WO2005063741A1 - Process for preparing amorphous (4r-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1,3]-dioxane-4-yl-acetic acid - Google Patents

Process for preparing amorphous (4r-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1,3]-dioxane-4-yl-acetic acid Download PDF

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WO2005063741A1
WO2005063741A1 PCT/SI2004/000045 SI2004000045W WO2005063741A1 WO 2005063741 A1 WO2005063741 A1 WO 2005063741A1 SI 2004000045 W SI2004000045 W SI 2004000045W WO 2005063741 A1 WO2005063741 A1 WO 2005063741A1
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Prior art keywords
pyrrol
dioxane
cis
phenylcarbamoyl
methylethyl
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PCT/SI2004/000045
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French (fr)
Inventor
Ljubomir Antoncic
Gorazd Sorsak
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Lek Pharmaceuticals D.D.
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Priority to SI200432013T priority Critical patent/SI1711489T1/en
Priority to AU2004309313A priority patent/AU2004309313A1/en
Priority to EP04809253A priority patent/EP1711489B1/en
Priority to CN2004800394510A priority patent/CN1902194B/en
Priority to US10/584,638 priority patent/US7943786B2/en
Priority to JP2006546935A priority patent/JP2007517028A/en
Priority to CA002551549A priority patent/CA2551549A1/en
Publication of WO2005063741A1 publication Critical patent/WO2005063741A1/en

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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07D—HETEROCYCLIC COMPOUNDS
    • C07D405/00—Heterocyclic compounds containing both one or more hetero rings having oxygen atoms as the only ring hetero atoms, and one or more rings having nitrogen as the only ring hetero atom
    • C07D405/02—Heterocyclic compounds containing both one or more hetero rings having oxygen atoms as the only ring hetero atoms, and one or more rings having nitrogen as the only ring hetero atom containing two hetero rings
    • C07D405/06—Heterocyclic compounds containing both one or more hetero rings having oxygen atoms as the only ring hetero atoms, and one or more rings having nitrogen as the only ring hetero atom containing two hetero rings linked by a carbon chain containing only aliphatic carbon atoms
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P3/00—Drugs for disorders of the metabolism
    • A61P3/06—Antihyperlipidemics
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07D—HETEROCYCLIC COMPOUNDS
    • C07D207/00—Heterocyclic compounds containing five-membered rings not condensed with other rings, with one nitrogen atom as the only ring hetero atom
    • C07D207/02—Heterocyclic compounds containing five-membered rings not condensed with other rings, with one nitrogen atom as the only ring hetero atom with only hydrogen or carbon atoms directly attached to the ring nitrogen atom
    • C07D207/30—Heterocyclic compounds containing five-membered rings not condensed with other rings, with one nitrogen atom as the only ring hetero atom with only hydrogen or carbon atoms directly attached to the ring nitrogen atom having two double bonds between ring members or between ring members and non-ring members
    • C07D207/34—Heterocyclic compounds containing five-membered rings not condensed with other rings, with one nitrogen atom as the only ring hetero atom with only hydrogen or carbon atoms directly attached to the ring nitrogen atom having two double bonds between ring members or between ring members and non-ring members with hetero atoms or with carbon atoms having three bonds to hetero atoms with at the most one bond to halogen, e.g. ester or nitrile radicals, directly attached to ring carbon atoms

Definitions

  • the present invention relates to a novel process for preparing amorphous (4R- cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)- pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester.
  • This compound is useful as an intermediate in preparing atorvastatin salts.
  • Atorvastatin is known pharmaceutical substance (Merck Index, 12 th edition, 1996, No. 897), and has the chemical name hemi calcium salt (R-(R*,R*))-2-(4- fluorophenyl)- ⁇ , ⁇ -dihydroxy-5-(1-methylethyl)-3-phenyl-4-((phenylamino)carbonyl)- 1 H-pyrrol-1-heptanoic acid.
  • Atorvastatin may exist in free acid form as well as in acid salts form and in hydrates and solvates forms. Atorvastatin is also known as lactone form that may be prepared from free acid form.
  • Solid atorvastatin salts exist in amorphous or crystalline form. Suitable salts of atorvastatin includes alkaline metal salts, earth alkaline metal salts, preferred for pharmaceutical use are earth alkaline salts, such as a calcium salt.
  • EP 330172 discloses the preparation of (4R-cis)-6-[2-[3-phenyl-4- (phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2- dimethyl-[1,3]-dioxane-4-yl-acetic acid - tertiary butyl ester.
  • Compound of the formula I was prepared by the convergent synthesis with a chain of reactions.
  • the important last step includes reaction of (4R-cis)-1 ,1-dimethylethyl 6-(2- aminoethyl)-2,2-dimethyl-1 ,2-dioxane-4-acetate and 4-fluoro- ⁇ -[2-methyl-1- oxopropyl]- ⁇ -oxo-N-, ⁇ -diphenylbenzenebutaneamide (which includes mixture of all possible isomers) in a mixture of solvents that contains heptane and toluene. Reaction was carried out at reflux temperature followed by addition of 2-propanol and cooling. The product should be a yellow solid.
  • the patent does not teach in which polymorphous form is the product and does not define the melting point of the product.
  • example 3 it is disclosed the use of acetonitrile for dissolving crude amorphous substance of the formula I and than heating the obtained mixture at the reflux temperature. Afterwards the mixture is cooled and allowed to stay overnight. The precipitate formed is filtered, washed and dried. The product obtained is in crystal form I.
  • the atorvastatin producing starting compound of the formula I dissolves quickly and completely in aprotic solvents, e.g. tetrahydrofurane, because the first step in the synthesis of atorvastatin salts includes usually dissolving said starting compound in an aprotic solvent.
  • the dissolving process should provide a clear solution as fast as possible and if this is not the case more solvent may be added and more time for stirring should be spent.
  • filtering may be applied to minimize the impurities in the final product. Crystalline products are generally less soluble (or they dissolve slowly due to the large crystals), and are from one aspect more difficult for purification in comparison to amorphous products.
  • the presence of water in the solvent for dissolving a compound of the formula I to prepare atorvastatin may result in a loss of starting compound because the portion of it that does not dissolve in the reaction mixture cannot react with reagents and may be lost during the reaction process by filtration.
  • a comparison between the solubility of amorphous and crystalline compound of the formula I shows that the amorphous substance is better soluble in aprotic organic solvents, such as for example ethers, such as diisopropyl ether, cyclic carbohydrates such as methyl cyclohexane, and lower alcohols (C1-C4 alcohols) such as isopropanol.
  • aprotic organic solvents such as for example ethers, such as diisopropyl ether, cyclic carbohydrates such as methyl cyclohexane, and lower alcohols (C1-C4 alcohols) such as isopropanol.
  • ethers such as diisopropyl ether
  • cyclic carbohydrates such as methyl cyclohexane
  • C1-C4 alcohols lower alcohols
  • oily impure substance of the formula I obtained from processes disclosed in EP 330172 and US 5155251 is used for the production of atorvastatin salts, in the first step which includes dissolution of compound of formula I in THF, impure reaction mixture resulted that should be purified before further procedure steps which includes filtration step and more time consumed and energy spend.
  • amorphous form of a compound of the formula I in the synthesis of atorvastatin calcium has an advantage because of better solubility in aprotic organic solvents regarding crystall forms and increased purity compared with the use of a crystalline form containing very large crystalls or the impure oily product of a compound of the formula I.
  • Figure 1 An X-ray powder diffraction pattern of amorphous (4R-cis)-6-[2-[3- phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyI)-pyrrol-1-yl]-ethyl]- 2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester (compound of the formula I) obtained from Example 4.
  • Figure 2 DSC thermogram of amorphous compound of the formula I obtained from Example 2.
  • the present invention provides therefore a process for preparing amorphous compound of the formula I, that may be used for preparing amorphous atorvastatin calcium.
  • the process of the present invention is simple and may therefore easily be scaled up to an industrial scale.
  • the invention in a second aspect relates to a process of preparing amorphous compound of the formula I, by dissolving the compound of the formula I, having specific polymorphous form, which may be any crystalline form, such as crystalline form I or form II of the compound of the formula I as well as any form wherein the crystalline status cannot be determined, e.g. oily form or mixture of known polymorphous forms, in an organic solvent, selected from the group consisting of lower alkanols (C1 to C4 alkanoles) in which compound of the formula I dissolves well, e.
  • specific polymorphous form which may be any crystalline form, such as crystalline form I or form II of the compound of the formula I as well as any form wherein the crystalline status cannot be determined, e.g. oily form or mixture of known polymorphous forms, in an organic solvent, selected from the group consisting of lower alkanols (C1 to C4 alkanoles) in which compound of the formula I dissolves well, e.
  • temperature range should be from 25- 100°C, preferably 30-60°C, most preferably at 50-60°C until the solution is still absolutely clear, that means to the point when there is no dimness in the solution.
  • water is added to the solution to produce a precipitate of amorphous compound of the formula I, which is filtered and optionally dried. Drying is carried out according to known conventional drying methods, e.g. at room temperature or increased temperature of up to 60°C and under normal or reduced pressure such as from 1 to 50 mbar.
  • the obtained residue is amorphous compound of the formula I.
  • the HPLC purity determined for the product is more than 99%.
  • a further aspect of the present invention concerns a process of preparing amorphous compound of the formula I by dissolving crystalline compound of the formula I in an inert organic solvent, selected from the group consisting of lower alkanoles e.g. methanol, chlorinated lower alkanes, e.g. chloroform and methylene chloride, ketones such as acetone, aromatic hydrocarbons such as benzene and toluene, cyclic ethers such as tetrahydrofuran and nitriles such as acetonitrile, at room or increased temperature up to 60 °C.
  • the amount of solvent is not critical but should be high enough to produce a completely clear solution.
  • reduced pressure scale should be from 1-5 mbar, at room or increased temperature, the temperature range should be from 25-100°C, preferably 30-60°C, most preferably at 50-60°C, to completely remove the solvent from the mixture. Thereafter the residue is optionally dried. Drying is carried out according to known conventional drying methods, e.g. at room temperature or increased temperature of up to 60°C and under normal or reduced pressure such as from 1 to 50 mbar. The obtained residue is amorphous compound of the formula I. The HPLC purity determined for the product is more than 99%.
  • the following non-limiting Examples illustrate the present invention without limiting the scope of the invention to said Examples.
  • Example 6 X-ray powder diffraction analysis of amorphous compound of the formula I.
  • Amorphous compound of the formula I obtained from Example 4 has an X-ray powder diffraction pattern substantially as shown in Figure 1.
  • the X-ray powder diffraction pattern is measured with a Philips PW1710 difractometer in reflection geometry.
  • the instrument is regularly calibrated with a silicon standard.
  • a standard Philips back-loading sample holder is used.
  • Sample storage, mounting, and data collection are performed at room temperature.
  • Data collection parameters are: 2 ⁇ range from 4 ° to 37 °, step scan mode in steps of 0.04 ° 2 ⁇ , integration time 1 second at each step.
  • Example 7 DSC analysis of amorphous compound of the formula I
  • the DSC (Differential Scanning Calorimetry) analysis is performed on an Mettler Toledo DSC822e analyzer. Measurement is performed in an unsealed Al pan with a heating rate of 5 K/min. The heating interval is 40-160 °C.
  • the thermogram of amorphous compound of the formula I prepared by Example 2 is expressed in Figure 2.
  • the DSC curve shows the thermal transformation of amorphous compound of the formula I into crystalline forms.
  • the DSC curve there is clearly seen the formation of crystals of Form II at around 120 °C and melting point of these crystals at 136 °C.

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Abstract

The invention relates to a process of preparing amorphous (4R-cis)-6-[2-[3-phenyl-­4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-­dimethyl-[1,3]-dioxane-4-yl-acetic acid - tertiary butyl ester which is a useful pharmaceutical intermediate in the preparation of atorvastatin salts.

Description

PROCESS FOR PREPARING AMORPHOUS (4R-CIS) -6 - [2 - [3 -PHENYL-4- (PHENYLCARBAMOYL) (4 -FLUOROPHENYL) -5- (1-METHYLETHYL) -PYRROL-1-YL] -ETHYL] -2,2-DIMETHYL- [1,3] - DIOXANE-4-YL-ACΞTIC ACID
Field of the Invention
The present invention relates to a novel process for preparing amorphous (4R- cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)- pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester. This compound is useful as an intermediate in preparing atorvastatin salts.
Technical Background
Atorvastatin is known pharmaceutical substance (Merck Index, 12th edition, 1996, No. 897), and has the chemical name hemi calcium salt (R-(R*,R*))-2-(4- fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-((phenylamino)carbonyl)- 1 H-pyrrol-1-heptanoic acid. Atorvastatin may exist in free acid form as well as in acid salts form and in hydrates and solvates forms. Atorvastatin is also known as lactone form that may be prepared from free acid form. Solid atorvastatin salts exist in amorphous or crystalline form. Suitable salts of atorvastatin includes alkaline metal salts, earth alkaline metal salts, preferred for pharmaceutical use are earth alkaline salts, such as a calcium salt.
The compound (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5- (1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid tertiary butyl ester of the formula I
Figure imgf000003_0001
was first described in EP 330172 and is known as an important intermediate for the preparation of atorvastain by using specific synthesis procedure. The patent EP 330172 discloses the preparation of (4R-cis)-6-[2-[3-phenyl-4- (phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2- dimethyl-[1,3]-dioxane-4-yl-acetic acid - tertiary butyl ester. Compound of the formula I was prepared by the convergent synthesis with a chain of reactions. The important last step includes reaction of (4R-cis)-1 ,1-dimethylethyl 6-(2- aminoethyl)-2,2-dimethyl-1 ,2-dioxane-4-acetate and 4-fluoro-α-[2-methyl-1- oxopropyl]-γ-oxo-N-,β-diphenylbenzenebutaneamide (which includes mixture of all possible isomers) in a mixture of solvents that contains heptane and toluene. Reaction was carried out at reflux temperature followed by addition of 2-propanol and cooling. The product should be a yellow solid. The patent does not teach in which polymorphous form is the product and does not define the melting point of the product. When we tried to rework said procedure we obtained instead of yellow solid, slight yellow oily product that did not crystallize. We found out that the oily product was not pure and because of containing significant amount of impurities as such is not suitable for use in the preparation of atorvastatin salts. The purity was less than 70%, determined by HPLC analysis. Another patent that discloses the same process for the preparation of the compound of the formula I is US 5155251 and rework of this procedure also gave oily impure product. WO 03/024959 discloses new crystalline forms I and II of the compound of the formula I, and a process of preparation thereof. The application disclose the process that uses an organic solvents for the preparation of crystal polymorphs of compound shown in the formula I. E.g. in example 3 it is disclosed the use of acetonitrile for dissolving crude amorphous substance of the formula I and than heating the obtained mixture at the reflux temperature. Afterwards the mixture is cooled and allowed to stay overnight. The precipitate formed is filtered, washed and dried. The product obtained is in crystal form I.
Constantly there is a strong demand for pure and uniform products having physical properties appropriate for easily scaling-up procedure and use in industrial scale. Above mentioned prior art discloses processes for the preparation of the compound of the formula I. As said above synthesis process, disclosed in the EP 330172 and US 5155251 for the preparation o f the compound shown in the formula I is not reproducible as the product obtained is oily without tendency to crystallize. Oily products were impure and as such not favourable in the preparation of atorvastatin because the purity of end product atorvastatin depends on the purity of the starting compound. Crystallization processes from prior art WO 03/024959 provides crystal forms of the compound of the formula I that dissolves slowly in organic solvents and also may be impure.
It is very important that the atorvastatin producing starting compound of the formula I dissolves quickly and completely in aprotic solvents, e.g. tetrahydrofurane, because the first step in the synthesis of atorvastatin salts includes usually dissolving said starting compound in an aprotic solvent. The dissolving process should provide a clear solution as fast as possible and if this is not the case more solvent may be added and more time for stirring should be spent. Also if the obtained solution is not clear, filtering may be applied to minimize the impurities in the final product. Crystalline products are generally less soluble (or they dissolve slowly due to the large crystals), and are from one aspect more difficult for purification in comparison to amorphous products. The reason for this is that a larger crystals in the crystalline product may incorporate a larger amount of impurities and residual solvents during the crystal formation. Therefore If some quantity of water, or maybe other solvents and impurities is incorporated in large crystals this water cannot be easily removed therefrom during a drying process. Also impurities incorporated inside the crystal cannot be washed out during the washing process, that is generally used after membrane filtration. Hence, if a compound of the formula I is dissolved for the reaction to prepare atorvastatin salts, said incorporated water and potential impurities also dissolves in the solvent and result in a mixture of water with the aprotic solvent used for dissolving the starting compound. A compound of the formula I has a very poor solubility in water or is practically insoluble in water. Therefore, the presence of water in the solvent for dissolving a compound of the formula I to prepare atorvastatin may result in a loss of starting compound because the portion of it that does not dissolve in the reaction mixture cannot react with reagents and may be lost during the reaction process by filtration. Higher volumes of the organic solvent which may be necessary to dissolve a compound of the formula I due to the presence of water, have to be recovered which will increase energy consumption.
A comparison between the solubility of amorphous and crystalline compound of the formula I shows that the amorphous substance is better soluble in aprotic organic solvents, such as for example ethers, such as diisopropyl ether, cyclic carbohydrates such as methyl cyclohexane, and lower alcohols (C1-C4 alcohols) such as isopropanol. In the case of tetrahydrofuran (THF) that is generally used as the solvent for dissolution of compound of the formula I in the synthesis of atorvastatin calcium it was found that some dimness appeared if crystal form of the pyrrole compound of the formula I was dissolved. However, a perfectly clear solution was obtained if amorphous compound of the formula I was dissolved in THF. If the solution as in the case mentioned above is not clear, further purification steps, e.g. by filtering and/or adding of active charcoal may become necessary to obtain a clear solution to be used for further reactions in order to avoid impurities in the final product such as atorvastatin calcium. Additional purification steps implicates increased reaction times and higher production costs.
If the oily impure substance of the formula I, obtained from processes disclosed in EP 330172 and US 5155251 is used for the production of atorvastatin salts, in the first step which includes dissolution of compound of formula I in THF, impure reaction mixture resulted that should be purified before further procedure steps which includes filtration step and more time consumed and energy spend.
In said application WO03/024959 which discloses the processes for the preparation of crystal forms of the compound of the formula I, amorphous compound of the formula I is used as starting material but the patent application is silent on how this amorphous starting material is prepared.
The use of an amorphous form of a compound of the formula I in the synthesis of atorvastatin calcium has an advantage because of better solubility in aprotic organic solvents regarding crystall forms and increased purity compared with the use of a crystalline form containing very large crystalls or the impure oily product of a compound of the formula I.
Description of the Drawings
Figure 1 : An X-ray powder diffraction pattern of amorphous (4R-cis)-6-[2-[3- phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyI)-pyrrol-1-yl]-ethyl]- 2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester (compound of the formula I) obtained from Example 4. Figure 2: DSC thermogram of amorphous compound of the formula I obtained from Example 2.
Detailed Description of the Invention
As mentioned above, there exists a constant need for preparing amorphous compound of the formula I because the processes for the preparation of atorvastatin salts demand pure and in organic solvents fast dissolving starting compound of the formula I which is a key intermediate in the synthesis of atorvastatin salts.
In a first aspect the present invention provides therefore a process for preparing amorphous compound of the formula I, that may be used for preparing amorphous atorvastatin calcium. The process of the present invention is simple and may therefore easily be scaled up to an industrial scale.
The purity of the oily products, obtained by processes disclosed in EP 330172 and US 5155251 was low, as it was determined by HPLC at lower than 70% of HPLC purity. As we are talking about pure products, we understand that pure product means the degree of HPLC purity of at least 85%, preferably more than 95%, most preferably more than 99% of chromatographic purity determined by HPLC method. We prepared our amorphous product of the compound of the formula I by using methods here disclosed with more than 99% of HPLC purity.
In a second aspect the invention relates to a process of preparing amorphous compound of the formula I, by dissolving the compound of the formula I, having specific polymorphous form, which may be any crystalline form, such as crystalline form I or form II of the compound of the formula I as well as any form wherein the crystalline status cannot be determined, e.g. oily form or mixture of known polymorphous forms, in an organic solvent, selected from the group consisting of lower alkanols (C1 to C4 alkanoles) in which compound of the formula I dissolves well, e. g., methanol and concentrating the solution under normal or reduced pressure at room or increased temperature, temperature range should be from 25- 100°C, preferably 30-60°C, most preferably at 50-60°C until the solution is still absolutely clear, that means to the point when there is no dimness in the solution. Thereafter, water is added to the solution to produce a precipitate of amorphous compound of the formula I, which is filtered and optionally dried. Drying is carried out according to known conventional drying methods, e.g. at room temperature or increased temperature of up to 60°C and under normal or reduced pressure such as from 1 to 50 mbar. The obtained residue is amorphous compound of the formula I. The HPLC purity determined for the product is more than 99%.
A further aspect of the present invention concerns a process of preparing amorphous compound of the formula I by dissolving crystalline compound of the formula I in an inert organic solvent, selected from the group consisting of lower alkanoles e.g. methanol, chlorinated lower alkanes, e.g. chloroform and methylene chloride, ketones such as acetone, aromatic hydrocarbons such as benzene and toluene, cyclic ethers such as tetrahydrofuran and nitriles such as acetonitrile, at room or increased temperature up to 60 °C. The amount of solvent is not critical but should be high enough to produce a completely clear solution. Then the solvent is evaporated off under normal or reduced pressure, reduced pressure scale should be from 1-5 mbar, at room or increased temperature, the temperature range should be from 25-100°C, preferably 30-60°C, most preferably at 50-60°C, to completely remove the solvent from the mixture. Thereafter the residue is optionally dried. Drying is carried out according to known conventional drying methods, e.g. at room temperature or increased temperature of up to 60°C and under normal or reduced pressure such as from 1 to 50 mbar. The obtained residue is amorphous compound of the formula I. The HPLC purity determined for the product is more than 99%. The following non-limiting Examples illustrate the present invention without limiting the scope of the invention to said Examples.
Preparation of amorphous (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4- fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl- acetic acid - tertiary butyl ester (compound of the formula I).
Example 1 :
5 g of the compound of the formula I are dissolved in 100 ml of methanol. The clear solution is concentrated at reduced pressure of 2 mbar to a point where the solution is still totally clear , i.e. to a volume of approximately 20 ml. Then 200 ml of water are added and an amorphous residue precipitates. The precipitate is filtered off and dried at reduced pressure of 50 mbar at 60 °C for 5 hours. The yield of amorphous compound of the formula I is 4.46 g.
Example 2:
5 g of the compound of the formula I are dissolved in 100 ml of acetonitrile to obtain the clear solution. The solution is dried at reduced pressure of 2 mbar at 60 °C until a completely dry product is obtained. The yield of amorphous compound of the formula I is 5 g.
Example 3:
5 g of the compound of the formula I are dissolved in 10 ml of methylene chloride. The obtained clear solution is dried at reduced pressure of 2 mbar at 60 °C until a completely dry product is obtained. The yield of amorphous compound of the formula I is 5 g. The HPLC purity of the obtained product is 99.4%.
Example 4:
5 g of the compound of the formula I are dissolved in 5 ml of chloroform. The clear solution is allowed to stand without a cover at room temperature long enough (several hours) to completely evaporate solvent from the material. After that the residue is dried at reduced pressure of 50 mbar for 5 hours at 50 °C. The yield of the amorphous compound of the formula I is 5 g.
Example 5:
5 g of the compound of the formula I are dissolved in 5 ml of chloroform. The obtained clear solution is dried at reduced pressure of 2 mbar at 60 °C until a completely dry product is obtained. The yield of amorphous compound of the formula I is 5 g.
Example 6: X-ray powder diffraction analysis of amorphous compound of the formula I.
Amorphous compound of the formula I obtained from Example 4 has an X-ray powder diffraction pattern substantially as shown in Figure 1.
The X-ray powder diffraction pattern is measured with a Philips PW1710 difractometer in reflection geometry. The instrument is regularly calibrated with a silicon standard. A standard Philips back-loading sample holder is used. Sample storage, mounting, and data collection are performed at room temperature. Instrumental parameters are: CuKα radiation (30 mA, 40 kV, λ = 1.5406 A, variable divergence slit (approx. 12 x 16 mm irradiated area), 0.4 mm receiving slit, graphite monochromator on the secondary side, scintillation counter. Data collection parameters are: 2Θ range from 4 ° to 37 °, step scan mode in steps of 0.04 ° 2Θ, integration time 1 second at each step.
Example 7: DSC analysis of amorphous compound of the formula I
The DSC (Differential Scanning Calorimetry) analysis is performed on an Mettler Toledo DSC822e analyzer. Measurement is performed in an unsealed Al pan with a heating rate of 5 K/min. The heating interval is 40-160 °C. The thermogram of amorphous compound of the formula I prepared by Example 2 is expressed in Figure 2.
The DSC curve shows the thermal transformation of amorphous compound of the formula I into crystalline forms. In the DSC curve there is clearly seen the formation of crystals of Form II at around 120 °C and melting point of these crystals at 136 °C.

Claims

Claims
1. A process for the preparation of amorphous (4R-cis)-6-[2-[3-phenyl-4- (phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]- 2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester, which comprises dissolving (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4- fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]- dioxane-4-yl-acetic acid - tertiary butyl ester in an organic solvent and isolation of an amorphous product.
2. The process according to claim 1 , wherein an organic solvent is selected from the group consisting of lower C1-C4 alkanols.
3. The process according to claims 1 and 2, wherein an organic solvent is methanol.
4. A process for the preparation of amorphous (4R-cis)-6-[2-[3-phenyl-4- (phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]- 2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester, which comprises: a) dissolving (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4- fluorophenyl)-5-(1 -methylethyl)-pyrrol-1 -yl]-ethyl]-2,2-dimethyl-[1 ,3]- dioxane-4-yl-acetic acid - tertiary butyl ester in an organic solvent, b) concentrating the solution, c) adding water, d) precipitating the amorphous product, e) optionally isolating the precipitated product to obtain amorphous (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5- (1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl- acetic acid - tertiary butyl ester.
5. The process according to claim 4, wherein an organic solvent is selected from the group of lower C1-C4 alkanols.
6. The process according to claim 4, wherein an organic solvent is methanol.
7. The process according to claim 4, wherein the concentration of the solution is performed at reduced pressure to a point where the solution is clear.
8. A process for the preparation of amorphous (4R-cis)-6-[2-[3-phenyl-4- (phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]- 2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester, which comprises dissolving crystalline (4R-cis)-6-[2-[3-phenyl-4- (phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]- 2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester in an inert organic solvent and isolation of an amorphous product.
9. The process according to claim 8, wherein an inert organic solvent is selected from the group consisting of lower alkanoles, chlorinated lower alkanes, ketones, aromatic hydrocarbons, cyclic ethers and nitriles.
10. The process according to claims 8 and 9, wherein an inert organic solvent is selected from the group consisting of methanol, chloroform, methylene chloride, acetone, benzene, toluene, tetrahydrofuran and acetonitrile.
11. The process according to claim 8 wherein the process for the preparation of amorphous (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)- 5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester, comprises: a) dissolving crystalline (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2- (4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl- [1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester in an inert organic solvent, b) evaporation of the inert organic solvent, c) isolation of the amorphous product.
12. The process according to claim 11 , wherein the dissolving of crystalline (4R-cis)-6-[2-[3-phenyI-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1- methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester in an inert organic solvent is performed at about room temperature or under heating up to about 60 °C.
13. The process according to claim 11 , wherein an inert organic solvent is selected from the group consisting of lower alkanoles, chlorinated lower alkanes, ketones, aromatic hydrocarbons, cyclic ethers and nitriles.
14. The process according to claims 11 and 13, wherein an inert organic solvent is selected from the group consisting of methanol, chloroform, methylene chloride, acetone, benzene, toluene, tetrahydrofuran and acetonitrile.
15. The process according to anyone of claims 8 and 11 wherein the isolation of the amorphous product comprises evaporating the inert organic solvent at room or increased temperature and at normal or reduced pressure.
16. (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1 - methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester in an solid amorphous form.
17. (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-f luorophenyl)-5-(1 - methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester in an solid amorphous form with HPLC purity higher than 85%.
18. (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1- methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester in an solid amorphous form with HPLC purity higher than 95%.
19. (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1 - methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester in an solid amorphous form with HPLC purity higher than 99%.
20. (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1- methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester in an solid amorphous form having an X-ray powder diffraction pattern substantially as shown in Figure 1.
21. (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1- methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester in an solid amorphous form having a DSC thermogram substantially as shown in Figure 2.
22. A process for the production of atorvastatin calcium comprising the steps of: a) dissolving the (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4- fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4- yl-acetic acid - tertiary butyl ester in the organic solvent, b) isolating amorphous (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4- fluorophenyl)-5-(1 -methylethyl)-pyrrol-1 -yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4- yl-acetic acid - tertiary butyl ester and c) using amorphous (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4- fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4- yl-acetic acid - tertiary butyl ester in the synthesis of atorvastatin.
23. Use of (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1- methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester in an amorphous form in the production of atorvastatin.
24. The use of (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)- 5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1 ,3]-dioxane-4-yl-acetic acid - tertiary butyl ester according to claim 22 wherein atorvastatin is in the form of a calcium salt.
PCT/SI2004/000045 2003-12-29 2004-12-27 Process for preparing amorphous (4r-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1,3]-dioxane-4-yl-acetic acid WO2005063741A1 (en)

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SI200432013T SI1711489T1 (en) 2003-12-29 2004-12-27 Process for preparing amorphous (4r-cis)-6-s2-s3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methyl)-pyrrol-1-ylc-2,2-dimethyl-s1,3c-dioxane-4-yl-acetic acid
AU2004309313A AU2004309313A1 (en) 2003-12-29 2004-12-27 Process for preparing amorphous (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1,3]-dioxane-4-yl-acetic acid
EP04809253A EP1711489B1 (en) 2003-12-29 2004-12-27 Process for preparing amorphous (4r-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methyl)-pyrrol-1-yl]-2,2-dimethyl-[1,3]-dioxane-4-yl-acetic acid
CN2004800394510A CN1902194B (en) 2003-12-29 2004-12-27 Process for preparing amorphous (4r-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methyl)-pyrrol-1-yl]-2,2-dimethyl-[1,3]-dioxane-4-yl-acetic acid
US10/584,638 US7943786B2 (en) 2003-12-29 2004-12-27 Process for preparing amorphous (4R-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1,3]-dioxane-4-yl-acetic acid
JP2006546935A JP2007517028A (en) 2003-12-29 2004-12-27 Amorphous (4R-cis) -6- [2- [3-phenyl-4- (phenylcarbamoyl) -2- (4-fluorophenyl) -5- (1-methylethyl) -pyrrol-1-yl ] -Ethyl] -2,2-dimethyl- [1,3] -dioxan-4-yl-acetic acid
CA002551549A CA2551549A1 (en) 2003-12-29 2004-12-27 Process for preparing amorphous (4r-cis)-6-[2-[3-phenyl-4-(phenylcarbamoyl)-2-(4-fluorophenyl)-5-(1-methylethyl)-pyrrol-1-yl]-ethyl]-2,2-dimethyl-[1,3]-dioxane-4-yl-acetic acid

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