# Patent

## Title
Moisture resistant container systems for rapidly bioavailable dosage forms

## Abstract

Provided are rapidly bioavailable solid oral dosage forms of acute pain medications, and moisture resistant packaging that enables the formulation of such rapidly bioavailable dosage forms.

## Background
FIELD OF THE INVENTION
The present invention concerns rapidly bioavailable solid oral dosage forms and moisture resistant packaging that enables the formulation of such dosage forms. The invention is particularly concerned with packaging systems for acute pain medications.
BACKGROUND
The bioavailability of pharmaceutical products is a critical concern in rational drug design. The pharmacokinetics of a drug, which measure the time it takes a drug to become bioavailable and its concentration profile in serum over time, can have a significant effect on the effectiveness of a drug, as well as its safety. Pharmacokinetics are of particular concern for drugs that require an immediate onset of action, such as drugs used in the treatment of acute pain.
Various factors can influence the time it takes for a drug to become bioavailable in therapeutically effective concentrations. For orally administered solid dosage forms, some of the most important parameters include the disintegration/dissolution time of the drug, the stability and solubility of the molecule in the gastrointestinal tract, and first pass metabolism, to mention just a few. For some drugs such as potassium diclofenac the pH of the formulation can also affect its bioavailability. For example, it is known that diclofenac potassium has a tendency to precipitate in an acidic environment, thereby making it less bioavailable. This problem is highlighted in bioavailability studies of Cataflam, a commercially marketed form of diclofenac potassium, which exhibits two concentration peaks in the bloodstream when orally ingested.
When rapid bioavailability is desired, preferred modes of administration include parenteral, inhalation, mucosal and buccal administration. Tablets and capsules are generally available only in immediate release, extended release, and delayed release formats, and are not typically employed when rapid bioavailability is desired because of the time it takes for the dosage form to dissolve, and the resulting delay in gastrointestinal absorption. A novel delivery system for orally delivering diclofenac in a rapidly bioavailable tablet has been proposed in PCT/EP97/02709 (published as WO 97/44023), but solid oral dosage forms based on this type of platform are clearly the exception and not the rule.
OBJECTS OF THE INVENTION
It is an object of the present invention to increase the rate of bioavailability of solid oral dosage forms, such as tablets and capsules.
Another object of the present invention is to increase the bioavailability of acute pain medications.
It is another object to provide packaging for rapidly bioavailable solid oral dosage forms that preserves and enhances their bioavailability, stability and physical handling properties.
SUMMARY OF THE INVENTION
It has unexpectedly been discovered that diclofofenac potassium tablets, particularly those formulated for rapid disintegration and dissolution, can be made to disintegrate and dissolve faster by limiting their moisture uptake during storage, and allowing them to become harder over time. Whereas one would normally expect a tablet to disintegrate faster as it softens, the inventors have discovered that diclofenac potassium tablets disintegrate slower when the tablet softens, and that the tablet will not become softer if it is protected from moisture. In other words, the inventors have discovered that one can make diclofenac potassium tablets disintegrate faster, and hence be more rapidly bioavailable, simply by preventing them from absorbing moisture during storage. These results are counterintuitive and support the patentability of the present invention.
Therefore, in one embodiment the invention provides a method of packaging a rapidly bioavailable diclofenac potassium tablet comprising: (a) formulating a potassium diclofenac tablet for rapid bioavailability; and (b) packaging said tablet in a moisture resistant bottle that prevents said tablet from absorbing more than 2.0 wt. % moisture in three months when stored at 40° C. and 75% relative humidity. In another embodiment, the invention provides a method for treating a patient suffering from acute pain by administering the tablets packaged according to the present invention. Tablets are formulated for rapid bioavailability in the sense that they are specially formulated to quickly disintegrate or dissolve rapidly when ingested in the stomach, for example in less than ten or even five minutes.
Additional advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.


DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Definitions
As used in the specification and claims, the singular forms a, an and the include plural references unless the context clearly dictates otherwise. For example, the term a pharmaceutical excipient may refer to one or more pharmaceutical excipients for use in the presently disclosed formulations and methods.
USP means the United States Pharmacopeia and National Formulary (USP 28-NF 23). Rockville, Md.: United States Pharmacopeia Convention; 2004, unless stated to the contrary. USP 28<701> refers to physical test 701, disintegration, contained on pages 2411-2412 of the USP. USP 28 <711> refers to physical test 711, dissolution, contained on pages 2412-2414 of the USP.
A dosage form, as used herein, refers to a formulation that is ready for administration to a subject. As used herein, it specifically refers to solid dosage forms, including, but not limited to, tablets, capsules and powders. Tablets are most preferably employed, though it will be understood that other solid oral dosage forms can also benefit from the teachings of the present invention. An “intact” dosage form refers to a dosage form which is ingested in the form it is provided. Intact dosage forms are therefore to be distinguished from orally disintegrating tablets which disintegrate in the mouth before being ingested, or effervescent tablets which are dissolved in water before being ingested. In preferred embodiments of this invention, the dosage form is a tablet, and the tablets are ingested in an intact form.
Cmax refers to the maximum plasma concentration of a drug following oral administration of the solid oral dosage form to patients. Normalized Cmax refers to the value obtained by dividing Cmax into the dosage strength of the solid oral dosage form.
AUC refers to the area under the curve that tracks the plasma concentration (ng/ml) of a drug over a given time following the oral administration of the solid oral dosage form to patients. AUC can be measured from 0 to 12 hours or from 0 to 24 hrs following the administration and in these cases are referred to as AUC ((0-12) )or AUC ((0-24)), respectively.
Normalized AUC is obtained by dividing the AUC into the dosage strength of the solid oral dosage form of the drug. For example, if the AUC ((0-12)) is 160 hr·ng/ml following the oral administration of a solid oral dosage form containing 200 mg of active ingredient, the normalized AUC ((0-12) )is 0.8 hr·ng/ml/mg.
An excipient is considered “freely soluble” in the context of this application if the excipient meets the requirements for either “freely soluble” or “very soluble” excipients set forth in the United States Pharmacopeia. Therefore, an excipient that is “freely soluble” in water is an excipient for which 10 or fewer parts of water are required to dissolve one part of the excipient material at 20° C.
Diclofenac is chemically described as [(2,6-dichloro-anilino)-2-phenyl]-2-acetic acid, and is represented by the following chemical structure:




When used herein, the term diclofenac means the acetic acid form of diclofenac, and any of its pharmaceutically acceptable salts. Therefore, when a weight ratio is given, it will be understood that the ratio refers to the relative weight of diclofenac acid in the ratio, and the relative weight of diclofenac potassium (or other salt) in the ratio.

Acute pain conditions include pain that is temporary or passing, in contrast to chronic pain that is recurring or constant. Acute pain conditions thus include pain deriving from soft tissue disorders such as sprains and strains, soft tissue lascerations, migraine attacks, and other painful conditions such as renal colic, acute gout, dysmenorrhoea, and following invasive surgical procedures. While the invention is particularly useful in the treatment of acute pain, it will also be understood that the compositions of the present invention are also useful in chronic pain conditions. Examples of chronic pain conditions include rheumatoid arthritis, osteoarthritis, and ankylosing spondylitis; and periarticular disorders such as bursitis and tendonitis.
Reducing Moisture Uptake to Improved Bioavailability
As discussed above, the invention relates to moisture resistant packaging, and the use of moisture resistant packaging to decrease the disintegration/dissolution time of diclofenac potassium dosage forms. In one embodiment the invention provides a method of packaging a rapidly bioavailable diclofenac potassium tablet comprising: (a) formulating a solid oral potassium diclofenac dosage form (preferably a tablet) for rapid bioavailability; and (b) packaging said dosage form in a moisture resistant bottle that prevents said dosage form from absorbing more than 4.0 3.0, 2.0 or even 1.0 wt. % moisture in three months when stored at 40° C. and 75% relative humidity. In another embodiment the invention relates to methods of using rapidly bioavailable diclofenac potassium dosage forms that are packaged in moisture resistant bottles, and provides a method of treating acute pain comprising: (a) providing a rapidly bioavailable solid oral potassium diclofenac dosage form (preferably a tablet) in a moisture resistant bottle that prevents said dosage form from absorbing more than 2.0 wt. % moisture in three months when stored at 40° C. and 75% relative humidity; and (b) administering said diclofenac potassium dosage form to a patient suffering from acute pain.
Various methods can be used to ensure that the tablets do not absorb more moisture than is called for by the present invention. A hermetic seal on the bottle is perhaps most important, which could constitute nothing more than a foil or other laminar seal at the opening to the bottle. A dessicant pouch, such as a silica gel pouch, may also be used for absorbing any moisture that does enter the bottle.
The dosage forms are rapidly bioavailable in the sense that they are specially formulated to disintegrate/dissolve quickly when ingested into the stomach. Numerous means are available for promoting the disintegration or dissolution of diclofenac tablets or capsules, including, for example, the shell used for the capsule, formulation excipients such as disintegrants, pH buffers, effervescing agents, freely soluble excipients, hygroscopic excipients, surfactants that promote the disintegration and dissolution of the dosage form and the active molecule, and counterions of the drug molecule. The dosage forms of the present invention are typically characterized by an inverse relationship between disintegration rate and moisture uptake. The hardness of the tablets is typically greater than about 4.1 kp, and more typically greater than about 6.0 or 8.0 kp.
Disintegration times for the dosage forms of the present invention, when tested according to USP 28 <701>, are preferably less than about 20 minutes, 15 minutes, 10 minutes, 5 minutes, or even 4 minutes, and greater than about 1, 2 or 3 minutes, most preferably from about 3 to about 5 minutes. Dissolution times for the dosage forms of the present invention, when tested according to USP 28 <711>, based on the time it takes to dissolve 90 or 95 wt. % of the drug substance, are preferably less than about 20 minutes, 15 minutes, 10 minutes, 5 minutes, or even 3 minutes, and greater than about 1 or 2 minutes. In a preferred embodiment, the dissolution profile for the dosage forms of the present invention is in accordance with the following specification: not less than 85, 90 or 95% dissolved after 15 minutes in simulated intestinal fluid (e.g. water) at pH=6.8
Mean tmax attained by the dosage forms of the present invention is preferably less than about 40 minutes, 35 minutes, 30 minutes, 25 minutes or 20 minutes, and greater than about 5 minutes, 10 minutes or 15 minutes. Mean tmax is preferably from about from about 5 to about 30 minutes, from about 10 to about 30 minutes, or from about 13 to about 27 minutes. The corresponding coefficient of variation for most diclofenac tablets is normally in the range of 70-90%, which means that the Tmax is strongly variable and dependent on the physical characteristics of the patient (Physicians' Desk Reference, 52 edition, 1998, pag. 1831)). In contrast, the inter-subject coefficient of variability for said tmax for dosage forms of the present invention is preferably less than about 80, 75, 60, 50, 49, 46, 40, 35, 30% or 25%.
Mean Cmax attained by the formulations of the present invention, for a 50 mg. formulation, is preferably greater than about 1400 ng/ml (0.028 liter−1), 1500 ng/ml (0.03 liter−1), 1600 ng/ml (0.032 liters−1) or 1700 ng/ml (0.034 liter−1), and less than about 2500 ng/ml (0.05 liter−1) or 2300 ng/ml (0.046 liter−1). A preferred range is 1500-2500, 1700-2500, or 1700-2300 ng/ml for a 50 mg. formulation. The inter-subject coefficient of variability for said Cmax preferably is less than about 70, 60, 50, 45 or 40%. In contrast to other commercially marketed diclofenac formulations, the formulations of the present invention preferably display only one meaningful peak blood concentration after ingestion. Compare FIGS. 3 and 4.
Preferred Cmax and tmax ranges for various dosage forms of the invention are set forth below in Table A:










TABLE A







Mean Cmax (ng/ml)
Mean tmax (min)


















50 mg.
1500-2100; 1750-2000;
5-35; 10-30;


diclofenac tablet
1600-1900
12-25; 15-20


or capsule


25 mg.
700-1150; 750-950;
5-35; 10-30;


diclofenac tablet
800-900; 850-1050;
15-30; 15-25


or capsule
900-1000


12.5 mg.
350-650; 400-600;
5-35; 10-30;


diclofenac tablet
450-550
15-25


or capsule









In one embodiment the rapid bioavailability is achieved by incorporating in the dosage form means for generating a gaseous and alkaline environment when orally ingested into the stomach. Suitable means for generating a gaseous and alkaline environment that is not harmful to the gastrointestinal mucosa include, but are not limited to, sodium carbonate, potassium carbonate, sodium bicarbonate, potassium bicarbonate, calcium carbonate, magnesium carbonate, sodium glycine carbonate, disodium hydrogen phosphate, sodium dihydrogen phosphate, and mixtures thereof. Suitable gas generating means are not limited to those which are based upon a reaction which forms carbon dioxide. Reactants which evolve oxygen or other gases and which are safe for human consumption are also considered within the scope of the present invention.
The dosage form also preferably includes a hygroscopic excipient which may double as the means for generating an alkaline and gaseous environment. Products that at relative humidity of 80% (RH=80%) and 25° C. demonstrate low water absorption ability (lower than 1% during 24 hrs) have a hygroscopic point below 80% (j<80% RH) and are not considered hygroscopic within the meaning of this invention. A hygroscopic excipient could thus have the ability to absorb greater than about 1 wt. %, 3 wt. %, 5 wt. % or 7 wt. % moisture within a twenty four hour period in a humidity chamber maintained at 80% RH and 25° C. Alternatively, a hygroscopic excipient could be defined as an excipient that is able to absorb greater than about 0.75 wt. %, 1 wt. %, 2 wt. %, 3 wt. % or 4 wt. % moisture within a twenty four hour period in a humidity chamber maintained at 60% RH and 25° C. Various hygroscopic excipients could be used in practicing the present invention, including various water-soluble hygroscopic polyhydroxy compounds or esters thereof such as glycerol and its mono- and diesters derived from low molecular weight carboxylic acids, e.g., monoacetin and diacetin (respectively, glyceryl monoacetate and glyceryl diacetate), ethylene glycol, diethylene glycol, triethylene glycol, 1,3-propanediol, trimethylolethane, trimethylolpropane, pentaerythritol, sorbitol, and the like. Other examples of hygroscopic or water-swellable materials include pharmaceutically acceptable disintegrants such as crosslinked polyvinylpyrrolidone, starch NF, and hygroscopic. In a preferred embodiment the hygroscopic excipient is potassium bicarbonate or sodium bicarbonate.
The means for generating a gaseous and alkaline environment and/or hygroscopic excipients are typically employed in a weight ratio relative to the diclofenac of greater than about 1:5, 2:5, 2:1, 3:1 or 5:1. If desired, an upper limit on the buffer: diclofenac ratio can be placed at about 20:1, 10:1, 5:1, 1:1, 4:5 or 3:5. Ranges can be selected from any two of the foregoing values that are mathematically possible. In a preferred embodiment, the buffer:diclofenac weight ratio ranges from about 1:5 to about 4:5. As a total percentage of the dosage form, the means for generating a gaseous and alkaline environment preferably makes up greater than about 5, 7 or 9 wt. % of the dosage form formulation, and less than about 25, 20 or 15 wt. % of the formulation. The means preferably yields a pH greater than about 7.0, 7.5, 7.8 or 8.0, and less than about 9.2, 9.0, 8.8 or 8.5 when the dosage form is mixed with 50 ml of water at 25 degrees Celsius. Alternatively, the means preferably yields a pH greater than about 6.8, 7.0, 7.2, or 7.5, and less than about 8.8, 8.5, 8.3 or 8.0 when the dosage form is mixed with 200 ml of water at 25 degrees Celsius.
Alternatively, the dosage form itself can be characterized by its hygroscopicity. In the present invention, dosage forms that at relative humidity of 80% (RH=80%) demonstrate low water absorption ability (lower than 1% during 24 hrs) have a hygroscopic point below 80% (j<80% RH) and are not hygroscopic at normal conditions. A hygroscopic dosage form could thus have the ability to absorb greater than about 1 wt. %, 1.25 wt. %, 1.5 wt. % or 2 wt. % moisture within a twenty four hour period in a humidity chamber maintained at 80% RH and 25° C. Alternatively, a hygroscopic dosage form could be defined as a dosage form that is able to absorb greater than about 0.50 wt. %, 0.75 wt. %, 1 wt. %, 1.25 wt. %, or 1.5 wt. % moisture within a twenty four hour period in a humidity chamber maintained at 60% RH and 25° C.
Tests performed on 50 mg. diclofenac potassium tablets of the present invention maintained at 25° C. and 60% RH over twenty four hours showed an increase in KF (% water) from 1.995% (at time zero) to 3.456% (after 24 hours). Tests performed on 50 mg. diclofenac potassium capsules of the present invention maintained at 25° C. and 60% RH over twenty four hours showed an increase in KF (% water) from 1.905% (at time zero) to 2.93% (after 24 hrs.). The final dosage form will not typically contain greater than about 5 wt. % water, initially or after 1, 2 or 3 years of storage.
The dosage form can also be formulated to be rapidly bioavailable by incorporating at least 20 wt. %, 30 wt. %, 40 wt. %, 50 wt. %, or 60 wt. % of excipients that are freely soluble in water. An excipient is considered freely soluble in the context of this application if 1 part of excipient is soluble in 1-10 parts of water at 20° C. Examples of freely soluble excipients include mannitol, dextrates (i.e. a purified mixture of saccharides resulting from the controlled enzymatic hydrolysis of starch), dextrin, dextrose, fructose, lactilol, lactose anhydrous, sorbitol, sucrose, and compressible sugar. Of these, mannitol and lactilol are particularly preferred due to their beneficial non-hygroscopic properties, which improves their processability and handling during the manufacturing process. In a preferred embodiment the dosage form will comprise from about 30 to about 80 wt. % of the combined hygroscopic diluent and freely soluble diluent, from about 35 to about 75 wt. % of the combined hygroscopic diluent and freely soluble diluent, or from about from about 40 to about 70 wt. % of the combined hygroscopic diluent and freely soluble diluent. In addition, the hygroscopic diluent and freely soluble excipient will preferably be present in a weight ratio of from about 1:20 to about 5:1, from about 1:10 to about 3:1, from about 1:8 to about 1:1, from about 1:8 to about 1:2, or from about 1:4 to about 1:1.
Yet another way to render the dosage forms rapidly bioavailable is to incorporate a surfactant that aids in the solubility of the dosage form, such as sodium lauryl sulfate. Preferred surfactants will have an HLB value of at least 10 or 12, and preferably at least about 14 or 15. An upper bound can also be placed on the HLB of the surfactant, preferably of 60, 50 or 40. In certain preferred embodiments, the HLB value of the surfactant is from about 15 to 60, and in further embodiments the HLB is most preferably from about 20 to about 50. Suitable pharmaceutically-acceptable anionic surfactants include, for example, those containing carboxylate, sulfonate, and sulfate ions. The most common cations associated with these surfactants are sodium, potassium, ammonium and triethanolamine. The chain length of the fatty acids typically range from 12 to 18. Although a large number of alkyl sulfates are available as surfactants, one particularly preferred surfactant is sodium lauryl sulfate, which has an HLB value of about 40. Other suitable wetting agents include glyceryl monooleate, sorbitan ester, docusate sodium, and cetrimide.
A preferred class of acute pain medications for use in the present invention are non-steroidal anti-inflammatory drugs including, among others, fenamic acid derivatives, indene derivatives, and ibufenac derivatives. Csàky and Barnes in “Cutting's Handbook of Pharmacology,” Appleton-Century-Crofts, Norwalk, CN (1984). Fenamic acid derivatives are broadly classified as o-anilino derivatives of benzoic, phenylacetic, and nicotinic acids and are defined by Csàky and Barnes as including flufenemic acid, mefenamic acid, meclofenamic acid, clonixeril, clonixin, flunixin, and diclofenac, including the pharmaceutically acceptable salts thereof. Indene derivatives generally are acetic acid, propionic acid, and benzoic acid derivatives containing a pyrrole (or a pyrazole, pyrroline or pyrrolidine) ring and are defined by Csàky and Barnes as including indomethacin, carprofen, etodolac, fendosal, indoprofen, prodolic acid, sermetacin, zidometacin, and zomeprirac, including the pharmaceutically acceptable salts thereof. Compounds not so classified by Csàky and Barnes but related in being acetic acid, propionic acid, or benzoic acid, derivatives and here so classified include tolmetin, sulinac, cicloprofen, and cinchophen, including the pharmaceutically acceptable salts thereof. Ibufenac derivatives are acetic and propionic acid derivatives bearing a substituted aromatic hydrocarbon ring, such as phenyl or naphthyl, and are defined by Csàky and Barnes as including iflunisal, fenoprofen, ibuprofen, naproxen, alclofenac, amfenac, cliprofen, fenclofenac, fenclorac, fluprofen, ketoprofen, naproxol, fenbufen, and ibufenac, including the pharmaceutically acceptable salts thereof.
Diclofenac acid and its pharmaceutically acceptable salts are a particularly preferred acute pain medication, especially diclofenac potassium. Other pharmaceutically acceptable salts include those of sodium and other alkali and alkaline earth metals, or salts of organic nature, such as the salts of basic amino acids, such as lysine, arginine and ornithine. In a preferred embodiment, 10-60 mg. or 50 mg. of diclofenac potassium is used in the final dosage form, although other amounts could be used including 12.5, 25, 37.5, 75 or 100 mg. The diclofenac preferably has a loss on drying of not less than 0.5%, and an average particle size of greater than 100 microns, and less than 400 microns.
EXAMPLES
Example 1
Tablet Core Formulations
Uncoated diclofenac tablets containing 50 mg. of diclofenac potassium were prepared based on the formulations given in Table 1 below. Formulations were prepared using alcoholic granulation (Tablet C) and direct compression (Tablet B).











TABLE 1






Tablet C
Tablet B




Names of
(alcoholic
(direct


ingredients
granulation)
compression)
Function
Standard



















Active






ingredients


Diclofenac
50 mg.*
50 mg
Active
Eur. Ph.


potassium


ingredient


Tablet cores


excipients


Potassium
22
22
Buffering agent
Eur. Ph.


hydrogen


carbonate


Mannitol
50
119.9
Diluent and
Eur. Ph.





disintegrating





agent


Maize starch
25
/
Binder diluent
Eur. Ph.


Methocel A4C
0.2
/
Thichener
Eur. Ph.


Crospovidone
1.0
6.0
Binder
Eur. Ph.


Sodium lauryl
0.1
0.1
Solubilizing
Eur. Ph.


sulphate


agent


Magnesium
4.5
2.0
Lubricant agent
Eur. Ph.


stearate


Ultramyl
2.5
/
Lubricant agent
Eur. Ph.


Aerosil
1.0
/
Lubricant agent
Eur. Ph.


Total weight
156.3
200.0 mg





*Units are in milligrams unless otherwise specified.






Example 2
Stability Testing
Stability tests were conducted in various blister packaging materials on the tablet cores (Tablet B and Tablet C), and on Tablet B tablets coated with an aqueous polymer coating suspension (Tablet BA) and an alcoholic polymer coating solution (Tablet BB). Stability testing was restricted to three different blister types. The properties of the forming and lidding films used in the three blister materials tested are as follows:

    
    
        PVDC-coated PVC and hard aluminum (25 μm, coated on the underside with a vinyl lacquer) are the materials of the forming film and the lidding part of the tested blister 1, respectively. The thickness of the PVDC coat is 40 μm while that of the PVC film is 250 μm.
        PVDC-coated PVC and hard aluminum (25 μm, coated on the underside with a vinyl lacquer) are the materials of the forming film and the lidding part of the tested blister 2, respectively. The thickness of the PVDC coat is 80 μm while that of the PVC film is 250 μm.
        OPA/Al/PVC and hard aluminum (25 μm, coated on the underside with a vinyl lacquer) are the materials of the forming film and the lidding part of the tested blister 3, respectively. Nylon (Oriented Polyamide)-Aluminum-PVC (OPA/Al/PVC) is a laminate, which consists of 25 μm OPA/45 μm aluminum/60 μm PVC.
    
    


An appropriate quantity of tablet cores (Tablets B and C) and coated tablets (Tablets BA and BB), original packaging (blisters 1-3) was stored in Weiss-Enet climatic chambers for six months under the following conditions of temperature and relative humidity:














Temperature (° C.)
Relative humidity (±1%)









25
60



30
60



40
75










Samples were withdrawn at suitable intervals and subjected to testing for Diameter, thickness, Hardness, Weight, Disintegration time in water (37° C.), Water content, Dissolution buffered ph 7.5 medium, and Assay. The measurements were performed on six tablet cores or coated tablets taken at random in all instances, and the average values were recorded. The results are given in Tables 2-7 below.







TABLE 2







Influence of packaging material (blisters 1, 2 and 3) on the stability of Tablets B and C stored at 25° C. (RH = 60%)a
















Tablet
Tablet
Tablet B
Tablet B
Tablet
Tablet C
Tablet C
Tablet C



Bb
Blister 1c
Blister 2
Blister 3
Cd
Blister 1c,e
Blister 2c
Blister 3e






















Time
3
6
3
6
3
6
Time
3
6
3
6
3
6


Tests
zero
months
months
months
months
months
months
zero
months
months
months
months
months
months
























Diameterf
7.0
7.0
/
7.1
7.1
7.0
7.1
7.0
7.0
/
7.0
/
7.0
/


(mm)


Thicknessf
4.4
4.4
/
4.4
4.5
4.4
4.4
3.5
3.6
/
3.5
/
3.5
/


(mm)


Hardnessf
71
65
/
65
63
71
74
31
24
/
25
/
32
/


(N)


Weight
198
201
/
200
199
199
198
154
157
/
155
/
155
/


(mg)


Water
2.4
3.2
/
2.8
2.7
2.6
2.5
3.5
3.5
/
5.0
/
4.2
/


contentg


(%)


Disintegration
2:50
6:12
/
3:43
3:56
2:33
2:33
3:05
2:28
/
2:23
/
2:12
/


timeh


(min.:sec.)


Dissolutioni
93
96
/
98
96
95
99
95
96
/
98
/
97
/


after 20


min. (%)


Assayj
96.6
95.6
/
96.0
96.2
99.8
99.0
97.0
96.4
/
97.8
/
99.2
/


(%)





aAll values are average values determined on six units taken at random.


bMatrix tablets produced by direct compression of the mixture F11 with a rotary tablet machine.


cStability in blister 1 was interrupted after 3 months.


dMatrix tablets produced from the mixture F3 (alcoholic granulation) with a rotary tablet machine.


eStability of batch no. 990310C was interrupted after 3 months.


fErweka TBH 30 HD apparatus.


gDetermined according to Eur. Ph. (Karl Fischer semi-micro water determination).


hDetermined in water (37° C.) according to Eur. Ph..


iDetermined in buffered pH 7.5 medium according to Eur. Ph..


jDetermined by high performance liquid chromatography (HPLC).













TABLE 3







Influence of packaging material (blisters 1, 2 and 3) on the stability of Tablets B and C stored at 30° C. (RH = 60%)a
















Tablet
Tablet B
Tablet B
Tablet B
Tablet
Tablet C
Tablet C
Tablet C



Bb
Blister 1c
Blister 2
Blister 3
Cd
Blister 1c,e
Blister 2e
Blister 3c






















Time
3
6
3
6
3
6
Time
3
6
3
6
3
6


Tests
zero
months
months
months
months
months
months
zero
months
months
months
months
months
months
























Diameterf
7.0
7.1
/
7.1
7.1
7.1
7.1
7.0
7.1
/
7.0
/
7.0
/


(mm)


Thicknessf
4.4
4.5
/
4.5
4.5
4.4
4.5
3.5
3.6
/
3.6
/
3.4
/


(mm)


Hardnessf
71
66
/
60
64
72
71
31
24
/
27
/
31
/


(N)


Weight
198
202
/
200
202
199
199
154
158
/
157
/
154
/


(mg)


Water
2.4
6.4
/
3.6
3.1
2.2
2.5
3.5
6.4
/
5.7
/
4.0
/


contentg


(%)


Disintegration
2:50
5:32
/
5:09
5:49
2:40
2:30
3:05
2:17
/
2:09
/
2:35
/


timeh


(min.:sec.)


Dissolutioni
93
95
/
94
95
93
96
95
97
/
96
/
98
/


after 20


min. (%)


Assayj
96.6
94.2
/
95.4
96.0
96.0
96.4
97.0
97.2
/
97.2
/
100.0
/


(%)
















TABLE 4







Influence of packaging material (blisters 1, 2 and 3) on the stability of Tablets B and C stored at 40° C. (RH = 75%)a
















Tablet
Tablet B
Tablet B
Tablet B
Tablet
Tablet C
Tablet C
Tablet C



Bb
Blister 1c
Blister 2
Blister 3
Cd
Blister 1c,e
Blister 2c
Blister 3c






















Time
3
6
3
6
3
6
Time
3
6
3
6
3
6


Tests
zero
Months
months
months
months
months
months
zero
months
months
months
months
months
months
























Diameterf 
7.0
7.2
/
7.1
7.1
7.0
7.1
7.0
7.1
/
7.0
/
7.0
/


(mm)


Thicknessf 
4.4
4.5
/
4.5
4.6
4.6
4.4
3.5
3.7
/
3.6
/
3.5
/


(mm)


Hardnessf 
71
64
/
67
62
71
70
31
23
/
27
/
30
/


(N)


Weight
198
205
/
201
205
198
200
154
161
/
158
/
154
/


(mg)


Water
2.4
5.3
/
3.6
5.2
2.1
2.2
3.5
7.3
/
6.2
/
4.0
/


contentg


(%)


Disintegration
2:50
7:20
/
6:16
6:12
3:17
3:31
3:05
2:27
/
2:28
/
2:23
/


timeh


(min.:sec.)


Dissolutioni
93
92
/
95
96
94
95
95
92
/
95
/
94
/


after 20


min. (%)


Assayj
96.6
92.6
/
92.6
92.2
96.0
96.3
97.0
97.2
/
96.4
/
99.4
/


(%)
















TABLE 5







Influence of packaging material (blisters 1, 2 and 3) on the stability of film-coated Tablets BA and BB stored at 25° C. (RH = 60%)a
















Tablet
Tablet BA
Tablet BA
Tablet BA
Tablet
Tablet BB
Tablet BB
Tablet BB



BAb
Blister 1c
Blister 2
Blister 3
BBd
Blister 1c
Blister 2
Blister 3






















Time
3
6
3
6
3
6
Time
3
6
3
6
3
6


Tests
zero
months
months
months
months
months
months
zero
months
months
months
months
months
months
























Diameterf
7.1
7.1
/
7.1
7.1
7.1
7.2
7.1
7.1
/
7.1
7.2
7.1
7.2


(mm)


Thicknessf
4.6
4.6
/
4.5
4.6
4.5
4.5
4.5
4.6
/
4.5
4.7
4.5
4.5


(mm)


Hardnessf
128
116
/
108
103
127
130
114
108
/
112
95
114
116


(N)


Weight
204
206
/
204
205
204
204
203
207
/
204
211
203
204


(mg)


Water
2.5
4.4
/
2.9
3.0
2.1
3.2
2.3
3.5
/
2.8
3.1
2.3
3.0


contentg


(%)


Disintegration
3:23
6:15
/
4:28
4:42
3:24
4:28
3:26
7:00
/
4:09
9:02
3:13
4:12


timeh


(min.:sec.)


Dissolutioni
93
95
/
96
98
94
95
96
93
/
94
94
97
96


after 20


min. (%)


Assayj
95.8
95.0
/
96.0
96.3
98.4
98.7
95.6
93.4
/
94.4
94.0
96.4
96.8


(%)
















TABLE 6







Influence of packaging material (blisters 1, 2 and 3) on the stability of film-coated Tablets BA and BB stored at 30° C. (RH = 60%)a
















Tablet
Tablet BA
Tablet BA
Tablet BA
Tablet
Tablet BB
Tablet BB
Tablet BB



BAb
Blister 1c
Blister 2
Blister 3
BBd
Blister 1c
Blister 2
Blister 3






















Time
3
6
3
6
3
6
Time
3
6
3
6
3
6


Tests
zero
months
months
months
months
months
months
zero
months
months
months
months
months
months
























Diameterf
7.1
7.1
/
7.1
7.1
7.1
7.1
7.1
7.1
/
7.1
7.1
7.1
7.1


(mm)


Thicknessf
4.6
4.6
/
4.5
4.6
4.5
4.5
4.5
4.6
/
4.5
4.6
4.3
4.6


(mm)


Hardnessf
128
103
/
110
110
130
128
114
99
/
104
100
112
114


(N)


Weight
204
206
/
205
206
204
203
203
207
/
206
206
203
203


(mg)


Water
2.5
5.5
/
3.1
3.6
2.2
3.0
2.3
4.1
/
3.2
3.8
3.3
2.6


contentg 


(%)


Disintegration
3:23
5:59
/
4:33
6.11
3:39
3:51
3:26
5:54
/
6:29
5:22
3:40
4:00


timeh


(min.:sec.)


Dissolutioni
93
95
/
96
95
94
97
96
94
/
96
93
93
96


after 20


min. (%)


Assayj
95.8
94.8
/
94.4
96.8
96.8
98.2
95.6
94.6
/
94.0
98.5
97.8
97.0


(%)
















TABLE 7







Influence of packaging material (blisters 1, 2 and 3) on the stability of film-coated Tablets BA and BB stored at 40° C. (RH = 75%)a
















Tablet
Tablet BA
Tablet BA
Tablet BA
Tablet
Tablet BB
Tablet BB
Tablet BB



BAb
Blister 1c
Blister 2
Blister 3
BBd
Blister 1c
Blister 2
Blister 3






















Time
3
6
3
6
3
6
Time
3
6
3
6
3
6


Tests
zero
months
months
months
months
months
months
zero
months
months
months
months
months
months
























Diameterf
7.1
7.1
/
7.2
7.2
7.1
7.1
7.1
7.2
/
7.1
7.1
7.1
7.1


(mm)


Thicknessf
4.6
4.6
/
4.6
4.7
4.5
4.6
4.5
4.6
/
4.6
4.6
4.5
4.6


(mm)


Hardnessf
128
102
/
110
104
130
125
114
93
/
102
99
115
111


(N)


Weight
204
209
/
207
210
204
204
203
210
/
208
204
204
203


(mg)


Water
2.5
5.3
/
4.2
5.0
2.2
2.7
2.3
5.2
/
4.2
5.6
3.1
3.6


contentg


(%)


Disintegration
3:23
7:18
/
6:51
6:48
3:50
3:30
3:26
9:16
/
6:45
4:18
4:15
3:16


timeh


(min.:sec.)


Dissolutioni
93
93
/
94
96
95
96
96
94
/
95
96
97
96


after 20


min. (%)


Assayj
95.8
95.0
/
95.4
98.1
98.2
96.3
95.6
94.0
/
95.6
96.7
98.0
95.2


(%)









Example 3
Diclofenac K Tablet Dissolution Profile Comparison
Using the dissolution test procedure described in the European Pharmacopeia, the dissolution profiles for two tablets (Ex. 3a and 3b) having the composition set forth in Table 8 were generated. The only difference between the two tablets was the source of the diclofenac potassium. Dissolution profiles of 50 mg. diclofenac potassium tablets marketed as Voltaren Rapid and Voltfast were also generated, and graphs of the contrasting dissolution profiles were superimposed, to produce FIGS. 1 and 2 hereto.







TABLE 8







Composition of Test Formulations










Names of
Unit

Reference to


Ingredients
(mg.)
Function
Standards













Drug Substance





Diclofenac
50.0
Anti-inflammatory
Eur. Ph.


Potassium

agent


Matrix Tablet


Excipients


Potassium
22.0
Buffering Agent
Eur. Ph.


Bicarbonate


Mannitol
116.4
Diluent and
Eur. Ph.




Disintegrant Agent


Sodium Lauryl
0.1
Solubilizing Agent
Eur. Ph.


Sulfate


Macrogols (as
1.5
Lubricant Agent
Eur. Ph.


Macrogol 6000)


Crospovidone
6.0
Binder
Eur. Ph.


Magnesium
4.0
Lubricant Agent
Eur. Ph.


Stearate


Film-Coating


Excipients


Clear Opadry
4.0
Coating Agent
In House





Specifications


Total Weight
204.0









Example 4
Diclofenac K Tablet Pharmacokinetic Profile Comparison
A further comparative test was carried out on immediate release formulations T1 and T2, as reported below in Table 9. A comparative bioavailabilty study was carried out on 6 healthy volunteers of both sexes in order to evaluate the in vivo results of the pharmacokinetic profiles of the present formulations if compared to those of a bioequivalent fast release formulation such as Voltaren Rapid® (50 mg of diclofenac potassium), by Novartis. The results, which are reported in FIGS. 3-6 are also in this case excellent: the Tmax is in fact prompter with the present formulations (T1=18.6 min, T2=16.8 min vs R1 40.8 min) and the Cmax is higher (T1=1878.3 ng/ml and T2=1744.8 ng/ml vs R1 1307 ng/ml); furthermore, also in this case the Tmax of both present formulations shows a coefficient of variation lower than reference formulation (T1=12.9% and T2=25% vs R1=95.6%).







TABLE 9







Formulation of Comparison Tablets













Reference, K salt, 50 mg,



T1, K salt, 50 mg, tablets
T2, K salt, 50 mg, tablets
Voltaren ® Rapid tablets














Description
Diclofenac potassium
Diclofenac potassium
Diclofenac potassium



50 mg film-coated tablets
50 mg film-coated tablets
50 mg film-coated tablets



(by alcoholic granulation)
(by direct compression)


Active
Diclofenac potassium mg 50
Diclofenac potassium mg 50
Diclofenac potassium mg 50


ingredient


Excipients
Potassium bicarbonate mg 22
Potassium bicarbonate mg 22
Calcium phosphate



Mannitol mg 50
Mannitol 400 mg 119.9
Saccharose



Maize starch mg 25

Maize starch



Hydroxypropylmethylcellulose mg 0.2

Talc



Sodium laurylsulfate mg 0.1
Sodium laurylsulfate mg 0.1
Sodium carboxymethylcellulose



Polyvinylpyrrolidone mg 1
Polyvinylpyrrolidone mg 6
Colloidal anhydrous silicium



Sodium starch glycollate mg 2.5

Polyvinylpyrrolidone



Magnesium stearate mg 4.5
Magnesium stearate mg 2
Microcrystalline cellulose



Silicium aerosil FK 160 mg 1

Magnesium stearate



Coating Opadry Clear
Film Coating Opadry Clear
Polyethylenglycole



(HPMC 2910 and
(HPMC 2910,
Titanidioxide (E171)



polyethyleneglycol 400) mg 4
polyethyleneglycol 400) mg 4
Iron oxide red (E172)


Total weight
160.3 mg
204 mg
















TABLE 10







Pharmacokinetics of Comparison Tablets.









PK results











Test 1 (K, tablets 50 mg)
Test 2 (K, tablets 50 mg)
Reference (K, tablets 50 mg)















Cmax
Mean
1873.30
1744.8
1307.0



SD
553.80
572.3
558.4



CV %
29.5
32.8
42.7



Min
1228.9
1057.4
581.8



Max
2516.5
2468.9
1935.5


AUC
Mean
1219
1237
1168



SD
246
276
282



CV %
20.2
22.3
24.1



Min
874
848
913



Max
1615
1668
1642


tmax
Mean
0.31 h (18.6 min)
0.28 h (16.8 min)
 0.68 h (40.8 min)



SD
0.04
0.07
0.65



CV %
12.9
25.0
95.6



Min
0.25 h (15 min)  
0.17 h (10.2 min)
0.25 h (15 min) 



Max
0.33 h (19.8 min)
0.33 h (19.8 min)
2.00 h (120 min)









Throughout this application, various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which this invention pertains. It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

## Claims

1. A method of packaging a rapidly bioavailable diclofenac potassium tablet comprising:
a) formulating a 50 mg. diclofenac potassium tablet dosage form for rapid bioavailability, in a formulation comprising:
i) at least 20 wt. % of one or more alkali metal carbonate or bicarbonate salt excipients that are freely soluble in water, and
ii) from about 30 to about 80 wt % of a hygroscopic diluent and said one or more freely soluble diluents at a weight ratio of from about 1:20 to about 5:1, wherein said hygroscopic diluent absorbs greater than about 0.5 wt. % water within a twenty four hour period in a humidity chamber maintained at 60% relative humidity (“RH”) and 25° C.; and

b) packaging said dosage form in a moisture resistant bottle that prevents said dosage form from absorbing more than 4 wt. % moisture in three months when stored at 40° C. and 75% relative humidity.

2. The method of claim 1 wherein said rapid bioavailability comprises a time to maximum plasma concentrations (tmax) of from about 5 to about 30 minutes, and a maximum plasma concentration (Cmax) of from about 1700 to about 2300 ng/ml.

3. The method of claim 1 wherein said rapid bioavailability has been established to comprise a time to maximum plasma concentrations (tmax) of from about 13 to about 27 minutes, and a maximum plasma concentration (Cmax) of from about 1500 to about 2500 ng/ml wherein said tmax has exhibited an inter-subject variability of less than about 49%.

4. The method of claim 1 wherein said dosage form yields one maximum plasma concentration (Cmax) peak when orally ingested.

5. The method of claim 1 wherein said bottle comprises a foil seal at the cap and one or more dessicant pouches inside said bottle.

6. The method of claim 1 wherein said dosage form comprises from about 7 to about 20 wt. % of an excipient that absorbs greater than about 1 wt. % water within a twenty four hour period in a humidity chamber maintained at 80% RH and 25 degrees Celcius.

7. The method of claim 1 wherein said dosage form absorbs greater than about 1 wt. % water within a twenty four hour period in a humidity chamber maintained at 80% RH and 25 degrees Celcius.

8. The method of claim 1 wherein said dosage form further comprises at least 20 wt. % of mannitol, lactose, sucrose, or a combination thereof.

9. The method of claim 1 wherein said dosage form further comprises a surfactant.

10. The method of claim 1 wherein said dosage form further comprises a surfactant having a hydrophilic lipophilic balance (“HLB”) greater than 14.

11. The method of claim 1 wherein said dosage form further comprises sodium lauryl sulfate.

12. The method of claim 1 wherein said dosage form further comprises an excipient base that comprises an inverse relationship between disintegration rate and moisture uptake.