COMPOSITIONS AND METHODS FOR MUCOSAL DELIVERY

Abstract: A dosage unit comprising a water-soluble hydrocolloid and a mucosal surface-coat-forming film, such film including an effective dose of active agent. In the dosage unit slidenafil citrate, nicotine, hydromorphone, oxybutynine or estradiol are used as active agents.

Description: COMPOSITIONS AND METHODS FOR MUCOSAL DELIVERY Technical Descπption The present invention is directed to a device and method for administering agents in a dissolving film configuration Background to the Invention Many pharmaceutical dosage forms are administrated orally in the form of solid shaped articles such as tablets, pills, caplets and capsules that retain their shape under moderate pressure. Generally these dosage forms are designed to be swallowed whole or chewed to deliver the medication with adequate amounts of liquid. Some patients, particularly pediatπc and geπatπc patients, have difficulty swallowing or chewing solid dosage forms. Certain patients such as children or animals resist taking medication, and may try to hide a solid pill in order to spit it out later. In addition, many pediatπc and geπatπc patients are unwilling to take a solid dosage form because the active agent is difficult to swallow or is retained in the pharynx or gullet even when liquids are consumed with the dosage unit. Furthermore, the availability of liquids at the time of administeπng medications may be limited for certain patients and may be restπcted for certain diseases and/or treatments. Chewable tablets provide some advantages over the conventional tablets. However, they are not suitable for children weaπng braces and the taste of the medication may be unpleasant and difficult to mask in a chewable tablet. At the same time, water may be still required for the administration of chewable tablets. In addition, the standard oral dosage forms, such as tablets, pills, caplets, and capsules, are designed for short residence time m the mouth Absorption of the agent from these dosage forms occurs in the gastrointestinal (GI) tract, after the agent has separated from the dosage form and dissolved in the gastπc fluids. For some active agents, it is desirable to achieve absorption through the oral mucosal tissues in order to accelerate onset of the therapeutic effect. Many active agents are poorly absorbed, even after they are dispersed in the stomach, because of low solubility or slow dissolution rate in the gastπc fluids. Tablets may be formulated so as to be quick dissolving. These tablets are commonly placed on the tongue and disintegrate rapidly in the oral cavity. However, these dosage units are not fixed to a mucosal surface and may move around in the mouth Consequently, they do not overcome a πsk associated with choking or gagging that occurs with subjects having limited control of their swallowing reflexes. However, once placed in the mouth, these tablets dissolve rapidly in the saliva to provide a liquid formulation which is then swallowed. Quick dissolving tablets may be formed from a particulate support matπx containing the therapeutic agent, where the particulate support matnx is a protein (US 5,807,576, US 5,635,210, US 5,595,761). Alternatively, the tablet may be formed from a laminate with several layers and an outer coating (JP 100535518). Tablets have also been manufactured from shearform matπces which are substantially amorphous sugar formed when crystalline sugar is subjected to heat and shear (WO 95/07194; WO 95/35293) Other methods of forming quick dissolving tablets include wet granulation methods (EP 0627 218) and dry granulation methods (EP 0124027A1) and by freeze- drying techniques (EP 0084705A2). Generally, quick dissolving tablets are formed using complex multi-step manufactuπng processes. In addition, these tablets may have poor mechanical strength, are fragile and fπable and have insufficient holding capacity for active ingredients (US 5,720,974) and may be difficult to store and handle. Therapeutic compounds are sometimes provided as powders or granules which may be difficult to swallow and cause unpleasant sensations in the mouth. Furthermore, many quick dissolving tablets contain particulates (>25 microns) which leave a "gπtty" and unpleasant taste the mouth. In the elderly, powders may cause choking and discomfort associated with trapping of granules in dentures. Powders and granules are generally packaged in a sealed pouch which requires teaπng before use. This causes problems for geπatπc patients and those suffeπng from arthπtis in the fingers as well as for children. Consequently, problems of spillage of the contents aπse in this group of patients. Furthermore, these oral preparations should be taken with water which for certain patients are inconvenient and may cause reduced patient compliance. Liquid, syrups or suspensions are an alternative to solid dosage forms and are considered desirable for pediatπc and geπatπc patients who have problems in swallowing tablets. However, these dosage forms are often difficult to measure accurately and administer easily Liquid formulations deteπorate rapidly upon exposure to heat or atmosphere and consequently have a relatively short shelf life Furthermore, liquid formulations require a relatively large volume and are bulky to store. In addition to solid and liquid dosage forms, rapidly dissolving buccal/oral delivery systems have been developed These systems are commonly freeze dπed preparations which are more expensive to manufacture as compared to tablets (US 5,648,093) Furthermore, freeze dπed preparations are bπttle and fragile when handled and must be kept in dry conditions to avoid disintegration The instability of freeze- dπed preparations has been reduced somewhat by the addition of manmtol (US 4,946,684). WO 9820862 reports a film that is formed according to a method that does not utilize freeze drying and avoids problems descnbed in the art such as πgidity of the films, delayed softening and poor solubility in the mouth (US 4,876,092: EP 0200508; EPO 381194; CA-PS 1-26331; DE 2449865.5; DE 3630603; EP 0452446 and EP 0219762). However, the film descnbed m WO 9820862 relies on the use of at least two different non-ionic surfactants to achieve immediate wettabihty. It is desirable that a dosage unit should provide a non-invasive, effective and economic means to deliver an active agent to the target site. Where the target site is the plasma, additional issues anse concerning the rate of delivery of the active agent to that site as measured by bioavailabi ty. For many types of active agent, fast onset of the therapeutic effect is desirable. Traditional oral dosages, such as tablets, are limited in onset time by the rate of absorption in the gastro-mtestinal tract. Formulations have been developed which, when applied in the mouth, lead to faster onset that the traditional oral dosages because they target the oral mucosa. These formulations include dosage units containing 75%-90% polyethylene glycol that melt at body temperature, in the mouth.( US 5,004.601 and 5,135,752) Other formulations include liquid forms, lozenges or tablets that are administered subhngually or by a sweetened matπx on a stick. (US 5,770,606, Streisand et al. and Zhang et al., Chπstie et al., Sasaki et al ). Whereas the above references address the delivery route, they do not address the problems of bioavailabihty that aπse from poor solubility or low dissolution rate A delivery device that addresses the above limitations would represent a desirable improvement on existing delivery systems. Summary of the Invention A novel dosage unit and its method of manufacture and use is provided. In an embodiment, the dosage unit includes a water-soluble hydrocoUoid, mucosal surface- coat-forming film, such film including an effective dose of an active agent In an embodiment of the invention, the hydrocoUoid includes a polymer selected from the group consisting of a natural, semi-natural and synthetic biopolymer being exemplified by a polysacchande and a polypeptide In addition to the hydrocoUoid. the film may further include one or more of an emulsifier. a plasticizer, a taste modifying agent, a water soluble inert filler, a preservative, a buffeπng agent, a coloπng agent, a permeation enhancer, and a stabilizer The film may further include an active agent selected from the group consisting of a therapeutic agent, a dietary supplement and a hygiene aid. Embodiments of the invention utilize effective amounts of slidenafil citrate, nicotine, hydromoφhone , oxybutynine or estradiol as active agents in the dosage unit. The active agent may be encapsulated within a second polymer having dissolution properties that are different from those of the hydrocoUoid. More than one active agent may be included in the film. In an embodiment of the invention, the emulsifier may have a concentration of 0 l-10%w The water inert filler may include a concentration range of 0.5-50% and the preservative may include a concentration range of 001-10%. A mucosal adhesion enhancer such as starch graft copolymer may be included in the dosage unit. In embodiments of the invention, the dosage unit may further include any of the following features a dry film thickness in the range of 1-20 mil, more particularly less than 10 mils, a dry tack value of less than 3.5g, more particular less than 2 g, a wet tack value of greater than 35g, a tensile strength greater than 1500psι, a modulus in the range of 35,000-300,000 psi, a tear propagation resistance in the range 0 001N-1N, a disintegration time m a range from 1-300 seconds, a dissolution time in a range from 10- 600 seconds, and a percentage elongation less than 20% In embodiments of the invention, methods are provided for making a dosage unit, that include in one embodiment, dissolving a hydrocoUoid in a solvent so as to form a substantially homogeneous preparation; adding to the hydrocoUoid preparation, an active agent and at least one reagent selected from the group consisting of an emulsifier, a plasticizer, a taste modifier, a water soluble inert filler, a coloπng agent, a preservative, a permeation enhancer, a stabilizer and a buffeπng agent to form a coatable mixture, and forming a mucosal surface-coat forming film from the mixture for packaging as a dosage unit. The method may further include the step of coating the mixture onto a backing film. In a further embodiment, the reagents including a hydrocoUoid, an active agent, and at least one reagent selected from the group consisting of an emulsifier. a plasticizer. a taste modifier, a water soluble inert filler, a coloπng agent, a preservative, a permeation enhancer, a stabilizer, and a buffeπng agent, may be combined in any order in a vessel having a heating source and a mechanical mixing device, the combined ingredients being mixed duπng and after the addition of the ingredients to the vessel, an effective amount of heat being applied for melting a substantial portion of the mixture. The mixture may then be formed into a film in a dry extrusion process. In an embodiment of the invention, a method is provided for adm istenng an active agent to a subject, that includes obtaining a water-soluble hydrocoUoid, mucosal surface-coat-forming film, such film including an effective dose of an active agent; and placing the film on a mucosal surface coat forming film m the subject; so as to release the active agent In a further embodiment of the invention, a dosage unit is provided that includes a water soluble hydrocoUoid and an effective dose of sildenafil citrate in a mucosal- surface contacting film. More particularly, an effective dose of sildenafil citrate is formed into a solid dispersion with xyhtol for treating erectile dysfunction. The sildenafil/xyhtol dispersion may be mixed with at least one reagent selected from the group consisting of an emulsifier, a plasticizer, a taste modifier, a coloπng agent, a preservative, a permeation enhancer, a stabilizer and a buffeπng agent. The solid dispersion of sildenafil and xylitol may aπse at a ratio of 9 parts sildenafil to one part xy tol. According to embodiments of the invention directed to a dosage unit and method of making a dosage unit suitable for erectile dysfunction, the water solubility of sildenafil in the solid dispersion is at least 20 mg/ml, more particularly about 50mg/ml More particularly, the film may be capable of completely dissolution at the oral mucosal surface within 10-600 seconds. Bπef Descnption of the Figures Figure 1 shows possible application sites in the oral cavity for the inventive dosage unit (1) is the upper lip, (2) is the gingiva. (3) is the hard palate: (4) is the cheek, (5) is the lingual. (6) is the sublingual, (7) is the lower lip Figure 2 illustrates one manufactunng process for the dosage unit (8) is the mixing and degassing tank: (9) is the coating slot with thickness controller; (10) is the polyester backing belt; (11) is the drying oven with aeration controller; (12) is the intraoral film; (13) is the die cutting and (14) is the intraoral unit dose. Figure 3 shows examples of packaging and dispensing devices for the intraoral delivery system. (15) is a heat sealed single pouch: (16) is a multi-unit blister card; (17) is a multi-unit dispensing pack. 17(a) the container snap and 17(b) the lid closure: (18) is a multi-unit roll-type dispenser cylinder; (19) is a perforated film stπp; and (20) is a single dose film. Figure 4 demonstrates the disintegration and dissolution time of the intraoral delivery system as a function of thickness.— • - is disintegration time and — ° ~ is dissolving time. Figure 5 shows the release profiles of — τ — nicotine, — v — oxybutymn, -- • ~ hydromoφhone and — ° ~ estradiol. Figure 6 shows the pharmacokinetics in six subjects after administration of a dissolving film sildenafil formulation and after administration of the commercial tablet containing the same dosage of sildenafil. Sildenafil film ~ o - Viagra - v -. Detailed Descπption of Invention Delivery of active agents in solid form via the mouth causes problems to patients who may choke on the dosage unit. This effect is caused at least in part by the mobility of the dosage unit within the mouth. We have developed a new class of dosage units which are not mobile in the mouth because on contact with the moist mucosal surface, the film becomes a coating that adheres to the mucosal surface and then disintegrates and dissolves over a time frame controlled in the design of the dosage. The dosage unit, in an embodiment of the invention, is in the form of a flexible, non-tacky, dry conveniently packaged film. Once removed from the package and placed on a mucosal surface, the mucosal surface-coat-forming film hydrates substantially immediately to form a coating on the moist surface of the mucous membrane and then disintegrates and dissolves to release the active agent from the film. The dosage unit may release the active agent over a peπod of time that is determined by a number of different factors These factors include the dimensions of the film, the concentration of the active agent, the solubility of the agent at the mucosal surface and how the agent is dispersed throughout the film. The thickness of the film is a factor in determining the rate of dissolution. A thick film will dissolve more slowly than an otherwise similar thin film. A thick film may be desirable for its holding capacity for active agents that are required in high dosages. Although the surface area of a film can be adjusted up to about 5 square centimeters, increased thickness may also be desirable for puφoses of achieving effective active agent dosages. The active agent can form a solid dispersion with a water soluble inert filler for puφoses of increasing the solubility of the agent when released from the film thereby enhancing bioavailabihty of the active agent. This is exemplified here by sildenafil which is incoφorated in a film with a water soluble inert filler, for example, xylitol, which has been found here to enhance the bioavailabihty of this agent. Solubihzing agents that are well known in the art may be included in the film. The extent of uptake of the active agent from the dosage unit at the mucosal surface can be controlled by the dissolution rate of the film. A dissolving film will release the active agent and this in turn will cause the active agent to be swallowed and taken up in the GI tract. In contrast, slow release of the active agent at the mucosal surface will give πse to increased uptake by the mucosal surface. A further parameter governing the release of an active agent at the mucosal surface is the manner in which the agent is dispersed in the film. For example, the agent may be dispersed as colloidal particles or microencapsulated within the film or alternatively may be mixed throughout the film as a reagent dunng casting. The dosage unit of the invention may be used as a vehicle for dehveπng a wide range of active agents. For example, the active agent may be a small molecule, a protein, a nucleic acid including antisense molecules or other biological or synthetic molecules. The term "mucosal surface-coat-formmg" as applied to a film as used in this descπption and in the following claims unless specified otherwise , means a film that coats the mucosal surface on contact, and may not thereafter be manually recovered or moved from the contact site; and subsequently disintegrates and dissolves so as to release the active agent. It should be noted that for puφoses of the descπption of the invention and the claims, "mucosal surface" refers to any moist surface of the body This includes the surfaces identified in Figure 1. It further includes a wound surface where lymph fluid bathes the tissue surface Embodiments of the present invention include a process, composition and method of use for a quick dissolving film for local and systemic delivery of pharmaceutical agents to a mucosal surface in a subject In the following text, specific reference may be made to the oral cavity by way of example. However, it is not intended to limit the scope of the invention to the oral cavity The dosage unit of the invention may be applied to any mucosal surface as deemed appropnate for the systemic or local delivery of an active agent including vaginal, rectal, and ocular surfaces. For puφoses of oral delivery, the films may be applied on lingual, sub-lingual, buccal, gmgival, and palatal surfaces (Figure 1). For vaginal delivery of such agents as contraceptive agents including nonoxynol or anti-infectives including antifungal agents, antibactenal agents and anti-viral agents, or fragrant or hygiene agents; the film should be non-sticky when removed from the packaging but should have mucoadhesive properties when applied in the vagina. Although films containing active agents for use in the vagina have been used, they appear to have some significant drawbacks most particularly the lack of adhesive properties at the mucosal surface. This makes these films impractical to administer. (US 5,380,529; 5,595,980 and 5,529,782). Embodiments of the invention provide improved dosage forms to deliver active agents that are appropnate for all age groups and that physician, parents, patients and family members can administer easily These dosage forms are economical to prepare and have an extended shelf life They are easy to handle and non-tacky before administration so as to avoid disintegration pπor to use and are conveniently packaged for shelf life, ease of storage and distnbution The dosage form may be administered to the subject by placing the film on a mucous surface, at which time the film becomes a mucoadhesive coating, characteπzed by the property that it can no longer exist in an independent form and is subsequently dispersed in solution Embodiments of the invention provide a delivery system for active agents and other active agents that will dissolve and completely release their contents on a moist mucosal surface -for example in the oral cavity The release of the active agent occurs without mastication or the need for intake of water With particular reference to the oral cavity, an embodiment of the invention provides active agents that remain in the oral cavity for treatment or modification of the oral environment; for example, for penodontal disease treatment or breath-odor control Furthermore, embodiments of the invention further provide improvements that include, improved organoleptic properties (smell and taste), and texture and feel of dosage forms intended to be placed in the oral cavity; a dosage form which "melts" in the mouth and leaves a smooth pleasant after feel following dissolution; and a prolonged retention of the active agent in the mouth following dissolution of the quick dissolving dosage form to extend the residence time of the active agent cleared from the mouth by the production of saliva and subsequent swallowing. Depending on the optimal program for a specific application of the invention, the disintegration time and the dissolution time can be controlled within a prescnbed range by adjustment of the formulation and the thickness of the film. In some cases, it is desirable for release of the active agent to occur after dissolution of the film. For these applications, the active agent may be encapsulated in a matenal with dissolution properties that are different from those of the hydrocoUoid. Encapsulation of the active agent also may be utilized to achieve masking of taste for active agents that are bitter. In some cases, two or more different active agents may be included m the film. An example where multiple active agents frequently are administered is cold medications, which often contain several active agents. "Coating solution" is defined here and in the claims as a viscous and homogeneous mixture of hydrocolloids, active agents and other additives in a solvent The coating solution is treated according to the method of the invention to form a film "Subject" is defined here and in the claims as a human or animal species. "Thickness" is defined here and in the claims by measurements in mil (a mil = one thousandth of an inch) determined when a film is placed between two microscopic slides. "Permeation enhancer" as defined here and in the claims is a natural or synthetic molecule which facilitates the absoφtion of an active agent through a mucosal surface "Enzyme inhibitor" as defined here and in the claims is a natural or synthetic molecule which inhibits enzymatic metabolism of an active agent in the saliva or in a mucosal tissue. "Water Content" is defined here and in the claims as % residual water content per unit dose as measured according to the Karl Fisher method and expressed as percent of the dry weight of the film. "The hydration rate" is defined here and in the claims as the speed of absorbing water at 25°C and 75% relative humidity in 24 hours "Percentage of swelling" is defined here as a percentage of the initial volume that is increased before dissolving. In an embodiment of the invention, the percentage of swelling is less than 10% in 60 seconds. Taste modifying agents include flavoπng agents, sweetening agents and taste masking agents and are exemplified by: the essential oils or water soluble extracts of menthol, wintergreen, peppermint, sweet mint, spearmint, vanillin, cherry, chocolate, cinnamon, clove, lemon, orange, raspberry, rose, spice, violet, herbal, fruit, strawberry, grape, pineapple, peach, kiwi, papaya, mango, coconut, apple, coffee, plum, watermelon, nuts, durean, green tea, grapefruit, banana, butter, camomile, sugar, dextrose, lactose, mannitol, sucrose, xyhtol, mahtol, acesulfame potassium, talin, glycyrrhizin, sucralose, aspartame, sacchaπn, sodium sacchaπn, sodium cyclamate and honey. Emulsifying agents include solubihzers and wetting agents and are exemplified by polyvmyl alcohol, sorbitan esters, cyclodextπns, benzyl benzoate, glyceryl monostearate, polyoxyethylene alkyl ethers, polyoxyethylene stearates, poloxamer, polyoxyethylene castor oil deπvatives, hydrogenated vegetable oils, bile salts, polysorbates and ethanol. Plasticizers may include glyceπn. sorbitol, propylene glycol, polyethylene glycol, tπacetin. tπethyl citrate (TEC), acetyl tπethyl citrate (ATEC) and other citrate esters Active agents (for human and vetennary applications) include therapeutic agents, nutπtional supplements and hygiene aids. The therapeutic agents are exemplified by analgesics, a-adrenergic receptor blockers, anti-Alzheimer's disease medication, antianginal. antianxiety, antiarrythmics, antiarthπtics, antibiotics, anticoagulants/thrombolytics, anticonvulsants/anti-Parkinson medication, anti- depressants, anti-diabetics, anti-dianheal. anti-epileptics, anti-fungal, anti-gout, anti- heartworm medication for dogs, anti-histamines, anti-hypertensives, anti-inflammatoπes, anti-infectives, antimigrames, anti-nasuants/anti-emetics, anti-neoplastics/anti-tumor active agents, anti-pruitics, anti-psychotics, anti-pyretics, anti-spasmodics, anti-virals, bronchial dilators/anti-asthmatics, calcium antagonists, cardiac agents, cardiotonics, central nervous system actives, contraceptives, coronary vasodilators, cough/cold remedies, dietary supplements, including vitamins and minerals, diuretics, fertility active agents, flea control agents for animals (Ivermectin), H 2 receptor antagonists, herbal actives, hormones, hypoglycemics, hypohpidemics, muscle relaxants, ovulation stimulators, peptide active agents, polypeptide active agents, proteins such as insulin, calcitonin, LHRH and the like. Sedatives and hypnotics, sexual dysfunction active agents, sleep aids, smoking cessation aids, steroids and steroidals, tranqui zers, laxatives, ophthalmic preparations, nutntional supplements, breath fresheners, breath deodorants, saliva substitutes, antigingivitis agents, anti-cavity agents, anti-plaque agents, diagnostic indicators, and local anesthetics. Also included are active agents for treatment of osteoporosis, hormone replacement, treatment of penodontal disease, antiseptics, corticosteroids, non steroidal anti-inflammatory agents, antiviral agents and vaccines Water soluble inert fillers include mannitol, xyhtol, sucrose, lactose, maltodextπn, dextran, dextπn, modified starches, dextrose, sorbitol, and dextrates. The water soluble inert fillers may be used in embodiments of the invention as inert earners to form a high water soluble dispersion with active agents. Buffeπng agents include acidulants and alkalizing agents exemplified by citπc acid, fumanc acid, lactic acid, tartaπc acid, malic acid, as well as sodium citrate, sodium bicarbonate and carbonate, sodium or potassium phosphate and magnesium oxide. Coloπng agents may include FD & C coloπng agents, natural coloπng agents, and natural juice concentrates, pigments such as titanium oxide, silicon dioxide and zinc oxide. Stabilizers as used here and in the claims, include anti-oxidants, chelating agents, and enzyme inhibitors as exemplified by ascorbic acid, vitamin E, butylated hyroxyanisole (BHA), butylated hydroxytoluene (BHT), propyl gallate, dilauryl thiodipropionate, thiodipropionic acid, gum guaiac, citπc acid, edetic acid and its salts and glutathione. Preservatives which here include anti -microbial agents and non-organic compounds are exemplified by sodium benzoate, parabens and denvatives, sorbic acid and its salts, propionic acids and its salts, sulfur dioxide and sulfites, acetic acid and acetates, nitπtes and nitrates The mechanical properties of the film is determined by tensile strength modulus, percent elongation (ASTM D882. standard test method for tensile properties of thin plastic sheet) and tear propagation resistance (ASTM D1938, standard test method for tear propagation resistance of plastic film and thm sheet by single tear method) The mechanical properties are measured here using standard protocols as descnbed in Annual Book of ASTM Standards, Amencan National Standards Institute, NY 1995. The "tensile strength" (psi) is the property of film that requires a load to cause load deformation failure of film. The "% elongation" is measured when the film snaps as sufficient force is applied so as to exceed the elastic limit. The "release study" is the percentage of active agents released from the film as a function of time in a suitable dissolution vessel and medium under specified conditions of temperature and pH. "Dry tack" is quantitative values for tackiness (grams) of dry film by Texture Analyzers (Model TA.XT2ι with 6mm diameter stainless steel cylinder probe) from Texture Technologies Coφ. The tackiness after the addition of 10 ml of water on the same surface area is defined as the wet tack (gram) to simulate the adhesion of film upon the contact with a moist mucosal surface. In an embodiment of the invention, the dry tack ranges from 0.2-3.5grams, with a preferred range of 0.4-2.0grams and the wet tack is in the range of 35-150 grams with a preferred range of 40-100 grams. 'Tear propagation resistance" is defined here and in the claims as the average force (N) necessary to propagate a tear across a film or sheet under a specified rate of extension as defined in ASTM D1938 and is mteφreted from the load time chart. In a preferred embodiment of the invention, the tear resistance ranges from 0.001N-1N with a preferred range of 0.01 - 1 N. "Disintegration time" is defined here and in the claims as the time (second) at which a film breaks when brought into contact with water or saliva In an embodiment of the invention, the disintegration time ranges from 1-300 seconds. "Dissolving time" is defined here and in the claims as the time (seconds or minutes) at which not less than 80% of the tested film is dissolved in an aqueous media or saliva. In an embodiment of the invention, the dissolution time ranges from 10-600 seconds. "Modulus" is a measurement of stiffness of a film A factor that plays a significant role in determining the properties of mucosal surface-coat-forming composition is the viscosity of the hydrocoUoid. The viscosity of the hydrocoUoid depends on its molecular size, deπvation, hydrophobicity and hydrophihcity and the presence of other additives in the formulation. A compaπson of films formed from the hydrocoUoid, hydroxymethylcellulose, having different viscosity values is shown in Table 9a and 9b In embodiments of the invention, a hydrocoUoid concentration in the range of 5- 99% of the dry weight of the films is provided, more particularly greater than 10% These films have dry tack and wet tack properties that improve ease of handling and use The low dry tack properties of the film provide for a physically attractive and easily handled film that is neither fragile nor sticky and can be easily removed from packaging and placed on a mucosal surface. The wet tack properties of the film provide the advantage of stickiness of the moistened film such that when the film is placed on the mucosa, it remains attached at that site until it dissolves. In contrast, if the wet tack is too low, the film can move in the mouth and may be swallowed before dissolving and possibly give πse to choking. Furthermore, the low moisture content and low dry tack of the film enhances the shelf-life of the film and the flexibility of the dosage forms. These properties render the films suitable for easy making, packaging, handling and application. In an embodiment of the invention, a water soluble polymer (2% polymer solution) is selected having a gelation temperature greater than 70°C The hydration rate of a hydrocoUoid having these features is rapid with a percentage moisture absoφtion of polymers in the range of 5-20% at 75% humidity at room temperature. The hydration rate is selected according to the desired wettabihty of the film thereby obviating the need for surfactants. The wet tack of the hydrated film ranges from 35-150 grams more particularly 40-100 grams The percentage swelling may be less than 10% within 60 seconds. The film is cast so as to have a thickness of l-20mιl The water content of the film ranges from 0 5-10% with a preferred range of 1-5% In embodiments of the invention, the film may be formed using a mixture of two or more types of the same hydrocoUoid that differ only in molecular weights and/or different degrees of substitution The time of dissolution of the film is in the range of 10-600seconds, (see Figure 4), the time of disintegration of the film may be 1-300 seconds The active agent in the film may be encapsulated in a polymer having different chemical or physical properties from the hydrocoUoid of the film and having dissolution properties different from those of the hydrocoUoid. Examples of the films formed according to the invention having properties that fall into the above ranges are provided m Table 1,3,6 and 7 The ease of handling is characteπzed by the dry tack of the film and the flexibility is reflected by the tensile strength, modulus, % elongation and tear resistance of the film. For example, the dry tack is in the range of 0 2-3.5 grams more particularly 0.4-2.0 grams. The tensile strength may be in the range of 1500-10,000 psi, more particularly 2000-8000, more particularly greater than 2000psι, the modulus is in the range of 35,000 -300,000 and the % elongation is less than 20% more particularly 1-10% for a film having a thickness of 2 mil. In embodiments of the invention, the hydrocoUoid may be a water soluble non-gellmg (at room temperature) natural polysacchande or denvatives including pectin and denvatives, guar gum arable, tragacanth gum, xanthan gum, gellan sodium salt, propyleneglycol algmate, starches (amylose, amylopectin), modified starches, hydroxyethyl starch, pullulan, carboxymethyl starch, gum ghatti, okra gum, karaya gum, dextrans, dextπns and maltodextnns, konjac, acemannan from aloe, locust bean gum, tara gum, quince seed gum, fenugreek seed gum, scleroglucan, gum arable, psyllium seed gum, tamannd gum, oat gum, quince seed gum, carrageenans, scleraglucan, succmoglucan, larch arabinogalactan. flaxseed gum, chondroitin sulfates, hyaluronic acid, curdlan. chitosan, deacetylated konjac, and rhizobium gum. In embodiments of the invention, the hydrocoUoid may be a water soluble non- gelling polypeptide or protein exemplified by gelatins, albumins, milk proteins, soy protein, and whey proteins. The hydrocoUoid may further be selected from a group of synthetic hydrocolloids exemplified by any of the following: polyethylene-imine, hydroxyethyl cellulose, sodium carboxymethyl cellulose, carboxymethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methyl cellulose, methyl cellulose, ethyl cellulose, polyacry c acids, low molecular weight polyacrylamides and their sodium salts (carbomers), polyvinylpyrolhdone, polyethylene glycols, polyethylene oxides, polyvinyl alcohols, pluronics, tetronics, and other block co-polymers, carboxyvinyl polymers, and colloidal silicon dioxide. A preferred embodiment of the invention utilizes a hydroxypropyl methyl cellulose having a methoxy content of about 19-30% and hydroxypropyl content of 7-12% and a molecular weight of approximately 50,000 - 250,000 daltons (Table 9) In addition to hydrocolloids and the active agents, the films may contain any or all of the following ingredients: emulsifying agents, solubihzing agents, wetting agents, taste modifying agents, plasticizers, active agents, water soluble inert fillers, preservatives, buffenng agents, coloπng agents, and stabilizers. In a preferred embodiment, the percentage dry weight concentration of at least single ingredients incoφorated in a film in each of the following categoπes is as follows: emulsifying agent (0.1%-10%), plasticizer (0.5-20%), active agents (0.01-75%), taste modifying agents (0.1-10%), colonng agents (0.01-5%), water soluble inert fillers (0.5-50%), preservatives (0.01-10%), buffenng agents (0.1-10%) and stabilizers (0.01-5%). Methods for manufactunng the dosage unit of the invention include the solvent casting methods as shown in Figure 2 or alternatively extrusion methods as exemplified in Example 11. The extrusion method involves blending ingredients to form a film using mechanical force and moderate heat. Significantly, the above processes do not rely on a freeze drying step. Nor do the above processes rely on extremes of heat or cold duπng manufacture. In an embodiment of the invention, the solvent casting method includes a natural or synthetic hydrocoUoid that is completely dissolved or dispersed in water or m a water alcoholic solution under mixing to form a homogenous formulation. In addition to the active agent and the hydrocoUoid, any of the ingredients listed above may be added and dispersed or dissolved uniformly in the hydrocoUoid solution. The active ingredients and flavoπng agents can be incoφorated before or after film forming This homogeneous mixture (coating solution) with a solid content of 5-50% and a viscosity of 500-15000cps was degassed (8) and coated on the non-sihconized side of a polyester film (10) at 5-50mιl wet film thickness (9), more preferably 5-20mιl wet film thickness and dπed under aeration at a temperature between 40-100°C so as to avoid destabilizing the agents contained within the formulation (11). The manufactunng process for forming the dosage unit is illustrated in Figure 2 The dry film formed by this process is a glossy, stand alone, self supporting, non-tacky and flexible film (12) The dry film is then cut into a suitable shape (13) and surface area for active agent delivery at the preferred site. For example, the cast film can be die-cut into different shapes and sizes using a rotary die The film may be cut into a size that contains for example, a single dosage unit. For example, a dosage unit may include a film size with surface area of 5cm 2 that contains a dosage of active agent in the range of 20-250 mg (14). The size of the film may be vaπed according to the dosage required. The dosage contained in each square centimeter is selected according to the active agent. Films are then packaged into a single pouch package, multi-unit blister card or multiple unit dispensers (Figure 3). In contrast to the above method, the dry extrusion method does not rely on placing the hydrocoUoid in a solvent. Instead, the ingredients of the dosage unit are mixed together in dry form and heated. The heated blend is then forced through an extrusion die to form a film of selected thickness. The film can then be cut and packaged. The dry extrusion method has a number of advantages. First, it is an economical process. Second, because there is no drying oven, extrusion of the film is faster than solvent coating. Third, the dry extrusion avoids the step of removing residual solvent. Some residual solvent is generally present in the solvent coating process and can affect the safety or stability of the film. Where a film requires an organic solvent rather than water, removal of the solvent from the film may be required by environmental regulations. The extrusion process avoids any need for recovenng solvent and avoids residual solvent in the film. The dosage unit may be prepared for use by selecting a film that is capable of delivenng an effective dose and administeπng the film to the patient by placing it on a mucosal surface such as the oral mucosa (Figure 1) where it dissolves in the body fluid for example, saliva (0 5-10 minutes) and is swallowed in liquid form. Figure 4 graphically represents the rate of disintegration and dissolution for different thickness films. Figure 5 shows the release profile of four active agents from films according to Examples 5-8 The fraction of the dose absorbed through the mucosal tissue can be facilitated by the use of a permeation enhancer into the film. The overall bioavailabihty of the active agent which is absorbed both locally at the mucous membrane and systemically within the gastrointestinal system is improved compared to the same dose of the active agent given in a conventional oral tablet or capsule dosage form This is exemplified in Figure 6 and Table 11 which show the improved bioavailabihty of Sildenafil film over Viagra The oral retention characteπstics, mouth feel properties, flavor and taste of the film can be modified based on the hydrocoUoid and other excipients used to prepare the films and the medications The invention is illustrated but not meant to be limited to the examples provided below According to Examples 1-8, the hydrocoUoid was dissolved in water under agitated mixing to form a uniform and viscous solution Additional ingredients were then added sequentially to the viscous solution such as peppermint, aspartame, propyl glycol, benzoic acid and citπc acid under agitated mixing until they were uniformly dispersed or dissolved m the hydrocoUoid. The resultant mixture was degassed m a vacuum chamber until trapped air bubbles were removed. The viscosity, pH and specific gravity were measured. The formulation was then coated on the non-siliconized side of a polyester film at a wet thickness of 10 mil and dned in a hot air circulating oven at 50°C for 9 minutes. A glossy, substantially transparent, stand alone, self-supporting, non-tacky and flexible film was obtained after drying. The dry film was cut into different shapes for measurement of dry tack, wet tack, tensile strength modulus, elongation, tear resistance, residual water content, disintegration and dissolution. The dosage form was 25-250 mg in vanous shapes, sizes, and thickness Example 9 shows how the properties of dosage units vary when different hydroxymethylcellulose polymers are utilized. Example 10 shows how mucoadhesion can be increased up to at least 84% using an enhancer exemplified by starch graft copolymer In vivo studies of the dosage unit show that it is well tolerated by patients (Example 12) and shows enhanced bioavailabihty (Example 13) Examples Examples 1-3. Quick dissolving films, compositions and associated properties The films were prepared as follows: a homogeneous mixture of ingredients was prepared in a coating solution in the amounts indicated in Table 1 The amounts are given as percentage weight of coating solution. The mixture was degassed in a vacuum chamber and coated on the non-siliconized side of a polyester film and dned in a hot air circulating oven to form a self supporting non-tacky and flexible film The film was then cut into dosage units ready for packaging Table 3: Dry weight percentages for components of Example 1 according to Tables 1 and 2. 00/42992 Table 4 Mean values for parameters according to Example 1 in Table 1 Examples 4 - 8: Hydropropylmethylcellulose based quick dissolving intraoral film containing therapeutic agents The films were prepared according to Examples 1 - 3. Therapeutic agents were added to the homogeneous mixture (coating solution) pnor to forming the film. Table 5: Table 8: Properties of the film formed according to the formulation in Table 7 Example 9- A compaπson of properties of dosage units using different hydrox y propylmethylcellulose polymers The properties of a dosage unit according to the invention may be modified by varying individual components. For example, the dissolution of the film may be prolonged by using hydroxypropylmethylcellulose (HPMC) with higher molecular weight as shown below in Table 9. Table 9a: Properties of selected commercial hydroxypropylmethylcellulose polymers. * Each value is the mean S±D, n=6 Table 9b Properties of films prepared according to Example 1, using different hydroxypropylmethylcellulose polymers Λ C, W CΛ H H G H M CΛ S PI H H t r w Example 10. Enhancement of mucoadhesion The enhancement of mucoadhesion was similarly applicable to films of varying thickness. The following formulations were prepared: Table 10 • Starch graft copolymers were prepared by polymenzation in water using 1:3 Amioca com starch: acrylic acid (supplied by NSCC) and are descnbed in further detail in US Patent 4,690,996 and Block and Graft Copolymeπzation, vol 1, RJ.Ceresa, ed. John Wiley and Sons 1973 both references herein incoφorated by reference. •• Mucoadhesion was tested using a tensile instrument (e.g. Texture Analyzer) which measures force of detachment of the invention product from a simulated mucosal tissue matenal. The mucosal-like matenal is prepared from a mixture of 3.25% gellan gum and 1.6% mucin in water. The product to be tested was brought into contact with the simulated mucosal surface for 5 seconds and detached. The force of detachment was measured as the value of mucoadhesion in grams force (g or gf). Test conditions used are as follows: speed of applιcatιon=3mm/s, speed of detachment=2mm/s, force applied before detachment=150g, contact tιme=5s, contact surface = 122.7mm 2 Example 11 Preparation of film using dry extrusion techniques 77 8g Polyethylene Oxide (Polyox®WSR N-10) was mixed using mechanical force and additional ingredients were added dunng the mixing as follows: 5.5g Estradiol. 3.7g Peppermint, 3 7g Propylene Glycol, 3.0g Aspartame. 2.6g Citπc Acid. 3.7g Cremphor EL 40 and 0.05g Benzoic acid.. The temperature was maintained at about 70°C The blend was allowed to mix at 70°C until uniform. It was then forced through an extrusion die to form a film 5 mils in thickness. The film was then cut into dosage forms ready for packaging. Example 12: Human clinical acute imtation study An initial clinical imtation study of placebo samples formulated according to Example 1 was conducted. Six HPMC-based films were applied by each of 12 subjects within one hour. The site of application and the oral mucosae were evaluated for any acute imtation pnor to each application, immediately after each application, one hour and 24 hours after last application. The following indications: erythema, edema, bullae, maceration and discharge were scored on a scale of 0-4. There was no measurable imtation for any of the sites examined and for any of the indications duπng each application, or one hour and 24 hours after the last application. Each subject was asked to assess the mouth feel, product taste, sensation and dissolution time for each application. All twelve subjects did not expeπence any sensation for any application All subjects descnbed films gave them very smooth mouth feel and indicated the taste of freshness the film delivered into the oral cavity for each application All subjects felt the dissolution time of the film was very short (<2 min) The majonty of the subjects stated a preference for the film compared with tablets or capsules. All of the subjects indicated that they preferred the film to solutions or syrups. Example 13: Human pharmacokmetics study showing increased bioavailabihty of a active agent delivered by an dosage unit in the form of a film A dissolving film suitable for administration via the oral mucosa and containing the active agent, sildenafil citrate, formulated according to Table 7 The properties of the dosage unit are descnbed in Table 8. A two way crossover study was conducted compaπng intraoral sildenafil, applied sublingually, with a commercial tablet (Viagra®) at the same dosage. The average plasma levels and the pharmacokinetics analysis are displayed in Figure 6 and Table 11. Figure 6 and Table 11 show that the bioavailabihty of the equivalent dosage from the dissolving film is about 25% higher than the bioavailabihty of the tablet. Table 11 : A companson of pharmacokinetic parameters of Sildanedil film and Viagra film * Area under the curve

Claims: What is claimed' 1. A dosage unit, compπsing: a water-soluble hydrocoUoid, mucosal surface- coat-forming film, such film including an effective dose of an active agent. 2. A dosage unit according to claim 1, wherein the film has a dry tack value of less than 3.5g. 3. A dosage unit according to claim 1, wherein the film has a dry tack value of less than 2.0g. 4. A dosage unit according to claim 1, wherein the film has a water content of 0.1%- 10%. 5. A dosage unit according to claim 4, wherein the film has a water content of less than 5%. 6 A dosage unit according to claim 1, wherein the film has a wet tack value of greater than 35g. 7. A dosage unit according to claim 2, wherein the film has a wet tack value of greater than 35g. 8. A dosage unit according to claim 1, where the hydrocoUoid has a gelation temperature that is greater than 70°C for a 2% polymer solution. 9. A dosage unit according to claim 1, wherein the hydrocoUoid has a hydration rate in 24 hours of 5-20% at 75% humidity at room temperature. 10 A dosage unit according to claim 1, wherein the hydrocoUoid is present at a concentration in the range of 5%-99% 11. A dosage unit according to claim 1, wherein the hydrocoUoid is a polymer selected from the group consisting of a natural, semi-natural and synthetic biopolymer 12. A dosage unit according to claim 11, wherein the hydrocoUoid is selected from the group consisting of a polysacchaπde and a polypeptide. 13. A dosage unit according to claim 11, wherein the hydrocoUoid is a hydroxypropylmethylcellulose polymer. 14. A dosage unit according to claim 11, wherein the hydroxypropylmethylcellulose polymer has a molecular weight of less than 200,000. 15. A dosage unit according to claim 1, wherein the film further includes one or more of an emulsifier, a plasticizer, a taste modifying agent, a water soluble inert filler, a preservative, a coloπng agent and a stabilizer. 16. A dosage unit according to claim 15, wherein the emulsifier has a concentration in the range of 0.1 - 10 %w 17. A dosage unit according to claim 15, wherein the taste modifying agent consists of one or more of a sweetening agent, a flavoπng agent and a taste masking agent. 18. A dosage unit according to claim 15, wherein the film contains the water soluble inert filler has a concentration in the range of 0.5 to 50%. 19 A dosage unit according to claim 15, wherein the preservative has a concentration in the range of 0.01 to 10%. 20. A dosage unit according to claim 1 wherein the active agent is present at a concentration in the range of 0 01 to 75%. 21. A dosage unit according to claim 1, wherein the active agent is selected from the group consisting of a therapeutic agent, a dietary supplement and a hygiene aid. 22. A dosage unit according to claim 21, wherein the therapeutic agent is sildenafil citrate. 23. A dosage unit according to claim 21, wherein the therapeutic agent is selected from the group consisting of nicotine, hydromoφhone. oxybutynine and estradiol 24. A dosage unit according to claim 1, wherein the film has a dry film thickness in the range of 1-20 mil. 25. A dosage unit according to claim 24, wherein the film has a dry film thickness less than 10 mils. 26. A dosage unit according to claim 1, wherein the film has a tensile strength greater than 1500psι. 27 A dosage unit according to claim 1, wherein the film has a % elongation less than 20%. 28. A dosage unit according to claim 1, wherein the film disintegrates in a range from 1-300 seconds. 29. A dosage unit according to claim 1, wherein the film has a modulus in a range from 35,000-300,000 psi. 30. A dosage unit according to claim 1, wherein the film has a dissolving time in a range from 10-600 seconds 31 A dosage unit according to claim 1, wherein the film has a tensile strength greater than 1,500 psi, a % elongation less than 20%, a disintegration time in a range from 1-300 seconds and a dissolution time in a range from 10-600 seconds. 32. A dosage unit according to claim 1, wherein the film has an effective wettabi ty profile in the absence of a mixture of two nonionic surfactants. 33. A dosage unit according to claim 1, wherein the active agent is encapsulated within a polymer, wherein the polymer is chemically or physically distinct from the hydrocoUoid, the encapsulated agent being dispersed within the film. 34. A dosage unit according to claim 1, wherein the dosage unit compπses more than one active agent. 35. A dosage unit according to claim 1, wherein the dosage unit further compπses a mucosal adhesion enhancer, the mucosal adhesion enhancer being located in the film 36. A dosage unit according to claim 35, wherein the mucosal adhesion enhancer is a starch graft copolymer. 37 A dosage unit according to claim 35, wherein the mucosal adhesion enhancer is present at 0%-50% by weight 38. A method of making a dosage unit suitable for mucosal administration, compnsing: (a) dissolving a hydrocoUoid in a solvent so as to form a substantially homogeneous preparation, (b) adding to the hydrocoUoid preparation, an active agent and at least one reagent selected from the group consisting of an emulsifier, a plasticizer, a taste modifier, a water soluble inert filler, a colonng agent, a preservative, a permeation enhancer, a stabilizer and a buffeπng agent to form a coatable or extrudable mixture: and c) forming a mucosal surface-coat forming film from the mixture for packaging as a dosage unit. 39. A method according to claim 38, wherein step (b) further compnses coating the mixture onto a backing film. 40. A method of making a dosage unit suitable for mucosal administration, compπsing. (a) combining, in any order, in a vessel having a heating source and a mechanical mixing device, a hydrocoUoid, an active agent, and at least one reagent selected from the group consisting of an emulsifier, a plasticizer, a taste modifier, a water soluble inert filler, a colonng agent, a preservative, a permeation enhancer, a stabilizer, and a buffenng agent; (b) mixing the combined ingredients dunng and after the addition of the ingredients to the vessel and applying an effective amount of heat for melting a substantial portion of the mixture; and (c) forming the mixture into a film. 41 A method according to claim 40, wherein step (b) further compnses coating or extruding the mixture onto a backing film. 42. A method according to claim 40, wherein step (c) further compπses removing the flexible film from the backing film and die cutting the film to form the dissolving dosage unit. 43 A method for admmisteπng an active agent to a subject, compnsing. (a) obtaining a water-soluble hydrocoUoid, mucosal surface coat- forming- film, such film including an effective dose of an active agent: and (b) placing the film on a mucosal surface in the subject so as to release the active agent. 44 A method according to claim 43, wherein the film has a dry tack value of less than 3.5g. 45. A method according to claim 43, wherein the film has a water content of 0.1%- 10%. 46. A method according to claim 43, wherein the hydrocoUoid has a hydration rate in 24 hours of 5-20% at 75% humidity at room temperature. 47. A method according to claim 43, wherein the hydrocoUoid is present at a concentration in the range of 5-99%. 48. A method according to claim 43, wherein the hydrocoUoid is a hydroxypropylmethylcellulose polymer. 49. A method according to claim 48, wherein the hydroxypropylmethylcellulose polymer has a molecular weight of less than 200,000 50. A method according to claim 43, wherein the hydrocoUoid mixture further includes one or more of an emulsifier, a plasticizer, a taste modifying agent, a water soluble inert filler, a preservative, a colonng agent and a stabilizer. 51. A method according to claim 43, wherein the active agent is present at a concentration in the range of 0 01 to 75% 52. A method according to claim 43, wherein the active agent is selected from the group consisting of a therapeutic agent, a dietary supplement and a hygiene aid. 53. A method according to claim 52, wherein the therapeutic agent is sildenafil citrate. 54. A method according to claim 52, wherein the therapeutic agent is selected from the group consisting of nicotine, hydromoφhone, oxybutynine and estradiol. 55. A method according to claim 43, having a dry film thickness in the range 56. A dosage unit, comprising: a water soluble hydrocoUoid and an effective dose of sildenafil citrate in a mucosal-surface contacting film. 57. A dosage unit according to claim 56, wherein the sildenafil citrate forms a solid dispersion with xyhtol. 58. A method of treating erectile dysfunction; compnsing: (a) obtaining a film including a solid dispersion of an effective dose of sildenafil and xylitol in a water soluble hydrocoUoid; and (b) applying the film to an oral mucosal surface. 59. A method according to claim 58, wherein the film substantially completely dissolves at the oral mucosal surface in 10-600 seconds. 60.A method according to claim 59, wherein the film substantially completely dissolves within 200 seconds. 61. A method of making a dosage unit for mucosal administration, suitable for treating erectile dysfunction , compnsing: (a) combining, in any order, in a vessel having a heating source and a mechanical mixing device, a hydrocoUoid. a solid dispersion of sildenafil and xyhtol, and at least one reagent selected from the group consisting of an emulsifier, a plasticizer, a taste modifier, a coloπng agent, a preservative, a permeation enhancer, a stabilizer, and a buffenng agent; (b) mixing the combined ingredients dunng and after the addition of the ingredients to the vessel and applying an effective amount of heat for melting a substantial portion of the mixture; and (c) forming the mixture into a film. 62. A method according to claim 61, wherein the ratio of sildenafil to xyhtol 63. A method according to claim 61, wherein the water solubility of sildenafil is at least 20 mg/ml. 64. A method according to claim 63, wherein the water solubility of sildenafil is about 50 mg/ml. 65. A dosage unit, compnsing: an effective dose of sildenafil citrate; the sildenafil citrate being formed in a solid dispersion with a water soluble inert filler, the solid dispersion being mixed with film forming reagents including a hydropolymer so as to form a film, the film being capable of dissolving on a mucosal surface so as to release the sildenafil citrate. 105456

Inventors: BURANACHOKPAISAN THITIWAN, CHEN LI-LAN H, OSBORNE JAMES, PFISTER WILLIAM R, RENN DONALD W, TAN HOCK SENG, TAO LI, BURANACHOKPAISAN, THITIWAN, CHEN, LI-LAN, H., OSBORNE, JAMES, PFISTER, WILLIAM, R., RENN, DONALD, W., TAN, HOCK, SENG, TAO, LI
Applicants: LAVIPHARM LAB INC, LAVIPHARM LABORATORIES, INC.
Application year: 1999
Main classification: A61K9
IPC codes: A61K9, A61K31, A61K47, A61P1, A61P15, A61P31