Title:  Controlled release formulation for treating COPD

United States Patent:  6,713,509

Issued:  March 30, 2004

Inventors:  Faulkner; Patrick G. (Collegeville, PA); Lucca; Jaime J. (Phoenixville, PA); Wrzosek; Thomas J. (Downingtown, PA)

Assignee:  SmithKline Beecham Corporation (Philadelphia, PA)

Appl. No.:  913997

Filed:  August 22, 2001

PCT Filed:  February 22, 2000

PCT NO:  PCT/US00/04713

PCT PUB.NO.:  WO00/50011

PCT PUB. Date:  August 31, 2000

Abstract

This invention relates to a controlled or sustained release formulation designed to deliver a PDE4 inhibitor for treating an inflammatory disease such as asthma or COPD and the like.

SUMMARY OF THE INVENTION

In a first aspect this invention relates to a pharmaceutically formulation for treating effectively inflammation in a mammal with a PDE4 inhibitor while avoiding adverse events, the process comprising mixing a pharmaceutically acceptable excipient capable of forming a controlled-release formulation with a therapeutically effective amount of a PDE4 inhibitor, which amount if administered as an immediate release preparation would clause adverse events.

In a further aspect this invention relates to a method for administering a PDE4 inhibitor in a prophylactically effective, non-emesis-causing amount for up to about 24 hours for use in the prophylaxis of a disease susceptible of to being warded off by the administration of a PDE4 ihnibitor, which method comprises confecting said compound with at least one pharmaceutically acceptable excipient capable of forming a controlled release formulation containing said compound.

In another aspect this invention relates to an improved method for preventing the onset of or treating a human suffering from a diseases which can be treated by inhibiting the PDE 4 enzyme wherein the improvement comprises confecting and/or administering a controlled release formulation comprising said compound with at least one pharmaceutically acceptable excipient capable of forming a controlled release formulation with said compound wherein said formulation has a release profile that provides a therapeutically effective, non-emisis-causing concentration of said drug in said subject for up to about 24 hours.

In yet a further aspect, this invention relates to the manufacture of a pharmaceutically acceptable dosage form which is a controlled release formulation comprising mixing a PDE 4 inhibitor with at least one excipient capable of forming a controlled release composition with said compound wherein said dosage form has a release profile that provides a therapeutically effective, non-emisis causing concentration of said drug in said subject for up to about 24 hours.

In yet another aspect, this invention relates to a method for treating inflammation or for dilating bronchi, particularly in regards to treating asthma or COPD, by administering a controlled release formulation containing a PDE 4 inhibitor wherein said formulation has a release profile that provides a therapeutically effective, non-emisis-causing concentration of said drug in said subject for up to about 24 hours.

This invention also relates to a stable controlled release formulation comprising a Carbopol polymer, drug, dibasic calcium phosphate, optionally other excipients and between about 0.5-2.0% weight/weight of water.

DETAILED DESCRIPTION OF THE INVENTION

This invention covers controlled release formulations which contain a PDE 4 inhibitor, particularly an inhibitor that is specific for PDE 4. A preferred group of inhibitors are those that have an IC₅₀ ratio (high/low binding) of about 0.1 or greater as further described in co-pending U.S. application Ser. No. 08/456,274, now U.S. Pat. No. 6,143,782 and its published counter-part PCT application serial number published Jan. 05, 1995 as WO95/00139; this application is incorporated herein in full by reference as if fully set forth herein. A preferred standard for PDE 4-specific inhibitors which can be used in this invention is one where the compound has an IC₅₀ ratio of about 0.1 or greater; said ratio being the ratio of the IC₅₀ value for competing with the binding of 1 nM of [³ H]R-rolipram to a form of PDE 4 which binds rolipram with a high affinity over the IC₅₀ value for inhibiting the PDE 4 catalytic activity of a form which binds rolipram with a low affinity using 1 uM[³ H]-cAMP as the substrate.

Other PDE 4 inhibitors that may be included in these formulations include those set out in U.S. Pat. No. 5,552,438 issued Sep. 03, 1996. This patent and the compounds it discloses are incorporated herein in full by reference. The compound of particular interest, which is disclosed in U.S. Pat. No. 5,552,438, is cis-4-cyano-4-[3-(cyclopentyloxy)-4-methoxyphenyl]cyclohexane-1-carboxylic acid and its salts, esters, pro-drugs or physical forms. Other PDE 4 inhibitors which may be of interest include: AWD-12-281 from Astra (Hofgen, N. et al. 15th EFMC Int Symp Med Chem (September 6-10, Edinburgh) 1998, Abst P.98); a 9-benzyladenine derivative nominated NCS-613 (INSERM); D-4418 from Chiroscience and Schering-Plough; a benzodiazepine PDE4 inhibitor identified as CI-1018 (PD-168787; Parke-Davis/Warner-Lambert); a benzodioxole derivative Kyowa Hakko disclosed in WO 9916766; V-11294A from Napp (Landells, L. J. et al. Eur Resp J [Annu Cong Eur Resp Soc (September 19-23, Geneva) 1998] 1998, 12(Suppl. 28): Abst P2393); roflumilast (CAS reference No 162401-32-3) and a pthalazinone (WO 9947505) from Byk-Gulden; and a compound identified as T-440 (Tanabe Seiyaku; Fujii, K. et al. J Pharmacol Exp Ther,1998, 284(1): 162). Preferred compounds of this invention are those which have an IC₅₀ ratio of greater than 0.5, and particularly those compounds having a ratio of greater than 1.0. The most preferred compounds are roflumilast and cis-4-cyano-4-[3-(cyclopentyloxy)-4-methoxyphenyl]cyclohexane-1-carboxylic acid.

Other drugs useful in treating PDE4-related diseases can be incorporated into these formulations as well. Examples of other therapeutics by category are drugs which treat: inflammatory respiratory diseases such as bronchodilators, leukotriene receptor antagonists and leukotriene biosynthesis inhibitors; non-respiratory inflammatory diseases such as irritable bowel disease (IBD); immunomodulating drugs, cognition enhancers; drugs for treating rheumatoid arthritis, rheumatoid spondylitis, osteoarthritis, gouty arthritis and other arthritic conditions; sepsis; septic shock; endotoxic shock; gram negative sepsis; toxic shock syndrome; adult respiratory distress syndrome; cerebral malaria; silicosis; pulmonary sarcoidosis; drugs for treating bone resorption diseases; reperfusion injury; graft vs. host reaction; allograft rejections; fever and myalgias due to infection, such as influenza, cachexia secondary to infection or malignancy, cachexia secondary to human acquired immune deficiency syndrome (AIDS), AIDS, ARC (AIDS related complex); keloid formation; scar tissue formation; Crohn's disease; ulcerative colitis; pyresis; autoimmune diseases such as multiple sclerosis, autoimmune diabetes and systemic lupus erythematosis; drugs for treating viral infections such as cytomegalovirus (CMV), influenza virus, adenovirus, and the herpes virus, and drugs for treating yeast and fungal infections.

Exemplary types of compounds for treating respiratory diseases are leukotriene antagonists; mucolytics; antitussives and expectorants; antibiotics; oral or inhaled beta-agonists; phosphodiesterase inhibitors other that PDE4-specific inhibitors; nasal decongestants; elastase inhibitors; protein therapeutics such as IL4, IL5, IL8, and IL13 monoclonal antibodies, anti-IgE; or oral or inhaled corticosteriods. Particularly preferred combination therapies are the use of a therapeutic amount of a corticosteriod, a beta agonist, an anticholinergic, an inhaled cromone, a leukotriene antagonist, or an antibiotic to treat secondary infections.

These preparations are termed "controlled release" formulations. This phrase is intended to cover any formulation which can be characterized as having a release profile that releases a portion of its drug load, either at several time-points or continuously over time. This type of formula is sometimes also described as a sustained release formulation or a non-immediate-release delivery system. By way of further illustration and explanation, these delivery systems can be characterized as: i) delayed release, ii) controlled or prolonged release, iii) site-specific release, or iv) receptor release. A more detailed explanation of these different systems is available in the likes of Remington's Pharmaceutical Sciences, 18th Edition, Mack Publishing Co. Easton, Pa., U.S.A. 18042 or later additions or Drugs and Pharmaceutical Sciences, v 29: "Controlled Drug Delivery : Fundamentals and Applications, Second Edition, Edited by Joseph R. Robinson and Vincent H. Lee, Published by Marcel Dekker Inc.

The preferred forms of this invention are the delayed release formulations or the controlled or prolonged release preparations which are administered orally. A suppository could be effective as well. These several systems may be dissolution-dependent, as illustrated by encapsulated dissolution products or matrix dissolution products. Or they may be formulated using osmotic systems or ion exchange resins. The most preferred approach is to provide an oral controlled release product based on matrix dissolution technology.

Controlled release preparations used in this invention can be prepared by selecting excipients from any number of materials which provide the requisite controlled release profile needed to avoid side effects while providing a useful therapeutic concentration of the drug. Without intending to be limited, a preferred approach is to use a matrix dissolution technology based on acrylic acid polymers. Carbomer is the non-proprietary name for these materials. They are high molecular weight polymers prepared by cross-linking acrylic acids with the likes of allylsucrose or allyl ethers of pentaerythritol. Such polymers also go by the names acritamer or carbopol. The chemical name and CAS registry number for the class is carboxypolymethylene [54182-57-9]. Exemplary carbomers are carbomer 910 [91315-32-1], carbomer 934 [9007-16-3], carbomer 934P [9003-01-4] and carbomer 940 [76050-42-5]. These polymers contain between 56-68% of carboxylic acid groups, calculated on a dry basis. A blend of two or more carbomers of differing molecular weight can be used to modify and manipulate the release rate. Examples are given below. In addition, the preferred formula may contain a binding agent, fillers, lubricants, and the like.

The goal is to prepare a formulation which release the drug in a manner that provides therapeutically effective concentration within a range which treats COPD, or another PDE 4-modulated disease, over a number of hours, but which is not so high that it initiates a secondary reaction such as psychotropic activity and produces gastrointestinal effects, e.g., pyrosis, nausea or emesis. Thus the active ingredient will be present in the preparation an amount sufficient to provide a concentration in the blood stream which effects a therapeutic response over a period of up to about 24 hours, measure from the time of administration of when an oral preparation is consumed. A preferred time-frame for release of drug is where the release is effected in about 12 hours. The amount of drug must necessarily depend on the potency of the drug that is being administered, its bio-availability, metabolic disposition, clearance rate and the like. A highly potent drug which is well absorbed, and not rapidly metabolized or cleared from the system will necessarily dictate a concentration on the lower end of the spectrum of a continuum of possible drug load that can be accommodated by a given set of excipients. A compound which requires a higher concentration to effect a therapeutic response, or which is not absorbed well will need to be present in a higher concentration. Precise parameters can not be set forth for all compounds; some testing and modification of excipient and drug will be useful in optimizing the amount and release rate of a given formulation for the active compounds intended to be covered by this invention.

For the purposes of this invention, it is preferred to manufacture a product which contains between about 1 mg to 200 mg, more preferably 5 to 100 mg, most preferably between 5, or 10 to 60 mg of the active ingredient. Additional preferred dosage amounts are about within these ranges are 10, 15, 20, 30, 40, 50, 60, 70, 80 or 90 mg per preparation.

The preferred excipients for affecting release rate are carbomers, particularly a combination of two or more different carbomers. Especifically preferred are those carbomers known as Carbopols and are manufactured by BF Goodrich. Preferred carbomers are: Carbomer 934P (Carbopol 974P) and Carbomer 941P (Carbopol 971P).

A preferred formulation will have between about 1-25% by weight of a PDE 4 inhibitor, preferably an amount between 3-20% and optionally an amount between about 5 and 15%. Other specific amounts are set out in the Examples below. In regards to the carbomers, one or more may be used to realize the controlled release effect. It is preferred to use two carbomers in a given formulation. When a preferred formulation containing the acid set out above is prepared, one or both of two carbomers is used in a range between 0-9% each. These percentages are weight/weight percentages. Further specific preferred percentages of carbomers are given in the Examples set out below.

The following examples are provided to illustrate how to make and use the invention. They are not in any way intended to limit the scope of the invention in any manner or to any degree. Please refer to the claims for what is reserved to the inventors hereunder.

EXAMPLE 1

Experimental Design

The six direct compression components which were investigated in the study included the drug and five excipients. These components 1% w/w of magnesium stearate made up the formula. The five excipients were carbopol 971P, carbopol 974P, (manufactured BF Goodrich), lactose anhydrous direct tableting, dibasic calcium phosphate anhydrous and microcrystalline cellulose. Upper restraints were put on all the excipient components.

The component levels can be expressed in three different ways. First they can be expressed in terms of the actual components. In this case they would be expressed in mg. Real values are the components expressed as percents or fractions of the total components:

Real=Actual/(total of actuals)

R_i =A_i /.SIGMA.A_i

The last component values are called Pseudo components. Pseudo components are defined as:

Pseudo=(Real-L_i)/(1-L)

where L_i =lower constraint in real value

and L=sum of lower constraints in real values

Pseudo components are generally used when fitting models because of better mathematical stability over the original units. Components and component restraints are summarized below in Table 1.

EXAMPLE 2

Experimental Run Selection

A list of candidate points was generated. The list included extreme vertices, centers of edges, face centroids, axial centers, and the overall centroid. The number of runs was decided on by the type or degree of model to be fitted. A second-order design with 6 components contains 21 terms. At least as many design points as terms was needed to fit the model. Adding additional points for error estimation and model lack of fit testing brings the total to 28 runs. Starting with the candidate list of points and using a D-optimality program, the set of points that minimizes the variance of the fitted model coefficients were selected. The runs that were selected are listed in Table 2.

EXAMPLE 3

Preparation of Controlled Release Formulation

Blending

The blends were made up in accordance with Table 2, excipients and drug were placed in a blender and mixed. The magnesium stearate was then added and mixed for an additional 3 minutes. During the blending process, excipients and drug were mixed, passed through a screen and then mixed again.

Compression

Approximately 350 mg of each mix was compressed into tablets. A target tablet strength of 10 kp was used.

EXAMPLE 4

Physical Measurements--Dissolution

Three compacts of each formula were prepared for dissolution. These were run using USP Apparatus II, 50 rpm, paddles, 900 ml of pH 7.5 buffer. Samples (20 ml, volume replaced) were taken at 1, 3, 5, 8 and 12 hours and then analyzed for cis-4-cyano-4-[3-(cyclopentyloxy)-4-methoxyphenyl]cyclohexane-1-carboxylic acid using UV.

EXAMPLE 5

Analysis of Release Rates: Model Fitting--Dissolution Slope

The response % dissolved was found to have a linear relationship to time (hr.). There for the response used to access dissolution was the slope of the dissolution curve, expressed as %/hr.

The model fitted to the data was a second order Scheffe model of the form:

y=.beta.₁ x₁ +.beta.₂ x₂ +.beta.₃ x₃ . . . +.beta.₁₂ x₁ x₂ +.beta.₁₃ x₁ x₃ +.beta.₂₃ x₂ x₃ . . .

where x_i are the component fractions .beta._i coefficients represent linear blending of the components. When only linear blending is present the response for any given blend is the sum of each component contribution. .beta._ij terms represent nonlinear blending. These second order nonlinear terms represent either synergism or antagonism between the two components.

The final model after reduction of non-significant terms is presented in Table 3. All of the linear blending terms and eight second order terms were included in the model. This model was formed after the exclusion of three run results based on their high residuals. The explanation for these outliers was that for some of the formulations the tablets broke apart suddenly, rather than remained intact as did the majority of formulations.

There exists strong correlations among the coefficients of the model. This is due to the wide disparity in the constraint ranges. The resulting design space is a narrow sliver with very poor design properties. The practical result is that some terms can be interchanged with little effect on the apparent fit of the model. Model interpretation is best done graphically by representing the predicted response as a function of the components.

Summary statistics for the model are summarized in Table 3 above. The statistics indicate no lack of fit for the model. The adjusted R-square was 0.986, which means that almost all of the variation in the data is explained by the model.

EXAMPLE 6

Model Interpretation--Component Effects, Dissolution

There are two graphical representations based on the prediction model that are useful in understanding the effects of changing the component amounts. The two graphical tools are response traces plots and contour plots. Response trace plots show the effects of changing each component along an imaginary line from a reference blend to the L-pseudocomponent system lower bound vertex. This directional change in composition called "Piepels Direction" is illustrated in FIG. 1 with a dashed line.

FIG. 2 shows the response traces for all six components. The X-axis represents the change of that component over its range in the design space from low to high in relationship to the reference blend. From the plot it can be seen that the two carbopols have the steepest or biggest effect on the dissolution. Their effects are opposite of one another. Increasing carbopol 971 decreases dissolution rate, while increasing carbopol 974 increases it. As more drug is added the dissolution rate decreases. Increasing A-Tab or lactose has about the same effect in decreasing the dissolution rate. And lastly increasing avicel increases the dissolution rate. The reference blend used in generating the data underlying the graphics in FIG. 2 is set out in Table 4.

Contour plots can be made using the triangular coordinate system by holding three of the components constant and varying the remaining three. Several different contour plots are shown in FIGS. 3A and 3B. Much of the same information that is contained in the trace plots can be seen in the contour plots.

Predictions--Confirmation

Using the reduced 2'd order Scheffe model for dissolution a formula was identified to meet a target dissolution of 11%/hr (Table 5). A formula was desired that contained no lactose or avicel (microcrystalline cellulose). A predicted value of 11.45%/hr was found to be in good agreement with the actual value of 11.1%/hr.

EXAMPLE 7

Controlled Release Formulation

Three sets of controlled release formulations were prepared using the blending and compression techniques described in Example 3. One set was formulated to give a fast release rate. The second and third formulations were designed to give a medium and slow release rate. Specific details for each set of tablets are given in Table 6.

Opadry White was suspended in the purified water and that suspension was used to coat the tablets; water was removed during the coating process an ddid not form part of the final product.

These formulations gave in-vitro dissolution data (% released) as per Table 7.

EXAMPLE 8

Controlled Release Formulation--Different Drug Loads

Using the experimental design techniques outlined in Example 1, multiple drug/excipient composition were identified to prepare 5 different drug concentrations which had the desired dissolution profile. Using the blending and compression techniques described in Example 3 tablets were prepared as per the ingredients and amounts set out in Table 8.

Opadry White was suspended in the purified water and that suspension was used to coat the tablets; water was removed during the coating process an ddid not form part of the final product.

A typical dissolution profile for these tablets is given in Table 9.

EXAMPLE 9

Controlled Release Formulations

Controlled release tablets were prepared containing five different drug loads. Ingredients and the amount of each ingredient per drug load are set out in Table 10. Tablets were prepared as described in Example 3.

EXAMPLE 10

Stabilized Formulation

Low moisture levels in certain Carbopol-based controlled release preparations may compromise the stability of the active ingredient cis-4-cyano-4-[3-(cyclopentyloxy)-4-methoxyphenyl]cyclohexane-1-carboxylic acid. High moisture levels may compromise the release rate of such formulations. A representative controlled release formulation based on Carbopols is given in Table 1.

In this examplary formulation if the moisture level falls below about 0.5%, some degradation of the acid is observed. The combination of cis-4-cyano-4-[3-(cyclopentyloxy)-4-methoxyphenyl]cyclohexane-1-carboxylic acid and dibasic calcium phosphate (anhydrous) appears to be unstable when moisture is removed from the system. Analyses of degraded tablets indicates that the cyclopentyloxy group is cleaved and results in the formation of cyclopentene and cis-4-cyano-4-[3-hydroxy-4-methoxyphenyl]cyclohexane-1-carboxylic acid. It is not known why this occurs when the moisture level is below 0.5% nor is it known how to stop this from occuring, other than to maintain the specified levels of hydration.

Conversely, if the moisture level in this formulation raises above about 2.0% the rate of release of drug substance from the tablet changes from initial.

An optimum moisture level will be in the range of about 0.8-1.3%w/w range, preferably in the range of about 0.9-1.2% w/w range. This range is applicable to the full range of concentrations of dibasic calcium phosphate present in formulations prepared within this invention.

The technique for measuring moisture level in this representative tablet was as follows:

The analysis was performed using a Omnimark MARK2 Moisture Analyzer. The Unit determines the moisture content using Infrared heat to dry the sample at a programmed temperature of 120^oCelsius with a standby temperature of 80^oCelsius. It calculates the percent loss on drying from the initial weight and the final weight of the sample. The results are printed out as % w/w automatically when the analysis is finished. The analysis usually takes 2 to 3 minutes for one measurement of a sample with a moisture level of less than 1.5%w/w.

A homogeneous and representative sample was used. The following sample preparation was used for each measurement:

Crush tablets to a fine powder using a mortar and pestle.

Use approximately 2 grams of sample for moisture determination.

Spread the sample evenly on the dish to obtain a thin layer that covers as much of the surface as possible.

EXAMPLE 11

Preparation of Controlled Release Beads

Nonpareil (sugar) beads are placed in a fluid bed coating machine. An aqueous suspension of cis-4-cyano-4-[3-(cyclopentyloxy)-4-methoxyphenyl]cyclohexane-1-carboxylic acid and a suitable binder (e.g. povidone or hydroxypropyl methyl cellulose) and a wetting agent if needed (e.g. tween 80) are sprayed onto the beads. A coating solution (e.g. ethylcellulose) is applied to slow the release rate of the acid. The release rate of the drug is inversely proportional to the film weight applied. These controlled release beads of the acid can then be delivered in a variet of ways to either adult or pediatric patients.

Claim 1 of 4 Claims

We claim:

1. A stable controlled release pharmaceutical composition comprising a controlled release excipient, dibasic calcium phosphate, a PDE4-specific inhibitor in an amount of 10 mg and 60 mg, optionally other excipients, and between about 0.5-2.0% weight/weight of water.

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