U.S. patent application number 12/387765 was filed with the patent office on 2009-09-03 for powder aerosolization apparatus and method.
Invention is credited to Michael T. Newhouse, John S. Patton.
Application Number | 20090217928 12/387765 |
Document ID | / |
Family ID | 23155847 |
Filed Date | 2009-09-03 |
United States Patent
Application |
20090217928 |
Kind Code |
A1 |
Patton; John S. ; et
al. |
September 3, 2009 |
Powder aerosolization apparatus and method
Abstract
An aerosolization device comprises a chamber adapted to contain
a powder pharmaceutical formulation, a lid at least partially
covering the chamber, at least one piercing element forcible
through the lid to provide access to the powder pharmaceutical
formulation, and a shapeable surface extending from the chamber,
the shapeable surface being adapted to undergo a shape change to
form a conduit. The powder pharmaceutical formulation may be
extracted from the chamber by a user inhaling through the conduit.
In another version, the lid is removable from the chamber without
the need for a piercing element.
Inventors: |
Patton; John S.; (Portola
Valley, CA) ; Newhouse; Michael T.; (Foster City,
CA) |
Correspondence
Address: |
Novartis Vaccines and Diagnostics, Inc.;Intellectual Property X-100B
4560 Horton Street
Emeryville
CA
94608
US
|
Family ID: |
23155847 |
Appl. No.: |
12/387765 |
Filed: |
May 7, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10175145 |
Jun 19, 2002 |
7540284 |
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12387765 |
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60299694 |
Jun 20, 2001 |
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Current U.S.
Class: |
128/203.15 |
Current CPC
Class: |
A61M 15/0036 20140204;
A61M 2202/064 20130101; A61M 15/0028 20130101 |
Class at
Publication: |
128/203.15 |
International
Class: |
A61M 15/00 20060101
A61M015/00 |
Claims
1. An aerosolization device comprising: a chamber adapted to
contain a powder pharmaceutical formulation; a lid at least
partially covering the chamber; and at least one piercing element
connected to the chamber, the piercing element being forcible
through the lid to provide access to the powder pharmaceutical
formulation, whereby the powder pharmaceutical formulation may be
extracted from the chamber by a user inhaling in proximity to the
chamber.
2. An aerosolization device according to claim I wherein the
chamber comprises a cavity formed in a surface.
3. An aerosolization device according to claim 2 wherein the
piercing element is integrally formed with the surface.
4. An aerosolization device according to claim 2 wherein the
piercing element is formed in one piece with the surface.
5. An aerosolization device according to claim 2 wherein at least a
portion of the piercing element is connected to the surface by a
perforated portion of the surface.
6. An aerosolization device according to claim 2 wherein the
piercing element comprises a pointed tab formed from the
surface.
7. An aerosolization device according to claim 6 wherein the
piercing element is located adjacent to the chamber and is bendable
to permit the pointed tab to pierce the lid.
8. An aerosolization device according to claim 2 wherein the
surface has a longitudinal axis and wherein two sides of the
surface that lie on opposing sides of the longitudinal axis are
bendable towards each other to pierce the lid.
9. An aerosolization device according to claim 1 wherein the lid
comprises a foil.
10. An aerosolization device according to claim 1 wherein the lid
and the piercing element lie in a common plane prior to piercing of
the lid.
11. An aerosolization device according to claim 1 further
comprising a conduit extending from the chamber.
12. An aerosolization device for aerosolizing a powder
pharmaceutical formulation contained within a chamber having a lid,
the aerosolization device comprising: a shapeable surface adapted
to undergo a shape change to form a conduit, and at least one
piercing element connected to the shapeable surface, the piercing
element being positioned so that is may be forced through the lid
to provide access to the powder pharmaceutical formulation, whereby
the powder pharmaceutical formulation may be extracted from the
chamber by a user inhaling through the conduit.
13. An aerosolization device according to claim 12 wherein the
shapeable surface is adapted to undergo a shape change in response
to a force being applied thereto by the user.
14. An aerosolization device according to claim 12 wherein the
shapeable surface includes means for encouraging the surface to
form the conduit.
15. An aerosolization device according to claim 14 wherein the
means for encouraging comprises one or more perforations.
16. An aerosolization device according to claim 12 wherein the
chamber is removably positionable on the shapeable surface.
17. An aerosolization device according to claim 12 wherein the
piercing element and the shapeable surface are one-piece.
18. An aerosolization device according to claim 12 wherein the
piercing element comprises a pointed tab formed from the shapeable
surface.
19. An aerosolization device according to claim 12 wherein the
piercing element and the shapeable surface lie in a common plane
prior to piercing of the lid and the formation of the conduit.
20. A method for aerosolizing a pharmaceutical formulation, the
method comprising: providing a chamber containing a powder
pharmaceutical formulation at least partially covered by a
puncturable lid; providing a surface that is shapeable into the
form of a conduit; and after the lid is punctured, aerosolizing the
powder pharmaceutical formulation in response to a user inhaling
through the conduit.
21. A method according to claim 20 wherein the surface is shapeable
into the form of a conduit in response to a force being applied by
the user.
22. A method for aerosolizing a pharmaceutical formulation, the
method comprising: shaping a shapeable surface into the form of a
conduit; puncturing the lid of a chamber containing a powder
pharmaceutical formulation; and inhaling through the conduit to
aerosolize the pharmaceutical formulation.
23. A method according to claim 22 wherein the step of shaping
comprises bending the shapeable surface.
24. A method according to claim 22 wherein the step of shaping
comprises bending the shapeable surface about at least one
perforation in the surface.
25. A method for aerosolizing a pharmaceutical formulation, the
method comprising: puncturing the lid of a chamber containing a
powder pharmaceutical formulation, wherein the puncturing is
performed with a piercing element attached to the chamber; and
inhaling through a conduit to aerosolize the pharmaceutical
formulation.
26. A method according to claim 25 wherein the step of puncturing
the lid comprises moving the piercing element out of a common plane
which contains the lid and the piercing element prior to piercing
of the lid and the formation of the conduit.
27. A method of making an aerosolization apparatus, the method
comprising: providing a surface; forming one or more perforations
in the surface so that the surface may be shaped into the form of a
conduit; and forming a member in the surface whereby a
pharmaceutical formulation may be positioned in proximity to the
conduit.
28. A method according to claim 27 wherein the member comprises a
chamber formed in the surface.
29. A method according to claim 27 wherein the member comprises a
recess into which a chamber containing the pharmaceutical
formulation may be positioned.
30. A method of making an aerosolization apparatus, the method
comprising: providing a surface; forming a chamber in the surface
and providing a powder pharmaceutical formulation within the
chamber; and forming at least one piercing element in the surface
with which the powder pharmaceutical formulation may be
accessed.
31. A method according to claim 30 wherein the piercing element is
formed by providing one or more perforations in the surface.
32. A method according to claim 30 wherein the piercing element may
be bent to force the piercing element through a lid covering at
least a portion of the chamber.
33. An aerosolization device comprising: a chamber adapted to
contain a powder pharmaceutical formulation; a lid removably
covering at least a portion of the chamber; and a shapeable surface
extending from the chamber, the shapeable surface being adapted to
undergo a shape change to form a conduit, whereby the powder
pharmaceutical formulation may be extracted from the chamber by a
user inhaling through the conduit.
34. An aerosolization device according to claim 33 wherein the
shapeable surface is adapted to undergo a shape change in response
to a force being applied thereto by the user.
35. An aerosolization device according to claim 33 wherein the
shapeable surface includes means for encouraging the surface to
form the conduit.
36. An aerosolization device according to claim 35 wherein the
means for encouraging comprises one or more perforations.
37. An aerosolization device according to claim 33 wherein the
surface is substantially flat before undergoing the shape
change.
38. An aerosolization device according to claim 33 wherein the lid
comprises a foil.
Description
[0001] This application is a divisional of U.S. patent application
Ser. No. 10/175,145, which claims priority of U.S. Provisional
Application No. 60/299,694, filed Jun. 20, 2001, which are all
incorporated herein by this reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to the field of
aerosolizing a powder pharmaceutical formulation, such as a dry
powder drug and/or vaccine.
[0003] The need for effective therapeutic treatment of patients has
resulted in the development of a variety of techniques for
delivering a pharmaceutical formulation to a patient. Traditional
techniques for delivering a pharmaceutical formulation involve,
needle injection and oral delivery in the form of a pill, capsule,
or the like. Inhaleable drug delivery, where an aerosolized
pharmaceutical formulation is orally or nasally inhaled by a
patient to deliver the formulation to the patient's respiratory
tract, has also proven to be an effective manner of delivery. In
one inhalation technique, a pharmaceutical formulation is delivered
deep within a patient's lungs where it may be absorbed into the
blood stream. Many types of inhalation devices exist including
devices that aerosolize a dry powder pharmaceutical formulation.
However, these devices are often cumbersome and/or are difficult or
costly to manufacture and/or are inadequate at delivering the
pharmaceutical formulation.
[0004] Pulmonary delivery has been shown to be a particularly
promising pharmaceutical formulation delivery technique for certain
therapies. For example, the delivery of proteins and polypeptides,
which can be difficult to deliver by other routes of
administration, can be effectively delivered by inhalation. Such
pulmonary delivery is effective both for systemic delivery and for
localized delivery to treat diseases of the lungs. In addition,
pulmonary delivery of some vaccines has been shown to be more
effective than needle injection. This is believed to be due to this
technique conferring mucosal as well as systemic immunity. For
example, inhaled measles vaccines have been successfully
administered to millions of Mexican and thousands of South African
children safely and more effectively than injected vaccines.
[0005] Therefore, it is desirable to be able to offer the benefits
of pulmonary delivery without the need of a cumbersome, expensive,
and/or inefficient device. It is further desirable to be able to
provide an aerosolization device that is simple and efficient to
make and/or operate.
SUMMARY
[0006] The present invention satisfies these needs. In one aspect
of the invention an aerosolization device comprises a chamber
adapted to contain a powder pharmaceutical formulation, a lid at
least partially covering the chamber, at least one piercing element
forcible through the lid to provide access to the powder
pharmaceutical formulation, and a shapeable surface extending from
the chamber, the shapeable surface being adapted to undergo a shape
change to form a conduit, whereby the powder pharmaceutical
formulation may be extracted from the chamber by a user inhaling
through the conduit.
[0007] In another aspect of the invention, an aerosolization device
comprises a chamber adapted to contain a powder pharmaceutical
formulation, a lid at least partially covering the chamber, and at
least one piercing element connected to the chamber, the piercing
element being forcible through the lid to provide access to the
powder pharmaceutical formulation, whereby the powder
pharmaceutical formulation may be extracted from the chamber by a
user inhaling in proximity to the chamber.
[0008] In another aspect of the invention, an aerosolization device
for aerosolizing a powder pharmaceutical formulation contained
within a chamber having a lid comprises a shapeable surface adapted
to undergo a shape change to form a conduit, and at least one
piercing element connected to the shapeable surface, the piercing
element being positioned so that is may be forced through the lid
to provide access to the powder pharmaceutical formulation, whereby
the powder pharmaceutical formulation may be extracted from the
chamber by a user inhaling through the conduit.
[0009] In another aspect of the invention, a method of aerosolizing
a pharmaceutical formulation comprises providing a chamber
containing a powder pharmaceutical formulation at least partially
covered by a puncturable lid, providing a surface that is shapeable
into the form of a conduit, and after the lid is punctured,
aerosolizing the powder pharmaceutical formulation in response to a
user inhaling through the conduit.
[0010] In another aspect of the invention, a method of aerosolizing
a pharmaceutical formulation comprises shaping a shapeable surface
into the form of a conduit, puncturing the lid of a chamber
containing a powder pharmaceutical formulation, and inhaling
through the conduit to aerosolize the pharmaceutical
formulation.
[0011] In another aspect of the invention, a method of aerosolizing
a pharmaceutical formulation comprises puncturing the lid of a
chamber containing a powder pharmaceutical formulation, wherein the
puncturing is performed with a piercing element attached to the
chamber, and inhaling through a conduit to aerosolize the
pharmaceutical formulation.
[0012] In another aspect of the invention, a method of making an
aerosolization apparatus comprises providing a surface, forming one
or more perforations in the surface so that the surface may be
shaped into the form of a conduit, and forming a member in the
surface whereby a pharmaceutical formulation may be positioned in
proximity to the conduit.
[0013] In another aspect of the invention, a method of making an
aerosolization apparatus comprises providing a surface, forming a
chamber in the surface and providing a powder pharmaceutical
formulation within the chamber, and forming at least one piercing
element in the surface with which the powder pharmaceutical
formulation may be accessed.
[0014] In another aspect of the invention, an aerosolization device
comprises a chamber adapted to contain a powder pharmaceutical
formulation, a lid removably covering at least a portion of the
chamber, and a shapeable surface extending from the chamber, the
shapeable surface being adapted to undergo a shape change to form a
conduit, whereby the powder pharmaceutical formulation may be
extracted from the chamber by a user inhaling through the
conduit.
[0015] According to one embodiment of the invention, an inhalation
device comprises a chamber containing a unit dosage of a powdered
medicament that is covered by a pierceable lid. A bendable surface
extends from the chamber and contains at least one piercing
element. The bendable surface may be manually shaped to form a
conduit through which the medicament is extracted during inhalation
through the conduit. The piercing element is operably coupled to
the chamber in such a configuration that the lid covering the
chamber is forcibly pierced by the element when the bendable
surface is manually shaped to form the conduit for inhalation, when
the element is squeezed through the lid, or the like.
[0016] In another embodiment, an inhalation device comprises a
device body having a conduit region defining a conduit and a
storage region having a chamber containing a unit dosage of a
powdered medicament that is covered by a pierceable lid. At least
one piercing element is operably coupled to the device body and is
configured to be forced through the lid to provide access to the
medicament. In this way, the medicament is extractable from the
chamber by inhaling through the conduit. Conveniently, the conduit
may be formed at the time of manufacture, such as by using a
machine to roll the device body into the conduit after the device
body has been stamped from a sheet of material. Alternatively, the
device body may be rolled into a conduit by the user prior to
inhalation.
[0017] This invention also provides techniques for forming an
aerosolization device as well as for aerosolizing a powdered
medicament. The aerosolization device in one embodiment is formed
from a receptacle comprising a bendable surface, at least one
piercing element, and a chamber with a pierceable lid. The piercing
element is employed to gain access to the powder by piercing the
lid, and the bendable surface is manipulated to form a conduit. A
user inhales through the conduit to extract the powder from the
chamber and entrain the lo powder in the gas stream produced by the
user. Hence, a relatively simple and inexpensive way is provided to
administer a unit dose of a medicament to a patient utilizing the
same receptacle used to store the medicament.
[0018] In some embodiments, the aerosolization device may be
separate from a receptacle containing the powder. In this way, the
aerosolization device may be reused with different receptacles,
while still being relatively simple and inexpensive. For example,
one such an inhalation device comprises a device body having a
conduit region defining a conduit and a holding region that is
adapted to hold a receptacle having a chamber containing a unit
dosage of a powdered medicament that is covered by a pierceable
lid. At least one piercing element is operably coupled to the
device body and is configured to be forced through the lid to
provide access to the medicament. In this way, a user may simply
insert the receptacle into the holding region of the device, force
the piercing element through the lid, and then inhale through the
conduit to extract and aerosolize the medicament.
[0019] In one aspect, the holding region includes a depression for
receiving the chamber of the receptacle. In this way, the
receptacle is held in place while being opened and during
aerosolization.
[0020] Such an aerosolization device may incorporate many of the
features of the aerosolization devices having an integrated chamber
as previously described, and vice versa. For example, the conduit
region may comprise a sheet of material that is fashioned to form
the conduit. This may be done at the time of manufacture, or by the
user. Further, the device body may conveniently be formed from a
stamping process. As another example, the piercing element may be
spaced apart from the conduit to facilitate squeezing of the
piercing element through the lid. As a further example, another
piercing element is operably coupled to the device body, such as on
an opposite side of the chamber. In this way, more than one hole
may be provided in the lid. The piercing element may also have a
variety of shapes and sizes, such as having a single point,
multiple points, curves, and flat.
[0021] In one particular aspect, any of the devices may be
configured such that the piercing element stops penetration at a
known distance so that the size of the opening is consistent with
each operation. This may be accomplished by providing the user with
tactile feedback when the proper penetration has been achieved. For
example, the piercing element may be configured to be forced
through the lid until the piercing element contacts a bottom of the
chamber. Further, the piercing element may be configured to spring
back out of the chamber when released to leave the hole fully open.
This may be accomplished by constructing the piercing element of a
resilient material that returns to its initial shape after being
squeezed.
DRAWINGS
[0022] These features, aspects, and advantages of the present
invention will become better understood with regard to the
following description, appended claims, and accompanying drawings
which illustrate exemplary features of the invention. However, it
is to be understood that each of the features can be used in the
invention in general, not merely in the context of the particular
drawings, and the invention includes any combination of these
features, where:
[0023] FIG. 1 is a schematic bottom perspective view of an
aerosolization device of the invention;
[0024] FIG. 2 is a schematic sectional side view of the
aerosolization device of FIG. 1;
[0025] FIG. 3 is a schematic top view of a version of an
aerosolization device;
[0026] FIG. 4 is a schematic perspective view of the aerosolization
device of FIG. 3 being converted into a aerosolization
configuration;
[0027] FIG. 5 is a schematic end view of the aerosolization device
of FIG. 3 after being converted into the aerosolization
configuration;
[0028] FIG. 6 is an illustration of the aerosolization device of
FIGS. 3-5 in use;
[0029] FIG. 7 is a schematic perspective view of another version of
an aerosolization device;
[0030] FIG. 8 is a schematic end view of the aerosolization device
of FIG. 7;
[0031] FIG. 9 is a schematic end view of the aerosolization device
of FIG. 7 holding a receptacle;
[0032] FIG. 10 is a schematic top view of the aerosolization device
of FIG. 7 before it is converted into its aerosolization
configuration;
[0033] FIG. 11 is a schematic end view of another version of the
aerosolization device;
[0034] FIG. 12 is a schematic side view of another version of an
aerosolization device;
[0035] FIG. 13 is a schematic end view of the aerosolization device
of FIG. 12;
[0036] FIG. 14 is a schematic top view of the aerosolization device
of FIG. 12 before being converted into its aerosolization
configuration;
[0037] FIG. 15 is a schematic side view of another version of an
aerosolization device;
[0038] FIGS. 16A-16F illustrate various embodiments of piercing
elements that may be used with an aerosolization device according
to the invention;
[0039] FIGS. 17A-17F illustrate various hole patterns that may be
formed in the lid of a receptacle by piercing elements according to
the invention;
[0040] FIGS. 18A and 18B illustrate an alternative lid
configuration and various hole patterns that may be formed in the
lid by piercing elements according to the invention;
[0041] FIG. 19 is a schematic top view of another version of an
aerosolization device; and
[0042] FIG. 20 is a schematic perspective view of another version
of an aerosolization device.
DESCRIPTION
[0043] The present invention relates to the aerosolization of a
pharmaceutical formulation, such as a drug and/or vaccine. Although
the process is illustrated in the context of delivering a dry
powder pharmaceutical formulation, the present invention can be
used in other processes and should not be limited to the examples
provided herein.
[0044] The present invention provides, for example, simple and easy
ways to deliver a pharmaceutical formulation, such as a dry powder
drug and/or vaccines in a simple, inexpensive and efficient manner.
The apparatus and methods disclosed are particularly useful in
delivering unit dosages via inhalation administration routes, such
as through the mouth, the nose, and the like. According to one
embodiment of the invention, pulmonary delivery may be achieved by
creating an aerosolization device out of a receptacle used to store
the powder. The aerosolization device may be adapted to aerosolize
the pharmaceutical formulation as a user inhales. In this way, a
user may be provided with a relatively inexpensive receptacle that
contains a unit dose of a dry powder, convert the receptacle into
an inhalation device, and inhale the powder to deliver the dose. In
some cases, the receptacle may be fashioned into the shape of an
inhaler at the time of manufacture so that all the user needs to do
is to open the chamber and then inhale through the device. In other
cases, the shaping may be performed by the user just before
inhaling through the device.
[0045] As one example, an aerosolization device having an
integrated receptacle may comprise a device body having a conduit
region defining a conduit and a storage region having a chamber
containing a unit dosage, or other amount, of a powdered
pharmaceutical formulation that is covered by a lid, such as a
pierceable lid. At least one piercing element may be operably
coupled to the device body and is configured to be forced through
the lid to provide access to the medicament. Subsequently, the user
may inhale through the conduit to extract and aerosolize the
powder. Hence, with such a configuration, the user may easily form
an aersolization device out of a receptacle, pierce the receptacle
and then inhale to receive the medicament.
[0046] In another embodiment, an aerosolization device may be used
with separate receptacles, and may include many of the same
features as the aerosolization device having an integrated
receptacle. In this version, the aersolization device may be reused
while still being simple to use and relatively inexpensive.
Aerosolization devices using a separate receptacle may comprise a
device body having a conduit region defining a conduit and a
holding region for holding a receptacle having a chamber containing
a unit dosage of a powdered medicament that is covered by a
pierceable lid. At least one piercing element is operably coupled
to the device body and is configured to be forced through the lid
to provide access to the medicament. With such a configuration, the
user simply needs to insert the receptacle, pierce the lid, and
then inhale through the conduit to extract and aerosolize the
medicament.
[0047] Hence, the inhalation devices of the invention, whether
including an integrated receptacle or not, may have a variety of
features in common. For example, they both may be fabricated to
pre-form the conduit, or come as a sheet where the user forms the
conduit. As another example, the inhalation devices may include
similar piercing elements, conduit designs, and the like. Also the
receptacle chambers may have similar sizes and shapes.
[0048] The invention may utilize a variety of receptacles that may
be converted into an aerosolization device or be used with a
separate aerosolization device. Such receptacles may have a cavity
or chamber having a sealed unit dose of powder. The sealed chamber
protects the powder from the environment and increases its shelf
life. The chamber is connected to some type of material that can be
manipulated to form a conduit that passes over the chamber. In this
way, the unit dose of powder may be packaged and shipped in the
form of a receptacle in a relatively inexpensive manner. When ready
to receive the dose, the user simply opens the cavity, forms the
conduit (if needed), and inhales through the conduit to extract the
powder in a gas stream created by the inhalation. As the user
continues to inhale, the aerosolized powder flows to the user's
lungs. Alternatively, such receptacles may simply be placed into a
separate inhalation device which is used to pierce the lid in a
similar manner.
[0049] In one version, the aerosolization device may comprise or
accommodate a receptacle that may be used to store a pharmaceutical
formulation, such as a "blister package" type of receptacle where a
"blister" or cavity is formed in a piece of material and a lid or
seal is placed over the cavity to seal the powder within the
cavity. Examples of such receptacles are described in U.S. Pat.
Nos. 5,785,049; 5,740,794; 5,865,012, and 6,809,228 and in
copending U.S. application Ser. Nos. 09/312,434, filed May 14,
1999; and 09/731,318, filed Dec. 6, 2000, the disclosures of all of
which being incorporated herein by reference in their entireties.
One advantage of modifying a blister package into an aerosolization
device is that commercially available equipment and known
techniques may be used to form and fill such receptacles in a cost
efficient manner. Such receptacles may also be formed and filled in
a high throughput manner. For instance, techniques for filling such
receptacles are described in U.S. Pat. Nos. 5,826,663 and
6,182,712, both of which are incorporated herein by reference in
their entireties.
[0050] The aerosolization device of the invention may be
constructed of a wide variety of materials. For example, the device
may be formed from any type of material that may be stamped to form
the cavity. Molded materials may also be used to form the cavity or
any other portion of the device. The materials should also be
conducive with the type of contained pharmaceutical formulation.
Examples of materials that may be used include those described in
the above cited patents and patent applications. The shapeable or
bendable material that is used to form the conduit may comprise
essentially any type of deformable material that will hold its
shape, including metals, such as aluminum, and stainless steel,
paper products, and the like. Further, the piercing elements may be
formed from a material with spring-link characteristics so that
they move back to their original position after being inserted into
the cavity. In this way, the piercing elements will not interfere
with the aerosolization and delivery process.
[0051] One convenient way to construct the receptacle is by using a
metal bottom that has a stamped cavity so that one or more edges
extend from the cavity. A foil covering may be sealed over the
cavity to seal the powder. The edges may then be bent or rolled to
form the conduit. The formation of the conduit may be done at the
time of manufacture using equipment designed to roll the edges into
the shape of a conduit. Alternatively, the conduit may be formed by
the user, thereby further reducing the cost of the inhalation
device.
[0052] To provide access to the pharmaceutical formulation, a
variety of techniques may be used. For example, one way to gain
access to the pharmaceutical formulation is by piercing the chamber
at one or more locations. When the chamber is covered by a
pierceable lid, access to the powder may be gained by using a
pointed or sharpened surface that pierces the lid. For example, one
or more pointed tabs may be used to pierce or cut the lid. These
may be operably connected to the chamber so that the lid may be
pierced simply by manipulating the tab so that its pointed end
faces the lid and then forcing the tab through the lid. For
example, the user may simply place the device between the thumb and
forefinger and squeeze the tab through the lid. Conveniently, the
piercing tabs may be cut from the edges of the receptacle that are
used to form the conduit. With this configuration, the tabs may be
bent and pushed into the lid to pierce the foil prior to forming
the conduit. As another example, the receptacle may include an
opening tool that is removable so that the user may remove the tool
from the receptacle and then pierce or remove the lid. For
instance, the tool may comprise a portion of the receptacle that is
held in place by tabs separated by score lines. In this way, the
tool may be torn from the receptacle prior to use. As another
option, an opening tool may be provided along with the packaging
used to store the receptacle.
[0053] The number and size of openings formed in the cavity may
vary depending on the application and the type of powder. For
example, a single opening or a plurality of openings could be
formed of a size suitable to accommodate sufficient airflow to
disperse and aerosolize the powder. Optionally, one or more vent
openings may also be formed. The openings are formed in locations
which are tangential to the gas stream flowing through the conduit
so that the flowing gas stream may draw the powder out of the
cavity due to a venturi effect.
[0054] A variety of techniques may be used to form the conduit. For
example, the cavity may be located along a central axis of the
receptacle so that opposing edges of the receptacle may be rolled
or bent until they touch each other or overlap to form the conduit.
Alternatively, the cavity may be offset toward one side so that
only one side needs to be bent or rolled to form the cavity. The
conduit may have a cross sectional area of about 0.5 mm to about 3
mm. Further, the cross sectional area of the conduit may vary along
its length. For example, the conduit may have a smaller opening
nearest the chamber. The length of the conduit may be in the range
from about 2.5 cm to about 10 cm. In one aspect, the conduit may be
preformed by a packaging machine and the piercing elements
positioned close to and directly above the chamber so that a simple
squeeze of the wings between the thumb and fore finger will pierce
the lid and open the chamber.
[0055] A gas stream flowing through the conduit may be generated by
the user by inhaling at one end of the conduit. The gas stream may
be sufficient to aerosolize the pharmaceutical formulation in the
chamber. For example, flow rates that may be generated to extract a
powder may be in the range from about 10 L/min to about 90 L/min.
In this version, the pharmaceutical formulation may be inhaled
orally or through the nose.
[0056] A wide variety of pharmaceutical formulations powders may be
aerosolized using the techniques of the invention. Examples of
drugs and vaccines that may be aerosolized include antibiotics,
antibodies, antiviral agents, antiepileptics, and bronchodilators,
and viruses and may be inorganic and organic compounds, including,
without limitation, drugs which act on the peripheral nerves,
adrenergic receptors, cholinergic receptors, the skeletal muscles,
the cardiovascular system, smooth muscles, the blood circulatory
system, synaptic sites, neuroeffector junctional sites, endocrine
and hormone systems, the immunological system, the reproductive
system, the skeletal system, autacoid systems, the alimentary and
excretory systems, the histamine system and the central nervous
system, and the like. The powders may have a particle size in the
range from about 0.5 .mu.m to about 10 .mu.m, and more preferably
from about 0.5 .mu.m to about 5 .mu.m. For some cases, such as for
nasal or buccal deposition, the particles sizes may be in the range
from about 10 .mu.m to about 50 .mu.m. The chamber in the
receptacle may be configured to hold unit dosages in the range from
about 0.5 mg to about 50 mg. The invention will find one particular
use with drugs or vaccines where variability in the delivered dose
is permissible. Such variability may occur if some powder remains
in the chamber after inhalation. In such cases extra powder may be
stored in the chamber.
[0057] Hence, in one advantageous use of the present invention,
large populations may be vaccinated in a simple and efficient
manner, without the risk of cross contamination with infectious
agents. The aerosolization devices of the invention provide for the
administration of unit dosages, or other amounts, and in some
embodiments the drug carrier unit and the aerosolization device are
integrated with each other so that the device is inexpensive and
may be discarded after the unit dose has been inhaled. The
aerosolization devices may also be relatively small and light
weight so that they may be easily shipped and stored. They are easy
to assembly and operate so that they may be used by a wide variety
of patients.
[0058] Referring to FIG. 1, a bottom view of an embodiment of an
aerosolization device 100 is shown. The aerosolization device 100
comprises at least one shapeable portion 102. In this version of
FIG. 1, the shapeable portion 102 comprises a bendable receptacle
material 104, like plastic or metal, whose overall shape may, for
example, be that of a rectangle, with the two longer sides having
edges 120 and edge 124. This bendable receptacle material 104 is in
a sufficient gauge or thickness that can be bent, molded, formed
and/or rolled into a desired shape. The bendable receptacle
material 104 includes or is connected to a dosage chamber 108 that
protrudes out the bottom side of the flat sheet. Conveniently, any
shape and size of the dosing chamber 108 can be utilized as long as
it is suitable for holding the contents of a given pharmaceutical
formulation, such as a dry powder pharmaceutical formulation. In
the version shown, the placement of the dosing chamber 108 is
symmetrical across a longitudinal central axis 112 of the bendable
receptacle material 104. In this way, its centroid lies on the
central axis 112 and to one side of a minor axis 116. Other
embodiments could have the placement of the centroid of the dosing
chamber 108 anywhere along the entire longitudinal central axis
112. The shapeable portion 102 may be the entire aerosolization
device or just a portion thereof, and there may be more than one
shapeable portions. The shapeable portion 102 may be designed to be
shaped by a subsequent manufacturing process or may be designed to
be shaped by a user of the device during or just before usage.
[0059] The dosing chamber 108 may be formed by the joining of the
bendable receptacle material 104 to a lid covering material 208 in
order to encapsulate a dry powder dosage 204, as shown in the
sectional view of the aerosolization device 100 of FIG. 2. A
bonding joint 212 exists between the two joined materials 104, 208.
Joint 212 may be an adhesive substance such as glue, a bonding film
such as double sided tape, a layer that results from the
manufacturing process of which may include chemical reactions and
heat bonds, or the like. The bonding joint 212 is formed in such a
fashion that any additional treatment of edge 120 is possible.
[0060] The aerosolization device 100 may comprise one or more means
for encouraging the shapeable portion into a desired shape. For
example, as shown in the version of FIG. 3, one or more
perforations may be cut through the lid covering material 208
and/or the bendable receptacle material 104. A rolling perforation
312 may be included as a series of longitudinal cuts in a dashed
line fashion that are cut through the two joined materials 104,
208. Rolling perforations 308 may be used to weaken the bendable
material's rigidity in such a manner that the two joined materials
104, 208 can be more easily rolled into a conduit, such as a
tube-like shape. Alternatively other means for encouraging the
shapeable portion into a desired shape may be included. For
example, the shapeable portion may be composed of shape memory
material or may be biased into a desired configuration.
[0061] Additionally or alternatively, one or more perforations may
be provided to define one or more piercing elements. For example,
as shown in FIG. 3, a piercing element perforation 308 is provided
in the form of a perforation line that is cut through the two
joined materials 104, 208 in two places. When separated along
perforations 308, a piercing element 304 with a piercing point 306
is formed. In this version, the piercing element perforations 308
form the piercing element 304 by joining two perforations of the
same length at a single endpoint. The piercing element 304 that
results is in the shape of a triangle with two sides being formed
by two piercing element perforations 308 and one side remaining
attached to one or both of the two joined materials 104, 208. The
piercing point 306 is designed to penetrate the lid covering
material 208 of dosing chamber 108 and allow for the extraction of
the dry powder dosage 204.
[0062] Two piercing elements 304 are shown in the embodiment of
FIG. 3, one on each side of the dosing chamber 108 and symmetrical
to the longitudinal central axis 112. Similarly, two rolling
perforations 312 are cut longitudinally into the convertible
storage receptacle 100 and symmetrical to the longitudinal central
axis 112 to help the user roll the two joined materials 104, 208
into a conduit or a tube-like shape. Alternatively, the rolling
perforations 312 may not extend only along a portion of the length
of the aerosolization device 100. For example, the rolling
perforations 312 may extend from the end of the device which is to
be engaged by the user and may terminate just before the piercing
elements so that only the portion downstream of the chamber 108 is
shaped. A cut from the edges 120, 124 to the rolling perforations
312 may be provided to facilitate this shaping of the downstream
portion. Depending on the types of materials 104, 208 used, it may
not be necessary to use any rolling perforations 312.
[0063] Referring to FIG. 4, an isometric view of aerosolization
device 100 is shown being converted into a ready to use form. This
view illustrates how the process of rolling the two joined
materials 104, 208 forms a conduit for inhalation by the user. FIG.
4 also illustrates how the piercing elements 304 can be rolled
separately from the leading edges 120, 124 to penetrate lid
covering material 208 and access the contents of dosing chamber
108. Conveniently, the conduit may be formed by rolling edge 120 of
the two joined materials 104, 208 in a direction rotating clockwise
from the longitudinal central axis 112, and by rolling edge 124 of
the two joined materials 104, 208 in a direction rotating counter
clockwise from the longitudinal central axis 112.
[0064] To provide access to dosing chamber 108, the piercing
elements may be separated from leading edges 120, 124 at the
piercing element perforations 308 and rolled in a tight enough arc
such that the piercing point can penetrate the lid covering
material 208. Alternatively, the partially-rolled piercing elements
304 may be squeezed using fingertips or some other mechanism until
penetration of the lid covering material 208 by the piercing
elements 304 is achieved. When releasing piercing elements 304,
they preferably spring back out of chamber 108, leaving holes in
the lid to permit the powder to be extracted. FIG. 5 shows an end
view of aerosolization device in its ready to use configuration 400
after piercing elements 304 have formed access holes and after the
conduit has been formed.
[0065] Referring to FIG. 6, aerosolization device 100 is shown in
use in its aerosolization configuration 400. After piercing
elements 304 have formed access holes into dosing chamber 108 and
the two joined materials 104, 208 have been rolled to form conduit
508, the user holds the inhaler device 400 between the lips and
inhales. The flow of air across the opening of the chamber 108
draws the powder pharmaceutical formulation out of the chamber and
aerosolizes the powder so that it may be inhaled by the user. In
addition, the aerosolization device 100 may be designed so that a
portion of the flowing gas passes through the chamber to collect
the pharmaceutical formulation and/or so that a venturi is formed
that assists in drawing the pharmaceutical formulation out of the
chamber.
[0066] FIG. 7 illustrates a version an aerosolization device 600 on
which a separate receptacle 602 may be removably positioned.
However, it will be appreciated that receptacle 602 could be
incorporated into inhalation device 600 in a manner similar to
other embodiments. Device 600 comprises a device body 604 having a
holding region 606 and a conduit region 608. Holding region 606
includes a depression 609 that is configured to receive receptacle
602. More specifically, receptacle 602 includes a chamber 610 that
is covered by a pierceable lid 612 and includes an amount of a
powdered medicament that is to be inhaled. Receptacle 602 is
inserted into holding region 606 as indicated by the arrow until
chamber 610 rests within depression 609 of holding region 606. In
another version, the depression 609 may be replaced by an opening
shaped to receive the chamber 610.
[0067] Device body 604 further includes a pair of piercing elements
614 and 616 that are conveniently disposed on either side of
depression 609. As best shown in FIG. 8, piercing elements 614 and
616 are positioned over holding region 606 so that they may be
squeezed to penetrate lid 612. Such a process is illustrated in
FIG. 9 where the arrows represent the direction of movement of
piercing elements 614 and 616. Piercing elements 614 and 616 are
constructed of a material that permits them to spring back to the
position shown in FIG. 8 after lid 612 has been pierced. In this
way, piercing elements 614 and 616 will not interfere with the
aerosolization process. One convenient way to force piercing
elements 614 and 616 through lid 612 by grasping holding region 606
between the user's forefinger and thumb and then squeezing to force
piercing elements 614 and 616 through lid 612.
[0068] The user may further be provided with instructions as to the
depth of penetration of piercing elements 614 and 616 so that holes
of consistent size may be repeatedly produced each time device 600
is operated. For example, the user may be instructed to depress
piercing elements 614 and 616 until the user feels them contact the
bottom of chamber 610. Alternatively, elements 614 and 616 could be
provided with markers, tabs, detents, or the like that indicate
when piercing elements 614 and 616 have been depressed to the
proper depth.
[0069] Conduit region 608 defines a conduit 618 that is formed from
rolling two sides 620 and 622 of device body 604 into the shape
shown. Conduit 618 may conveniently formed at the time of
manufacture or rolled into the shape shown by the user when ready
to receive a medication. Sides 620 and 622 are preferably
constructed of a material that will hold its shape so that conduit
618 may maintain its shape for extended periods.
[0070] After receptacle 602 has been inserted into holding region
606 and holes have been formed in lid 612, the user places his
mouth over an end 624 of device 600 and inhales. In so doing, a gas
stream is created through conduit 618 and passes over lid 612. In
so doing, the powder is extracted from chamber 610 and is drawn
into the flowing gas stream where it is aerosolized and delivered
through end 624 to the patient, as discussed above.
[0071] FIG. 10 illustrates device 600 prior to being fashioned into
the shape shown in FIG. 7. FIG. 10 is provided to illustrate that
device 600 may be conveniently formed by stamping device body 604
from a sheet of material, with the stamping process also forming
depression 609. Sides 620 and 622 may then be rolled to form
conduit 618. Similarly, piercing elements 614 and 616 may be bent
so as to be positioned over depression 609 as shown in FIG. 7.
[0072] As with all the embodiments described herein, conduit 618
may have a variety of shapes. In some embodiments, conduit 618 may
be fashioned so that the gas stream flowing over lid 612 is
maximized during inhalation to facilitate extraction of the powder.
One example of such a configuration is illustrated in FIG. 11 where
sides 620 and 622 have been formed so as to form a pair of conduits
626 and 628. These conduits serve to channel gas streams across lid
612 to facilitate aerosolization. Such an embodiment is
particularly useful with the configuration of piercing elements 614
and 616 which provide access holes on opposing sides of chamber
610.
[0073] Another way to increase the gas flow over the receptacle is
to taper the conduit in the direction of the receptacle. Such an
example is illustrated in FIGS. 12 and 13. These figures illustrate
an aerosolization device 630 that is configured to be used with a
separate receptacle in a manner similar to that previously
described in connection with device 600. However, it will be
appreciated that device 630 could include an integrated receptacle
similar to other embodiments. Device 630 comprises a device body
634 having a holding region 636 and a conduit region 638. Conduit
region 638 includes a conduit 640 that is formed by rolling two
sides 642 and 644 of device body 634. As best shown in FIG. 14,
device body 634 is constructed so that sides 642 and 644 when
rolled together form a tapered conduit. In this way, when the user
inhales from an end 646, the gas flow is accelerated to increase
the flow rate across the receptacle.
[0074] Aerosolization device 630 further includes a pair of
piercing elements 648 and 650 that are configured to pierce holes
within the receptacle lid in a manner similar to that previously
described in connection with device 600. As shown, piercing
elements 648 and 650 include a flat end rather than a pointed end
as with device 600. In this way, an elongate slit is provided when
the piercing elements are forced through the lid. As described in
greater detail hereinafter, each of the inhalation devices
described herein may be provided with a variety of piercing
elements depending on the desired hole size and pattern that is to
be produced within the receptacle lid.
[0075] In the embodiments of FIGS. 7 and 12, the piercing elements
are generally spaced apart from the conduit to facilitate easy
squeezing of the piercing elements to form the access holes. In
some cases, the piercing elements may be provided within the
conduit itself. One such example is illustrated in FIG. 15 where an
aerosolization device 652 is shown. Aerosolization device 652
includes a holding region 654 having a depression 656 for holding a
receptacle in a manner similar to other embodiments. Further,
piercing elements 658 are positioned on either side of depression
656. A conduit 660 extends along the length of device 652, but only
partially along holding region 654 as shown. This configuration
permits piercing elements 658 to be squeezed through the lid of the
receptacle in a manner similar to that described with other
embodiments. As the same time, conduit 660 is formed along the
length of the device to facilitate air flow across the receptacle
lid when extracting and aerosolizing the powdered medicament.
[0076] As previously described, each of the inhalation devices
described herein may employ a variety of piercing elements. Various
non-limiting examples of such piercing elements are illustrated in
FIGS. 16A-16F and are identified by reference numerals 662a-662f.
For example, the piercing elements may have a single point 662a; a
truncated region 662b; a double point 662c, 662d; a curved region
662e; and more than two points 662f. With each of the piercing
elements, the edges may be sharpened or relatively thin to
facilitate piercing of the receptacle lid. Further, it will be
appreciated that each inhalation device may include one or more of
the same and/or different piercing elements so that a variety of
hole sizes and/or patterns may be produced.
[0077] Merely by way of example, some hole patters are illustrated
in FIGS. 17A-17F. As shown, the hole sizes may be semi-circular,
circular, oval, elongate, and the like. Further, the holes may be
positioned at various locations in the receptacle lid. In some
cases, the hole sizes may also be different within the same lid.
For example, the holes may be longitudinally offset and
semi-circular 665a; laterally offset and elongate 665b;
longitudinally offset and laterally elongate 665c; longitudinally
offset and longitudinally elongate 665d; singular 665d; and of
different shapes 665e.
[0078] Further, it will be appreciated that the shape of the
chamber may be varied to facilitate extraction of the powder. As
shown in FIGS. 18A and 18B, a receptacle lid 670 has a straight
edge 672 and two curved edges 674 to facilitate placement of
different hole configurations and locations. Further, it will be
appreciated that other chamber configurations may be produced as
well as other hole shapes and/or sizes and/or locations to
facilitate extraction of the powdered medicament.
[0079] In another version, the pharmaceutical formulation within
the chamber 108, 602 may be accessed by means other than by
piercing the lid. For example, as shown in the version of FIG. 19,
the receptacle 108 may be covered by a lid 700 that may be peeled
away from the chamber 108 to expose the pharmaceutical formulation
within the chamber 108. Such peelable lids are commonly known in
the art. The version of FIG. 19 is substantially the same as the
version of the 3 but with the piercing elements replaced by the
peelable lid 700. Similarly, as shown in FIG. 20, the piercing
elements of the version shown in FIG. 7 can be replaced with a
peelable lid 700 on the removably positionable blister package.
[0080] In a preferred version, the invention provides a system and
method for aerosolizing a pharmaceutical formulation and delivering
the pharmaceutical formulation to the lungs of the user. The
pharmaceutical formulation may comprise powdered medicaments,
liquid solutions or suspensions, and the like, and may include an
active agent.
[0081] The active agent described herein includes an agent, drug,
compound, composition of matter or mixture thereof which provides
some pharmacologic, often beneficial, effect. This includes foods,
food supplements, nutrients, drugs, vaccines, vitamins, and other
beneficial agents. As used herein, the terms further include any
physiologically or pharmacologically active substance that produces
a localized or systemic effect in a patient. An active agent for
incorporation in the pharmaceutical formulation described herein
may be an inorganic or an organic compound, including, without
limitation, drugs which act on: the peripheral nerves, adrenergic
receptors, cholinergic receptors, the skeletal muscles, the
cardiovascular system, smooth muscles, the blood circulatory
system, synoptic sites, neuroeffector junctional sites, endocrine
and hormone systems, the immunological system, the reproductive
system, the skeletal system, autacoid systems, the alimentary and
excretory systems, the histamine system, and the central nervous
system. Suitable active agents may be selected from, for example,
hypnotics and sedatives, psychic energizers, tranquilizers,
respiratory drugs, anticonvulsants, muscle relaxants, antiparkinson
agents (dopamine antagonists), analgesics, anti-inflammatories,
antianxiety drugs (anxiolytics), appetite suppressants,
antimigraine agents, muscle contractants, anti-infectives
(antibiotics, antivirals, antifungals, vaccines) antiarthritics,
antimalarials, antiemetics, anepileptics, bronchodilators,
cytokines, growth factors, anti-cancer agents, antithrombotic
agents, antihypertensives, cardiovascular drugs, antiarrhythmics,
antioxicants, anti-asthma agents, hormonal agents including
contraceptives, sympathomimetics, diuretics, lipid regulating
agents, antiandrogenic agents, antiparasitics, anticoagulants,
neoplastics, antineoplastics, hypoglycemics, nutritional agents and
supplements, growth supplements, antienteritis agents, vaccines,
antibodies, diagnostic agents, and contrasting agents. The active
agent, when administered by inhalation, may act locally or
systemically.
[0082] The active agent may fall into one of a number of structural
classes, including but not limited to small molecules, peptides,
polypeptides, proteins, polysaccharides, steroids, proteins capable
of eliciting physiological effects, nucleotides, oligonucleotides,
polynucleotides, fats, electrolytes, and the like.
[0083] Examples of active agents suitable for use in this invention
include but are not limited to one or more of calcitonin,
erythropoietin (EPO), Factor VIII, Factor IX, ceredase, cerezyme,
cyclosporin, granulocyte colony stimulating factor (GCSF),
thrombopoietin (TPO), alpha-1 proteinase inhibitor, elcatonin,
granulocyte macrophage colony stimulating factor (GMCSF), growth
hormone, human growth hormone (HGH), growth hormone releasing
hormone (GHRH), heparin, low molecular weight heparin (LMWH),
interferon alpha, interferon beta, interferon gamma, interleukin-1
receptor, interleukin-2, interleukin-1 receptor antagonist,
interleukin-3, interleukin-4, interleukin-6, luteinizing hormone
releasing hormone (LHRH), factor IX, insulin, pro-insulin, insulin
analogues (e.g., mono-acylated insulin as described in U.S. Pat.
No. 5,922,675, which is incorporated herein by reference in its
entirety), amylin, C-peptide, somatostatin, somatostatin analogs
including octreotide, vasopressin, follicle stimulating hormone
(FSH), insulin-like growth factor (IGF), insulintropin, macrophage
colony stimulating factor (M-CSF), nerve growth factor (NGF),
tissue growth factors, keratinocyte growth factor (KGF), glial
growth factor (GGF), tumor necrosis factor (TNF), endothelial
growth factors, parathyroid hormone (PTH), glucagon-like peptide
thymosin alpha 1, IIb/IIIa inhibitor, alpha-1 antitrypsin,
phosphodiesterase (PDE) compounds, VLA-4 inhibitors,
bisphosponates, respiratory syncytial virus antibody, cystic
fibrosis transmembrane regulator (CFTR) gene, deoxyreibonuclease
(Dnase), bactericidal/permeability increasing protein (BPI),
anti-CMV antibody, 13-cis retinoic acid, macrolides such as
erythromycin, oleandomycin, troleandomycin, roxithromycin,
clarithromycin, davercin, azithromycin, flurithromycin,
dirithromycin, josamycin, spiromycin, midecamycin, leucomycin,
miocamycin, rokitamycin, andazithromycin, and swinolide A;
fluoroquinolones such as ciprofloxacin, ofloxacin, levofloxacin,
trovafloxacin, alatrofloxacin, moxifloxicin, norfloxacin, enoxacin,
grepafloxacin, gatifloxacin, lomefloxacin, sparfloxacin,
temafloxacin, pefloxacin, amifloxacin, fleroxacin, tosufloxacin,
prulifloxacin, irloxacin, pazufloxacin, clinafloxacin, and
sitafloxacin, aminoglycosides such as gentamicin, netilmicin,
paramecin, tobramycin, amikacin, kanamycin, neomycin, and
streptomycin, vancomycin, teicoplanin, rampolanin, mideplanin,
colistin, daptomycin, gramicidin, colistimethate, polymixins such
as polymixin B, capreomycin, bacitracin, penems; penicillins
including penicillinase-sensitive agents like penicillin G,
penicillin V, penicillinase-resistant agents like methicillin,
oxacillin, cloxacillin, dicloxacillin, floxacillin, nafcillin; gram
negative microorganism active agents like ampicillin, amoxicillin,
and hetacillin, cillin, and galampicillin; antipseudomonal
penicillins like carbenicillin, ticarcillin, azlocillin,
mezlocillin, and piperacillin; cephalosporins like cefpodoxime,
cefprozil, ceftbuten, ceftizoxime, ceftriaxone, cephalothin,
cephapirin, cephalexin, cephradrine, cefoxitin, cefamandole,
cefazolin, cephaloridine, cefaclor, cefadroxil, cephaloglycin,
cefuroxime, ceforanide, cefotaxime, cefatrizine, cephacetrile,
cefepime, cefixime, cefonicid, cefoperazone, cefotetan,
cefmetazole, ceftazidime, loracarbef, and moxalactam, monobactams
like aztreonam; and carbapenems such as imipenem, meropenem,
pentamidine isethiouate, albuterol sulfate, lidocaine,
metaproterenol sulfate, beclomethasone diprepionate, triamcinolone
acetamide, budesonide acetonide, fluticasone, ipratropium bromide,
flunisolide, cromolyn sodium, ergotamine tartrate and where
applicable, analogues, agonists, antagonists, inhibitors, and
pharmaceutically acceptable salt forms of the above. In reference
to peptides and proteins, the invention is intended to encompass
synthetic, native, glycosylated, unglycosylated, pegylated forms,
and biologically active fragments and analogs thereof.
[0084] Active agents for use in the invention further include
nucleic acids, as bare nucleic acid molecules, vectors, associated
viral particles, plasmid DNA or RNA or other nucleic acid
constructions of a type suitable for transfection or transformation
of cells, i.e., suitable for gene therapy including antisense.
Further, an active agent may comprise live attenuated or killed
viruses suitable for use as vaccines. Other useful drugs include
those listed within the Physician's Desk Reference (most recent
edition).
[0085] The amount of active agent in the pharmaceutical formulation
will be that amount necessary to deliver a therapeutically
effective amount of the active agent per unit dose to achieve the
desired result. In practice, this will vary widely depending upon
the particular agent, its activity, the severity of the condition
to be treated, the patient population, dosing requirements, and the
desired therapeutic effect. The composition will generally contain
anywhere from about 1% by weight to about 99% by weight active
agent, typically from about 2% to about 95% by weight active agent,
and more typically from about 5% to 85% by weight active agent, and
will also depend upon the relative amounts of additives contained
in the composition. The compositions of the invention are
particularly useful for active agents that are delivered in doses
of from 0.001 mg/day to 100 mg/day, preferably in doses from 0.01
mg/day to 75 mg/day, and more preferably in doses from 0.10 mg/day
to 50 mg/day. It is to be understood that more than one active
agent may be incorporated into the formulations described herein
and that the use of the term "agent" in no way excludes the use of
two or more such agents.
[0086] The pharmaceutical formulation may comprise a
pharmaceutically acceptable excipient or carrier which may be taken
into the lungs with no significant adverse toxicological effects to
the subject, and particularly to the lungs of the subject. In
addition to the active agent, a pharmaceutical formulation may
optionally include one or more pharmaceutical excipients which are
suitable for pulmonary administration. These excipients, if
present, are generally present in the composition in amounts
ranging from about 0.01% to about 95% percent by weight, preferably
from about 0.5 to about 80%, and more preferably from about 1 to
about 60% by weight. Preferably, such excipients will, in part,
serve to further improve the features of the active agent
composition, for example by providing more efficient and
reproducible delivery of the active agent, improving the handling
characteristics of powders, such as flowability and consistency,
and/or facilitating manufacturing and filling of unit dosage forms.
In particular, excipient materials can often function to further
improve the physical and chemical stability of the active agent,
minimize the residual moisture content and hinder moisture uptake,
and to enhance particle size, degree of aggregation, particle
surface properties, such as rugosity, ease of inhalation, and the
targeting of particles to the lung. One or more excipients may also
be provided to serve as bulking agents when it is desired to reduce
the concentration of active agent in the formulation.
[0087] Pharmaceutical excipients and additives useful in the
present pharmaceutical formulation include but are not limited to
amino acids, peptides, proteins, non-biological polymers,
biological polymers, carbohydrates, such as sugars, derivatized
sugars such as alditols, aldonic acids, esterified sugars, and
sugar polymers, which may be present singly or in combination.
Suitable excipients are those provided in WO 96/32096, which is
incorporated herein by reference in its entirety. The excipient may
have a glass transition temperatures (Tg) above about 35.degree.
C., preferably above about 40.degree. C., more preferably above
45.degree. C., most preferably above about 55.degree. C.
[0088] Exemplary protein excipients include albumins such as human
serum albumin (HSA), recombinant human albumin (rHA), gelatin,
casein, hemoglobin, and the like. Suitable amino acids (outside of
the dileucyl-peptides of the invention), which may also function in
a buffering capacity, include alanine, glycine, arginine, betaine,
histidine, glutamic acid, aspartic acid, cysteine, lysine, leucine,
isoleucine, valine, methionine, phenylalanine, aspartame, tyrosine,
tryptophan, and the like. Preferred are amino acids and
polypeptides that function as dispersing agents. Amino acids
falling into this category include hydrophobic amino acids such as
leucine, valine, isoleucine, tryptophan, alanine, methionine,
phenylalanine, tyrosine, histidine, and proline.
Dispersibility-enhancing peptide excipients include dimers,
trimers, tetramers, and pentamers comprising one or more
hydrophobic amino acid components such as those described
above.
[0089] Carbohydrate excipients suitable for use in the invention
include, for example, monosaccharides such as fructose, maltose,
galactose, glucose, D-mannose, sorbose, and the like;
disaccharides, such as lactose, sucrose, trehalose, cellobiose, and
the like; polysaccharides, such as raffinose, melezitose,
maltodextrins, dextrans, starches, and the like; and alditols, such
as mannitol, xylitol, maltitol, lactitol, xylitol sorbitol
(glucitol), pyranosyl sorbitol, myoinositol and the like.
[0090] The pharmaceutical formulation may also include a buffer or
a pH adjusting agent, typically a salt prepared from an organic
acid or base. Representative buffers include organic acid salts of
citric acid, ascorbic acid, gluconic acid, carbonic acid, tartaric
acid, succinic acid, acetic acid, or phthalic acid, Tris,
tromethamine hydrochloride, or phosphate buffers.
[0091] The pharmaceutical formulation may also include polymeric
excipients/additives, e.g., polyvinylpyrrolidones, derivatized
celluloses such as hydroxymethylcellulose, hydroxyethylcellulose,
and hydroxypropylmethylcellulose, Ficolls (a polymeric sugar),
hydroxyethylstarch, dextrates (e.g., cyclodextrins, such as
2-hydroxypropyl-.beta.-cyclodextrin and
sulfobutylether-.beta.-cyclodextrin), polyethylene glycols, and
pectin.
[0092] The pharmaceutical formulation may further include flavoring
agents, taste-masking agents, inorganic salts (for example sodium
chloride), antimicrobial agents (for example benzalkonium
chloride), sweeteners, antioxidants, antistatic agents, surfactants
(for example polysorbates such as "TWEEN 20" and "TWEEN 80"),
sorbitan esters, lipids (for example phospholipids such as lecithin
and other phosphatidylcholines, phosphatidylethanolamines), fatty
acids and fatty esters, steroids (for example cholesterol), and
chelating agents (for example EDTA, zinc and other such suitable
cations). Other pharmaceutical excipients and/or additives suitable
for use in the compositions according to the invention are listed
in "Remington: The Science & Practice of Pharmacy", 19.sup.th
ed., Williams & Williams, (1995), and in the "Physician's Desk
Reference", 52.sup.nd ed., Medical Economics, Montvale, N.J.
(1998), both of which are incorporated herein by reference in their
entireties.
[0093] "Mass median diameter" or "MMD" is a measure of mean
particle size, since the powders of the invention are generally
polydisperse (i.e., consist of a range of particle sizes). MMD
values as reported herein are determined by centrifugal
sedimentation, although any number of commonly employed techniques
can be used for measuring mean particle size. "Mass median
aerodynamic diameter" or "MMAD" is a measure of the aerodynamic
size of a dispersed particle. The aerodynamic diameter is used to
describe an aerosolized powder in terms of its settling behavior,
and is the diameter of a unit density sphere having the same
settling velocity, generally in air, as the particle. The
aerodynamic diameter encompasses particle shape, density and
physical size of a particle. As used herein, MMAD refers to the
midpoint or median of the aerodynamic particle size distribution of
an aerosolized powder determined by cascade impaction.
[0094] In one version, the powdered formulation for use in the
present invention includes a dry powder having a particle size
selected to permit penetration into the alveoli of the lungs, that
is, preferably 10 .mu.m mass median diameter (MMD), preferably less
than 7.5 .mu.m, and most preferably less than 5 .mu.m, and usually
being in the range of 0.1 .mu.m to 5 .mu.m in diameter. The
delivered dose efficiency (DDE) of these powders may be greater
than 30%, more preferably greater than 40%, more preferably greater
than 50% and most preferably greater than 60% and the aerosol
particle size distribution is about 1.0-5.0 .mu.m mass median
aerodynamic diameter (MMAD), usually 1.5-4.5 .mu.m MMAD and
preferably 1.5-4.0 .mu.m MMAD. These dry powders have a moisture
content below about 10% by weight, usually below about 5% by
weight, and preferably below about 3% by weight. Such powders are
described in WO 95/24183, WO 96/32149, WO 99/16419, and WO
99/16422, all of which are all incorporated herein by reference in
their entireties.
[0095] Hence, the inhalers of the invention provide a number of
significant advantages. For example, the invention takes advantage
of the benefits offered by the pulmonary delivery of dry powdered
drugs or vaccines and provides unique ways to accomplish the
pulmonary delivery. The advantages of using powders over liquids
include greater dispersion reaching distal (alveolar) regions of
the lung, the ability to confer mucosal and systemic immunity, and
the promising delivery of proteins and polypeptides. Further,
powders have other advantages over liquid vaccines including the
absence of cold-chain, simpler administration, lower transportation
costs, lower likelihood of infection, and the absence of
preservatives. In terms unique ways to accomplish pulmonary
delivery, the invention in some embodiments maximizes the
utilization of the packaging of the powdered medicament such that
the packaging receptacle stores the unit dosage and inexpensively
forms an inhaler that is used to administer it. This in turn lowers
the cost of production, shipping and storage. In other embodiments,
the inhalation device may be reused with relatively inexpensive
receptacles.
[0096] While the principles of the invention have been described
above in connection with specific apparatuses and methods, it is to
be clearly understood that this description is made only by way of
example and not as limitation on the scope of the invention.
* * * * *