DRY POWDER INHALER

专利摘要:
dry powder inhaler and method of delivering a dry powder. it is a pulmonary drug delivery system that includes a breath fed dry powder inhaler with or without a cartridge to deliver a dry powder formulation. the inhaler and cartridge may be provided with a drug delivery formulation comprising, for example, a diketopiperazine and an active ingredient, which includes small organic molecules, peptides and proteins, including hormones such as insulin and glucagon-like peptide 1 for the treatment of diseases and disorders, for example diseases and disorders, including endocrine disease such as diabetes and/or obesity.
公开号:BR112015000529B1
申请号:R112015000529-2
申请日:2013-07-12
公开日:2022-01-11
发明作者:Chad C. Smutney；Benoit Adamo；Brendan F. Laurenzi；P. Spencer Kinsey
申请人:Mannkind Corporation；
IPC主号:

专利说明:

[001] This application claims the benefit under Title 35 USC §119(e) of United States Provisional Patent Application Serial Number US61/671,041, filed July 12, 2012, the contents of which are incorporated herein. document as a reference in its entirety. FIELD OF TECHNIQUE
[002] The present disclosure relates to dry powder inhalation systems that include dry powder inhalers, cartridges and pharmaceutical compositions for delivering one or more drugs to the pulmonary tract and pulmonary circulation for the treatment of local and/or local diseases or disorders. or systemic. BACKGROUND
[003] Drug delivery systems for treating disease that introduce active ingredients into the circulation are diverse and include oral, transdermal, inhalation, subcutaneous and intravenous administration. Drugs delivered by inhalation are typically delivered using positive pressure relative to atmospheric pressure in propellant air. Such drug delivery systems deliver drugs as aerosols, nebulized or vaporized. More recently, drug delivery to lung tissue has been achieved with dry powder inhalers. Dry powder inhalers can be breath activated or breath fed and can deliver drugs by converting drug particles in a carrier into a fine dry powder that is trapped in an air stream and inhaled by the patient. Drugs delivered using a dry powder inhaler are no longer just intended to treat lung disease, but can also be absorbed into the systemic circulation so that they can be used to treat many conditions, including but not limited to diabetes and obesity.
[004] Dry powder inhalers, used to deliver medication to the lungs, contain a dosing system of a powder formulation usually in bulk supply or quantified in individual doses stored in unit dose compartments such as hard gelatine capsules or packets of the blister type. The bulky containers are equipped with a patient-operated metering system to isolate a single dose of dust immediately prior to inhalation. Dosage reproducibility requires that the drug formulation be uniform and that the dose can be delivered to the patient with consistent, reproducible results. Therefore, the dosing system ideally operates to completely discharge the entire formulation effectively during an inspiratory maneuver when the patient receives their dose. However, full discharge is not generally required, as long as reproducible dosing can be achieved. The flow properties of the powder formulation and the long-term physical and mechanical stability thereof are more critical for bulky containers than for single unit dose compartments. Good hydration protection can be achieved more easily for unit dose compartments such as blisters. However, the materials used to manufacture blisters allow air into the drug compartment and subsequently the formulations can lose their viability with prolonged storage. Additionally, dry powder inhalers that use blister packs to deliver a medicament via inhalation may experience inconsistency in dose delivery to the lungs due to variations in air duct architecture resulting from perforation of films and detachment of film from blisters.
[005] Dry powder inhalers in the art can generate suitable drug particles or inhalation plumes during an inspiratory maneuver by de-agglomerating the powder formulation within a cartridge or capsule. The amount of fine powder discharged from the mouthpiece of the inhaler during inhalation is largely dependent on, for example, interparticle forces in the powder formulation and effectiveness of the inhaler in separating such particles so that they are suitable for inhalation. An important feature of the inhaler is the ability of the inhaler to effectively and repeatedly discharge its entire powder content to deliver a precise dose. In addition, the inhaler must be designed with internal conduits that prevent dust retention and therefore induce a costly loss of the active agent to be delivered, which can be typical of, for example, amorphous and/or cohesive and/or cohesive powders. or crystalline powders. Therefore, the inhaler's structural design must provide air ducts that effectively deliver the powder from its reservoir during use. The benefits of delivering drugs via the pulmonary circulation are numerous and may include rapid entry into the arterial circulation, prevention of drug degradation through liver metabolism, ease of use, i.e. lack of discomfort of administration via other routes of administration. .
[006] Dry powder inhaler products developed for pulmonary delivery have met with current limited success due to lack of practicality and/or cost of manufacture. Some of the persistent problems seen with prior art inhalers include lack of robustness, inconsistency in dosing, equipment inconvenience, insufficient de-agglomeration, problems with delivery of propellant use separation light, reduced powder discharge or loss of powder due to dust retention inside an inhaler and/or patient non-compliance. In some cases, effective powder delivery from an inhaler also depends on the type of powder, i.e. crystalline versus amorphous powder. Certain types of amorphous powders tend to cake and smear as they revolve, which leads to a decrease in inhaler emptying or de-agglomeration effectiveness, and particularly in drug delivery to a user. Therefore, an inhaler is designed and manufactured with consistent powder delivery properties, which is easy to use without discomfort, and has distinct inhaler configurations that can allow for better patient compliance. BRIEF DESCRIPTION
[007] Described here are generally dry powder inhalation systems for pulmonary delivery, wherein the systems include dry powder inhalers and containers containing cartridges for dry powder inhalers for the rapid and effective delivery of formulations of dry powder. dry powder to the pulmonary tract. Dry powder formulations of inhalation systems comprise active agents for the treatment of one or more diseases. Such diseases may include, but are not limited to, local or systemic diseases or disorders, including, but not limited to, diabetes, obesity, pain, headaches such as migraine, immune and central or peripheral nervous system disorders and the like, as well as for the delivery of a vaccine formulation. Dry powder inhalers can be breath-fed, compact, reusable or disposable systems, which can be of various shapes and sizes and comprise a system of airflow conduit paths for the effective and rapid delivery of dry powder medications.
[008] In one embodiment, the inhaler may be a single-dose, reusable or disposable inhaler that can be used with or without a cartridge. Use without a cartridge refers to systems where cartridge-like structures are provided that are integral to the inhaler and the inhaler is for single use and disposable. Alternatively, in some embodiments, the systems comprise a cartridge that is supplied separately and installed in the inhaler for use, for example, by a user. In such an embodiment, the inhaler may be a reusable inhaler and a new cartridge is installed in the inhaler with each use. In another embodiment, the inhaler can be a disposable or reusable multi-dose inhaler that can be used with single-dose cartridges installed in the inhaler or cartridge-like structures built-in or structurally configured with a portion of the inhaler.
[009] In further embodiments, the dry powder inhalation system comprises a dry powder inhalation device or inhaler with or without a cartridge and a pharmaceutical formulation comprising an active ingredient or active agent for pulmonary delivery. In some embodiments, delivery of powder is to the deep lung, including the alveolar region, and in some such embodiments, one or more active agents are delivered to the lungs and absorbed into the pulmonary circulation for systemic delivery. The system may also comprise a dry powder inhaler with or without a unit dose cartridge and a drug delivery formulation comprising, for example, a pharmaceutically acceptable carrier or substance, for example a diketopiperazine and an active ingredient such as small molecules, peptides, polypeptides and proteins, including insulin, oxytomidulin, oxytocin, peptide YY, parathyroid hormone, glucagon-like peptide-1 and the like. In alternative embodiments, pharmaceutically acceptable carriers and/or excipients, including polyethylene glycol, polyvinylpyrrolidone, saccharides, oligosaccharides, polysaccharides, including lactose, trehalose, mannose, mannitol, sorbitol, and the like; amino acids including leucine, lysine, isoleucine, trileucine, arginine, cysteine, cystine, histidine and methionine; and/or derivatives thereof.
[010] In an exemplary embodiment, a dry powder inhaler is provided comprising: a) a first element comprising a mouthpiece; b) a second element comprising a container; and c) at least two rigid air ducts; wherein one of the at least two rigid air ducts, in use, is configured to have a baffle or rod to direct the movement of powder within a powder container in a substantially U-shaped configuration of a door air intake through a container headspace and through an air outlet or dispensing port to reach a second airflow conduit in the mouthpiece of the inhaler prior to delivery to a user. In such other embodiments with the present document, the dry powder inhaler comprises a predetermined equilibrium airflow distribution during use through the air conduit through the powder container and through the air conduit in the mouthpiece. The inhaler system also comprises high-resistance airflow paths as described below.
[011] In one embodiment, the dry powder inhaler comprises a housing, a movable member and a mouthpiece, wherein the movable member is operably configured to move a container from a powder confinement position to a powder dosing position. In this and other embodiments, the movable member may be a slide, a sliding tray, or a carriage that is movable through various mechanisms.
[012] In another embodiment, the dry powder inhaler comprises a housing and mouthpiece structurally configured to have an open position and a closed position and a mechanism operatively configured to receive, retain and reconfigure a cartridge from a containment position to a position delivery, dosing or dispensing by moving the inhaler from the open to the closed position. In versions of such an embodiment, the mechanism may also reset a cartridge installed in the inhaler from the dosing position to an alternate position after use when the inhaler is opened to discharge a used cartridge, thus indicating to a user that the cartridge is depleted. In one embodiment, the mechanism may reconfigure a cartridge to a disposable or discard configuration. In such embodiments, the housing is structurally configured to be movably attached to the mouthpiece through various mechanisms, including a hinge. The mechanism can be configured to receive and reconfigure a cartridge installed in the inhaler from a confining position to the dosing position and can be designed to be operated manually or automatically upon movement of the inhaler components, e.g. by closing. the device from an open configuration. In one embodiment, the mechanism for reconfiguring a cartridge comprises a slide or slide tray attached to the mouthpiece and movably attached to the housing. In another embodiment, the mechanism is mounted or adapted to the inhaler and comprises a gear mechanism integrally mounted within, for example, a hinge of the inhaler device. In yet another embodiment, the mechanism operatively configured to receive and reconfigure the cartridge from a containment position to a dosing position comprises a cam which can reconfigure the cartridge by rotating, for example, the housing or nozzle.
[013] In an alternative embodiment, the dry powder inhaler can be produced as a single-use unit dose disposable inhaler, which can be provided with a container configured to hold a powdered medication and the container is movable in a configuration of confinement for a one-user dosing configuration, wherein the inhaler may have a first and a second configuration wherein the first configuration is a confinement configuration and the second configuration is a dispense dose configuration. In such an embodiment, the inhaler may be provided with or without a mechanism for reconfiguring the powder container. According to the most recent realization aspects, the container can be reconfigured directly by the user. In some aspects of this embodiment, the inhaler and container may be manufactured as a two-piece inhalation system in which powdered medication is supplied to the container prior to mounting the device in a containment configuration. In such an embodiment, the container is attached or inserted into the inhaler body and is movable from a confinement configuration to a dosing configuration, for example, sliding relative to the top portion of the inhaler which comprises a mouthpiece.
[014] In yet another embodiment, an inhaler is described comprising a canister mounting area configured to receive a canister and mouthpiece having at least two inlet passages and at least one outlet passage. In one embodiment, one inlet passage of the at least two inlet passages is in fluid communication with the container area and the other of the at least two inlet passages is in fluid communication with the at least two outlet passages via a pathway. flow configured to derive the container area.
[015] In one embodiment, the inhaler has opposite ends, such as a proximal end for contacting a user's lips or mouth and a distal end and comprises a mouthpiece and a medication container; wherein the mouthpiece comprises a top surface and a bottom or subsurface. The nozzle subsurface has a first area configured relatively flat to maintain a container in a sealed or containment configuration and a second area adjacent to the first area that is elevated relative to the first area. In such an embodiment, the container is movable from the containment configuration to the dosing configuration and vice versa, and in the dosing configuration, the second raised area of the mouthpiece subsurface and the container form or define an air inlet passageway to allow allow ambient air to enter the internal volume of the container or expose the interior of the container to ambient air. In one embodiment, the mouthpiece may have a plurality of openings, for example, an inlet port, an outlet port, and at least one port for communicating with a medication container in a dispensing or dosing position, and can be configured to have integrally attached panels that extend from the sides of the bottom surface of the inhaler and that have flanges that project towards the center of the inhaler mouthpiece, which serve as rails and support for the container on the mouthpiece so that the container can move along the tracks from the containment position to a dispensing or dosing position and back to the containment if desired. In one embodiment, the medication container is configured with wing-like protuberances or small wings that extend from its top rim to conform to flanges on the mouthpiece panels. In one embodiment, the medication container can be moved manually by a user from the containment position to a dosing position and back to the containment position after dosing or by means of a slide, sliding tray or conveyor.
[016] In another embodiment, a single-use disposable unit dose inhaler can be constructed to have a slide incorporated and operatively configured with respect to the mouthpiece. In such an embodiment, a bridge on the slide may adjoin or rest over an area of the medication container to move the container along the mouthpiece panel rails from the containment position to the dispensing or dosing position. In such an embodiment, the slide may be manually operated to move the container over the nozzle rails.
[017] In a specific embodiment, a single-use disposable unit dose inhaler is structurally configured to have a powder confinement configuration and a powder dosing configuration, wherein the inhaler comprises two elements and has a top surface, a bottom surface, the proximal end and a distal end; a first element and a second element; the first element having at least three openings and comprising a mouthpiece at the proximal end; a body, a subsurface configured to conform to the second element and having a protruding structure or shank configured to extend downwardly into the second element; the first member being further configured to have a first flow path having an air inlet and an air outlet for delivering a stream of air into a subject's mouth during an inhalation; and a third opening configured to form an air conduit and a second flow path with the second element in the powder metering configuration; wherein the second element is configured to conform to the subsurface of the first element and is movable with respect to the first element to form an inhaler confinement configuration or a dosage configuration; the second element comprising a container or reservoir, having an opening configured to receive and retain a powder and form an air inlet and an air conduit or a second flow path with the first element in the dosing configuration; wherein, in the powder dispensing configuration, a powder is exposed to ambient air to be dispensed or discharged during an inhalation. In that and other embodiments, a dry powder inhaler in a dosage configuration comprises a rod-like or protruding structure that extends downwardly into the void space or chamber of the container and serves to deflect the powder. In such an embodiment, the flow of air entering the powder container or reservoir primarily travels in a path closely related to the shape of the container which is structurally configured substantially in the shape of the letter U such that a portion of the air conduit extends from the air inlet in the form of a letter s open on its side and the powder is lifted and transferred or transported from such second air stream to the first air stream into an individual's mouth and via airlines.
[018] In one embodiment, the dry powder inhaler comprises one or more air inlets and one or more air outlets. When the inhaler is closed, at least one air inlet may allow flow to enter the inhaler and at least one air inlet allows flow to enter a cartridge compartment or the interior of the cartridge or container adapted for inhalation. In one embodiment, the inhaler has an opening structurally configured to communicate with the cartridge placement area and with a cartridge inlet port when the cartridge container is in a dosing position. Flow entering the inner cartridge may exit the cartridge through an outlet or dispensing port or ports; or the stream entering an inhaler canister may exit through at least one of the dispensing passages. In such an embodiment, the cartridge inlet port or ports is/are structurally configured so that all airflow or a portion of the airflow entering the interior of the cartridge is directed to the outlet or dispensing port or ports.
[019] The medication container or powder reservoir can be structurally configured to have two opposite, relatively curvilinear sides, which can direct airflow. In one embodiment, the flow entering the air inlet during an inhalation enters the powder container or reservoir and may circulate within the container around its axis relatively perpendicular to the axis of the dispensing ports, and thus the flow can effectively lift, swirl and fluidize a powdered medication contained in the cartridge or reservoir before exiting through dispensing ports or outlets. In another embodiment, the stream entering the air inlet during an inhalation can lift the powder from the powder reservoir container and translate or transport the powder particles entrained in the air stream into a second stream in the inhaler. In this and other embodiments, the de-agglomerate in the air duct can be further de-agglomerated to form finer dust particles through a change in direction or velocity, i.e., acceleration or deceleration of the particles in the flow path. In certain embodiments, the change in acceleration or deceleration can be achieved by changing the angle and geometries, for example, of the dispensing port or ports, the nozzle conduit and/or their interfaces. In the inhalers described in the present invention, the fluidization mechanism and the acceleration of particles as they travel through the inhaler are methods by which de-agglomeration and delivery of a dry powder formulation is effected.
[020] In specific embodiments, a method for de-agglomerating and dispersing a dry powder formulation comprises one or more steps, such as stirring within a main container region initiated and intensified through the flow entering the container; rapid acceleration of powder flow through dispensing ports exiting the container; additional powder acceleration induced by a change in direction or speed as the powder exits the dispensing port; shearing powder particles trapped in a flow gradient, wherein the flow at the top of the particle is faster than the flow at the bottom of the particle; flow deceleration due to expansion of the cross-sectional area within the nozzle air duct; expansion of air trapped within a particle due to the particle moving from a region of higher pressure to a region of lower pressure, or collisions between particles and flow conduit walls at any point in the passageways of flow.
[021] In another embodiment, a dry powder inhaler comprises a mouthpiece; a slide, a sliding tray or a transport; a housing, a hinge and a gear mechanism configured to effect movement of the slide or slide tray; wherein the nozzle and housing are movably fixed via the hinge.
[022] Cartridges for use with the dry powder inhaler can be manufactured to contain any dry powder medication for inhalation. In one embodiment, the cartridge is structurally configured to be adaptable to a specific dry powder inhaler and can be produced in any size and shape depending on the size and shape of the inhaler with which it will be used, for example if the inhaler has a mechanism that allows a translational movement or a rotational movement. In one embodiment, the cartridge may be configured with a gripping mechanism, for example, that has a beveled edge on top of the cartridge that corresponds to a compatible beveled edge on an inhaler so that the cartridge is held in place during use. In one embodiment, the cartridge comprises a container and a lid or cover, wherein the container can be fitted to a surface of the lid and can be movable with respect to the lid, or the lid can be movable over the container and can achieve different configurations depending on of its position, for example a confinement setting, a dosing setting or an after use setting. Alternatively, the cover may be removable.
[023] An exemplary embodiment may comprise a housing for retaining the medicament configured to have at least one inlet passage to allow flow within the housing; at least one dispensing passage to allow flow out of the housing; the inlet passage is configured to direct at least a portion of the flow into the dispensing passage or the particles reaching the dispensing passage within the housing in response to the pressure gradient. Each of the dispensing passage(s) and the inlet gas passage may independently be shaped such as oblong, rectangular, circular, triangular, square and oval-shaped and may be in close proximity to each other. In one embodiment and during inhalation, a cartridge fitted to the inhaler in a dosing position allows airflow to enter the housing and mix with the powder to fluidize the medication. The fluidized drug may move within the housing so that the drug gradually exits the housing through the dispensing passage, wherein the fluidized drug exiting the dispensing passage is subjected to shear and diluted by a secondary flow that is not from inside the housing. In one embodiment, the airflow in the internal volume rotates in a circular fashion so as to lift a powdered medication in the container or housing and recirculate the entrained powder particles or powder mass in the internal volume of the container so as to promote revolving. flow before the particles exit the canister dispensing ports or one or more of the inhaler inlet ports or air outlet ports or dispensing passages and wherein the recirculating flow may generate swirl or non-vortex flow. Air in the internal volume acts to de-agglomerate the drug. In one embodiment, the axis of rotation is primarily perpendicular to gravity. In another embodiment, the axis of rotation is primarily parallel to gravity. The secondary flow not originating from the interior of the housing additionally acts to de-agglomerate the drug. In such an embodiment, the pressure differential is created by user inspiration. A cartridge for a dry powder inhaler comprising: a housing configured to hold a medicament; at least one inlet port for allowing flow into the housing and at least one dispensing port for allowing flow out of the housing; the at least one inlet port is configured to direct at least a portion of what enters the at least one inlet port into the at least one dispensing port within the housing in response to a pressure differential.
[024] A unit dose cartridge for an inhaler is described which comprises: a substantially flat cartridge top of arrow-like configuration having one or more inlet passages, one or more dispensing passages, two downwardly extending side panels, each of the two side panels having a track; and a movable container engaged with the track of the side panels of the cartridge top and comprising a chamber configured to be relatively cup-like in shape with two relatively flat, parallel sides and a relatively rounded bottom and an interior surface defining an internal volume. ; wherein the container is configurable to achieve a containment position and a cartridge top dosing position; wherein, during use with a dry powder inhaler during an inhalation, a flow entering the internal volume is diverted as it enters the internal volume, with a portion of the flow exiting through the one or more dispensing passages and a portion flow that rotates within the internal volume and lifts a powder into the internal volume before exiting through the dispensing passages.
[025] In one embodiment, an inhalation system for pulmonary drug delivery is provided, comprising: a dry powder inhaler comprising a housing and a mouthpiece having an inlet and an outlet port, a air between the inlet and outlet and an opening structurally configured to receive a cartridge; a cartridge mounting mechanism, such as a slide; a cartridge configured to fit the dry powder inhaler and containing a dry powder medicament for inhalation; wherein the cartridge comprises a container and a lid having one or more inlet ports or one or more dispensing ports; the dry powder inhaler system, in use, has a predetermined balance distribution of air flow through the cartridge relative to the total flow delivered to the patient.
[026] In the disclosed embodiments of the present invention, the dry powder inhaler system comprises a predetermined mass flow balance within the inhaler. For example, an equilibrium flow of approximately 20% to 70% of the total flow leaving the inhaler into the patient is delivered through the dispensing ports or passed through the cartridge, while approximately 30% to 80% is generated from other sources. inhaler ducts. Furthermore, the bypass flow or flow that does not enter and exit the cartridge can be recombined with the flow that leaves the cartridge dispensing port inside the inhaler to dilute, accelerate and, most importantly, de-agglomerate the fluidized powder before it leaves the mouthpiece. .
[027] In the embodiments described herein, the dry powder inhaler is provided with relatively rigid air ducts or a plumbing system and high levels of flow resistance to maximize de-agglomeration of the powdered medication and facilitate delivery. The inhalation systems disclosed herein comprise conduits that exhibit resistance to flow during use, maintaining low flow rates that minimize high inert forces on powder particles discharged from the inhaler, preventing deposition or impact of powder particles with the throat into the upper respiratory tract and thus maximizing dust particle deposition in the lungs. Consequently, the present inhalation systems provide an effective and consistent discharge of powder medication from the inhalers after repeated use due to the fact that the inhalers are provided with air conduit geometries that remain constant and cannot be changed. In some embodiments, the dry powder medicament is consistently dispensed from an inhaler in less than about 3 seconds, or generally less than 1 second. In some embodiments, the inhaler system may have a high resistance value of, for example, from about 0.065 to about 0.200 (VkPa)/liter per minute. Therefore, in inhalation systems, decreases in peak inhalation pressures between 2 and 20 kPa produce resulting peak flow rates between about 7 and 70 liters per minute. Such flow rates result in more than 75% of cartridge contents being dispensed in fill masses between 1 and 30 mg or more. In some embodiments, such performance characteristics are achieved by end users in a single inhalation maneuver to produce cartridge dispense percentages greater than 90%. In certain embodiments, the inhaler and cartridge system are configured to deliver a single dose by discharging the powder from the inhaler as a continuous stream of powder delivered to a patient.
[028] In one embodiment, a method is provided for effectively de-agglomerating a dry powder formulation during an inhalation in a dry powder inhaler. The method may comprise the steps of providing a dry powder inhaler that comprises a container having an air inlet, dispensing ports that communicate with an air conduit from the mouthpiece and that contain and deliver a formulation to an individual in need. of the formulation; generating a flow of air in the inhaler through the subject's inspiration, so that about 20 to about 70% of the air flow entering the inhaler enters and leaves the container; allowing airflow to enter the container inlet, circulate and revolve the formulation on a geometric axis perpendicular to the dispensing ports to fluidize the formulation so as to generate a fluidized formulation; accelerating metered amounts of fluidized formulation through the dispensing ports and into the air conduit and decelerating the flow of air containing the fluidized formulation in the air conduit of the inhaler mouthpiece before reaching the subject. In some specific embodiments, 20% to 60% of the total flow through the inhaler passes through the cartridge during dose delivery.
[029] In another embodiment, a method is provided for de-agglomerating and dispersing a dry powder formulation for inhalation, comprising the steps of: generating an air flow in a dry powder inhaler comprising a mouthpiece and a container that has at least one inlet port and at least one dispensing port and which contains a dry powder formulation; wherein the container forms an air passageway between the at least one inlet port and the at least one dispensing port and the inlet port directs a portion of the airflow entering the container to the at least one dispensing port; allowing the air flow to revolve the powder within the container on an axis substantially perpendicular to the at least one dispensing port so as to lift and mix the dry powder medication in the container to form a mixture of medication and water flow air; and accelerating the flow of air out of the container through the at least one dispensing port. In one embodiment, the inhaler mouthpiece is configured to have a gradually expanding cross-section to slow the flow and minimize powder deposition within the inhaler and promote maximum delivery of powder to the patient. In one embodiment, for example, the cross-sectional area of the oral delivery region of an inhaler can be from about 0.05 cm 2 to about 0.25 cm 2 over an approximate length of about 3 cm. Such dimensions depend on the type of powder used with the inhaler and the dimensions of the inhaler itself.
[030] In one embodiment, a cartridge for a dry powder inhaler is provided comprising: a cartridge top and a container defining an internal volume; wherein the cartridge top has a subsurface that extends over the container; the subsurface is configured to engage the container and comprises an area for containing the internal volume and an area for exposing the internal volume to ambient air. In one aspect of this embodiment, the container may optionally have one or more protuberances or rods that extend from the subsurface or inner surface of the top into the void space of the container. The bulges can be of any shape or size as long as they can direct or deflect the flow, particularly downwards in the container during use. In specific embodiments, the bulge may be configured on the cap of a cartridge that extends from the surface so as to face the internal volume of the container in proximity to an air inlet in the dosing configuration. Alternatively, the bulge may be projected onto the surface of the mouthpiece to contact the internal volume of a container and in proximity to the air inlet formed by the container in the dosing configuration.
[031] In an alternative embodiment, there is provided a method for particle delivery through a dry powder delivery device comprising: inserting into the delivery device a cartridge for the confinement and dispensing of particles comprising a housing that encloses the particles , a dispensing passage and an inlet gas passage; wherein the housing, dispensing passage and inlet gas passage are oriented such that when an inlet gas enters the inlet gas passage, the particles are de-agglomerated through at least one de-agglomeration mode as described in present document to separate the particles and the particles together with a portion of the inlet gas are dispensed through the dispensing passage; simultaneously forcing a gas through a delivery conduit in communication with the dispensing passage, thereby causing the inlet gas to enter the inlet gas passage, de-agglomerating the particles, and dispensing the particles together with a portion of the gas of admission through the dispensation passage; and, delivering the particles through a delivery conduit of the device, for example, into an inhaler mouthpiece. In the embodiments described in the present document, to carry out the de-agglomeration of powder, the dry powder inhaler can be structurally configured and provided with one or more zones of de-agglomeration of powder, in which the de-agglomeration zones, during an inhalation maneuver, can facilitate the stirring of a powder through the stream of air entering the inhaler, the acceleration of the stream of air containing a powder, the deceleration of the stream containing a powder, the shearing of dust particles, the expansion of air trapped in the dust particles powder and/or combinations thereof.
[032] In another embodiment, the inhalation system comprises a breath-fed dry powder inhaler, a cartridge containing a drug, wherein the drug may comprise, for example, a drug formulation for pulmonary delivery, such as a composition comprising a carrier, for example a saccharide, oligosaccharide, polysaccharide or a diketopiperazine and an active agent. In some embodiments, the active agent comprises peptides and proteins, such as insulin, glucagon-like peptide-1, oxytomidulin, peptide YY, exendin, parathyroid hormone, analogues thereof, vaccines, small molecules including, antiasthmatics, vasodilators, vasoconstrictors, muscle relaxants, neurotransmitter agonists or antagonists and the like.
[033] The inhalation system can be used, for example, in methods to treat conditions that require localized or systemic delivery of a drug, for example, in methods to treat diabetes, pre-diabetes conditions, respiratory tract infection, osteoporosis, lung disease, pain, including headaches including migraine, obesity, disorders and disorders of the central and peripheral nervous system, and prophylactic use, such as vaccinations. In one embodiment, the inhalation system comprises a kit comprising at least one of each of the components of the inhalation system for treating the disease or disorder.
[034] In one embodiment, there is provided a method for the effective delivery of a formulation into the bloodstream of an individual, which comprises an inhalation system comprising an inhaler that includes a cartridge containing a formulation comprising a diketopiperazine, wherein the inhalation system delivers a powder plume comprising diketopiperazine microparticles that have a volume mean geometric diameter (VMGD) in the range of about 2.5 μm to 10 μm. In an exemplary embodiment, the VMGD of the microparticles can vary in the range of about 2 µm to 8 µm. In an exemplary embodiment, the VMGD of the powder particles can be from 4 µm to about 7 µm in a single inhalation of the filler formulation in the range between 3.5 mg and 10 mg of powder. In this and other embodiments, the inhalation system delivers more than about 90% of the dry powder formulation of the cartridge.
[035] In another embodiment, a dry powder inhaler is provided comprising: a) a mouthpiece configured to deliver a dry powder to an individual via oral inhalation; b) a container housing and c) rigid air ducts extending between the container housing and the mouthpiece and configured to communicate with ambient air; wherein the dry powder inhaler is configured to emit more than 75% of a dry powder as powder particles from a container oriented in the container housing in a single inhalation and the emitted powder particles have a volumetric mean geometric diameter (VMGD) less than about 5 microns when a user inhales through the mouthpiece to generate a peak inspiratory pressure of about 2 kPa in up to two seconds and an area under the curve (AUC) in up to 1 second for a pressure-dependent curve time of at least about 1.0, 1.1 or 1.2 kPa*sec. In another embodiment, the AUC within 1 second for a pressure versus time curve is between about 1.0 and about 15 kPa*sec.
[036] In some embodiments, a method is also provided for delivering a dose of a dry powder medication with the use of a high strength dry powder inhaler comprising: providing a high strength dry powder inhaler which contains a dose a dry powder medication and inhale from the inhaler with sufficient force (or effort) to achieve a peak inspiratory pressure of at least 2 kPa within 2 seconds; and generating an area under a curve in the first second (AUC0 at 1 sec.) of a pressure versus inspiration time curve of at least about 1.0, 1.1, or 1.2 kPa*sec; wherein more than 75% of the dry powder dose is discharged or emitted from the inhaler as dust particles. In some embodiments, the VMGD of the emitted particles is smaller than about 5 microns.
[037] In another embodiment, a method for delivering a properly de-agglomerated dose of a dry powder medication using a high strength dry powder inhaler comprising: providing a high strength dry powder inhaler containing a dose of a dry powder medicine; inhale from the inhaler with sufficient force to achieve a peak inspiratory pressure of at least 2 kPa within 2 seconds; and generating an area under a curve in the first second (AUC0 at 1 sec.) of an inspiration pressure-time curve of at least about 1.0, 1.1, or 1.2 kPa*second; wherein the VMGD (x50) of the emitted powder is less than about 5 µm. In an alternative embodiment, the dry powder is composed of microparticles having an average particle size, and the VMGD (x50) of the emitted particles from the powder is not greater than 1.33 times the average particle size when the inhaler is used properly. ideal, for example at about 6 kPa.
[038] In another embodiment, a use of a high strength dry powder inhaler for the delivery of a dry powder is described wherein the dry powder inhaler having an airflow resistance value in the range of about 0.065 (VkPa)/liter per minute to about 0.200 (VkPa)/liter per minute and containing the dry powder dose, where sufficient force is applied to achieve a peak inspiratory pressure of at least 2 kPa within 2 seconds ; and wherein an area under a curve in the first second (AUC0 at 1 sec.) of a pressure versus time curve of inspiration of at least about 1.0, 1.1, or 1.2 kPa*sec. is generated; and wherein more than 75% of the dry powder dose is discharged or emitted from the inhaler the powder particles.
[039] In some embodiments, the inhalation systems described herein are used to treat patients in need of treatment of a disease or disorder described herein with the use of a medicament as described.
[040] In yet another embodiment, a high strength dry powder inhaler used to deliver a dry powder medication to a patient is described, characterized in that the dry powder inhaler is provided with a flow resistance value of air in the range of about 0.065 (VkPa)/liter per minute to about 0.200 (VkPa)/liter per minute and containing a dose of the dry powder medicine in which, during use, sufficient force is applied to achieve a pressure peak inspiratory effort of at least 2 kPa within 2 seconds; and an area under a curve is generated in the first second (AUC0 to 1 sec.) of a pressure versus time curve of inspiration of at least about 1.0, 1.1, or 1.2 kPa*sec.; and wherein more than 75% of the dry powder dose is discharged or emitted from the inhaler as dust particles.
[041] In another embodiment, an inhalation system is provided which comprises an inhaler, a cartridge containing a dry powder formulation for delivery to the systemic circulation comprising diketopiperazine microparticles; wherein the diketopiperazine microparticles deliver a plasma level (exposure) of diketopiperazine that has a 2-hour AUC0 of between 1300 ng*min./ml and 3200 ng*min./ml per mg of diketopiperazine emitted in a single inhalation. In another exemplary embodiment, an inhalation system is provided wherein an inhaler, a cartridge containing a dry powder formulation for delivery to the systemic circulation comprising microparticles of diketopiperazine; wherein the diketopiperazine microparticles deliver a plasma level (exposure) of diketopiperazine that has an AUCo a ~ greater than 2300 ng*min./ml per mg of powder emitted in a single inhalation. In one aspect of such accomplishments, the DKP is FDKP. In this and other embodiments, diketopiperazine microparticles do not cause a reduction in lung function as assessed by lung function tests and measured as forced expiration volume in one second (FEV1). In certain embodiments, the measured plasma exposure of FDKP in an individual may be greater than 2500 ng*min./ml per mg of FDKP powder emitted in a single inhalation. In alternative embodiments, the measured plasma exposure, AUCo to ~ FDKP of an individual may be greater than 3000 ng*min./ml per mg of FDKP powder emitted in a single inhalation. In yet another embodiment, the measured plasma exposure of AUCo to " FDKP in a subject can be less than or about 5,500 ng*min./ml per mg of FDKP emitted in a single inhalation of a dry powder composition comprising FDKP In some embodiments, the mentioned level of exposure represents an individual exposure. In alternative embodiments, the mentioned level of exposure represents an average exposure. Active agent quantities, including contents and exposures, may alternatively be expressed in units of activity or mass.
[042] In these and other embodiments, the microparticles may additionally comprise an active ingredient. In specific embodiments, the active ingredient is insulin. In another exemplary embodiment, an inhalation system is provided which comprises an inhaler, a cartridge containing a dry powder formulation for delivery to the systemic circulation comprising insulin-containing diketopiperazine microparticles; wherein the diketopiperazine microparticles deliver a plasma level (exposure) of insulin with a 2-hour AUC0 greater than 160 μU*min./ml per units of insulin in the powder formulation emitted in a single inhalation. In one aspect of such an embodiment, the inhalation system is configured to deliver and target a plasma insulin level or exposure where the average 2-hour AUC0 of insulin is in the range of about 100 to 1000 μU*min./ml per units of insulin in the powder formulation delivered in a single inhalation. In some embodiments, the mentioned level of exposure represents an individual exposure. In alternative embodiments, the mentioned level of exposure represents an average exposure.
[043] In another exemplary embodiment, an inhalation system is provided which comprises an inhaler, a cartridge containing a dry powder formulation for delivery to the systemic circulation comprising insulin-containing diketopiperazine microparticles; wherein the diketopiperazine microparticles deliver a plasma level (exposure) of insulin with a 4-hour AUC0 greater than 100 μU*min./ml per filled U of insulin emitted in a single inhalation. In one aspect of such an embodiment, the inhalation system is configured to deliver to a patient a formulation of insulin and fumaryl diketopiperazine that achieves a plasma exposure of insulin that has an AUC0 at 4 hours measured in the range of 100 to 250 μU*min. ./ml per U of insulin-filled dose, delivered in a single inhalation. In aspects of such embodiments, the 4-hour AUC0 may be greater than 110, 125, 150, or 175 μU*min./ml per U of filled insulin, emitted in a single inhalation. In that and other embodiments, the insulin content of the formulation comprises from about 10 to about 20% (w/w) of the formulation.
[044] In yet another exemplary embodiment, an inhalation system is provided which comprises an inhaler, a cartridge containing a dry powder formulation for delivery to the systemic circulation comprising insulin-containing diketopiperazine microparticles; wherein the diketopiperazine microparticles deliver a plasma level of insulin with a Cmax. above 10 μU/ml per mg of powder emitted in a single inhalation, within 30 minutes of administration. In one aspect of such an embodiment, the administered insulin formulation generates a Cmax. in the range of about 10 to 20 μU/ml per mg of powder emitted in a single inhalation and within 30 minutes after administration. In further aspects of such an embodiment, Cmax. of insulin can be achieved within 25, 20, or 15 minutes of administration. In alternatives to such realizations of Cmax, Cmax. reached after pulmonary inhalation of the formulation is greater than 3 μU/ml per U of insulin filled in a cartridge or in the range of 3 U to 6 U, or 4 U to 6 μU/ml per U of insulin in a cartridge dose.
[045] In another embodiment, an inhalation system comprising: a dry powder inhaler; and a dry powder formulation comprising a plurality of powder particles of a diketopiperazine is provided, wherein the inhalation system is configured to deliver the diketopiperazine into the pulmonary circulation of a subject and the diketopiperazine can be measured in the plasma of the subject having an average exposure or AUCo to ~ greater than 2300 ng*min./ml per mg content of diketopiperazine in the dry powder formulation administered in a single inhalation. In one embodiment, the inhalation system further comprises a cartridge configured to fit the breath fed dry powder inhaler. In this and other embodiments, the diketopiperazine in the formulation is bis-3,6-(N-Fumaryl-4-aminobutyl)-2,5-diketo-diketopiperazine (FDKP).
[046] In embodiments where FDKP is used in the formulation, the system can deliver the FDKP to the systemic circulation at a Tmax. of less than 1 hour. In some embodiments, Tmax. for FDKP may be less than 15 or 30 minutes after administration of FDKP in a single inhalation. In this and other embodiments, the AUC is measured from 0 to 2 hours, 0 to 4 hours, or 0 to ~.
[047] In another embodiment, an inhalation system is provided comprising: a breath fed dry powder inhaler and a dry powder formulation comprising a plurality of diketopiperazine particles; wherein the inhalation system is operatively configured to emit a dust plume comprising diketopiperazine microparticles having a volumetric mean geometric diameter in the range of 2 µm to 8 µm and a geometric standard deviation of less than 4 µm.
[048] In yet another embodiment, an inhalation system is provided for pulmonary delivery of a drug, the system comprising: a breath-fed dry powder inhaler and a dry powder formulation comprising a plurality of diketopiperazine particles ; wherein the inhalation system is operationally configured to emit more than 90% of the powder particles that dissolve and are absorbed into the blood in less than 30 minutes or less than 25 minutes so as to yield a peak concentration of diketopiperazine after an inhalation unique to the dry powder formulation. In some embodiments, the system emits more than 95% of the dust particles in a single inhalation, such particles being absorbed into the circulation.
[049] In one embodiment, an inhalation system is provided comprising: a dry powder inhaler; and a dry powder formulation comprising a plurality of dry powder particles comprising insulin; wherein the inhalation system is configured to deliver insulin to the pulmonary circulation of a subject and the insulin can be measured in a subject's plasma at an exposure that has a mean 2-hour AUC0 greater than 160 uU*min./ml per unit of insulin emitted in the dry powder formulation administered in a single inhalation.
[050] In one embodiment, the inhalation system, the dry powder formulation is administered to a subject via oral inhalation and the formulation comprises insulin powder particles that can deliver the insulin to the subject's systemic circulation, wherein a Cmax . for insulin is measured less than 30 minutes after administration to a patient in a single inhalation.
[051] In one embodiment, an inhalation system is provided comprising: a breath fed dry powder inhaler and a powder formulation comprising a plurality of diketopiperazine particles; wherein the inhalation system is operatively configured to emit a dust plume comprising diketopiperazine microparticles having a volumetric mean geometric diameter in the range of 2 µm to 8 µm and a geometric standard deviation of less than 4 µm.
[052] In yet another embodiment, an inhalation system for pulmonary delivery of a drug is provided, comprising: a breath-fed dry powder inhaler and a powder formulation comprising a plurality of diketopiperazine particles; wherein the inhalation system is operatively configured to emit powder particles which are absorbed into the blood to yield a peak drug concentration in less than or in 30, 25, 20, or 15 minutes.
[053] In one embodiment, a dry powder inhaler comprising a mouthpiece configured to deliver a dry powder to an individual via oral inhalation, a container configured to hold a dry powder, and air conduits extending between the container and the mouthpiece and configured to communicate with ambient air, wherein the dry powder inhaler is configured to emit more than 75% of the dry powder as dust particles in a single inhalation and the emitted dust particles have a volumetric mean geometric diameter of less than 5 microns when a user inhales through the mouthpiece to generate a peak inspiratory pressure of about 2 kPa within two seconds and an AUC0 at 1 sec. a pressure versus inspiration time curve of at least about 1.0, 1.1, or 1.2 kPa*sec; wherein more than 75% of the dry powder dose is discharged or emitted from the inhaler as dust particles.
[054] In yet another embodiment, a method of delivering a dose of a dry powder medication to an individual is disclosed with the use of a high strength dry powder inhaler comprising the steps of providing a dry powder inhaler that has an airflow resistance value in the range of about 0.065 (VkPa)/liter per minute to about 0.200 (VkPa)/liter per minute and contains a dose of a dry powder medicament; inhale from the inhaler with sufficient force to achieve a peak inspiratory pressure of at least 2 kPa within 2 seconds; and generate an AUC0 at 1 sec. a pressure versus inspiration time curve of at least about 1.0, 1.1, or 1.2 kPa*sec; wherein more than 75% of the dry powder dose is discharged or emitted from the inhaler as dust particles. BRIEF DESCRIPTION OF THE DRAWINGS
[055] Figure 1 represents an exemplary embodiment of the inhaler used in the inhalation system that shows an isometric view of the inhaler in a closed configuration.
[056] Figures 2, 3, 4, 5, and 6 represent the side, top, bottom, proximal and distal views, respectively, of the inhaler in Figure 1.
[057] Figure 7 represents a perspective view of an embodiment of the inhalation system comprising the inhaler of Figure 1 in an open configuration showing a corresponding cartridge and mouthpiece cover.
[058] Figure 8 represents an isometric view of the inhaler of Figure 6 in an open configuration with a cartridge installed in the holder in cross-section through the mean longitudinal axis with a cartridge installed in the cartridge holder and in a containment configuration and the closed inhaler configuration and cartridge dosing configuration.
[059] Figure 9 represents a perspective view of an embodiment of the inhalation system as shown in Figures 1 to 7 comprising the inhaler and cartridge mounted in a dosage configuration shown in cross-section through the median longitudinal plane.
[060] Figure 10 illustrates a perspective view of an alternative embodiment of a dry powder inhalation system, the inhaler shown in an open configuration, illustrating the type and orientation of a corresponding cartridge that can be installed in the inhaler.
[061] Figure 11 represents an isometric view of the dry powder inhaler of Figure 10 in an open configuration.
[062] Figure 12 illustrates an exploded view of the inhaler embodiment of Figure 1 showing the component parts of the inhaler.
[063] Figure 13 illustrates a perspective view of the inhaler in Figure 10 in the open configuration and shows a cartridge installed in the inhaler.
[064] Figure 14 illustrates an average longitudinal section of the inhaler shown in Figure 12 showing the cartridge container in the confinement configuration and in contact with the slide and the gear mechanism in contact with the slide.
[065] Figure 15 illustrates a perspective view of the inhaler in Figure 10 in the closed configuration and with a cartridge in the holder.
[066] Figure 16 illustrates an average longitudinal section of the inhaler depicted in Figure 1 showing the cartridge container in the dosing configuration and the airflow path established through the container.
[067] Figure 17 illustrates a perspective view of a cartridge embodiment for use with the inhaler of Figure 1 and representing the cartridge in a containment configuration.
[068] Figure 18 illustrates a top view of the cartridge embodiment of Figure 17, showing the component structures of the cartridge top surface.
[069] Figure 19 illustrates a bottom view of the cartridge embodiment of Figure 17, which shows the cartridge subsurface component structures.
[070] Figure 20 illustrates a perspective view of a cartridge embodiment of Figure 17 in average longitudinal cross-section and in a confinement configuration.
[071] Figure 21 illustrates a perspective view of a cartridge embodiment of Figure 17 in an average longitudinal cross-section and in a dosing configuration.
[072] Figure 22 represents a perspective view of an alternative embodiment of a cartridge in a containment configuration.
[073] Figures 23 to 27 represent the cartridge realization shown in Figure 22 in top, bottom, proximal, distal and side views, respectively.
[074] Figure 28 represents a perspective view of the cartridge realization shown in Figure 22 in a dosage configuration.
[075] Figures 29 and 30 are cross-sections through the longitudinal geometric axis of the cartridge realization of Figures 22 and 28, respectively.
[076] Figure 31 is a schematic representation of the flow movement within the powder confinement area of a dry powder inhaler as indicated by the arrows.
[077] Figure 32 is a schematic representation of an embodiment of a dry powder inhaler showing the flow paths and flow direction through the inhaler as indicated by the arrows.
[078] Figures 33A, 33B, 33C and 33D represent an embodiment of a dry powder inhaler configured for use with a U-shaped air duct. Figures 33A represent an isometric view of the top of the inhaler. Figure 33C is a bottom view of the top of the inhaler. Figure 33B is an isometric view and 33D is a top view of the bottom portion of the inhaler comprising a container.
[079] Figure 34 represents a cross-section through the median longitudinal plane of a single-use cartridge embodiment with a reusable inhaler and in a containment configuration.
[080] Figure 35 represents a cross-section through the median longitudinal plane of a cartridge embodiment shown in Figure 50, in a dosage configuration that shows a deflector in the internal volume of the container.
[081] Figure 36 represents a cross-section through the median longitudinal plane of a single-use cartridge embodiment with a reusable inhaler and in a containment configuration and configured with a protrusion to fit an inhaler.
[082] Figure 37 represents a cross-section through the median longitudinal plane of a cartridge embodiment shown in Figure 52, in a dosage configuration that shows a deflector in the internal volume of the container.
[083] Figure 38 represents a cross-section through the mid-longitudinal plane of a multi-use inhaler system realization as shown in Figure 1 and which contains a cartridge, wherein the inhaler system is in a dosing configuration and shows the nozzle configured with a protrusion to adapt to the outlet port cartridge as shown in Figure 35.
[084] Figure 39 illustrates a graph of measurements of the flow and pressure relationship based on Bernoulli's principle for an exemplary realization of the flow resistance of an inhaler.
[085] Figure 40 represents the particle size distribution obtained with a laser diffraction apparatus using an inhaler and cartridge containing a dry powder formulation for inhalation comprising insulin and fumaryl diketopiperizine particles.
[086] Figure 41 represents graphical representations of data obtained from the average of all tests performed for an example inhalation system (DPI 2) and MEDTONE® (MTC), which show the cumulative geometric particle size distribution of particles emitted from inhalation systems of different cartridge powder contents.
[087] Figure 42 depicts graphs of inhalation recordings with an inhalation monitoring system and performed by an individual with an exemplary inhalation system without (curve A) and with (curve B) a powder formulation.
[088] Figure 43 is a graph of plasma FDKP concentration of samples taken from the same subject as in Figure 36 during 6 hours after inhalation of a dry powder formulation containing FDKP microparticles.
[089] Figure 44 is a graph of insulin concentrations over time by dose group.
[090] Figure 45 is a graph of FDKP concentrations over time by dose group.
[091] Figure 46 is a graph of glucose excursions for each subject in the Study.
[092] Figure 47 is a graph of an exemplary inhalation profile of a present device during use that shows peak inspiratory pressure in up to two seconds.
[093] Figure 48 is a graph of exemplary inhalers showing performance criteria for the present inhalers.
[094] Figure 49 is a schematic representation of the flow movement within the powder confinement area of a dry powder inhaler realized as indicated by the arrows.
[095] Figure 50 is a schematic representation of an embodiment of a dry powder inhaler in medium longitudinal section showing the flow paths and flow direction through the inhaler as indicated by the arrows.
[096] Figure 51 is a schematic representation of an alternative inhaler embodiment showing flow movement within the powder confinement area of a dry powder inhaler as indicated by arrows having an air conduit system, substantially , U-shaped across the container.
[097] Figure 52 is a schematic representation of a medium longitudinal sectional embodiment utilizing the air duct system shown in Figure 45 in a single-use dry powder inhaler that shows the flow paths and flow direction through the inhaler as indicated by the arrows representing the substantially U-shaped duct of air through a container and that deflector bulge on the container void space.
[098] Figure 53 represents a bar graph showing data obtained with a formulation comprising salmeterol delivered by an inhaler embodiment described in the present invention and compared to delivery of the same formulation using a prior art inhaler.
[099] Figure 54 represents a bar graph showing data obtained with a formulation comprising fluticasone delivered by an inhaler embodiment described in the present invention and compared to delivery of the same formulation using a prior art inhaler. . DETAILED DESCRIPTION
[0100] Generally disclosed herein are dry powder inhalers, cartridges for dry powder inhalers and inhalation systems for delivering one or more pharmaceutical drugs to a patient via pulmonary inhalation. In one embodiment, an inhalation system comprises a breath-fed dry powder inhaler and a cartridge containing a pharmaceutical formulation comprising a pharmaceutically active substance or active ingredient and a pharmaceutically acceptable carrier. The dry powder inhaler comes in a variety of shapes and sizes and can be reusable or single-use, easy to use, is inexpensive to manufacture and can be produced in high volumes in simple steps using plastics or other acceptable materials. In addition to complete systems, inhalers, filled cartridges and empty cartridges constitute additional embodiments disclosed herein. The present inhalation system can be designed to be used with any type of dry powder. In particular, the inhaler system is used alone, which comprises a canister or can be configured to use replaceable canisters for multiple uses. Alternatively, the inhaler system may include designs that include a multi-use inhaler comprising a plurality of integrally built-in containers that hold individual powder doses for dispensing one at a time. Methods for the effective and consistent delivery of a pharmaceutical formulation to the systemic circulation using the inhalers described in the present invention are also disclosed.
[0101] The present disclosure also includes exemplary inhaler system designs for use with any type of dry powders, in particular, certain amorphous dry powder medicament compositions. In one embodiment, the amorphous dry powder comprises particles that are highly dispersible and prone to smearing and/or slurrying upon repeated stirring action, including particle-to-particle interactions or particle-to-container surface collisions. Staining and/or pasting of the powder particles can lead to increased and undesired retention of the dry powder being delivered by the inhaler system, leading to a decrease in the mass of powder delivered from the inhaler system.
[0102] As used herein, "dry powder" refers to a fine particulate composition that is not suspended or dissolved in a propellant or other liquid. It is not intended to necessarily imply a complete absence of all water molecules.
[0103] As used herein, "amorphous powder" refers to dry powders that do not have a definite shape, shape or repeating structure, including all non-crystalline powders.
[0104] In one embodiment, the dry powder is a relatively cohesive powder that requires an ideal de-agglomeration condition. In one embodiment, the inhalation system provides a miniature, reusable, breath-powered inhaler in combination with single-use cartridges that contain pre-metered doses of a dry powder formulation.
[0105] As used herein, the term "a unit dose inhaler" refers to an inhaler that is adapted to receive a single container, a dry powder formulation and deliver a single dose of a dry powder formulation via inhalation from the container to a user. It should be understood that in some cases, multiple unit doses will be required to provide a user with a specified dosage.
[0106] As used herein, the term "a multi-dose inhaler" refers to an inhaler that has a plurality of containers, each container comprising a pre-measured dose of a dry powder medication and the inhaler delivering a single dose of a medicine powder via inhalation at any time.
[0107] As used herein, a "container" is a shell configured to hold or contain a dry powder formulation, a shell that contains powder and may be a structure with or without a lid. Such a container may be provided separately from the inhaler or may be structurally integrated within the inhaler (e.g. non-removable). Furthermore, the container can be filled with a dry powder. A cartridge may also include a container.
[0108] As used herein, a "mass of powder" refers to an agglomeration of particles of powder or agglomerate that have irregular geometries such as width, diameter and length.
[0109] As used herein, the term "microparticle" refers to a particle with a diameter of about 0.5 to about 1,000 μm, regardless of the exact exterior or interior structure. However, for pulmonary delivery, microparticles that are smaller than 10 µm are generally desired, specifically those with average particle sizes smaller than about 5.8 µm in diameter.
[0110] As used herein, a “rigid air duct” refers to an air duct that is associated with an air path through the inhalation system that does not change in geometry or remains constant, for example, in a reusable inhaler, the air ducts remain the same after repeated use. The rigid air conduit may be associated with a mouthpiece, canister, inhaler housing, canister, canister housing or the like.
[0111] As used herein, a "unit dose" refers to a pre-measured dry powder formulation for inhalation. Alternatively, a unit dose can be a single container that has multiple doses of formulation that can be delivered via inhalation as single metered amounts. A unit dose cartridge/container contains a single dose. Alternatively, it may comprise multiple individually accessible compartments, each containing a unit dose.
[0112] As used herein, "U-shaped" refers to the path of a flow through the internal volume of a cartridge that is substantially shaped in the form of the letter u and in which a flow of air entering the container at an angle substantially perpendicular and parallel to the mouthpiece of the inhaler is deflected in a substantially downward direction and exiting at an angle substantially perpendicular to the mouthpiece.
[0113] As used herein, the term "about" is used to indicate that a value includes the standard deviation of error for the device or method that is employed to determine the value.
[0114] In embodiments of the present invention, the present devices can be manufactured through various methods, however, in one embodiment, the inhalers and cartridges are produced, for example, through injection molding techniques, thermoforming, with the use of various types of plastic materials, including polypropylene, cyclolefin copolymer, nylon, polyesters such as polyethylenes and other compatible polymers and the like. In certain embodiments, the dry powder inhaler may be assembled using top-down mounting of individual component parts. In some embodiments, the inhalers are provided in compact and discrete sizes, such as from about 2.54 cm (1 inch) to about 5 inches (12.7) in dimension, and generally the width and height are shorter than the device length. In certain embodiments, the inhaler is provided in various shapes, including relatively rectangular, cylindrical, oval, tubular, square, oblong, and circular bodies.
[0115] In the embodiments described and exemplified in the present invention, the inhalation system comprises an inhaler, cartridge or container and a dry powder formulation, wherein the inhalers are configured with the cartridge to effectively fluidize, de-agglomerate or transform into aerosol A dry powder formulation using at least one relatively rigid flow conduit path to allow a gas, such as air, to enter the inhaler. For example, the inhaler is provided with a first air/gas path for entering and exiting a cartridge containing the dry powder and a second air path which can be merged with the first air flow path leaving the cartridge. . Flow ducts, for example, can be of different shapes and sizes, depending on the inhaler configuration. General Examples of inhalers and cartridges that can be used in the present inhalation system are disclosed, for example, in Patent Application Serials US 12/484,125 (US 2009/0308390), 12/484,129 (US 2009/0308391), 12/484,137 (US 2009/0308392, US 8,424,518), 12/717,884 (US 2010/0197565) and PCT/US2011/041303, all of which are hereby incorporated in their entirety by reference by all reveal in relation to inhalation systems.
[0116] In the embodiments exemplified herein, each inhaler may be used with a suitable cartridge. However, the inhalation system may perform more effectively when the inhaler and cartridge are designed to match each other. For example, the cartridge mounting area of an inhaler can be designed to house only a specific cartridge and therefore the structural configurations of the cartridge and inhaler openings are compatible or fit together, for example as keying areas. or surfaces that can help as safety parameters for users. Examples of a corresponding inhaler and cartridge follow herein as the inhaler 302 which can be used with the cartridge 170, 981 and the inhaler 900 which can be used with the cartridge 150. Such inhalers and cartridges have been disclosed in the Patent Applications of US Serial Nos. 12/484,125; 12/484,129, and 12/484,137 (US 8,424,518), all of which are hereby incorporated in their entirety by reference for all they disclose in relation to inhalers and cartridges and, where appropriate, for additional or alternative technical details, resources and/or background teachings.
[0117] One embodiment of a dry powder inhaler is exemplified in Figures 1 through 9. In such an embodiment, the dry powder inhaler has two configurations, i.e. a closed configuration is illustrated in Figures 1 through 6 and 9 and a closed configuration is illustrated in Figures 1 through 6 and 9. The open position is illustrated in Figures 7 and 8. The dry powder inhaler 302 in the open configuration allows for the installation or removal of a cartridge containing a medicament for inhalation. Figures 1 to 6 depict the inhaler 302 in a closed configuration from several views and having a relatively rectangular body comprising a housing 320, the mouthpiece 330 superior to the body and extending outside the body. A mouthpiece portion 330 tapers toward the end to contact a user and has an opening 335. The inhaler 302 also comprises a gear mechanism 363 and a slide. The inhaler 302 can be manufactured using, for example, a four-part top-down assembly manner. Mouthpiece 330 further comprises air conduit 340 configured to run along the longitudinal axis of the inhaler and has an oral placement portion 312, air inlet 310 and air outlet 335 configured to have their surface angled or beveled with respect to the longitudinal axis of the air conduit and the cartridge port opening 355 which is in fluid communication with the housing 320 and/or a cartridge installed in the housing 320 to allow air flow to enter the air conduit 340 from the housing or from a cartridge installed in the inhaler during use. Figure 1 illustrates the inhaler 302 in isometric view in a closed position having a thinner body 305 than the inhaler 300 formed by housing 320 and cover portion 308 of mouthpiece 330, which extends over and engages housing 320 through of a locking mechanism 312, for example, a bulge. Figures 2 to 6 represent side, top, bottom, proximal and distal views, respectively, of the inhaler of Figure 1. As shown in the Figures, the inhaler 302 comprises the mouthpiece 330 which has an oral placement section 312, a portion Extender configured as a cover 308 that can be attached to housing 320 in at least one location as shown in Figure 7. Mouthpiece 330 can pivot to open relative to a proximal position of a user's hands in an angled direction through the mechanism. hinge 363. In such an embodiment, the inhaler 302 is also configured to have the gearing mechanism 363 as shown in Figure 8 integrated within the hinge for opening the inhaler or mouthpiece 330 with respect to housing 320.
[0118] The gear or rack mechanism 319 which is a part of the slide 317 and the pinion 363 are configured with the nozzle as a part of the hinge mechanism to engage the housing 320, which housing may also be configured to house the slide 317. In such an embodiment, the slide 317 is configured as a separate part and has a rack-shaped portion that engages the configured gear wheel on the hinge mechanism. Hinge mechanism 363 allows movement of mouthpiece 330 to an open or cartridge loading configuration and inhaler 302 configuration or closed position in an angular direction. The gear mechanism 363 in the inhalers 300, 302 can actuate the slide to allow simultaneous movement of the slide 317 within the housing 320 when the inhaler is actuated to open and close by movement of the mouthpiece 330, the slide 317 being integrally configured with rack 319 as a part of gear mechanism 363. During use with a cartridge, inhaler gear mechanism 363 can reconfigure a cartridge through slide movement 317 during inhaler closing, from a confining configuration of cartridge after a cartridge is installed in the inhaler housing or mounting area for a dosing setup when the inhaler is closed. The movement of mouthpiece 330 to an open inhaler configuration after inhalation with a cartridge 170, or to a disposable configuration after a subject has dosed a dry powder formulation. In the embodiment illustrated herein, the hinge and gear mechanism are provided at the distal end of the inhaler, however, other configurations may be provided such that the inhaler opens and closes for loading or unloading a cartridge as a configuration similar to a clam.
[0119] As shown in Figure 1 and during use, the airflow enters the inhaler through the air inlet 310 and simultaneously into the air conduit 340, which passes the cartridge 170 through the air inlet 355. In the exemplary embodiment, the internal volume of air conduit 340 of nozzle 330 extending from inlet port 355 to outlet port 335 is greater than about 0.2 cm 3 . In another example of embodiments, the internal volume is about 0.3 cm3 or about 0.3 cm3 or about 0.4 cm3 or about 0.5 cm3 . In another exemplary embodiment, such an internal volume of the mouthpiece is greater than 0.2 cm 3 , is the internal volume of the mouthpiece 330. In an exemplary embodiment, the internal volume of the mouthpiece is in a range of 0.2 to 6.5 cm 3 . A powder contained within the cartridge container 175 is fluidized or entrained in the air stream entering the cartridge by swirling the powder contents. The fluidized powder then gradually exits through the dispensing port 173, 127 and into the air duct of the nozzle 340 and is further de-agglomerated and diluted with the air stream entering the air inlet 310, before exiting through the air duct 340. output port 335.
[0120] In one embodiment, housing 320 comprises one or more component ports, for example, a top portion 316 and a bottom portion 318. The top and bottom portions are configured to fit together in a seal fitted to form a housing which houses the slide 317 and the hinge and/or gear mechanisms 363. The housing 320 is also configured to have one or more openings 309 to allow airflow within the housing, a locking mechanism 313, such as protuberances or snap rings to engage and secure mouthpiece cover portion 308 in the closed position of inhaler 302. Housing 320 is also configured to have a cartridge holder or cartridge mounting area 315 that is configured to match the cartridge type to be used with the inhaler. In such an embodiment, the cartridge or holder placement area is an opening in the top portion of housing 320, such opening also allowing the bottom portion of cartridge or container to rest on slide 317 once a cartridge is installed in the housing. inhaler 302. The housing may further comprise handle areas 304, 307 configured to assist a user of the inhaler in firmly or securely gripping the inhaler to open it for loading or unloading a cartridge. Housing 320 may additionally comprise flanges configured to define an air channel or conduit, for example two parallel flanges 303 which are also configured to direct airflow into the inhaler air inlet 310 and into the cartridge air inlet from the cartridge air conduit positioned on the inhaler. Flanges 310 are also configured to prevent a user from obstructing the inlet port 310 of the inhaler 302.
[0121] Figure 7 represents an isometric view of the inhaler of Figure 1 in an open configuration with the mouthpiece cover, e.g. cap 342 and cartridge 170, which are configured to match the cartridge mounting area and allow a cartridge is installed in the cartridge holder 315 for use. In one embodiment, reconfiguration of a cartridge from a containment position, as supplied after manufacture, may be performed once the cartridge is installed in cartridge holder 315, which is configured within housing 320 and to adapt to the inhaler. so that the cartridge has the proper orientation in the inhaler and can only be inserted or installed in one way or orientation. For example, cartridge 170 may be configured with locking mechanism 301 which is compatible with a locking mechanism configured on the inhaler housing, for example, the inhaler mounting area or holder may comprise a beveled edge 301 which corresponds to a beveled edge 180 on the cartridge, for example of the cartridge 170 to be installed in the inhaler. In such an embodiment, the beveled edges form the locking mechanism that prevents the cartridge from escaping the holder 315 during movement of the slide 317.
[0122] In a specific embodiment illustrated in Figures 8 and 9, the cartridge cover is configured with a beveled edge so that it remains secured in the housing mounting area during use, such mounting area having compatible beveled edges. Figures 8 and 9 also show rack mechanism 319 configured with slide 317 to effect movement of a cartridge container 175 of cartridge 170 slidably under the cartridge top to align the container under the configured cartridge subsurface top. to have dispensing port(s) in a closed inhaler configuration or cartridge dispensing or dosing position or configuration when the inhaler 302 is ready to dispense a user. In the dosing configuration, an air inlet port forms at the rim of the cartridge top and at the rim of the container, due to the fact that the subsurface of the cartridge top is elevated relative to the containment subsurface. In such a configuration, an air duct is defined through the cartridge by the air inlet, the internal volume of the cartridge that is exposed to ambient air and the openings in the cartridge top or dispensing port in the cartridge top, such an air duct being air is in fluid communication with air duct 340 of the nozzle.
[0123] The inhaler 302 may additionally include a mouthpiece cap 342 to protect the oral placement portion of the mouthpiece. Figure 8 depicts the inhaler of Figure 1 in cross-section through the mean longitudinal axis with a cartridge installed in the cartridge holder and in an open configuration and in a closed configuration, Figure 9 in a cartridge dispensing or dosing configuration.
[0124] Figure 8 illustrates the position of the cartridge 350 installed in the bracket or mounting area 315 and which shows the internal compartment parts of the inhaler 302 and the cartridge 170 in relation to each other, including the projection 326 with dispensing ports 327 ; the gear mechanism 360, 363, and snap-in fittings 380 that help keep the device in a closed configuration.
[0125] Figures 10 to 16 illustrate yet another embodiment of the dry powder inhaler of the inhalation system. Figure 10 depicts the inhaler 900 in an open configuration that is structurally configured similarly to the inhaler 302 shown in Figures 1 to 9. The inhaler 900 comprises mouthpiece 930 and housing subassembly 920 that are secured to each other via a hinge, such that mouthpiece 930 pivots with respect to housing subassembly 920. Mouthpiece 930 additionally comprises integrally formed side panels 932 wider than housing 920, such engagement with housing protrusions 905 achieving the closed configuration of the inhaler 900. Nozzle 930 further comprises air inlet 910, air outlet 935; the airflow conduit 940 that extends from the air inlet 910 to the air outlet 935 to contact a user's lips or mouth and the passage 955 in the floor or bottom surface that communicates with the air conduit 955. inhaler airflow 940. Figure 12 illustrates the inhaler 900 in an exploded view showing the component ports of the inhaler, including the mouthpiece 930 and housing subassembly 920. As shown in Figure 12, the mouthpiece is configured as a single component and additionally comprises a bar. , cylinder or tube 911 configured with teeth or gear 913 to pivot with respect to housing 920 such that movement of mouthpiece 930 relative to housing 920 in the angular direction achieves closure of the device. An air channel 912 can be provided to the housing which can direct a flow of air to the air inlet of the mouthpiece 910. The air channel 912 is configured so that, during use, a user's finger placed over the channel cannot limit or obstruct the flow of air into the air duct 940. In an alternative embodiment, the passage 955 may be configured in the form of a projection to be adapted, for example, to the cartridge 975 to form the second passing airflow through a container in the dosing configuration to discharge the powder into the container during an inhalation.
[0126] Figure 12 illustrates housing subassembly 920 comprising two parts fabricated to produce a housing and comprising a top portion having a cartridge placement or mounting area 908 and a notch 918 that is configured to define a air intake when the inhaler is in a closed configuration. Figure 12 illustrates housing 920 as a housing, which additionally comprises two component ports for ease of fabrication, although fewer or more parts may be used. The bottom portion of the housing formation has no openings and includes a tray 922 and is connected to the top or cover portion 925 to form a housing or housing 920. The tray 922 is configured with notches 914 configured near its distal end, which houses the bar, cylinder or tube 911 in the formation of a nozzle hinge 930. The tray 922 also houses the slide 917. The slide 917 is configured to be movable within the tray 922 and has a cartridge receiving area 921 and an arm-like structure having openings 915 for engaging the teeth or gear 913 of the nozzle 930 so that, during closing of the device for use, movement of the nozzle 930 relative to the housing 920 moves the slide in a proximal direction , which results in a slide adjacent to a cartridge container seated on the support or mounting area of the inhaler 908 and can move the container from a confined position to a dosing position. In such an embodiment, a cartridge seated in cartridge holder 908 has the air inlet opening in a dosing configuration facing the proximal end of the inhaler or the user. Cover housing 925 is configured so that it can be securely attached to tray 922 by causing, for example, protrusions 926 s to extend from the bottom lip as a gripping mechanism. Figure 12 illustrates the inhaler 900 in the open configuration representing the position and orientation of a cartridge 150 in a containment configuration to be installed in the mounting area of the inhaler. Figure 13 further illustrates the inhaler 900 in the open configuration with the cartridge 150 seated in the cartridge holder in the containment configuration. Figure 14 illustrates an average longitudinal section of the inhaler in Figure 13 showing the position of gear 913 with respect to slide 917 in the containment configuration of cartridge container 151, which adjoins slide 917. In such an embodiment, container 151 moves relative to cartridge top 156. Upon closing of inhaler 900 (Figure 15) and as mouthpiece 930 moves to reach a closed configuration, slide 917 pushes container 151 until the dosage configuration is reached and passageway nozzle 955 slides over cartridge boss 126 such that dispensing ports 127 are in communication with nozzle conduit 940 and an airflow path is established for dispensing through air inlet passage 918, the cartridge air inlet 919 and dispensing ports 127 in air conduit 940. As seen in Figure 16, mouthpiece 930 and therefore air conduit 940 have an hourglass configuration, relatively tapered approximately in the middle of the distal end. In such an embodiment, the slide 917 is configured so that when the inhaler is open after use, the slide cannot reset a cartridge to the containment configuration. In some variations of such an embodiment, it may be possible or desirable to reconfigure the cartridge, depending on the powder medication used.
[0127] In the embodiments disclosed herein, the inhaler passages, e.g. 355, 955 may be provided with a seal, e.g. compressed ribs, conformable surfaces, gaskets and o-rings to prevent airflow leakage into the system so that the air flow only moves through the cartridge. In another embodiment, to effect the seal, the seal may be provided to the cartridge. Inhalers are also provided with one or more de-agglomeration zones, which are configured to minimize dust accumulation or deposition. De-agglomeration zones are provided, for example, on the cartridge, including on the container and dispensing ports, and at one or more locations in the nozzle air duct.
[0128] Cartridge embodiments for use with inhalers are described above, such as cartridges 150, 170 illustrated, respectively, in Figures 10, 13, 14, 16 to 21 and Figures 7 to 9, 22 to 30. present cartridges are configured to form a housing that has at least two configurations and contains a dry powder medicament in a tightly sealed and contained storage position. In that and other embodiments, the cartridge may be reconfigured within an inhaler from a powder confinement position to an inhalation or dosing configuration.
[0129] In certain embodiments, the cartridge comprises a lid or top and a container having one or more passages, a containment configuration and a dosing configuration, an outer surface, an inner surface defining an inner volume; and the containment configuration restricts communication to the internal volume and the dispensing configuration forms an air passage through the internal volume to allow a flow of air to enter and exit the internal volume in a predetermined manner. For example, the cartridge container may be configured so that a stream of air entering the cartridge air inlet is directed through the air vents within the internal volume to measure the medicament exiting the cartridge so that the discharge rate of a powder is controlled; and wherein the air flow in the cartridge can revolve substantially perpendicular to the outgoing air flow direction, mixing and fluidizing a powder in the internal volume before exiting through the dispensing passages.
[0130] In one embodiment, the cartridge may be encoded with one or more indicators, including marking, engraving, color, covers, flanges, ridges and the like. For example, if color is selected, color pigments of various types that are compatible with plastics and pharmaceutical formulations or that are pharmaceutically acceptable can be incorporated during cartridge manufacture. In this and other embodiments, the color may denote a specific active ingredient or dose strength, for example, a green cap may be indicative of 6 units of a FDKP and insulin formulation. Pharmaceutically acceptable colors can be green, blue, teal, poppy red, lilac, yellow, orange, etc.
[0131] Figure 17 further illustrates the cartridge 150 comprising the top or lid 156 and the container 151 defining an interior space or volume. Figure 18 further exemplifies the cartridge top 156 having opposite ends and comprising recess area 154 and protrusion 126 at opposite ends of a longitudinal axis X and the relatively rectangular array of panels 152 along the sides and on the longitudinal axis X, which are integrally configured and attached to the top 156 at their ends. The lip 158 of the top of cartridge 156 extends downwardly and is continuous with the panels 152. The panels 152 extend downwardly from either side of the top 156 on the longitudinal axis X and are separated from the area from the protrusion 126 and the recess area 154 by a longitudinal space or slot 157. Figures 17 to 21 also show each panel 152 which further comprises a flange 153 structurally configured to be engaged with the protuberances or wings 166 of the container 151, the container support 151 and allows the container 151 to be movable from a containment position under the recess area 154 to a metering position under the protrusion area 126. The panels 152 are structurally configured with a stop 132 at each end to prevent the container 151 moves beyond its end where they are attached to the lip 158. In such an embodiment, the container 151 or lid 156 may be movable, for example, through is of translational motion over top 156 or top 156 may be movable with respect to container 151. In one embodiment, container 151 may be movable by sliding over flanges 153 over cover 156 when cover or top 156 is in place. or the cap 156 may be slidable over a stationary container 151 depending on the inhaler configuration. The lip 158 proximate the ridge 126 has the recess area that forms a part of the perimeter of the inlet port 119 in the cartridge dosing configuration.
[0132] Figure 19 illustrates a bottom view of cartridge 150 showing the relationship of structures in a containment configuration, such as container 151, dispensing ports 127, panels 152, flanges 153 and the area under boss 126 or subsurface 168 which is relatively hollow or recessed. Figure 20 illustrates a cross-section through the mean longitudinal axis X of the cartridge 150 in a confinement configuration and showing the container 151 in fitted contact with the lid 156 in the recess area 154 and supported by the flanges 153. 126 is hollow and can be viewed in a position relatively higher than the top rim of the container 151. Figure 21 illustrates the cartridge 150 in a dosing configuration in which the side view of the container 151 and the panel 158 under the area of the ledge 126 form an inlet port 119 that allows flow to enter the cartridge 151.
[0133] In another embodiment, a translation cartridge 170 is illustrated in Figures 22 to 30, which is in an alternative embodiment of the cartridge 150 and can be used, for example, with the inhaler 302 shown in Figures 1 to 9 Figure 22 depicts cartridge 170 comprising a housing comprising a top or lid 172 and a container 175 defining an interior space, wherein the cartridge is shown in a containment configuration. In such a cartridge configuration, the cartridge top 172 is configured to form a seal with the container 175 and the container or lid is movable relative to each other. Cartridge 170 can be configured from a containment position (Figures 22 and 29) to a dosing position (Figures 24 to 28 and 30) and to a disposable position (not shown), for example in the middle of the cartridge, to indicate that the cartridge has been used. Figure 22 also illustrates the various features of cartridge 170, the top 172 comprising side panels 171 configured to partially cover the exterior of the container. Each side panel 172 comprises a flange 177 at its lower edge that forms a track for the wing-like structures of the container support 175, which allows movement of the container 175 along the lower edge of the top 172. The cartridge top 172 further comprises a relatively flat outer surface at one end, a relatively rectangular protrusion 174 having a dispensing opening or port 173, and a recessed or concave area configured internally to hold the contents of the container 175 in a tight seal. In one embodiment, the dispensing port can be configured to be various sizes, for example, the width and length of the opening can be from about 0.025 cm to about 0.25 cm in width and from about 0.125 cm to about 0.125 cm. 0.65 cm long at its entrance inside the cartridge. In one embodiment, the dispensing port inlet measures approximately 0.06 cm wide to 0.3 cm long. In certain embodiments, the cartridge top 172 may comprise various shapes that may include gripping surfaces, for example, tabs 176, 179 and other configurations to orient the cartridge in the correct orientation for proper placement in the holder, and a gripping mechanism, e.g. for example, a beveled or beveled edge 180 to securely fit a matching inhaler. Flanges, external protrusion geometry, tabs and various other shapes can form keying surfaces that may indicate, facilitate and/or require proper placement of the cartridge in the inhaler. Additionally, such structures can be varied from one inhaler and cartridge pairing system to another in order to correlate a specific drug or dosage delivered by the cartridge to a specific inhaler. In such a way, a cartridge intended for an inhaler associated with a first drug or dosage can be prevented from being placed in or operated with a similar inhaler associated with a second drug or dosage.
[0134] Figure 23 is a top view to exemplify the general shape of a cartridge top 172 with protrusion 174, dispensing port 173, recessed area 178, and tabs 176 and 179. Figure 24 is a view bottom of cartridge 170 showing container 175 in a dosing position that is supported by its aso-like protrusions 182 by each flange 177 of top 172. Figure 25 depicts cartridge 170 in a dosing configuration that further comprises a delivery inlet. air 181 formed by a notch in the top of cartridge 172 and the side view of the container 175. In such a configuration, the air inlet 181 is in communication with the interior of the cartridge and forms an air duct with dispensing port 173. During , cartridge air inlet 181 is configured to direct the flow of air entering the inner cartridge at dispensing port 173. Figure 26 depicts cartridge 170 from the opposite end of the dosing configuration or from the rear view of Fig. ra 25.
[0135] Figure 27 illustrates a side view of cartridge 150, showing the relationship of structures in a dosing configuration, such as container 175, boss 174, side panels 172, and flap 176. Figure 28 illustrates a cartridge 170 in a dosage configuration for use and comprising a container 175 and a top 172 having a relatively rectangular air inlet 181 and a relatively rectangular dispensing port 173 which perforates a ledge 174 which is located in a , relatively centered on the upper surface of the cartridge top 172. The protrusion 174 is configured to fit into a passage in a wall of an inhaler mouthpiece. Figures 29 and 30 illustrate cross-sections through the mean longitudinal axis X of the cartridge 170 in a confinement configuration and dosing configuration, respectively, showing the container 175 in contact with the subsurface of the lid 172 of the recess area 178 and supported by flanges 177 which form tracks for the container to slide from one position to another. As shown in Figure 29, in the containment configuration, the container 175 forms a seal with the subsurface of the cartridge top 172 in the recess area 178. Figure 30 depicts the cartridge 170 in the dosing configuration where the container is at the opposite end. of the recess area 181 and the container 175 and the cartridge top form an air inlet 181 which allows ambient air to enter the cartridge 170 and to form an air duct with the dispensing port 173 and the interior of the container 175. In such an embodiment, the subsurface top of the cartridge, at which the dosing position is reached, is relatively flat and the interior surface of the container 175 is configured to be approximately U-shaped. , slightly above the top surface of the cartridge top 172.
[0136] In other embodiments of the cartridge, the cartridge can be adapted to dry powder inhalers that are suitable for use with an inhaler with a swivel mechanism to move the inhaler or cartridge from a containment configuration to a dosing position, in that the cartridge top is movable relative to the container or to move the container relative to the top to achieve alignment of the dispensing ports with the container in a dosing position or to move both the container and the top to the containment configuration.
[0137] In the embodiments described herein, the cartridges may be configured to deliver a single unit, a pre-measured dose of a dry powder medicament in varying amounts depending on the dry powder formulation used. Examples of cartridges such as cartridge 150, 170 can be structurally configured to contain a dose of, for example, 0.1 mg to about 50 mg of a dry powder formulation. Therefore, the size and shape of the container may vary depending on the size of the inhaler and the amount or mass of powder medication to be delivered. For example, the container may be relatively cylindrical in shape with two opposing sides that are relatively flat and are approximately 0.4 cm apart to about 2.0 cm apart. To optimize inhaler performance, the height of the inner side of the cartridge along the Y axis may vary depending on the amount of powder that is intended to be contained in the chamber. For example, a fill of 5mg to 15mg of powder may ideally require a height of about 0.6cm to about 1.2cm.
[0138] In one embodiment, a medicament cartridge for a dry powder inhaler is provided, comprising: a housing configured to hold a medicament; at least one inlet port for allowing flow into the housing and at least one dispensing port for allowing flow out of the housing; the at least one inlet port is configured to direct at least a portion of the flow entering the at least one inlet port in the at least one dispensing port within the housing in response to a pressure differential. In one embodiment, the inhaler cartridge is formed from a high density polyethylene plastic. The cartridge has a container having an internal surface defining an internal volume and comprising a bottom and side walls adjoining one another and having one or more openings. They may have a cup-like structure and have an opening with a rim and are formed by a cartridge top and a container bottom that are configurable to define one or more inlet ports and one or more dispensing ports. The cartridge top and container bottom are configurable with respect to a containment position and a dispensing or dosing position.
[0139] In the embodiments described in this document, an inhaler and dry powder cartridge form an inhalation system that can be structurally configured to effect an adjustable or modular airflow resistance, as the system can be effected by varying the area in cross-section through any section of your airflow ducts. In one embodiment, the dry powder inhaler system may have an airflow resistance value of from about 0.065 to about 0.200 (VkPa)/liter per minute. In other embodiments, a check valve may be employed to prevent air flow through the inhaler until a desired pressure drop, such as 4 kPa, has been reached, at which point the desired resistance reaches a value in the range determined in the present invention.
[0140] In the embodiments disclosed herein, the dry powder inhaler system is configured to have a predetermined flow balance distribution during use, which has a first flow path through the cartridge and a second flow path through, for example from the nozzle air duct. Figure 31 and Figure 32 show a schematic representation of air conduits established by the structural configurations of cartridge and inhaler that direct the flow balance distribution. Figure 31 represents the general direction of flow through a cartridge in the dispensing or dosing position of a dry powder inhaler as shown by the arrows. Figure 32 illustrates the flow movement of an embodiment of a dry powder inhaler showing the flow paths of the inhaler in the dosing position as indicated by the arrows.
[0141] Figures 33A, 33B, 33C and 33D represent a further embodiment of a dry powder inhaler configured as a single-use inhaler comprising a substantially U-shaped air duct during use. Such Figures show an inhaler comprising two parts and which is shown in a disassembled configuration (Figures 33A and 33B) and which comprises a top portion 1000 (Figure 33A) with a body 1004 and a mouthpiece 1016. The top portion 1000 which comprises a first air inlet, e.g. 1030, shown in Figure 33C and a second air inlet 1032 which is in fluid communication with the internal volume of the container 1010 of the second portion or element 1008 in the dosing configuration. The air inlet 1032 is configured to form a portion of an air inlet in the internal volume of the container 1010 and allows a flow of air entering the internal volume 1010 of the container to carry a powder during an inhalation and then the port. air may exit the internal volume of container 1010 through air port 1032 to impinge on a secondary air stream at the nozzle air duct 1016 and outlet 1002. Nozzle 1016 may be configured to be positioned in the mouth of a user. At least one of the air inlet passages in the mouthpiece is configured to fit the bottom portion 1008 (Figure 33B) comprising a container 1010 and form an air duct with said container in a dosing configuration. Bottom portion 1008 may further include a thrust surface 1012 that may be used to activate the device when biased distally to move distally with respect to the top portion of inhaler 1000 to bring the container into the dosage configuration for use. Guide ribs 1020 may also be included in the bottom portion 1008 to assist in seating and positioning the bottom portion 1008 with the top portion 1000. The inhaler may be provided with a dose of powder in a containment configuration, where the container is sealed to prevent communication or formation of an air conduit with the mouthpiece in a fixed non-dosing configuration. Figure 33A is an isometric view of the top portion of the inhaler 1000 which is configured to fit a bottom portion, Figure 33B. Figure 33C represents the top portion of the inhaler 1000 showing its bottom view to engage with the bottom portion of the top surface of the inhaler which comprises the rails for adapting to the wings 1018 of the bottom portion 1008, which comprises the container 1010 so that the two parts are movable relative to each other and which additionally comprises the baffle surface 1014 between the two air inlets 1030,1032. Figure 33D depicts the bottom surface of the bottom portion 1008 of the inhaler, so as to further show the wing-like structures or wings 1018 for adapting to or engaging with the top portion 1000 of the inhaler comprising the mouthpiece 1016 to form the inhaler. and comprising a powder container 1010 or reservoir. Top portion 1000 may further include one or more compatibility features 1024, e.g., fasteners, which may engage one or more complementary compatibility features 1022 with the bottom portion, e.g., locking tabs. Figure 33C is a bottom view of the top portion of the inhaler showing a baffle surface 1014 and an opening for communicating with the container and a second conduit. Figure 33B is an isometric view of the bottom portion and 33D is a top view of the bottom portion 1008 of the inhaler showing the container adapted to a structure configured to mount or adapt to the top portion 1000, wherein it can be configured in a confinement configuration and a dosing configuration. In this inhaler embodiment, the inhaler is supplied with a pre-filled metered powder, or a dose of powder into which the container is filled during manufacture prior to mounting the top portion comprising the mouthpiece in a confinement configuration in an area over the bottom surface of the mouthpiece, which is configured to seal the container. Prior to use, the canister is pushed forward distally from the air outlet side of the inhaler towards the rear end of the inhaler so that the canister forms an air duct with the mouthpiece through the inhaler inlet closest to the nozzle air outlet. In such an embodiment, the inhaler comprises two airflow ducts, one completely through the mouthpiece and the other that forms through the canister and converges with the airflow through the mouthpiece to deliver the powder particles to the air outlet. from the mouthpiece and to the individual while using the inhaler.
[0142] Figures 34 and 35 represent a cross-section through the longitudinal plane of the cartridge 975, in the confinement and dosage configurations, respectively. Figures 34 and 35 depict an alternative cartridge embodiment similar to cartridge 170 comprising a lid 976 and a container 977 that are secured together and movable relative to each other in a translational motion. Cartridge 975 is similar to cartridge 170, but without a protrusion surrounding the air outlet, but can be fitted to inhaler 950 (Figure 38) as described, for example, in Figures 1 to 16, where passage 955 in the The inhaler mouthpiece is configured within a protrusion structure 952 which can adapt to the cartridge 975 in forming a rigid airflow duct leading to the mouthpiece air duct through the air outlet 979, through the cap 976 and which communicates with cartridge container 977 to reach the internal volume of cartridge 974 for powder confinement in the dosage configuration; and in further forming an air conduit through cartridge 975 communicating with ambient air through an air inlet 980 when the inhaler is in the dosing position and ready for use. Cartridge 975 further comprises a bulge or baffle 978 configured into the subsurface of cap 976 at the exposed end of the cartridge in the containment configuration. In a dosing configuration, the baffle 978 is situated proximal to the air inlet 980 so that during an inhalation, the pressure differential generated by a user causes a stream of air to enter through the air inlet 980 of the 975 cartridge. to change the downward direction into the internal volume 974 of the cartridge container 977 by deflecting the air stream in a downward direction so as to lift, fluidize and insert any powder in the container 977 into the air stream and deliver it through from the air outlet 979 inside the mouthpiece of the inhaler through the passage of the inhaler 955 to impinge a second stream of air in the air duct of the mouthpiece, prior to delivery to the user.
[0143] In an alternative embodiment of a cartridge, Figures 36 and 37 represent the cartridge 981 in cross-section through its longitudinal median plane, in the confinement and dosing configurations, respectively. As seen in Figures 36 and 37, the cartridge 981 comprises a lid 982 and a container 983 and is similar to the cartridge 975, except that it is configured with a protrusion 985 to fit an inhaler as described in Figures 1 to 7 In such an embodiment, cartridge 981 is designed similarly to cartridge 170 in its external configuration and the two parts are movable relative to each other in a translational movement, however, cartridge cover 982 is configured to comprise a baffle 984 at its subsurface to form a substantially U-shaped airflow conduit through cartridge 981 that has an air inlet port 986 and an air outlet or outlet port 987 and passes through the cartridge 981 through of its internal volume 990. In such an embodiment, during use and in a dosing configuration of such a cartridge in an inhaler, a flow of air is deflected downwards in the cartridge container and fluidizes and entrains the particles. of powder in the container to assume a U-shaped direction, where dust particles entrained in the air stream are immediately directed or delivered towards the air outlet port 987, in a direction approximately perpendicular to the nozzle and exits the cartridge 981 at the air outlet ports 987 and into the airflow duct of the nozzle, so as to dispense the powder with or with substantially no swirling action on the volume of the container 990.
[0144] In one aspect of this embodiment, the container 977, 983 may optionally have one or more protuberances or rods that extend from the subsurface or inner surface of the cartridge top or cap 976, 982 into a space void or internal volume 974, 990 of container 977, 983. The protuberances or deflector 978, 984 may be of any shape or size as long as they can direct or deflect flow, particularly downwards in the container during an inhalation in the dosage configuration . In specific embodiments, the bulge 978, 984 may be configured on the cap of a cartridge extending from the surface facing the inner volume of the container 975, 981 near an air inlet 980, 986 in the dosing configuration. Alternatively, the bulge 978, 984 may be projected on the surface of the mouthpiece to contact the internal volume of a container and close to the air inlet formed by the container in the dosing configuration on a single-use inhaler (Figure 33C). The length of the bulge or deflector can be any size, depending on the depth of the container, the type of powder and/or the amount of powder being delivered from the inhaler. In one embodiment, the length of the bulge is greater than 1%, greater than 5%, or greater than 10% of the depth of the inner container volume. In this and other embodiments of the container, the length of the bulge or baffle is less than 95% of the internal volume of the container.
[0145] Figure 38 shows a schematic representation of a cross-section through its longitudinal median plane of an inhaler as illustrated in Figures 1 to 7 with the 975 cartridge in a dosing configuration. As visualized in Figure 38, the cartridge 975 in the dosing configuration forms a rigid air duct, through its internal volume 974, with the mouthpiece 312 by forming an air duct between the cartridge and the air outlet port. 955 and ambient air at the air inlet port of cartridge 980 forms a first airflow conduit for the inhaler. A second airflow conduit is shown in Figure 38, which is defined by the air inlet 310 and the air outlet of the inhaler 340, with the air passage diverting the air conduit through the cartridge 975. To form a seal with cartridge 975, mouthpiece 312 is configured to have a ledge 952 that houses passage 955 and thus defines a rigid air duct between cartridge 975 and mouthpiece 312.
[0146] In a specific embodiment, a single-use disposable unit dose inhaler structurally configured to have a powder confinement configuration and a powder dosing configuration, the inhaler comprises two elements and has a top surface, a proximal end and a distal end; a first element and a second element; the first member has at least three openings and comprises a mouthpiece at the proximal end; a body, a subsurface configured to conform to the second element and having a protruding structure or shank configured to extend downwardly into the second element; the first member is further configured to have a first flow path having an air inlet and an air outlet for delivering a stream of air into a subject's mouth during an inhalation; and a third opening configured to form an air conduit and a second flow path with the second member in the powder metering configuration; the second element is configured to conform to the subsurface of the first element and is movable with respect to the first element to form an inhaler confinement configuration or a dosage configuration; the second comprises a container or reservoir having an opening configured to receive and retain a powder and form an air inlet and an air conduit or second flow path with the first element in the dosing configuration; wherein in the powder dispensing configuration, a powder is exposed to ambient air to be dispensed or discharged during an inhalation. In that and other embodiments, a dry powder inhaler in a dosage configuration comprises a rod-like or protruding structure that extends downwardly into the void space or chamber of the container and serves to deflect the powder. In such an embodiment, a stream of air entering the powder container or reservoir primarily travels in a path closely related to the shape of the container that is structurally configured substantially in the shape of the letter U, causing a portion of the air duct to extends from the air inlet in the form of an open letter s without its side and the powder is lifted and transferred or transported from such second air stream to the first air stream into the subject's mouth and airways .
[0147] In an alternative embodiment, the substantially U-shaped configuration of the second flow path may be adapted for a multi-purpose inhaler, wherein the inhaler and replaceable cartridge are similarly configured as described above. In such an embodiment, a cartridge top may be configured to have a bulge or rod that extends into the void space of the container to deflect a flow of air entering a cartridge.
[0148] The balance of mass flow within an inhaler is approximately 20% to 70% of the volume passing through the flow path of the cartridge, and approximately 30% to 90% through the start portion of the mouthpiece conduit. . In such an embodiment, the airflow delivery through the cartridge mixes the medicament by swirling to fluidize or aerosolize the dry powder medicament in the cartridge container. The airflow that fluidizes the powder inside the container then lifts the powder and gradually lets the powder particles out of the cartridge container through the dispensing ports, then shearing the airflow entering the duct nozzle is converged with the air stream containing the drug emanating from the cartridge container. The predetermined or metered outflow air from the cartridge is converged with bypass airflow entering the mouthpiece air duct to further dilute and de-agglomerate the powdered medication before leaving the mouthpiece outlet port and entering the patient. .
[0149] In yet another embodiment, an inhalation system for delivering a dry powder formulation to a patient is provided, which comprises an inhaler comprising a container mounting area configured to receive a container and a mouthpiece having at least two inlet passages and at least one outlet passage; wherein an inlet passage of the at least two inlet passages is in fluid communication with the container area and one of the at least two inlet passages is in fluid communication with the at least one outlet passage through a configured flow path to derive the container area to deliver the dry powder formulation to the patient; wherein the flow conduit configured to bypass the container area delivers from 30% to 90% of the total flow through the inhaler during an inhalation.
[0150] In another embodiment, an inhalation system for delivering a dry powder formulation to a patient is also provided, which comprises a dry powder inhaler comprising a container region and a container; the dry powder inhaler and the container, in combination, are configured to have rigid flow ducts in a dosage configuration and a plurality of framework regions that provide a mechanism for de-agglomerating powder from the inhalation system during use; wherein at least one of the plurality of mechanisms for de-agglomeration is an agglomerate size exclusion passage in the container region having a smallest dimension between 0.25 mm and 3 mm. The term “rigid flow ducts” denotes air ducts of the inhalation system that do not change in terms of geometry after repeated use, i.e. the ducts remain the same or constant and are not variable from one use to the next in opposition. systems that operate with punch mechanisms for use with conduit configuration and blisters that may exhibit variability in conduit configuration from capsule to capsule or blister to blister.
[0151] In an alternative embodiment, an inhalation system for delivering a dry powder formulation to a patient is provided, which comprises a dry powder inhaler comprising a mouthpiece and a container; the dry powder inhaler and the container, in combination, are configured to have rigid flow ducts in a dosage configuration and a plurality of framework regions that provide a mechanism for de-agglomerating powder from the inhalation system during use; wherein at least one of the plurality of mechanisms for de-agglomeration is an air conduit configured in the mouthpiece that directs a flow into an outlet passage in fluid communication with the container. In specific embodiments, the inhalation system includes a container which further comprises mechanisms for deagglomerating cohesive powder which comprise a cup-like structure configured to guide a flow entering the container to rotate, to be recirculated in the internal volume of the cup-like structure. cup and lift a powder medicine so that it drags the powder clumps in the stream until the powder mass is small enough before it leaves the container. In such an embodiment, the cup-like structure has one or more radii configured to prevent flow stagnation.
[0152] In embodiments described herein, the cartridge is structurally configured so that the inlet opening is in close proximity to the dispensing ports on a horizontal and vertical geometric axis. For example, the inlet property with respect to dispensing ports can be immediately close to the air inlet up to approximately the width of a cartridge, although this relationship can vary depending on the flow rate, physical and chemical properties of the powder. Due to such proximity, the flow from the inlet passes through the opening to the dispensing ports within the cartridge to create a flow configuration that prevents fluidized powder or powder entrained within the air stream from exiting the cartridge. In this way, during an inhalation maneuver, the flow entering the cartridge container can turn the dry powder formulation into the cartridge container and the fluidized powder arriving at the outlet or dispensing ports of a cartridge can be impeded by the flow entering the cartridge inlet port, thus, flow within the cartridge may be restricted from exiting the cartridge container. Due to differences in inertia, density, velocity, charge interaction and flow position, only certain particles can navigate the necessary pathway to exit the dispensing ports. Particles that do not pass through the exit port must continue to revolve until they have the proper mass, charge, velocity, or position. Such a mechanism can effectively measure the amount of medication that comes out of the cartridge and can contribute to the de-agglomeration of the powder. To additionally help to measure the fluidized powder that comes out, the size and quantity of dispensing ports can be varied. In one embodiment, two dispensing ports are used, configured so that they are circular in shape, each 0.10 cm in diameter and positioned close to the inlet passage close to the midline of the container at about 0.2 cm. from the center line towards the air inlet port. Other embodiments may have, for example, dispensing ports of various shapes, including rectangular, where the cross-sectional area of the one or more dispensing ports is in the range of 0.05 cm 2 to about 0.25 cm 2 . In some embodiments, the size range of the dispensing ports can be from about 0.05 cm to about 0.25 cm in diameter. Other shapes and cross-sectional areas may be employed as long as they are similar in terms of cross-sectional area to the values given in the present invention. Alternatively, for more cohesive powders, a larger cross-sectional area of the dispensing port can be provided. In certain embodiments, the cross-sectional area of the dispensing port can be increased depending on the size of the clusters relative to the minimum opening dimension of the port or ports, so that the length versus width of the port remains large. In one embodiment, the inlet passage has a wider dimension than the width of the dispensing port or ports. In embodiments where the inlet passage is rectangular, the air inlet passage comprises a width in the range of about 0.2 cm to approximately the maximum width of the cartridge. In one embodiment the height is about 0.15 cm and the width is about 0.40 cm. In alternative embodiments, the container may have a height of from about 0.05 cm to about 0.40 cm. In specific embodiments, the container can be from about 0.4 cm to about 1.2 cm in width and from about 0.6 cm to about 1.2 cm in height. In one embodiment, the container comprises one or more dispensing ports with each port having a diameter between 0.012 cm to about 0.25 cm.
[0153] In specific inhalation systems, a cartridge is provided for a dry powder inhaler comprising a cartridge top and a container, wherein the cartridge top is configured relatively flat and having one or more openings and one or more flanges having rails configured to engage the container; wherein the container has an internal surface defining an internal volume and is movably attached to the rails on the one or more flanges on the top of the cartridge and configurable to achieve a containment position and a dispensing or dosing position by movement along along the rails of one or more flanges.
[0154] In another embodiment, the inhalation system comprises a housing that has one or more outlet ports configured to exclude a mass of powder from a dry powder composition that has a smaller dimension greater than 0.5 mm and less than 3 mm In one embodiment, a cartridge for a dry powder inhaler, comprising a housing having two or more rigid parts; wherein the cartridge has one or more inlet ports and one or more dispensing ports, wherein the one or more inlet ports have a total cross-sectional area that is greater than the total cross-sectional area of the dispensing ports, including wherein a total cross-sectional area of the one or more dispensing ports is in the range of 0.05 cm 2 to about 0.25 cm 2 .
[0155] The medicine container or powder reservoir is structurally configured to have two opposite, relatively curvilinear sides that can direct the flow of air. In one embodiment, the flow entering the air inlet during an inhalation enters the powder container or reservoir and may circulate within the container around an axis relatively perpendicular to the axis of the dispensing ports, and thus the flow can effectively lift, swirl and fluidize a powder medication contained in the cartridge or reservoir before exiting through dispensing ports or outlets. In another embodiment, the stream entering the air inlet during an inhalation can lift the powder from the powder reservoir container and translate or transport the powder particles entrained in the air stream into a second stream in the inhaler. In this and other embodiments, the de-agglomerate in the air duct can be further de-agglomerated to form finer dust particles through a change in direction or velocity, i.e., acceleration or deceleration of the particles in the flow path. In certain embodiments, the change in acceleration or deceleration can be achieved by changing the angle and geometries, for example, of the dispensing port or ports, the nozzle conduit and/or their interfaces. In the inhalers described in the present invention, the fluidization mechanism and the acceleration of particles as they travel through the inhaler are methods by which de-agglomeration and delivery of a dry powder formulation is effected.
[0156] In one embodiment, a method for de-agglomerating and dispersing a dry powder formulation for inhalation, comprising the steps of: generating an air stream in a dry powder inhaler comprising a mouthpiece and a container having at least an inlet port and at least one dispensing port and contains a dry powder formulation; the container forms an air duct between the at least one inlet port and the at least one dispensing port and the inlet port directs a portion of the airflow entering the container to the at least one dispensing port; allowing the air stream to revolve the powder within the container so as to lift and mix the dry powder medicament in the container to form a mixture of medicament and air stream; and accelerating the flow of air out of the container through the at least one dispensing port. In such an embodiment, powdered medication passing through the dispensing ports can be accelerated immediately due to the reduction in the cross-sectional area of the outlet ports relative to the inlet port. This change in velocity can further de-agglomerate the fluidized and aerosolized powder medication during inhalation. Additionally, due to the inertia of the particles or groups of particles in the fluidized drug, the velocity of the particles exiting the dispensing ports is not equal. Faster moving airflow in the nozzle duct imparts a drag or shear force to each particle or group of particles of the slower moving fluidized powder exiting the outlet or dispensing port or ports, which can further de-agglomerate the medicine.
[0157] Powder medication passing through the dispensing port or ports is accelerated immediately due to the reduction in the cross-sectional area of the outlet or dispensing ports relative to the container, which are designed to be narrower in cross-sectional area than the air inlet of the container. This change in speed can further de-agglomerate the fluidized powder medication. Additionally, due to the inertia of the particles or groups of particles in the fluidized drug, the velocity of the particles exiting the dispensing ports and the velocity of the flow passing the dispensing ports are not equal.
[0158] In the embodiments described herein, the powder exiting the dispensing ports may be further accelerated, for example, by means of an imparted change in the direction and/or velocity of the fluidized drug. The directional change of fluidized powder exiting the dispensing port and entering the nozzle duct can occur at an angle from approximately 0° to approximately 180°, e.g. approximately 90° with respect to the geometric axis of the dispensing port. dispensation. Changing the flow velocity and direction can further de-agglomerate the fluidized powder through the air ducts. The change in direction can be achieved through changes in the geometric configuration of the airflow duct and/or by impeding the airflow leaving the dispensing ports with a secondary airflow entering the nozzle inlet. The fluidized powder in the nozzle conduit expands and decelerates as it enters the oral placement portion of the nozzle before exiting due to an increase in cross-sectional area in the conduit. Gas trapped in clusters also expands and can help break individual particles apart. This is an additional de-agglomeration mechanism of the achievements described in this document. The airflow-containing drug can enter the patient's oral cavity and be effectively delivered, for example, to the pulmonary circulation.
[0159] Each of the de-agglomeration mechanisms described in this document and a part of the inhalation system represent a multi-stage approach that maximizes powder de-agglomeration. Maximum de-agglomeration and powder delivery can be achieved by optimizing the effect of each individual mechanism, including one or more acceleration/deceleration, entrainment or expansion conduits of trapped gas within the agglomerates, interactions of powder properties with material properties of the inhaler components, which are integral features of the present inhaler system. In the embodiments described herein, the inhalers are provided with relatively rigid air ducts or a plumbing system to maximize de-agglomeration of the powder medication so that there is consistency of powder medication discharge from the inhaler during repeated use. Due to the fact that the present inhalers are provided with conduits that are rigid or remain the same and cannot be altered, variations in air conduit architecture that result from film puncture or film peeling associated with prior art inhalers with the use of blister packs are avoided.
[0160] In one embodiment, a method is provided for de-agglomerating a powder formulation in a dry powder inhalation system comprising: providing the dry powder formulation in a container having an internal volume for a dry powder inhaler; allowing a stream to enter the container which is configured to direct a stream to lift, drag and circulate the dry powder formulation until the powder formulation comprises powder masses small enough to pass through one or more dispensing passages into the interior from a mouthpiece. In such an embodiment, the method may further comprise the step of accelerating the powder masses entrained in the stream exiting the one or more dispensing passages and entering the nozzle.
[0161] In embodiments disclosed herein, a dry powder medicament is consistently dispensed from the inhaler in less than about 2 seconds. The present inhaler system has a high resistance value of about 0.065 to about 0.20 (VkPa)/liter per minute. Therefore, in the inhalation system comprising a cartridge, peak inhalation pressure drops between 2 and 20 kPa produce resulting peak flow rates through the system between 7 and 70 l/min. In some embodiments, the pressure differential for the inhaler and cartridge system may be below 2 kPa. Such flow rates result in more than 75% of the cartridge contents being dispensed into fill masses of between 1 and 30 mg of powder or greater amounts. In some embodiments, such performance characteristics are achieved by end users through a single inhalation maneuver to produce a cartridge dispensing percentage greater than 90%. In other embodiments, such performance characteristics are achieved by end users through a single inhalation maneuver to produce a cartridge dispensing percentage of about 100%. In certain embodiments, the inhaler and cartridge system are configured to deliver a single dose by discharging the powder from the inhaler as a continuous stream of powder delivered to a patient. In some embodiments, it may be possible to configure the inhalation system to deliver powder during use as one or more powder discharge pulses, depending on particle sizes. In one embodiment, an inhalation system is provided for delivering a dry powder formulation to the lungs of a patient, comprising a dry powder inhaler configured to have flow ducts with total resistance to flow in a dosage configuration whose value ranges from about 0.065 to about 0.200 (VkPa)/liter per minute. In this and other embodiments, the total resistance to flow of the inhalation system is relatively constant over a pressure differential range between 0.5 kPa and 7 kPa.
[0162] The structural configuration of the inhalation system allows the deagglomeration mechanism to produce respirable fractions greater than 50% and particles smaller than 5.8 μm. Inhalers can discharge more than 85% of a powder medication contained in a container during an inhalation maneuver. In general, the inhalers herein depicted in the Figures in the present invention can discharge more than 90% of the contents of the cartridge or container in less than 3 seconds at pressure differentials between 2 and 5 kPa with fill masses of up to 30 mg.
[0163] In another embodiment, the present systems have a lower performance threshold. Such a performance limit is assigned based on the inhalation of a dry powder as described herein, where an average specific particle size distribution is achieved. A graph of peak inspiratory pressure, PIP versus AUC can be formed, where a triangular area exists, where PIP values are physically impossible to achieve for a device given the AUC values. However, an acceptable area can be formed based on horizontal and vertical lines that represent passing criteria. The inhalation systems described herein have a lower limit for acceptable performance of a PIP of about 2 kPa and an AUC of at least about 1.0, 1.1 or 1.2 kPa*sec.
[0164] In other embodiments, there is a lower limit and an upper limit for AUC. For example, the AUC can be in the range from 1.0 to about 15 kPa*sec, from about 1.0 to about 10 kPa*sec, from about 1.1 to about 15 kPa*sec. ., from about 1.2 to about 10 kPa*sec., from about 1.2 to about 15 kPa*sec., or from about 1.2 to about 10 kPa*sec.
[0165] In another embodiment, properly de-agglomerated doses of a dry powder medication using a high strength dry powder inhaler are achieved by providing a high strength dry powder inhaler which contains a dose of the powder medication dry; inhaling from the inhaler with sufficient force to achieve a peak inspiratory pressure of at least 2 kPa within 2 seconds; and generating an area under the curve in the first second (AUC0 at 1 sec.) of an inspiration pressure-time curve of at least about 1.0, 1.1, or 1.2 kPa*second; wherein the VMGD (x50) of the emitted powder is less than about 5 µm. In some embodiments, a patient exerts a two (2) second peak inspiratory pressure (2 second PIP) greater than or equal to 2 kPa and less than or equal to 15 or 20 kPa. In another embodiment, the dry powder medicament includes the microparticles wherein the VMGD average particle size (x50) of the emitted powder particles is not greater than 1.33 times the average particle size when the inhaler is used optimally. In this and other embodiments, the optimal use of the inhaler by a patient is when a patient exerts a peak inspiratory pressure in two (2) seconds (2-second PIP) of about 6 kPa.
[0166] The high strength dry powder inhaler, in some embodiments, comprises a dose of a dry powder medication that is inhaled by the patient with sufficient force (or effort) to achieve a peak inspiratory pressure of at least 2 kPa at up to 2 seconds; and generating an area under the curve in the first second (AUC0 at 1 sec.) of a pressure vs. inspiration time curve of at least about 1.0, 1.1, or 1.2 kPa*sec.; wherein more than 75% of the dry powder dose is discharged or emitted from the inhaler as dust particles. In some VMGD embodiments the emitted particles are smaller than about 5 microns.
[0167] Properly de-agglomerated doses of a dry powder medication using a high strength dry powder inhaler can be achieved by providing a high strength dry powder inhaler which contains a dose of a dry powder medication; inhale from the inhaler with sufficient force to achieve a peak inspiratory pressure of at least 2 kPa within 2 seconds; and generating an area under the curve in the first second (AUC0 at 1 sec.) of an inspiration pressure-time curve of at least about 1.0, 1.1, or 1.2 kPa*second; wherein the VMGD (x50) of the emitted powder is less than about 5 µm. In another embodiment, the dry powder medicament includes the microparticles wherein the VMGD average particle size (x50) of the emitted powder particles is not greater than 1.33 times the average particle size when the inhaler is used optimally.
[0168] While the present inhalers are primarily described as breath-powered, in some embodiments, the inhaler may be provided with a source to generate the pressure differential necessary to de-agglomerate and deliver a dry powder formulation. For example, an inhaler may be adapted for a gas powered source, such as the stored energy source of compressed gas, such as from a nitrogen canister, which may be supplied to the air intake ports. A spacer can be provided to capture the plume so that the patient can inhale at a comfortable pace.
[0169] In the embodiments described in the present invention, the inhaler may be provided as a reusable inhaler or as a single-use inhaler. In alternative embodiments, a similar principle of de-agglomeration can be adapted for multi-dose inhalers, where the inhaler can comprise a plurality, for example, of cartridge-like structures in a single tray and a single dose can be metered as needed. In variations of such an embodiment, the multi-dose inhaler can be configured to deliver sufficient doses, for example, for a day, a week, or a month's supply of medication. In the multi-dose embodiments described herein, end-user convenience is optimized. For example, in prandial regimens, breakfast, lunch and dinner dosages are achieved with a system configured to deliver a dosage for a duration of 7 days in a single device. Additional end-user convenience is provided through a system configured with an indicator mechanism that indicates the day and dosage, eg day 3 (D3), lunch time (L).
[0170] In one embodiment, the dry powder medicament may comprise, for example, a pharmaceutically acceptable carrier or excipient, for example, a diketopiperazine and a pharmaceutically active ingredient. The dry powder may comprise diketopiperazine having the formula 2,5-diketo-3,6-di(4-X-aminobutyl)piperazine, wherein X is selected from the group consisting of succinyl, glutaryl, maleyl and fumaryl. In such an embodiment, the dry powder composition may comprise a diketopiperazine salt.
[0171] In such an embodiment, the pharmaceutically active ingredient or active agent may be any type depending on the disease or condition being treated. In another embodiment, the diketopiperazine can include, for example, symmetric molecules and asymmetric diketopiperazines that have utility for forming particles, microparticles and the like, which can be used as carrier systems for the delivery of active agents to a target site in the body. The particles, microparticles and the like may comprise diketopiperazine having the formula 2,5-diketo-3,6-di(4-X-aminobutyl)piperazine, wherein X is selected from the group consisting of succinyl, glutaryl, maleyl and smoke. In such an embodiment, the dry powder composition may comprise a diketopiperazine salt. The term 'active agent' herein refers to the therapeutic agent or molecule, such as protein or peptide or biological molecule, to be encapsulated, associated, joined, complexed or entrapped or absorbed in the diketopiperazine formulation. Any form of an active agent can be combined with a diketopiperazine. The drug delivery system can be used to deliver biologically active agents that have therapeutic, prophylactic or diagnostic activities.
[0172] A class of drug delivery agents that have been used to produce microparticles that overcome problems in pharmaceutical techniques, such as drug instability and/or insufficient absorption, are the 2,5-diketopiperazines. The 2,5-diketopiperazines are represented by the compound of general Formula 1 as shown below, wherein the E1 and E2 ring atoms at positions 1 and 4 are either O or N to create the diketomorpholine and diketodioxane substitution analogues, respectively, and by the at least one of the side chains R1 and R2 located at positions 3 and 6, respectively, contains a carboxylic acid (carboxylate) group. Compounds according to Formula 1 include, without limitation, diketopiperazines, diketomorpholines and diketodioxanes and their substitution analogues.
formula 1
[0173] As used herein, "a diketopiperazine" or "a DKP" includes diketopiperazines and pharmaceutically acceptable salts, derivatives, analogs and modifications thereof that fall within the scope of general Formula 1.
[0174] These 2,5-diketopiperazines have proved useful in drug delivery, specifically those bearing acidic R1 and R2 groups (see, for example, US Patent 5,352,461 entitled "Self Assembling Diketopiperazine Drug Delivery System", 5,503. 852 titled “Method For Making Self-Assembling Diketopiperazine Drug Delivery System”, 6,071,497 titled “Microparticles For Lung Delivery Comprising Diketopiperazine”, and 6,331,318 titled “Carbon-Substituted Diketopiperazine Delivery System”, each of which is now incorporated by reference in its entirety due to all teachings relating to diketopiperazine and diketopiperazine mediated drug delivery). Diketopiperazines can be transformed into drug-absorbing microparticles. Such a combination of a drug and a diketopiperazine may confer improved drug stability and/or absorption characteristics. Such microparticles can be administered via a variety of administration routes. As dry powders, such microparticles can be delivered via inhalation to specific areas of the respiratory system, including the lung.
[0175] Fumaryl diketopiperazine (bis-3,6-(N-fumaryl-4-aminobutyl)-2,5-diketo-diketopiperazine; FDKP) is a preferred diketopiperazine for pulmonary applications:

[0176] FDKP provides a beneficial microparticle matrix due to its low acid solubility, however it is readily soluble at neutral or basic pH. Such properties allow FDKP to crystallize under acidic conditions and the crystals assemble to form particles. The particles readily dissolve under physiological conditions where the pH is neutral. In one embodiment, the microparticles disclosed herein are FDKP microparticles loaded with an active agent, such as insulin.
[0177] FDKP is a chiral molecule that has trans and cis isomers regarding the arrangement of substituents on substituted carbons in the diketopiperazine ring. As described in Patent Application Publication No. 2010/0317574, entitled “Diketopiperazine microparticles with defined isomer contents,” more robust aerodynamic performance and particle morphology consistency can be obtained by confining the isomer content to approximately 45 to 65% trans. Isomer ratio can be controlled in the synthesis and recrystallization of the molecule. Exposure to ring epimerization of base promoters that leads to racemization, for example, during removal of protective groups from terminal carboxylate groups. However, increasing the methanol content of the solvent in this step leads to an increased content of trans isomers. The trans isomer is less soluble than the cis isomers and control of temperature and solvent composition during recrystallization can be used to promote or reduce enrichment for the trans isomer in such a step.
[0178] Microparticles that have a diameter between about 0.5 and about 10 microns can reach the lungs, successfully bypassing most natural barriers. A diameter of less than about 10 microns is needed to cross the throat curve and a diameter of about 0.5 microns or more is needed to avoid being exhaled. Diketopiperazine microparticles with a specific surface area (SSA) between about 35 and about 67 m 2 /g exhibit characteristics beneficial to drug delivery to the lungs, such as improved aerodynamic performance and improved drug adsorption.
[0179] As described in PCT Publication no WO2010144789 entitled “Diketopiperazine microparticles with defined specific surface areas”, the size and shape distribution of FDKP crystals are affected by the balance between the nucleation of new crystals and the growth of existing crystals. Both phenomena largely depend on concentrations and supersaturation in the solution. The characteristic crystal size of FDKP is an indication of the relative rates of nucleation and growth. When nucleation is dominant, many crystals are formed, however, they are relatively small due to the fact that they compete for FDKP in the solution. When growth is dominant, there are fewer competing crystals and the characteristic crystal size is larger.
[0180] Crystallization largely depends on supersaturation which, in turn, largely depends on the concentration of components in the feed stream. Higher supersaturation is associated with the formation of many small crystals; lower supersaturation produces fewer larger crystals. In terms of supersaturation: 1) increases FDKP concentration increases supersaturation; 2) increasing ammonia concentration shifts the system to a higher pH, increases equilibrium solubility and decreases supersaturation; and 3) increasing the concentration of acetic acid increases supersaturation by shifting the endpoint to the lower pH where the equilibrium solubility is lower. Decreasing concentrations of such components induces the opposite effects.
[0181] Temperature affects FDKP microparticle formation through its effect on FDKP solubility and the kinetics of FDKP nucleation and crystal growth. At low temperatures, small crystals are formed with high specific surface area. Suspensions of such particles exhibit high viscosity indicating high interparticle attractions. The temperature range of about 12°C to about 26°C produced particles with acceptable (or better) aerodynamic performance with various inhaler systems that include the inhaler systems disclosed herein.
[0182] These current devices and systems are useful in pulmonary delivery to powders with a wide range of characteristics. Embodiments of the invention include systems comprising an inhaler, an integral or installable unit dose cartridge and powder of defined characteristic(s) that provide an improved or optimal performance range. For example, the devices constitute an effective de-agglomeration mechanism and thus can deliver cohesive powders effectively. This is different from the approach taken by many others who have sought to develop dry powder inhalation systems based on free-flowing or optimized-flow particles (see, for example, US Patent Nos. 5,997,848 and 7,399,528, Patent Application No. US 2006/0260777; and Ferrari et al. AAPS PharmSciTech 2004; 5(4) Article 60). Thus, the realizations include the systems in addition to a cohesive powder.
[0183] The cohesiveness of a powder can be evaluated according to its flowability or correlated to evaluations of shape and irregularity, such as roughness. As discussed in Pharmacopoeia U.S. USP 29, 2006 section 1174, four techniques commonly used in pharmaceutical techniques to assess powder flowability: angle of repose; (Carr's) compressibility index and Hausner ratio; flow through an orifice; and shear cell methods. For the last two, no scale, in general, was developed due to the diversity of the methodology. Flow through an orifice can be used to measure flow rate or, alternatively, to determine a critical diameter that allows flow. Relevant variables give the shape and diameter of the orifice, the diameter and height of the powder bed, and the material from which the apparatus is produced. Shear cell devices include cylindrical, annular and flat varieties and offer a high degree of experimental control. For either of these two methods, descriptions of equipment and methodology are crucial, but despite the lack of general scales, they are successfully used to provide qualitative and relative characterizations of powder flowability.
[0184] The angle of repose is determined as the angle suggested by a cone-like pile of material in relation to the horizontal base on which it was poured. The Hausner Ratio is the unsettled volume divided by the salvaged volume (which is the volume after utilization no longer produces any changes in volume) or, alternatively, the salvaged density divided by the bulk density. The compressibility index (CI) can be calculated from the Hausner ratio (HR) as CI = 100 x (1-(1/HR)).
[0185] Despite little variation in experimental methods, generally accepted scales of flow properties have been published for angle of repose, compressibility index, and Hausner ratio (Carr, RL, Chem. Eng. 1965, 72:163 to 168 ).

[0186] The Transport Equipment Manufacturers Association (CEMA) code provides a very different characterization of the angle of repose.

[0187] Powders with a flow character according to the table above, which is excellent or good, can be characterized in terms of cohesiveness as non-cohesive or minimally cohesive and powders with less flowability, as cohesive and so as to split them additionally between moderately cohesive (corresponding to a regular or passable flow character) and highly cohesive (corresponding to any degree of insufficient flow character). In assessing the angle of repose by the CEMA scale, powders with an angle of repose > 30° can be considered cohesive and those with > 40°, highly cohesive. The powders in each of these ranges or combinations thereof constitute distinct embodiment aspects of the invention.
[0188] Cohesiveness can also be correlated with roughness, a measure of particle surface irregularity. Roughness is the ratio of the actual specific surface area of the particle to that of an equivalent sphere:

[0189] Methods for direct measurement of roughness, such as air permeability, are also known in the art. Roughness of 2 or greater was associated with increased cohesiveness. It should be remembered that particle size also affects flowability so larger particles (eg on the order of 100 microns) can have reasonable flowability despite having a very high roughness. However, for particles useful for deep lung delivery, such as those with main particle diameters of 1 to 3 microns, even a roughness slightly or 2 to 6 can be cohesive. Highly cohesive powders can have roughness > 10 (see Example A below).
[0190] Many of the examples below involve the use of dry powders that comprise FDKP. The component microparticles are self-assembled aggregates of crystalline plates. It is known that powders comprising particles with plate-like surfaces generally have insufficient flowability, i.e., are cohesive. In fact, smooth spherical particles generally have the best fluidity, with fluidity generally decreasing as the particles become oblong, have sharp edges, become substantially two-dimensional and irregularly shaped, have irregular interlocking shapes. or are fibrous. Without intending to be limiting, the present depositors understand that the crystalline plates of the FDKP microparticles can intercalate and interlace so as to contribute to the cohesiveness (the inverse of flowability) of bulky powders comprising them and, in addition, making the powder more difficult to de-agglomerate than less cohesive powders. Furthermore, factors that affect the structure of particles can have effects on aerodynamic performance. It is observed that as the specific surface area of the particles increases beyond a threshold value, their aerodynamic performance, measured as a respirable fraction, tends to decrease. Additionally, FDKP has two chiral carbon atoms in the piperazine ring, so the N-fumaryl-4-aminobutyl branch can be in cis or trans configurations with respect to the ring plane. It is observed that as the trans-cis ratio of FDKP used in the manufacture of microparticles moves away from an ideal range that includes the racemic mixture, the respirable fraction is reduced and at greater departures from the preferential range, the morphology of the particles in SEM becomes visibly different. Accordingly, embodiments of the invention include device systems plus diketopiperazine powders with specific surface areas within the preferred ranges and the device plus FDKP powders with trans-cis isomer ratios in the preferred ranges.
[0191] FDKP microparticles either unmodified or containing a drug, eg insulin, constitute highly cohesive powders. The FDKP microparticles were measured to have a Hausner ratio of 1.8, a compressibility index of 47% and an angle of repose of 40°. Insulin-loaded FDKP microparticles (TECHNOSPHERE® insulin; TI; MannKind Corporation, Valencia, CA) were measured to have a Hausner ratio of 1.57, a compressibility index of 36%, and an angle of repose of 50°. °± 3 °. Additionally, in a critical orifice test, it was estimated that it would be necessary to establish flow under gravity for an orifice diameter on the order of 60 to 90 cm (2 to 3 feet) (a bed height of 30.48 cm is suggested). (2.5 feet)); the increased pressure increased the required diameter size). Under similar conditions, a free-flowing powder requires an orifice diameter on the order of only 1 s 2 cm (Taylor, M.K. et al. AAPS PharmSciTech 1, art. 18).
[0192] Accordingly, in one embodiment, the present inhalation system is provided which comprises a dry powder inhaler and a container for deagglomerating the cohesive powder, which comprises a dry cohesive powder having a Carr index in the range of 16 to 50 In one embodiment, the dry powder formulation comprises a diketopiperazine, including FDKP, and a peptide or protein, including an endocrine hormone, such as insulin, GLP-1, a parathyroid hormone, oxytomidulin, and others as mentioned elsewhere. in this revelation.
[0193] Microparticles that have a diameter between about 0.5 and about 10 microns can reach the lungs, successfully overcoming most natural barriers. A diameter of less than about 10 microns is needed to cross the throat curve and a diameter of about 0.5 microns or more is needed to avoid being exhaled. The findings disclosed herein show that microparticles with an SSA between about 35 and about 67 m 2 /g exhibit characteristics beneficial to drug delivery to the lungs, such as improved aerodynamic performance and improved drug adsorption.
[0194] Also disclosed herein are FDKP microparticles that have a trans-specific isomeric ratio of from about 45 to about 65%. In such an embodiment, the microparticles provide enhanced buoyancy.
[0195] In one embodiment, there is also provided a system for the delivery of an inhalable dry powder comprising: a) a cohesive powder comprising a medicament, and b) an inhaler comprising a housing that defines an internal volume to contain a powder, the housing comprising a gas inlet and a gas outlet wherein the inlet and outlet are positioned so that the gas flowing within the internal volume through the inlet is directed into the gas flowing towards the exit. In one embodiment, the system is useful for de-agglomerating a cohesive powder that has a Carr index of 18 to 50. The system may also be useful for delivering a powder when the cohesive powder has an angle of repose of 30° to 55°. Cohesive powder can be characterized by a critical hole size of < 97.53 cm (3.2 ft) for funnel flow or < 73.15 cm (2.4 ft) for mass flow, a roughness > 2. Exemplary cohesive powder particles include particles comprising FDKP crystals wherein the FDKP isomer ratio is in the range of 50% to 65% trans:cis.
[0196] In another embodiment, the inhalation system may comprise an inhaler comprising a mouthpiece and upon application of a pressure drop of >2 kPa across the inhaler generates a particulate plume that is emitted from the mouthpiece in which 50 % of emitted particles have a VMGD of < 10 microns, where 50% of emitted particles have a VMGD of < 8 microns or where 50% of emitted particles have a VMGD of < 4 microns.
[0197] In yet another embodiment, a system for delivering a dry powder capable of inhalation, which comprises: a) a dry powder comprising particles composed of FDKP crystals in which the ratio of FDKP isomers in the range from 50% to 65% trans:cis and a drug; and b) an inhaler comprising a housing containing powder, the chamber comprising a gas inlet and a gas outlet; and the housing in which the chamber is to be mounted and which defines two flow paths, a first flow path which allows the gas to enter the gas inlet of the chamber, a second flow path which allows the gas to be bypassed from the chamber gas inlet; wherein the flow derived from the gas entering the housing is directed to collide with the flow leaving the housing substantially perpendicular to the direction of the gas leaving flow.
[0198] In certain embodiments, a system for the delivery of an inhalable dry powder is provided, comprising: a) a dry powder comprising particles composed of FDKP crystals, wherein the microparticles have an SSA between about from 35 to about 67 m2/g, which exhibits characteristics beneficial to drug delivery to the lungs, such as improved aerodynamic performance and improved adsorption of drug per milligram and a drug; and b) an inhaler comprising a housing containing powder, wherein the housing comprises a gas inlet and a gas outlet; and a housing in which the chamber is to be mounted and which defines two flow paths, a first flow path allowing gas to enter the gas inlet of the chamber, a second flow path allowing gas to be bypassed from the inlet chamber gas; wherein the flow that is derived from the gas inlet chamber is directed to impinge on the flow leaving the housing substantially perpendicular to the direction of the gas outlet flow.
[0199] A system for the delivery of a dry powder capable of inhalation is also provided, comprising: a) a dry powder comprising a medicament, and b) an inhaler comprising a powder containing a cartridge, the cartridge being comprises a gas inlet and a gas outlet and a housing in which the cartridge is to be mounted and which defines two flow paths, a first flow path allowing gas to enter the gas inlet of the cartridge, a second flow path flow that allows gas to be derived from the gas inlet of the housing and a mouthpiece and upon application of a pressure drop of > 2 kPa across the inhaler, a particulate plume is emitted from the mouthpiece where 50% of the particles emitted have a VMGD of < 10 microns, wherein the flow that is derived from the gas inlet of the cartridge is directed to impinge on the flow leaving the housing substantially perpendicular to the direction of the gas outlet flow.
[0200] Active agents for use in the compositions and methods described herein may include any pharmaceutical agent. These may include, for example, synthetic organic compounds, including vasodilators, vasoconstrictor molecules, neurotransmitter analogs, neurotransmitter antagonists, steroids, antinociceptive agents, peptides and polypeptides, polysaccharides and other sugars, lipids, inorganic compounds, and nucleic acid molecules that have therapeutic, prophylactic, or diagnostic. Peptides, proteins and polypeptides are all chains of amino acids linked through peptide bonds.
[0201] Examples of active agents that can be delivered to a target or site in the body using diketopiperazine formulations include hormones, anticoagulants, immunomodulatory agents, vaccines, cytotoxic agents, antibiotics, vasoactive agents, neuroactive agents, anesthetics or sedatives, steroid molecules such as glucocorticoids including fluticasone, budesonide, mometasone, ciclesonide, flunisolide, betamethasone and triamcinolone, decongestants, antivirals, antisense, antigens and antibodies. More particularly, such compounds include insulin, heparin (including low molecular weight heparin), calcitonin, felbamate, sumatriptan, parathyroid hormone and active fragments thereof, growth hormone, erythropoietin, AZT, DDI, macrophage colony stimulating factor (GM-CSF), lamotrigine, chorionic gonadotropin releasing factor, luteinizing releasing hormone, beta-galactosidase, exendin, vasoactive intestinal peptide, argatroban, small molecules including anticancer and cell receptor inhibitors or analogues such as as neuroreceptors, including antinociceptive agents; triptans including, sumatriptan succinate, almotriptan malate, rizatriptan benzoate, Zolmitriptan, eletriptan hydrobromide, naratriptan hydrochloride, β2-agonists such as salbutamol, fenoterol, formoterol, terbutaline, pirbuterol, bitolterol, indacaterol and the like, and vaccines. Antibodies and fragments thereof may include, but are not limited to, anti-SSX-241-49 (synovial sarcoma, X breakpoint 2), anti-NY-ESO-1 (esophageal tumor associated antigen), anti-PRAME ( preferentially expressed melanoma antigen), anti-PSMA (prostate-specific membrane antigen), anti-Melan-A (melanoma tumor-associated antigen), and anti-tyrosinase (melanoma tumor-associated antigen).
[0202] In certain embodiments, a dry powder formulation for delivering a pharmaceutical formulation to the pulmonary circulation comprises an ingredient or active agent, including, a peptide, a protein, a hormone, analogues thereof, or combinations thereof, wherein the ingredient active is insulin, calcitonin, growth hormone, erythropoietin, granulocyte macrophage colony stimulating factor (GM-CSF), chorionic gonadotropin releasing factor, deoxyribonuclease, luteinizing releasing hormone, follicle stimulating hormone (FSH) ), oxytocin, vasoactive intestinal peptide, parathyroid hormone (including black bear PTH), parathyroid hormone-related protein, glucagon-like peptide 1 (GLP-1), exendin, oxytomidulin, peptide YY, interleukin-inducible tyrosine kinase 2, Bruton's tyrosine kinase (BTK), inositol-requiring kinase 1 (IRE1) or analogues, active fragments, PC-DAC modified derivatives or O-glycol forms isolated from them. In specific embodiments, the pharmaceutical composition or dry powder formulation comprises fumaryl diketopiperazine and the active ingredient is one or more selected from insulin, parathyroid hormone 1-34, GLP-1, oxytomidulin, peptide YY, heparin and analogues thereof; small molecules including neurotransmitters, derivatives and/or analogs or inhibitors/antagonists, antinociceptive agents such as pain modulators, headache medications, anti-migraine drugs including vasoactive agents such as triptans and vaccine and adjuvants thereof; immunosuppressive molecules and anticancer drugs.
[0203] In one embodiment, a method of self-administration of a dry powder formulation to the lung of a person with a dry powder inhalation system is also provided, comprising: obtaining a dry powder inhaler in a closed position and which has a mouthpiece; obtaining a cartridge comprising a pre-metered dose of a dry powder formulation in a containment configuration; open the dry powder inhaler to install the cartridge; closing the inhaler to effect movement of the cartridge to a dose position; place the mouthpiece in a person's mouth and inhale once, deeply, to deliver the dry powder formulation.
[0204] In one embodiment, a method for delivering an active ingredient comprising: a) providing a dry powder inhaler that contains a cartridge with a dry powder formulation comprising a diketopiperazine and the active agent; and b) delivering the active ingredient or agent to an individual in need of treatment. The dry powder inhaler system can deliver a dry powder formulation such as insulin FDKP that has a respirable fraction greater than 50% and particle sizes less than 5.8 μm.
[0205] In yet a further embodiment, a method for treating obesity, hyperglycemia, insulin resistance and/or diabetes is disclosed. The method comprises administering a dry powder composition or inhalation formulation comprising a diketopiperazine having the formula 2,5-diketo-3,6-di(4-X-aminobutyl)piperazine, wherein X is selected from group consisting of succil, glutaryl, maleyl and fumaryl. In such an embodiment, the dry powder composition may comprise a diketopiperazine salt. In yet another embodiment of the present invention, there is provided a dry powder composition or formulation, wherein the diketopiperazine is 2,5-diketo-3,6-di-(4-fumaryl-aminobutyl)piperazine with or without a carrier or excipient. pharmaceutically acceptable.
[0206] In one embodiment, the inhalation system is provided for delivering a dry powder formulation to the lungs of a patient, comprising a dry powder inhaler configured to have flow ducts with total resistance to flow in a configuration of dosage whose value varies in the range of 0.065 to about 0.200 (VkPa)/liter per minute.
[0207] In one embodiment, a dry powder inhalation kit is provided which comprises a dry powder inhaler as described above and one or more medicament cartridges comprising a dry powder formulation for treating a disorder or disease such as disease of the respiratory tract, diabetes and obesity. In such an embodiment, the kit may comprise materials with instructions for use.
[0208] The improved cartridge emptying and de-agglomeration capabilities of the inhalation systems described herein contribute to increased bioavailability of the dry powder formulation. In specific embodiments, the dry powders are powders that contain diketopiperazine. The term bioavailability refers to exposure to both the active ingredient (e.g. insulin) and diketopiperazine (in such embodiments called diketopiperazine powders) resulting from delivery to an individual's systemic circulation, as commonly assessed by the AUC of a plot. of concentration as a function of time. By normalizing such measurements to dosage, a characteristic of the system can be revealed. The dosage used in the normalization exposure may be based on the filled or emitted dose and may be expressed in unit mass of powder. Alternatively, exposure can be normalized to a cartridge of a specific fill mass. Either way, exposure can be further adjusted to account for the specific diketopiperazine or active ingredient content of a specific formulation, i.e. exposure can be normalized to the amount of active agent or the amount of diketopiperazine in the filled or emitted dose. . Individual-related variables, eg fluid volume, can affect the observed exposure, so in many embodiments, the bioavailability of the system will be expressed as a range or threshold.
[0209] In one embodiment, the powder formulation may comprise FDKP microparticles and insulin as the active agent for treating diabetes, wherein the insulin content of the formulation may be 3 U/mg, 4 U/mg, 6 U /mg of powder or higher. The amount of insulin or dose to be administered may vary depending on the patient's need. For example, in one embodiment, a single dose for a single inhalation may contain up to about 60 U of insulin for the treatment of hyperglycemia in diabetes.
[0210] The pharmacokinetic profile of insulin is an important factor in determining its physiological effect. With insulin exposures similar to an insulin administration, a formulation that provides a pharmacokinetic profile characterized by a rapidly reached peak is more effective in suppressing prandial glucose excursions and hepatic glucose release than an insulin administration that results in in a slow rise to Cmax. and characterized by an extended plateau. Thus, the inhalation systems disclosed herein also result in more effective delivery of insulin such that similar levels of Cmax. can be achieved with lower doses of insulin compared to prior art systems. If stated otherwise, such inhalation systems achieve a higher dose normalized Cmax. EXAMPLE 1 MEASURING THE RESISTANCE AND FLOW DISTRIBUTION OF A DRY POWDER INHALER CARTRIDGE SYSTEM
[0211] Several dry powder inhaler designs were tested to measure their resistance to flow - an important characteristic determined, in part, by the geometries or configurations of the inhaler paths. Inhalers that exhibit high resistance require a greater pressure drop to yield the same flow rate as inhalers of lower resistance. Briefly, to measure the resistance of each inhaler and cartridge system, different flow rates are applied to the inhaler and the resulting pressures through the inhaler are measured. Such measurements can be achieved using a vacuum pump attached to the mouthpiece of the inhaler to supply the pressure drop, and a flow controller and pressure gauge to change the flow and record the resulting pressure. According to Bernoulli's principle, when the square root of the pressure drop is plotted as a function of flow rate, the inhaler resistance is the slope of the linear portion of the curve. In such experiments, the resistance of the inhalation system, which comprises a dry powder inhaler and cartridge as described herein, was measured in the dosing configuration using a resistance measuring device. The dosing configuration forms an air path through the air ducts of the inhaler and through the cartridge in the inhaler.
[0212] Due to the fact that different inhaler designs exhibit different resistance values due to slight variations in the geometries of their air paths, multiple experiments were conducted to determine the optimal range of pressure settings to use with a specific design. Based on Bernoulli's principle of linearity between the square root of pressure and flow rate, the intervals to assess linearity were predetermined for the three inhalers used after multiple tests, so that the proper definitions could be used with other batches of the product. same inhaler design. An example graph for an inhaler can be seen in Figure 39 for an inhalation system represented in Figure 7. The graph represented in Figure 39 indicates that the resistance of the inhalation system as represented in Figure 7 can be measured with a good correlation at first. Bernoulli at flow rates in the range of about 10 to 25 l/min. The graph also shows that the resistance of the exemplary inhalation system was determined to be 0.093 VkPa/LPM. Figure 39 illustrates that flow and pressure are related. Therefore, as the slope of the line on the square root of pressure versus flow graph decreases, that is, inhalation systems that exhibit lower resistance, the change in flow for a given change in pressure is greater. Consequently, superior strength inhalation systems exhibit less variability in flow rates for given changes in patient-delivered pressure with a breath-powered system.
[0213] The data in Tables 1 show the results of a set of experiments using the inhalation system described in Figures 10 (DPI 1) and Figure 7 (DPI 2). For dry powder inhaler 1 (DPI 1), the cartridge illustrated in project 150, Figures 17 to 21, was used and the cartridge illustrated in project 170, Figures 22 to 30, was used with DPI 2. Consequently, DPI 1 used Cartridge 1 and DPI 2 used Cartridge 2. TABLE 1

[0214] Table 1 illustrates that the resistance of the inhalation system tested in the present invention is 0.0874 and 0.0894 VkPa/LPM, respectively for DPI 1 and DPI 2. The data show that the resistance of the inhalation system flow is, in part, determined by the geometry or configuration of the air ducts within the cartridge. EXAMPLE 2 MEASUREMENT OF PARTICLE SIZE DISTRIBUTION USING AN INHALER SYSTEM WITH AN INSULIN FORMULATION
[0215]Particle size distribution measurements with a laser diffraction apparatus (Helos Laser Diffraction System, Sympatec Inc.) with an adapter (MannKind Corp., Patent Application Serial US 12/727,179, the disclosure of which is (herein incorporated by reference for the teaching of the relevant subject matter) were made from a formulation of various milligram (mg) amounts of an insulin and fumaryl diketopiperazine particles supplied in a cartridge inhaler system as described in the present invention (the inhaler of Figures 1 to 9 with cartridge 170 shown in Figures 22 to 30). The device is attached, at one end, to tubing that is fitted with a flow meter (TSI, Inc. Model 4043) and a valve to regulate pressure or flow from a source of compressed air. Once a laser system is activated and the laser beam is ready to measure a plume, a pneumatic valve is actuated to allow the powder to be discharged from an inhaler. The laser system measures the plume exiting the inhaler device automatically based on predetermined measurement conditions. The laser diffraction system is operated by software integrated with the device and controlled by a computer program. Measurements were produced from samples containing different amounts of powder and different batches of powder. Measurement conditions are as follows: • Initial laser measurement trigger conditions: when > 0.6% laser intensity is detected on a specific detector channel; • End laser measurement trigger conditions: when < 0.4% laser intensity is detected on a specific detector channel; • Distance between vacuum source and inhaler chamber is approximately 9.525 cm.
[0216] Multiple tests were performed using different amounts of powder or filler mass in the cartridges. Cartridges were only used once. Cartridge weights were determined before and after powder discharge from the inhaler to determine discharged powder weights. Measurements on the device were determined at several pressure drops and repeated multiple times as indicated in Table 2 below. Once the dust plume is measured, the data is analyzed and plotted. Table 2 represents data obtained from the experiments, where CE denotes emptying the cartridge (discharged powder) and Q3 (50%) is the geometric diameter of the 50th percentage of the cumulative powder particle size distribution of the sample and q3 (5.8 μm) denotes the percentage of particle size distribution smaller than 5.8 μm geometric diameter. TABLE 2


[0217] The data in Table 2 showed that 92.9% to 98.4% of the total powder fill mass was emitted from the inhalation system. Additionally, the data indicate that, irrespective of the fill mass, 50% of the particles emitted from the inhalation system had a geometric diameter of less than 4.7 μm as measured at the various times and pressure drops tested. Furthermore, between 60% and 70% of the emitted particles have a geometric diameter smaller than 5.8 μm.
[0218] Figure 40 represents data obtained from an experiment in which 10 mg of powder fill mass was used. The graph shows the particle size distribution of the sample containing particles from a formulation comprising insulin and fumaryl diketopiperazine resulted in 78.35% of the measured particles having a particle size of < 5.8 μm. The laser detected 37.67% optical concentration during the measurement duration of 0.484 seconds under the above measurement conditions. The data show that the inhalation system effectively de-agglomerates the FDKP formulation of insulin to small sizes over a relevant and lower range of user inhalation capabilities, ie pressure drops. Small geometric sizes for such a cohesive formulation (Carr index = 36%) are believed to be breathable. EXAMPLE 3 MEASUREMENT OF DUST DISCHARGE FROM A CARTRIDGE AS A MEASUREMENT OF INHALATION SYSTEM PERFORMANCE
[0219] Experiments were conducted using the inhalation system described in the present invention using multiple inhaler prototypes depicted in Figures 1 to 9 with prototypes of cartridge 170 as shown in Figures 22 to 30. Multiple cartridges were used with each inhaler. Each cartridge was weighed on an electronic scale before filling. Cartridges were filled with a predetermined mass of powder, reweighed, and each filled cartridge was placed in an inhaler and tested for emptying efficacy of a powder formulation, i.e., batches of TECHNOSPHERE® insulin powder (Insulin FDKP; typically 3 U to 4 U insulin/mg powder, approximately 10 to 15% insulin w/w). Multiple pressure drops were used to characterize performance consistency. Table 3 represents the results of this test using 35 cartridge discharge measurements per inhaler. In the data in Table 3, all tests were performed using the same batch of clinical grade FDKP insulin powder. The results show that relevant user pressure drops, in the range of 2 to 5 kPa, demonstrate highly effective emptying of powder from the cartridge. TABLE 3

EXAMPLE 4 PREDICTIVE DEPOSITION MEASUREMENT THROUGH ANDERSEN CASCADE IMPACT
[0220] The experiments were conducted using an Andersen Cascade Impactor to collect stage plate powder deposits during a simulated dose delivery using flow rates of 28.3 LPM. Such a flow rate resulted in a pressure drop across the inhalation system (DPI plus cartridge) of approximately 6 kPa. The depositions in the plate stages were analyzed gravimetrically using filters and electronic balances. The fill weights of a cohesive powder in 10 mg, 6.6 mg and 3.1 mg of filler mass were evaluated for inhalation system performance. Each impact test was conducted with five cartridges. The cumulative dust mass collected in the 2-F stages was measured according to aerodynamic particle sizes smaller than 5.8 μm. The ratio of collected dust mass to cartridge fill content was determined and is provided as a percentage of respirable fraction (RF) to fill weight. The data are presented in Table 4.
[0221] Data shows that a respirable fraction in the range of 50% to 70% was achieved with multiple batches of powder. Such a range represents a typical normalized performance of the inhalation system.
[0222] Inhaler performance system performance measurements were repeated 35 times with a different cartridge. Fill mass (mg) and discharge time (seconds) were measured for each inhaler cartridge system used. Additionally, the percentage of respirable fraction, ie particles suitable for pulmonary delivery, in the powder was also measured. The results are shown in Table 4 below. In the table, the % RF/fill is equal to the percentage of particles that have a size (< 5.8 μm) that would travel to the lungs in the powder; CE indicates emptying of cartridge or powder delivered; RF indicates the respirable fraction. In Table 4, Test numbers 1 to 10 were conducted using a second batch of a clinical grade FDKP insulin powder, however, the test powder for 11 to 17 used the same powder as the tests conducted and presented in Table 3. TABLE 4

[0223] The above data show that the present inhalation system comprising a dry powder inhaler and a cartridge containing a cohesive powder, i.e. TECHNOSPHERE® insulin (FDKP particles comprising insulin) can effectively discharge almost any the powder content, due to the fact that more than 85% and in most cases more than 95% of the total powder content of a cartridge in varying fill masses and pressure drops were obtained consistently and to a significant degree of emptying. Andersen's cascade impact measurements indicated that more than 50% of the particles are in the respirable range, where particles are smaller than 5.8 μm, and in the range of 53.5% to 73% of the total dust emitted. EXAMPLE 5 INSULIN RUGOSITY TECHNOSPHERE® (TI)
[0224] The roughness is the ratio of the actual specific surface area of the particle to that of an equivalent sphere. The specific surface area of a sphere is:
where def = 1.2 μm is the heavy surface diameter of TI particles from Sympatec/RODOS laser diffraction measurements.
[0225] An average sphere with the same density as the TI particle matrix (1.4 g/cm3) would therefore have an SSA of

[0226] These were, for IT particles with a specific surface area (SSA) of approximately 40 m2/g

[0227] For particles of similar sizes with a specific surface area of 50 or 60 m2/g, the roughness would be approximately 14 and 16 respectively. EXAMPLE 6 ANALYSIS OF GEOMETRIC PARTICLE SIZE OF FORMULATIONS ISSUED BY VOLUMETRIC MEDIUM GEOMETRIC DIAMETER (VMGD) CHARACTERIZATION
[0228]Laser diffraction of dry powder formulations emitted from dry powder inhalers is a common methodology employed to characterize the level of de-agglomeration subjected to a powder. The methodology indicates a measure of geometric size rather than aerodynamic size as is the case with standard industry impact methodologies. Typically, the geometric size of the emitted powder includes a volumetric distribution characterized by the average particle size, VMGD. Especially, the geometric sizes of the emitted particles are differentiated with enhanced resolution compared to the aerodynamic sizes provided by impact methods. Smaller sizes are preferred and result in a greater likelihood of individual particles being delivered to the pulmonary tract. In this way, differences in inhaler de-agglomeration and prime performance may be easier to resolve with diffraction. In such experiments, an inhaler as specified in Example 3 and an inhaler in question are tested with laser diffraction at pressures analogous to the patient's actual inspiratory capacities to determine the efficiency of the inhalation system to de-agglomerate the powder formulations. Specifically, the formulations include cohesive diketopiperazine powders with an ingredient loaded with active insulin and without it. Such powder formulations have characteristic surface areas, isomer ratios and Carr indices. A VMGD and container emptying effectiveness during the test are reported in Table 5. FDKP powders have an approximate Carr index of 50 and TI powder has an approximate Carr index of 40. TABLE 5

[0229] Such data in Table 5 show an improvement in powder de-agglomeration over a given inhaler system compared to the inhaler system described herein. Diketopiperazine formulations with surface areas in the range of 14 to 56 m2/g demonstrated emptying efficiencies in excess of 85% and a VMGD of less than 7 microns. Similarly, formulations that have an isomer ratio in the range of 45 to 66% trans demonstrated improved performance relative to the device in question. Finally, it was found that the performance of the inhaler system with formulations characterized with Carr indices from 40 to 50 was also improved in relation to the device in question. In all cases, the reported VMGD values were below 7 microns. EXAMPLE 7 IN VITRO PERFORMANCE IMPROVEMENT PERFORMED IN A FUTURE GENERATION DRY POWDER DELIVERY SYSTEM
[0230] TECHNOSPHERE® formulations have been successfully delivered to patients with MEDTONE® delivery system (MTDS, MannKind Corporation, Valencia, CA). The system includes dry powder formulations, pre-measured in single-use cartridges and inserted into a reusable MEDTONE® breath-powered, high-resistance inhaler. An improved delivery system (DPI 2 as described in Example 1) was developed as an alternative to MTDS. In vitro powder performance for such systems was compared for various inhaler performance parameters. For DPI 2, a single flush per cartridge was used compared to two flushes per cartridge in the MEDTONE® system.
[0231] Particle sizing through laser diffraction and emitted mass quantification as described above were used in such experiments. A laser diffraction instrument (Sympatec HELOS) was fitted with an innovative pressurized inhaler chamber to facilitate the analysis of dust plumes. The MTDS cartridges were discharged twice per determination versus once with DPI 2. Inhalation systems were used with peak pressures of 4 kPa to assess the powder emptying percentage and volumetric mean geometric diameter (VMGD) with formulations. of TECHNOSPHERE® (FDKP inhalation powder) and TECHNOSPHERE® insulin (FDKP insulin inhalation powder).
[0232] The results of the experiments are shown in Table 6 and Figure 41. In summary, for DPI 2, the powder emptying percentages were 97.8% (3.5 mg FDKP insulin fill weight; n = 20), 96.8% (6.7 mg FDKP insulin fill weight; n = 20), and 92.6% (10.0 mg FDKP inhalation powder fill weight; n = 15); the VMGDs (microns) were 4.37, 3.69 and 6.84, respectively. For the MTDS, the powder emptying percentages were 89.9% (5.0 mg FDKP insulin fill weight; n = 30), 91.7% (10.0 mg FDKP insulin fill weight; FDKP; n = 30), and 89.4% (10.0 mg FDKP inhalation powder fill weight; n = 30); the VMGDs (microns) were 10.56, 11.23 and 21.21, respectively.
[0233] Figure 41 represents the graphical representations of the data obtained from the average of all tests performed for each inhalation system. As seen in Figure 41, the cumulative particle size distribution is smaller for DPI 2 than for MEDTONE®. When compared to MEDTONE®, the DPI 2 inhalation system produces a higher percentage of smaller particles. This evidences an improved de-agglomeration mechanism provided in the DPI 2 system. Such data support the clinical use of DPI 2 as a viable and improved alternative to deliver FDKP inhalation powder formulations. The emptying percentage has been improved with DPI 2 so as to give users the significant advantage of a single flush per cartridge compared to two flushes with MTDS. The reductions in geometric mean particle size suggest an increased powder de-agglomeration at DPI 2. The clinical impact of such improved de-agglomeration must now be evaluated. TABLE 6

EXAMPLE 8 IMPROVEMENT IN FDKP BIOAVAILABILITY WITH AN EXEMPLARY PERFORMANCE OF INHALATION SYSTEM
[0234] To assess the safety and tolerability of various fill weights of TECHNOSPHERE® Inhalation Powder (FDKP Inhalation Powder) delivered by DPI 1 described in Example 1 above, measurements were performed using the inhalation system, i.e. ie, inhaler and cartridge that contain various fill weights of a dry inhalation powder, modified VAS and CQLQ and peak flows from the inhalation system. The MEDTONE® inhaler system was used for comparison. Experiments were also conducted to collect data from systems used to assess the effect of changing inhalation efforts and inhalation times on the pharmacokinetics (PK) of FDKP inhaled as FDKP Inhalation Powder via the DPI 1 inhaler. was from crystalline powder formulations.
[0235] At the beginning of the study, subjects were monitored and instructed to practice taking “short” and “long” inhalations with the inhalation system fitted with a pressure sensing device as disclosed in Patent Application Serial US 12/ 488,469, which can detect the presence of a dose emitted from the device during use. During an inhalation maneuver, the patient was instructed to maintain a nominal pressure differential of 4 to 6 kPa combined with a short inhalation of 3 to 4 seconds or a long inhalation of 6 to 7 seconds. To generate a strong inhalation, the subject provided a nominal inhalation time of about 6.5 seconds and a peak pressure of 7 kPa. On the other hand, to generate a single inhalation, the subject provided a nominal inhalation time of about 6.5 seconds and a peak pressure of 5 kPa. Coupled with the inhalation monitoring device, gravimetric evaluation of the mass of powder discharged from the cartridge was performed. This enabled a link between determinations of inhalation maneuver during dosing, pharmacokinetic profile, and cartridge discharge mass for each individual.
[0236] The study was a two-part, open label crossover study in healthy volunteers. In Part 1, a three-way 3-period crossover study of 10 and 15 mg FDKP inhalation powder was inhaled via the 1 DPI inhaler and 10 mg via the MEDTONE® inhaler. Ten subjects were administered an inhalation powder dose of FDKP and measurements of safety and tolerability (CQLQ, VAS, and peak flows) were performed. Blood samples from subjects were taken prior to dosing and at 5, 10, 15, 25, 30, 60, 120, 240, and 360 minutes after dosing to assess FDPK pharmacokinetics with each treatment.
[0237] In Part 2, after determining the tolerability of FDKP inhalation powder in Part 1, 10 mg was then used in Part 2. Part 2 was performed as a 2-part 2-way crossover study to evaluate the effect of flow rate (15 versus 30 LPM) and inhalation time (3 versus 6 seconds). For each parameter tested (ie, flow rate and inhalation time), ten subjects were crossed for each parameter with a total of 20 subjects for all parameters. FDPK pharmacokinetics were evaluated with each treatment of blood samples taken from subjects. Measurements of pulmonary parameters (FEV1) were performed before and after inhalation of FDKP inhalation powder. The results of such experiments are shown in Table 7 and in Figures 42 and 43.
[0238] Representative data from the results of the experiments are shown in Table 7 below which illustrates the mean AUC0 at 6 hours for the FDKP measured for the subjects tested as well as the mean Cmax. TABLE 7

[0239] Figure 42 represents an example of the profile of an individual using DPI 1 with a 10 mg dose of FDKP as monitored by the detection device which shows a powder free inhalation practice of about 4 seconds and one inhalation dosing time of about 1 second with a dose of FDKP powder. Figure 42 also shows that the cartridge discharge mass was measured gravimetrically as 10.47 mg, which resulted in the subject having a systemic exposure of FDKP characterized by a 6-hour AUC0 of 31.433 ng*min./ml. The normalized AUC/mg of FDKP powder delivered was 3.003 ng*min./ml per mg. Figure 43 shows the concentration of FDKP in blood plasma monitored over 6 hours, which shows a Cmax. of about 270 ng/ml in about 10 min.
[0240] The DPI 1 inhalation system containing 10 mg of FDKP powder delivered almost twice as much FDKP into the blood as the MEDTONE® inhaler contains 10 mg. The DPI 1 inhalation system that contains 15 mg of FDKP inhalation powder on average did not deliver a proportional exposure dose compared to the DPI 1 system that contains 10 mg of powder, due to the fact that several subjects did not have a good exposure to dust, as perceived in the significantly higher standard deviation. The variations in the data in Part 1 of the experiments may be due to the fact that some subjects do not use the inhalers in the proper position during dosing.
[0241] The results data of 10 mg DPI 1 dose for longer, shorter, heavier, or simpler inhalation compared to the MEDTONE® Inhaler System are listed in Table 8. The study was conducted in three parts. as indicated in Table 8. Table 8 illustrates the delivery of FDKP to the pulmonary circulation measured as the AUCo ~ mean of the FDKP values obtained in the experiments. The data are exemplary regarding the effectiveness and performance of the DPI 1 inhalation system compared to the MEDTONE® inhaler system and show that DPI 1 was more effective in delivering FDKP to the systemic circulation, better at about 30% of the time. than the MEDTONE® inhaler, where the values for DPI 1 were in the range of AUCo to ~ 2,375 to 5,277 ng*min./ml per mg of FDKP emitted in the formulation. The AUCo a ~ for MEDTONE® ranged from 1465 to 2403 ng*min./ml per mg of FDKP emitted in the formulation after two inhalations. TABLE 8: FDKP DELIVERED THROUGH DPI 1 AND MT IN A 3-PART STUDY


[0242] The amount of 10 mg of FDKP was delivered by DPI device 1, which is more effective in delivering FDKP as measured by plasma AUC of FDKP by almost twofold increase over MEDTONE®. FDKP delivery is independent of inhalation time and inhalation effort. The data show that DPI 1 has improved bioavailability and efficacy over MEDTONE® as assessed by the AUC of FDKP and the effect of changing inhalation parameters on the AUC of FDKP. The Cmax. for FDKP in this study was greater than about 100 ng/ml with DPI 1 (one puff) and a lower value with MEDTONE® (two puffs), ie 96 ± 30 ng/ml. EXAMPLE 9 IMPROVEMENT IN BIOAVAILABILITY OF FDKP AND INSULIN WITH AN EXEMPLARY INHALATION SYSTEM
[0243] This study was designed to assess the relative bioavailability of various fill weights of TECHNOSPHERE® Insulin Inhalation Powder (FDKP Insulin) delivered by the Pulmonary Inhalation Delivery System (DPI 2) compared to the MEDTONE® Inhaler, as determined by the pharmacokinetics (PK) of insulin and FDKP.
[0244] This was a PK (insulin and FDKP), crossover and open labeling study in healthy volunteers. C-peptide corrections were used to determine the relative amounts of insulin delivered via inhalation as a function of insulin of endogenous origin. Twenty-four subjects (12 per branch) were administered a dose of 6.7 mg and 7.3 mg FDKP insulin inhalation powder (20 U and 22 U insulin, respectively, and about 10% insulin p /p) with the use of DPI 2 and 10 mg of FDKP insulin inhalation powder (30 U insulin) with the use of MEDTONE®. Subsequently, 12 subjects were administered 20 U using either 2 DPI or 30 U via MEDTONE® in a 3-way crossover branch of the study. Subject samples were taken prior to dosing and at 7, 15, 30, 60, 120, 240, and 360 minutes after dosing to assess FDPK pharmacokinetics with each treatment.
[0245] Data show that 20 U or 22 U of insulin with the use of DPI 2 delivered similar exposures of insulin and FDKP compared to 30 U of insulin given with MEDTONE®. For insulin, plasma exposure results (AUC0 at 2 hours) were 3407 ± 1460 uU*min./ml vs. 4,154 ± 1,682 uU*min./ml for 20 U of DPI 2 and 30 U of MEDTONE®, respectively, and 4,661 ± 2,218 uU*min./ml vs. 3,957 ± 1,519 uU*min./ml for DPI 2 which contains 22 U and 30 U of MEDTONE®, respectively. In a 3-way crossover branch, plasma insulin exposures were 4091 ± 1189 uU*min./ml and 3763 ± 1652 uU*min./ml for DPI 2 and MEDTONE®, respectively.
[0246] The results of the 3-way study also showed a reduction in Tmax. for insulin from 20.8 ± 18.7 minutes in MEDTONE® to 14.8 ± 8.94 minutes in DPI 2 (20 U) and at 13.6 ± 4.3 minutes using the DPI 2 system ( 22 U). In the 3-way crossover study, where 6.7 mg of FDKP insulin was delivered at DPI 2 vs. 10.0 mg of FDKP insulin powder delivered in MEDTONE®, FDKP plasma exposures (AUC0-2hr) normalized to mass delivered were 2059 ng*min./ml/mg (mean of 16 subjects doses) for DPI 2 compared to 1,324 ng*min./ml/mg for MEDTONE® (mean doses of 17 subjects). In such an exemplary embodiment, bioavailability studies were conducted with approximately 10% insulin content in the powder formulation. Consequently, superior bioavailabilities (not normalized for powder content) can be obtained by providing a higher concentration of insulin and similar results can be achieved with other active ingredients. Similarly, formulations that contain higher contents of an active ingredient yield lower bioavailability of FDKP (not normalized for powder content).
[0247] In summary, DPI 2 was more effective at delivering insulin as measured by plasma insulin exposures than MEDTONE®. The DPI 2 system delivered insulin exposures with 20U insulin similar to the MEDTONE® 30U insulin.
[0248] Additional results from the above experiments are presented in the tables below. The study described in the example immediately above was continued in two additional parts. In the second part of this study, subjects received a dose of 10 U of insulin in a dry powder formulation of FDKP using 2 DPI or 15 U insulin in FDKP using the MEDTONE® inhalation system. In the 3rd part of that study, subjects received 20 U of insulin in FDKP formulation using 2 DPI or 30 U using MEDTONE® in a 3-fold crossover. The blood insulin concentration was measured and the results were analyzed and evaluated.
[0249] The plasma insulin and FDKP exposures (AUC0 at 2 hours) achieved from subjects treated using DPI 2 20 U are similar to those obtained from subjects using the MEDTONE® Inhaler. The data are shown in Table 9. The values shown were obtained from all dose groups that used DPI 2 with 20U insulin, part I and III, while the values for the MEDTONE® Inhaler of 30U insulin were obtained of parts I, Ia and III. Plasma exposure of lower-than-expected AUC of insulin to DPI 2 22 U is most likely secondary to insufficient time points during the terminal elimination phase of insulin. It was recognized that some of the late time points did not contribute to the AUC calculation and with an amendment they were moved up in the timing sequence which provided improved results for AUC final. This change in insulin pharmacokinetic time points after the DPI 2 22 U insulin cohort was completed improved subsequent time-of-concentration profiles. Lower doses of DPI 2 10 U and MEDTONE® Inhaler 15 U were also similar. Insulin concentrations of all subjects are plotted in Figure 44. FDKP exposure for DPI 2 20 U and MEDTONE® Inhaler 30 U, as well as FDKP exposure for DPI 2 10 U and MEDTONE® Inhaler 15 U, were all found within bioequivalent criteria. There is a good correlation with FDKP exposure and insulin exposure. FDKP concentrations of all subjects are plotted by dose group in Figure 45.
[0250] The data in Table 9 are representative of the inhaler system performance disclosed herein and show that the mean plasma AUC0-inf measured for subjects in the experiment ranged from 1879 to 3383 ng*min./ml per mg of FDKP emitted with MEDTONE® with two inhalations and for DPI 2 from 2773 to 5124 ng*min./ml per mg of FDKP emitted in the formulation after a single inhalation. The data also show that the mean AUC0-inf for FDKP per mg of mass FDKP emitted in the formulation for all subjects was greater than 3500 or 3568 ng*min./ml.
[0251] The mean plasma insulin AUC0 at 2hr in this study for DPI 2 was in the range of about 96 to 315 μU*min./ml per unit of insulin in the powder formulation administered in a single inhalation, where the mean insulin was in the range of 168 to 216 μU*min./ml per unit of insulin in the powder formulation administered in a single inhalation. The AUC0-inf values (AUCo a “) for MEDTONE ranged from about 76 to about 239 μU*min./ml per unit of insulin in the powder formulation given in two puffs. It was previously noted that the first inhalation with the MEDTONE® Inhaler System provides less than half of the total insulin emitted with two inhalations per cartridge typically used (data not shown), and the same characteristic is similarly exhibited for FDKP when used as an agent. delivery in the formulation.
[0252] Postprandial glucose excursions were assessed in each subject during the test meal used to establish the C-Peptide and insulin ratio, as well as during dietary challenges following insulin administration with DPI 2 or MEDTONE®. Glucose excursions in each subject comparing DPI 2 or MEDTONE® are shown in Figure 46. The doses used in the study were not titrated to the subject, so the magnitude of the response varies between subjects, but generally comparable glucose excursions were seen in each individual between treatments with the two inhalers. TABLE 9. INSULIN AND FDKP PHARMACOKINETIC PARAMETERS USING FDKP INSULIN DRY POWDER FORMULATION



[0253]The bioavailability of the inhalers was also evaluated in comparison to the bioavailability of fumaryl diketopiperazine or FDKP administered by intravenous bolus using FDKP radiolabeling and measured as AUC AUC0 a ~ The results of this study showed that for the MEDTONE system ®, the bioavailability was calculated to be about 26% and 32% for 10 mg and 20 mg, respectively, of delivered FDKP powder. The bioavailability obtained measured using DPI 1 in a model analysis to deliver 10 mg FDKP was 57% when compared to 10 mg FDKP administered by an IV bolus injection. A model analysis of data obtained using FDKP insulin formulation was used to assess inhaler system performance or delivered powder effectiveness as measured by AUC0 a ~ for FDKP with the use of DPI 2 and a single inhalation of the powder. . DPI 2 delivered 64% of the 6.7 mg total filled FDKP into the systemic circulation compared to 46% for MEDTONE® with two inhalations. For this FDKP insulin formulation, the FDKP content was about 6 mg. EXAMPLE 10 PHARMACOKINETIC PARAMETERS BASED ON C-PEPTIDE CORRECTED INSULIN CONCENTRATION VALUES AND GEOMETRIC AVERAGES
[0254] In an arm of the study conducted as described in Example 9, 46 normal healthy volunteers were studied using a Phase 1, randomized, open-label, crossover study protocol. The studies were conducted to assess the bioequivalence of insulin formulation of FDKP administered using DPI 2 inhalers that require a single inhalation to deliver a dose contained in a cartridge, compared to MEDTONE®, which requires two inhalations per cartridge to deliver a dose. Additionally, experiments were conducted to assess whether a dose of two-cartridge FDKP insulin inhalation powder containing 10 U doses delivered an insulin concentration to an individual would be bioequivalent to a cartridge containing a 20U dose of insulin with the use of DPI 2 inhalers and FDKP insulin formulation administered by oral inhalation. Subjects were administered FDKP insulin by oral inhalation using either DPI 2 or MEDTONE®. Subjects received a single dose of 20 U insulin, two doses of 10 U insulin using 2 DPI inhalers, or 30 U insulin using a MEDTONE® inhaler. Blood samples were collected from each treated subject at different times over a period of 2 hours. Samples were analyzed to measure insulin concentration. Pharmacokinetic parameters for the study were based on C-Peptide-corrected insulin concentration values. The results obtained from the study are shown in Table 10 below. TABLE 10

[0255] The data indicate that the use of 20 U of insulin administered by oral inhalation to subjects using a FDKP insulin formulation with a DPI 2 delivery system is statistically bioequivalent to administering 30 U of the same formulation with the using a MEDTONE® inhaler. The data also indicate that administering two 10 U doses of an oral inhalation FDKP insulin formulation with DPI 2 inhaler yields similar systemic exposure of insulin as compared to a single 20 U dose of insulin from a FDKP insulin formulation with use of the same type of inhaler or DPI 2. Therefore, two 10 U doses of FDKP insulin formulation insulin yields bioequivalent insulin concentration in the systemic circulation as a single 20 U dose of FDKP insulin with the use of the system of DPI 2 inhaler and administered by pulmonary inhalation. Bioavailability data also indicate that the use of DPI 2 to dose patients, at least as exemplified with an insulin/FDKP formulation, that at dosing with this inhalation system, dosing appears to be linear and proportional for at least the ranges of insulin tested, or a range of 10 U to 30 U.
[0256] The results also indicate that the DPI 2 delivery system is about 33% more effective in delivering the same dose as the formulation. Therefore, DPI 2 provides similar exposures of one dose of insulin with a 33% dose reduction when compared to the MEDTONE® inhaler. EXAMPLE 11 CHARACTERIZATION OF INHALATION PROFILES USING METRICS BASED ON IN VITRO INHALER PERFORMANCE
[0257] An inhalation system described with the present document consists of a dry powder inhaler (DPI 2) with a cartridge. The DPI 2 was fitted with a BLUHALE™ apparatus as disclosed in Patent Application Serial Number US 12/488,469 (US 2009/0314292 , the disclosure of which is incorporated herein by reference for all that teaches in relation to the maneuver of inhalation and efforts and measurements thereof), which measures the pressure differential generated in an inhaler for a period during and after an inhalation maneuver. Figure 47 is an exemplary graphical profile of a DPI 2 in which the pressure drop across the inhaler was measured over a 5 second period during and after a single inhalation. Peak inspiratory pressure at 2 sec, or PIP (2), denotes the highest point on the curve or the highest pressure reached during the first two seconds after starting an inhalation. Figure 47 shows that PIP (2) for DPI 2 was about 5 kPa and the area under the curve within 1 second, or AUC (1) was 3.7 kPa*sec. EXAMPLE 12 INHALER PERFORMANCE THRESHOLD TEST BASED ON Particle SIZE DIAMETER TESTS
[0258] Type 2 DPI inhalers were used in these experiments. Individual inhalers were loaded with a cartridge containing a dry powder formulation comprising microparticles comprising insulin and FDKP to test device performance. Inhalers were previously used to collect profiles as exemplified in Example 11 above. After collecting the inhalation profiles with BLUHALE™, the inhalers were adapted to an inhalation simulator as described in Patent Application No PCT/US2010/055323, the disclosure of which is incorporated herein by reference for all that teaches in regarding the inhalation maneuver and efforts and measurements thereof, to reproduce exemplary inhalation by a user. Inhalation profiles using the simulator were then applied to discharge powder from two inhalers into a laser diffraction apparatus, as described in Example 2 above, to measure the particle size distribution. The laser diffraction apparatus measures the volumetric mean geometric diameter (VMGD). Values were considered acceptable if 50% of the emitted particles were less than 4.88 μm in diameter, which was selected based on a 33% increase in average particle size for an ideally used DPI 2. Two doses of powder inhalers were loaded into the laser diffraction apparatus and powder discharges or emissions were obtained with the various inhalation profiles, ie different PIP (2) and AUC (1) values. The test was repeated 5 times for each inhaler for a total of ten measurements and the data were analyzed and plotted. Figure 48 shows the results of the experiments as a graph of PIP (2) versus AUC (1) for the two inhalers, where each point on the graph represents the average of 10 puffs. Cartridge (or emitted dry powder) emptying was greater than 87% during all discharges. The triangular inhalation threshold region of the graph represents the area on the graph where PIP (2) values are physically impossible to obtain for a device given the AUC (1) values. Inhalation maneuvers that were deemed to have passed criteria based on the above specifications and were above and to the right of the Gen 2 pass criteria lines in Figure 48 performed acceptable. The data in Figure 48 shows that the lower limit for acceptable performance of the present devices is at PIP (2) of about 2 kPa and AUC (1) at least about 1.2 kPa*sec. However, in other experiments, acceptable performance was also demonstrated at an AUC(1) of at least about 1.0 or at least about 1.1 kPa*sec. EXAMPLE 13
[0259] An inhaler system as exemplified in Figure 7 (Device 2) and comprising a cartridge that contains an air conduit through the powder container or reservoir that generates an O-shaped trajectory (Figures 49 and 50) was tested with a formulation comprising the pharmaceutical carrier or excipient, lactose and two active agents to assess its performance compared to a prior art inhaler (Device 1, Diskus, GSK). The sample consisted of a lactose formulation mixed with the active agents that comprised 250 μg of microzinated fluticasone and 50 μg of microzinated salmeterol as active ingredients. Lactose was used as the pharmaceutically acceptable carrier. Inhaler performance was measured with the two different inhalers containing the same amount of powder (11.5 mg) using an inhalation simulation apparatus as described in International Patent Application PCT/US2010/055323 (WO/ 2011/056889), the disclosure of which is incorporated herein by reference for its teaching of relevant individual matter. The inhalers have been tested at pressure differentials of 2 kPa and 4 kPa, which are pressure drops that a person can typically generate with a prior art inhaler such as Device 1. The total or emitted powder discharge from the inhaler in an inhalation single was measured at 2 and 4 kPa pressure. These pressures generate peak flows during the simulation, as reported in Table 11. Representative data from these experiments are also presented in Table 12. TABLE 11

[0260] The data in Table 11 and Figures 53 and 54 show that the present inhaler (Device 2) delivered nearly twice as much active ingredient in its powder plume as the prior art inhaler (Device 1) for each of the ingredients actives, fluticasone and salmeterol in the formulation using the same pressure differential and in different pressure differentials. The data also show that the present inhaler (Device 2) generated lower peak flow rates, i.e. 82.6 liters/minute at 2 kPa than the prior art inhaler (Device 1), compared to the flow rate of peak of 21.4 litres/minute for the present inhaler (Device 2). This phenomenon was measured and found to be consistent at a pressure differential of 4 kPa. EXAMPLE 14
[0261] These experiments were conducted to test various inhaler designs when trying to improve percent dose discharge or device emptying increase to acceptable ranges for certain types of powders used. It has been found that, for example, amorphous powders tend not to discharge well from a standard inhaler and the loss of active agent in the product is costly to a patient. In these experiments, therefore, two types of dry powder inhalers were designed and built. An O-series dry powder inhaler (Figure 49 and 50) wherein the inhaler comprises rigid ducts that generate a recirculating action and revolving airflow through the powder container during an inhalation in an O-shape before air flow leaves the container. A second inhaler or U-series was also designed and constructed for comparison in which the dry powder inhaler comprised a rigid air duct through the substantially U-shaped container and configured with a baffle so that, during use, a flow of air entering the container redirects the flow of air into the container empty space or space in a U-shaped/half-lunar path or downwards before leaving the container. Powders tested were either crystalline or amorphous.
[0262] The microparticles can be crystalline plate assemblies with irregular surfaces and internal voids, as is typical of those made by pH controlled precipitation of DKP acids. In such embodiments, the active agents may be captured by the precipitation process or coated onto the crystalline surfaces of the microparticle. The microparticles can also be spherical shells or collapsed spherical shells comprised of salts of DKP with the active agent dispersed therein. Typically, such particles can be obtained by spray drying a co-solution of the DKP and the active agent. The DKP salt in such particles may be amorphous. The above descriptions are to be understood as illustrative. Other forms of microparticles are contemplated and encompassed by the term.
[0263] DKP microparticles can be obtained by pH-based precipitation of the free acid (or base) which results in self-assembling microparticles comprised of aggregated crystalline plates. Particle stability can be enhanced by small amounts of a surfactant, such as polysorbate-80, in the DKP solution from which the particles are precipitated (see, for example, Patent Publication No. of drug formulation based on increasing the affinity of crystallin microparticle surfaces for active agents" which is incorporated herein by way of reference in its entirety for all that it teaches regarding the formation and loading of DKP microparticles and dry powders thereof). Finally, the solvent can be removed to obtain a dry powder. Suitable solvent removal methods include lyophilization and spray drying (see, for example, US Patent Publication No. 2007/0196503 entitled "A method for improving the pharmaceutical properties of microparticles comprising diketopiperazine and an active agent" and US Patent No. 6,444,226 entitled "Purification and stabilization of peptide and protein pharmaceutical agents" each of which is incorporated herein by way of reference in its entirety for all it teaches regarding the formation and loading of DKP Microparticles and dry powders thereof) . Free acid or base microparticles are distinct from microparticles composed of DKP salts. Such particles are typically formed (rather than dried) by spray drying, which results in spheres and/or collapsed spheres of an amorphous salt (rather than a free acid or base) so that they are entities chemically, physically, and morphologically. different.
[0264] Methods for synthesizing diketopiperazines are described in, for example, Katchalski, et al. J. Amer. Chem. Soc. 68, 879 to 880 (1946) and Kopple, et al., J. Org. Chem. 33(2), 862 to 864 (1968), the teachings of which are incorporated herein by reference in their entirety. 2,5-Diketo-3,6-di(aminobutyl)piperazine (Katchalski et al. refers to this as lysine anhydride) can also be prepared by cyclodimerization of N-.ipsilon.-PL-lysine in molten phenol , similar to the Kopple method, followed by removal of the blocking (p)-groups with a suitable reagent and conditions. For example, CBz protecting groups can be removed using 4.3M HBr in acetic acid. This route may be preferable as it uses a commercially available raw material, it involves reaction conditions that are reported to preserve the stereochemistry of the raw materials in the product, and all steps can easily be scaled up for manufacturing. Methods for synthesizing diketopiperazines are also described in U.S. Patent No. 7,709,639, entitled, "Catalysis of Diketopiperazine Synthesis," which is also incorporated by reference herein for its teachings therein.
[0265] Schematic and illustrative examples of O-shaped airflow ducts are shown in Figures 49 and 50, where flow movement within the powder confinement area of a dry powder inhaler system travels through the container or path inlet port powder reservoir that moves powder by primarily lifting, swirling, and recirculating actions as dust particles integrated into the airflow are dispensed through the dispensing passage. A substantially U-shaped conduit configuration through the powder container or reservoir is illustrated in Figures 51 and 52. In Figure 52, the direction of flow through this type of inhaler is schematically shown and indicated by arrows from the air inlets. , through the air ducts formed by the air inlet (horizontal arrow) and through the empty space of the container (semicircular arrow) and the air outlet (perpendicular arrow) to the inhaler mouthpiece. Figures 50 and 52 also illustrate exemplary embodiments comprising two airflow paths; one through the mouthpiece and one through the canister, where the two flow paths intersect at an angle of about 90° and closer to the distal end of the inhaler.
[0266] Rigid flow conduits, as illustrated in Figures 49 and 51, can be adapted to any type of dry powder inhaler to deliver different types of powder compositions. In these experiments, crystalline and amorphous powders were tested with both types of airflow ducts designed in the same type of inhaler, a single-use disposable. Fumaryl diketopiperazine (TECHNOSPHERE®) was used as a crystalline powder and a spray dried amorphous powder formulation comprising 50% insulin and 50% FDKP disodium salt was also tested. Inhaler performance was tested and evaluated from measurements using various parameters such as pressure differential, powder content before and after testing various powders through a single simulated inhalation. The particle size distribution of the powder plume discharged for each inhaler used was also measured as described in Example 7 above. Representative data are presented in Table 12 below. TABLE 12

[0267] In the realization of an inhaler that comprises the U-shaped airflow conduit through the container or reservoir (U series), the data indicate that this inhaler was more suitable to deliver amorphous powders in high content of an active agent , as exemplified by the composition comprising Na2FDKP and insulin, where the average percentage of powder delivered from a 25 mg dose delivered using data collected from 5 samples from the same inhaler was 89.23% +/- 3.4% in a single inhalation compared to 51.63% +/- 10.04% for the inhaler comprising O-shaped conduit (O series). Low powder masses also show similar properties. The data also indicate that inhalers with U-shaped air ducts were also effective in de-agglomerating amorphous powders. That is, the particle size distribution is similar for both types of inhaler with the use of amorphous powders, e.g. 50% of the powder plume discharged was comprised of particles smaller than or equal to 2.13 μm (VMGD) for the O-series compared to 2.28 μm for the U-series. The data demonstrate that U-series inhalers are most useful with amorphous powders, which have at least 50% active agent to peptide content for produce a plume suitable for inhalation with improved discharge/emptying and similar levels of de-agglomeration as achieved with O-series inhalers. The data also indicate acceptable discharges from a formulation comprising crystalline particles.
[0268] Table 11 also indicates that the O-shaped airflow conduit produced by the powder container or reservoir was most effective in de-agglomerating crystalline powders such as TECHNOSPHERE®, as shown by the smaller particle size distribution (X16 , X50 and X84) obtained with this type of inhaler, in which 50% of the powder plume discharged was comprised of particles having a geometric diameter of 6.86 μm compared to 11.19 μm for inhalers comprising the U-shaped air flow for the same powder dose at a pressure differential of 4 kPa.
[0269] The preceding revelations are illustrative achievements. It should be appreciated by those skilled in the art that the devices, sets of procedures, and methods disclosed herein elucidate representative embodiments that function well in the practice of the present disclosure. However, those skilled in the art should, in light of the present disclosure, note that many changes can be made to the specific embodiments that are disclosed and still obtain a similar or similar result without departing from the spirit and scope of the invention.
[0270] Unless otherwise noted, all numbers expressing amounts of ingredients, properties such as molecular weight, reaction conditions, and so on, used in the specification and claims are to be understood to be modified in all instances by the term "about". Accordingly, unless otherwise indicated, the numerical parameters presented in the specification and claims appended below are approximations that may vary depending on the desired properties sought to be obtained by the present invention. At the very least, and not in an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be understood in light of the number of significant digits reported and applying sets of common rounding procedures. Notwithstanding the fact that the numerical ranges and parameters that present the broad scope of the invention are approximations, the numerical values presented in the specific examples are reported as accurately as possible. Any numerical value, however, inherently contains certain errors that necessarily result from the standard deviation found in its respective test measurements.
[0271] The terms "a" and "an" and "the" and similar referents used in the context of describing the invention (especially in the context of the following claims) are to be understood to cover both the singular and the plural, unless otherwise indicated in this document or clearly contradicted by the context. The citation of ranges of values in this document is merely intended to serve as an abbreviated method of referring individually to each separate value that falls within the range. Unless otherwise indicated in this document, each individual value is incorporated into the specification as if it were individually cited in this document. All methods described herein may be performed in any suitable order, unless otherwise stated herein or otherwise clearly contradicted by the context. The use of any and all examples, or example language (eg, "as") provided herein is intended merely to better illuminate the invention and does not impose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed to indicate any unclaimed element essential to the practice of the invention.
[0272] The use of the term "or" in the claims is used to mean "and/or", unless explicitly stated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers only to alternatives and "and/or".
[0273] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member may be referred to and claimed individually or in any combination with other group members or other elements found herein. It is anticipated that one or more members of a group may be included in, or excluded from, a group for reasons of convenience and/or patentability. When any such inclusion or exclusion occurs, the specification is hereby deemed to contain the group as modified, therefore filling in the written description of all Markush groups used in the appended claims.
[0274] Preferred embodiments of this invention are described herein, including the best mode known to the inventors to carry out the invention. Obviously, variations in these preferred embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects those of ordinary skill in the art to employ such variations as appropriate, and the inventors intend that the invention be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the individual subject matter cited in the claims appended thereto as permitted by applicable law. Furthermore, any combination of the elements described above in all possible variations thereof is encompassed by the invention, unless otherwise stated herein or otherwise clearly contradicted by the context.
[0275] Specific embodiments disclosed herein may be further limited in the claims with the use of language consisting of or essentially consisting of. When used in the claims, whether as filed or added by amendment, the transitional term "consisting of" excludes any element, step, or ingredient not specified in the claims. The transitional term “consisting essentially of” limits the scope of a claim to specified materials or steps and those that do not materially affect the basic and innovative characteristic(s). Embodiments of the invention so claimed are inherently or expressly described and permitted herein.
[0276] Additionally, numerous references have been made to patents and publications in print throughout this specification. Each of the references and printed publications cited above are hereby individually incorporated by reference in their entirety.
[0277] Furthermore, it is to be understood that the embodiments of the invention disclosed herein are illustrative of the principles of the present invention. Other modifications that may be employed are within the scope of the invention. Thus, by way of example, but not limitation, alternative configurations of the present invention may be used in accordance with the teachings herein. Consequently, the present invention is not limited to what is precisely as shown and described.

权利要求:
Claims (16)
[0001]
1. DRY POWDER INHALER (950) comprising: a) a first element comprising a mouthpiece (312); b) a second element comprising a dry powder container (977) located in a cartridge (975), and substantially shaped in the shape of the letter u; and c) at least two rigid air ducts extending between the cartridge (975) and the mouthpiece (312) and configured for communication with ambient air; characterized in that one of the at least two rigid air ducts in a dry powder inhaler dosing configuration has a baffle or rod (978) for directing airflow in a U-shaped path through an internal volume (974) of the cartridge (975), the flow of air entering the cartridge (975) from a direction parallel to the nozzle (312) to a direction substantially downward to a direction substantially parallel to the nozzle (312) through the dry powder in the cartridge (975) to a direction substantially perpendicular to the nozzle (312) for exiting the cartridge (975); and wherein in a containment configuration, the dry powder is sealed from the at least two air ducts and the baffle or rod.
[0002]
2. DRY POWDER INHALER (950) according to claim 1, characterized in that it has an airflow resistance value in the range from about 0.065 (VkPa)/liter per minute to about 0.200 (VkPa)/liter per minute.
[0003]
A DRY POWDER INHALER (950) according to claim 1, wherein the dry powder is a formulation for oral inhalation and comprises an amount of from about 1 mg to about 50 mg of the dry powder.
[0004]
A DRY POWDER INHALER (950) according to claim 1, characterized in that the dry powder comprises a diketopiperazine or a pharmaceutically acceptable salt thereof.
[0005]
DRY POWDER INHALER (950) according to claim 4, characterized in that diketopiperazine is of the formula 2,5-diketo-3,6-bis(NX-4-aminobutyl)piperazine, wherein X is selected from the group which consists of fumaryl, succinyl, maleyl, malonyl, oxalyl and glutaryl.
[0006]
6. DRY POWDER INHALER (950) according to claim 5, characterized in that diketopiperazine is
[0007]
DRY POWDER INHALER (950) according to claim 3, characterized in that the dry powder comprises a drug or an active agent.
[0008]
8. DRY POWDER INHALER (950), according to claim 7, characterized in that the active agent is an endocrine hormone, vaccines, small molecules, including antiasthmatics, vasodilators, vasoconstrictors, muscle relaxants, neurotransmitter agonists or antagonists.
[0009]
DRY POWDER INHALER (950) according to claim 3, characterized in that the dry powder comprises a peptide, a polypeptide or fragments thereof, a small organic molecule or a nucleic acid molecule.
[0010]
10. DRY POWDER INHALER (950) according to claim 9, characterized in that said peptide is insulin, glucagon, glucagon-like peptide-1, parathyroid hormone, deoxyribonuclease, oxytocin, oxyntomodulin, peptide YY, an exendin, analogs of the themselves or fragments thereof.
[0011]
DRY POWDER INHALER (950) according to claim 9, characterized in that, if the dry powder comprises a small organic molecule, the small organic molecule is a vasodilator, a vasoconstrictor, a neurotransmitter agonist or a neurotransmitter antagonist. .
[0012]
DRY POWDER INHALER (950) according to claim 1, characterized in that the container (977) is integrated into the cartridge (975) and filled with a dry powder.
[0013]
DRY POWDER INHALER (950) according to claim 1, characterized in that the container (977) is separable from the inhaler and is filled with a dry powder.
[0014]
A DRY POWDER INHALER (950) according to claim 1, characterized in that the powder is an amorphous powder.
[0015]
DRY POWDER INHALER (950) according to claim 11, characterized in that the small organic molecule is a triptan or an opiate.
[0016]
DRY POWDER INHALER (950) according to claim 15, characterized in that triptan is sumatriptan or rizatriptan.

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法律状态:
2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-11-12| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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优先权:

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申请号 | 申请日 | 专利标题

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US201261671041P| true| 2012-07-12|2012-07-12|

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US61/671,041|2012-07-12|

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PCT/US2013/050392|WO2014012069A2|2012-07-12|2013-07-12|Dry powder drug delivery systems and methods|

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