Method of forming an aerosol for inhalation delivery

Abstract

The present invention relates to the inhalation delivery of aerosols containing small particles. Specifically, it relates to a method of forming an aerosol for use in inhalation therapy. In a method aspect of the present invention, a method of forming an aerosol for use in inhalation therapy is provided. The method involves the following steps: (a) heating a substrate coated with a composition comprising a drug at a rate greater than 1000° C./s, thereby forming a vapor; and, (b) allowing the vapor to cool, thereby forming an aerosol, which is used in inhalation therapy. In another method aspect of the present invention, a method of forming an aerosol for use in inhalation therapy is provided. The method involves the following steps: (a) heating a substrate coated with a composition comprising a drug to form a vapor, wherein the coated composition is in the form of a film less than 10μ thick; and, (b) allowing the vapor to cool, thereby forming an aerosol, which is used in inhalation therapy. In another method aspect of the present invention, a method of forming an aerosol for use in inhalation therapy is provided. The method involves the following steps: (a) heating a substrate coated with a composition comprising a drug to form a vapor in less than 100 milliseconds, wherein the vapor has a mass greater than 0.1 mg; and, (b) allowing the vapor to cool, thereby forming an aerosol, which is used in inhalation therapy.

1 . A method of forming an aerosol for use in inhalation therapy comprising:
 (a) heating a substrate coated with a composition comprising a drug, thereby forming a vapor;   (b) establishing an airflow over the surface of the coated composition during said heating; and   (c) allowing the vapors to cool in the air flow thereby forming an aerosol comprising the drug, wherein a dose of the drug is vaporized in less than 1 second.   
     
     
         2 . The method according to  claim 1 , wherein a dose of the drug is vaporized in less than 500 milliseconds. 
     
     
         3 . The method according to  claim 2 , wherein a dose of the drug is vaporized in less than 100 milliseconds. 
     
     
         4 . The method according to  claim 3 , wherein the formed aerosol is greater than 80 percent by weight of the drug. 
     
     
         5 . The method according to  claim 3 , wherein the formed aerosol contains less than 5 percent by weight of drug decomposition products. 
     
     
         6 . The method according to  claim 3 , wherein the formed aerosol is stable over 1 second. 
     
     
         7 . The method according to  claim 3 , wherein the formed aerosol has an MMAD in the 10 nm to 100 nm range. 
     
     
         8 . The method according to  claim 3 , wherein the formed aerosol has an MMAD in the 1 μm to 3 μm range. 
     
     
         9 . The method according to  claim 3 , wherein the geometric standard deviation of the form aerosol is other than 1. 
     
     
         10 . The method according to  claim 3 , wherein the film is less than 10 μm thick. 
     
     
         11 . The method according to  claim 10 , wherein the film is less than 5 μm thick. 
     
     
         12 . The method according to  claim 10 , wherein the film is between 10 nm and 5 μm thick. 
     
     
         13 . The method according to  claim 10 , wherein the film is less than 3 μm thick. 
     
     
         14 . The method according to  claim 12 , wherein the film is between 10 nm and 3 μm thick.