Drug condensation aerosols and kits
Abstract
The present invention provides novel condensation aerosols for the treatment of disease and/or intermittent or acute conditions. These condensation aerosols have little or no pyrolysis degradation products and are characterized by having an MMAD of between 1-3 microns. These aerosols are made by rapidly heating a substrate coated with a thin film of drug having a thickness of between 0.05 and 20 μm, while passing a gas over the film, to form particles of a desirable particle size for inhalation. Kits comprising a drug and a device for producing a condensation aerosol are also provided The device contained in the kit typically, has an element for heating the drug which is coated as a film on the substrate and contains a therapeutically effective dose of a drug when the drug is administered in aerosol form, and an element allowing the vapor to cool to form an aerosol. Also disclosed, are methods for using these aerosols and kits.
Claims
exact text as granted — not AI-modified1 - 82 . (canceled)
83 . A drug supply article comprising:
a substrate having a surface; a layer of a drug applied to the substrate surface, the layer of the drug having a select thickness and a select surface area, the select thickness providing less than 10% degradation of the drug and the select surface area providing a therapeutically effective drug dosage upon vaporization of the layer of the drug.
84 . The drug supply article of claim 83 further comprising the substrate having a surface to mass ratio of greater than 1 cm 2 /gram.
85 . The drug supply article of claim 83 further comprising the substrate having a surface to volume ratio of greater than 100/meter.
86 . The drug supply article of claim 83 wherein the substrate comprises more than one surface.
87 . The drug supply article of claim 83 further comprising the surface being planar.
88 . The drug supply article of claim 83 further comprising the surface being cylindrical.
89 . The drug supply article of claim 83 wherein the substrate comprises surface characteristics of a metallic foil.
90 . The drug supply article of claim 83 wherein the substrate is made of a material selected from the group consisting of metal, metal alloys, ceramics and filled polymers.
91 . The drug supply article of claim 83 wherein the surface is substantially free of surface irregularities.
92 . The drug supply article of claim 83 wherein the surface is substantially impermeable.
93 . The drug supply article of claim 83 wherein the surface comprises an impermeable coating.
94 . The drug supply article of claim 83 wherein the substrate is heat-conductive.
95 . The drug supply article of claim 83 wherein the substrate comprises a metallic foil.
96 . The drug supply article of claim 95 further comprising the metallic foil being one of aluminum and stainless steel.
97 . The drug supply article of claim 95 wherein the metallic foil has a thickness of between about 0.1-0.25 mm.
98 . The drug supply article of claim 83 wherein the temperature of vaporization is between 200-600° C.
99 . The drug supply article of claim 83 wherein the select thickness is between about 0.05-20.0 microns.
100 . The drug supply article of claim 83 wherein the select thickness is between about 0.5-10.0 microns.
101 . The drug supply article of claim 83 wherein the select thickness is between about 0.5-5.0 microns.
102 . The drug supply article of claim 83 further comprising the select thickness providing vaporization of at least about 50% of a total volume of drug applied to the substrate surface.
103 . The drug supply article of claim 83 further comprising the drug being a prodrug.
104 . The drug supply article of claim 83 further comprising the drug being in one of a free base, free acid or salt form of the drug.
105 . The drug supply article of claim 83 wherein the select surface area is between about 0.05-500 cm 2 .
106 . The drug supply article of claim 83 wherein the select surface area is between about 0.5-100 cm 2 .
107 . The drug supply article of claim 83 wherein the select surface area is calculated as follows:
surface area (cm 2 )=therapeutically effective dosage(g)/[select thickness (cm)×drug density (g/cm 3 ).
108 . The drug supply article of claim 83 wherein the drug is heat stable.
109 . The drug supply article of claim 83 wherein the drug is pure.
110 . The drug supply article of claim 83 wherein the drug is combined with at least one of a pharmaceutically acceptable excipient or solvent.
111 . The drug supply article of claim 83 wherein the drug has a molecular weight between about 200-700.
112 . The drug supply article of claim 83 wherein the drug has a molecular weight greater than about 350.
113 . The drug supply article of claim 83 wherein the drug comprises at least two drugs.
114 . The drug supply article of claim 83 further providing vaporization in less than about 2 seconds at a temperature of at least 200° C.
115 . A drug supply article comprising:
a substrate having a surface; a layer of a drug applied to the substrate surface, the layer of the drug having a select thickness and a select surface area, the select thickness providing vaporization of the drug in less than 2 seconds at a temperature of at least 200° C. and the select surface area providing a therapeutically effective drug dosage upon vaporization of the layer of the drug.
116 . The drug supply article of claim 115 wherein the select thickness provides vaporization of the drug in less than 500 milliseconds.
117 . The drug supply article of claim 115 wherein the temperature is at least about 250° C.
118 . The drug supply article of claim 115 wherein the temperature is at least about 300° C.
119 . The drug supply article of claim 115 wherein the temperature is at least about 300° C.
120 . The drug supply article of claim 115 wherein the temperature is at least about 350° C.
121 . The drug supply article of claim 115 wherein the temperature is between about 200-600° C.
122 . The drug supply article of claim 115 further comprising the substrate having a surface to mass ratio of greater than 1 cm 2 /gram.
123 . The drug supply article of claim 115 further comprising the substrate having a surface to volume ratio of greater than 100/meter.
124 . The drug supply article of claim 115 wherein the substrate comprises more than one surface.
125 . The drug supply article of claim 115 further comprising the surface being planar.
126 . The drug supply article of claim 115 further comprising the surface being cylindrical.
127 . The drug supply article of claim 115 wherein the substrate comprises surface characteristics of a metallic foil.
128 . The drug supply article of claim 115 wherein the substrate is made of a material selected from the group consisting of metal, metal alloys, ceramics and filled polymers.
129 . The drug supply article of claim 115 wherein the select thickness is between about 0.05-20.0 microns.
130 . The drug supply article of claim 115 further comprising the select thickness providing vaporization of at least about 50% of a total volume of drug applied to the substrate surface.
131 . The drug supply article of claim 115 further comprising the drug being a prodrug.
132 . The drug supply article of claim 115 further comprising the drug being in one of a free base, free acid or salt form of the drug.
133 . The drug supply article of claim 115 wherein the select surface area is between about 0.05-500 cm 2 .
134 . The drug supply article of claim 115 further comprising the select thickness providing less than about 10% degradation of the drug upon vaporization.
135 . A drug supply article comprising:
a substrate having a surface; a layer of a drug applied to the substrate surface, the layer of the drug having a select thickness and a select surface area, the select thickness providing vaporization of at least about 50% of a total volume of drug and the select surface area providing a therapeutically effective drug dosage upon vaporization of the layer of the drug.
136 . A method of making a drug supply article comprising:
a) determining a therapeutically effective volume of the drug for delivery as a condensation aerosol; b) applying a layer of the drug to a substrate in a select thickness providing less than 10% degradation of the drug upon vaporization of the drug and a select surface area providing the therapeutically effective volume upon vaporization of the drug.
137 . The method of claim 136 further comprising when the drug is in a solid form, prior to step b), dissolving the drug in a solvent to form a liquid solution.
138 . The method of claim 137 wherein step b) is performed by coating the solution on the substrate.
139 . The method of claim 137 wherein the coating is performed by one of dipping the substrate into the solution, spraying the solution onto the substrate and brushing the solution onto the substrate.
140 . The method of claim 136 further comprising when the drug is in a liquid form at room temperature, prior to step b) mixing a thickening agent with the drug to provide application of a solid drug film.
141 . The method of claim 136 further comprising the substrate having a surface to mass ratio of greater than 1 cm 2 /gram.
142 . The method of claim 136 further comprising the substrate having a surface to volume ratio of greater than 100/meter.
143 . The method of claim 136 wherein the substrate comprises more than one surface.
144 . The method of claim 136 further comprising the surface being planar.
145 . The method of claim 136 further comprising the surface being cylindrical.
146 . The method of claim 136 wherein the substrate comprises surface characteristics of a metallic foil.
147 . The method of claim 136 wherein the select thickness is between about 0.05-20.0 microns.
148 . The method of claim 136 further comprising the select thickness providing vaporization of at least about 50% of a total volume of drug applied to the substrate surface.
149 . The method of claim 136 further comprising the drug being a prodrug.
150 . The method of claim 136 further comprising the drug being in one of a free base, free acid or salt form of the drug.
151 . The method of claim 136 wherein the select surface area is between about 0.05-500 cm 2 .
152 . A method of making a drug supply article comprising:
determining a therapeutically effective volume of a drug for delivery as a condensation aerosol; and applying the drug to a substrate in a select thickness providing vaporization of the drug in less than 2 seconds at a temperature of at least 200° C. and a select surface area providing the therapeutically effective volume upon vaporization.
153 . A method of making a drug supply article comprising:
determining a therapeutically effective volume of the drug for delivery as a condensation aerosol; and applying the drug to the substrate in a select thickness providing vaporization of at least about 50% of a total volume of drug and the select surface area providing a therapeutically effective volume of the drug upon vaporization of the layer of the drug.
154 . A method of applying a drug coating to a substrate comprising:
a) determining a therapeutically effective volume of the drug for delivery as a condensation aerosol; b) applying a layer of the drug to the substrate in a select thickness providing less than 10% degradation of the drug upon vaporization of the drug and a select surface area providing the therapeutically effective volume upon vaporization of the drug.
155 . The method of claim 154 further comprising when the drug is in a solid form, prior to step b), dissolving the drug in a solvent to form a liquid solution.
156 . The method of claim 155 wherein step b) is performed by coating the solution on the substrate.
157 . The method of claim 155 wherein the coating is performed by one of dipping the substrate into the solution, spaying the solution onto the substrate and brushing the solution onto the substrate.
158 . The method of claim 154 further comprising when the drug is in a liquid form at room temperature, prior to step b) mixing a thickening agent with the drug to provide application of a solid drug film.
159 . The method of claim 154 further comprising the substrate having a surface to mass ratio of greater than 1 cm 2 /gram.
160 . The method of claim 154 further comprising the substrate having a surface to volume ratio of greater than 100/meter.
161 . The method of claim 154 wherein the substrate comprises more than one surface.
162 . The method of claim 154 further comprising the surface being planar.
163 . The method of claim 154 further comprising the surface being cylindrical.
164 . The method of claim 154 wherein the substrate comprises surface characteristics of a metallic foil.
165 . The method of claim 154 wherein the select thickness is between about 0.05-20.0 microns.
166 . The method of claim 154 further comprising the select thickness providing vaporization of at least about 50% of a total volume of drug applied to the substrate surface.
167 . The method of claim 154 further comprising the drug being a prodrug.
168 . The method of claim 154 further comprising the drug being in one of a free base, free acid or salt form of the drug.
169 . The method of claim 154 wherein the select surface area is between about 0.05-500 cm 2 .
170 . A method of applying a drug coating to a substrate comprising:
determining a therapeutically effective volume of the drug for delivery as a condensation aerosol; and applying the drug to the substrate in a select thickness providing vaporization of the drug in less than 2 seconds at a temperature of at least 200° C. and a select surface area providing the therapeutically effective volume upon vaporization.
171 . A method of applying a drug coating to a substrate comprising:
determining a therapeutically effective volume of the drug for delivery as a condensation aerosol; and applying the drug to the substrate in a select thickness providing vaporization of at least about 50% of a total volume of drug and the select surface area providing a therapeutically effective volume of the drug upon vaporization of the layer of the drug.
172 . A device for making a condensation aerosol from a drug comprising:
a first chamber configured to receive a substrate bearing a drug layer; a heater within the chamber in operative association with the drug layer to vaporize the drug layer; carrier gas flow means for flowing a carrier gas through the first chamber at a first velocity sufficient to transport the vaporized drug away from the heater before greater than 10% degradation of the drug; and a second chamber in fluid communication with the first chamber, the second chamber being configured to produce aerosol particles of a therapeutically effective size.
173 . The device of claim 172 wherein the carrier gas flow means further comprises:
means for flowing the carrier gas through the second chamber at a second velocity, the second velocity being less than the first velocity.
174 . The device of claim 173 further comprising:
the second chambering being configured to provide a stable concentration of the aerosol particles of a therapeutically effective size.
175 . The device of claim 174 wherein the stable concentration is about 10 9 particles/mL.
176 . The device of claim 172 wherein the therapeutically effective size is MMAD between 0.2-5 microns.
177 . The device of claim 172 wherein the heater is configured to heat in a manner producing vaporization in less than 500 milliseconds for a select drug layer.
178 . The device of claim 172 wherein the drug layer has a thickness providing less than 10% degradation of the drug upon vaporization.
179 . The device of claim 173 wherein the carrier gas flow means comprises a carrier gas inlet and mouth piece configured so that upon inhalation at the mouth piece by a patient the first and second velocities of carrier gas flow results.
180 . The device of claim 179 further comprising means for activating the heater upon inhalation by a patient.
181 . The device of claim 179 further comprising means for providing air to the mouth piece for augmenting the flow of carrier gas to a patient during inhalation.
182 . The device of claim 172 wherein the heater is configured to vaporize the drug at a rate greater than 0.5 mg/sec.
183 . The device of claim 172 wherein the carrier gas flow means is configured to provide a volume of carrier gas flow through the first and second chambers at between about 4-50 L/minute.
184 . The device of claim 172 wherein the carrier gas flow means is configured to provide a volume of carrier gas flow through the first and second chambers at between about 5-30 L/minute.
185 . The device of claim 179 wherein the carrier gas flow means comprises a gas flow control valve upstream of the first chamber for limiting the gas flow rate through the second chamber.
186 . The device of claim 185 wherein the gas flow control valve comprises a deformable flap operatively associated with the carrier gas inlet adapted to redirect carrier gas flow away from the inlet increasingly with increasing pressure drop across the valve.
187 . The device of claim 185 further comprising a bypass valve communicating with the mouth piece for offsetting the decrease in airflow produced by the gas flow control valve to provide a total volumetric airflow through the mouthpiece sufficient for a user to sense a full breath being drawn in.
188 . A method of administering a drug of a type administered orally or by injection in combination with a solvent or excipient to a patient for inhalation by the patient comprising:
a) determining a therapeutically effective dose of the drug for administration as a condensation aerosol by inhalation by a patient; b) providing a volume of the drug sufficient to provide the therapeutically effective dose upon vaporization on a substrate without any excipient or solvent; c) vaporizing the drug; d) condensing the drug to produce a condensation aerosol; and e) delivering the condensation aerosol to a patient for inhalation.
189 . The method of claim 188 wherein step c) comprises heating the drug in less than 2 seconds at a temperature of at least 200° C.
190 . The method of claim 188 wherein step d) comprises providing the drug as a layer on the substrate having a thickness providing less than 10% degradation upon vaporization of the drug.
191 . The method of claim 188 wherein in step b) the drug is in a solid state.
192 . The method of claim 188 further comprising providing a carrier gas to capture the vaporized drug, the carrier gas flowing at a velocity providing less than 10% degradation of the drug during step c).
193 . The method of claim 188 wherein step d) is performed under conditions providing therapeutically effective size particles.
194 . The method of claim 193 wherein the therapeutically effective size particles have a MMAD between 0.2-5 microns.
195 . The method of claim 188 wherein the condensation aerosol has a stable concentration of particles.
196 . A method of making a condensation aerosol from a drug of the type administered orally or by injection in combination with a solvent or excipient to a patient for inhalation by the patient comprising:
a) determining a therapeutically effective dose of the drug for administration as a condensation aerosol by inhalation by a patient; b) providing a volume of the drug sufficient to provide the therapeutically effective dose upon vaporization on a substrate without any excipient or solvent; c) vaporizing the drug; and d) condensing the drug to produce a condensation aerosol.
197 . The method of claim 196 wherein step c) comprises heating the drug in less than 2 seconds at a temperature of at least 200° C.
198 . The method of claim 196 wherein step d) comprises providing the drug as a layer on the substrate having a thickness providing less than 10% degradation upon vaporization of the drug.
199 . The method of claim 196 wherein in step b) the drug is in a solid state.
200 . The method of claim 196 further comprising providing a carrier case to capture the vaporized drug, the carrier gas flowing at a velocity providing less than 10% degradation of the drug during step c).
201 . The method of claim 196 wherein step d) is performed under conditions providing therapeutically effective size particles.
202 . The method of claim 201 wherein the therapeutically effective size particles have a MMAD between 0.2-5 microns.
203 . The method of claim 196 wherein the condensation aerosol has a stable concentration of particles.
204 . An aerosol for delivery of a drug by inhalation comprising condensation particles having an MMAD between 0.2-5 microns and a stable concentration of the condensation particles.
205 . The aerosol of claim 204 wherein the aerosol is at least 90% free of additional compounds.
206 . The aerosol of claim 204 wherein the drug is a heat stable drug.
207 . The aerosol of claim 204 wherein the MMAD is between 1-3 microns.
208 . The aerosol of claim 204 wherein the drug is a solid at room temperature.
209 . The aerosol of claim 205 wherein the stable concentration of particles is about 10 9 particles/mL.
210 . An aerosol for delivery of a heat stable drug by inhalation, wherein the heat stable drug is a solid at room temperature, the aerosol comprising a condensation aerosol that is at least 90% free of other compounds and has condensation particles of an MMAD between 0.2-5 microns.
211 . The aerosol of claim 204 wherein the MMAD is between 1-3 microns.
212 . The aerosol of claim 204 further comprising a stable concentration of condensation particles.
213 . The aerosol of claim 204 further comprising a concentration of condensation particles of about 10 9 particles/mL.
214 . An aerosol for delivery of a drug by inhalation comprising condensation particles having an MMAD between 0.2-5 microns and a particle density greater than 10 6 particles/mL.
215 . The aerosol of claim 214 wherein the aerosol is at least 90% free of additional compounds.
216 . The aerosol of claim 214 wherein the drug is a heat stable drug.
217 . The aerosol of claim 214 wherein the MMAD is between 1-3 microns.
218 . The aerosol of claim 214 wherein the drug is a solid at room temperature.
219 . The aerosol of claim 214 further comprising a particle density of about 10 9 particles/mL.
220 . A device for delivery of a condensation aerosol for inhalation comprising:
an aerosolizer comprising a drug on a substrate and a heater for vaporizing the drug; a site of inhalation; and a passageway linking the aerosolizer with the site of inhalation, the passageway being configured to cause condensation of the vaporized drug into a condensation aerosol.
221 . The device of claim 220 wherein drug comprises a unit dose of drug in solid form on the substrate.
222 . The device of claim 220 wherein the passageway is configured to produce condensation particles having a MMAD between 0.2-5 microns.
223 . The device of claim 220 wherein the heater is configured to reach a temperature of at least 200° C. in less than 2 seconds.
224 . The device of claim 223 wherein the temperature is between about 200-600° C.
225 . The device of claim 220 further comprising means for providing a carrier gas at a first velocity to the aerosolizer for entraining the vaporized drug in the carrier gas and for providing the vaporized drug and the carrier gas in the passageway at a second velocity, the first velocity being greater than the second velocity.
226 . The device of claim 225 wherein the first velocity prevents more than 10% thermal degradation of the drug.
227 . The device of claim 220 further comprising means for providing the carrier gas at a volumetric flow rate of between about 4-50 L/minute.
228 . The device of claim 220 further comprising means for providing the carrier gas at a volumetric flow rate of between about 5-30 L/minute.
229 . The device of claim 220 wherein the heater comprises an electrical resistance element.
230 . The device of claim 220 wherein the heater comprises a source of electromagnetic radiation.
231 . The device of claim 220 wherein the heater comprises exothermic means for producing exothermic chemical reactions.
232 . The device of claim 231 wherein the exothermic means comprises one of exothermic salvation, hydration of pyrophoric materials and oxidation of combustible materials.
233 . A method of making an aerosol for delivery to a patient comprising:
vaporizing a drug; entraining the vaporized drug in a carrier gas flowing at a first velocity; and condensing the vaporized drug in the carrier gas with the carrier gas flowing at a second velocity less than the first velocity.
234 . The method of claim 233 wherein the first velocity is sufficient to prevent more than 10% thermal degradation of drug.
235 . The method of claim 233 further comprising producing a carrier gas volumetric flow rate between about 4-50 L/minute.
236 . The method of claim 233 further comprising producing a carrier gas volumetric flow rate between about 5-30 L/minute.
237 . The method of claim 233 wherein the second velocity provides formation of particles having an MMAD between 0.2-5 microns.
238 . The method of clam 237 wherein the second velocity provides a stable concentration of particles.
239 . The method of claim 233 wherein the vaporizing step is performed by heating the drug at greater than 200° C. for less than 2 seconds.
240 . The method of claim 239 wherein the temperature is between about 200-600° C.
241 . A device for delivery of a condensation aerosol of a drug by inhalation comprising:
a housing; vaporizing means within the housing for vaporizing a solid composition of a drug within the housing; an air inlet and mouthpiece associated with the housing and airflow means for providing an airflow across the vaporizing means from the inlet to the mouthpiece upon inhalation by a patent at the mouthpiece; and condensing means for condensing a drug vapor between vaporizing means and the mouthpiece.
242 . The device of claim 241 further where in the airflow means is configured for providing a first velocity of airflow across the vaporizing means and a second velocity of airflow through the condensing means upon inhalation by a patient at the mouthpiece.
243 . The device of claim 242 wherein the first flow velocity prevents more than 10% degradation of a drug by the vaporizing means.
244 . The device of claim 243 wherein the second flow velocity provides formation of aerosol particles having an MMAD between 0.2-5 microns.
245 . The device of claim 241 wherein the airflow means further comprises augmenting means for providing a second flow of air in communication with the mouthpiece otherwise separate from the airflow through the condensing means.
246 . The device of claim 245 wherein the augmenting means is configured to provide a total rate of airflow to a patient necessary to sense a full breath during inhalation.
247 . The device of claim 241 wherein the vaporizing means comprises a heater configured to vaporize a solid composition.
248 . The device of claim 247 wherein the heater is configured to reach a temperature of at least 200° C. in less than 2 seconds.
249 . The device of claim 248 wherein the temperature is between about 200-600° C.
250 . The device of claim 242 wherein the airflow means is configured to provide a volumetric flow rate of between about 4-50 L/minute.
251 . The device of claim 242 wherein the airflow means is configured to provide a volumetric flow rate of between about 5-30 L/minute.
252 . The device of claim 247 wherein the heater comprises an electrical resistance element.
253 . The device of claim 247 wherein the heater comprises a source of electromagnetic radiation.
254 . The device of claim 247 wherein the heater comprises exothermic means for producing exothermic chemical reactions.
255 . The device of claim 254 wherein the exothermic means comprises one of exothermic salvation, hydration of pyrophoric materials and oxidation of combustible materials.
256 . The device of claim 241 further comprising means for actuating the vaporizing means upon initiation of inhalation by a patient.
257 . A drug vaporizer comprising:
a substrate; a layer containing a drug coated on the substrate having a thickness of 0.5-5 microns; and a heating element operatively associated with the substrate.
258 . The device of claim 257 wherein the heater comprises an electrical resistance element.
259 . The device of claim 257 wherein the heater comprises a source of electromagnetic radiation.
260 . The device of claim 257 wherein the heater comprises exothermic means for producing exothermic chemical reactions.
261 . The device of claim 257 wherein the exothermic means comprises one of exothermic salvation, hydration of pyrophoric materials and oxidation of combustible materials.
262 . The device of claim 257 wherein the heating element produces a temperature of at least 200° C. in less than 2 seconds.
263 . The device of claim 257 wherein the heating element produces a temperature of between 200-600° C. in less than 200 milliseconds.
264 . The device of claim 257 wherein the heating element produces substantially complete vaporization of the drug from the substrate in less than 2 seconds.
265 . The device of claim 257 wherein the heating element produces substantially complete vaporization of the drug from the substrate in less than 0.5 seconds.
266 . The device of claim 257 wherein the heating element provides a temperature and a rate of vaporization providing less than 10% thermal degradation of the drug.
267 . The device of claim 266 wherein the drug layer has an area providing a therapeutically effective dose of drug upon vaporization.Cited by (0)
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