Gradual Release Structures Made From Fiber Spinning Techniques

The invention is related to delivery systems for the gradual release of active agents and processes for making such systems and is particularly directed to delivery systems using heat sensitive active agents with biodegradable polymers and melt spinning processes for making such systems.

The present invention is an advance in the art of delivery systems for the gradual release of active agents. This invention enables an active agent to be gradually released through the direct interaction of the agent and a solvent either within channels in the structure enclosing the active agent or through exposure of the active agent to the solvent when the structure enclosing the active agent is deformed or through diffusion of the active agent through the wall material.

Prior to the present invention, the gradual release of active agents, such as drugs, could be accomplished by the diffusion of the active agent through an encapsulating material. A discussion of such encapsulated structures is found in R. Dunn & D. Lewis, Fibrous Polymers for the Delivery of Contraceptive Steroids to the Female Reproductive Tract, Controlled Release of Pesticides and Pharmaceuticals 125-46 (D. Lewis ed. 1981), which describes fiber-like structures. Alternatively, an encapsulating shell around the active agent could be ruptured causing exposure of the active agent to various solvents.

Melt blending is another technique that was used prior to the present invention to obtain a mixture of active agent and support material to form a gradual release structure. In melt blending a polymer and an active agent are mixed and melted together. This molten mixture is then cast and solidified. The solidified mixture could then be ground or otherwise shaped for its intended end use. The present invention provides benefits over melt blending techniques by reducing the processing steps required with that technique and reducing the time that the active agent is exposed to heat during processing.

A delivery system is provided for the gradual release of an active agent. The system comprises an active agent and a wall material. The delivery system is formed by melt spinning a mixture of particles of active agent and wall material, having more than about 10 but less than about 55 percent by weight active agent, into a fiber. The fiber has a longitudinal dimension and a cross sectional dimension, the cross sectional dimension being at no greater than about 1 mm. The fiber has an exterior surface. The particles of active agent are dispersed through out the wall material such that the particles of active agent are gradually released from the fiber when the fiber is contacted with a solvent for the active agent.

A process is provided for making a delivery system for the gradual release of an active agent which comprises the steps of preparing a mixture of active agent and wall material, having more than about 10 but less than about 55 percent by weight active agent. This mixture is melt spun into a fiber using a die no greater in diameter than about 1 mm and at a temperature less than about 140.degree. C. The melt spun fibers are then cut.

To aid in understanding the invention one is directed towards the drawings and the detailed description of the present preferred embodiment of the invention.

FIG. 1 is an illustration of a gradual release structure in fiber form.

FIG. 1A is an illustration of the gradual release structure of FIG. 1 after it has been subjected to a solvent.

FIG. 2 is a Scanning Electron Photomicrograph (SEPM) of a gradual release structure showing the end and side of a fiber.

FIG. 3 is a SEPM of a gradual release structure showing the side of a fiber.

FIGS. 4 & 5 are SEPMs of a gradual release structure showing the ends of a fiber and the channels within the encapsulating structure.

FIG. 6 is an SEPM showing the side and end of a fiber.

FIG. 7 is a SEPM showing the side of a fiber.

FIGS. 8 & 9 are SEPMs showing the ends of a fiber.

FIG. 10 is a SEPM of a gradual release structure showing a fiber with a crystalline active agent oriented along the length of the fiber parallel to the longitudinal axis.

An embodiment of a structure made in accordance with the present invention is a fiber having a support matrix. The support matrix is made up of a wall material. An active agent is dispersed throughout the support matrix and may be in contact with itself forming a contiguous phase within the support matrix. The active agent, however, does not necessarily have to be in a contiguous phase. The ends of the support matrix have openings, exposing the active agent. Additionally, the active agent may be exposed along openings on the sides of the fiber. This structure may be made by stretching an already formed fiber. It is believed that the stretching action causes the wall material to orient itself longitudinally. The amount of active agent in this structure is from about 10 percent by weight to about 55 percent by weight. It is believed, however, that loading as low as a fraction of a percent of active agent will impart gradual release characteristics to the structure. The loading of the structure is influenced by the characteristics of the active agent such as its solubility or extractability from the support matrix.

After the fibers are formed by melt spinning they may be stretched by applying a draw, or stretching force, to the fibers. The draw can be applied at a winder or by venturi after the fibers exit the die. Other methods of stretching fibers known to the art may also be employed.

In this structure gradual release of the active agent occurs when the fiber is brought in contact with a solvent, or dispersing media, for the active agent. The wall material is less soluble in the solvent then the active agent and preferably the wall material should be substantially insoluble in the solvent under the conditions in which the fiber is being used.

It is presently believed that the solvent first dissolves the active agent in the openings at the ends of the support matrix. If the active agent is in a contiguous phase within the support matrix, the active agent in those openings is dissolved and spaces or channels in the support matrix are created. The solvent fills these channels and begins to dissolve the newly exposed active agent, which was in contact with the now dissolved active agent located in the openings at ends of the support matrix. Thus, the length of the channels in the support matrix gradually increases as the active agent directly in contact with the solvent is dissolved.

It is presently believed that the support matrix does not prevent the dissolution of the active agent because the active agent is in a contiguous phase. Rather, the support matrix serves to limit the rate of dissolution by restricting the area of active agent in direct contact with the solvent of the ends of the channels within the support matrix. Thus, the solvent can gradually work its way into the fiber by following the contiguous phase of active agent.

Additionally, it is presently believed that, depending on the stiffness of the wall material making up the support matrix, the support matrix can be deformed to expose new surface areas of active agent and thus bring them in direct contact with the solvent. For instance, when fibers are incorporated into a chewing material, the pressure from chewing will flatten, stretch, and deform the fibers exposing new surface areas of active agent to the solvent. This gradual release by deformation should occur even if the active agent is not in a contiguous phase. Higher molecular weight polymers used as wall material will not as readily exhibit this gradual release by deformation.

Furthermore, it is theorized that if the active agent is not in a contiguous phase the deformation of the support matrix may create channels, similar to those described above, through which the solvent can be brought in contact with the active agent.

Finally, depending on the wall material chosen, the active agent chosen, and the solvent being used, an extremely small amount of the active agent may dissolve by diffusion through the wall material.

Another embodiment of a gradual release structure made in accordance with the present invention is illustrated in FIG. 1. In this embodiment the structure is in the form of a fiber 11 having a support matrix 12. The support matrix is made up of a wall material. An active agent 13 is dispersed throughout the support matrix and is in contact with itself forming a contiguous phase within the support matrix. The ends 14 and 15 of the support matrix have openings, exposing the active agent. Additionally, the active agent may be exposed along the sides of the fiber as can be seen in FIGS. 2 and 3. The active agent makes up at least about 25 percent of the structure by weight.

Gradual release of the active agent in this embodiment occurs when the fiber is brought in contact with a solvent, or dispersing media, for the active agent. The wall material is less soluble in the solvent then the active agent and preferably the wall material should be substantially insoluble in the solvent under the conditions in which the fiber is being used. As illustrated in FIG. 1A, the solvent first dissolves the active agent in the openings at the ends 14 and 15 of the support matrix. As this material is dissolved spaces or channels 13a in the support matrix are opened. The solvent fills these channels and begins to dissolve the newly exposed active agent, which was in contact with the now dissolved active agent located in the openings at ends of the support matrix. Thus, the length of the channels in the support matrix gradually increase as the active agent directly in contact with the solvent is dissolved.

It is presently believed that the support matrix does not prevent the dissolution of the active agent because the active agent is in a contiguous phase. FIG. 1 and 1A. Rather, the support matrix serves to limit the rate of dissolution by restricting the area of active agent in direct contact with the solvent to the end of the channels within the support matrix. Thus, the solvent can gradually work its way into the fiber by following the contiguous phase of active agent. Additionally, depending on the wall material chosen, the active agent chosen, and the solvent being used a small amount of the active agent may dissolve by diffusion through the wall material. Gradual release by deformation may also be exhibited by this structure.

FIGS. 4 and 5 contain SEPMs of fibers made in accordance with the present invention. These fibers were subjected to a solvent. The spaces or channels 13a where the active agent was dissolved out are shown in these SEPMs.

Another embodiment of a gradual release structure made in accordance with the present invention is illustrated in FIG. 10. In this embodiment the active agent is crystaline in form. Here it is aspartame. In this embodiment the crystaline active agent is oriented along the length of the fiber or parallel to the longitudinal direction of the fiber.

The active agent can be any material such as artificial sweeteners, powdered flavor oil, or drugs, which the gradual release of may be desired. They must be solid or in the form of powders, including liquids encapsulated by spray drying techniques or liquids adsorbed or absorbed into or onto a supporting matrix, i.e., silica, zeolite, carbon black, or porous matrices. Combinations of different active agents in the same structure may also be employed. For purposes of illustration, possible active agents may be: high intensity sweeteners, such as aspartame, alitame, acesulfam-k and its salts, saccharin and its salts, thaumatin, sucralose, cyclamic acid and its salts, monellin, and dihydrochalcones; acidulents, such as malic acid, citric acid, tartaric acid, and fumaric acid; salt, such as sodium chloride and potassium chloride; bases, such as, magnesium hydroxide and urea; flavors, such as spray dried natural or synthetic flavors, flavor adsorbed onto silica, and absorbed into maltodextrin; flavor modifiers, such as thaumatin; breath fresheners, such as zinc chloride, encapsulated menthol, encapsulated anise, zinc glucinate, and encapsulated chlorophyll; pesticides and herbicides such as Abate.RTM., Malathion.RTM. (active ingredient, Diethyl 2-(dimethexyphosphionthioylthio) succinate), Dursban.RTM., Naned.RTM., Fenthion.RTM., and sodium salt of (2,4-Dichlorophienoxy) acetic acid; pharmaceuticals such as ibuprofen, antacids, anti-inflammatory substances, coronary dilators, cerebral dilators, peripheral vasodilators, anti-infectives, psychotropics, anti-manics, stimulants, anti-histamines, laxatives, decongestants, vitamins, gastro-intestinal sedatives, anti-diarrheal preparations, anti-anginal drugs, vasodilators, anti-arrhythmics, anti-hypertensive drugs, anti-coagulants, analgesics, sedatives, neuromuscular drugs, mineral and nutritional additives, anabolic drugs, expectorants, and cough suppressants; and fertilizers.

Care must be taken to avoid the degradation of the active agent from high temperatures, shear, or other conditions, which may occur during formation. The wall material can be any spinnable synthetic or natural polymer such as polyethylene, polyvinylacetate, polyesters, chitosan, and copolymers and polymer blends of these polymers. The active agent and wall material must meet the solubility requirements discussed above. Additionally, they must be immiscible with each other and capable of being uniformly dispersed when mixed together during the melt spinning procedure.

While any extrudable thermoplastic is suitable, the use of biodegradable polymers is beneficial for many applications. Examples of biodegradable polymers useful in this invention include copolymers of lactic and glycolic acid (PLGA), polypropylene fumarate (PPF), copolymers of fumaric and succinic acids, polyalkyl-L-glutamic acid, polyglycolic acid, poly-methyl-L-glutamic acid, polymers of glutamic acid, copolymers of glutamic acid, poly--1--glutamic acid and lysine.

The release rate of the resulting structure can be modified by crosslinking the polymer. For example, crosslinking of the polylactic/polyglycolic acid copolymer can be achieved by maleic anhydride.

The gradual release structures of the present invention may have an application in any situation in which the gradual release of an active agent is needed.

Gradual release structures that embody the present invention are made by melt spinning a uniform mixture of active agent and wall material into a fiber. The general principles for melt spinning polymers are well known in the art and are described in F. Billmeyer, Jr., Text Book of Polymer Science, 518-22 (Wiley International Edition, 2nd), which is incorporated herein by reference. In this process a mixture of a polymer for the wall material and an active agent are prepared in powder or pellet form. The particles of polymer and active agent are mixed together into a homogeneous phase. The concentration of active agent in this mixture is such that the particles of active agent may be in contact with each other. The mixture is melt spun to produce fibers. These fibers are then gently broken into smaller sizes. Any grinding machine or knife which reduces the length of fiber without excessively damaging the support matrix is suitable. Fiber brittleness eases the cutting process of the fiber and can be achieved by concentrating the solid active agent particles.

The fact that a polymer or polymer blend initially shows an unacceptably high pressure for extrusion, does not automatically eliminate the possibility of using it in this process. Processability often can be improved by increasing the processing temperature, introducing plasticizers, changing nozzle dimensions, adding dispersing agents, or modifying it by blending with other polymers.

By way of example, this process is carried out on two types of equipment.

A Model 1125 Instron Capillary Rheometer, with capillary hole diameter of 152 microns is used to extrude fibers. The barrel diameter is 3/8 inches. The die has a Length to diameter ratio of 0.083 and has 1 hole. In this application of the process L-aspartyl-L-phenylalanine methyl ester (Aspartame) is used as the active agent. A polyvinylacetate (PVAc) having a molecular weight from about 50,000 to 80,000 is chosen as the wall material.

This laboratory scale Capillary Rheometer can not provide enough mixing action during extrusion. Thus, prior to extrusion, samples are pre-blended by two methods. In one method, PVAc is dissolved in Methylene Chloride (CH.sub.2 Cl.sub.2) at room temperature, and then Aspartame is mixed into this solution. The solvent is evaporated overnight under vacuum at 60.degree. C. to form a solid material. This material is ground to a powder to facilitate addition into the rheometer.

This method is indicated in Table 1 as "Solution Blended." In the other method, samples are prepared for extrusion by directly blending the Aspartame with a polymer melt of the wall material in a heated beaker at 140.degree. C. The blend is dried under vacuum at 60.degree. C. for about 5 hours to remove water. This method is indicated in Table 1 as "Melt Blended."

Using these two methods of mixing the wall material and the active agent, fibers with varying amounts of Aspartame are produced. The parameters used for these examples are set out in the following Table 1. The Jet Speed is the speed of the material being meltspun in the capillary.

Table 1, shows that the spinnability of PVAc blends is good and not highly dependent on the Aspartame loading level. The extrudates of PVAc/ Aspartame blends shown in Table 1 are brittle at 17% Aspartame loading. Brittleness increases as the Aspartame loading level increases. The diameter of the extruded fibers due to die swell is slightly larger than the capillary, which is 152 microns.

The extruded fibers are gently ground with a mortar and pestle. The diameter to length ratio of these ground fibers is narrowly distributed with no major breakage of fibers along the longitudinal direction.

FIGS. 2 through 5 are SEPMs of fibers having 29% by weight Aspartame in PVAc that are prepared by the solution blending technique described above and extruded at 150.degree. C. FIGS. 6 through 9 are SEPMs of fibers having 17% by weight Aspartame in PVAc that are prepared by the melt blending technique described above and extruded at 140.degree. C. Both samples are extracted with water as the solvent for four hours. The spaces shown in the SEPMs are places from which Aspartame is dissolved. FIGS. 8 and 9 show that at 17% loading, the solid particles of Aspartame are isolated in the polymer. Thus, Aspartame could not completely dissolve out into the water without physical deformation of the polymeric structure. At 29% loading, FIGS. 4 and 5, however, the solid particles of Aspartame form a contiguous phase as illustrated in FIG. 1. Thus, channels in the encapsulating structure are opened and the Aspartame is gradually released, until virtually none remains.

Liquid Chromatography analysis is carried out on the fibers spun at 140.degree. C. and at 150.degree. C. in examples 1 through 9 to determine the amount of thermal degradation of Aspartame occurring during the melt spinning process discussed above. At 140.degree. C. thermal degradation of Aspartame is less than 10%. At 150.degree. C. the percent thermal degradation of Aspartame approached 20%.

The residence time of Aspartame/polymer blend in the Capillary Rheometer used to prepare the above samples is about twenty minutes. In production scale spinning, residence time could be reduced to around 20 seconds to two minutes. This would greatly reduce the degree of Aspartame degradation. At 90.degree.-100.degree. C. using a twin screw extruder at 2 minutes residence time, no degradation is observed.

In Examples 10-28 a type LSM 30:34 twin screw extruder from American Leistritz Extruder Corporation is used to produce the fibers. Generally, a homogeneous mixture of wall material and active agent in powdered form are poured into a hopper on the extruder. The hopper feed screws force the mixture through heated sections of the extruder, melting the polymer, and then through a die. The die consists of a plurality of holes having a specific diameter and length. Upon leaving the die the fibers are stretched by either drawing them with a winder or by blowing air past them with a venturi.

The twin screw extruder consists in this case of two sets of eight element screws. These screws can operate in an intermeshing fashion in either a co-rotational or a counter rotational mode, These screws can function as kneading elements or conveying elements. For the following examples four kneading elements alternating with four conveying elements are used. Other configurations are possible and will depend on the process conditions and the types of materials being melt spun and the degree of mixing required.

The twin screw extruder used in the following examples is divided into eight zones. The temperature of each zone is controlled. For example, a mixture of percent by weight PVAc with a molecular weight of about 30,000, 25 percent by weight PVAc with a molecular weight of about 15,000, and 25 percent by weight Aspartame is melt spun to produce fibers. Operating the extruder with a 1 mm die having 5 holes at 30 rpm, results in the production of 5 pounds of fiber per hour. The following temperatures in degrees centigrade are used for each zone:

Operating the extruder with a 1 mm die having holes at 333 rpm, results in the production of 50 pounds of fiber per hour. The following temperatures in degrees centigrade are used for each zone:

In the following examples dies having a diameter of 1 mm and 0.3 mm are used. The 1 mm die has holes and has a diameter to length ratio of about 4. The 0.3 mm die has 34 holes and has a diameter to length ratio of 2.3. The temperatures set out in these examples are an average of all heating zones on the extruder.

Using a 1 mm die, fibers having 10% by weight Acesulfam-K (a high intensity sweetener purchased from Hoecht, of W. Germany) as the active agent and having PVAc with a molecular weight of about 50,000-80,000 as the wall material are extruded at 110.degree.-115+ C. The fibers are drawn by a winder and have a thickness of 0.2-0.3 mm. The Acesulfam-K particles disperse very well in the fibers and the fibers exhibit a gradual release of the active agent when chewed alone.

Using a 1 mm die, fibers having by weight Acesulfam-K as the active agent and having PVAc with a molecular weight of about 50,000-80,000 as the wall material are extended at 110.degree. C. The fibers are drawn by a winder. The fibers are between 0.3-0.4 mm in thickness. The Acesulfam-K particles disperse very well in the fibers and the fibers exhibit a gradual release of the active agent when chewed alone.

Using a 1 mm die, fibers having 10% by weight Aspartame as the active agent and having PVAc with a molecular weight of about 50,000-80,000 as the wall material are extruded at 100.degree. C. The fibers are drawn by a winder and have a thickness of 0.2-0.3 mm. The Aspartame disperses very well in the fibers and the fibers exhibit a gradual release of the active agent when chewed alone.

Using a 1 mm die, fibers having 10% by weight Aspartame as the active agent and having PVAc with a molecular weight of about 50,000-80,000 as the wall material are extruded at 100.degree. C. The fibers are drawn by the winder and have a thickness of about 0.2 mm. The Aspartame disperses very well in the fibers and the fibers exhibit an excellent gradual release of the active agent when chewed alone.

Using a 1 mm die, fibers having 35% by weight Sodium Saccharin as the active agent and having PVAc with a molecular weight of about 50,000-80,000 as the wall material are extruded at 100.degree. C. The fibers are drawn at the winder and are 0.4-0.5 mm thick. The Sodium Saccharin dispersed very well in the fibers, although the fibers are softer than those of examples 10-13. The fibers exhibit a gradual release of the active agent when chewed alone.

Using a 1 mm die, fibers having 35% by weight Saccharin Acid as the active agent and having PVAc with a molecular weight of about 50,000-80,000 as the wall material are extruded at 100.degree. C. The fibers are drawn at the winder and are 0.4-0.5 mm thick. The Saccharin Acid disperses very well in the fiber, although the fibers are softer than those of examples 10-13. The fibers exhibit a gradual release of the active agent when chewed alone.

Using a 1 mm die, fibers having 6.13% by weight NaCl, 3.87% by weight KCl as the active agents and having PVAc with a molecular weight of about 30,000 as the wall material are extruded at 113.degree. C. The fibers are drawn at the winder and are 0.12 mm in thickness. The NaCl and KCl particles are dispersed in the fiber. The fibers exhibit good gradual release of the active agent when chewed alone.

Using a 1 mm die, fibers having 6.13% by weight NaCl, 3.87% by weight KCl as the active agents and having PVAc with a molecular weight of about 15,000 as the wall material are extruded at 90.degree. C. The fibers are drawn by air blowing and are 0.12 mm in thickness and are slightly weaker than the fibers of Example 16. The fibers exhibit a gradual release of the active agent when chewed alone.

Using a 1 mm die fibers having 24.52% by weight Na Cl, and 15.48% KCl by weight as the active agents and having Allied Chemical PE 735 as the wall material are extruded at 85.degree.-90.degree. C. The fibers are 0.96 mm thick and are drawn by air blowing. The fibers exhibit gradual release of salts.

Using a 1 mm die, fibers having 25% by weight Diamonium Phosphate as the active agent and having PVAc with a molecular weight of about 50,000-80,000 as the wall material are extruded at 100.degree. C. The fibers are drawn by air blowing and have a thickness of 0.20-0.38 mm.

Using a 1 mm die, fibers having 25% by weight NaF as the active agent and having PVAc with a molecular weight of 50,000-80,000 are extruded at 90.degree.-100.degree. C. The fibers are drawn by air blowing and have a thickness of 0.18-0.25 mm.

Using a 1 mm die, fibers having 25% by weight Mg (OH).sub.2 as the active agent and having PVAc with a molecular weight of about 50,000-80,000 as the wall material are extruded at 90.degree.-100.degree. C. The fibers are drawn by air blowing and have a thickness of 0.25 mm.

Using a 1 mm die, fibers having 25% by weight Acesulfam-K as the active agent and having PVAc with a molecular weight of about 30,000 as the wall material are extruded at 90.degree.-100.degree. C. The fibers are drawn by air blowing and have a thickness of 0.13 mm.

Using a 0.3 mm die, fibers having 25% by weight Aspartame as the active agent and having PVAc with a molecular weight of about 50,000-80,000 as the wall material are extruded at 90.degree.-100.degree.1/2 C. In making the fibers of this example prior to extrusion the PVAc and Aspartame are premixed in methylene chloride, following the solution blended method described above. The fibers are drawn by a winder and have a thickness of 0.127 mm.

Using a 1 mm die, fibers having 10% by weight ibuprofen as the active agent and having 90% by weight poly-1-glutamic acid as the wall material are extruded at 100.degree. C. The fibers are drawn to a diameter of 0.2-0.3 mm by a winder.

Using a 1 mm die, fibers having 25% by weight thiamine as the active agent and having 75% by weight poly-methyl-L-glutamic acid as the wall material are extruded at 100.degree. C. The fibers are drawn to a diameter of 0.2-0.3 mm by a winder.

Using a 0.3 mm die, fibers having 25% by weight ascorbic acid as the active agent and having 75% by weight polypropylene fumarate as the wall material are extruded at 90.degree. C. The fibers are drawn to a diameter of 0.15 mm by a winder.

Using a 1.0 mm die, fibers having 10% by weight of 25% spray dried malathion as the active agent and having 75% by weight polyglycolic acid as the wall material are extruded at 140.degree. C. No draw is applied.

Using a 1.0 mm die, fibers having 50% by weight of a sodium salt 2, 4-D as the active agent and having 50% by weight polylactic acid as the wall material are extruded at 130.degree. C. No draw is applied.

Many variations of the invention suggest themselves to those skilled in the art in view of the above disclosure without departing from the spirit and scope of this invention.