CN105102436B - 微晶二酮哌嗪组合物以及方法 - Google Patents

微晶二酮哌嗪组合物以及方法 Download PDF

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CN105102436B
CN105102436B CN201480015837.1A CN201480015837A CN105102436B CN 105102436 B CN105102436 B CN 105102436B CN 201480015837 A CN201480015837 A CN 201480015837A CN 105102436 B CN105102436 B CN 105102436B
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diketopiperazine
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布赖恩·R·威尔逊
约瑟夫·J·古尔纳利
马歇尔·L·格兰特
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Abstract

本发明公开了一种通过改进方法制备的DKP微晶，所述DKP微晶不会不可逆地自组装成微粒。所述微晶可通过雾化分散并通过喷雾干燥重新形成为具有球壳形态的颗粒。可通过对含有待整合到微晶二酮哌嗪颗粒中的组分的溶液进行喷雾干燥来将活性剂和赋形剂整合到所述颗粒中。特别地，所述微晶颗粒组合物适用于一种或多种肽、蛋白质、核酸和/或有机小分子的肺部药物递送。

Description

微晶二酮哌嗪组合物以及方法
技术领域
本文公开了微晶二酮哌嗪(DKP)颗粒、组合物、制备所述颗粒的方法以及使用所述颗粒的方法。特别地，所述颗粒可用作疾病或病症(例如内分泌起源的，包括糖尿病和肥胖症)的治疗中药物或活性剂的递送系统。
背景技术
多年来药物的递送已成为一个重要的问题，特别是当待递送的化合物通过口服给药至受试者时，其在到达目标位置之前在胃肠道中所遇到的条件下是不稳定的。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，许多化合物不起作用或者表现出低或多变的效力。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。
由于与口服药物递送有关的这些问题，研究了至肺部的药物递送。例如通常递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、或流感或其它呼吸系统疾病的疫苗。其它药物(包括核苷酸药物)已经被递送到肺部，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递送到肺部。将全身性试剂递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摄取。肺部药物递送系统存在许多困难，例如推进剂的使用，并且诸如蛋白质和肽的生物试剂的雾化可导致待递送试剂的变性和过度损耗。与肺部药物递送所有这些形式相关的另一个问题是：由于使药物通过所有的天然屏障(诸如沿气管的纤毛)和试图以均匀的体积和重量进行给药的问题，所以难以将药物递送到肺部。
因此，肺部药物递送具有改进的空间。
发明概述
本公开提供了改进的微晶颗粒、组合物、制备颗粒的方法、以及使药物向肺部的递送得到改善以治疗受试者的疾病和病症的方法。本文所公开的实施方案通过提供包含微晶二酮哌嗪颗粒的结晶二酮哌嗪组合物而实现改进的递送，所述微晶二酮哌嗪颗粒具有高的药物吸附能力，从而生成具有高药物含量的一种或多种活性剂的粉末。用本发明微晶颗粒制备的粉末可以以较小的粉末剂量递送增加的药物含量。粉末可通过多种方法制备，包括根据起始物料利用无表面活性剂的溶液或含表面活性剂的溶液的方法。
本文所公开的某些实施方案可包括含多种基本上均匀的微晶颗粒的粉末，其中所述颗粒具有基本上中空的球形结构并且包括外壳，该外壳可以是多孔的，并且包括不自组装的二酮哌嗪的晶粒(crystallite)。
本文所公开的某些实施方案包括含多种基本上均匀的微晶颗粒的粉末，其中所述颗粒具有基本上中空的球形结构并且包括外壳，该外壳可以是多孔的，并且包括不自组装的二酮哌嗪的晶粒，并且所述颗粒的体积中值几何直径(volumetric median geometricdiameter)小于5μm。
在本文的一个具体实施方案中，高达约92％的微晶颗粒的体积中值几何直径≤5.8μm。在一个实施方案中，颗粒的外壳由联锁的(interlocking)二酮哌嗪晶体构成，它们的表面吸附有一种或多种药物。在一些实施方案中，所述颗粒可将药物包埋在其内部空隙体积中和/或将药物吸附到晶粒表面以及将药物包埋在球体的内部空隙体积中的组合。
在某些实施方案中，提供了包含多种基本上均匀形成的微晶颗粒的二酮哌嗪组合物，其中所述颗粒具有基本上中空的球形结构并且包括外壳，该外壳包含不自组装的二酮哌嗪的晶粒；其中所述颗粒通过包括以下步骤的方法形成：将溶液中反式异构体含量在约45％至65％范围内的二酮哌嗪和乙酸溶液在不存在表面活性剂的情况下合并，同时在高剪切混合器中在高达2,000psi的高压下均化以形成沉淀；用去离子水洗涤悬液中的沉淀；浓缩悬液并且在喷雾干燥装置中干燥悬液。
该方法还可包括在喷雾干燥步骤之前，边混合边添加包含活性剂或活性成分(诸如药物或生物活性试剂)的溶液的步骤，以使得活性剂或活性成分被吸附和/或包埋到颗粒上或内。通过该方法制备的颗粒在喷雾干燥之前可以在亚微米尺寸范围内。
在某些实施方案中，提供了包含多种基本上均匀形成的微晶颗粒的二酮哌嗪组合物，其中所述颗粒具有基本上中空的球形结构并且包括外壳，该外壳包含不自组装的二酮哌嗪的晶粒，并且颗粒的体积平均几何直径(volumetric mean geometric diameter)小于等于5μm；其中所述颗粒通过包括以下步骤的方法形成：将溶液中的二酮哌嗪和乙酸溶液在不存在表面活性剂的情况下合并，同时在高剪切混合器中在高达2,000psi的高压下均化以形成沉淀；用去离子水洗涤悬液中的沉淀；浓缩悬液并且在喷雾干燥装置中干燥悬液。
该方法还可包括在喷雾干燥步骤之前，边混合边添加包含活性剂或活性成分(诸如药物或生物活性试剂)的溶液的步骤，以使得活性剂或活性成分被吸附和/或包埋到颗粒上或内。通过该方法制备的颗粒在喷雾干燥之前可以在亚微米尺寸范围内。
在某些实施方案中，提供了包含多种基本上均匀形成的微晶颗粒的二酮哌嗪组合物，其中所述颗粒具有基本上中空的球形结构并且包括外壳，该外壳包含不自组装的二酮哌嗪的晶粒，并且所述颗粒的体积平均几何直径小于等于5μm；其中所述颗粒通过包括以下步骤的方法形成：将溶液中的二酮哌嗪和乙酸溶液在不存在表面活性剂且不存在活性剂的情况下合并，同时在高剪切混合器中在高达2,000psi的高压下均化以形成沉淀；用去离子水洗涤悬液中的沉淀；浓缩悬液并且在喷雾干燥装置中干燥悬液。
该方法还可包括在喷雾干燥步骤之前，边混合边添加包含活性剂或活性成分(诸如药物或生物活性试剂)的溶液的步骤，以使得活性剂或活性成分被吸附和/或包埋到颗粒上或内。通过该方法制备的颗粒在喷雾干燥之前可以在亚微米尺寸范围内。
在一个实施方案中，组合物可包含含有一种或多种活性成分的微晶颗粒；其中所述活性成分是肽、蛋白质、核酸分子、小有机分子或它们的组合。在其中活性成分是肽、寡肽、多肽或蛋白质的实施方案中，肽、寡肽、多肽或蛋白质可以是内分泌激素、神经递质、血管活性肽、受体肽、受体激动剂或拮抗剂等。在一些实施方案中，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、肽YY、瘦蛋白(leptin)或所述内分泌激素的类似物。在一些实施方案中，赋形剂可通过加入到喷雾干燥步骤中所用的一种、另一种或所有原料中而整合到颗粒中。
在其中组合物包含胰岛素作为活性成分的一个实施方案中，组合物可含有量为高达例如每毫克待递送至患者的粉末9单位或10单位的胰岛素。在该实施方案中，胰岛素可以在使用干粉吸入器的单次吸入中以高达例如100单位的量递送至患者。可以将组合物给药至需要胰岛素以治疗糖尿病和/或高血糖的患者。
在一个示例性实施方案中，结晶二酮哌嗪组合物包含式2,5-二酮-3,6-二(N-X-4-氨基烷基)哌嗪的二酮哌嗪，其中烷基表示含有3至20个碳原子的烷基，包括丙基、丁基、戊基、己基、庚基等；并且式为例如2,5-二酮-3,6-二(N-X-4-氨基丁基)哌嗪，其中X选自富马酰基、琥珀酰基、马来酰基、丙二酰基和戊二酰基或它们的盐。在一个具体实施方案中，二酮哌嗪是具有下式的(二-3,6-(N-富马酰基-4-氨基丁基)-2,5-二酮-二酮哌嗪：
在多种实施方案中，提供了制备适用于肺部给药的包含微晶颗粒的干粉的方法，其中该方法可使用无表面活性剂的溶液或包含表面活性剂的溶液进行。在一个方面，二酮哌嗪包含含量在约45％至65％范围内的反式异构体。
本文所公开的某些实施方案包括由包含游离酸二酮哌嗪的起始物料制备包含结晶二酮哌嗪微粒的干粉的方法。
本文所公开的某些实施方案包括由包含二酮哌嗪盐的起始物料制备包含结晶二酮哌嗪微粒的干粉的方法。
在一个实施方案中，该方法包括：
将二酮哌嗪溶解在氨水中形成第一溶液；
在小于6.0的近似pH下在高压下将第一溶液和包含约10.5％乙酸的第二溶液同时进料于高剪切混合器中；
使第一溶液和第二溶液均化以形成悬液，所述悬液包含在所述悬液中的二酮哌嗪晶粒，其中该悬液具有颗粒尺寸在约0.05μm至约10μm直径范围内的晶粒的双峰分布；
在空气或气体流下雾化悬液；以及
通过喷雾干燥将颗粒再成型为干粉，所述干粉包含具有基本上中空的球体的微晶颗粒。
在另一个实施方案中，该方法包括：
将二酮哌嗪溶解在氢氧化钠水溶液和任选的表面活性剂中以形成第一溶液；
在小于6.0的近似pH下在高压下将第一溶液和包含约10.5％乙酸的第二溶液以及任选的表面活性剂同时进料于高剪切混合器中；
使第一溶液和第二溶液均化以形成悬液，所述悬液包含在所述悬液中的二酮哌嗪晶粒，其中该悬液具有颗粒尺寸在约0.05μm至约10μm直径范围内的晶粒的双峰分布，并且包含含量在约45％至65％范围内的反式异构体；
在空气或气体流下雾化悬液；以及
通过喷雾干燥将颗粒再成型为干粉，所述干粉包含具有基本上中空的球体的微晶颗粒。
在一个实施方案中，该方法包括：
将二酮哌嗪溶解在氨水中形成第一溶液；
在小于6.0的近似pH下在高压下将第一溶液和包含约10.5％乙酸的第二溶液同时进料于高剪切混合器中以形成悬液，所述悬液包含在所述悬液中的二酮哌嗪晶粒，其中该悬液具有颗粒尺寸在约0.05μm至约10μm直径范围内的晶粒的双峰分布；
在空气或气体流下雾化悬液；以及
通过喷雾干燥将颗粒再成型为干粉，所述干粉包含具有基本上中空的球体的微晶颗粒。
该方法还可包括在雾化悬液之前，向二酮哌嗪晶粒悬液加入第三溶液的步骤；其中该溶液含有药物或药学活性成分，并且可以在空气或气体(包括氮气)下使用进入配有高效率旋风分离器的喷雾干燥器中的外部混合双流体喷嘴来进行雾化步骤。
在某些实施方案中，通过激光衍射测定，悬液中的颗粒具有作为双峰曲线的粒径分布；其中颗粒的第一峰的平均粒径为约0.2μm至约0.4μm，并且颗粒的第二峰的平均尺寸为约2.1μm至约2.4μm直径。
在一些实施方案中，雾化悬液的步骤使用约700升氮气/小时的氮气流作为处理气体，并且喷嘴温度可保持在约25℃。
通过上述方法形成的微晶颗粒悬浮于溶液(诸如水或其它水基溶剂)中时不自组装。在一个具体实施方案中，该方法包括式2,5-二酮-3,6-二(N-X-4-氨基丁基)哌嗪的二酮哌嗪，其中X选自富马酰基、琥珀酰基、马来酰基、丙二酰基和戊二酰基。在一个具体实施方案中，该方法包括在高剪切混合器中均化二酮哌嗪的溶液，其中二酮哌嗪是(二-3,6-(N-富马酰基-4-氨基丁基)-2,5-二酮-二酮哌嗪或其盐，包括二钠盐、二钾盐、镁盐、钙盐和二锂盐。
在一个实施方案中，包含尺寸基本上均匀的多种微晶颗粒的结晶二酮哌嗪组合物作为喷雾干燥步骤的产物被获得。
在一个实施方案中，包含具有双峰尺寸分布的多种微晶颗粒的结晶二酮哌嗪组合物作为晶粒形成步骤的产物被获得。
当使用分裂(disruption)步骤时，双峰分布的较大物质可偏移到较小尺寸。
某些实施方案包括形成二酮哌嗪酸的微晶颗粒用于制备运载较大药物含量的干粉的方法，其包括使用二酮哌嗪盐作为起始化合物，包括2,5-二酮-3,6-二(N-富马酰基-4-氨基丁基)哌嗪二钠盐，该方法包括：
将二酮哌嗪盐溶解在包含量为约0.2％至约6％(w/w)的表面活性剂的水中以形成第一溶液；
将第一溶液与包含约8％至约12％(w/w)乙酸的第二溶液在高剪切混合器中在小于6.0的近似pH下在高压下同时合并；
均化第一溶液和第二溶液以形成悬液，所述悬液包含所述悬液中的二酮哌嗪晶粒，其中该悬液具有颗粒尺寸在约0.05μm至约10μm直径范围内的晶粒双峰分布；
在空气或气体流下雾化悬液；以及
通过喷雾干燥将颗粒再成型为干粉，所述干粉包含具有基本上中空的球体的二酮哌嗪酸的微晶颗粒。
在一个具体实施方案中，微晶颗粒可通过包括以下的方法制备：制备包含水中的二酮哌嗪(例如2,5-二酮-3,6-(N-富马酰基-4-氨基丁基)哌嗪二钠盐)和表面活性剂(诸如聚山梨醇酯80)的第一溶液；制备包含浓度为约10.5％(w/w)的乙酸和浓度为约0.5％(w/w)的表面活性剂的第二溶液；将第一溶液和第二溶液在高剪切混合器中混合以形成悬液；任选地测试悬液以测定粒径分布，以使得悬液包含双峰粒径分布，其中颗粒的尺寸在约0.2μm至约10μm直径范围内，其中颗粒的第一峰的平均直径为约0.4μm并且颗粒的第二峰的平均直径为约2.4μm，以及喷雾干燥悬液以获得干粉。
某些实施方案可包括分裂步骤，以减小双峰分布中的较大尺寸群体的尺寸，例如利用超声、搅拌或均化。在一些实施方案中，可以在雾化悬液之前进行分裂步骤。
在本文的一些实施方案中，用于制备微晶二酮哌嗪颗粒的方法还可包括使用去离子水的洗涤步骤。在一个实施方案中，可以例如使用进入配有高效率旋风分离器的喷雾干燥器中的外部混合双流体喷嘴来进行雾化步骤。
该方法还可包括在分散和/或喷雾干燥之前向悬液加入包含一种或多种活性剂的溶液的步骤，其中活性剂是肽、寡肽、多肽、蛋白质、核酸分子或小有机分子。肽可以是内分泌激素，包括胰岛素、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、肽YY、瘦蛋白或所述内分泌激素的类似物等。该方法可任选地包括添加包含表面活性剂和/或药学上可接受的载体包括氨基酸(诸如亮氨酸、异亮氨酸)和/或单糖、二糖或寡糖(诸如乳糖、海藻糖等)、或糖醇(包括甘露糖醇、山梨糖醇等)的溶液的步骤。
在另一个实施方案中，可以使用本发明方法制备包含多于一种活性剂的组合物。制备此类组合物的方法包括以下步骤：制备包含多于一种活性剂的微晶二酮哌嗪颗粒，其中将每种活性剂/成分单独地在溶液中处理并加入单独的二酮哌嗪颗粒悬液，并且改变溶液条件以促进活性剂吸附到晶粒表面上，然后将两种或更多种包含活性剂的单独的悬液共混，然后分散和喷雾干燥颗粒。在一个不同的工序中，共混物包含含有二酮哌嗪颗粒但没有活性剂的悬液，例如，以便实现更低的活性剂总含量。在一个替代性实施方案中，可以在分散和喷雾干燥颗粒之前，将一种或多种含有单一活性剂的独立的溶液与包含二酮哌嗪颗粒的单一悬液合并。所得的干粉包含含有两种或更多种活性成分的组合物。在这些实施方案中，可根据待治疗的患者群体的需要控制组合物中每种成分的量。
在另一个实施方案中，干粉包含含有2,5-二酮-3,6-二(N-X-4-氨基丁基)哌嗪的组合物，其中X是富马酰基，并且组合物包含基本上均匀的含药物的微晶颗粒；其中颗粒的形状为具有基本上中空核心的基本上的球体并且晶粒形成球体的外壳。在另一个实施方案中，干粉包含式2,5-二酮-3,6-二(N-X-4-氨基丁基)哌嗪的二酮哌嗪和药物，其中药物是肽，其中肽可具有多种肽长度、分子尺寸或质量，包括：胰岛素、胰高血糖素样肽-1、胰高血糖素、毒晰外泌肽、甲状旁腺激素、降钙素、胃泌酸调节素等。
另一些实施方案包括药物递送系统，其包括具有或不具有药筒的吸入器，其中药筒是单位剂量干粉药剂容器(例如药筒)，以及包含本文所公开的颗粒和活性剂的粉末。在一个实施方案中，与干粉一起使用的递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，能够对经过管道的气流赋予高阻力以使粉末解聚和分散。在一个实施方案中，吸入系统的阻力值为例如每分钟约0.065至约0.200(√kPa)/升。在某些实施方案中，干粉可以通过用吸入系统的吸入有效地递送，其中峰值吸入压差可以在约2至约20kPa的范围内，其可以产生的所得峰值流速在约7和70升/分钟之间。在某些实施方案中，吸入系统被配置为通过使粉末作为递送给患者的粉末的连续流或者一个或更多个脉冲从吸入器排出而提供单剂量。在本文所公开的一些实施方案中，干粉吸入器系统包括吸入器内的预定质量流平衡，其中吸入器管道被设计为在吸入期间具有不同的流分布。例如，占离开吸入器并进入患者的总流量约10％至70％的流平衡是通过一个或多个分配端递送的，其中气流通过空气管道，该管道被设计为具有包含粉末制剂的区域，并且其中约30％至90％的气流是在吸入操纵期间从吸入器的其它管道产生的。此外，旁流或未进入并离开粉末容器区域(例如通过药筒)的流可以与离开吸入器内粉末分配端的流重新组合，从而使流化粉末在离开口器之前被稀释、加速并最终解聚。在一个实施方案中，约7至70升/分钟范围内的流速导致1和50mg之间的填充质量中超过75％的容器或药筒内容物中被分配。在某些实施方案中，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％的可吸入级分/填充量的粉末剂量。
在某些实施方案中，包括吸入器的药物递送系统可包括这样的吸入器，该吸入器特别适合与包含干粉的颗粒形态(例如结晶或无定形形态)一起使用。
在一些具体实施方案中，所提供的吸入系统包括干粉吸入器、包含FDKP反式异构体含量为45％和65％之间的富马酰基二酮哌嗪微晶颗粒和一种或多于一种活性剂的干粉制剂。在吸入系统的这个实施方案的一些方面，该干粉制剂提供在单位剂量药筒中。或者，该干粉制剂可以预装填在吸入器中。在该实施方案中，吸入系统的结构配置允许吸入器的解聚机制产生高于50％的可吸入级分；也就是说，多于一半的包含在吸入器(药筒)中的粉末作为小于5.8μm的颗粒射出。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。在某些实施方案中，吸入器可以排出单吸入所含的高于85％的粉末药物。在一个实施方案中，吸入器可以在2kPa和5kPa之间的压差下以高达30mg的填充质量在小于3秒的时间内排出高于90％的药筒内容物或容器内容物。
本文所公开的实施方案还包括方法。在一个实施方案中，治疗内分泌相关的疾病或病症的方法包括：将包含FDKP微晶颗粒(包含反式异构体含量可为约45％至约65％的FDKP)和适用于治疗所述疾病或病症的药物的干粉制剂给药至需要其的人，其中微粒通过本发明方法制备。一个实施方案包括治疗胰岛素相关的病症的方法，其包括：将包含上述FDKP微晶颗粒的干粉给药至需要其的人。该方法包括：将含有反式异构体含量在约45％至65％范围内的富马酰基二酮哌嗪微晶颗粒的干粉制剂给药至受试者，其中颗粒是中空球体并且不含有任何表面活性剂。在多种实施方案中，胰岛素相关的病症可以特别地包括或排除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、分泌功能障碍、受损的胰岛素早期释放、胰腺β-细胞功能损失、胰腺β-细胞损失和代谢病症。在一个实施方案中，干粉包含胰岛素。在另一些实施方案中，干粉包含胃泌酸调节素、肽YY、瘦蛋白、催产素、胰高血糖素、毒晰外泌肽、其GLP-1类似物或它们的组合。
本文所公开的另一个实施方案包括将肽(包括GLP-1、胃泌酸调节素、肽YY、催产素、胰岛素)递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，将包含本文所公开的二酮哌嗪微晶颗粒的干粉给药至肺深部。在该实施方案的一些方面中，吸入器系统的具体特征是指定的。
附图说明
以下附图形成本说明书的一部分，并被包括以进一步说明本发明所公开的实例的某些方面。通过结合本文展示的具体实施方案的详细描述并参考一个或多个这些附图，可以更好地理解本公开内容。
图1A和1B是包含胰岛素的富马酰基二酮哌嗪颗粒并显示冻干颗粒在低放大率(1A)和高放大率(1B)下的固体组合物的扫描电子显微照片(SEM)。
图2描绘了通过概率密度函数(pdf，左y-轴)和累积分布函数(cdf，右y-轴)尺度测定的图1A和1B中描绘的颗粒的粒径分布的图示。
图3描绘了从由悬液制备的一个实施方案获得的颗粒的粒径分布的图示，在所述悬液中，微晶颗粒在任何所用溶液中不含表面活性剂的情况下形成。该图示出了通过概率密度函数(pdf，左y-轴)和累积分布函数(cdf，右y-轴)尺度测定的微晶颗粒的典型双峰分布。
图4描绘了从本文一个实施方案回收的FDKP颗粒在低放大率(2500X)下的SEM，在所述实施方案中将无表面活性剂的颗粒悬液冻干。
图5描绘了在无表面活性剂的情况下形成的如图4中描绘的悬液中的冻干粒径分布的图示，并且示出了通过概率密度函数(pdf，左y-轴)尺度和累积分布函数(cdf，右y-轴)尺度测定的粒径的增加。
图6描绘了要求保护的一个实施方案的SEM(2500X)，示出了由喷雾干燥的无表面活性剂的溶液制成的微晶颗粒。
图7描绘了分散于水中的喷雾干燥的无表面活性剂的颗粒的粒径分布的图示。
图8描绘了分散于0.01M HCl(pH 2)中的喷雾干燥的无表面活性剂的颗粒的粒径分布的图示。
图9描绘了通过在存在表面活性剂的情况下用乙酸使Na2FDKP结晶形成的悬液的双峰粒径分布的图示。
图10A和10B描绘了通过将由Na2FDKP制成的晶体悬液喷雾干燥而制备的颗粒在2,500X(10A)和10,000X(10B)放大率下的两张扫描电子显微照片。
图11A和11B描绘了具有约10重量％胰岛素的喷雾干燥的无表面活性剂的FDKP颗粒在2,500X(11A)和5,000X(11B)放大率下的扫描电子显微照片。
图12A和12B是通过将由Na2DKP制成的晶体悬液喷雾干燥而制备的颗粒在2,500X(12A)和10,000X(12B)放大率下的两张扫描电子显微照片。
图13描绘了通过将由Na2FDKP和聚山梨醇酯80的溶液结晶形成的FDKP悬液喷雾干燥而形成的颗粒的尺寸分布的图示。颗粒被分散于水中以供测定。
图14描绘了喷雾干燥的组合粉末和具有单独的活性剂的晶粒悬液的粒径分布的图示。第1代表包含两种不同活性剂的组合微晶粉末组合物的粒径分布；在单独的二酮哌嗪-活性剂颗粒悬液中，其中一种组合物含有FDKP-GLP-1颗粒并且另一种含有FDKP-胰岛素(3)的悬液，其在被喷雾干燥之前被组合。
发明详述
如所述，将药物递送至肺部提供了很多优势。但是由于传送药物经过天然的物理屏障的问题，所以难以将药物以均一体积和重量递送至肺部。本文公开了结晶二酮哌嗪组合物、干粉和制备颗粒的方法。结晶组合物和来自其的干粉包含二酮哌嗪微晶颗粒，该颗粒为基本上均匀限定的球体，该球体包括含有二酮哌嗪晶粒的外壳和核心。在某些实施方案中，核心可以是中空的。在一个实施方案中，二酮哌嗪具有确定的反式异构体含量，这可有利于作为药物递送剂的颗粒、颗粒的制备方法和使用颗粒治疗的方法。与标准现有技术颗粒相比，本文所公开的颗粒具有以更小剂量运载并递送药物含量至患者的更高的能力。
如本发明所用，“类似物”包括与另一种化合物具有结构相似性的化合物。因此，与另一种(母体化合物)具有结构相似性的模拟母体化合物的生物或化学活性的化合物是类似物。只要类似物能够以一些相关方式相同地、互补地或竞争地模拟母体化合物的生物或化学性质，不存在使化合物被确定为类似物所需要的元素或官能团取代的最小或最大数量。在一些情况下，类似物包含独立或连接到另一个分子的母体化合物的片段并且还可以含有其它变型。本文所公开的化合物的类似物可以具有与其母体化合物相等、更小或更大的活性。
如本发明所用，术语“微粒”是指直径为约0.5至约1000μm的颗粒，不考虑确切的外部或内部结构。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。直径必须小于约10微米以便通过喉咙的转角，而直径必须为约0.5微米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“可吸入级分”(RF)中所含的颗粒比例最大化，其公认的是使用标准技术(例如用安得森多级撞击取样器(Anderson Cascade Impactor))测定的空气动力学直径为约0.5至约5.7微米的那些颗粒，尽管一些参考文献使用稍微不同的范围。其它冲击器也可以用于测定空气动力学粒径，诸如NEXT GENERATION IMPACTORTM(NGITM,MSP Corporation)，其中可吸入级分是通过相似空气动力学尺寸(例如<6.4μm)定义的。在一些实施方案中，使用激光衍射装置来测定粒径，例如2010年3月18日提交的美国专利申请序列号12/727,179中公开的激光衍射装置，其相关教导全部并入本文，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，在多种实施方案中，≥80％、85％或90％的药筒排空和≤12.5μm、≤7.0μm、≤5.8μm或≤4.8μm的射出颗粒的VMGD可以表现出越来越好的空气动力学性能。本文所公开的实施方案显示，反式异构体含量为约45％至约65％之间的FDKP颗粒表现出有利于将药物递送至肺部的特性，诸如提高的空气动力学性能。
基于填充量的可吸入级分(RF/填充量)表示在用作剂量的填充粉末含量排出之后从吸入器射出的适于吸入的粉末剂量百分比，即从填充剂量中射出并且尺寸适于肺部递送的颗粒百分比，其为颗粒空气动力学性能的量度。如本发明所述，40％或大于40％的RF/填充量值反映出可接受的空气动力学特性。在本文所公开的某些实施方案中，基于填充量的可吸入级分可以大于50％。在一个示例性实施方案中，基于填充量的可吸入级分可以高达约80％，其中使用标准技术测定，约80％的填充量以颗粒尺寸<5.8μm射出。
如本发明所用，术语“干粉”是指不悬浮或溶解在推进剂、载体或其它液体中的精细颗粒组合物。这并不必然意味着所有水分子完全不存在。
具体RF/填充量值可以取决于用于递送粉末的吸入器。粉末通常易于团聚并且某些结晶DKP颗粒形成特别粘性的粉末。干粉吸入器的一个功能是使粉末解聚以使得所得的颗粒包含适于通过吸入递送剂量的可吸入级分。然而，粘性粉末的解聚通常不彻底，所以当测定通过吸入器递送的可吸入级分时，所看到的粒径分布与原始颗粒的粒径分布不匹配，也就是说，曲线向较大的颗粒偏移。吸入器的设计在其解聚效率方面不同，因此使用不同设计观察到的RF/填充量的实际值也将不同。然而，在吸入器之间作为异构体含量的函数的最佳RF/填充量是相同的。
如本发明所用，术语“约”用于表示值包括确定该值所用设备或方法的测定标准偏差。
如本发明所用，术语“无表面活性剂”用于表示制备微晶颗粒的方法中所用的任何试剂(包括溶液和/或悬液)中不存在表面活性剂。
如本发明所用，术语“晶粒”用于指二酮哌嗪颗粒的完整晶体单元，其可具有不同的尺寸。
如本发明所用，“微晶颗粒”包含通过激光衍射测定，具有0.05μm至约100μm的粒径分布，颗粒尺寸小于50μm、小于20μm、或小于10μm直径的二酮哌嗪晶粒。在一个实施方案中，晶粒的尺寸可以在0.01至1μm范围内。
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。2,5-二酮哌嗪是由如下所示通式1的化合物表示，其中E1和E2独立地为N或更具体地为NH。在另一些实施方案中，E1和/或E2独立地为氧或氮，以使得E1和E2的取代基中的任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六环(diketodioxane)。
已经表明这些2,5-二酮哌嗪可用于药物递送，特别是那些带有酸性R1和R2基团的，如以下所述：例如标题为“Self Assembling Diketopiperazine Drug Delivery System”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以及标题为“Carbon-Substituted Diketopiperazine Delivery System”的美国专利No.6,331,318，上述各通过全文引用，将其关于二酮哌嗪和二酮哌嗪介导的药物递送的所有教导并入本文中。二酮哌嗪可以形成整合药物的微粒或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。这些微粒可以通过多种给药途径来给药。作为干粉，微粒可以通过吸入递送到呼吸系统的特定区域，包括肺部。
此类现有技术微粒通常是通过以下获得：游离酸(或碱)的基于pH的沉淀产生由聚集的结晶板构成的具有玫瑰形态的自组装微粒。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(诸如聚山梨醇酯-80)来增强(参见例如标题为“Method ofdrug formulation based on increasing the affinity of crystallinemicroparticle surfaces for active agents”的美国专利No.7,799,344，其通过全文引用，将其关于DKP微粒的形成和加载及其干粉的所有教导并入本文中)。最后可以除去溶剂得到干粉。除去溶剂的方法包括冻干和喷雾干燥(参见例如标题为“A method forimproving the pharmaceutic properties of microparticles comprisingdiketopiperazine and an active agent”的美国专利No.8,039,431和标题为“Purification and stabilization 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干粉的所有教导并入本文中)。本文所公开的颗粒不同于现有技术颗粒之处在于它们是物理和形态上均不同的实体并且通过改进的方法制得。本文提及的FDKP应理解为游离酸或溶解的阴离子。
其它现有技术颗粒通过喷雾干燥DKP溶液而获得，从而获得无定形DKP盐颗粒，它们通常具有塌缩球体形态，诸如标题为“Diketopiperazine salts for drug deliveryand related methods”的美国专利No.7,820,676和8,278,308中所公开的那些。
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)中描述，它们的教导全部以引用方式并入本文。2,5-二酮-3,6-二(氨基丁基)哌嗪(Katchalski等称之为赖氨酸酐)还可以通过N-ε-P-L-赖氨酸在熔融苯酚中的环化二聚(这与Kopple方法类似)，随后通过适当的试剂和条件除去封闭性的(P)-基团来制备。例如，使用4.3M HBr的乙酸溶液可以除去CBz保护基。这种途径使用可商购获得的起始物料，其涉及据报道保持起始物料在产物中的立体化学的反应条件并且所有步骤都可以很容易地扩大规模用于生产。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以引用方式并入本文中。
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)是用于肺部应用的一种优选的二酮哌嗪：
FDKP提供了有利的微粒基质，因为它在酸中的溶解度低但是在中性或碱性pH中易于溶解。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。如所述，直径在约0.5和约10μm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。
FDKP在二酮哌嗪环上有两个不对称中心。所制备的FDKP是几何异构体的混合物，根据侧链相对于二酮哌嗪中心“环”的排列，其被记为“顺式-FDKP”和“反式-FDKP”。R,R和S,S对映异构体具有从二酮哌嗪环(下面的A和B)的相同平面侧伸出的丙烯基(酰胺基丁基)“侧臂”，因此被称为顺式异构体；而R,S化合物具有从二酮哌嗪环(下面的C)的相反平面侧伸出的“侧臂”，因此被称为反式异构体。
已经用反式异构体含量在约45至约65％范围内的FDKP制备出具有可接受的空气动力学性能的FDKP微粒粉末，其通过中等效率的吸入器(诸如标题为“Unit DoseCartridge 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以引用方式并入本文)用RF/填充量来测试。异构体含量在该范围内的颗粒在高效吸入器(诸如在2009年6月12日提交的标题为“A Dry Powder Inhalerand System for Drug Delivery”的美国专利No 8,499,757、2009年6月12日提交的标题为“Dry Powder Inhaler and System for Drug Delivery”的美国专利No8,424,518、2013年7月12日提交的标题为“Dry Powder Drug Delivery System and Methods”的美国专利申请No.13/941,365以及2010年3月4日提交的标题为“Improved Dry Powder Drug DeliverySystem”的美国专利申请No.12/717,884中所公开的那些，这些公开内容就相同方面的教导以引用方式并入本文中)中的表现也很好。包含含有高于65％反式FDKP的微粒的粉末趋于具有较低且较多变的RF/填充量。富含反式异构体的FDKP微粒具有改变的形态而且会导致难以处理的粘稠的悬液。
反式异构体含量为约45％至约65％的FDKP微粒的制剂提供了具有可接受的空气动力学性能的粉末，如美国专利No.8,227,409中所公开的，其公开内容就相同方面的教导以引用方式并入本文中。确定的比表面积小于67m2/g的FDKP颗粒的制剂也提供了具有可接受的空气动力学性能的用于吸入的干粉，如2010年6月11日提交的标题为“Diketopiperazine Microparticles with Defined Specific Surface Areas”的美国专利No.8,551,528中所公开的，其公开内容就相同方面的教导以引用方式并入本文中。但是这些FDKP粉末倾向于是粘性的，并且吸入器被设计为克服这种特性。
因此需要制备具有粘性更小的颗粒组合物的二酮哌嗪粉末，这将允许更有效的药物递送和更少的吸入器回避设计(design around)。本公开确定，如通过FDKP和FDKP二钠盐示例的制备二酮哌嗪微晶颗粒的本发明方法提供了具有可接受的空气动力学性能的微晶干粉，其中粉末的粘性更低，密度不同，具有在悬液中不自组装的替代物理结构，并且提供了增加的药物内容物容量，包括递送一种或多种活性剂，这是未预料到的。
已确定，通过制备二酮哌嗪微粒的不同方法，能够提高颗粒均匀性的一致性。制备组合物的本发明方法以及包含本发明微晶二酮哌嗪颗粒的组合物提供了具有有利的物理和形态学空气动力学性能的用于肺部吸入的干粉。
活性剂的选择和整合
在包含FDKP的示例性实施方案中，至少只要本文所述的微晶颗粒保持上述异构体含量，它们便可以采用有利于递送至肺部和/或药物吸收的其它附加特性。标题为“Methodfor Drug Delivery to the Pulmonary System”的美国专利No.6,428,771描述了将DKP颗粒递送至肺部，其就相同方面的教导以引用方式并入本文中。标题为“Purification andStabilization of Peptide and 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以引用方式并入本文中。可以操作微粒表面性能来实现如标题为“Method of Drug Formulationbased on Increasing the Affinity of Crystalline Microparticle Surfaces forActive Agents”的美国专利No.7,799,344(其就相同方面的教导以引用方式并入本文中)中所述的期望特性。标题为“Method of Drug Formation based on Increasing theAffinity of Active Agents for Crystalline Microparticle Surfaces”的美国专利No.7,803,404描述了促进活性剂吸附到微粒上的方法。美国专利No.7,803,404也就相同方面的教导以引用方式并入本文中。这些教导可应用于活性剂到悬液中晶粒的吸附，例如，在喷雾干燥之前。
本文所述的微晶颗粒可以包含一种或多种活性剂。如本文所用，可与“药物”互换使用的“活性剂”是指医药物质，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、多糖和其它糖、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它多肽融合的单链抗体、或对抗癌抗原的治疗性或诊断性单克隆抗体。活性剂可以属于多种生物活性和种类，诸如血管活性剂、神经活性剂(包括阿片类激动剂和拮抗剂)、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、感染性物质、炎症介质、激素、细胞表面受体激动剂和拮抗剂以及细胞表面抗原。更特别地，活性剂可以以非限制性方式包括细胞因子、脂质因子(lipokine)、脑啡肽、炔烃、环孢菌素、抗-IL-8抗体、包括ABX-IL-8的IL-8拮抗剂；包括PG-12的前列腺素，包含LY29311、BIIL 284和CP105696的LTB受体阻滞剂；诸如舒马曲坦的曲坦类和棕榈油酸酯、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)、生长素释放肽、肥胖抑制素、肠抑素、粒细胞巨噬细胞集落刺激因子(GM-CSF)、糊精、糊精类似物、胰高血糖素样肽1(GLP-1)、氯吡格雷、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、胆囊收缩素(CCK)、分泌素、促胃液素、胰高血糖素、胃动素、生长激素抑制素、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(ΙΤΒ4)受体拮抗剂、镇痛剂、痛敏肽、痛稳素、孤啡肽FQ2、降钙素、CGRP、血管紧张素、P物质、神经激肽A、胰多肽、神经肽Y、δ-促睡眠肽和血管活性肠肽；以及所述活性剂的类似物。
在由FDKP或FDKP二钠盐形成的微晶颗粒上递送的药物含量通常可高于0.01％(w/w)。在一个实施方案中，要用微晶颗粒递送的药物含量可为约0.01％(w/w)至约75％(w/w)、约1％至约50％(w/w)、约10％(w/w)至约30％(w/w)、或约10％至约20％(w/w)。在一个实施方案中，例如，如果药物是胰岛素，本发明的微粒通常包含约10％至45％(w/w)或约10％至约20％(w/w)的胰岛素。在某些实施方案中，颗粒的药物含量可以根据待递送的药物形式和尺寸而变化。在其中使用GLP-1作为活性剂的一个实施方案中，GLP-1含量可高达粉末含量的40％(w/w)。
在一个实施方案中，包含多于一种活性剂的组合物可使用本发明方法通过吸附来制备，例如通过在形成干粉之前将活性剂结合到晶粒。
在一个实施方案中，包含多于一种活性剂的组合物可使用本发明方法通过将活性剂包埋在晶粒之间和之中来制备，例如在不用首先使活性剂吸附到晶粒的情况下，通过喷雾干燥材料来制备。
制备此类组合物的方法可包括以下步骤：制备包含多于一种活性剂的微晶二酮哌嗪颗粒；其中将每种活性剂/成分单独地在溶液中处理并加入单独的二酮哌嗪颗粒悬液，然后将两种或更多种单独的包含活性剂的悬液共混，然后分散和喷雾干燥颗粒。
在某些实施方案中，晶粒可与包含一种或多种活性剂的溶液混合。
在某些实施方案中，晶粒可与包含一种或多种活性剂的溶液混合，其中改变溶液条件以促进活性剂吸附到晶粒表面上。
多种活性剂的每一种可吸附到单独的等分试样或晶粒物质。然后可以将等分试样吸附的晶粒混合在一起并喷雾干燥。或者，等分试样可不含活性剂，以便在不改变用于使活性剂吸附到晶粒上的条件的情况下，调整干粉中的活性剂总含量。
在一个替代性实施方案中，可以在分散和喷雾干燥以再成型颗粒之前将一种或多种含有单一活性剂的独立溶液与包含二酮哌嗪颗粒的悬液组合。所得的干粉组合物包含两种或更多种活性成分。在该实施方案中，可根据待治疗的患者群体的需要控制组合物中每种成分的量。
从上述公开内容显而易见的是，本发明所公开的实施方案的微粒可具有多种不同形式并且可以整合多种不同的药物或活性剂。
实施例
包括以下实施例以证实所公开的微晶二酮哌嗪颗粒的实施方案。本领域的技术人员应当理解，以下实施例中公开的技术代表发明人在实践本公开时开发的能够很好地发挥作用的技术，并因此可视为构成其实践的优选模式。然而，根据本公开，本领域的普通技术人员应当理解，在不脱离本发明的范围下，可以对具体实施方案进行许多改变，仍可获得相同或类似的结果。
实施例1
制备标准FDKP微粒-出于比较目的，使用现有技术制备方法如美国专利No.7,799,344、7,803,404和8,227,409中所公开的制备FDKP微粒作为标准颗粒，所述专利的公开内容就其相关主题的教导以引用方式并入本文中。概括地说，典型的FDKP颗粒形成方法：将各自含有0.05％(w/w)聚山梨醇酯80(PS80)的FDKP和乙酸的进料溶液在高剪切混合器中合并。下表1显示了FDKP和胰岛素原液的组分。
表1.-通过0.2μm膜过滤的10.5％乙酸溶液
组分 重量％
去离子水 89.00
GAA 10.50
10％聚山梨醇酯80 0.50
表2.-通过0.2μm膜过滤的2.5％FDKP溶液
组分 重量％
去离子水 95.40
FDKP 2.50
NH4OH 1.60
10％聚山梨醇酯80 0.50
可以用1份胰岛素和9份约2重量％的乙酸制备浓缩的胰岛素原液。可以将胰岛素原液重量分析地加入悬液中获得约11.4重量％的负载。可以将含胰岛素的悬液混合至少约15分钟，然后用约14至约15重量％的氨水从约3.5的初始pH滴定至约4.5的pH。可以使用低温造粒机使悬液在液氮中速冻以形成颗粒，例如，如美国专利No.8,590,320中所公开的，其公开内容全文以引用方式并入本文，并且冻干产生散的载有胰岛素的FDKP微粒，其形成自组装成具有如图1A和1B中所见的开放结构的FDKP颗粒的小晶体或集落。
对所形成的颗粒样品进行研究以测定这些悬液中颗粒的尺寸分布，结果示于图2中。图2中的数据显示了粒径分布测量值的图示，其以作为概率密度函数(pdf，左y-轴)和累积分布函数(cdf，右y-轴)的对数刻度描绘。数据显示，悬液中颗粒具有在约1.0至约10μm直径范围内并且集中于2μm或约2μm的单峰尺寸分布。
制备微晶FDKP颗粒–将2.5％(w/w)FDKP溶解在碱性氨水溶液(1.6％氨)中。在2.0的近似pH下在高压下将10.5％(w/w)乙酸原液加入高剪切混合器(Sonolator)以制备颗粒。将形成的颗粒在去离子水中洗涤。据发现，在溶液中不存在表面活性剂的情况下，二酮哌嗪微粒不稳定，然而，在制备颗粒中未向任何溶液或试剂加入表面活性剂。
在这些实验中，使用双重进料高剪切混合器，在约16℃±约2℃的温度和2000psi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0.001平方英寸喷嘴进料，从而通过均化形成沉淀。在质量和温度大约相等的去离子(DI)水贮池中收集沉淀。将沉淀浓缩并用去离子水通过切向流过滤洗涤。悬液可最终浓缩至固体约小于5％，例如，基于FDKP的初始质量计约2至3.5％。通过烘干法可以测定被浓缩的悬液的固体含量。就含有活性成分(即胰岛素和/或GLP-1)的样品而言，使用上述FDKP悬液，其中向该悬液加入胰岛素原液(将溶解在2％乙酸中的胰岛素加入悬液同时混合，然后用氢氧化铵将悬液pH滴定至pH4.5±0.3。相似地，在搅拌下将溶解在2％乙酸原液中的GLP-1重量分析地加入FDKP-悬液。将GLP-1FDKP悬液滴定至pH 4.5±0.1。使用外部混合双流体喷嘴将胰岛素-FDKP悬液和GLP-1-FDKP悬液的每一种独立地分散到配有高效率旋风器的Niro SD-MicroTM喷雾干燥器中。使用氮作为处理气体(25kg/h)和雾化流体(2.8kg/hr)。在喷雾干燥器中使用表3中所列的两种处理条件处理样品。
表3.
就对照样品而言，以相同方式(除开胰岛素或GLP-1装填步骤)制备空白的FDKP微晶颗粒。
图3显示了来自上述实验的数据，其中进料溶液不含表面活性剂。图3是示出FDKP颗粒悬液的粒径分布的图，其表现出颗粒的典型双峰粒径分布。本文的颗粒尺寸在约0.1至约10μm直径范围内，其中一个颗粒群体集中于0.2μm直径，并且另一个颗粒群体集中于2.1μm直径。
悬液的样品经冻干而未喷雾干燥。图4是冻干颗粒在2,500x放大率下的SEM。如图4中所见，在冻干类似悬液之后，形成大的薄片状颗粒，并且当在重悬浮于水中时得到大得多的平均尺寸，如图5所示。图5显示了由在不使用表面活性剂的情况下制得的颗粒冷冻干燥的样品的悬液中的粒径分布。在该研究中，再悬浮颗粒的粒径直径从约1增大至约90μm或更大。
图6显示了来自使用本发明方法和如上所述喷雾干燥形成的微晶FDKP颗粒的不含表面活性剂的制剂的粉末样品的扫描电子显微照片的典型的2,500x放大图。如图6中所见，颗粒的结构为包括晶粒外壳的均匀球体。当喷雾干燥不含表面活性剂的悬液时，形成物理直径为约4μm的颗粒，如图6所示。与标准FDKP颗粒不同，这些颗粒在分散于水中时解离成直径为0.2μm的颗粒，如图7所示。因此，已证实表面活性剂在颗粒完整性方面具有作用。将颗粒分散在0.01M盐酸中抑制了颗粒解离，如图8所示。溶解的FDKP可以在喷雾干燥期间沉淀，并且能够沿着初始颗粒之间的边界沉积并且可充当粘固剂(cement)。FDKP“粘固剂”溶解于水中并且颗粒解离成0.2μm初始颗粒；FDKP在酸中的较低溶解度防止解离并且保护颗粒完整性。
实施例2
通过替代性方法使用二酮哌嗪盐制备微晶FDKP颗粒-作为替代地，FDKP晶粒可由含有表面活性剂的进料溶液形成。在不使用氨作为试剂的情况下，通过将FDKP二钠盐(Na2FDKP)溶解在含有聚山梨醇酯80(PS80)作为表面活性剂的水中来制备FDKP的进料溶液。还制备了含有乙酸(10.5％w/w)和PS80(0.5％w/w)的进料溶液。在DUAL FEEDSONOLATOR中混合两种进料溶液使FDKP结晶并且产生图9中示出的双峰粒径分布。如图9所示，约26％的所形成的初级晶体的直径为约0.4μm并且约74％的较大颗粒的直径为约2.4μm。对该悬液进行处理并喷雾干燥以获得颗粒，并且在SEM下观察。在2,500x和10,000x放大率下采集SEM显微照片并示于图10A和10B中。图10A和10B表明颗粒是类似的并且形状为球体，但小于实施例1的图6中所示，其中使用FDKP作为游离酸制备颗粒。下表4显示了针对通过冻干制备的粉末和通过喷雾干燥(SD)使用FDKP二钠盐制备的粉末测定的一些物理特性。
表4
数据显示，相比冻干粉末，由喷雾干燥的颗粒制成的粉末表现出更高的可吸入级分(62.8％对比28％)、更高的药筒排空(％CE，88.2％对比83.8％)以及更高的堆密度(0.159g/mL对比0.019g/mL)和振实密度(0.234g/mL对比0.03g/mL)。
实施例3
制备含有活性剂的微晶FDKP颗粒–通过将活性剂溶液加入不含表面活性剂的FDKP晶粒的悬液来将活性药物成分(活性剂)引入颗粒，然后喷雾干燥混合物以如实施例1中所述除去溶剂。还通过标准自组装方法，使用在溶液中的PS-80制备了对照颗粒(FDKP-胰岛素)用于制备肺部吸入的粉末。在该研究中，将胰岛素溶解在稀乙酸中并加入如实施例1中制备的不含表面活性剂的FDKP晶粒的悬液(样品1和2，表5)。将悬液喷雾干燥以获得含有约10重量％胰岛素的干粉。粉末样品被用于多种分析，包括通过高阻力吸入器递送以及扫描电子显微镜法，并且结果示于表5中。颗粒的尺寸与不含胰岛素的颗粒(实施例1)大致相同并且颗粒形态(图11)与图6所示相同。此外，样品1和2两者均为比标准颗粒紧实度低的粉末，并且样品1颗粒比对照具有更大的比表面积(SSA)。胰岛素的分布是未知的，颗粒表面上没有明显的胰岛素沉积，表明胰岛素在颗粒内部或整合到颗粒壁中。
表5
然而，表5中所示的数据显示，在相同胰岛素含量下，不含表面活性剂的粉末与标准颗粒的表现不同。例如，在相同胰岛素含量下，不含表面活性剂的粉末比标准颗粒(85％)更有效地从吸入器释放(96.4％)。药筒排空百分比(％CE)的增大表明粉末具有增大的流动性。由于用于测试粉末的吸入器是针对对照粉末设计的，因此对于对照颗粒的可吸入级分(基于填充量的RF％)更高。
实施例4
通过替代性方法使用二酮哌嗪盐制备微晶FDKP颗粒–在该研究中，使用FDKP二钠盐制备如实施例2所述的FDKP盐颗粒悬液。将胰岛素溶液加入如实施例2中制备的不含表面活性剂的FDKP微晶的悬液。将悬液喷雾干燥以获得含有约10重量％胰岛素的干粉。所形成颗粒的形态(分别)以2,500x和10,000x放大率示于图12A和12B的SEM中。如图12A和12B中所见，形态与不含胰岛素的颗粒相同，显示出如图13所示的颗粒中值直径为2.6μm的球形结构，还显示直径在约1.0μm至约10μm范围内的颗粒。
实施例5
制备含有多于一种活性剂的微晶FDKP颗粒–在另一个实施方案中，可以使用本发明方法制备包含多于一种活性剂的组合物。制备此类组合物的方法包括如上针对每种单独的活性剂所公开的步骤，以形成待整合到组合物中的活性剂的每一种的活性剂-FDKP悬液。然后，合并悬液并共混形成混合物。然后将共混的混合物分散并如上所述喷雾干燥以制备包含多于一种活性剂的微晶二酮哌嗪颗粒。在一个示例性研究中，制备胰岛素和GLP-1组合粉末。
将如实施例1制备的FDKP晶粒悬液与多种活性剂(例如，生长素释放肽、低分子肝素、胃泌酸调节素)的溶液混合并喷雾干燥，以获得性能类似于实施例3中的颗粒。
实施例6
制备含有两种活性剂的微晶FDKP颗粒-
通过首先制备含有胰岛素的FDKP晶粒悬液和含有GLP-1的晶粒的第二悬液，来制备含有两种活性剂(GLP-1和胰岛素)的组合粉末。然后将两种悬液混合并将合并的悬液喷雾干燥，以获得含有两种活性剂的干粉。按照实施例1中所述制备晶粒悬液；在添加活性剂之后，将悬液调节至pH4.5以促进吸附到晶粒上。图14是示出喷雾干燥的组合粉末(1)和含有单独活性剂、FDKP-胰岛素(2)和FDKP-GLP-1的晶粒悬液的粒径分布的数据图。
如图14所示，组合粉末的粒径分布集中于两种单独的悬液的粒径分布之间并且显著更窄。组合粉末包含直径为约1μm至约10μm的颗粒。含有胰岛素的晶粒比直径在约0.5μm至约50μm范围内的含有GLP-1的晶粒小(约0.25μm至约10μm)。喷雾干燥中的雾化步骤可使悬液中的初始晶粒集落解离，并重新形成具有取决于悬液中的条件和喷雾干燥条件的粒径分布的颗粒。
实施例7
将包含结晶二酮哌嗪颗粒的干粉组合物给药至受试者。
如上文实施例1所述制备包含用FDKP二钠盐(Na2FDKP)制成的微晶二酮哌嗪微粒的干粉制剂，从而使每毫克组合物含有9U胰岛素。包含药筒的高阻力吸入器(Dreamboattm吸入器，MannKind Corporation)被制成施用至被诊断为患有糖尿病的受试者的每剂含有1mg至10mg。含有胰岛素剂量的吸入器被提供给待治疗的患者，患者在饭前、饭中或饭后以单次吸入吸入胰岛素剂量。
除非另外指明，在所有情况下，说明书和权利要求中所使用的所有表示成分数量、性质(如分子量)、反应条件等的数值均应理解成受术语“约”修饰。因此，除非有相反的说明，否则以下说明书和所附权利要求中列出的数值参数均为近似值，其可根据想要通过本发明获得的期望性质而改变。在最低程度上，每个数字参数并不旨在将等同原则的应用限制于权利要求保护的范围，至少应该根据所报告数字的有效数位和通过惯常的四舍五入法来理解每一个数字参数。虽然设定本发明的广泛范围所给出的数字范围和参数为近似值，但具体实例中所示的数值会尽可能准确地报告。然而，任何数值都固有地包含一定的误差，这些误差不可避免地由在其相应的试验测定中存在的标准偏差引起。
除非本发明另有指明，或与上下文明显矛盾，否则在描述本发明的上下文中(特别是在下列权利要求书的上下文中)不使用数量词修饰时应当被理解为既包括单数又包括复数。本发明对值的范围的列举仅仅是为了用作单独提及落在该范围内的每个单独数值的速记方法。除非本发明另外指明，否则每个单独的值均包括在本说明书中，就像在本发明中单独列举一样。本发明所述的全部方法都能以任何合适的顺序进行，除非本发明中另外指明或明显与上下文相矛盾。使用本发明提供的任何和所有实例或示例性语言(例如“诸如”)仅仅是为了"更好地阐明本发明，而不是对受权利要求书保护的本发明的范围进行限制。说明书中的任何语言均不应理解为指示任何未要求保护的要素对于本发明的实施而言是必须的。
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”的定义，但是权利要求中所用术语“或”是指“和/或”。
在本发明所公开的本发明的替换性要素或实施方案的分组不应被理解为限制。每个组成员可以单独地或者以与该组其它成员或本发明中找到的其它要素的任意组合被指代并且要求保护。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。当出现任何此类包括或删除时，在本发明将说明书视为包括如此修改的组，从而满足所附权利要求书中所用的所有马库什组的书面说明。
本发明的优选实施方案在本发明中有所描述，包括发明人已知的实施本发明的最佳模式。当然，在阅读前述说明后，那些优选实施方案的变型形式将对本领域的普通技术人员变得显而易见。发明人预期熟练的技术人员可适当地采用此类变型，并且发明人意欲使得本发明以与本发明具体描述不同的方式实施。因此，本发明包括适用法律允许的所附权利要求列举的主题的所有修改形式和等同形式。此外，本发明涵盖上述要素在其所有可能的变化形式中的任何组合，除非本发明中另外指明，或换句话讲与语境明显矛盾。
本发明所公开的具体实施方案还可限制于的使用由语言组成的或基本上由语言组成的权利要求内。当用于权利要求中时，无论根据修正提交还是添加，过渡术语“由……组成”排除了权利要求中未指明的所有要素、步骤或成分。过渡术语“基本上由……组成”将权利要求的范围限制于指定材料或步骤以及不会显著影响基本和新特性的那些材料或步骤。固有地或明确地描述并且在本发明中实施了受权利要求书保护的本发明的实施方案。
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。上述引用的参考文献和印刷公开物中的每一个分别以引用方式全文并入本发明。
此外，应当理解本发明所公开的本发明实施方案是为了阐述本发明的原理。可采用的其它修改形式在本发明的范围之内。因此，本发明可供选择的模型可根据本发明的内容以举例的方式，但不限于其利用。因此，不会准确地如所示和所述限制本发明。

Claims (24)

1.一种结晶二酮哌嗪组合物，其包含多种微晶颗粒，所述颗粒的尺寸均匀，具有中空的球形结构并且包括外壳，所述外壳包含不自组装的二酮哌嗪的晶粒，其中所述颗粒的体积中值几何直径小于5μm。
2.根据权利要求1所述的结晶二酮哌嗪组合物，其中高达92％的所述微晶颗粒的体积中值几何直径≤5.8μm。
3.根据权利要求1所述的结晶二酮哌嗪组合物，其中所述微晶颗粒还包含一种或更多种活性成分。
4.根据权利要求3所述的结晶二酮哌嗪组合物，其中所述一种或更多种活性成分是肽、蛋白质、核酸分子或小有机分子。
5.根据权利要求4所述的结晶二酮哌嗪组合物，其中所述肽是内分泌激素。
6.根据权利要求5所述的结晶二酮哌嗪组合物，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、肽YY或瘦蛋白。
7.根据权利要求1所述的结晶二酮哌嗪组合物，其中所述二酮哌嗪是式3,6-二(N-X-4-氨基丁基)-2,5-二酮哌嗪的二酮哌嗪，其中X选自富马酰基、琥珀酰基、马来酰基、丙二酰基和戊二酰基或其盐。
8.根据权利要求7所述的结晶二酮哌嗪组合物，其中所述二酮哌嗪是3,6-二(N-富马酰基-4-氨基丁基)-2,5-二酮哌嗪。
9.一种制备适合作为干粉用于肺部给药的微晶二酮哌嗪颗粒的方法，所述颗粒的尺寸均匀，具有中空的球形结构并且包括外壳，所述外壳包含不自组装的二酮哌嗪的晶粒，所述方法包括：
a)形成在0.05μm至10μm范围的粒径中具有双峰分布的悬液中的二酮哌嗪颗粒；
b)使用喷雾干燥器在空气或气体流下雾化所述悬液，以及
c)通过喷雾干燥将颗粒再成型为干粉，所述干粉包含具有中空的球体的微晶二酮哌嗪颗粒。
10.根据权利要求9所述的方法，其中粒径的双峰分布中颗粒的第一峰平均为0.2μm至2.4μm，颗粒的第二峰的平均尺寸为2.1μm至2.4μm。
11.根据权利要求9所述的方法，其中所述二酮哌嗪为式3,6-二(N-X-4-氨基丁基)-2,5-二酮哌嗪的二酮哌嗪，其中X选自富马酰基、琥珀酰基、马来酰基、丙二酰基和戊二酰基。
12.根据权利要求11所述的方法，其中所述二酮哌嗪是3,6-二(N-富马酰基-4-氨基丁基)-2,5-二酮哌嗪。
13.根据权利要求9所述的方法，其还包括将包含一种或更多种活性剂的溶液加入步骤a)所述悬液的步骤。
14.根据权利要求9所述的方法，其还包括将表面活性剂加入所述溶液或悬液的步骤。
15.根据权利要求14所述的方法，其中所述表面活性剂是聚山梨醇酯80。
16.根据权利要求13所述的方法，其中所述一种或更多种活性剂是肽、蛋白质、核酸分子或小有机分子。
17.根据权利要求16所述的方法，其中所述肽是内分泌激素。
18.根据权利要求17所述的方法，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、肽YY或瘦蛋白。
19.根据权利要求9或11所述的方法，其中所述二酮哌嗪是二酮哌嗪的二钠盐、镁盐、锂盐、钙盐或钾盐。
20.一种制备干粉组合物的方法，其包括：
将二酮哌嗪盐溶解在包含量为0.2重量％至6重量％的表面活性剂的水中形成第一溶液；
将所述第一溶液与包含8重量％至12重量％乙酸的第二溶液在高剪切混合器中在小于6.0的近似pH下在高压下同时合并；
使所述第一溶液和第二溶液均化以形成悬液，所述悬液包含在所述悬液中的二酮哌嗪的晶粒，其中所述悬液具有粒径在0.05μm至10μm直径范围内的晶粒的双峰分布；
在空气或气体流下雾化所述悬液；以及
通过喷雾干燥将所述颗粒再成型为干粉，所述干粉包含微晶颗粒，其中所述颗粒的尺寸均匀，具有中空的球形结构并且包括外壳，所述外壳包含不自组装的二酮哌嗪的晶粒。
21.根据权利要求19所述的方法，其中雾化所述悬液包括在氮气下利用进入配有高效率旋风分离器的喷雾干燥器中的外部混合双流体喷嘴。
22.权利要求6所述的结晶二酮哌嗪组合物在制备用于治疗高血糖和/或糖尿病的药物中的用途。
23.一种干粉，其包含权利要求1所述的结晶二酮哌嗪组合物。
24.根据权利要求23所述的干粉，其还包含一种或更多种活性剂，并且其中所述一种或更多种活性剂是肽、蛋白质、核酸分子，或小有机分子。
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