SHAPED ARTICLES AS OBTAINED FROM A THERMOPLASTIC STARCH MELT

Abstract: Shaped articles, as obtained from a thermoplastic melt, which melt comprises a medium and a phase, the medium functioning as a dispersion medium with respect to the phase, the phase likewise functioning as a disperse phase with respect to the medium, the phase being present in the thermoplastic melt at a concentration sufficient to effect an increase in dissolution of said articles by comparison with the rate of dissolution of articles made from a thermoplastic melt absent said phase, said medium consisting of a melt comprising destructurised starch and said phase comprising at least a hydrophilic material.

Description: --- Shaped articles as obtained from a thermoplastic starch melt The present invention relates to a thermoplastic melt comprising a dispersion medium consisting of a melt comprising molten starch, and a disperse phase comprising at least one hydrophilic, preferably hygroscopic, material. The terms molten starch, disperse phase, dispersion medium, hydrophilic material, and hygroscopic material are defined hereinafter. It is known that natural starch which is found in vegetable products can be treated at elevated temperatures to form a melt. It is believed that such a melt is formed as a consequence of the starch material being heated above the glass transition and melting temperatures of its components. Preferably the starch material contains a defined amount of water and melt formation is carried out at an elevated temperature in a closed volume, and hence at an elevated pressure. It is, however, known to form a starch melt in an open volume, essentially in the absence of water, but in the presence of a liquid having a boiling point higher than the starch glass transition and melting temperature. Melt formation of starch is known. European Patent Application 84300940.8 (Publication No. 118 240) and PCT Patent Application PCT/CH89/00185 (Publication No. W0 90/05161) describe methods of producing starch melts. Reference is also made to European Patent Applications 88810455.1 (Publication No. 298,920), 88810548.3 (Publication No. 304,401) and 89810046.6 (Publication No. 326,517) which further describe starch melts, methods of making such melts, and uses of same. These patent applications are incorporated herein by reference. Starch contained in starch melts and in articles made therefrom is often called "destructurised" starch or "destructured" starch. Different degrees of destructurisation are possible which can be measured by various methods. One method, for example, is to measure the remaining amount of granular structure which is contained in the destructurised starch. This can be determined by known microscopic methods. It is an advantage of the present invention that articles possessing excellent physical properties may be formed from starch which has a relatively low degree of destructurisation, i.e wherein uniform thermoplastic melt formation per se is sufficient. It is preferred that the destructured starch used in the present invention has been heated to a high enough temperature and for a time sufficient so that specific endothermic transition analysis as represented by differential scanning calorimetry indicates that a specific relatively narrow peak just prior to oxidative and thermal degradation has disappeared, as is described in European Patent Application No. 89810046.6 (Publication No. 326 517) The term "destructurised" starch will be used herebelow, and is thus to be construed accordingly. An important property of destructurised starch is its capability to take up water and to disintegrate as a consequence thereof. For many purposes the rate of disintegration of articles made from such destructurised starch is insufficient. Thus, for example, pharmaceutical containers which are fabricated from such destructurised starch in general exhibit a lower dissolution rate than pharmaceutical containers in the form of dip moulded hard gelatin capsules. The present invention provides a solution to the aforementioned insufficiency. According to the present invention, there is provided shaped articles, as obtained from a thermoplastic melt, which melt comprises a medium and a phase, the medium functioning as a dispersion medium with respect to the phase, the phase likewise functioning as a disperse phase with respect to the medium, the phase being present in the thermoplastic melt at a concentration sufficient to effect an increase in dissolution of said articles in comparison with the rate of dissolution of articles made from a thermoplastic melt absent said phase, said medium consisting of a melt comprising destructurised starch and said phase comprising at least one hydrophilic material. The invention particularly provides shaped articles in the form of a member selected from the group consisting of bottles, sheets, films, packaging materials, pipes, rods, laminated films, sacks, bags, foams, granules and powders. The invention most particularly provides shaped articles in the form of pharmaceutical containers , especially adapted for use as a carrier material for pharmaceutically and veterinarilly active compounds, as well as for numerous non-pharmaceuticals which are filled in such pharmaceutical containers. The invention still further provides a process for producing a thermoplastic melt, which melt comprises a medium and a phase, the medium functioning as a dispersion medium with respect to the phase, the phase likewise functioning as a disperse phase with respect to the medium, the phase being present in the thermoplastic melt at a concentration sufficient to effect an increase in dissolution of articles made therefrom in comparison with the rate of dissolution of articles made from a thermoplastic melt absent said phase, said medium consisting of a melt comprising destructurised starch and said phase comprising at least one hydrophilic material, which process comprises heating starch, optionally with additives, to a temperature above its melting point and glass transition temperature, characterised in that the material which forms the disperse phase is added to said starch either before, during or after melt formation. The invention still further provides the thermoplastic melt produced by the above process, which melt may be used in a process of forming shaped articles. The invention still further provides a process of shaping the thermoplastic melt to form said shaped articles, which process is selected from the group consisting of injection moulding, blow moulding, extrusion, coextrusion, compression moulding, vacuum forming, and thermoforming. The terms "dispersion medium" and "disperse phase" within the context of the invention are to be construed in accord with the following: The thermoplastic melt of the present invention consists of material comprised by a medium and material comprised by a phase. It is a requirement of the present invention that the phase be incompletely miscible with the medium when both are present in the thermoplastic melt i.e. that the phase is dispersed in, but not dissolved in, the material comprised by the dispersion medium. The phase may thus include course particles having a particle size of from about 100 to about 500um, or particles of smaller size (from about 10 to about lOOum) to form colloidal systems, or larger particles when such behave likewise when present in the thermoplastic melt . The term "hydrophilic material" within the context of this invention means a material which is water-soluble or water- swellable, i.e. a material which is able to take up water at room temperature in an amount of at least 10 grams per 100 grams of material, and preferably in an amount of at least 20 grams per 100 grams of material. The term "hygroscopic material" within the context of the invention is to be construed in accord with the following: A hygroscopic material is one which readily absorbs and/or adsorbs and retains moisture from the environment at room temperature, bur does not liquify due to dissolution of said material by absorption, adsorption and retention of said moisture. Such material may absorb and/or adsorb and retain water in an amount of up to 1000 times its own weight. The term "hydrophilic material" as used herein includes hygroscopic materials . The disperse phase is preferably comprised by a fibrous polymer selected from the group consisting of polyvinylpyrrolidone and polysaccharides such as cellulose, chitin, starch or chitosan, which preferably are cross-linked and in which some of the hydroxyl groups of the anhydroglucose groups are substituted. The average particle size of the fibrous polymers of the disperse phase is preferably in the range of from about 10 to about 500um. More preferred such average particle sizes are from about 20 to about 300um, and most preferred such sizes are from about 20 to about lOOum. Such polymers have been previously used at concentrations of about 27o to about 6% as a disintegrant in tablets made by cold compression of dry components. When used in wet processing, such as the dip moulding of hard gelatin capsules, such materials do not promote disintegration of the capsule indicating that when processed in the presence of moisture such polymers substantially lose their capacity to act as disintegrants . When water is added to starch mixed with such polysaccharide fibres, it is assumed that such fibres absorb enough water to render them ineffective as disintegrant materials. In addition, said disperse phase material is present in a relatively low concentration and under conditions of melt formation is enveloped entirely by the starch medium. The disperse phase material remains in this enveloped form once the melt has cooled and is solidified. It is therefore surprising to find that solidified thermoplastic starch melts incorporating such materials exhibit excellent dissolution characteristics . The hydrophilic material, which may be present in the thermoplastic melt at a concentration of up to about 4%, preferably up to about 2%, by weight based on the weight of the thermoplastic melt, may comprise a polymer of cellulose, chitin, chitosan and starch, which may be substituted and/or cross linked as mentioned above. Said hydrophilic material may also be a polyvinylpyrrolidone po mer. The thermoplastic melt may further comprise at least one member of the group consisting of fillers, lubricants, mould release agents, plasticisers , stabilisers and colouring agents. The invention is further apparent from the following description. The starch which is used to form the melt of destructurised starch includes at least one member of the group consisting of chemically non-modified starches of vegetable origin, which starches are composed mainly of amylose and/or amylopectin and are derived from potatoes, rice, tapioca, corn, pea, rye, oats and wheat. Such starch includes pre-extruded starches; physically modified starch; irradiated starch; and starch in which divalent ions associated with phosphate groups therein have been removed, either partly or wholly, and optionally replaced, either partly or wholly, by different divalent ions or with mono or polyvalent ions. It has been found that starches with a water content in the range of about 5 to 40% by weight, based on the weight of the starch water composition, when heated at elevated temperatures and in a closed vessel exhibit a specific narrow endothermic transition prior to the endothermic transition characterising its oxidative and thermal degradation. Such a specific narrow endothermic transition may be determined by differential scanning calorimetric analysis (DSC) and is indicated on a DSC diagram by a specific relatively narrow peak substantially immediately prior to the endotherm characteristic of its oxidative and thermal degradation. This peak disappears as soon as the specific endothermic transition has been traversed. The term "starch" as used herein thus includes starches, so treated as to have traversed this specific endothermic transition. The term "starch" further includes starch derivatives, i.e. substituted starches with a degree of substitution of up to about 1. Such substituents are preferably hydroxyalkyl such as hydroxyethyl or hydroxypropyl, and said starches are preferably thus substituted to a degree of 0.05 to 0.5, and more preferably from 0.05 to 0.25. In this sense, the starches described above may be either wholly or partly replaced with such starch derivatives . Preferably the starch is destructurised in the presence of water which may be present in the thermoplastic melt at between about 5 and 40%, and preferably at between about 5 to 30% by weight, based on the weight of the thermoplastic melt. In order to work with the material near to the equilibrium water content which exists when such is exposed to a free atmosphere, however, the starch material has a water content of between about 10 and 20% by weight, and preferably of between about 14 and 18% by weight, based on the weight of the thermoplastic melt. The starch component of the thermoplastic melt includes destructurised starch prepared by other methods, for example, in the absence of water. The hydrophilic material of the disperse phase preferably has a melting point which is higher than the glass transition temperature of the destructurised starch and preferably absorbs up to a thousand times its own weight in water. The precise amounts of water absorbed vary according to the nature of the hydrophilic material and the ionic strength of the aqueous environment. For example, the amount of water absorbed by the hydrophilic material is generally reduced as the ionic strength in which it is situated is increased. The material comprises a polymer of glucose moieties, and preferably is selected from the group consisting of cellulose, chitin, starch and chitosan. Preferably, at least some of the hydroxyl groups of anhydroglucose moieties comprised by the polymer are substituted, with, for example, a member from the group consisting of carboxy-carboxyalkyl, sulfoalkyl, and salts thereof, and dialklyaminoalkyl, - or quaternary derivative thereof. Such derivatives are, for example, carboxymethylcellulose, diethylaminoethyl cellulose, triethanolamine cellulose, polyethyleneimine cellulose and carboxymethyl starch. In the preferred embodiment, the disperse phase is comprised by the compounds mentioned above, which are internally cross linked. These polymers are preferably substituted to a degree of between 0.5 and 1.2 and preferably are substituted to a degree of about 0.7. Preferably such materials are of a strand or fibrous type, and have an average strand or average fibre length of from about 10 to about 500um. More preferred such average strand or fibre sizes are from about 20 to about 300um, and most preferred such sizes are from about 20 to about lOOum. Said materials are preferably cross linked to such an extent that they are substantially water-insoluble. Preferred cross linked materials include cross-linked carboxymethyl starch, internally cross-linked carboxymethyl cellulose and salts thereof, and cross-linked cellulose amines possessing tertiary or quaternary amino groups. Internally cross linked sodium carboxymethyl cellulose is listed in the US-National Formulary as Croscarmellose Sodium Type A as sold by FMC Corporation (Philidelphia, USA) under the Trade name Ac-Di-Sol. The average strand or fibre size of said cross-linked carboxymethyl cellulose is from about 70 to about 80um, and it has been used previously at concentrations of between 2 and 6% as a disintegrant in tablets and capsules made by a cold compression process. A molten system comprising destructurised starch, where generally temperatures of between 160 and 180°C as well as high pressures are used is considerably different from a conventional pharmaceutical tablet manufactured at room temperature. Chemically modified suitable starches comprised by the material, such as carboxymethyl starch or sodium starch glycolate are available under the Trade names of Explotab (Edward Mendell Company Incorporated Carmel, New York) and Primojel (Generichem Corp. Little Falls, New Jersey). The average fibre or strand size of said modified starches is about 70um. A further material suitable as the hydrophilic material of the disperse phase is microcrystalline cellulose as sold under the trade name Avicel PH-101 by Fluka Chemie AG of Industriestarsse 25, CH-9470 Buchs , Switzerland. The average fibre or strand size of said microcrystalline cellulose is from about 20 to about lOOum, depending upon the grade used. A still further material suitable as the hydrophilic material of the disperse phase is a cross linked polyvinylpyrrolidone as sold under the Trade name Polyplasdone XL (GAF Corp. , New York), or Kollidon. The average fibre or strand size of said polyvinylpyrrolidone depends on the precise grade used, but is typically in the range of from about 20 to about 250um. Pullulan, or pullulan derivatives, which are, or are rendered substantially insoluble in starch, by cross linking or acetylation, for example, may be used as the hydrophilic material of the disperse phase. The pullulan or derivative may be substituted to between about 0.5 and 1.0. The hydrophilic material is present in the thermoplastic melt at a concentration of between about 0.1 and 4%, by weight, based on the weight of the thermoplastic melt. Preferably the material is present in the thermoplastic melt at a lower concentration of between about 0.3 and about 2%, by weight, based on the weight of the thermoplastic melt, and most preferably is present in the thermoplastic melt at a concentration of between about 0.5 and about 1%, by weight, based on the weight of the thermoplastic melt. Starch may be mixed with the hydrophilic material and optionally other additives as mentioned hereinbelow in any desired sequence. For example, the starch may be mixed with all of the intended additives to form a blend, which blend may then be heated to form a thermoplastic melt. The starch may, however, be mixed with optional additives, the starch destructurised and granulated before addition of the hydrophilic material, which mix may then be further processed. Preferably, however, the starch is mixed with additives together with the hydrophilic material to form a free flowing powder, which is useful for continuous processing, and destructurised and either granulated or moulded directly into a shaped article, for example a pharmaceutical container. Thus , the starch and all of the intended additives can be mixed in a conventional mixer, the water content of the starch being adjusted to between 5 and 40%. The thus formed mixture is passed through an extruder to produce granulates or pellets as one form of shaped article suitable for further processing. It is, however, possible to avoid the granulation step and to process the obtained melt directly using down stream equipment to produce pharmaceutical capsules, other containers, films (including blown films), sheets, profiles, pipes, tubes and other shaped articles. The sheets may be used subsequently in thermoforming processes. In order to destructurise the starch, and / or form a thermoplastic melt according to the invention, it is suitably heated in a screw and barrel of an extruder for a time sufficient to enable uniform melt formation of the starch so that the starch is destructurised. The temperature is preferably within the range of 105°C to 240°C, and more preferably within the range of from 130 to 190°C, the precise temperature being dependent up on the type and nature of the starch used. It is preferred that potato or corn starch is used. For thermoplastic melt formation according to the invention, the composition preferably is heated in a closed volume, such as a closed vessel, or in the finite volume created by the sealing action of unmolten feed material, which action is apparent in the screw and barrel of injection moulding equipment . Thus the screw and barrel of an injection moulding machine, or an extruder is to be understood as being a closed vessel. Pressures created in such an enclosed volume correspond to the vapour pressure of water at the used temperature. It will be appreciated that pressures may be applied or generated as is known to be possible in the use of said screw and barrel. The preferred applied and/or generated pressures are in the range of pressures which occur in extrusion and are known per Se, being up to about 150 x 10 5N/m2, preferably up to about 75 x 10 5N/m2 and most preferably up to about 50 x 105N/m2. The thus obtained destructurised starch composition is granulated and is ready to be mixed with further components according to a chosen mixing and processing procedure to obtain a granular mixture of destructurised starch starting material to be fed to the screw barrel. The melt obtained in the screw and barrel may, however, be injection moulded directly into a suitable mould, i.e directly further processed to a final product if all desired components are already present. Within the screw the granular mixture is heated to a temperature which is generally within the range of about 80 to about 200°C, preferably within the range of about 120 to about 190°C and most preferably within the range of about 130 to about 190°C. The minimum pressures under which the melts are formed correspond to the water vapour pressures produced at said temperatures. The process is carried out in a closed vessel, as defined above, and a range of pressures suitable for extrusion or injection moulding processes are from zero to about 150 x 105N/m2, preferably from zero to about 75 x 105N/m2 and most preferably from zero to about 50 x 10 5N/m2. In forming an injection moulded article with the thermoplastic melt of the present invention, the range of pressures customarily used in injection moulding are used, viz, from about 300 x 10 5 N/m 2 to about 3000 x 10 5 N/m 2 . It is preferred, however, that pressures from about 700 x 10 5N/m2 to about 2000 x 10 5N/m2 are used in the injection moulding process. Preferably the thermoplastic melt comprises at least one member selected from the group consisting of fillers, lubricants, mould release agents, plasticisers, stabilisers and colouring agents. Suitable fillers include, for example, oxides of magnesium, aluminium, silicon, and titanium. The fillers are present in the thermoplastic melt at a concentration of up to about 20% by weight, and preferably between about 3.0 and about 10%, by weight, based on the weight of the thermoplastic melt. The lubricants include stearates of aluminium, calcium, magnesium, and tin, as well as magnesium silicate, silicones and substances which function in like manner. The lubricants are present in the thermoplastic melt in concentrations of about 0.1 to about 5% by weight, and preferably at about 0.1 to about 3% by weight, based on the weight of the melt. Plasticisers include low molecular weight poly(alkylene oxides), such as, for example, poly(ethylene glycols), ρoly(propylene glycols) poly(ethylene-propylene glycols), organic plasticisers of low molecular mass, such as, for example, glycerol; pentaerythritol; glycerol monoacetate, diacetate, or triacetate; propylene glycol; sorbitol; sodium diethylsulfosuccinate; triethyl citrate and tributyl citrate and other substances which function in like manner. Such plasticisers are preferably present in the thermoplastic melt at a concentration of between about 0.5% and about 25% by weight, and more preferably between about 0.5% and about 10% by weight, based on the weight of all of the components, including the water therein. Preferably the sum of the plasticiser and water content of the thermoplastic melt does not exceed about 25% by weight, and most preferably does not exceed about 20% by weight, based on the weight of the thermoplastic melt. Stabilisers include antioxidants such as thiobisphenols , alkylidenbisphenols , secondary aromatic amines; stabilisers against photo-decomposition, such as, for example, uv absorbers and quenchers; hydroperoxide decomposers; free radical scavengers, and anti-microbial agents. Colouring agents include known azo dyes, organic or inorganic pigments, or colouring agents of natural origin. Inorganic pigments are preferred, such as the oxides of iron or titanium, these oxides being present in the thermoplastic melt at a concentration of between about 0.1 and about 10% by weight, and preferably present at a concentration of between about 0.5 and about 3% by weight, based on the weight of the thermoplastic melt. Still further substances which may be added to the starch material of the thermoplastic melt include animal or vegetable fats, preferably in their hydrogenated forms, especially those which are solid at room temperature. Such fats preferably have a melting point of at least 50°C and include triglycerides of C12-, C14- , C16-, and C18- fatty acids. The fats are added to the material comprising the thermoplastic melt alone without extenders or plasticisers, or to the melt together with mono- or di- glycerides or phosphatides , of which lecithin is preferred. Said mono- and diglycerides are preferably derived from said animal or vegetable fats. The total concentration of said fats, mono-, di- glycerides and phosphatides may be up to 5% by weight, based on the weight of the thermoplastic melt. The materials described herein above form thermoplastic melts on heating under conditions of controlled water content and temperature and pressure. Such melts may be processed in the manner used for conventional thermoplastic materials, such as injection moulding, blow moulding, extrusion, coextrusion, compression moulding, vacuum forming, and thermoforming to produce shaped articles . Such articles include containers, bottles, sheets, films, packaging materials, pipes, rods, laminated films, sacks, bags, foams , granules and powders . Particularly preferred articles are pharmaceutical containers , in the form of capsules , especially when such are used as a carrier material for pharmaceutically and veterinarilly active compounds . Such compounds include biocides, such as insecticides and pesticides, where it is desired subsequently to release rapidly such compounds therefrom. The invention will be further apparent from a consideration of the following examples. Example 1 Drug containers were prepared both with and without a disperse phase. (a) Drug Container Composition without Disperse phase 81.0 parts of natural potato starch, 1 part of a lubricant/mould release agent (hydrogenated fat), 0.5 parts of a melt flow accelerator (lecithin), 0.5 parts of an opacifier (titanium dioxide) and 17 parts of water were mixed in a powder mixer for 10 minutes to form a free flowing powder. The hydrogenated triglyceride contained the fatty acids C18:C16:C14 in the ratio of 65:31:4 respectively. The thus formed powder was fed into a hopper and thence to a screw barrel having a temperature of 170 to 180°C and an applied pressure of 55 to 75 bar where it was maintained for 7 minutes. It was then injected at an injection moulding pressure of 1400 bar into an injection moulding tool for the production of capsule body and cap parts, the mould wall of which tool was maintained at 40°C. After cooling and ejection from the mould, dimensionally stable capsule body and cap parts were obtained, which could easily be processed on a filling machine. (b) Drug Container Composition containing Disperse Phase 80.25 parts of natural potato starch, 1 part of hydrogenated fat, 0.5 parts of lecithin, 0.5 parts of titanium dioxide, 0.75 parts of disperse phase in the form of a dry powder, and 17 parts of water were mixed in a powder mixer for 10 minutes to form a free flowing powder. The hydrogenated triglyceride contained the fatty acids C18:C16:C14 in the ratio of 65:31:4 respectively. The disperse phases, which were present at 0.75% by weight, based on the weight of the thermoplastic melt, were (1) Croscarmellose sodium; (2) cross linked polyvinylpyrrolidone; (3) carboxymethyl cellulose; (4) carboxymethyl starch; and (5) microcrystalline cellulose (Avicel). The thus formed powder was fed into a hopper and thence to a screw barrel at an applied pressure of 55 to 75 bar where it was maintained for 7 minutes. For (1) the temperature of the barrel was 170 to 180°C; for (2) the temperature was 160 to 170°C; for (3) the temperature was 155 to 165°C; for (4) the temperature was 160 to 170°C and for (5) the temperature was 150 to 160°C. The thus formed melts were then injected at an injection moulding pressure of 1400 bar for (2) and (4); 1200 bar for (1); 1600 bar for (3); and 1500 bar for (5), into an injection moulding tool for the production of capsule body and cap parts, the mould wall of which was maintained at 40°C. After cooling and ejection from the mould, dimensionally stable capsule body and cap parts were obtained, which could easily be processed on a filling machine. The containers from (a) and (b) above were filled with identical formulations of paracetamol powder comprising 85.54 parts paracetamol, 2.5 parts of maize starch, 11.7 parts of microcrystalline cellulose (Avicel) and 0.26 parts of hydrogenated cottonseed oil. The containers were filled with the paracetamol formulation using a Bosch (CAPILL) filling machine, which machine additionally sealed the body and cap parts of the capsule. The dissolution rates of paracetamol from the two samples produced as described under (a) and (b) above were determined using the standard USP test procedure for paracetamol capsules. The results of the determination are given in Table 1. The pharmaceutical container in Table 1 is given as CAPILL (Trade name) . Table 1 CAPILL with 0.75 % cross linked polyvinyl polypyrrolidone as disperse phase 71 89 94 CAPILL with 0.75 % carboxy methyl cellulose (not cross-linked) as disperse phase 83 95 99 CAPILL with 0.75 % carboxy methyl starch as disperse phase 97 100 CAPILL with 0.75 % microcrystalline cellulose (Avicel) as disperse phase 85 97 100 Example 2 Example 1 was repeated with the aim of comparing a capsule made without a disperse phase and with the addition of cros¬ carmellose sodium as the disperse phase to the thermoplastic melt from which the capsule walls are made. The 85.5 parts of paracetamol of Example 1 were replaced by 85.5 parts of aspirin and the standard USP test procedure for aspirin capsules was used. The results are given in Table 2. Table 2 % Aspirin dissolved after 15 min 30 min 45 min CAPILL without Croscarmellose sodium 17 CAPILL with 0.75 % Croscarmellose sodium 57 74 85 Example 3 In a further test, the aspirin dissolution rate was measured using a modified USP test procedure in which 0.5ug of alpha amylase was added to the dissolution medium and the basket stirring rate was increased from 100 to 150 rpm. The results obtained are given in Table 3. Table 3 % Aspirin dissolved after 15 min 30 min 45 min CAPILL without Croscarmellose sodium 19 44 57 Example 4 Example 3 was repeated, but the disperse phase material was cross linked polyvinylpolypyrrolidone, present in a concentra¬ tion of 3% by weight of the empty pharmaceutical capsule. The results are given in Table 4. Table 4 % Acetaminophen dissolved after 15 min 30 min 45 min CAPILL without Croscarmellose sodium 38 82 93 CAPILL with 3.0% cross linked polyvinyl polypyrrolidone 70 95 100 The addition of hydrophilic materials, as disclosed herein, to the starch composition forming the destructurised starch melt in quantities similar to those found in tablets, i.e at concentrations of from 2 to 6% yields a material which behaves relatively poorly in melt formation and injection moulding processes. The addition of relatively minor quantities, 0.75% for example, of such materials to the starch composition forming the destructurised starch melt has the surprising effect of being useful in the melt formation process as well as in increasing considerably the dissolution rate of a drug added to a container produced therefrom. It will be appreciated that it is not intended to limit the invention to the above examples only, many variations thereto and modifications thereof being possible to one skilled in the art without departing from its scope.

Claims: CLAIMS 1. Shaped articles, as obtained from a thermoplastic melt, which melt comprises a medium and a phase, the medium functioning as a dispersion medium with respect to the phase, the phase likewise functioning as a disperse phase with respect to the medium, the phase being present in the thermoplastic melt at a concentration sufficient to effect an increase in dissolution of said articles by comparison with the rate of dissolution of articles made from a thermoplastic melt absent said phase, said medium consisting of a melt comprising destructurised starch and said phase comprising at least a hydrophilic material. 2. Shaped articles according to claim 1, in which the hydrophilic material comprises a hygroscopic material. 3. Shaped articles according to either of claims 1 or 2, wherein the starch of the melt of destructurised starch is at least one member selected from the group consisting of chemically non-modified starches of vegetable origin, which starches are composed mainly of amylose and/or amylopectin and are derived from potatoes, rice, tapioca, corn, pea, rye, oats, wheat, including physically modified starch, irradiated starch, starch in which divalent ions associated with phosphate groups therein have been removed, either partly or wholly, and optionally replaced, either partly or wholly, by different divalent ions or with mono or polyvalent ions; pre-extruded starches and starches which have been so heated as to undergo the specific endothermic transition characteristically preceding oxidative and thermal degradation. 4. Shaped articles according to either of claims 1 or 2, in which the starch is substituted, and has a degree of substitution of up to about 1, preferably between 0.05 and 0.5, and most preferably between about 0.05 and 0.25. 5. Shaped articles according to any preceding claim, in which the hydrophilic material has a melting point which is higher than the glass transition temperature of starch. 6. Shaped articles according to any preceding claim, wherein said hydrophilic material is present in said thermoplastic melt at a concentration of between about 0.1 and about 4% by weight, preferably between about 0.3 and about 2% by weight, and most preferably at a concentration of between about 0.5 and about 1% by weight, based on the weight of said thermoplastic melt. 7. Shaped articles according to any preceding claim, wherein said hydrophilic material comprises a polymer of glycosidically linked hexose sugars, selected from glucose and mannose. 8. Shaped articles according to any preceding claim, wherein the polymer is selected from the group consisting of cellulose, chitin, starch and chitosan. 9. Shaped articles according to any preceding claim, wherein at least some of the hydroxyl groups of anhydroglucose moieties comprised by said polymer are substituted with a member selected from the group consisting of carboxy- , carboxyalkyl, sulfoalkyl, and salts thereof, and dialklyaminoalkyl- , and quaternary derivatives thereof. 10. Shaped articles according to any preceding claim, wherein the degree of substitution of said groups on said polymer is from about 0.5 to about 1.2, and preferably is about 0.7. 11. Shaped articles according to any preceding claim, wherein said polymer is selected from the group consisting of carboxymethyl cellulose and salts thereof, diethylaminoethyl cellulose and salts thereof, triethanolamine cellulose and salts thereof, polyethyleneimine cellulose and salts thereof and carboxymethyl starch and salts thereof. 12. Shaped articles according to any preceding claim, wherein the polymers are -Stranded or fibrous and have a length of from about 10 to about 500um, preferably from about 20 to about 300, and most preferably from about 20 to about lOOum. 13. Shaped articles according to any preceding claim, wherein the polymers are crosslinked and are selected from the group consisting of cross-linked carboxymethyl starch and salts thereof, internally cross-linked carboxymethyl cellulose and salts thereof, and cellulose amines possessing tertiary or quaternary amino groups. 14. Shaped articles according to any preceding claim, in which said polymer is a pullulan or a substituted pullulan or a pullulan derivative or substituted pullulan derivative, which is substantially insoluble in starch. 15. Shaped articles according to any preceding claim, wherein said hydrophilic material consists of internally cross linked polyvinylpyrrolidone and salts thereof. 16. Shaped articles according to any preceding claim, in which the destructurised starch comprises a water content of between about 5 and about 40% by weight, preferably between about 5 and about 30% by weight, more preferably between about 10 and about 20% by weight, and most preferably between about 14 and about 18% by weight, based on the weight of said thermoplastic melt. 17. Shaped articles according to any preceding claim, wherein said thermoplastic melt further comprises at least one member selected from the group consisting of fillers, lubricants, mould release agents, plasticisers, stabilisers and colouring agents. 18. Shaped articles according to any preceding claim, in the form of a member selected from the group consisting of pharmaceutical containers, bottles, sheets, films, packaging materials, pipes, rods, laminated films, sacks, bags, foams, granules and powders. 19. Shaped articles according to any preceding claim, when used as a carrier material comprising at least one member selected from the group consisting of pharmaceutically and veterinarilly active compounds, and non-pharmaceutical or veterinary compounds. 20. The thermoplastic melt which is used to form a shaped article according to any preceding claim, before said melt is formed into a shaped article. 21. A process for producing a thermoplastic melt, which melt comprises a medium and a phase, the medium functioning as a dispersion medium with respect to the phase, the phase likewise functioning as a disperse phase with respect to the medium, the phase being present in the thermoplastic melt at a concentration sufficient to effect an increase in dissolution of articles made therefrom in comparison with the rate of dissolution of articles made from a thermoplastic melt absent said phase, said medium consisting of a melt comprising destructurised starch and said phase comprising at least one hydrophilic material, which process comprises heating starch, optionally with additives, to a temperature above its melting point and glass transition temperature and for a sufficient time to form a thermoplastic melt, characterised in that the material which forms the disperse phase is added to said starch either before, during or after melt formation. 22. A process of shaping the thermoplastic melt, as obtained by the process of claim 21, to form shaped articles according to any one of claims 1 to 19, which process is at least one member selected from the group consisting of injection moulding, blow moulding, extrusion, coextrusion, compression moulding, vacuum forming, foaming and thermoforming.

Inventors: COLE EWART THOMAS, EGLI MARKUS, COLE, EWART, THOMAS, EGLI, MARKUS
Applicants: WARNER LAMBERT CO, WARNER-LAMBERT COMPANY
Application year: 1991
Main classification: C08L3
IPC codes: A61J3, A61K9, A61K47, A61L31, C08J5, C08L3