CN104721825B - 具有确定比表面积的二酮哌嗪颗粒 - Google Patents

具有确定比表面积的二酮哌嗪颗粒 Download PDF

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CN104721825B
CN104721825B CN201510047997.0A CN201510047997A CN104721825B CN 104721825 B CN104721825 B CN 104721825B CN 201510047997 A CN201510047997 A CN 201510047997A CN 104721825 B CN104721825 B CN 104721825B
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insulin
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马歇尔·L·格兰特
格雷森·W·斯托厄尔
保罗·曼金
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Abstract

本申请涉及具有确定比表面积的二酮哌嗪颗粒以及包含二酮哌嗪微粒的组合物。本文公开了比表面积小于约67m2/g的二酮哌嗪微粒。所述二酮哌嗪微粒可以是富马酰基二酮哌嗪并且可以包含诸如胰岛素的药物。

Description

具有确定比表面积的二酮哌嗪颗粒
本申请是申请日为2010年06月11日、申请号为201080026116.2(PCT/US2010/038298)的发明专利申请“具有确定比表面积的二酮哌嗪颗粒”的分案申请。
相关申请的交叉引用
本申请根据35U.S.C.§119(e)要求2009年6月12日递交的美国临时专利申请No.61/186,773的优先权，通过引用将其全文结合在本文中。
技术领域
本文公开了比表面积小于约67m2/g的二酮哌嗪微粒。FDKP微粒可用作疾病或失调(例如由内分泌引起的那些，包括糖尿病和肥胖症)的治疗中药物或活性剂的输送系统。
背景技术
多年来药物的输送已成为一个重要的问题，特别是当待输送的化合物通过口服给药给予被受试者而在到达其目标位置之前在胃肠道中遇到的条件下不稳定时。例如，在许多情况下优选口服给药，特别是从易于给药、患者依从性和降低的成本方面来考虑。但是，口服给药时很多化合物不起作用或者显示出较低或多变的药效。这可能是因为药物在消化道的条件下不稳定或者因为它们未被有效吸收。
由于与口服药物输送有关的这些问题，所以研究了将药物输送至肺部的方案。例如通常输送到肺部的药物被设计为对肺部组织起作用，例如血管扩张剂、表面活性剂、化疗剂、或流感或其他呼吸系统疾病的疫苗。其他药物(包括核苷酸药物)已经被输送到肺部，因为肺部代表特别适合治疗的组织，例如囊肿性纤维化的基因治疗，其中将表达有缺陷的腺苷脱氨酶的逆转录病毒载体给药至肺部。
也可以将具有全身效应的试剂药物输送到肺部。将全身性试剂输送到肺部的好处包括大的表面积和易于通过肺部粘膜表面吸收。与肺部药物输送所有这些形式有关的一个问题是：由于使药物通过所有的天然屏障(例如沿气管排列的纤毛)和试图以均匀的体积和重量进行给药都很麻烦，所以难以将药物输送到肺部。
因此，药物的肺部输送存在改善的空间。
发明概述
本发明提供了使药物向肺部的输送得到改善的系统、微粒和方法。本文中公开的实施方式是通过提供比表面积(SSA)介于约35m2/g和约67m2/g之间的二酮哌嗪(DKP)微粒而实现改善的输送。比表面积在该范围的DKP微粒显示出有利于输送至肺部的特性，例如改善的气动性能和改善的药物吸附。
本文中公开的一个实施方式包括比表面积小于约67m2/g的二酮哌嗪微粒。另一个实施方式包括比表面积为约35m2/g到约67m2/g的二酮哌嗪微粒。另一个实施方式包括不存在活性剂时比表面积大于约35m2/g而活性剂吸附到颗粒之后比表面积小于约67m2/g的二酮哌嗪微粒。
在另一个实施方式中，比表面积范围为约35m2/g到约67m2/g的富马酰基二酮哌嗪(FDKP)微粒包含药物或活性剂，其中所述比表面积是将药物加到颗粒之前测定的。活性剂结合到颗粒上往往会降低SSA。在FDKP微粒的各种实施方式中，药物可以是例如肽或蛋白质，包括内分泌激素，诸如胰岛素、胰高血糖素样肽-1(GLP-1)、胰高血糖素、促胰岛素分泌肽、甲状旁腺激素、脑肠肽、降钙素、胃泌酸调节素等。比表面积范围为约35m2/g到约67m2/g的FDKP微粒的另一个实施方式可以包含其含量能够根据制备微粒所用的合成工艺的下游条件而变化的药物/肽。在一个具体的例子中，FDKP微粒可以被制备成药物/肽含量能够根据目标剂量或输送剂量而变化。例如，其中的药物是胰岛素，胰岛素组分在含有微粒的粉末制剂中的含量可以为约3U/mg到约4U/mg。在某些实施方式中，药物被吸附在微粒的表面。在此类载有药物的微粒的其他实施例中，载有药物的微粒的SSA小于约62m2/g。
本文中公开的实施方式还包括含有微粒的干粉。在一个实施方式中，干粉包含比表面积小于约67m2/g的FDKP微粒。另一个实施方式包括比表面积为约35m2/g至约67m2/g的二酮哌嗪微粒。另一个实施方式包括比表面积为约35m2/g至约67m2/g含有药物或活性剂的二酮哌嗪微粒。
在干粉的实施方式中，FDKP微粒包含药物。在干粉的另一个实施方式中，所述药物是不同分子大小或不同质量的肽，包括胰岛素、胰高血糖素样肽-1(GLP-1)、胰高血糖素、促胰岛素分泌肽、甲状旁腺激素、降钙素、胃泌酸调节素等。在干粉的一个实施方式中，所述药物是胰岛素，胰岛素在FDKP微粒中的含量为约3U/mg到约4U/mg。
其他实施方式涉及药物输送系统，其包括吸入器、单位剂量的干粉药剂容器(例如药盒)、含有本文所公开的微粒和活性剂的粉末制剂。在一个实施方式中，与干粉一起使用的药物输送系统包括含有高阻力吸入器的吸入系统，所述高阻力吸入器具有空气管道，能够将高阻力赋予经过使粉末制剂解聚和分散的管道的气流。在一个实施方式中，吸入系统的阻力值为例如约0.065(√kPa)/(升·分钟)到约0.200(√kPa)/(升·分钟)。在某些实施方式中，干粉可以通过吸入系统的吸入有效地输送，其中最大的吸入压差可以在约2kPa到约20kPa之间，由此可以产生的最大流量为约7至70升/分钟。在某些实施方式中，配置吸入系统从而通过使粉末作为连续流或者作为输送给患者的粉末的一个或更多个脉冲从吸入器排出而提供单次剂量。在本文公开的一些实施方式中，干粉吸入器系统包括吸入器内的预定质量流量平衡。例如，占离开吸入器并进入患者体内的总流量约10％至70％的流量是通过一个或更多个分配端输送，其中气流通过含有粉末制剂的区域，并且其中约30％至90％的气流是在吸入器的其他管道产生的。此外，旁通流或未进入并离开粉末容器(例如通过药盒)的物料流可以与离开吸入器内分配端的物料流重新组合，从而使流化粉末离开吸入器接口管之前被稀释、加速并最终解聚。在一个实施方式中，吸入器系统的流量范围为约7-70升/分钟，这导致以1-30mg的填充质量填充的容器或药盒内容物中超过75％被分配。在某些实施方式中，上述吸入系统在单次吸入中可以射出以百分比计高于40％、高于50％、高于60％或高于70％的可吸收分数/填充量的粉剂。
在特别的实施方式中，所提供的吸入系统包括干粉吸入器、含有富马酰基二酮哌嗪微粒和一种或更多种活性剂的干粉制剂，其中未加载的FDKP微粒的比表面积小于约67m2/g。在吸入系统的这个实施方式的一些方面，在单位剂量药盒中提供干粉制剂。或者，干粉制剂可以预加载或预填充在吸入器中。在该实施方式中，吸入系统的结构配置考虑了吸入器的解聚机理从而产生高于50％的可吸收分数；也就是说，多于一半的包含在吸入器(药盒)中的粉末作为小于5.8μm的颗粒射出。在一个实施方式中，吸入器在给药期间可以排出容器内所含的高于85％的粉末药物。在某些实施方式中，吸入器可以排出单次吸入所含的高于85％的粉末药物。在某些实施方式中，吸入器可以在2kPa到5kPa的压差下以至多30mg的填充质量在小于3秒的时间内排出高于90％的药盒内容物或容器内容物。
本文中公开的实施方式还包括方法。在一个实施方式中，治疗内分泌相关的疾病或失调的方法包括：将包含比表面积小于约67m2/g的FDKP微粒和适用于治疗所述疾病或失调的药物的干粉制剂给药至需要其的人。另一个实施方式包括比表面积为约35m2/g到约67m2/g的二酮哌嗪微粒。另一个实施方式包括含有活性剂且比表面积小于约62m2/g的二酮哌嗪微粒。一个实施方式包括治疗胰岛素相关的失调的方法，其包括：将包含上述FDKP微粒的干粉制剂给药至需要其的人。该方法包括将含有SSA在上述范围内的富马酰基二酮哌嗪微粒的干粉制剂给药至受试者。在各种实施方式中，胰岛素相关的失调可以具体包括但不限于下列中的任何一种或所有：糖尿病前期(pre-diabetes)、1型糖尿病(蜜月期、后蜜月期或二者)、2型糖尿病、妊娠期糖尿病、低血糖症、高血糖症、胰岛素抵抗、内分泌功能失调、受损的胰岛素早期释放、胰腺β-细胞功能的丧失、胰腺β-细胞的减少和代谢失调。在一个实施方式中，所述干粉包含胰岛素。在其他实施方式中，所述干粉包含胰高血糖素和促胰岛素分泌肽或GLP-1。
本文中公开的其他实施方式包括制备适合作为干粉用于肺部给药的微粒的方法。在一个实施方式中，该方法包括：通过以比表面积为约52m2/g的微粒作为生产目标来调整制备条件，形成在95％的置信限内比表面积约35m2/g到约67m2/g二酮哌嗪微粒。在另一个实施方式中，制备条件的调整包括增大或降低温度或进料溶液中氨水、乙酸和/或二酮哌嗪的浓度。
本文中公开的另一个实施方式包括制备适合作为包含二酮哌嗪(例如FDKP)的干粉用于肺部给药的微粒的方法。在一个实施方式中，制备微粒的方法包括合成FDKP化合物或组合物，其中微粒的比表面积为约35m2/g到约67m2/g，使用标准表面积分析仪测定FDKP微粒的表面积并以m2/g来评估表面积。在其他实施方式中，在加入活性剂之前而不是之后测定比表面积，或者在加入活性剂之前和之后都测定比表面积；SSA小于约62m2/g。在一个实施方式中，FDKP的合成包括：a)将FDKP组合物溶解在pH为碱性的溶液中以形成FDKP溶液；b)提供挥发性酸的溶液；以及c)在高剪切混合器中使FDKP溶液和挥发性酸的溶液混合在一起来制备微粒。
在特别的实施方式中，用于制备比表面积为约35m2/g到约67m2/g的FDKP微粒的方法包括皂化反应和重结晶。在一个实施方式中，公开了制备适合作为干粉用于肺部给药的微粒的方法，该方法包括：a)合成FDKP化合物或组合物；b)将步骤a)的FDKP化合物溶解在pH为碱性的溶液中以形成FDKP溶液；d)提供挥发性酸的溶液；以及e)在高剪切混合器中使FDKP溶液和挥发性酸的溶液混合在一起来制备微粒。该方法可以进一步包括在颗粒形成之后测定颗粒的比表面积。
在具体的实施方式中，合成比表面积小于约67m2/g的FDKP微粒的方法包括：在约14℃到约18℃的温度下，使等质量的约10.5重量％的乙酸和约2.5重量％的FDKP溶液通过高剪切混合器(例如Dual-feed SONOLATORTM)在2000psi的压力下通过0.001in2的喷嘴来形成悬浮液。该方法还可以包括下列步骤：使微粒从溶液中沉淀出，并在质量和温度大约相同的去离子水贮水池中收集所形成的微粒。在该实施方式中，悬浮液所含的微粒含量为约0.8％固体。在某些实施方式中，该方法还包括通过在例如去离子水中使用切向流过滤技术洗涤微粒而浓缩微粒悬浮液。在该实施方式和其他实施方式中，可以首先将沉淀浓缩至约4％固体，然后进一步用去离子水洗涤。在一些实施方式中，基于所用的FDKP组合物的初始质量，悬浮液通常可以浓缩至约10％固体。通过烘干法可以测定被浓缩的悬浮液的固含量。在本文公开的实施方式中，该方法还包括在颗粒干燥之后测定颗粒的比表面积。
在本文公开的组合物和方法的具体实施方式中，比表面积小于约67m2/g的二酮哌嗪微粒使用了式为2，5-二酮-3，6-二(N-X-4-氨基丁基)哌嗪的二酮哌嗪，其中X选自由富马酰基、琥珀酰基、马来酰基和戊二酰基组成的组。在示例性实施方式中，二酮哌嗪为式(二-3，6-(N-富马酰基-4-氨基丁基))-2，5-二酮哌嗪或2，5-二酮-3，6-二(N-富马酰基-4-氨基丁基)哌嗪。
本文公开的另一个实施方式包括用于制备比表面积小于约67m2/g且含有药物或活性剂的FDKP微粒的方法，其中所述比表面积是将药物加到颗粒之前测定的。在该实施方式中，所述方法包括：将包含活性剂(例如肽，包括胰岛素、胰高血糖素、胰高血糖素样肽-1、胃泌酸调节素、肽YY等)的溶液加入微粒悬浮液中；将氨水加入悬浮液从而例如使悬浮液的pH升高到pH 4.5；对反应保温，使产生的悬浮液在液氮中速冻，并冷冻干燥所形成的小粒从而制备含有比表面积小于约67m2/g的FDKP微粒的干粉。在该实施方式的另一方面，活性剂吸附到微粒之后微粒的比表面积小于约62m2/g。
在一个实施方式中，公开了一种将胰岛素输送至需要其的患者的方法，该方法包括：通过患者对干粉的吸入，将含有比表面积小于约62m2/g(基于未加载的微粒为67m2/g)的二酮哌嗪微粒的干粉给药至肺深部。在该实施方式中，吸入器系统的特征是指定的。
本文中公开的另一个实施方式包括将药物(例如胰岛素)输送至需要其的患者的方法，该方法包括：通过患者对干粉的吸入，将干粉给药至肺深部；其中所述干粉包含含有胰岛素的二酮哌嗪微粒；其中所述微粒是由二酮哌嗪形成的并且比表面积在约35m2/g到约67m2/g的范围内。在该实施方式的一个方面，活性剂吸附到微粒之后，微粒的比表面积小于约62m2/g。在该实施方式中，吸入器系统的特征是指定的。其他实施方式涉及治疗胰岛素相关的失调的方法，其包括：将上述干粉制剂给药至需要其的人。在各种实施方式中，胰岛素相关的失调可以具体包括但不限于下列中的任何一种或所有：糖尿病前期、1型糖尿病(蜜月期、后蜜月期或二者)、2型糖尿病、妊娠期糖尿病、低血糖症、高血糖症、胰岛素抵抗、内分泌功能失调、受损的胰岛素早期释放、胰腺β-细胞功能的丧失、胰腺β-细胞的减少和代谢失调。
在一个实施方式中，治疗内分泌相关的疾病或失调的方法包括：将包含比表面积小于约67m2/g的FDKP微粒和适用于治疗所述疾病或失调的药物的干粉制剂给药至需要其的人。在该实施方式的一个方面，活性剂吸附到微粒之后，微粒的比表面积小于约62m2/g。一个实施方式包括治疗胰岛素相关的失调的方法，其包括：将含有上述FDKP微粒的干粉给药至需要其的人。该方法包括将含有比表面积小于约67m2/g的FDKP微粒和胰岛素的干粉制剂给药至受试者。在该实施方式的一个方面，活性剂吸附到微粒之后，微粒的比表面积小于约62m2/g。在各种实施方式中，胰岛素相关的失调可以具体包括但不限于下列中的任何一种或所有：糖尿病前期、1型糖尿病(蜜月期、后蜜月期或二者)、2型糖尿病、妊娠期糖尿病、低血糖症、高血糖症、胰岛素抵抗、内分泌功能失调、受损的胰岛素早期释放、胰腺β-细胞功能的丧失、胰腺β-细胞的减少和代谢失调。在一个实施方式中，所述干粉包含胰岛素。在其他实施方式中，所述干粉包含胰高血糖素、促胰岛素分泌肽或GLP-1。
附图说明
以下附图构成本说明书的一部分，用于进一步说明本文公开的实施例的某些特定方面。通过参考一个或更多个附图，并结合本文所列的具体实施方式的详细描述，可以更好地理解本发明。
图1A和1B分别描绘了具有高比表面积和低比表面积(SSA)的微粒。
图2描绘了总体上为球形的富马酰基二酮哌嗪(FDKP)。
图3提供了FDKP制备工艺的示意图。
图4A和4B描绘了根据图3所示的示意图而制备的微粒/胰岛素粉末的SSA的估计值和实际值。
图5A-C描绘了RF/填充量、(FDKP微粒的)SSA与进料溶液温度之间的关系。
图6A描绘了RF/填充量与FDKP微粒/胰岛素粉末的SSA之间的关系，并示出SSA＞约62m2/g的粉末的RF/填充量＜40％的可能性为5％。图6B示出了由于从进料浓度预测SSA的不确定性而得到的SSA的制备目标。
图7描绘了作为微粒/胰岛素粉末的SSA的函数的RF/填充量。每一个点表示不同批次的微粒/胰岛素粉末。
图8A描绘了微粒/胰岛素粉末的SSA对固含量为约4％的微粒悬浮液的表观粘度的影响。图8B描绘了悬浮液粘度和粉末性能之间的关系。
图9描绘了上清液中的胰岛素浓度，它是FDKP微粒的SSA的函数。
发明详述
如上所述，将药物输送至肺部具有很多优势。但是由于输送药物经过天然的物理屏障，所以难以将药物以相同体积和重量输送至肺部。本文中公开了作为药物递送剂的比表面积小于约67m2/g的二酮哌嗪微粒、制备所述微粒的方法和使用所述微粒治疗的方法。
在本文中使用时，术语“微粒”是指直径为约0.5μm到约1000μm的颗粒，不考虑精确的外部或内部结构。直径为约0.5μm到约10μm的微粒可以成功穿过大部分天然屏障到达肺部。直径必须小于约10μm以便通过喉咙的转角，而直径必须为约0.5μm或更大以避免被呼出。为了到达被认为发生最有效吸收的肺深部(或肺泡区)，优选使“可吸收分数”(RF)中所含的颗粒比例最大化，通常可接受的是使用标准技术(例如Anderson Cascade Impactor)测定的空气动力学直径为约0.5μm到约5.7μm的那些颗粒，尽管一些参考文献使用稍微不同的范围。其他冲击器也可以用于测定空气动力学颗粒直径，例如NEXT GENERATIONIMPACTORTM(NGITM，MSP Corporation)，可吸收分数是通过相似的空气动力学粒径(例如＜6.4μm)定义的。在一些实施方式中，使用激光衍射装置来测定粒径，例如2010年3月18日递交的美国专利申请No.12/727,179中公开的激光衍射装置，其相关教导通过引用全部结合在本文中，其中测定了颗粒的体积中值几何直径(VMGD)来评估吸入系统的性能。例如，在各种实施方式中，≥80％、85％或90％的药盒排空率和≤12.5μm、≤7.0μm或≤4.8μm的射出颗粒的VMGD可以表现出越来越好的气动性能。本文中公开的实施方式显示出：比表面积小于约67m2/g的FDKP微粒表现出有利于将药物输送至肺部的特性(例如改善的气动性能)。
基于填充量的可吸收分数(RF/填充量)表示填充剂量中射出的尺寸适合肺部给药的颗粒百分比，其为微粒气动性能的量度。如本文中所述，40％或大于40％的RF/填充量值表现出可接受的气动特性。在本文公开的某些实施方式中，基于填充量的可吸收分数可以大于50％。在一个示例性实施方式中，基于填充量的可吸收分数可以高达约80％，其中使用标准技术测定，约80％的填充量以＜5.8μm的粒径射出。
在本文中使用时，术语“干粉”指的是不悬浮或溶解在推进剂、载体或其他液体中的精细颗粒组合物。并不意味着所有水分子完全不存在。
应该理解的是特定的RF/填充量值可以取决于用于输送粉末的吸入器。粉末通常易于团聚并结晶成DKP微粒形式，特别是粘附性粉末。干粉吸收器的一个功能是使粉末解聚从而使所产生的颗粒包含适于通过吸入输送剂量的可吸收部分。但是，粘附性粉末的解聚通常不彻底，所以当测定通过吸入器输送的可吸收分数时，所看到的颗粒尺寸分布与最初的颗粒尺寸分布不匹配，也就是说，分布曲线向较大的颗粒偏移。吸入器的设计在其解聚效率方面变化，因此使用不同设计观察到的RF/填充量的实际值也将不同。但是，从一个吸入器到另一个吸入器的作为比表面积的函数的最佳RF/填充量是类似的。
在本文中使用时，术语“约”用于表示一个值包括确定该值所用设备或方法的测定标准偏差。
二酮哌嗪
已经用于克服药学领域中难题(例如药物不稳定性和/或较差的吸收)的一类药物递送剂是2，5-二酮哌嗪。2，5-二酮哌嗪是由下面的通式1表示的化合物，其中E1和E2独立地为N或更具体地为NH。在其他实施方式中，E1和/或E2独立地为氧或氮，从而使E1和E2取代基中的一个为氧而另一个为氮，该式得到取代类似物二酮吗啉；或者当E1和E2都是氧时，该式得到取代类似物二酮二氧杂环己烷。
已经表明这些2，5-二酮哌嗪可用在药物输送中，特别是那些带有酸性R1和R2基团的2，5-二酮哌嗪(参见例如，标题为“Self Assembling Diketopiperazine Drug DeliverySystem”的美国专利No.5,352,461，标题为“Method For Making Self-AssemblingDiketopiperazine Drug Delivery System”的美国专利No.5,503,852，标题为“Microparticles For Lung Delivery Comprising Diketopiperazine”的美国专利No.6,071,497和标题为“Carbon-Substituted Diketopiperazine Delivery System”的美国专利No.6,331,318，上述文献通过全文引用，将其关于二酮哌嗪的教导和二酮哌嗪作为媒介的药物输送的教导包含在本文中)。二酮哌嗪可以形成混入药物的微粒和形成药物可以吸附到其上的微粒。药物和二酮哌嗪的组合可以赋予改善的药物稳定性和/或吸收特性。这些微粒可以通过各种给药途径来给药。作为干粉，这些微粒可以通过吸入输送到呼吸系统的特定区域，包括肺部。
这些微粒通常是通过下列方法得到：通过游离酸(或碱)的pH沉淀法产生由聚集的结晶板组成的自组装微粒。颗粒的稳定性可以通过从其中沉淀出颗粒的DKP溶液中的少量表面活性剂(例如聚山梨酸酯-80)来增强(参见例如标题为“Method of drug formulationbased on increasing the affinity of crystalline microparticle surfaces foractive agents”的美国专利申请No.2007/0059373，该文献通过全文引用，将其关于DKP微粒的形成和加载及其关于干粉的教导包含在本文中)。最后可以除去溶剂得到干粉。除去溶剂的适当方法包括冷冻干燥和喷雾干燥(参见例如标题为“A method for improving thepharmaceutic properties of microparticles comprising diketopiperazine and anactive agent”的美国专利申请No.2007/0196503和标题为“Purification andstabilization of peptide and protein pharmaceutical agents”的美国专利No.6,444,226，每一篇文献都通过全文引用，将其关于DKP微粒的形成和加载及其关于干粉的教导包含在本文中)。本文中公开的微粒不同于由DKP盐组成的微粒。那些微粒通常通过喷雾干燥形成(而不是通过喷雾干燥来干燥)，产生无定形盐(而不是游离酸或碱)的球体和/或塌陷球，所以它们是化学、物理和形态上均不同的实体。本文中提到的FDKP理解为游离酸或溶解的阴离子。
合成二酮哌嗪的方法在例如Katchalski等J.Amer.Chem.Soc.68，879-880(1946)和Kopple等J.Org.Chem.33(2)，862-864(1968)中有所描述，它们的教导通过引用全部结合在本文中。2，5-二酮-3，6-二(氨基丁基)哌嗪(Katchalski等称之为赖氨酸酸酐)还可以通过N-ε-P-L-赖氨酸在熔融苯酚中的环化二聚来制备(这与Kopple方法类似)，随后通过适当的试剂和条件除去保护性的(P)-基团。例如，使用4.3M在乙酸中的HBR可以除去CBz保护基。这种方法是优选的，因为其使用可商购的起始物料，其包括据报道用于保持起始物料在产物中的立体化学性的反应条件并且所有步骤都可以很容易地按比例放大用于生产。合成二酮哌嗪的方法在标题为“Catalysis of Diketopiperazine Synthesis”的美国专利No.7,709,639中也有描述，其就相同方面的教导也通过引用结合在本文中。
富马酰基二酮哌嗪(二-3，6-(N-富马酰基-4-氨基丁基)-2，5-二酮-二酮哌嗪；FDKP)是肺部应用的一种优选的二酮哌嗪。
FDKP提供了一种有利的微粒基质，因为它在酸中的溶解度低但是易于溶解在中性或碱性pH中。这些性能允许FDKP结晶，并使晶体在酸性条件下自组装成微粒。颗粒在pH为中性的生理条件下易于溶解。如前所述，直径在约0.5和约10微米之间的微粒可以成功穿过大部分天然屏障到达肺部。在该尺寸范围内的颗粒可以很容易地由FDKP制备。
如前所述，直径在约0.5和约10微米之间的微粒可以成功穿过大部分天然屏障到达肺部。在该尺寸范围内的颗粒可以很容易地由带酸性基团的二酮哌嗪制备，例如FDKP(同样相关的分子如2，5-二酮-3，6-二(4-X-氨基丁基)哌嗪，其中X为琥珀酰基、戊二酰基或马来酰基)中的羧基。经过酸沉淀之后，得到由结晶板的聚集体组成的自组装微粒。这些板的尺寸与颗粒的比表面积有关，颗粒的比表面积又转而影响颗粒的结构、加载能力和气动性能。
DKP微粒的比表面积是平均晶体尺寸的量度，并且可以用于估计晶核的相对分布和微粒特性的增长。比表面积取决于微粒晶体的尺寸，而微粒基质的密度(ρ)与晶体的特性尺寸L成反比。比表面积是一群颗粒总体的性能而不是其中每一个单独颗粒的特性。本文中公开的实施方式显示出：比表面积小于约67m2/g的微粒通过中等效率的吸入器(例如标题为“Unit Dose Cartridge and Dry Powder Inhaler”的美国专利No.7,464,706中公开的吸入器，其就相同方面的教导通过引用结合在本文中)表现出有利于将药物输送至肺部的特性(例如改善的气动性能)。比表面积小于约62m2/g的另一个可选的实施方式提供了更高水平的保证，即一个批次的颗粒将满足最小的气动性能标准。由于比表面积还影响载药/容纳的能力，所以为了改善的药物吸附能力，各种实施方式需要大于或等于约35m2/g、40m2/g或45m2/g的比表面积。此外，当比表面积降至低于35m2/g时，即使用高效的吸入器(例如在标题为“A Dry Inhaler and System for Drug Delivery”的美国专利申请No.12/484,125和2010年3月4日递交的标题为“Improved Dry Powder Drug DeliverySystem”的美国专利申请No.12/717,884中公开的那些，其就相同方面的教导通过引用结合在本文中)也观察到不一致的药盒排空率。
比表面积范围的上限
本文中所定义的比表面积范围的上限受到微粒气动性能的限制。本文所述的研究已经证实：当比表面积增大至高于约50m2/g时，RF/填充量的值趋于降低。此外，当比表面积增大时，RF/填充量的分布变宽，无法得到RF/填充量的选择标准(例如RF/填充量＞40％)的可能性增大。因此在一些实施方式中，可以选择上限为约67m2/g。根据采集到的大量制备的数据的拟合曲线，预测该值能提供＞40％的RF/填充量。在另一个实施方式中，可以选择上限为约62m2/g。62m2/g的上限提供具有令人满意的在95％置信限内的RF/填充量值的微粒(参见图6A)。
为微粒的比表面积设置上限的另一原因是：高比表面积的微粒的悬浮液的粘度往往比较低比表面积的微粒的悬浮液的粘度高几个数量级。该现象可能反映出与较小晶体有关的颗粒间吸引力增大。冷冻干燥之后，较强的吸引力可能产生不能有效解聚的聚集体，从而可能降低RF/填充量，因为悬浮液粘度与RF/填充量负关联。
微粒的比表面积是用冷冻干燥的松散粉末测定的，并且不能从微粒的形成条件准确预测。因此，期望目标比表面积为约52m2/g。将约52m2/g设为比表面积的目标，预期仅有5％的微粒超过更保守的上限62m2/g(图6B)。在这可能超过62m2/g的5％的微粒中，期望仅有5％(0.25％)表现出RF/填充量＜40％。因而这些制备条件将提供在超过99％的置信限中RF/填充量＞40％的微粒。
比表面积范围的下限
本文中所定义的比表面积范围的下限受到载药需求的限制。微粒必须具有足以加载所需药量的比表面积。如果药物未被充分吸附(即：留在溶液中)，未吸附的药物可能使所形成的微粒桥接起来从而导致聚集体的形成。聚集体会不利地影响气动特性。对胰岛素来说，为了避免在适当的治疗剂量下通过胰岛素桥接，需要的比表面积下限约为35m2/g。桥接还可能导致较差的药盒排空率，如上所述，这可能发生在比表面积较低的粉末中。为了更加确保可以避免这些问题并且使负载量最大化，可以使用稍微高一些的比表面积下限，例如40或45m2/g。或者，影响气动性能的其他因素可以保持在更窄的容限内。图1A显示了具有高比表面积的微粒簇。图1B显示了在比表面积低的粉末中通过胰岛素桥接的颗粒。
FDKP微粒的形成
制备FDKP微粒的第一步是微粒的形成：通过pH诱导FDKP结晶，并使FDKP晶体自组装为总体上为球形(图2)的微粒。因此，微粒的制备基本上是一个结晶过程。过量的溶剂可以通过重复离心、倾析和再悬浮或通过渗滤来洗涤悬浮液而除去。
为了形成载有胰岛素的FDKP微粒，通过将胰岛素储存溶液加入FDKP微粒悬浮液，使胰岛素在悬浮期间(即：在冷冻干燥之前)可以直接吸附在微粒上。在一个实施方式中，在加入胰岛素储存溶液之后还可以进行控制pH的步骤。该步骤可以在进一步处理前在悬浮期间促进胰岛素吸附到微粒上。悬浮液的pH增大到约4.5将在悬浮期间促进全部胰岛素吸附微粒上，而不会使FDKP从微粒基质过度溶解，并且还能改善胰岛素在药物产品中的稳定性。悬浮液可以在液氮中逐滴速冻(即：低温粒化)并冷冻干燥以便除去溶剂，得到干粉。在可选的实施方式中，悬浮液可以被喷雾干燥从而得到干粉。图3提供了适当的制备方法的示意图。
在一个实施方式中，提供了用于制备含有胰岛素的本发明的FDKP微粒的制备方法。概括地说，使用高剪切混合器，例如Dual-feed SONOLATORTM，或例如在2009年11月2日递交的美国专利申请No.61/257,311(其内容通过引用全部结合在本文中)中公开的高剪切混合器，在约16℃±约2℃的温度下，通过Dual-feed SONOLATORTM在2000psi下使等质量的约10.5重量％乙酸和约2.5重量％的FDKP溶液(表1和表2)通过0.001-in2的喷嘴进料。在质量和温度大约相等的去离子水(DI)贮水池中可以收集到沉淀。所得到的悬浮液包含约0.8％的固体。通过切向流过滤技术可以浓缩并洗涤沉淀。沉淀可以首先浓缩至约4％固体，然后用去离子水洗涤。悬浮液最终可以基于FDKP的初始质量浓缩至约10％固体。通过烘干法可以测定被浓缩的悬浮液的固含量。
在一个实施方式中，浓缩的胰岛素储存溶液可以用1份胰岛素和9份约2重量％的乙酸来制备。胰岛素储存溶液可以通过称重法添加到悬浮液中从而得到约11.4重量％胰岛素的负载量。胰岛素-FDKP悬浮液可以混合至少15分钟。在一些实施方式中，混合可以进行更短或更长的时间。随后用约14到约15重量％的氨水使胰岛素-FDKP悬浮液从约为3.5的初始pH滴定至约为4.5的pH。悬浮液可以在液氮中速冻以形成颗粒，并且冷冻干燥从而产生松散的含有胰岛素的FDKP微粒。可以按相同方法制备空白的FDKP微粒，但是没有加载胰岛素和pH调节步骤。在一个实施方式中，本文中所述的含有微粒的FDKP-胰岛素松散粉末的密度为约0.2g/cm3至约0.3g/cm3。
表1.10.5％的乙酸溶液
组分 重量％
DI水 89.00
冰醋酸(GAA) 10.50
10％的聚山梨酸酯80 0.50
0.2μm过滤
表2.2.5％的FDKP溶液
组分 重量％
DI水 95.40
FDKP 2.50
NH<sub>4</sub>OH 1.60
10％的聚山梨酸酯80 0.50
0.2μm过滤
控制比表面积
FDKP晶体的尺寸分布和形状受新晶体的成核和已存在晶体的增长之间的平衡影响。这两种现象很大程度上取决于溶液的浓度和过饱和度。FDKP晶体的特性尺寸是成核和增长的相对速度的表征。当成核占主导地位时，形成许多晶体，但是它们都相对较小，因为它们都与溶液中的FDKP竞争。当增长占主导地位时，竞争的晶体变少，晶体的特性尺寸变大。
结晶过程很大程度上取决于过饱和度，过饱和度转而又很大程度上取决于进料流中各组分的浓度。较高的过饱和度与许多小晶体的形成有关；而较低的过饱和度将产生较少但更大的晶体。在过饱和度方面：1)增加FDKP的浓度将增大过饱和度；2)增加氨水的浓度使系统变为较高的pH(例如约pH4.5)，将增大平衡溶解度并降低过饱和度；3)增加乙酸的浓度，将通过使终点变为平衡溶解度较低的低pH值而使过饱和度增大。降低这些组分的浓度将导致相反的效果。
温度通过其对FDKP的溶解度和FDKP晶体成核和增长动力学的作用来影响FDKP微粒的形成。在低温下，形成比表面积高的小晶体。这些颗粒的悬浮液表现出高粘度，表明颗粒间吸引力较强。在约12℃到约26℃间的温度范围提供了在95％置信水平的RF/填充量＞40％。通过解释说明温度和比表面积之间的关系，可以使用为约13℃到约23℃的略窄但内在一致的温度范围。
最终，应该认识到的是：将活性剂吸附到微粒的表面上往往会降低比表面积。活性剂的吸附可以填充或阻塞构成颗粒的结晶板之间一些较窄的空间，从而降低比表面积。此外，活性剂的吸附增加了微粒的质量但基本上不影响微粒的直径(尺寸)。因为比表面积与微粒的质量成反比，所以比表面积将降低。
活性剂的选择和引入
只要本文所述的微粒保持小于约67m2/g的所需比表面积，它们便能采用有利于输送至肺部和/或药物吸附的其他附加特性。标题为“Method for Drug Delivery to thePulmonary System”的美国专利No.6,428,771描述了将DKP颗粒输送至肺部，其就相同方面的教导通过引用结合在本文中。标题为“Purification and Stabilization of Peptideand Protein Pharmaceutical Agents”的美国专利No.6,444,226描述了有利于使药物吸附到微粒表面的方法，其就相同方面的教导也通过引用结合在本文中。可以利用微粒表面性能来实现如标题为“Method of Drug Formulation based on Increasing theAffinity of Crystalline Microparticle Surface for Active Agents”的美国专利申请No.11/532,063(其就相同方面的教导通过引用结合在本文中)中所述的期望特性。标题为“Method of Drug Formulation based on Increasing the Affinity of ActiveAgents for Crystalline Microparticle Surfaces”的美国专利申请No.11/532,065描述了促进活性剂吸附到微粒上的方法。美国专利申请No.11/532,065也就相同方面的教导通过引用结合在本文中。
本文所述的微粒可以包含一种或更多种活性剂。在本文中使用时，可与“药物”互换使用的“活性剂”指的是医药物质，包括小分子药物、生物制剂和生物活性剂。活性剂可以是天然存在的、重组的或合成来源的，包括蛋白质、多肽、肽、核酸、有机大分子、合成有机化合物、多糖和其他糖、脂肪酸和脂质，以及抗体及其片段，所述抗体及其片段包括但不限于人源化抗体或嵌合抗体、F(ab)、F(ab)2、单独的单链抗体或与其他多肽混合的单链抗体、或对抗癌抗原的治疗性或诊断性单株抗体。活性剂可以包括多种生物活性和种类，例如血管活性剂、神经活性剂、激素、抗凝血剂、免疫调节剂、细胞毒性剂、抗菌素、抗病毒剂、抗原、传染物、炎症介质、激素和细胞表面抗原。更具体地，活性剂以非限制性方式包括细胞因子、脂质因子(lipokine)、脑啡肽、炔、环孢菌素、抗-1L-8抗体、包括ABX-1L-8的1L-8拮抗剂；包括PG-12的前列腺素，包含LY29311、BIIL284和CP105696的LTB受体阻滞剂；诸如舒马普坦(sumatriptan)的曲普坦类(triptan)和棕榈油酸酯、胰岛素及其类似物、生长激素及其类似物、甲状旁腺激素(PTH)及其类似物、甲状旁腺激素相关肽(PTHrP)、生长激素释放肽(ghrelin)、肥胖抑制素(obestatin)、肠抑素(enterostatin)、粒细胞集落刺激生物因子(GM-CSF)、糊精、糊精类似物、胰高血糖素样肽-1(GLP-1)、氯吡格雷(clopidogrel)、PPACK(D-苯基丙氨酰-L-丙基-L-精氨酸氯甲基酮)、胃泌酸调节素(OXM)、肽YY(3-36)(PYY)、脂联素(adiponectin)、胆囊收缩素(CCK)、胰泌素(secretin)、促胃液素(gastrin)、胰高血糖素、胃动素(motilin)、生长抑制素(somatostatin)、脑钠肽(BNP)、心钠肽(ANP)、IGF-1、生长激素释放因子(GHRF)、整合素β-4前体(ITB4)受体拮抗剂、孤啡肽(nociceptin)、痛稳素(nocistatin)、孤啡肽FQ2(orphanin FQ2)、降钙素、CGRP、血管紧张素(angiotensin)、P物质、神经激肽A(neurokinin A)、胰多肽、神经肽Y、δ-促睡眠肽和血管活性肠肽。微粒还可以用于输送其他试剂，例如造影剂(如Texas Red)。
在由比表面积小于约67m2/g的FDKP形成的微粒上输送的药物含量通常高于0.01％。在一个实施方式中，用具有上述比表面积的微粒输送的药物含量可以在约0.01％到约20％的范围内，这通常是对于肽(例如胰岛素)来说的。例如，如果药物是胰岛素，本发明的微粒通常含有3-4U/mg(约10-15％)的胰岛素。在某些实施方式中，颗粒的药物含量可以根据待输送的药物形式和尺寸来变化。
只要本文所述的微粒保持所需的比表面积，它们便能采用有利于输送至肺部和/或药物吸附的其他附加特性。标题为“Method for Drug Delivery to the PulmonarySystem”的美国专利No.6,428,771描述了将DKP颗粒输送至肺部，其就相同方面的教导通过引用结合在本文中。标题为“Purification and Stabilization of Peptide and ProteinPharmaceutical Agents”的美国专利No.6,444,226描述了使药物吸附到微粒表面的有利方法，其就相同方面的教导也通过引用结合在本文中。可以利用微粒表面性能来而实现如标题为“Method of Drug Formulation based on Increasing the Affinity ofCrystalline Microparticle Surface for Active Agents”的美国专利申请No.11/532,063(其就相同方面的教导通过引用结合在本文中)中所述的期望特性。标题为“Method ofDrug Formulation based on Increasing the Affinity of Active Agents forCrystalline Microparticle Surfaces”的美国专利申请No.11/532,065描述了促进活性剂吸附到微粒上的方法。美国专利申请No.11/532,065就相同方面的教导也通过引用结合在本文中。
实施例
以下实施例用于说明所公开的微粒的实施方式。本领域技术人员应当认识到，实施例中与本发明人发现的代表性技术一起公开的技术可以有效地用于实施本发明，因此这些技术被认为构成了实施本发明的优选方式。然而，本领域技术人员应当认识到，根据本发明的说明书，可以对公开具体实施方式进行许多改变，同时获得相同或类似的效果。
实施例1
I.制备过程
A.FDKP/胰岛素微粒产品的一般制备过程
微粒由富马酰基二酮哌嗪(FDKP)和胰岛素制成。将FDKP溶解在氨水(NH4OH水溶液)中形成溶液。该溶液的进料流与乙酸(HOAc)水溶液的进料流在高剪切混合器中合并以形成微粒的水性悬浮液。
FDKP进料流由约2.5重量％的FDKP、约1.6重量％的浓缩氨水(约28-约30重量％的NH3)和约0.05重量％的聚山梨酸酯80制成。乙酸原料流由约10.5重量％的冰醋酸和约0.05重量％的聚山梨酸酯80制成。两种进料流在使用之前都通过约0.2μm的膜过滤。
图3描绘了制备本发明的包含胰岛素的FDKP微粒的制备工艺的示意图。在该实施方式中，使用高剪切混合器，例如Dual-FeedSONOLATORTM，或例如在2009年11月2日递交的美国专利申请No.61/257,311(其内容通过引用全部结合在本文中)中公开的高剪切混合器，使等量(以质量计)的各种原料流通过装有#5喷嘴(0.0011平方英寸)的Dual-FeedSONOLATORTM泵入。为了使每一个进料流的流速相等，最小泵被设为50％，进料压力为约2000psi。接收容器含有与每一种进料流质量相等的DI水(例如：4kg FDKP进料流和4kgHOAc进料流将通过SONOLATORTM泵入含有4kg DI水的接收容器中)。
所产生的悬浮液通过使用0.2m2PES(聚醚砜)膜的切向流过滤方式浓缩并洗涤。悬浮液首先被浓缩至约4％固体，然后用DI水渗滤，最终浓缩至约16％名义固体含量。洗涤过的悬浮液的实际固体百分比是通过“干燥失重法”测定的。其他方法也可用于测定悬浮液的固体百分比，例如在2010年5月7日递交的标题为“Determine Percent Solids inSuspension Using Raman Spectroscopy”的美国临时专利申请No.61/332,292的中公开的方法，其教导内容通过引用结合在本文中。
制备胰岛素储存溶液，其含有约10重量％的胰岛素(按收到的原样使用)，溶剂为在DI水中含有约2重量％的HOAc，然后将胰岛素储存溶液无菌过滤。基于悬浮液的固含量，向混合的悬浮液中添加适量的储存溶液。随后调整所产生的微粒/胰岛素悬浮液，通过使用氨水将悬浮液的pH从约3.6的pH调节至约4.5的pH。
包含含胰岛素的FDKP微粒的悬浮液转移到冷冻制粒机/造粒机(例如在2009年11月2日递交的美国临时专利申请No.61/257,385中公开的，其内容通过引用全部结合在本文中)中，在液氮中通过速冻来造粒。冰粒被冷冻干燥来生产干粉。
B.在5％和10％的研究中所用的FDKP/胰岛素微粒产品的制备过程
在5％和10％的研究中，调查了进料浓度对比表面积和粉末空气动力学的影响。在5％的研究中，设计实验来确定三种因素(即：FDKP、氨水和乙酸的浓度)的影响，并在3×3析因实验中细查，其中高量和低量是偏离控制条件的5％。在10％的研究中，同样在3×3析因实验中细查FDKP、氨水和乙酸的浓度的影响，但是高量和低量偏离控制条件的10％。
表3.待评估的微粒形成条件
注释：如果没有特别指出的话，所有的进料溶液都含有约0.05重量％的聚山梨酸酯80，并且在约16℃下保存。
C.最终的测量
粉料的可吸收分数(RF/填充量)是气动性能和微粒尺寸分布的量度，并且可以用Anderson级联撞击式采样器通过测试来确定。为了得到RF/填充量值，将药盒用粉料填满并通过吸入器以约30L/min的速度排出。将在每一个吸附器的台上收集到的粉末称重，而所有收集到的粉末相对于药盒填充的总量进行标准化。因此，RF/填充量是在撞击器的那些台上收集到的代表可吸收部分的粉末质量除以加载在药盒中的粉末质量。
微粒的比表面积(SSA)是使用比表面积分析仪(TriStar3000Surface Area and Porosity Analyzer)通过氮吸附法测定，并且用BET(Brunauer-Emmett-Teller)表面积的形式来报告。比表面积取决于晶体的尺寸和微粒基质的密度(ρ)，与FDKP晶体的特性尺寸L成反比：
II.进料条件对比表面积的影响
对在5％和10％的研究中制备的所有粉末进行比表面积测定。通过线性回归方程来预测比表面积(参见图3)。预测的标准差对于5％的研究来说为±2m2/g，对于10％的研究来说为±5.6m2/g。这些结果与理论预期一致：较高的FDKP浓度、较高的HOAc浓度或较低的氨水浓度通过促进晶体成核来增大比表面积(产生较小的晶体)。
III.温度的影响
在一系列研究中调查了温度对颗粒性能的影响，其中除温度之外的进料溶液特征被设定在控制条件。进料溶液的温度范围为4-32℃。微粒粉末的比表面积和所产生的微粒粉末的RF/填充量都进行了测定。
在图5中RF/填充量、比表面积和温度是交汇的(RF/填充量是用含有胰岛素的微粒测定；绘制的比表面积是在吸附胰岛素之前的颗粒上测定的)。微粒粉末的RF/填充量在约18℃至约19℃附近最大(图5A)。短划线是预测的单侧低于95％的置信限(即：预计高于该曲线的值具有95％的可能性)。约12℃至约26℃的温度范围将以95％的置信水平提供RF/填充量＞40％。当RF/填充量相对于空白(不含药物)微粒粉末的比表面积绘制(图5B)时，所产生的曲线类似于温度曲线。但是，点的顺序相反(例如样本“A”现在出现在坐标轴的右端而样本“B”在左端)。比表面积为26-67m2/g的微粒以95％的置信水平提供RF/填充量＞40％。通过解释说明温度和比表面积之间的关系(图5C)，确定约13℃到约23℃的略窄但内在一致的温度范围用于颗粒的形成。
IV.比表面积对RF/填充量的影响
当比表面积高于50m2/g时，RF/填充量值趋于降低(图6A)。可以使用为约62m2/g的上限，同时仍使适当的RF/填充量值(即＞40％；图6B)保持95％的置信限
图7显示出当比表面积的上限增大时，RF/填充量的分布变宽，无法得到RF/填充量＞40％的选择标准的可能性增大。图8a显示出高比表面积(例如约67m2/g)的微粒的悬浮液的粘度往往比低比表面积(例如约＜14m2/g)的微粒的悬浮液的粘度高几个数量级，所述粘度通过Brookfield Viscometer(Brookfield Engineering Laboratories，Inc.，Middleboro，MA)测定。图8B显示出悬浮液的粘度与RF/填充量负相关。
V.比表面积和胰岛素的吸附
研究了比表面积与胰岛素吸附之间的关系。
如上所述制备用于5％和10％研究的微粒悬浮液并加载约11.4％的胰岛素。此外，还评估了通过控制进料浓度且进料溶液温度范围为约4℃到约32℃而形成的微粒。通过串行添加单滴14％的氨水，使所滴定的悬浮液的pH从约pH 3.6升高到约pH 4.5。分析经滴定的悬浮液和上清液样品的胰岛素浓度。将所有的悬浮液(已滴定和未滴定的)冷冻干燥从而产生干粉。使用TriStar 3000测定粉末的比表面积。
在低比表面积下，未结合的胰岛素的量与比表面积成线性关系(图9)。当比表面积高于约35m2/g时，产生至少95％的胰岛素吸附。胰岛素的吸附程度随比表面积升至约40m2/g继续增大。高于该比表面积时，微粒吸附了几乎所有的胰岛素。
这些研究结果暗示微粒比表面积的有利下限和上限为约35m2/g至约62m2/g。假如其中高于80％、或高于90％、或高于95％的微粒具有在上述范围内的比表面积，那么可以在95％置信限内为微粒提供有利的RF/填充量和药物吸附特性。
实施例2
通过体积中值几何尺寸(VMGD)表征对射出的制剂进行颗粒几何尺寸分析
干粉吸入器射出的干粉制剂的激光衍射是用于表征粉末所进行的解聚程度的常用方法。该方法是对几何尺寸的测量，而不是在目前的工业标准冲击方法中对空气动力学粒径的测量。通常，射出粉末的几何尺寸包括由中值颗粒尺寸VMGD表征的体积分布。重要地，射出颗粒的几何尺寸与通过冲击法提供的空气动力学粒径相比具有较高的分辨率。较小的尺寸是优选的，能产生单独颗粒被输送到肺气管的更大可能性。因此，吸入器解聚和最终性能的差异更易于通过衍射来解决。在这些实施方式中，在与病人深吸气量类似的压力下，用激光衍射来测试吸入器从而确定吸入系统使粉末制剂解聚的效率。特别地，所述制剂包含加载了和未加载活性胰岛素组分的粘着性二酮哌嗪粉末。这些粉末制剂具有特有的表面积、异构体比率和Carr指数。表4报导了VMGD和测试期间容器的排空效率。FDKP粉末的Carr指数约为50，而TI粉末的Carr指数约为40。
表4
表4的数据表明：在定义为DPI 2的吸入器中的粉末解聚相对于吸入器系统有所改善。已证明：比表面积范围为14-56m2/g的二酮哌嗪制剂的排空率高于85％且VMGD小于7微米。同样地，已证明：异构体比率范围为45-66％反式的制剂与对比产品相比具有改善的性能。但是，值得指出的是：即使用更高效的吸入器，在＜15m2/g下药盒排空率会降低，表明气动性能下降(减小)，因为反式异构体含量脱离本文公开的期望范围。最后，数据表明：用特征为Carr指数为40-50的制剂的吸入器系统的性能与现有设备相比也得到改善。在所有的情况下，所报道的VMGD值都低于7微米。
除非另有指明，本说明书和权利要求书中使用的表示成分数量、以及分子量、反应条件等性质的所有数字都应当被理解为：在所有情况下，用术语“约”加以了修饰。因此，除非有相反含义的说明，本说明书和所附权利要求书中示出的数量参数都是约数，它们可以根据本发明想要获得的性质而变动。至少，并且并非对权利要求书范围等同原则的应用加以限制，每个数量参数至少应按照报道的有效数字的数，以及应用普通的凑整技术来解释。虽然示出本发明宽广范围的数字范围和参数是约数，但是具体实施例中所示的数值却被尽可能地精确报道。但是，任何数值，必然含有一定误差，这是它们各自的检验测量方法中发现的标准偏差必然导致的。
除非本文另有指明，或与上下文明显矛盾，在描述本发明(特别是在下列权利要求书的上下文中)的上下文中使用的术语“一个”、“一种”和“这个”以及类似提法应当被理解为既包括单数又包括复数。本文中数值范围的叙述仅仅用作该范围内每个单独的值的速记方法。除非本文另有指明，每个单独的值被包括进说明书，这与在本文进行个别叙述一样。本文所述的所有方法都可以以任何合适的顺序来进行，除非本文另有指明，或与上下文明显矛盾。除非另有指明，本文提供的任何及所有例子，或者示例性的语言(例如，“例如”)仅用来更好地阐述本发明，而非对发明范围加以限制。说明书中任何语句都不应被解释为：表示对本发明的实施来说必要的、不要求保护的要素。
除非明确指出某个可选方式或可选方式之间互相排斥，尽管说明书支持某个可选方式和“和/或”的表述，但是权利要求中所用术语“或”是指“和/或”。
本文公开的本发明的替换性要素或实施方式的分组不应被理解为限制。每个组成员可被个别采用和被个别要求保护，或可以与该组其它成员或本文中找到的其它要素的任意组合和被要求保护。可以预见到，为了方便和/或可专利性的理由，组中的一个或多个成员可被包括进一组或从中删除。当任何此类包括或删除发生时，说明书在此被看作为含有经过改动的组，因此满足对所附权利要求书中所用的任何和全部马库什组的支持。
本文中描述了本发明的优选实施方式，其包括发明人已知用来实施本发明的最佳方式。当然，在阅读前述说明书的基础上，对这些优选实施方式中的改动对于本领域普通技术人员来说将是明显的。本发明的发明人预见了本领域技术人员合适地采用此类改动，发明人预期本发明可以以除了本文具体描述的方式之外的方式被实现。因此，只要适用法律允许，本发明包括对所附权利要求中提到的主题进行的所有改动和等同物。此外，所有可能的变化中，上面提到的要素的任何组合都被包括进本发明，除非本文另有指明，或与上下文明显矛盾。
本文公开的具体实施方式可以进一步使用“由...组成”或者“基本由...组成”的语言表达而被限制在权利要求书中。当用在权利要求书中时，不管是递交的或根据修改增加的，术语“由...组成”排除了未在权利要求中指定的任何要素、步骤或者成分。术语“基本由...组成”将权利要求的范围限制到特定材料或步骤以及实质上不会影响基本特性和新颖特性的那些材料和步骤。要求保护的本发明的实施例在此处固有地或者清楚地描述和应用。
此外，本说明书中提到了大量参考文献，包括专利和印刷公开物。上述参考文献和印刷公开物中的每种在此都通过引用被分别地整体包括进本文。
此外，应当理解本文公开的本发明实施方式是为了阐述本发明的原理。可以进行的其它改动也落在本发明的范围内。因此，举例而言，而非限制，可按照本文的教导来使用本发明的替代性构造。因此，本发明不被限制为仅仅是本文所示和所述的。

Claims (47)

1.一种干粉，其包含含有富马酰基二酮哌嗪微粒的组合物，所述微粒具有35m2/g到67m2/g的比表面积。
2.如权利要求1所述的干粉，其中，在所述微粒包含活性剂。
3.如权利要求2所述的干粉，其中，所述比表面积小于62m2/g。
4.如权利要求3所述的干粉，其中，所述活性剂是肽或蛋白质。
5.如权利要求4所述的干粉，其中，所述肽是内分泌激素。
6.如权利要求5所述的干粉，其中，所述内分泌激素是胰岛素、甲状旁腺激素、降钙素、胰高血糖素、胰高血糖素样肽-1、胃泌酸调节素、所述内分泌激素的类似物或活性片段。
7.如权利要求6所述的干粉，其中，所述内分泌激素是胰岛素。
8.如权利要求6所述的干粉，其中所述内分泌激素是胰岛素类似物或活性片段。
9.如权利要求6所述的干粉，其中所述内分泌激素是胰高血糖素样肽-1或者其类似物或活性片段。
10.如权利要求1所述的干粉，其中所述微粒具有40m2/g至67m2/g的比表面积。
11.如权利要求1所述的干粉，其中，所述微粒具有45m2/g至67m2/g的比表面积。
12.如权利要求1所述的干粉，其中，所述微粒具有35m2/g至56m2/g的比表面积。
13.如权利要求1所述的干粉，其中，所述微粒具有45m2/g至56m2/g的比表面积。
14.如权利要求8所述的干粉，其中，所述内分泌激素是胰岛素类似物。
15.如权利要求14所述的干粉，其中，所述微粒为10重量％至15重量％胰岛素。
16.如权利要求5所述的干粉，其中，所述内分泌激素是促胰岛素分泌。
17.如权利要求7所述的干粉，其中，所述微粒包含3-4U/mg胰岛素。
18.如权利要求15所述的干粉，其中，所述微粒包含富马酰基二酮哌嗪和11.4％胰岛素。
19.如权利要求2所述的干粉，其中，所述活性剂占微粒重量的0.01％至20％。
20.一种干粉，其包含含有富马酰基二酮哌嗪微粒的组合物，其中，所述微粒具有40m2/g至67m2/g的比表面积。
21.如权利要求20所述的干粉，其中，在所述微粒的表面上存在活性剂。
22.如权利要求21所述的干粉，其中，所述活性剂是血管活性剂、神经活性剂、激素、抗凝血剂、免疫调节剂、细胞毒性剂、抗菌素、抗病毒剂、抗原、传染物或炎症介质。
23.如权利要求21所述的干粉，其中，所述活性剂是胰岛素。
24.如权利要求23所述的干粉，其中，所述微粒包含富马酰基二酮哌嗪和11.4重量％胰岛素。
25.如权利要求21所述的干粉，其中，所述活性剂是GLP-1。
26.如权利要求21所述的干粉，其中，所述活性剂为所述微粒的重量的0.01％至20％。
27.如权利要求20所述的干粉，其中，所述微粒的至少一部分是晶状的。
28.如权利要求21所述的干粉，其中，所述微粒具有40m2/g至62m2/g的比表面积。
29.如权利要求20所述的干粉，其中，所述微粒含有晶体二酮哌嗪，所述晶体二酮哌嗪是在13℃至23℃的温度下从水溶液中结晶形成的。
30.含有富马酰基二酮哌嗪微粒和活性剂的干粉用于制造用于将所述活性剂输送给需要其的患者的吸入系统的用途，所述微粒具有40m2/g到67m2/g的比表面积。
31.如权利要求30所述的用途，其中，所述活性剂是内分泌激素，所述内分泌激素选自由下列物质组成的组：胰岛素、甲状旁腺激素、降钙素、胰高血糖素、胰高血糖素样肽-1、胃泌酸调节素、以及所述内分泌激素的类似物或活性片段。
32.如权利要求30所述的用途，其中，所述患者已诊断患有糖尿病。
33.一种吸入系统，其包含以呼吸为动力的吸入器和含有富马酰基二酮哌嗪微粒的干粉，所述微粒具有40m2/g至67m2/g的比表面积。
34.如权利要求33所述的吸入系统，其中，所述干粉是在单位剂量药盒中提供的。
35.如权利要求33所述的吸入系统，其中，所述干粉被预填充在所述吸入器中提供的。
36.如权利要求33所述的吸入系统，其包含1至30mg的所述干粉。
37.如权利要求36所述的吸入系统，其中，当所述吸入器的流速为7-70升/分钟时，超过75％的粉末被分配。
38.如权利要求37所述的吸入系统，其中，超过85％的粉末被分配。
39.如权利要求33所述的吸入系统，其中，可吸收分数/填充量大于40％。
40.如权利要求39所述的吸入系统，其中，可吸收分数/填充量大于50％。
41.如权利要求40所述的吸入系统，其中，可吸收分数/填充量大于60％。
42.如权利要求33所述的吸入系统，其还包含活性剂，所述活性剂包含内分泌激素，所述内分泌激素选自由下列物质组成的组：胰岛素、甲状旁腺激素、降钙素、胰高血糖素、胰高血糖素样肽-1、胃泌酸调节素、所述内分泌激素的类似物或活性片段。
43.如权利要求33所述的吸入系统，其还包含活性剂，所述活性剂包含胰岛素。
44.权利要求1-43中任意一项所述的微粒，其中所述微粒包含3,6-二(N-富马酰基-4-氨基丁基)-2,5-二酮哌嗪。
45.一种吸入系统，其包含以呼吸为动力的吸入器和含有3,6-二(N-富马酰基-4-氨基丁基)-2,5-二酮哌嗪微粒和胰岛素的干粉；其中所述微粒包含10重量％至15重量％胰岛素；其中所述微粒具有35m2/g至62m2/g的比表面积；并且其中所述干粉是在单位剂量药盒中提供的。
46.如权利要求22所述的干粉，其中，所述抗原包含细胞表面抗原。
47.如权利要求22所述的干粉，其中，所述激素包含内分泌激素。
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