a frustum having a zero
taper.)
[0117] The side wall 106 is composed of a plurality of thin-walled
panels 112 with reinforcing ribs 114, integrally formed on the
exterior of the side wall 106, interposed between adjacent panels.
The ribs may extend part way over the dome 108, and preferably
taper gradually in thickness at 116 so that they merge smoothly
with the peak of the dome. The ribs can be of various widths, as
shown.
[0118] At least part 118 of the outer surface of the annular rim
110 is preferably in the form of a tapered, frusto-conical surface
118, and optional part 120, which is the outermost extending part
of the rim 110 may be cylindrical. Part 110 extends outward from
the lower part of wall 106 by a distance preferably equal to the
thickness of the ribs at their lower ends, so that the ribs, which
are connected to the tapered part 118, merge smoothly with the
annular rim.
[0119] The capsule shell having the construction as shown in FIG.
10 can be used as a component of a single dosage capsule as well as
a component of a multiple dosage form as depicted in FIGS. 3-9. It
has the advantage that its walls panels can be extremely thin,
e.g., in the range of about 0.2 to 0.3 mm, for quick dissolution,
but is resistant to distortion and breakage by virtue of its
reinforcing ribs. In the preferred embodiment depicted in FIG. 10,
the capsule shell configuration has no sharp edges or other
external parts that could cause difficulty in handling or
swallowing.
[0120] For purposes herein representative examples of polymers
suitable for injection molding into single or multicomponent dosage
forms and for use in pharmaceutical applications, include, but are
not limited to, poly(ethylene) oxides (PEO), polyethylene glycol's
(PEG), mixtures of PEG's and PEO's, polyvinyl alcohol (PVA),
polyvinyl acetate, povidone (polyvinyl pyrrolidone), cellulose
derivatives such as carboxymethyl cellulose, methyl cellulose,
ethylcellulose, hydroxyethyl cellulose, hydroxypropylcellulose,
hydroxyethyl methylcellulose, hydroxypropylmethyl cellulose (HPMC),
hydroxypropylmethyl cellulose phthalate, cellulose acetate
phthalate, noncrystalline cellulose, starch and its derivatives
such as hydroxyethyl starch, sodium starch glycolate, natural
polymers (such as polysaccharides like pullulan, carrageenan,
xanthan, chitosan or agar gums), polyacrylates and poly
(meth)acrylates, and its derivatives such as the Eudragit family of
polymers available from Rohm Pharma, poly(alpha-hydroxy acids) and
its copolymers such poly(caprolactone), poly(lactide-co-glycolide),
poly(alpha-aminoacids) and its copolymers, polyglycolysed
glycerides (such as Gelucire.RTM. 44/14, Gelucirc.RTM. 50/02,
Gelucir.RTM.e 50/13 and Gelucire.RTM. 53/10), carboxyvinyl polymers
(such as Carbopols), and polyoxyethylene-polyoxypropylene
copolymers (such as Poloxamer 188.TM.); and combinations or
mixtures thereof.
[0121] Also potentially suitable for use herein are the polymers
poly(orthoesters), polyphosphazenes, poly(phosphoesters), and
polyanhydrides, and combinations or mixtures thereof may also be
suitable for use herein.
[0122] Additionally, hyaluronic acid, alginates, carragenen,
collagen, gelatin, and albumen may also be suitable for injection
molding herein, either alone or in combination with another
polymeric blend. It is recognized that the ultimate choice of
polymers if not previously approved by the regulatory agencies of
the world, are in the category of generally recognized as safe
(GRAS) approved. Ultimately, if the polymer does not dissolve to
release the contents of the component or sub-unit, the component
may contain pore-forming reagents to allow the contents of the
gastro-intestinal tract to enter the sub-unit and dissolve the
active agent(s) therein. In such a capacity the sub-unit or dosage
form will act more as a delivery device, and not as a capsule or
controlled release modifying reagent. It is recognized that the
choice of polymer will depend upon the desired outcome and the
regulatory agency under which approval is being sought.
[0123] More suitably, methacrylic acid copolymers (such as Eudragit
E.RTM., Eudragit E100.RTM. Eudragit.RTM. L and/or Eudragit.RTM. S),
poly(meth)acrylate copolymers, such as Eudragit.RTM. 4135F, and
ammonium methacrylate copolymers (such as Eudragit.RTM. RL and/or
Eudragit.RTM. RS), are suitable for injection molding. The group of
poly(meth)acrylate copolymers, such as Eudragit.RTM. 100 are a
preferred aspect of this invention.
[0124] Eudragit E100 is also referred to as
butylmethacylat-(2-dimethylami-
noethyl)-methacrylat-methylmethacylat-copolymer (1:2:1), is a
copolymer based on (2-dimethylaminoethyl)methacryalate, butyl
methacrylate and methyl methacrylate having a mean molecular weight
of about 150,000. It contains not less than 20.8 and not more than
25.5% dimethylaminoethyl groups in the dry substance. Eudragit is
produced by Roehm GmbH, Germany.
[0125] Acrylic and/or methacrylic acid-based polymers which are
soluble in intestinal fluids and which can be formed into capsules
are for example disclosed in U.S. Pat. No. 5,705,189 (Roehm GmbH)
the content of which is incorporated herein by reference in its
entirety. These poly(meth)acrylate copolymers were extrudable and
injection molded into capsule half s wherein the ratio of acrylic
and/or methacrylic acid was generally 20% w/w or more off the
copolymer (Examples 1-8). In these Examples, glycerol monostearate
was added on a 3-5% wt base of the polymer as a mold-releasing
agent.
[0126] A particular polymer disclosed in U.S. Pat. No. 5,705,189,
emulsion E2 (column 6, line 10) being a copolymer of methacrylic
acid, methyl methacrylate and methyl acrylate (suitably in a ratio
of 10:25:65) has been found to be a preferred polymer for use in
the present invention as an additional sub-unit component. This
ratio of components is also known as Eudragit .RTM. 4135F, and is a
solid product obtained from Eudragit FS 30D, and as noted is
available from Roehm Pharma, Germany. However, it has been found
that the unblended polymer alone is not suitable for injection
molding, but must be blended in accordance with the teachings
herein to produce suitable injection molded, non-distorted,
unwarped capsule/sub-unit components for assembly into either
single capsule or multi-compartment dosage forms.
[0127] For the polymer E4135F, at least one lubricant and one
dissolution modifying agent are necessary to achieve quality,
non-distortion molded components which readily release from the
injection molds. The polymers exemplified in U.S. Pat. No.
5,705,189 all have increased viscosity's relative to the blended
compositions as used in the this invention.
[0128] Therefore, one aspect of this invention is the novel
blending of excipients to render this polymer suitable for
injection molding into capsules and multi-compartmental units.
[0129] A preferred polymer is a material that preferentially
dissolves or disintegrates at different points in the digestive
tract. As noted above, such polymers include the known acrylic
and/or methacrylic acid-based polymers, which are soluble in
intestinal fluids, e.g. the Eudragit.TM. series of commercially
available polymers. Examples of these include Eudragit E.TM., such
as Eudragit E100.TM., which preferentially dissolves in the more
acid pH of the stomach, or enteric polymers such as Eudragit L.TM.
and/or Eudragit S.TM. which preferentially dissolve in the more
alkaline pH of the intestine.
[0130] Other preferred polymers also include polymers which are
insoluble but hydrate at a controlled rate, e.g. a predetermined
rate in the digestive tract, such as Eudragit RL.TM., e.g. Eudragit
RL 100.TM., and/or Eudragit RS.TM. e.g. Eudragit R100.TM., and/or
blends of such Eudragit.TM. polymers. One such blend would be the
combination of Eudragit RL and RS with the necessary glidants and
excipients.
[0131] The polymer Eudragit 4135F.TM. dissolves only above pH 7,
e.g. in the colon and so is suitable for formulation as a sustained
release component. In contrast, as noted, the polymer Eudragit
E100.TM. dissolves in acid as so is suitable for use as an
immediate release component.
[0132] Most of these pharmaceutically acceptable polymers are
described in detail in the Handbook of Pharmaceutical excipients,
published jointly by the American Pharmaceutical association and
the Pharmaceutical society of Britain.
[0133] Preferably, the polymeric carriers are divided into three
categories: (1) water soluble polymers useful for rapid dissolve
and immediate release of active agents, (2) water insoluble
polymers useful for controlled release of the active agents; and
(3) pH sensitive polymers for pulsatile or targeted release of
active agents. It is recognized that combinations of both carriers
may be used herein. It is also recognized that several of the
poly(meth)acrylates are pH dependent for the solubility and may
fall into both categories.
[0134] Water soluble polymers generally include but are not limited
to, poly(ethylene oxide), polyvinyl alcohol, polyvinyl pyrrolidone,
hyaluronic acid, alginates, carragenen, cellulose derivatives such
as carboxymethyl cellulose sodium, hydroxyethyl cellulose,
hydroxypropylcellulose, hydroxypropylmethyl cellulose,
hydroxypropylmethyl cellulose phthalate, cellulose acetate,
cellulose acetate butyrate, cellulose acetate propionate, cellulose
acetate phthalate, starch and its derivatives such as hydroxyethyl
starch, sodium starch glycollate, dextrin, chitosan and its
derivatives, albumen, zein, gelatin, and collagen.
[0135] Preferably, a water-soluble polymer for use herein either as
a base polymer material or as a dissolution modifying agent is
polyethylene oxide, such as the brand name POLYOX.RTM.. It is
recognized that the polymers may be used in varying molecular
weights, with combinations of molecular weights for one polymer
being used, such as 100K, 200K, 300K, 400K, 900K and 2000K. Sentry
POLYOX is a water soluble resin, which is listed in the NF and have
approximate molecular weights from 100K to 900K and 1000K to 7000K.
A preferred polyethylene oxide is POLYOX WSR-80, or POLYOX
WSR-205.
[0136] Water insoluble polymers generally include but are not
limited to, polyvinyl acetate, methyl cellulose, ethylcellulose,
noncrystalline cellulose, polyacrylates and its derivatives such as
the Eudragit family of polymers described above, poly(alpha-hydroxy
acids) and its copolymers such as poly(.epsilon.-caprolactone),
poly(lactide-co-glycolide), poly(alpha-aminoacids) and its
copolymers, poly(orthoesters), polyphosphazenes,
poly(phosphoesters), and polyanhydrides.
[0137] These pharmaceutically acceptable polymers and their
derivatives are commercially available and/or are prepared by
techniques known in the art. By derivatives it is meant, polymers
of varying molecular weight, modification of functional groups of
the polymers, or co-polymers of these agents, or mixtures
thereof.
[0138] Further, two or more polymers may be used in combination to
form blends having the desired characteristics, such as enhanced
flow, flexibility in molding or desired drug release profile.
[0139] It is recognized that polymeric composition which are first
melted in a melt extrusion process, may also contain additional
additives or excipients to assists in melt flow, strength,
brittleness, and other molding characteristics, these additional
excipients include but are not limited to, plasticizers, absorption
enhancers, additional surfactants, flavouring agents, dyes,
etc.
[0140] While the compositions herein may be molded in varying
wall-thickness, it is preferable that the capsules or components
have a wall-thickness of about 0.3 to about 0.8 mm. However,
dissolution performance will more appropriately tailor the wall
thickness depending upon the release profiles desired. Increases in
wall thickness may be necessary to reduce warping of the
components, or modification of the additional excipients in
addition to this may be necessary.
[0141] The polymer material(s) may include other substances to
modify their properties and to adapt them to various applications,
including but not limited to surfactants, absorption enhancers,
lubricants, plasticizers, dissolution modifying agents, processing
aids, colouring agents, flavouring agents and sweetening
agents.
[0142] Incorporation of a surfactant into the formulation may be
necessary or desired to lower the viscosity and surface tension of
the formulation/blend, however, in higher amounts it may adversely
effect the quality of the resulting dosage form. The surfactant
selection may be guided by HLB values but is not necessarily a
useful criterion. While HLB surfactants have been utilized herein,
such as Tween.RTM. 80 (HLB=10), Pluronic F68 (HLB=28), and SDS
(HLB>40), surfactants with lower HLB value surfactants, such as
Pluronic F92 may also be used.
[0143] A surfactant may also be called an oligomeric surface
modifier and includes, but is not limited to: Pluronics.RTM. (block
copolymers of ethylene oxide and propylene oxide), lecithin,
Aerosol OT.RTM. (sodium dioctyl sulfosuccinate), sodium lauryl
sulfate, Polyoxyl 40.TM. hydrogenated castor oil, polyoxyethylene
sorbitan fatty acid esters, i.e., the polysorbates such as
Tween.RTM., such as Tween 20, 60 & 80, the sorbitan fatty acid
esters, i.e., sorbitan monolaurate, monooleate, monopalmitate,
monosterate, etc. such as Span.RTM. or Arlacel.RTM., Emsorb.RTM.,
Capmul.RTM., or Sorbester.RTM., Triton X-200, polyethylene
glycol's, glyceryl monostearate, Vitamin E-TPGS.RTM.
(d-alpha-tocopheryl polyethylene glycol 1000 succinate), sucrose
fatty acid esters, such as sucrose stearate, sucrose oleate,
sucrose palmitate, sucrose laurate, and sucrose acetate butyrate,
etc.; and combinations and mixtures thereof. Preferred surfactants
are Vitamin E-TPGS.RTM., sodium lauryl sulfate, sucrose fatty acid
esters, lecithin, and the Pluronic groups. Suitably, the
formulation will contain from about 0 to about 10% w/w
surfactant(s). Preferably, the surfactant is a block copolymers of
ethylene oxide and propylene oxide. Preferably the block copolymers
of ethylene oxide and propylene oxide is present in an amount of
0.25 to about 5%, more preferably 0.5 to 2% w/w.
[0144] The polymeric carriers or a second oligomeric surface
modifiers, if appropriately chosen, may themselves act as
absorption enhancers. Suitable absorption enhancers for use herein,
include but are not limited to, chitosan, lecithin, lectins,
sucrose fatty acid esters such as the ones derived from stearic
acid, oleic acid, palmitic acid, lauric acid, and Vitamin E-TPGS,
and combinations or mixtures thereof. Suitably, the absorption
enhancers are present in a range of about 0-20% w/w.
[0145] Plasticizers are employed to assist in the melting
characteristics of the composition. Exemplary of plasticizers that
may be employed in this invention are triethyl citrate (TEC),
triacetin, tributyl citrate, acetyl triethyl citrate (ATEC), acetyl
tributyl citrate (ATBC), dibutyl phthalate, dibutyl sebacate (DBS),
diethyl phthalate, vinyl pyrrolidone glycol triacetate,
polyethylene glycol, polyoxyethylene sorbitan monolaurate,
propylene glycol, or castor oil; and combinations or mixtures
thereof. The polymeric material will determine which plasticizer is
suitable for use. For instance, triacetin is not preferred for use
with E100 or 4135F at levels of about 5% w/w, but may be suitable
for use with Eudragit RS or RL, or PVA. Suitably, the plasticizer
is present in an amount of about 0 to about 20% w/w. Preferably,
from about 0 about 5% w/w.
[0146] Dissolution modifying agents, or substances which assist in
release modification may also be referred to as hydrophilic
excipients. These excipients may be of assistance of the swelling,
erosion or dissolution of the shell. Many different classes of
agents may be used, such as the known disintegrants represented by
"Explotab" (sodium starch glycollate), "Kollidon-CL", (cross-linked
PVP), Kollidan VA 64 (copovidone) commercially available from BASF,
swelling agents such as polyvinyl pyrrolidone (PVP, also know as
POVIDONE, USP), manufactured by ISP-Plasdone or BASF-Kollidon,
primarily Grades with lower K values (K-15, K-25, but also K-30 to
K-90), cellulosic derivatives such as hydroxypropyl methyl
cellulose (HPMC), wicking agents such as low molecular weight
solutes, e.g. mannitol, lactose, and starch; inorganic salts such
as sodium chloride (typically at 5-10%); and combinations and
mixtures thereof. Use of sodium starch glycolate with Eudragit E100
as the sole polymer, however, has not found to be compatible for
injection molding. The dissolution modifying excipients are in the
range of about 2.5% to about 70% w/w.
[0147] More specifically, the class of agents known as swellable
solids for use as dissolution modifying agents, includes but is not
limited to poly(ethylene)oxide, hydroxypropylmethyl cellulose, and
other hydroxyalkylcellulose derivatives. Use of
hydroxypropylcellulose has not been found to produce suitable
moldable capsule shells with E100 as the sole polymer. Suitably,
the swellable solids used as dissolution modifying excipients are
in the range of about 5% to about 60% w/w, preferably from about 5%
to about 30% w/w.
[0148] Other suitable dissolution modifying excipients include, but
are not limited to the class of non-reducing sugars, such as
xylitol, or mannitol, present in the range of about 2.5 to 15% w/w,
preferably from 5 to 10% w/w. Also included are the class of water
soluble fillers, such as lactose, suitably present in the range of
about 5 to 20%, preferably from 5 to 10% w/w.
[0149] Another group of suitable dissolution modifying excipients
are the agents generally referred to as disintegrants, such as
crospovidone (cross-linked polyvinyl pyrrolidone) and Kollidon VA
64 (copovidone) commerically available from BASF; and combinations
or mixtures thereof. Kollidan VA 64, or copovidone is also known as
copolyvidone, copovidonum, copovidone or copovidon. It is ratio of
two monomers, vinylpyrrolidone and vinyl acetate.
[0150] Suitably, the disintegrants are present in the range of
about 5 to 50% w/w, preferably, 10 to 40%. It is recognized that
the one of more classes of dissolution modifying exipients may be
used alone or in combination as mixures, resulting in a range of
about 2.5 to 70% w/w.
[0151] A preferred dissolution modifying excipient is POLYOX for
use in a range of about 5 to 60% w/w, preferably about 20 to 30%
w/w. Combinations or mixtures of POLYOX with one or more
dissolution modifying excipients, such Starch 1500, copovidone,
lactose or HMPC are also a preferred embodiment of this
invention.
[0152] POLYOX can be seen as representative of a group of
hydrophilic non-ionic polymers which melt at the extrusion
temperature for the polymer blends, such as about 100.degree. C. or
greater (100-190.degree., preferably about 100-140.degree. C.). For
instance, Polyox N-80 is molten at 100.degree. C. Polyethylene
oxide is also referred to herein as a melt-processing aid and helps
to reduce sticking of the polymer in the moulds. Therefore it is
functioning as an ejection aid, and a lubricant.
[0153] Additional regents, generally classified as processing aids,
include strengthening agents, such as talc. Suitably, the
processing aids are present from about 0 to about 10% w/w,
preferably from 5 to 10% w/w.
[0154] A preferred formulation of the present invention is the use
of talc in combination with POLYOX and additional excipients, such
as a lubricant. Another preferred formulation is the combination of
POLYOX, and talc with co-povidone Suitable mold processing
lubricants or glidants for use herein, include but are not limited
to, stearyl alcohol, stearic acid, glycerol monosterate (GMS),
talc, magnesium stearate, silicon dioxide, amorphous silicic acid,
and fumed silica; and combinations or mixtures thereof. This
functions primarily as a flow promoter for the composition. A
preferred lubricant is stearyl alcohol, or GMS. A commercial grade
of stearyl alcohol, such as Crodacol S95 (Croda Oleochemicals) is
preferred for use herein. The material should be suitable for
milling.
[0155] Suitably, the amount of lubricant present in the formulation
is from about 0 to about 30% w/w, preferably from about 10 to about
25% w/w, and more preferably, 10 to 15% w/w.
[0156] If stearyl alcohol is used in a formulation of the present
invention, it is preferably from about 10 to 15% w/w, more
preferably from 10 to 12% w/w.
[0157] A combination of POLYOX and stearyl alcohol has also been
found to be effective for use with the polymer Eudragit E100.
[0158] Stearyl alcohol has the advantage that it acts as a mold
processing lubricant but causes no mold distortion, i.e. crumpling
of the multidosage compartment shell when the hot soft shell is
taken out of the mold, which might result from a lubricant which
made the blend flow better. An another alternate material also
useable as lubricant/flow promoters is lecithin (a natural
product). Suitably, the lubricants for use herein do not introduce
any metal ion contamination.
[0159] Preferred formulations selected were found to include the
polymer Eudragit E-100, a lubricant such as stearyl alcohol, a
dissolution modifying agent which is polyethylene oxide, preferably
Polyox N-80, optionally a strengthening agent, such as talc, and
optionally, Kollidon VA64. The present invention has determined
that the formulation constituents do not need to include a
plasticizer in order to mold the desired components. However, E-100
has still been found to be pH dependent, despite the formulation
constituents.
[0160] A more preferred formulation includes the polymer Eudragit
E-i 00 from about 30 to 60%, stearyl alcohol from about 10 to 12%,
Polyox N-80 from about 10 to 20%, talc from about 0 to 10%,
preferably 5 to 10%, and/or Kollidon VA64 from about 0 to 35%,
preferably 5 to 35%.
[0161] The final products of this invention, i.e. the capsules, and
or components or sub-units may additionally include materials in
the polymer materials of which they are made to enhance the ease
with which they can be welded together. The sub-units may
additionally be provided with constructional features and/or
include materials in the polymer materials of which they are made
to enhance the ease with which they can be welded together, e.g.
opacifier materials such as carbon (e.g. 0.2-0.5%), iron oxides or
titanium dioxide (e.g. 0.5-1.0%) to help the polymer to absorb
laser energy. Such opacifier materials are generally regarded as
safe.
[0162] For example each of a plurality of sub units, e.g. of the
capsule compartments, solid sub-units, or combinations thereof may
comprise the same or different polymer(s). For example each of a
plurality of sub units, e.g. of capsule compartments, solid
sub-units, or combinations thereof may comprise the same or
different drug substance. For example each sub-unit may contain the
same drug substance but release the contents into the
gastro-intestinal tract of the patient at a different rate, at
different times after administration to the patient or at different
places in the patient's gastrointestinal system. Alternatively each
sub-unit may contain a different drug substance, each of which may
be released at the same or a different rate or time after
administration or place in the patient's gastro-intestinal
system.
[0163] For example two or more sub-units, e.g. two capsule
compartments, may each contain different drug substances, and/or
different drug substance formulations, and/or the same drug in
different formulations, so that a combination of two or more drug
substances or formulations may be administered to a patient.
[0164] The dosage form of this invention enables the assembly
together of sub-units which differ in their drug content and/or
drug content release characteristics to provide a dosage form
tailored to specific administration requirements.
[0165] The dimensions and shape of each of the sub-units and hence
of the overall assembled dosage form may be determined by the
nature and quantity of the material to be contained therein and the
intended mode of administration and intended recipients. For
example, a dosage form intended for oral administration may be of a
shape and size similar to that of known capsules intended for oral
administration.
[0166] The dosage form is particularly suitable for presentation as
an oral dosage form containing one or more drug substances suitable
for oral administration, and appears to be suitable for all types
of such drug substance.
[0167] The drug substance(s) contained in any capsule compartment
may be present in any suitable form, e.g. as a powder, granules,
compact, microcapsules, gel, syrup or liquid provided that the
capsule compartment wall material is sufficiently inert to the
liquid content of the latter three forms. The contents of the
compartments, e.g. drug substances, may be introduced into the
compartments by standard methods such as those used conventionally
for filling capsules, such as dosating pins or die filling.
[0168] The sub-units may differ from each other in their drug
content release characteristics, and this may be achieved in
various ways. For example one or more solid sub-units and/or
capsule compartments may be substantially immediate release, i.e.
releasing their drug contents substantially immediately upon
ingestion or on reaching the stomach. This may for example be
achieved by means of the matrix polymer or the capsule compartment
wall dissolving, disintegrating or otherwise being breached to
release the drug content substantially immediately. Generally,
immediate-release sub-units are preferably provided by being
capsule compartments.
[0169] For example one or more solid sub-units and/or capsule
compartments may be sustained-release sub-units. Preferably these
are solid sub-units, as a bulk matrix of polymer is likely to
dissolve or disperse more slowly to release its drug content that a
thin walled capsule.
[0170] For example one or more solid sub-units and/or capsule
compartments may be pulsed-release sub-units for example releasing
their drug content at a specific predetermined point in a patient's
gastro-intestinal system. This may be achieved by the use of
polymer materials which dissolve or disperse only at defined pH
environments, such as the above mentioned Eudragit.RTM. polymers.
For instance, E100 is acid labile.
[0171] For example in the above-described capsule
compartment-linker-capsu- le compartment dosage form one capsule
compartment may be effectively immediate release and the other may
be sustained, delayed or pulsed release. To achieve this for
example one capsule compartment may be made of polymer materials
which cause the capsule compartment to release its drug content in
the stomach or upper part of the digestive tract, and the linker
(acting as a closure for the second compartment) and the second
compartment itself may be made of materials e.g. the above
described enteric polymers, which release their drug content only
in the intestinal environment.
[0172] Determination of the time or location within the
gastro-intestinal tract at which a sub-unit releases its drug
substance content may be achieved by for example the nature of the
sub-unit material, e.g. a solid sub-unit matrix polymer or a
capsule compartment wall material, or in the case of an end
compartment which is closed by a closure, by the nature of the
closure material. For example the wall of different, e.g. adjacent,
compartments may be made of polymers which are different or which
otherwise differ in their dissolution or disintegration
characteristics so as to endow different compartments with
different drug release characteristics. Similarly for example the
polymer matrix material of different, e.g. adjacent, solid
sub-units may be made of polymers which are different or which
otherwise differ in their dissolution or disintegration
characteristics so as to endow different solid sub-units with
different drug release characteristics.
[0173] For example the matrix, wall or closure material may be a
polymer which dissolves or disperses at stomach pH to release the
drug substance in the stomach. Alternatively the wall material of
different compartments may differ so that different compartments
have different release characteristics.
[0174] For example a solid sub-unit or a capsule compartment may
have respectively a matrix or a wall or a closure comprising an
enteric polymer which dissolves or disperses at the pH of the small
or large intestine to release the drug substance in the intestine.
Suitable such polymers have been described above, for example, with
reference to U.S. Pat. No. 5,705,189.
[0175] Additionally or alternatively the wall material may differ
in thickness between compartments so that thicker walled
compartments disrupt more slowly than thinner walled
compartments.
[0176] Additionally or alternatively the compartment walls or the
closure may have areas or points of weakness which preferentially
dissolve and may thereby determine the time of onset and/or rate of
release of the drug substance content. For example such points of
weakness may comprise holes, e.g. small holes, e.g. laser-drilled
holes in the compartment wall or the closure, these holes being
closed and/or covered with a film of a polymer material that
dissolves at a pre-determined point in the digestive tract, for
example an enteric polymer material. For example such points of
weakness may comprise thinned parts in a capsule compartment wall
formed during the molding operation in which the capsule
compartment is formed.
[0177] The sub-units may additionally or alternatively have surface
or other constructional features that modify their drug release
characteristics. For example solid sub-units may be provided with
internal cavities or channels to create a large surface area. For
example solid sub-units may be in the form of hollow cylinders,
donuts, or toroids, which shapes are known to tend towards
first-order dissolution or erosion in liquid media and
correspondingly to tend toward first-order release of drug content
dispersed therein.
[0178] Pharmaceutically acceptable agents, actives or drugs as used
herein, is meant to include active agents having a pharmacological
activity for use in a mammal, preferably a human. The
pharmacological activity may be prophylactic or for treatment of a
disease state.
[0179] As used herein the term's "active agent", "drug moiety" or
"drug" are used interchangeably.
[0180] Water solubility of an active agent is defined by the United
States Pharmacoepia. Therefore, active agents which meet the
criteria of very soluble, freely soluble, soluble and sparingly
soluble as defined therein are encompassed this invention.
[0181] Suitable drug substances can be selected from a variety of
known classes of drugs including, but not limited to, analgesics,
anti-inflammatory agents, anthelmintics, anti-arrhythmic agents,
antibiotics (including penicillin's), anticoagulants,
antidepressants, antidiabetic agents, antiepileptics,
antihistamines, antihypertensive agents, antimuscarinic agents,
antimycobactefial agents, antineoplastic agents,
immunosuppressants, antithyroid agents, antiviral agents,
anxiolytic sedatives (hypnotics and neuroleptics), astringents,
beta-adrenoceptor blocking agents, blood products and substitutes,
cardiac inotropic agents, corticosteroids, cough suppressants
(expectorants and mucolytics), diagnostic agents, diuretics,
dopaminergics (antiparkinsonian agents), haemostatics,
immunological agents, lipid regulating agents, muscle relaxants,
parasympathomimetics, parathyroid calcitonin and biphosphonates,
prostaglandins, radiopharmaceuticals, sex hormones (including
steroids), anti-allergic agents, stimulants and anorexics,
sympathomimetics, thyroid agents, PDE IV inhibitors, NK3
inhibitors, CSBP/RK/p38 inhibitors, antipsychotics, vasodilators
and xanthines.
[0182] Preferred drug substances include those intended for oral
administration and intravenous administration. A description of
these classes of drugs and a listing of species within each class
can be found in Martindale, The Extra Pharmacopoeia, Twenty-ninth
Edition, The Pharmaceutical Press, London, 1989, the disclosure of
which is hereby incorporated herein by reference in its entirety.
The drug substances are commercially available and/or can be
prepared by techniques known in the art.
[0183] The polymeric blends can be preferably selected from known
pharmaceutical polymers. The physico-chemical characteristics of
these polymers, as well as the thickness of the ultimate injection
molded component, will dictate the design of the dosage form, such
as rapid dissolve, immediate release, delayed release, modified
release such as sustained release, controlled release, or pulsatile
release. etc.
[0184] The polymer blends are made by well-known methods for
producing hot melt extrusions in which the selected ingredients are
fed into a feed hopper of an extrusion machine. Suitable well known
equipment is readily available for producing a hot melt extrusion
of the blends herein.
[0185] As shown in FIG. 11, a hot melt extruder 70 is shown
producing a strand 72 consisting of a homogeneous mixture of
polymer (Eudragit E100) and an excipient composition. The extruder
is a twin-screw extruder (one screw 74 being shown). The screws are
driven by a motor 76. The polymer and excipient composition are
introduced respectively through hoppers 78 and 80. The hoppers feed
the polymer and excipient simultaneously, and at substantially the
same location, to the interior of the barrel of the extruder at a
location near the end of the extruder remote from die 82. The
introduction of both the polymer and the excipient composition at
substantially the same location ensures a high degree of
homogeneity in the composition of the extruded strand 72, which as
mentioned previously is important especially in the case of a
thin-walled capsule compartment. Mixing elements 88 are provided at
intervals along the screws to knead the material as it is propelled
through the barrel of the extruder.
[0186] The strand 72 is conveyed by belt 90 toward a pelletizer 92
which comprises a pair of rolls 94 and a rotating cutter 96. The
pelletizer cuts the strand 72 into pellets 98, which are collected
and conveyed to an injection molder (not shown).
[0187] In the hot melt extruder, the polymer-excipient mixture is
gradually heated by heating coils shown schematically at 100, 102
and 104. The die is preferably separately heated. The heating coils
and the die heater are preferably set so that the temperature in
the hot melt extruder increases gradually from a relatively low
temperature, e.g. 50.degree. C., at the location at which the
polymer and excipient composition are introduced to a die
temperature in the range of about 105.degree. C. to about
125.degree. C. The highest temperature is preferably maintained at
a level not exceeding 120.degree. C., although a temperature of
125.degree. C. can be tolerated by a composition comprising
aminoalkylmethacrylate copolymer, polyethylene oxide, talc and
stearyl alcohol.
[0188] As shown in FIG. 12, a rheology plot comparing Eudragit E100
base polymer with the formulation of Example 1 demonstrates that
the addition of polyethylene oxide, talc and stearyl alcohol, as
processing aids reduces viscosity at a given shear rate and allows
components to be moulded at temperatures lower that their
degradation rate, causing no problems with degradation.
[0189] Fast Release/Pulse Capsules or Components
[0190] For production of an early release/pulse capsule or
component in a multidosage capsule, (such as a 2-4 hour window), in
contrast to an immediate release at less than 1 hour, while
suitable polymers are taught herein, the commercially available
Eudragit E100 (Rohm) is a preferred polymer for immediate release
characteristics. To make this polymer extrudable into the thin
walled component shells (such as a 0.5 mm wall thickness) E100 may
be blended with several excipients as described herein.
[0191] Preferably, Eudragit E100 is blended with dissolution
modifying agents such as POLYOX, and a lubricating agent such as
stearyl alcohol or GMS.
[0192] Slow/delayed Release/Pulse Capsules or Components
[0193] For production of a slow release, or a delayed release
capsule or component in a multidosage capsule, the polymer Eudragit
4135F (Roehm), as noted above is preferred. The principal problem
with Eudragit.RTM. 4135F in its unformulated state is its high
dissolution time, in excess of 30 hours in aqueous media e.g. in
SIF (simulated intestinal fluid). Therefore, to improve its
dissolution time the polymer is blended with one or more
hydrophilic excipients. This will enhance the absorption of water
by the Eudragit 4135F polymer, and so accelerate the rate at which
the blended polymer swells on absorption of water. As noted by the
Experimental section herein, a dissolution modifying excipient,
preferably a swellable solid excipient and optionally a second
dissolution modifying excipient, such as a disintegrant, a
lubricating agent, and if desired a surfactant, will produce a
stable, injection molded component which can be reliably reproduced
and injected from the mold with reduced, or no warpage of the
shell.
[0194] A preferred multicomponent dosage form is that disclosed in
PCT/EP00/07295, filed Jul. 27, 2000, published as WO 01/08666 on
Feb. 8, 2001, the contents of which are incorporated by reference
herein in its entirety. The multicomponent dosage form of this
application preferably uses an ultrasonic weld to seal to
components together. The Eudragit 4135F will open to release its
contents by swelling in the region of the ultrasonic weld, which
causes separation at the weld.
[0195] While PEG (polyethylene glycol), such as PEG 4000, 6450,
8000, produced by Dow and Union Carbide may be an acceptable
dissolution modifying excipient, in combination with the Eudragit
4135F it was found to act too much like a lubricant and resulted in
mold distortion of the hot molded shells when they are taken out of
the mold. Gelucire (a fatty acid PEG ester) may cause a similar
problem, due to traces of PEG in the Gelucire.
[0196] Preferably, the hydrophilic excipient is one which does not
melt at the extrusion temperature, e.g. the lactose, inorganic
salts, HPC, HPMC, such as Pharmacoat 603 (an HPMC with a glass
transition temperature 175.degree. C.).
[0197] As noted, the swellable solids are available commercially in
a number of grades by molecular weight. For examples 95K, or 80K
grades of HPC. A change in the molecular weight of HPC, for
instance, should retain the ability to hydrate the shell, but the
hydration rate may be slower, i.e. the rate of expansion will be
reduced. Hence, a longer dissolution time of the shell and release
of the components therein may result.
[0198] Spacer Components
[0199] This is the plug like linker that closes and connects the
two end compartments of the capsules (such as immediate release and
slow/sustained release compartments). This can be made of the same
polymer blend (4135F blend) as the slow/delayed release components,
etc., but can equally well be made of 4135F blended with a suitable
lubricant, such as stearyl alcohol, but without other hydrophilic
excipients. By not including the hydrophilic excipient in the
spacer the opening of the slow/delayed release component will be
improved because of the mismatch in water disturbance and thus
differential swelling, of the slow/delayed release component and
the spacer acting as a plug closure of the compartment.
[0200] Preferably, use of a delayed release polymer to form a
slow/delayed release component or sub-unit which is part of a
multicomponent dosage form, will provide for a means to release the
contents of the sub-unit by erosion/dissolution of the shell or
failure of the weld, as the thin region of the end cap compartments
which overlap the linker plug swells rapidly and will pull away
from the adjacent spacer, thereby opening the contents of the
sub-unit into the gastrointestinal fluids.
[0201] The multidosage components of the present invention can be
produced in accordance with the Description and the Examples
herein. Example 1 provides for a general summary of the extrusion
and moulding parameters used for Eudragit E100.
[0202] However, in general the extruder is preheated to the
appropriate temperature, approximately a temperature of about
95-120.degree. C., preferably 110.degree. C. The injection moulder
is preheated to the appropriate temperature, approximately a
temperature of 110-130.degree. C. across the screw/barrel and
130-150.degree. C., preferably 140.degree. C. on the
hot-tip/nozzle, which should be maintained throughout.
EXAMPLES
[0203] The invention will now be described by reference to the
following examples, which are merely illustrative and are not to be
construed as a limitation of the scope of the present invention.
All temperatures are given in degrees centigrade; all solvents are
highest available purity unless otherwise indicated.
Example 1
[0204] Manufacture of multicomponent pharmaceutical dosage forms
with pharmaceutically acceptable polymeric compositions as
described herein. Example 1 will describe a general process used to
mold the various multicomponent capsules and appropriate subunits.
Additional pharmaceutical compositions are shown and described
below.
1 Item number Material % w/w 1. Aminoalkylmethacrylate Copolymer
(Eudragit 60.0 E100) 2. Polyethylene oxide (PolyOx WSR N-80) 20.0
3. Talc (NF) 10.0 4. Stearyl alcohol, milled 10.0 Total 100 Using a
suitable blender mix together: Item 2. Polyethylene oxide (PolyOx
WSR N-80) Item 3. Talc (NF) Item 4. Stearyl alcohol, milled to form
a homogeneous powder blend.
[0205] Set up a suitable co-rotating twin screw hot melt extruder
with both a pellet feeder and a powder feeder together with strand
cooling equipment and a pelletizer. Fit the selected mold in the
injection molding machine. Example processing parameters are as
follows:
2 Extruder: Screw speed 150 rpm (range 125-175 rpm) Temperature of
zone 1 (feed zone) 50.degree. C. (range 40-70.degree. C.)
Temperature of zone 2 95.degree. C. (range 85-105.degree. C.)
Temperature of zone 3 100.degree. C. (range 90-110.degree. C.)
Temperature of zone 105.degree. C. (range 95-115.degree. C.)
Temperature of die 110.degree. C. (range 100-120.degree. C.)
Temperature of polymer strand 116.degree. C. (range 105-125.degree.
C.) Pellet feeder 1.20 kg/hour (1.0-1.4 kg/hour) Powder feeder 0.80
kg/hour (0.60-1.0 kg/hour) Strand cooling equipment: Appropriate
for extrusion rate used Pelletiser: Appropriate for extrusion rate
used Injection molder: Appropriate injection/cooling times,
temperature and injection pressure, dependent on machine type and
pellet formulation.
[0206] Pre-heat the extruder to the appropriate temperature. Load
the pellet feeder with the Aminoalkylmethacrylate Copolymer
(Eudragit E100) and the powder feeder with the blend. Start the
extruder screws rotating and then start the two feeders. Under
operating conditions, it has been found the port opening before the
die should be open to atmospheric conditions to force out any
water/vapor coming off the extrusion process. It has, however, been
found that the E100 formulations of the present invention do not
appear to have any excessive moisture problems when injection
molded.
[0207] Process the extruded strand along the cooling equipment into
the pelletiser and collect the pellets formed.
[0208] Input appropriate machine settings and pre-heat the
injection molder. Load the hopper with the pellets and mold the
multi-components units.
[0209] Additional examples or embodiments of this example have been
prepared, using the same process steps but with variant
formulations as shown below.
3 Example # Formulation constituent % w/w Example 2 Eudragit E100
75.0 Stearyl alcohol 5.0 PolyOx WSR N-80 20.0 Example 3 Eudragit
RS100:RL100 1:1 73.0 Hydroxypropylmethyl cellulose (Pharmacoat 603)
10.0 Lactose (regular) 5.0 Stearyl alcohol 12.0 Example 4 Eudragit
E100 60.0 Hydroxypropyl cellulose (Klucel LF) 10.0 Polyethylene
oxide (PolyOx WSR N-80) 20.0 Stearyl alcohol 10.0 Example 5
Eudragit E100 60.0 Hydroxypropylmethyl cellulose (Pharmacoat 603)
20.0 Polyethylene oxide (PolyOx WSR N-80) 10.0 Stearyl alcohol 10.0
Example 6 Eudragit E100 60.0 Starch 1500 20.0 Polyethylene oxide
(PolyOx WSR N-80) 10.0 Stearyl alcohol 10.0 Example 7 Eudragit E100
65.0 Glyceryl monostearate 5.0 Hydroxypropylmethyl cellulose
(Pharmacoat 603) 20.0 Stearyl alcohol 10.0 Example 8 Eudragit E100
65.0 Glyceryl monostearate 5.0 Starch 1500 20.0 Stearyl alcohol
10.0 Example 9 Eudragit E100 70.0 Stearyl alcohol 10.0 Polyethylene
oxide (PolyOx WSR N-80) 10.0 Kollidon VA-64 10.0 Example 10
Eudragit E100 60.0 Stearyl alcohol 10.0 Polyethylene oxide (PolyOx
WSR N-80) 10.0 Kollidon VA-64 20.0 Example 11 Eudragit E100 75.0
Stearyl alcohol 10.0 Polyethylene oxide (PolyOx WSR N-80) 10.0
Lactose (Regular) 5.0 Example 12 Eudragit E100 65.0 Stearyl alcohol
10.0 Glyceryl monostearate 5.0 Kollidon VA-64 20.0 Example 13
Eudragit E100 70.0 Eudragit RL 20.0 Stearyl alcohol 10.0 Example 14
Eudragit E100 60.0 Eudragit RL 20.0 PolyOx WSR N-80 10.0 Stearyl
alcohol 10.0 Example 15 Eudragit E100 55.0 Hydroxypropylmethyl
cellulose (Pharmacoat 603) 20.0 PolyOx WSR N-80 10.0 Lactose
(regular) 5.0 Stearyl alcohol 10.0 Example 16 Eudragit E100 55.0
Hydroxypropylmethyl cellulose (Pharmacoat 603) 15.0 PolyOx WSR N-80
10.0 Lactose (regular) 5.0 Starch 1500 5.0 Stearyl alcohol 10.0
Example 17 Eudragit E100 57.5 Hydroxypropylmethyl cellulose
(Pharmacoat 603) 15.0 PolyOx WSR N-80 10.0 Lactose (regular) 5.0
Starch 1500 2.5 Stearyl alcohol 10.0 Example 18 Eudragit E100 80.0
Sucrose ester (D-1811F) 10.0 PolyOx WSR N-80 10.0 Example 19
Eudragit E100 70.0 Sucrose ester (D-1811F) 10.0 PolyOx WSR N-80
10.0 Stearyl alcohol 10.0 Example 20 Eudragit E100 75.0 PolyOx WSR
N-80 10.0 Talc 5.0 Stearyl alcohol 10.0 Example 21 Eudragit E100
55.0 Kollidon VA64 35.0 Stearyl alcohol 10.0 Example 22 Eudragit
E100 70.0 PolyOx WSR N-80 20.0 Stearyl alcohol 10.0 Example 23
Eudragit E100 62.5 Kollidon VA64 17.5 PolyOx WSR N-80 10.0 Stearyl
alcohol 10.0 Example 24 Eudragit E100 67.5 Kollidon VA64 17.5 Talc
5.0 Stearyl alcohol 10.0 Example 25 Eudragit E100 80.0 Talc 10.0
Stearyl alcohol 10.0 Example 26 Eudragit E100 30.0 Kollidon VA64
35.0 PolyOx WSR N-80 20.0 Talc 5.0 Stearyl alcohol 10.0 Example 27
Eudragit E100 90.0 Stearyl alcohol 10.0 Example 28 Eudragit E100
45.0 Kollidon VA64 35.0 Talc 10.0 Stearyl alcohol 10.0 Example 29
Eudragit E100 42.5 Kollidon VA64 17.5 PolyOx WSR N-80 20.0 Talc
10.0 Stearyl alcohol 10.0 Example 30 Eudragit E100 48.75 Kollidon
VA64 26.25 PolyOx WSR N-80 10.0 Talc 5.0 Stearyl alcohol 10.0
Example 31 Eudragit E100 60.0 PolyOx WSR N-80 20.0 Talc 10.0
Stearyl alcohol 10.0 Example 32 Eudragit E100 52.5 Kollidon VA64
17.5 PolyOx WSR N-80 20.0 Stearyl alcohol 10.0 Example 33 Eudragit
E100 40.0 Kollidon VA64 35.0 PolyOx WSR N-80 10.0 Talc 5.0 Stearyl
alcohol 10.0 Example 34 Eudragit E100 63.75 Kollidon VA64 8.75
PolyOx WSR N-80 10.0 Talc 7.5 Stearyl alcohol 10.0 Example 35
Eudragit E100 60.0 Kollidon VA64 20.0 PolyOx WSR N-80 5.0 Talc 5.0
Stearyl alcohol 10.0 Example 36 Eudragit E100 55.0 Kollidon VA64
5.0 PolyOx WSR N-80 20.0 Talc 10.0 Stearyl alcohol 10.0 Example 37
Eudragit E100 50.0 Kollidon VA64 16.5 PolyOx WSR N-80 20.0 Talc 3.5
Stearyl alcohol 10.0 Example 38 Eudragit E100 60.00 Kollidon VA64
20.0 PolyOx WSR N-80 10.0 Talc 5.0 Stearyl alcohol 10.0 Example 39
Eudragit E100 65.0 Hydroxypropylmethylcellulose (Pharmacoat 603)
20.0 Lactose (regular) 5.0 Stearyl alcohol 10.0 Example 40 Eudragit
E100 57.0 PolyOx WSR N-80 20.0 Talc 10.0 Pluronic F-68 1% Stearyl
alcohol 12.0 Example 41 E100 75% Stearyl alcohol 3% Triacetin 2%
PolyOX N200 20% * Examples 20 to 38 were molded at 140.degree.
C.
Example 42
[0210] Manufacture of multicomponent pharmaceutical dosage forms
with Eudragit 4135F as a pharmaceutically acceptable polymer may be
made in accordance with the general description of Example 1 using
by way of example, the pharmaceutical composition as shown and
described below.
4 Item number Material % w/w 1. Copolymer of methacrylic acid,
methyl acrylate 73.0 and methylmethacrylate (Eudragit 4135) 2.
Hydroxypropyl Methylcellulose (Pharmacoat 603) 10.0 3. Lactose
monohydrate 5.0 4. Stearyl alcohol, milled 12.0 Total 100 Using a
suitable blender mix together: Item 2. Hydroxypropyl
Methylcellulose (Pharmacoat 603) Item 3. Lactose monohydrate Item
4. Stearyl alcohol, milled to form a homogeneous powder blend.
[0211] Set up a suitable co-rotating twin screw hot melt extruder
with both a pellet feeder and a powder feeder together with strand
cooling equipment and a pelletizer. Fit the selected mold in the
injection molding machine. Example processing parameters are as
follows:
5 Extruder: Screw speed 150 rpm (range 125-175 rpm) for a 19 mm
extruder, or 200 rpm (100-300 rpm) on a 16 mm extruder Temperature
of zone 1 60.degree. C. (range 30-75.degree. C.) (feed zone)
Temperature of zone 2 115.degree. C. (range 85-130.degree. C.)
Temperature of zone 3 120.degree. C. (range 90-135.degree. C.)
Temperature of zone 4 125.degree. C. (range 95-140.degree. C.)
Temperature of zone 5 130.degree. C. (range 100-145.degree. C.)
Temperature of strand die 135.degree. C. (range 105-150.degree. C.)
Pellet feeder 1.6 kg/hour (0.7-2.1 kg/hour) Powder feeder 0.6
kg/hour (0.26-0.79 kg/hour) Strand cooling equipment: Appropriate
for extrusion rate used Pelletiser: Appropriate for extrusion rate
used Injection molder: Appropriate injection/cooling times,
temperature and injection pressure, dependent on machine type and
pellet formulation.
[0212] Pre-heat the extruder to the appropriate temperature. Load
the pellet feeder with the Copolymer of methacrylic acid, methyl
acrylate and methylmethacrylate (Eudragit 4135F) and the powder
feeder with the blend. Start the extruder screws rotating and then
start the two feeders. Process the extruded strand along the
cooling equipment into the pelletiser and collect the pellets
formed.
[0213] Input appropriate machine settings and pre-heat the
injection molder. Load the hopper with the pellets and mold the
multi-components units.
[0214] Experimental Data
[0215] Representative formulations of the present invention in
dissolution testing showed satisfactory in-vitro dissolution
criteria of <45 mins when run in a pH of 1.2 with simulated
gastric fluid (SGF) and a paddle speed of 25rpm (USP2
conditions)
[0216] Examples 2, 8, 9 and 39 demonstrated a dissolution time of
<25 mins. Examples 20 to 38 demonstrated a dissolution time of
<30mins. Example 19 demonstrated a dissolution time of <40
mins, and Examples 5, 10, 14, 15, and 17 demonstrated a dissolution
time of <45 mins.
[0217] All publications, including but not limited to patents and
patent applications, cited in this specification are herein
incorporated by reference as if each individual publication were
specifically and individually indicated to be incorporated by
reference herein as though fully set forth.
[0218] The above description fully discloses the invention
including preferred embodiments thereof. Modifications and
improvements of the embodiments specifically disclosed herein are
within the scope of the following claims. Without further
elaboration, it is believed that one skilled in the area can, using
the preceding description, utilize the present invention to its
fullest extent. Therefore, the Examples herein are to be construed
as merely illustrative and not a limitation of the scope of the
present invention in any way. The embodiments of the invention in
which an exclusive property or privilege is claimed are defined as
follows.
* * * * *