POWDER FILLING PROCESSES

• US 20150190593A1
• Filed: 03/18/2015
• Published: 07/09/2015
• Est. Priority Date: 03/23/2006
• Status: Active Grant

• Current Assignee: Adamas Pharmaceuticals, Inc. (Supernus Pharmaceuticals, Inc.)
• Original Assignee: Adamas Pharmaceuticals, Inc. (Supernus Pharmaceuticals, Inc.)
• Inventors: Hodson, Peter D., Wilby, Matthew J.
• Granted Patent: US 10,022,508 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A61K 9/0075 for inhalation via a dry powder inhaler [DPI], e.g. comprising micronized drug mixed with lactose carrier particles
• CPC Class Codes: A61M 15/005 the dosages being arranged on a cylindrical surface
• CPC Class Codes: A61M 15/0051 the dosages being arranged on a tape, e.g. strips
• CPC Class Codes: A61M 2202/064 Powder
• CPC Class Codes: B05D 1/40 Distributing applied liquids or other fluent materials by members moving relatively to surface
• CPC Class Codes: B65H 18/28 Wound package of webs

Abstract

A method for filling a plurality of microdepressions in a major surface of a web with finely divided powder in which the web is fed continuously to and through a powder filling stage including a driven roller. A method of manufacturing an elongate carrier with microdepressions containing finely divided powder comprising steps filling a plurality of microdepressions in a major surface of a web as described, removing from upper surface of the web excess powder not filled within the microdepressions and remaining on areas of the surface between the depressions, and optionally slitting and/or cutting the web in width and/or length.

Claims

1. A method for filling a plurality of microdepressions in a major surface of a web, said microdepressions having a depth of about 5 to about 500 microns but less than the thickness of the web and an opening at the surface of the web of about 10 to about 500 microns in width, with finely a divided powder comprising a biologically active substance, said process comprising:

continuously feeding the web to and through a powder filling stage;

at the powder filling stage, filling the powder into said microdepressions on the surface of the web using a driven roller, wherein said roller is rotating about an axis generally transverse to said direction of web movement, while the surface speed of the roller and the web speed are different and wherein the roller and web are positioned relative to one another, such that between the upper surface of the web and the outer surface of the roller there is a gap; and

wherein the powder is fed either onto the web upstream of the roller of the powder filling stage or to the roller of the powder filling stage.

2. A method according to claim 1, further comprising the step of removing from said surface of the web excess powder not filled within the depressions and remaining on areas of the surface between the depressions.

3. A method according to claim 1, further comprising step(s) of slitting and/or cutting the filled web in predetermined widths and/or predetermined lengths.

4. A method according to claim 1, wherein said roller is rotating in the same direction as the web movement.

5. A method according to claim 1, wherein the surface speed of the roller is greater than the web speed.

6. A method according to claim 5, wherein the ratio of the roller surface speed to the web speed is at least 1.1.

7. A method according to claim 5, wherein the ratio of the roller surface speed to the web speed is at least 3 to 1.

8. A method according to claim 5, wherein the ratio of the roller surface speed to the web speed is at most 5 to 1.

9. A method according to claim 1, wherein the gap is 1.25 mm or less.

10. A method according to claim 1, wherein the gap is at least 0.2 mm and no greater than 1.25 mm.

11. A method according to claim 1, wherein the web is fed to the roller generally along a first plane and fed from the roller generally along a second plane, such that at the roller the web passes through a bend, wherein the first plane and the second plane define an angle of less than 180°

towards the roller.

12. A method according to claim 11, wherein the first plane and second plane define an angle of 160°

or greater towards the roller.

13. A method according to claim 1, wherein powder is fed either onto the web upstream of the roller or to the roller of the powder filling stage, such as to provide an accumulation of powder on the web upstream of and adjacent to the roller.

14. A method according to claim 1, further comprising sensing accumulation of powder on the roller and/or on the web upstream of the roller and in response to said sensing automatically controlling the powder feed.

15. A method according to claim 1, wherein the biologically active substance is a medicament suitable for administration by inhalation.

16. A method of manufacturing an elongate carrier with microdepressions containing finely divided powder said process comprising:

providing a web comprising a plurality of microdepressions in a major surface of the web, said microdepressions having a depth of about 5 to about 500 microns but less than the thickness of the web and an opening at the surface of the web of about 10 to about 500 microns in width,

continuously feeding the web to and through a powder filling stage at the powder filling stage, filling the powder into said microdepressions on the surface of the web using a driven roller, wherein said roller is rotating about an axis generally transverse to said direction of web movement, while the surface speed of the roller and the web speed are different and wherein the roller and web are positioned relative to one another, such that between the upper surface of the web and the outer surface of the roller there is a gap;

removing from said surface of the web excess powder not filled within the microdepressions and remaining on areas of the surface between the depressions; and

optionally slitting and/or cutting the web in predetermined widths and/or predetermined lengths; and

wherein the powder is fed either onto the web upstream of the roller of the powder filling stage or to the roller of the powder filling stage.

17. An elongate carrier according to claim 16 wound on a spool or in the form of a roll.

18. A dry powder inhaler comprising an elongate carrier according to claim 17.