MEANS FOR CREATING A MASS HAVING STRUCTURAL INTEGRITY

Abstract: The present invention relates to a rapidly disintegratable tablet for administration with or without the use of water. The tablet comprises at least one active substance and a mixture of excipients. The excipients provide desired characteristics and physical properties and when the tablet is sintered, excellent tablet binding characteristics are obtained. The tablet is intended for oral administration and dissolves in the presence of water. Also disclosed is a process for the preparation of a rapidly disintegratable tablet for administration with or without the use of water. The process comprising dissolving at least one carbohydrate and at least one structuring protein or polymer in a suitable solvent, wherein the solvent provides high porosity upon drying; spray-drying said dissolved mixture to obtain matrix or bead; dry blending at least one binding polymer, and at least one active drug with the matrix or bead to obtain a pretableting formulation or adding at least one active drug to the matrix or bead dissolved or dispersed components before spray-drying; compressing the formulation to obtain a tablet; and sintering the tablet for a sufficient time and temperature to allow the binding polymer to change status or melt and allow the polymer to resolidify as the temperature is reduced to ambient temperature.

Description: MEANS FOR CREATING A MASS HAVING STRUCTURAL INTEGRITY FTFTT) OF THR TNVF.NTTON The present invention relates to a quick dissolving or disintegrating solid dosage form intended primarily for oral administration to a patient. BACKGROUND OF THF, INVENTION Patient compliance remains a significant problem in health care. Compliance is dependent on a number of factors including but not limited to the route and frequency of drug administration. Frequency of administration can sometimes be decreased by administering long-acting, sustained release, or controlled release pharmaceutical formulations. These techniques have been of tremendous benefit, especially for oral administration. However, oral dosage forms themselves oftentimes have serious disadvantages that adversely affect patient compliance. Oral dosage forms remain a significant problem for a segment of the population. Many patients are unable or unwilling to swallow a solid dosage form. This problem occurs primarily in children and the elderly, however, problems with swallowing are not limited to those segments of the population. Certain conditions or disease states manifest themselves by swallowing difficulties. Otherwise healthy individuals can also exhibit problems with swallowing. Such swallowing difficulties irrespective of their cause can severely compromise patient compliance. In addition, swallowing difficulties are not limited to humans and swallowing remains a significant issue in medicating animals. The pharmaceutical industry has long-recognized the need for a form of oral administration which avoids the swallowing difficulties associated with a traditional tablet. Syrups, elixirs, microcapsules containing slurries and other novel tablet or capsule dosage forms have been developed. None of these dosage forms have been ideal and each has their own disadvantages. The disadvantages include a more costly process for preparation and/or more costly packaging materials. A number of researchers have described a wide variety of techniques for obviating or minimizing swallowing problems. Alkire et al, U.S. Patent No. 5,607,697 discloses an oral dosage form which is composed of a plurality of microparticles each having a core including an active ingredient and a compound which is sweet in taste and has a cooling sensation. Such a compound can be selected from the group consisting of mannitol, sorbitol, a mixture of artificial sweetener and menthol, a mixture of a sugar and menthol or methyl salicylate. Another solution to this problem was described in Wehling et al., U.S. Pat. No. 5,178,878 which relates to certain effervescent dosage forms containing microparticles. The effervescent dosage forms of Wehling et al. provide an effervescent dosage form for direct oral administration. The dosage form is designed to disintegrate rapidly in the mouth releasing its microparticles as a slurry for ingestion. The dosage forms produced in accordance with Wehling et al. can be placed in the patient's mouth and the effervescence contained therein can be activated on contact by the patient's saliva. The tablet then disintegrates. Kallstrand, et al., U.S. Pat. No. 4,994,260 relates to a pharmaceutical mixture. The mixture is used for the controlled release of a substance. According to Kallstrand, et al., a liquid dosage form is produced using either a dry powder or microcapsules which are suspended in a solution of a release-controlling substance, also referred to as a "sink." Alternatively, it is possible to encapsulate the release- controlling substance, together with a drug, within an encapsulating shell. The release-controlling substance may include, inter alia, carbohydrates and carbohydrate- related compounds, disaccharides, monosaccharides, glycerol, glycol, glycosides of monosaccharides and substances derived from ethylene glycol. Boder et al., U.S. Pat. No. 5,126,151 relates to an encapsulation mixture. Boder et al. refers to the construction of gums and candies in oral dosage forms. According to Boder et al., microcapsules are produced using a core material which can be selected from a wide variety of materials including sweeteners, medicaments, drugs, flavoring agents and the like. These materials can be used, either singularly or in combination, in either a single or multiple part delivery system. That is, one or more of these materials may be present within one coating matrix or may be separately coated by the matrix and employed alone or in combination in the final product. The resulting formulations are said to provide a masking of unpleasant tasting drugs such as potassium chloride and the like, making consumption of the drug more appealing to the patient. The dosage forms may be prepared in chewable tablet form. Also of interest may be Schobel et al, U.S. Pat. No. 4,824,681, and Wei et al., U.S. Pat. No. 4,590,075. Encapsulated sweeteners have also been used to provide an extended release of sweetening in, for example, chewing gum. Cousin et al., U.S. Pat. No. 5,464,632 discloses a rapidly disintegratable tablet for oral administration with or without the use of water. The tablet comprises an active substance and a mixture of excipients, wherein the active substance is multiparticulate and in the form of coated microcrystals, coated microgranules or uncoated microgranules and wherein the mixture of excipients comprises excipients which are responsible for the disintegration. The tablet is intended to be swallowed and disintegration occurs in less than sixty seconds under the action of excipients which are responsible for disintegration and which are selected from the group consisting of at least one disintegrating agent and at least one swelling agent. Cherukuri et al., U.S. Pat. No. 5,587,172 is directed to a comestible unit which disperses quickly in the mouth and is prepared by subjecting a feedstock comprising a carbohydrate capable of undergoing flash- flow processing without use of a solution to provide a shearform matrix; initiating crystallization of the shear/form matrix; forming flowable compactible micro-particulates by combining an additive with the shearform matrix; and compacting the micro-particulates resulting from step "c," which comprises at least partially crystallized shearform matrix, to form the final unit. Gole et al., U.S. Pat. No. 5,558,880 is concerned with a method for preparing a solid, porous delivery matrix comprising a porous network of matrix material that disperses rapidly in water comprising the steps of: (a) forming a matrix material dispersion containing from about 0.1% to about 7.5% matrix material by weight of the dispersion. The matrix material comprises a matrix forming agent and one or more amino acids having from about 2 to 12 carbon atoms. The matrix material dispersion is then lyophilized or subjected to solid-state dissolution to form the solid, porous delivery matrix. A number of companies have attempted to develop a quick dissolving oral tablet using lyophilization techniques. A number of disadvantages are also associated with those products. First, water-dissolving compounds interfere with the freeze-dry cycle. Second, the product oftentimes has an unpleasant or bad taste and, third, the lyophilization process itself is time-consuming and expensive. A lyophilized formulation cannot be used with water soluble active ingredients and is limited to low dosages of active ingredients. Further, these tablets are very fragile requiring special packaging procedures thereby increasing the cost of the final product. Yet another manufacturer uses effervescence to create a quick dissolving tablet. Carbon dioxide is generated within the tablet in order to blow the tablet apart. Once again, the tablets prepared by this process are very fragile and require special and costly packaging procedures. Another manufacturer utilizes spun sucrose ("cotton candy") as a quick dissolving tablet matrix. This is an undesirable technology because of the hygroscopic nature of spun sucrose. The resultant tablets, once again, are very fragile and require special packaging. Yet others have dissolved a preparation of a 3% gelatin bead using a spray- dried process. This is not very efficient in terms of throughput. Animal gelatin and sugars are used to prepare a spray-dried bead which is mixed with other ingredients and tablets are stamped out using a tableting machine. There remains a need in the art for quick dissolving oral tablets, i.e., tablets which dissolve, without the need for water or a liquid, in the mouth of a patient. Water or another suitable liquid may not be convenient or readily available or a patient may experience difficulty swallowing. In either situation it would be desirable to use a tablet which can incorporate a large amount of an active ingredient or drug and release the active ingredient upon contact with the surface of the mouth. Thus, while the art has long-struggled with developing a more desirable oral pharmaceutical dosage form, there remains a long-felt need for an improved oral dosage form. An object of the present invention is to develop a relatively quick dissolving oral dosage form that disintegrates in the mouth within approximately 60 seconds, preferably ten seconds, and has acceptable mouth feel. A further object of the present invention is to develop a tablet for oral administration with superior taste, convenient administration and a high load of active ingredient per unit dose without the need for expensive packaging procedures. SUMMARY OF THE INVENTION In accordance with the present invention, there is provided a rapidly disintegratable tablet for administration with or without the use of water, said tablet comprising at least one active substance and a mixture of excipients, wherein said excipients provide desired characteristics and physical properties and when the tablet is sintered, excellent tablet binding characteristics are obtained. The tablet is primarily intended for oral administration and dissolves or disintegrates in the presence of water. The mixture of excipients in the rapidly disintegratable tablet provide desirable mouthfeel characteristics and physical properties when the tablet is sintered. The sintering is preferably conducted at approximately 50° C to 120° C. The mixture can contain at least one binding polymer and the binding polymer is preferably polyethylene glycol having a molecular weight of approximately 1,000 to 1 million. The rapidly disintegratable tablet preferably contains a structuring polymer or protein, preferably gelatin, more preferably fish gelatin. Applicants have also discovered a process for the preparation of a rapidly dissolvable or disintegratable tablet for administration with or without the use of water. The process comprises dissolving at least one carbohydrate and at least one structuring protein or polymer in a suitable solvent, wherein said solvent provides high porosity upon drying; spray-drying said dissolved mixture to obtain a matrix or bead; dry blending at least one binding polymer, and at least one active drug with the matrix or bead to obtain a pretableting formulation or adding at least one active drug to the dissolved components pretableting before drying; compressing said pretableting formulation to obtain a tablet; and sintering said tablet for a sufficient time and temperature to allow the binding polymer to change status or melt and allow said polymer to resolidify as the temperature is reduced to ambient temperature. BRIEF DESCRIPTION OF THE DRAWINGS The figure provides a chart depicting a manufacturing process for preparing the quick dissolving tablet of the present invention. DETATEED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION The present invention involves the preparation of a quick dissolving porous tablet without lyophilization by creating a porous formulation thereby avoiding many of the disadvantages associated with the prior art. While such a quick dissolving tablet would be especially suitable for an immediate release formulation, it would also be useful for sustained and controlled release application. In addition, while the invention would be especially suitable for administering drugs to humans, it is anticipated that dosage units prepared by these teachings would be suitable for administering drugs to animals and for other uses such as rapid diagnostic testing kits. The present invention involves the formation of a spray-dried matrix or bead wherein the matrix or bead is later incorporated in the formation of a compressed tablet with additional binding and structuring agents wherein said binding and/structuring agents are activated with heat during a sintering step. The advantage of the present invention is that it can incorporate taste-masking technologies. Further, since the active ingredient or drug can be added to the formulation in a dry state, a wide variety of different types of compounds or active ingredients can be used in the formulation. The active ingredient can also be placed in a suspension or slurry that can be spray-dried independent of solubility. These are significant advantages associated with the practice of the present invention. The composition of the present invention can also carry a higher payload, i.e., a larger amount of active ingredient per unit dose while still maintaining a small tablet size. For instance, dosage ranges of up to 2,500 mg are possible, more likely 1,000 mg. Dosage ranges for humans typically extend from approximately 2 mg to 500 mg, preferably 10 mg to 250 mg. The process of the present invention also advantageously avoids the significant time and expense associated with lyophilization. Lyophilization limits the amount of active ingredient to approximately 100 mg per unit dose, cannot incorporate active ingredients that exhibit high water solubility which interfere with the freezing process, and eliminates the use of drug candidates that are associated with an undesirable taste. The process of the present invention is also advantageous because it does not rely on effervescence or carbon dioxide release since the amount of active ingredient is also limited in those processes because too much drug can interfere with the speed of the effervescence, and thereby affect the speed of dissolution/disintegration of the tablet. The desirable quick dissolving dosage form of the present invention dissolves or disintegrates rapidly in the mouth, generally within 3-60 seconds, preferably 10-30 seconds. The dosage form of the present invention also allows the incorporation of a wide range of dosage levels. The solubility or insolubility of the active ingredient or drug does not affect the formulation. The formulation of the present invention can incorporate both taste masked and controlled release forms. The formulation of the present invention allows the production of a robust oral dosage form that can be packaged in a wide variety of packaging configuration such as bulk bottles, strip, blister and the like. The process of the present invention provides an orally quick dissolving dosage form of one or more active ingredient or drugs in which taste masking can be incorporated, if desirable. The formulation is not limited to a specific class, category or type of active ingredient and allows for a wide range of such active ingredients or compounds, which can be either water soluble or water insoluble. The quick dissolving dosage forms of the prior art tend to be fragile, cannot incorporate tastemasking, and/or cannot be developed for many drug agents. The subject technology addresses the limitations of the current technologies and allows the formulation of a much more acceptable quick dissolving oral dosage form. In the practice of the present invention, a carbohydrate is combined with a structuring polymer or protein. Suitable carbohydrates for use in the practice of the present invention include sucrose, mannitol, sorbitol, xylose, dextrose, fructose, mannose and the like. The amount of carbohydrate useful in the practice of the present invention is an amount sufficient to provide bulk to the overall tablet formed and can range from approximately 20% to 95%. The structuring polymer or protein useful in the practice of the present invention can be agar, gelatin, albumen, chondroitin and the like. The preferred structuring polymer or protein gelatin. The most preferred gelatin is fish gelatin. Fish gelatin is especially advantageous since it has a low bloom strength which allows a very high concentration of material on the spray-dried matrix or bead of the present invention. The fish gelatin is also advantageous because it eventually provides a porous support structure that allows the tablet to readily dissolve in the mouth. There are other advantages associated with the use of fish gelatin as opposed to using regular gelatin. Regular gelatin can be derived from pigs or cows. Concerns relating to the preparation of kosher products or mad cow disease are eliminated by the use of fish gelatin. In addition, when regular gelatin having a 2 to 3% solids content gets into solution, it cannot be spray-dried because regular gelatin has a bloom strength of 100-300 and develops a viscosity that is too high for effective spray drying. Fish gelatin, on the other hand, has a bloom strength of only about 0-25 so the spray-drying process is thereby made more efficient. The amount of gelatin useful in the practice of the present invention is an amount sufficient to provide structure or support to the tablet and can range from approximately 0.1% to 20%, preferably 1 to 3%. The carbohydrate/protein mixture is then dissolved in a solvent. Suitable solvents include water, ethyl alcohol, isopropyl alcohol, and the like, or a mixture thereof. The preferred solvent is a combination of ethyl alcohol and water in a ratio ranging from approximately 1 : 100 to 1 :1. The solvent is present in an amount sufficient to provide the desired porosity to the tablet upon drying. The matrix or bead formed using carbohydrates and proteins or polymers for structure ultimately allows a low density tablet to be formed and the matrix or bead can be readily prepared using a spray-dry procedure. Thus, the strength of the ultimate tablet is enhanced by blending the spray-dried matrix or bead with a binding polymer along with the other active ingredients or components. Alternatively, when the active ingredient or compound is added to the solvent or dissolved components, a matrix or bead can be spray-dried thus containing the active ingredient. Thus the active drug or agent can be introduced into the process in a number of ways. The matrix or bead is obtained using any spray-dry technique known in the art. The spray-drying step is intended to produce a quick dissolving matrix or bead. The type of spray dry unit and the technique employed varies depending on the unit selected and can be readily determined by one skilled in the art in order to obtain the product of the present invention. A binding polymer can also be added to the spray-dried pretableting formulation along with the active drug. These three components can then be dry blended and compressed, preferably under light compression, to form a tablet. These compressed tablets are then sintered to form a robust ultimate tablet. Alternatively, the binding polymer can be introduced along with the structuring polymer or protein as well as the carbohydrate and/or solvent. Thus the binding polymer may be introduced into the process in a number of ways. In the variation of the process, the active drug may be added to the spray- dried pretableting formulation in the alternative route depicted on the right of the Figure. That is, the pharmaceutically active agent or drug could be introduced before the spray-drying step, either along with the solvent or along with the carbohydrates and structural polymer in the solvent. In yet another variation of the process, the binding polymer as depicted on the left side of the Figure may be added along with the structuring protein or carbohydrate or, alternatively, the binding polymer could be dissolved directly into the solvent in any order along with the carbohydrates, structuring protein and optional active ingredient. These variations of the process as well as other variations are well-known to those skilled in the art of pharmaceutical formulations. Preferred binding polymers or agents useful in the practice of the present invention includes polyethylene glycol; C 12 -C lg fatty acid alcohol, preferably stearyl alcohol; polypeptide; and the like. The polypeptide can be any arrangement of amino acids ranging from approximately 100 to 300,000 daltons. Any of the foregoing would be useful in the practice of the present invention. The preferred binding polymer is polyethylene glycol (PEG) having a molecular weight of approximately 1,000 to 1,000,000. The PEG, preferably melts at about 50°C to 90°C, and is intended to resolidify as the temperature of the final sintering step decreases. PEG is water soluble and can function both as a binder and as a capillary attractant. The amount of binding polymer useful in the practice of the present invention is an amount sufficient to melt upon sintering to provide rigidity or strength to the final tablet and can range from 0.5% to 25% of the weight of the final product. Any technique used for compression would be useful in the practice of the present invention, including hand compression or the use of tableting equipment. Such tableting equipment is discussed in Remington's Pharmaceutical Sciences, which is hereby incorporated by reference, in its entirety herein. The final step in the production of a quick dissolving/disintegrating tablet involves heat treating or sintering the compressed tablet. The heat treatment creates intratablet bonds and helps weld together the tablet shape. The heating can be conducted in an oven, a microwave, or the like. Typically, a laboratory oven is set at approximately 50°C to 100°C. The heating time depends on the exact composition of the mixture but can extend anywhere from 1 minute to 2 hours, preferably 3 minutes to 45 minutes. The heating step is intended to melt the binding polymer, such as a solid polyethyene glycol. More typically, the sintering is conducted at approximately 90 °C for approximately 10 minutes. The heat treating or sintering step improves the tablet's strength and durability thereby obviating the need for special packaging procedures and allows the tablets to be jostled during manufacture, shipping, and consumer use. Other means of heating/sintering can be employed and would be known to one familiar with industrial heating processes. Such heating processes as infrared heat, ultraviolet (UV) and other short wave radiation, microwave heat, radiant heat and industrial equipment designed with such attributes could be equally employed. Any pharmaceutical ingredient or active agent would be useful in the practice of the present invention, such ingredients or agents include systemically distributable pharmaceutical ingredients such as, vitamins, minerals, dietary supplements, as well as nonsystemically distributable drugs. Pharmaceutical ingredients may include, without limitation, antacids, analgesics, anti-inflammatory agents, antibiotics, antiviral agents, antiparasitic agents, laxatives, anorexics, antihistamines, antiasthmatics, bronchodilators, laxatives, antiflatulents, antimigraine agents, sedatives, antihyperactives, antihypertensives, tranquilizers, antidepressants, decongestants, beta blockers, H 2 -antagonists, antitussives, decongestants, alkaloids, ion exchange resins, anti-cholesterolemics, anti-lipid agents, antiarrhythmics, antipyretics, appetite suppressants, expectorants, anti-anxiety agents, anti-ulcer agents, coronary vasodilators, cerebral dilators, peripheral vasodilators, anti-infectious agents, psychotropics, antimanics, neuroleptic agents, central nervous system stimulants, gastrointestinal agents, sedatives, antidiarrheal preparations, anti-anginal drugs, peripheral and brain vasodilators, anti- hypertensive drugs, vasoconstrictors, tranquillizers, antipsychotics, antitumor or anticancer drugs, anticoagulants, antithrombotic drugs, hypnotics, anti-emetics, anti- nausea agents, anti-convulsants, neuromuscular drugs, hyper- and hypoglycemic agents, thyroid and antithyroid preparations, diuretics, antispasmodics, uterine relaxants, antiobesity drugs, anabolic drugs, erythropoietin drugs, hematopoietical agents, uricosuric agents, plant extracts, contrast mediums, cough suppressants, mucolytics or mucoregulators, antiuricemic drugs, immuno depressant drugs, cholesterol lowering agents, hormones, enzymes, drugs acting on the rhythm of the heart, drugs used in the treatment of arterial hypertension, agents, drugs acting on blood coagulability, anti-epileptic agents, muscle relaxants, anti-Parkinson drugs, anorexigenic drugs, vitamins, minerals, dietary supplements, nutritional additives and mixtures thereof. Especially preferred active ingredients contemplated for use in the present invention are antacids, H 2 -antagonists, and analgesics. For example, antacid dosages can be prepared using calcium carbonate alone or in combination with magnesium hydroxide, and/or aluminum hydroxide. Moreover, antacids can be used in combination with H 2 -antagonists. Analgesics include aspirin, ibuprofen, naproxen, acetaminophen and the like plus caffeine. Other preferred drugs or active ingredients for use in the present invention include antidiarrheals such as Immodium AD, antihistamines, antitussives, decongestants, vitamins, and breath fresheners. Also contemplated for use herein are anxiolytics such as Xanax, antipsychotics, such as Clozaril and Haldol; non-steroidal anti-inflammatories (NSAID's), such as Voltaren and Lodine; antihistamines such as Seldane, Hismanal, Relafen, and Tavist; antiemetics, such as Kytril and Cesamet; bronchodilators such as Ventolin and Proventil; antidepressants, such as Prozac, Zoloft, and Paxil; antimigraines such as Imigran, ACE-inhibitors, such as Vasotec, Capoten and Zeetril; anti-alzheimers agents, such as Nicergoline; and Ca +2 - Antagonists such as Procardia, Adalat, and Calan. The popular H 2 -antagonists which are contemplated for use in the present invention include cimetidine, ranitidine hydrochloride, famotidine, nizatidine, ebrotidine, mifentidine, roxatidine, pisatidine and aceroxatidine. The active ingredients most useful in the practice of the present invention comprise ibuprofen, nitroglycerin, clarithromycin and azithromycin. As used in this disclosure, the term vitamin refers to trace organic substances that are required in the diet. For the purposes of the present invention, the term vitamin(s) include, without limitation, thiamine, riboflavin, nicotinic acid, pantothenic acid, pyroxidine, biotin, folic acid, vitamin B 12 , lipoic acid, ascorbic acid, vitamin A, vitamin D, vitamin E and vitamin K. Also included within the term vitamin are the coenzymes thereof. Coenzymes include thiamine pyrophosphates (TPP), flavin mononucleotide (FMM), flavin adenine dinucleotide (FAD), nicotinamide adenine dinucleotide (NAD), nicotinamide adenide dinucleotide phosphate (NADP), Coenzyme A (CoA), pyridoxal phosphate, biocytin, tetrahydrofolic acid, coenzyme B 12 , lipoyllysine, 11 -cis-retinal, and 1,25-dihydroxycholecalciferol. The term vitamin(s) also includes choline, carnitine, and alpha, beta, and gamma carotenes. As used in this disclosure, the term mineral refers to inorganic substances, metals, and the like required in the human diet. Thus, the term mineral as used herein includes, without limitation, calcium, iron, zinc, selenium, copper, iodine, magnesium, phosphorus, chromium and the like, and mixtures thereof. The term dietary supplement as used herein means a substance which has an appreciable nutritional effect when administered in small amounts. Dietary supplements include, without limitation, such ingredients as bee pollen, bran, wheat germ, kelp, cod liver oil, ginseng, and fish oils, amino acids, proteins and mixtures thereof. As will be appreciated, dietary supplements may incorporate vitamins and minerals. In general, the amount of phaπnaceutical ingredient incorporated in each tablet may be selected according to known principles of pharmacy. An effective amount of pharmaceutical ingredient is specifically contemplated. By the term effective amount, it is understood that, with respect to, for example, pharmaceuticals, a pharmaceutically effective amount is contemplated. A pharmaceutically effective amount is the amount or quantity of a drug or pharmaceutically active substance which is sufficient to elicit the required or desired therapeutic response, or in other words, the amount which is sufficient to elicit an appreciable biological response when administered to a patient. As used with reference to a vitamin or mineral, the term "effective amount" means an amount at least about 10% of the United States Recommended Daily Allowance ("RDA") of that particular ingredient for a patient. For example, if an intended ingredient is vitamin C, then an effective amount of vitamin C would include an amount of vitamin C sufficient to provide 10% or more of the RDA. Typically, where the tablet includes a mineral or vitamin, it will incorporate higher amounts, preferably about 100% or more of the applicable RDA. The amount of active agent used can vary widely from a few milligrams to 2500 milligrams or more. Of course, the size of the dosage form, the requirements of other ingredients, and the number of, for example, tablets which constitute a single dose will impact the upper limit on the amount of the pharmaceutically active ingredient which can be used. Generally, however between about 0.1 and 2,500 milligrams of active agent will be used in accordance with the present invention. More preferably between about 1 and about 500 milligrams and most preferably between and about 5 and about 250 milligrams of active agent are used. Stated another way, between about 0.1 and about 67% of the dosage form may be the active agent, based upon the weight of the finished dosage form. More preferably, the amount of active agent may vary from between about 0.6 and about 34% by weight based on the total weight of the finished dosage form. (A 750 mg tablet was used for this calculation.) Other adjuvants may also be used in forming the quick dissolving/disintegrating tablet of the present invention or indeed, in formulating dosage forms as well. Adjuvants include, for example, calcium sulfate NF, dibasic calcium phosphate NF, tribasic calcium sulfate NF, starch, calcium carbonate, microcrystalline cellulose, modified starches, lactose, sucrose and the like, staRx, Avicel, Solka-Floc BW40 Alginic acid, Explotab, AUTOTAB, Guargum, Kaolin, Vecgum, Bentonite, and the like. In general, those may be used in up to 20% w/w, but often are used in amounts as low as 3-5% w/w. In addition to the ingredients in accordance with the present invention, the dosage forms in accordance with the present invention may include flavors, diluents, colors, binders, fillers, compaction vehicles, non-effervescent disintegrants, and lubricants such as those disclosed in Wehling et al. Fragrances, dyes, sweeteners (both artificial and natural) and other additives may be present as well. Flavors incorporated into the composition may be chosen from synthetic flavor oils and flavoring aromatics and/or natural oils, extracts from plants, leaves, flowers, fruits and so forth, and combinations thereof. These may include cinnamon oils, oil of wintergreen, peppermint oils, clover oil, hay oil, anise oil, eucalyptus, vanilla, citrus oil, such as lemon oil, orange oil, grape and grapefruit oil, fruit essences including apple, peach, pear, strawberry, raspberry, cherry, plum, pineapple, apricot and so forth. Flavors may be present in an amount ranging from about 0.5 to 3.0 percent. Lubricants according to the present invention may be used in the amount of up to 20 weight percent, and preferably between 0.5 and about 4 weight percent based on the total composition. Fillers may be used to increase the bulk of the tablet. Some of the commonly used fillers are calcium sulfate, both di- and tri-basic, starch, calcium carbonate, microcrystalline cellulose, modified starches, lactose, sucrose, mannitol, and sorbitol. The sweeteners may be chosen from the following non-limiting list: glucose (corn syrup), dextrose, invert sugar, fructose, and mixtures thereof (when not used as a carrier); saccharin and its various salts such as the sodium salt; dipeptide sweeteners such as aspartame; dihydrochalcone compounds, glycyrrhizin; Stevia Rebaudiana (Stevioside); chloro derivatives of sucrose such as sucralose; sugar alcohols such as sorbitol, mannitol, sylitol, and the like. Also contemplated are hydrogenated starch hydro lysates and the synthetic sweetener 3,6-dihydro-6-methyl-l,2,3-oxathiazin-4- one-2,2-dioxide, particularly the potassium salt (acesulfame-K), and sodium and calcium salts thereof. Other sweeteners may also be used. Other ingredients includes binders which contribute to the ease of formation and general quality of the tablet. Binders include starches, pregelatinized starches, gelatin, polyvinylpyrolidone, methylcellulose, sodium carboxymethylcellulose, ethylcellulose, polyacrylamides, polyvinyloxoazolidone, polyvinylalcohols and the like. Lubricants are also useful in tableting formulations. Lubricants can include, but are not limited to, the following: magnesium stearate, calcium, stearate, zinc stearate, hydrogenated vegetable oils, sterotex, polyoxyethylene, monostearate, talc, polyethyleneglycol, sodium benzoate, sodium lauryl sulfate, magnesium lauryl sulfate, light mineral oil and the like. Furthermore, dispersion enhancers can optionally be used to enhance the breakability of the compressed tablet in an aqueous environment. The dispersants can include starch, alginic acid, polyvinylpyrrolidones, guar gum, kaolin, bentonite, purified wood cellulose, sodium starch glycolate, isoamorphous silicate, and microcrystalline cellulose as high HLB emulsifier surfactants. Other ingredients can also be used in the present invention include glidants such as starch, talc, magnesium and calcium stearate, zinc stearate, dibasic calcium phosphate, magnesium carbonate, magnesium oxide, calcium silicate, and silica arogels. Also, color additives can be used in preparing tablets. Such color additives include food, drug and cosmetic colors (FD&C), drug and cosmetic colors (D&C), or external drug and cosmetic colors (Ext. D&C). These colors or dyes, along with their corresponding lakes, and certain natural and derived colorants are useful in the practice of the present invention. Lakes are dyes absorbed on aluminum hydroxide. Coloring agents may range from between 0.1 to 3.5 weight percent of the total composition. One skilled in the art of pharmaceutical formulations would know when to introduce the foregoing ingredients into the process. The most likely point of introduce would be during the dry blending step. The present invention is a method of making tablets which disintegrate quickly in the mouth of a patient. The quick dissolving/disintegrating units or dosage forms produced in accordance with the present invention disintegrate/dissolve nearly instantaneously. However, these tablets are capable of being manufactured so that they can be handled for packaging and distribution without deterioration of the integrity of the product. In the past, tablets have been made primarily by compressing feedstock under extremely high-pressure in order to provide the necessary hardness for handling required during packaging and distribution. Consequently, prior art tablets so produced were limited in that their high density reduces the capability of making them quickly disintegratable in the mouth. High density packing resulting from the high compression hinders the disintegration and wetting of the interior portion of the tablet. As a result of the present invention, however, a significant step forward has been made in the art of preparing tablets which disintegrate very quickly in the mouth. In fact, tablets produced by the present invention can preferably disintegrate within seconds. The quick disintegrating or dissolving tablet of the present invention may also be useful in an in vitro test kit, a diagnostic test kit containing reagents, an immunizing agent, skin antigen, aquaculture as nutrients or medicinals, oral hygiene tablet, localized infections in the mouth, a means to extemporaneously prepare an ophthalmic solution for administration to the eye, or the like. Thus the novel quick disintegrating or dissolving tablet of the present invention could have a wide variety of uses all of which would simply require exposure to an aqueous environment. The foregoing will be better understood with reference to the following examples which detail certain procedures for manufacture of tablets in accordance to the present invention. All references made to these examples are for the purposes of illustration. They are not to be considered limiting as to the scope and nature of the present invention. Example 1 The goal of this example was to formulate, blend and tablet a quick dissolving tablet containing taste masked chlorpheniramine maleate as the active ingredient. Descote is a trademark of Particle Dynamics, Inc., St. Louis, Missouri. Ingredient Amount, g %of Composition Descote® Chlorpheniramine Maleate, 10% 1.4 7 Spray Dried Matrix Bead 14.12 70.6 Polyethylene Glycol, PEG-3350 3.2 16 Sweeteners 0.6 3.0 Cab-O-Sil 0.14 0.7 Coloring Agents 0.1 0.5 Flavors 0.14 0.7 Magnesium Stearate 0.1 0.5 The target tablet weight was approximately 150 mg. The tablet was hand compressed using a l A inch round punch and die set. The mixture was blended for 10 minutes. The blend was compressed to produce a tablet having a weight of 150 mg. Compressed tablets were sintered at 50° C for 50 minutes in an oven. The tablets disintegrated in a USP Basket-Rack Assembly Disintegration Apparatus in about 10 seconds. Example 2 Chlorpheniramine maleate (CPM) was dissolved in the feed solution together with the other components of the tablet matrix. The solution was spray dried. The quick dissolving tablet matrix bead was produced. The bead contained 1.6% CPM. Ingredient Amount, g %of Composition Matrix with CPM 231 76.0% PEG-3350 30 9.9% Tri-Calcium Phospate 36 12.0% Cab-O-Sil 3 1.0% The target tablet weight was approximately 570 mg. The tablet was compressed on a Stokes BB-2 tablet press, equipped with nine stations of a Vi inch round flat beveled tooling. The mixture was blended for 3 minutes. The blend was compressed to produce a tablet having a weight of 570 mg. Compressed tablets were sintered at 90° C for 10 minutes in an oven. The tablets disintegrated in a USP Basket-Rack Assembly Disintegration Apparatus in under 15 seconds. Example 3 A quick dissolving formulation was prepared according to the present invention. Spray drying of the tablet matrix was carried out in a spray dryer with an attached active carbon filter for solvent recovery. The spray-dried matrix was processed as shown in the figures and the tablets prepared sintered at 90 °C, as also indicated in the figure. The tablets prepared exhibited a robust nature in that they could be dropped on a table at a height of 2 feet without damage, and yet disintegrated in the mouth within 30 seconds. Thus, while there had been described what are presently believed to be the preferred embodiments of the present invention, those skilled in the art will appreciate that other and further embodiments can be made without departing from the spirit of the invention and it is intended to include all such further modifications and changes as come within the true scope of the claims as set forth herein.

Claims: What is claimed is: 1. A rapidly disintegratable tablet for administration with or without the use of water, said tablet comprising at least one active substance and a mixture of excipients, wherein said excipients provide desired characteristics and physical properties and when the tablet is sintered, excellent tablet binding characteristics are obtained. 2. The rapidly disintegratable tablet according to claim 1 , wherein said tablet is intended for oral administration. 3. The rapidly disintegratable tablet according to claim 2, wherein said tablet dissolves in the presence of water. 4. The rapidly disintegratable tablet according to claim 3, wherein said mixture of excipients provide desired mouthfeel characteristics and physical properties when the tablet is sintered. 5. The rapidly disintegratable tablet according to claim 1, wherein said mixture of excipients comprises at least one binding polymer. 6. The rapidly disintegratable tablet according to claim 5, wherein said binding polymer is polyethylene glycol. 7. The rapidly disintegratable tablet according to claim 6, wherein said polyethylene glycol has a molecular weight of approximately 1 ,000 to 1 million. 8. The rapidly disintegratable tablet according to claim 1, wherein said mixture of excipients includes at least one structuring polymer or protein. 9. The rapidly disintegratable tablet according to claim 1, wherein said structuring polymer or protein is gelatin. 10. The rapidly disintegratable tablet according to claim 9, wherein said gelatin is fish gelatin. 11. The rapidly disintegratable tablet according to claim 1 , wherein said sintering is conducted in the range of approximately 50°C to 120°C. 12. The rapidly disintegratable tablet according to claim 1, wherein said active substance is selected from the group consisting of antacids, analgesics, anti- inflammatory agents, antibiotics, antiviral agents, antiparasitic agents, laxatives, anorexics, antihistamines, antiasthmatics, bronchodilators, laxatives, antiflatulents, antimigraine agents, sedatives, antihyperactives, antihypertensives, tranquilizers, antidepressants, decongestants, beta blockers, H 2 -antagonists, antitussives, decongestants, alkaloids, ion exchange resins, anti-cholesterolemics, anti-lipid agents, antiarrhythmics, antipyretics, appetite suppressants, expectorants, anti-anxiety agents, anti-ulcer agents, coronary vasodilators, cerebral dilators, peripheral vasodilators, anti-infectious agents, psychotropics, antimanics, neuroleptic agents, central nervous system stimulants, gastrointestinal agents, sedatives, antidiarrheal preparations, anti- anginal drugs, peripheral and brain vasodilators, anti-hypertensive drugs, vasoconstrictors, tranquillizers, antipsychotics, antitumor or anticancer drugs, anticoagulants, antithrombotic drugs, hypnotics, anti-emetics, anti-nausea agents, anti- convulsants, neuromuscular drugs, hyper- and hypoglycemic agents, thyroid and antithyroid preparations, diuretics, antispasmodics, uterine relaxants, antiobesity drugs, anabolic drugs, erythropoietin drugs, hematopoietical agents, uricosuric agents, plant extracts, contrast mediums, cough suppressants, mucolytics or mucoregulators, antiuricemic drugs, immuno depressant drugs, cholesterol lowering agents, hormones, enzymes, drugs acting on the rhythm of the heart, drugs used in the treatment of arterial hypertension, anti-migraine agents, drugs acting on blood coagulability, anti- epileptic agents, muscle relaxants, anti-Parkinson drugs, anorexigenic drugs, vitamins, minerals, dietary supplements, nutritional additives and mixtures thereof. 13. The rapidly disintegratable tablet according to claim 12, wherein said active substance is selected from antacids, analgesics, anti-inflammatory agents, coronary vasodilators, peripheral vasodilators, antibiotics, antiviral agents, antianxiety drugs, central nervous system stimulants, antihistamines, hormones, anti-hypertensive agents, bronchodilators, anti-migraine agents, muscle relaxants, anti-epileptic agents, anti-Parkinson drugs, decongestants, diuretics, hypnotic/sedative drugs and expectorants. 14. The rapidly disintegratable tablet according to claim 13, wherein said active substance is selected from ibuprofen, nitroglycerin, clarithromycin and azithromycin. 15. A process for the preparation of a rapidly disintegratable tablet for administration with or without the use of water, said process comprising: dissolving at least one carbohydrate and at least one structuring protein or polymer in a suitable solvent, wherein said solvent provides high porosity upon drying; spray-drying said dissolved mixture to obtain a matrix or bead; dry blending at least one binding polymer, and at least one active drug with the matrix or bead to obtain a pretableting formulation or adding at least one active drug to the solvent or dissolved mixture, or adding said binding polymer to the carbohydrate and/or structuring polymer or protein and/or solvent, thus said binding polymer and said active drug may optionally be added before said spray-drying, compressing said pretableting formulation to obtain a tablet; and sintering said tablet for a sufficient time and temperature to allow the binding polymer to change status or melt and allow said polymer to resolidify as the temperature is reduced to ambient. 16. The process according to claim 15, wherein said carbohydrate is selected from the group consisting of sucrose, mannitol, sorbitol, xylose, dextrose, fructose and mannose. 17. The process according to claim 15, wherein said structuring protein or polymer is selected from the group consisting of agar, gelatin, albumen, and chondroitin. 18. The process according to claim 17, wherein said structuring protein or polymer is gelatin. 19. The process according to claim 18, wherein said gelatin is fish gelatin. 20. The process according to claim 15, wherein said solvent is selected from the group consisting of water, ethyl alcohol, and mixtures thereof. 21. The process according to claim 15, wherein said binding polymer is selected from the group consisting of polyethylene glycol, fatty acid alcohols and polypeptides. 22. The process according to claim 21 , wherein said binding polymer is polyethylene glycol. 23. The process according to claim 22, wherein said polyethylene glycol has a molecular weight of approximately 1,000 to 1 million. 24. The process according to claim 15, wherein said sintering is conducted at approximately 50°C to 100°C and for approximately 3 minutes to two hours. 25. The process according to claim 24, wherein the sintering is conducted at approximately 90 °C for approximately 10 minutes.

Inventors: LAGOVIYER YURY, LEVINSON R SAUL, RILEY THOMAS C, STOTLER DENIS, LAGOVIYER, YURY, LEVINSON, R., SAUL, RILEY, THOMAS, C., STOTLER, DENIS
Applicants: KV PHARM CO, KV PHARMACEUTICAL COMPANY
Application year: 2000
Main classification: A61K9
IPC codes: A61K9, A61K47