WO2011159903A2 - Asenapine maleate - Google Patents

Asenapine maleate Download PDF

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Publication number
WO2011159903A2
WO2011159903A2 PCT/US2011/040710 US2011040710W WO2011159903A2 WO 2011159903 A2 WO2011159903 A2 WO 2011159903A2 US 2011040710 W US2011040710 W US 2011040710W WO 2011159903 A2 WO2011159903 A2 WO 2011159903A2
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WIPO (PCT)
Prior art keywords
formula
isomer
less
asenapine
asenapine maleate
Prior art date
Application number
PCT/US2011/040710
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English (en)
French (fr)
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WO2011159903A3 (en
Inventor
Srinivas Katkam
Srinivas Polavarapu
Venkata Madhavi Yaddanapudi
Krishna Vinigari
Narasimha Rao Pagadala
Rajeshwar Reddy Sagyam
Original Assignee
Dr. Reddy's Laboratories Ltd.
Dr. Reddy's Laboratories, Inc.
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Publication date
Application filed by Dr. Reddy's Laboratories Ltd., Dr. Reddy's Laboratories, Inc. filed Critical Dr. Reddy's Laboratories Ltd.
Priority to EP11796436.1A priority Critical patent/EP2582704A4/en
Priority to AU2011268335A priority patent/AU2011268335A1/en
Priority to CA2802990A priority patent/CA2802990A1/en
Priority to US13/703,555 priority patent/US8779161B2/en
Publication of WO2011159903A2 publication Critical patent/WO2011159903A2/en
Publication of WO2011159903A3 publication Critical patent/WO2011159903A3/en

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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07D—HETEROCYCLIC COMPOUNDS
    • C07D491/00—Heterocyclic compounds containing in the condensed ring system both one or more rings having oxygen atoms as the only ring hetero atoms and one or more rings having nitrogen atoms as the only ring hetero atoms, not provided for by groups C07D451/00 - C07D459/00, C07D463/00, C07D477/00 or C07D489/00
    • C07D491/02—Heterocyclic compounds containing in the condensed ring system both one or more rings having oxygen atoms as the only ring hetero atoms and one or more rings having nitrogen atoms as the only ring hetero atoms, not provided for by groups C07D451/00 - C07D459/00, C07D463/00, C07D477/00 or C07D489/00 in which the condensed system contains two hetero rings
    • C07D491/04—Ortho-condensed systems
    • C07D491/044—Ortho-condensed systems with only one oxygen atom as ring hetero atom in the oxygen-containing ring
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07D—HETEROCYCLIC COMPOUNDS
    • C07D491/00—Heterocyclic compounds containing in the condensed ring system both one or more rings having oxygen atoms as the only ring hetero atoms and one or more rings having nitrogen atoms as the only ring hetero atoms, not provided for by groups C07D451/00 - C07D459/00, C07D463/00, C07D477/00 or C07D489/00
    • C07D491/02—Heterocyclic compounds containing in the condensed ring system both one or more rings having oxygen atoms as the only ring hetero atoms and one or more rings having nitrogen atoms as the only ring hetero atoms, not provided for by groups C07D451/00 - C07D459/00, C07D463/00, C07D477/00 or C07D489/00 in which the condensed system contains two hetero rings
    • C07D491/04—Ortho-condensed systems
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P25/00—Drugs for disorders of the nervous system
    • A61P25/18—Antipsychotics, i.e. neuroleptics; Drugs for mania or schizophrenia

Definitions

  • aspects of the present application relate to processes for preparing asenapine and pharmaceutically acceptable salts thereof. Aspects of the present application also relate to a monoclinic form of asenapine maleate, which is stable to micronization; processes for its preparation; and pharmaceutically acceptable dosage forms thereof.
  • the drug compound having the adopted name "asenapine” has chemical names: iraA7s-5-chloro-2-methyl-2,3,3a,12b-tetrahydro-1 H-dibenz[2,3:6,7]oxepino [4,5-c]pyrrole; or (3af?S,12bf?S)-5-chloro-2-methyl-2,3,3a,12b-tetrahydro-1 H- dibenzo[2,3:6,7]oxepino [4,5-c]pyrrole; and is represented by structural Formula I.
  • the compound corresponding to Formula (I) is a frans-racemate. Both enantiomers within this racemate contribute to the physiologic effects of asenapine.
  • Asenapine maleate, represented by Formula (II) is very potent dopamine and serotonin antagonist with antipsychotic activity, having CNS- depressant activity (Th. de Boer et ai, "Org-5222. Antipsychotic, Dopamine D 2 Receptor Antagonist, 5-HT 2 Receptor Antagonist," Drugs of the Future, 18(12), pp. 1 1 17-1 123, 1993) and may be used in the treatment of depression (International Application Publication No. WO 99/32108 A1 .
  • Asenapine maleate is the active ingredient in sublingual tablets sold as SAPHRIS®, prescribed for acute treatment of schizophrenia in adults and acute treatment of manic or mixed episodes associated with bipolar I disorder in adults.
  • the asenapine is advantageously used as the maleate salt (U.S.
  • aspects of the present application relate to a monoclinic form of asenapine maleate, which is stable to micronization, and processes for preparation thereof.
  • the present application provides a monoclinic form of asenapine maleate, which is stable to micronization, with one or more of a powder X-ray diffraction (PXRD) pattern, a differential scanning calorimetry (DSC) curve, and a thermogravimetric analysis (TGA) curve, substantially as illustrated by Figs. 1 , 3, and 4, respectively.
  • PXRD powder X-ray diffraction
  • DSC differential scanning calorimetry
  • TGA thermogravimetric analysis
  • the present application relates to a microcrystalline monoclinic form of asenapine maleate and processes for preparation thereof.
  • Fig. 1 is an illustration of a PXRD pattern of a monoclinic form of asenapine maleate, which is stable to micronization, prepared according to Example 11.
  • Fig. 2 is an illustration of a PXRD pattern of a microcrystalline monoclinic form of asenapine maleate, prepared in Example 13, after micronization.
  • Fig. 3 is an illustration of a DSC curve of a monoclinic form of asenapine maleate, which is stable to micronization, prepared according to Example 11.
  • Fig. 4 is an illustration of a TGA curve of a monoclinic form of asenapine maleate, which is stable to micronization, prepared according to Example 11.
  • aspects of the present application relate to a monoclinic form of asenapine maleate, which is stable to micronization, and processes for preparation thereof.
  • the present application provide a monoclinic form of asenapine maleate, which is stable to micronization, with a powder X-ray diffraction (PXRD) pattern having at least two peaks located at about 9.5, 20.3, 21.9, 23.3, 25.1 , 26.1 , 26.6, 29.0, or 29.9 ⁇ 0.2 degrees 2-theta.
  • PXRD powder X-ray diffraction
  • the present application provide a monoclinic form of asenapine maleate, which is stable to micronization, with a powder X-ray diffraction (PXRD) pattern having at least three peaks located at about 9.5, 20.3, 21.9, 23.3, 25.1 , 26.1 , 26.6, 29.0, or 29.9 ⁇ 0.2 degrees 2-theta.
  • PXRD powder X-ray diffraction
  • the present application provides a monoclinic form of asenapine maleate, which is stable to micronization, with any one or more of a powder X-ray diffraction (PXRD) pattern, a differential scanning calorimetry (DSC) curve, and a thermogravimetric analysis (TGA) curve, substantially as illustrated by Figs. 1 , 3, and 4, respectively.
  • PXRD powder X-ray diffraction
  • DSC differential scanning calorimetry
  • TGA thermogravimetric analysis
  • the present application provides processes for the preparation of a monoclinic form of asenapine maleate, which is stable to micronization, comprising: a) providing a solution of asenapine in a solvent;
  • step b) combining the solution of asenapine prepared in step a) with a solution of maleic acid in a solvent;
  • Step a) involves providing a solution of asenapine in a solvent.
  • the solution of asenapine may be obtained by dissolving asenapine in a solvent, or it may be obtained directly from a reaction mixture, in which the compound is formed in the course of synthesis of asenapine. Any physical forms of asenapine, such as crystalline, amorphous, or their mixtures may be utilized for preparing the solution of asenapine in step a).
  • Solvents that may be employed for providing a solution of asenapine in step a) include, but are not limited to: C 3 -C 9 alcohol solvents, e.g., 2-propanol, 1 - propanol, 1 -butanol, 2-butanol, or the like; ester solvents, e.g., ethyl acetate, n- propyl acetate, n-butyl acetate, t-butyl acetate, or the like; or mixtures thereof.
  • the temperatures at which a solution may be obtained in step a) range from about 0°C to about the reflux temperature of the solvent that is used, or any other suitable temperatures.
  • Step b) involves combining the solution of asenapine obtained in step a) with a solution of maleic acid in a solvent.
  • step b) may be conducted by adding a solution of asenapine to a solution of maleic acid, or adding solution of maleic acid to a solution of asenapine.
  • Suitable solvents that may be used in step b) include, but are not limited to: C3-C9 alcohol solvents, e.g., 2-propanol, 1 -propanol, 1 -butanol, 2-butanol, or the like; ester solvents, e.g., ethyl acetate, n-propyl acetate, n-butyl acetate, t-butyl acetate, or the like; or mixtures thereof.
  • C3-C9 alcohol solvents e.g., 2-propanol, 1 -propanol, 1 -butanol, 2-butanol, or the like
  • ester solvents e.g., ethyl acetate, n-propyl acetate, n-butyl acetate, t-butyl acetate, or the like; or mixtures thereof.
  • Suitable temperatures that may be used in step (b) may be less than about 100°C, less than about 80°C, less than about 60°C, less than about 40°C, less than about 30°C, less than about 20°C, less than about 10°C, or any other suitable temperatures.
  • Step c) involves isolating the monoclinic form of asenapine maleate.
  • Isolation in step c) may involve one or more methods, including removal of solvent, cooling, concentrating the mass, using an anti-solvent, extraction with a solvent, adding seed crystals to induce crystallization, or the like. Stirring or other alternate methods such as shaking, agitation, or the like, may also be employed for the isolation. Suitable temperatures for isolation may be less than about 60°C, less than about 40°C, less than about 20°C, less than about 10°C, less than about 5°C, less than about 0°C, less than about -10°C, less than about -20°C, or any other suitable temperatures.
  • the isolated solid may be recovered by any methods, including decantation, centrifugation, gravity filtration, suction filtration, or any other suitable techniques for the recovery of solids.
  • the isolated compound may be further purified by recrystallization one or more times from a suitable solvent or a mixture of solvents, such as, but not limited to: C3-C9 alcohol solvents, e.g., 2-propanol, 1 -propanol, 1 -butanol, 2- butanol, or the like; ester solvents, e.g., ethyl acetate, n-propyl acetate, n-butyl acetate, t-butyl acetate, or the like; or mixtures thereof; optionally involving the addition of seed crystals of the monoclinic form.
  • the recovered solid may optionally be dried.
  • Drying may be carried out in a tray dryer, vacuum oven, air oven, cone vacuum dryer, rotary vacuum dryer, fluidized bed dryer, spin flash dryer, flash dryer, or the like.
  • the drying may be carried out at temperatures less than about 100°C, less than about 80°C, less than about 60°C, less than about 50°C, less than about 30°C, or any other suitable temperatures, at atmospheric pressure or under a reduced pressure, as long as the asenapine maleate is not degraded in quality.
  • the drying may be carried out for any desired times until the desired product quality is achieved.
  • the dried product may be subjected to a size reduction procedure to produce desired particle sizes. Milling or micronization may be performed before drying, or after the completion of drying of the product. Techniques that may be used for particle size reduction include, without limitation, ball, roller and hammer milling, or jet milling.
  • aspects of the present application relate to a microcrystalline monoclinic form of asenapine maleate and processes for preparation thereof.
  • the present application provides processes for the preparation of a monoclinic form of asenapine maleate, which is stable to micronization, comprising:
  • step b) optionally, seeding the solution prepared in step a with crystals of the monoclinic form; and c) isolating the monoclinic form of asenapine maleate.
  • Step a) involves providing a solution of asenapine maleate in a solvent.
  • the solution of asenapine maleate may be obtained by dissolving asenapine maleate in a solvent, or it may be obtained directly from a reaction mixture, in which the compound is formed in the course of synthesis of asenapine maleate. Any physical forms of asenapine maleate, such as crystalline, amorphous, or their mixtures may be utilized for preparing the solution of asenapine maleate in step a) .
  • Solvents that may be employed for providing a solution of asenapine maleate in step a) include, but are not limited to: C3-C9 alcohol solvents, e.g., 2- propanol, 1 -propanol, 1 -butanol, 2-butanol, or the like; ester solvents, e.g., ethyl acetate, n-propyl acetate, n-butyl acetate, t-butyl acetate, or the like; or mixtures thereof.
  • the temperatures at which a solution may be obtained in step a) range from about 0°C to about the reflux temperature of the solvent that is used, or any other suitable temperatures.
  • Step b) involves optionally seeding the solution obtained in step a) with crystals of the monoclinic form.
  • Crystals of monoclinic form that are used in step b) may be obtained by any of the processes of the present application.
  • Step c) involves isolating the monoclinic form of asenapine maleate.
  • Isolation in step c) may involve any methods, including removal of solvent, cooling, concentrating the mass, using an anti-solvent, extraction with a solvent, adding seed crystals to induce crystallization, or the like. Stirring or other alternate methods such as shaking, agitation, or the like, may also be employed for the isolation. Suitable temperatures for isolation may be less than about 60°C, less than about 40°C, less than about 20°C, less than about 10°C, less than about 5°C, less than about 0°C, or any other suitable temperatures.
  • the isolated solid may be recovered by any methods, including decantation, centrifugation, gravity filtration, suction filtration, or any other suitable techniques for the recovery of solids.
  • the recovered solid may optionally be dried. Drying may be carried out in a tray dryer, vacuum oven, air oven, cone vacuum dryer, rotary vacuum dryer, fluidized bed dryer, spin flash dryer, flash dryer, or the like. The drying may be carried out at temperatures less than about 100°C, less than about 80°C, less than about 60°C, less than about 50°C, less than about 30°C, or any other suitable temperatures, at atmospheric pressure or under a reduced pressure, as long as the asenapine maleate is not degraded in quality. The drying may be carried out for any desired times until the desired product quality is achieved.
  • the dried product may be subjected to a size reduction procedure to produce desired particle sizes. Size reduction may be performed before drying, or after the completion of drying of the product. Techniques that may be used for particle size reduction include, without limitation, ball, roller and hammer milling, or jet milling.
  • the present application provides processes for the preparation of a microcrystalline monoclinic form of asenapine maleate, comprising:
  • step b) combining the solution of asenapine obtained in step a) with a solution of maleic acid in a solvent;
  • Step a) involves providing a solution of asenapine in a solvent.
  • the solution of asenapine may be obtained by dissolving asenapine in a solvent, or it may be obtained directly from a reaction mixture, in which the compound is formed in the course of synthesis of asenapine. Any physical forms of asenapine, such as crystalline, amorphous, or their mixtures may be utilized for preparing the solution of asenapine in step a).
  • Solvents that may be employed for providing a solution of asenapine in step a) include, but are not limited to: C 3 -C 9 alcohol solvents, e.g., 2-propanol, 1 - propanol, 1 -butanol, 2-butanol, or the like; ester solvents, e.g., ethyl acetate, n- propyl acetate, n-butyl acetate, t-butyl acetate, or the like; or mixtures thereof.
  • the temperatures at which a solution may be obtained in step a) range from about 0°C to about the reflux temperature of the solvent that is used, or any other suitable temperatures.
  • Step b) involves combining the solution of asenapine obtained in step a) with a solution of maleic acid in a solvent.
  • step b) may be conducted by adding a solution of asenapine to a solution of maleic acid, or adding a solution of maleic acid to a solution of asenapine.
  • Suitable solvents that may be used in step b) include, but are not limited to: C3-C9 alcohol solvents, e.g., 2-propanol, 1 -propanol, 1 -butanol, 2-butanol, or the like; ester solvents, e.g., ethyl acetate, n-propyl acetate, n-butyl acetate, t-butyl acetate, or the like; or mixtures thereof.
  • C3-C9 alcohol solvents e.g., 2-propanol, 1 -propanol, 1 -butanol, 2-butanol, or the like
  • ester solvents e.g., ethyl acetate, n-propyl acetate, n-butyl acetate, t-butyl acetate, or the like; or mixtures thereof.
  • Suitable temperatures that may be used in step (b) may be less than about less than about 100°C, less than about 80°C, or less than about 60°C, or less than about 40°C, or less than about 30°C, or less than about 20°C, or less than about 10°C, or any other suitable temperatures.
  • Step c) involves isolating the microcrystalline monoclinic form of asenapine maleate.
  • Isolation in step c) may involve any methods, including removal of solvent, cooling, concentrating the mass, using an anti-solvent, extraction with a solvent, adding seed crystals to induce crystallization, or the like. Stirring or other alternate methods such as shaking, agitation, or the like, may also be employed for the isolation. Suitable temperatures for isolation may be less than about 60°C, less than about 40°C, less than about 20°C, less than about 10°C, less than about 5°C, less than about 0°C, or any other suitable temperatures.
  • the isolated solid may be recovered by any methods, including decantation, centrifugation, gravity filtration, suction filtration, or any other suitable techniques for the recovery of solids.
  • the isolated compound may be further purified by recrystallization one or more times from a suitable solvent, such as, but not limited to: C3-C9 alcohol solvents, e.g., 2-propanol, 1 -propanol, 1 -butanol, 2-butanol, or the like; ester solvents, e.g., ethyl acetate, n-propyl acetate, n-butyl acetate, t-butyl acetate, or the like; or mixtures thereof; optionally involving the use of seed crystals of the monoclinic form.
  • the recovered solid may optionally be dried.
  • Drying may be carried out in a tray dryer, vacuum oven, air oven, cone vacuum dryer, rotary vacuum dryer, fluidized bed dryer, spin flash dryer, flash dryer, or the like.
  • the drying may be carried out at temperatures less than about 100°C, less than about 80°C, less than about 60°C, less than about 50°C, less than about 30°C, or any other suitable temperatures, at atmospheric pressure or under a reduced pressure, as long as the asenapine maleate is not degraded in quality.
  • the drying may be carried out for any desired times until the desired product quality is achieved.
  • the present application provides processes for the preparation of a microcrystalline monoclinic form of asenapine maleate, comprising:
  • step b) optionally, seeding the solution obtained in step a) with crystals of the monoclinic form;
  • Step a) involves providing a solution of asenapine maleate in a solvent.
  • the solution of asenapine maleate may be obtained by dissolving asenapine maleate in a solvent, or it may be obtained directly from a reaction mixture, in which the compound is formed in the course of synthesis of asenapine maleate. Any physical forms of asenapine maleate, such as crystalline, amorphous, or their mixtures may be utilized for preparing the solution of asenapine maleate in step a).
  • Solvents that may be employed for providing a solution of asenapine maleate in step a) include, but are not limited to: C 3 -C 9 alcohol solvents, e.g., 2- propanol, 1 -propanol, 1 -butanol, 2-butanol, or the like; ester solvents, e.g., ethyl acetate, n-propyl acetate, n-butyl acetate, t-butyl acetate, or the like; or mixtures thereof.
  • the temperatures at which a solution may be obtained in step a) range from about 0°C to about the reflux temperature of the solvent that is used, or any other suitable temperatures.
  • Step b) involves optionally seeding the solution obtained in step a) with crystals of the monoclinic form. Crystals of the monoclinic form that are used in step b) may be obtained by any of the processes of the present application.
  • Step c) involves isolating the microcrystalline monoclinic form of asenapine maleate.
  • Isolation in step c) may involve any methods, including removal of solvent, cooling, concentrating the mass, using an anti-solvent, extraction with a solvent, adding seed crystals to induce crystallization, or the like. Stirring or other alternate methods such as shaking, agitation, or the like, may also be employed for the isolation. Suitable temperatures for isolation may be less than about 60°C, less than about 40°C, less than about 20°C, less than about 10°C, less than about 5°C, less than about 0°C, less than about -10°C, less than about -20°C, or any other suitable temperatures.
  • the isolated solid may be recovered by any methods, including decantation, centrifugation, gravity filtration, suction filtration, or any other suitable techniques for the recovery of solids.
  • the recovered solid may optionally be dried. Drying may be carried out in a tray dryer, vacuum oven, air oven, cone vacuum dryer, rotary vacuum dryer, fluidized bed dryer, spin flash dryer, flash dryer, or the like. The drying may be carried out at temperatures less than about 100°C, less than about 80°C, less than about 60°C, less than about 50°C, less than about 30°C, or any other suitable temperatures, at atmospheric pressure or under a reduced pressure, as long as the asenapine maleate is not degraded in quality. The drying may be carried out for any desired times until the desired product quality is achieved.
  • Milling or micronization techniques that may be used for particle size reduction include, without limitation sifting, milling using mills, such as, for example, ball, roller and hammer mills, or jet mills, including, for example, air jet mills, or any other conventional techniques.
  • the particle sizes of a drug substance can influence biopharmaceutical properties of its pharmaceutical products.
  • the particle sizes of the drug substance affects drug product manufacturing and dissolution, and hence the bioavailability from formulated products. Since asenapine maleate dissolves in saliva, the particle sizes are important. When drug substance particles are small, shorter periods of time are required to achieve high dissolved concentrations. From this perspective, smaller particles are preferred. In addition, smaller particle sizes tend to improve the homogeneity of powder blends, which may result in improved uniformity of the drug content in a pharmaceutical product.
  • Particle size distributions of a monoclinic form of asenapine maleate, which is stable to micronization, particles may be measured using any techniques known in the art.
  • particle size distributions of asenapine maleate particles may be measured using microscopy or light scattering equipment, such as, for example, a Malvern Master Size 2000 from Malvern Instruments Limited, Malvern, Worcestershire, United Kingdom.
  • the particle size distributions can be expressed, for example, in terms of d(90), d(50), and d(10) values, where the values (e.g., expressed in ⁇ ) are the maximum sizes for 90, 50, and 10 percent of the particles, respectively.
  • the present application provides processes for the preparation of a microcrystalline monoclinic form of asenapine maieate, comprising: micronizing a monoclinic form of asenapine maieate, which is stable to micronization, having particle size distributions where d(90) is at least 50 ⁇ .
  • processes of the present application provide a stable, polymorphically pure, microcrystalline, monoclinic form of asenapine maieate.
  • the present application provides pharmaceutical compositions comprising a monoclinic form of asenapine maieate, which is stable to micronization, together with at least one pharmaceutically acceptable excipient.
  • the present application provides pharmaceutical compositions comprising a microcrystalline monoclinic form of asenapine maieate, together with at least one pharmaceutically acceptable excipient.
  • the present application provides processes comprising reacting a c/s-isomer of Formula IX, or a mixture of a c/s-isomer of Formula IX and a irans-isomer of Formula X, with a suitable reagent to afford a mixture of c/s- isomer of Formula IX and frans-isomer of Formula X enriched with irans-isomer of Formula X:
  • Z represents oxygen, sulfur, or a methylene group
  • R represents an CrC 6 alkyl- or C 7 -Ci 0 (aryl)alkyl- group
  • R 1 and R 2 are each independently chosen from hydrogen, d-C 6 alkyl, hydroxy, CrC 6 alkoxy-, halo, nitro, amino, substituted amino, cyano, sulfonyl, carboxyl, substituted carboxy, or CF 3 -.
  • a c/s-isomer of Formula IX, or a mixture of a c/s-isomer of Formula IX and a irans-isomer of Formula X may be prepared using any processes known in the art. For example, it may be prepared by a process described for a mixture of c/s- and frans-2-methyl-3,4,4a,13b-tetrahydrodibenz[2,3;6,7]oxepino[4,5-c]pyridin- 1 (2/-/)-one; or by a process described for frans-5-chloro-2,3,3a,12b-tetrahydro-2- methyl-1 H-dibenz [2,3:6,7]oxepino[4,5-c]pyrrol-1 -one and c/s-5-chloro-2,3,3a,12b- tetrahydro-2-methyl-1 /-/-dibenz[2,3:6,7]oxepino [4,5-c]pyrrol-1
  • the resulting mixture of c/s-isomer of Formula IX and frans-isomer of Formula X enriched with frans-isomer of Formula X obtained above may contain c/s-isomer of Formula IX in amounts less than about 95%, less than about 90%, less than about 80%, less than about 70%, less than about 60%, less than about 50%, less than about 40%, less than about 30%, less than about 20%, less than about 10%, less than about 5%, less than about 4%, less than about 3%, less than about 2%, less than about 1 %, less than about 0.5%, less than about 0.2%, less than about 0.1 %, less than about 0.05%, by weight.
  • Suitable reagents for the above reaction include, but are not limited to, triethylamine, diisopropylethylamine, 1 ,8-diazabicyclo[5.4.0]undec-7-ene (DBU), 1 ,5-diazabicyclo[4.3.0]non-5-ene (DBN), pyridine, morpholine, n-propylamine, sodium methoxide, other organic bases, potassium hydroxide, sodium hydroxide, potassium tert-butoxide, potassium hexamethyldisilazane, sodium hexamethyldisilazane, or the like, or any mixtures thereof.
  • DBU 1 ,8-diazabicyclo[5.4.0]undec-7-ene
  • DBN 1 ,5-diazabicyclo[4.3.0]non-5-ene
  • pyridine morpholine
  • n-propylamine sodium methoxide
  • other organic bases potassium hydroxide
  • Formula IX and frans-isomer of Formula X, with a suitable reagent may be optionally carried out in a suitable solvent, such as, for example, an alcohol solvent, a ketone solvent, an aromatic hydrocarbon solvent, a hydrocarbon solvent, a halogenated hydrocarbon solvent, an ester solvent, e.g., ethyl acetate, n-propyl acetate, n-butyl acetate, t-butyl acetate, or the like; an ether solvent, a polar aprotic solvent, a nitrile solvent, water, or any mixtures thereof.
  • a suitable solvent such as, for example, an alcohol solvent, a ketone solvent, an aromatic hydrocarbon solvent, a hydrocarbon solvent, a halogenated hydrocarbon solvent, an ester solvent, e.g., ethyl acetate, n-propyl acetate, n-butyl acetate, t-butyl acetate,
  • Suitable temperatures that may be employed for the reaction of c/s-isomer of Formula IX, or a mixture of c/s-isomer of Formula IX and frans-isomer of Formula X, with a suitable reagent are less than about 100°C, less than about 80°C, less than about 60°C, less than about 40°C, less than about 20°C, less than about 0°C, or any other suitable temperatures.
  • Suitable times for completing the reaction of the mixture of c/s-isomer of Formula IX, or a c/s-isomer of Formula IX and frans-isomer of Formula X, with a suitable reagent depend on the temperature and other conditions, and may be generally about 30 minutes, or about 1 hour, or about 3 hours, or about 5 hours, or about 10 hours, or about 15 hours, or about 20 hours, or about 25 hours, or about 30 hours, or about 40 hours, or longer.
  • the c/s-isomer of Formula IX, or mixture of c/ ' s-isomer of Formula IX and frans-isomer of Formula X enriched with frans-isomer of Formula X, thus obtained may be separated by conventional separation techniques to afford a c/s-isomer of Formula IX and frans-isomer of Formula X, or their mixture enriched in one of the isomers.
  • separation techniques include, but are not limited to, chromatography, selective crystallization, or any other suitable techniques.
  • the solvents used for separating c/ ' s-isomer of Formula IX and frans-isomer of Formula X include, but are not limited to, alcohol solvents, ketone solvents, aromatic hydrocarbon solvents, hydrocarbon solvents, halogenated hydrocarbon solvents, ester solvents, ether solvents, polar aprotic solvents, nitrile solvents, water, or any mixtures thereof.
  • a frans-isomer of Formula X, or mixture of c/ ' s-isomer of Formula IX and frans-isomer of Formula X enriched with frans-isomer of Formula X may be further purified one or more times using any suitable techniques. For example, it may be purified by precipitation, slurrying in a suitable solvent, or any other suitable techniques. Precipitation may be achieved by crystallization, such as by cooling a solution, concentrating a solution, or by combining an anti-solvent with a solution of the product, or any other suitable methods.
  • Anti-solvents are liquids in which frans-isomer of Formula X is poorly soluble. Suitable anti-solvents include, but are not limited to, hydrocarbon solvents, ether solvents, water, or any mixtures thereof; or any other suitable anti-solvents.
  • Formula IX and frans-isomer of Formula X enriched with frans-isomer of Formula X may optionally be dried.
  • This drying may be carried out in a tray dryer, vacuum oven, air oven, fluidized bed dryer, spin flash dryer, flash dryer, rotary dryer, cone dryer, rotary cone dryer, or the like. Drying may be carried out at temperatures less than about 100°C, less than about 60°C, less than about 40°C, or any other suitable temperatures, at atmospheric pressure or under reduced pressure, and in the presence or absence of an inert atmosphere such as nitrogen, argon, neon, or helium. The drying may be carried out for any desired time periods to achieve the desired quality of the product, such as, for example, about 1 to about 15 hours, or longer.
  • the frans-isomer of Formula X or mixture of c/ ' s-isomer of Formula IX and frans-isomer of Formula X enriched with frar/s-isomer of Formula X, thus obtained may be optionally used for the preparation of compound of Formula XI or a mixture of c/s-isomer of Formula XII and frans-isomer of Formula XI enriched with irans-isomer of Formula XI:
  • R, R 1 , R 2 and Z are as defined above.
  • the c/s-isomer of Formula IX may be recovered from the mother liquors obtained after the separation using conventional processes known in the art, e.g., removal of solvent, cooling, concentrating the reaction mass, combining with an anti-solvent, extraction with a solvent, or the like. Stirring or other alternate methods such as shaking, agitation or the like may also be employed in the isolation.
  • the solvents and anti-solvents were described above.
  • the recovered c/ ' s-isomer of Formula IX, or mixture of c/ ' s- isomer of Formula IX and frans-isomer of Formula X enriched with c/ ' s-isomer of Formula IX, may be recycled by reacting with a suitable reagent, following the process as described above, to afford a frans-isomer of Formula X or a mixture of c/ ' s-isomer of Formula IX and frans-isomer of Formula X enriched with trans- isomer of Formula X.
  • a mixture of c/ ' s-isomer of Formula IX and frans-isomer of Formula X enriched with frans-isomer of Formula X thus obtained may be recovered as a residue by conventional methods.
  • the residue may be optionally dried. This drying may be carried out in a tray dryer, vacuum oven, air oven, fluidized bed dryer, spin flash dryer, flash dryer, rotary dryer, cone dryer, rotary cone dryer or the like. Drying may be carried out at temperatures less than about 100°C, less than about 60°C, less than about 40°C, or any other suitable temperatures, at atmospheric pressure or under reduced pressure, and in the presence or absence of an inert atmosphere such as nitrogen, argon, neon, or helium.
  • the drying may be carried out for any desired time periods to achieve the desired quality of the product, such as, for example, about 1 to about 15 hours, or longer.
  • the residue of c/s-isomer of Formula IX and frans-isomer of Formula X enriched with frans-isomer of Formula X thus obtained may be optionally used without purification for the preparation of a compound of Formula XI or mixture of c/s-isomer of Formula XII and frans-isomer of Formula XI enriched with frans- isomer of Formula XI.
  • the mixture of c/s-isomer of Formula IX and frans-isomer of Formula X enriched with frans-isomer of Formula X thus obtained may be directly used for the preparation of compound of Formula XI or mixture of c/s-isomer of Formula XII and frans-isomer of Formula XI enriched with frans-isomer of Formula XI, without further isolation or conventional work-up.
  • the present application includes processes for preparing a compound of Formula XI and the pharmaceutically acceptable salts thereof:
  • R, R , R 2 , and Z are as defined above, comprising one or more of the following steps, individually, or in the sequence recited:
  • Step a) involves reacting a mixture of c/s-isomer of Formula IX and irans- isomer of Formula X with a suitable reagent, to afford a mixture of c/s-isomer of Formula IX and irans-isomer of Formula X enriched with irans-isomer of Formula X.
  • the resulting mixture of c/s-isomer of Formula IX and irans-isomer of Formula X enriched with irans-isomer of Formula X obtained in a) may contain c/s-isomer of Formula IX in amounts less than about 95%, less than about 90%, less than about 80%, less than about 70%, less than about 60%, less than about 50%, less than about 40%, less than about 30%, less than about 20%, less than about 10%, less than about 5%, less than about 4%, less than about 3%, less than about 2%, less than about 1 %, less than about 0.5%, less than about 0.2%, less than about 0.1 %, or less than about 0.05%, by weight.
  • Suitable reagents for the reaction of step a) include, but are not limited to, triethylamine, diisopropylethylamine, 1 ,8-diazabicyclo[5.4.0]undec-7-ene (DBU), 1 ,5-diazabicyclo[4.3.0]non-5-ene (DBN), pyridine, morpholine, n-propylamine, any other organic base, sodium methoxide, potassium hydroxide, sodium hydroxide, potassium tert-butoxide, potassium hexamethyldisilazane, sodium hexamethyldisilazane, or the like, or any mixtures thereof.
  • DBU 1 ,8-diazabicyclo[5.4.0]undec-7-ene
  • DBN 1 ,5-diazabicyclo[4.3.0]non-5-ene
  • pyridine morpholine
  • n-propylamine any other organic base
  • Step a) may be optionally carried out in a suitable solvent, such as, for example, alcohol solvents, ketone solvents, aromatic hydrocarbon solvents, hydrocarbon solvents, halogenated hydrocarbon solvents, ester solvents, ether solvents, polar aprotic solvents, nitrile solvents, water, or any mixtures thereof.
  • suitable temperatures that may be employed for the reaction of a) are less than about 100°C, less than about 80°C, less than about 60°C, less than about 40°C, less than about 20°C, less than about 0°C, or any other suitable temperatures.
  • Suitable times for completing the reaction of a) depend on the temperature and other conditions, and may be generally less than about 30 hours, less than about 20 hours, less than about 10 hours, less than about 5 hours, less than about 2 hours, less than about 1 hour, or any other suitable times. Longer times also are suitable.
  • the mixture obtained from a) may be recovered as a residue by conventional methods.
  • the residue may optionally be dried. This drying may be carried out in a tray dryer, vacuum oven, air oven, fluidized bed dryer, spin flash dryer, flash dryer, rotary dryer, cone dryer, rotary cone dryer or the like. Drying may be carried out at temperatures less than about 100°C, less than about 60°C, less than about 40°C, or any other suitable temperatures, at atmospheric pressure or under reduced pressure, and in the presence or absence of an inert atmosphere such as nitrogen, argon, neon, or helium. The drying may be carried out for any desired time periods to achieve the desired quality of the product, such as, for example, about 1 to about 15 hours, or longer.
  • the residue comprising a mixture c/s-isomer of Formula IX and transformer of Formula X enriched with irans-isomer of Formula X thus obtained may be optionally used for the preparation of frans-compound of Formula XI or a mixture of compound of formula XI and a c/s-compound of Formula XII.
  • the mixture obtained from a) may be directly used for the preparation of a compound of Formula XI or a mixture of compound of formula XI and a c/s-compound of Formula XII, without further isolation or conventional work- up.
  • Step b) involves optionally separating the irans-isomer of Formula X, or a mixture of c/s-isomer of Formula IX and irans-isomer of Formula X enriched with frans-isomer of Formula X, from the mixture of a).
  • the mixture obtained from a) may be separated using conventional separation techniques, to afford a c/ ' s- isomer of Formula IX and frans-isomer of Formula X.
  • the separation techniques may involve chromatography, crystallization using a solvent or mixture of solvent, or any other suitable techniques.
  • the solvents used for separation of c/s-isomer of Formula IX and irans-isomer of Formula X may include, but are not limited to, alcohol solvents, ketone solvents, aromatic hydrocarbon solvents, hydrocarbon solvents, halogenated hydrocarbon solvents, ester solvents, ether solvents, polar aprotic solvents, nitrile solvents, water, or any mixtures thereof.
  • a frans-isomer of Formula X may be further purified one or more times using any suitable techniques.
  • a frans-isomer of Formula X may be purified by precipitation, slurrying in a suitable solvent, or any other suitable techniques. The precipitation may be achieved by crystallization, such as by cooling a solution or by combining a solution of the product with an anti- solvent, or any other suitable methods known in the art.
  • Anti-solvents are liquids in which frans-isomer of Formula X is poorly soluble. Suitable anti-solvents include, but are not limited to, hydrocarbon solvents, ether solvents, water, or any mixtures thereof; or any other suitable anti-solvents.
  • the mixture obtained from a) may be separated using conventional separation techniques to afford a c/s-isomer of Formula IX and a frans-isomer of Formula X, or their mixture enriched in one of the isomers.
  • the separation techniques include but are not limited to, chromatography, selective crystallization, or any other suitable techniques.
  • the solvents used for the separation of c/s-isomer of Formula IX and frans-isomer of Formula X include, but are not limited to, alcohol solvents, ketone solvents, aromatic hydrocarbon solvents, hydrocarbon solvents, halogenated hydrocarbon solvents, ester solvents, ether solvents, polar aprotic solvents, nitrile solvents, water, or any mixtures thereof.
  • the resulting c/s-isomer of Formula IX, frans-isomer of Formula X, or the mixture enriched in one of the isomers may optionally be dried.
  • This drying may be carried out at temperatures less than about 100°C, less than about 60°C, less than about 40°C, or any other suitable temperatures, at atmospheric pressure or under reduced pressure, and in the presence or absence of an inert atmosphere such as nitrogen, argon, neon, or helium.
  • the drying may be carried out for any desired time periods to achieve the desired quality of the product, such as, for example, about 1 to about 15 hours, or longer.
  • a c/s-isomer of Formula IX may be recovered from the mother liquors obtained after the separation by conventional processes, e.g., removal of solvent, cooling, concentrating the mass, combining with an anti-solvent, extraction with a solvent, or the like. Stirring or other alternate methods such as shaking, agitation or the like may also be employed for isolation.
  • the solvent and anti-solvent may any of those described hereinabove.
  • the recovered c/ ' s-isomer of Formula IX, or mixture of c/s-isomer of Formula IX and irans-isomer of Formula X enriched with c/ ' s-isomer of Formula IX, may be recycled by reacting with a suitable reagent, following the process as described above, to afford a irans-isomer of Formula X or a mixture of c/s-isomer of Formula IX and irans-isomer of Formula X enriched with irans-isomer of Formula X.
  • the irans-isomer of Formula X or mixture of c/ ' s-isomer of Formula IX and irans-isomer of Formula X enriched with irans-isomer of Formula X, thus obtained may be directly used, without purification, for the preparation of a compound of Formula XI or a mixture of c/ ' s-isomer of Formula XII and trans- isomer of Formula XI enriched with irans-isomer of Formula XI.
  • Step c) involves converting the irans-isomer of Formula X, or mixture of c/s- isomer of Formula IX and irans-isomer of Formula X enriched with irans-isomer of Formula X, with a suitable reagent to afford a irans-isomer of Formula XI or a mixture of c/s-isomer of Formula XII and irans-isomer of Formula XI enriched with irans-isomer of Formula XI.
  • Step c) may be carried out using any suitable techniques, including, for example, reduction.
  • Suitable reduction techniques include, but are not limited to, metal mediated reduction, such as with zinc and acetic acid, zinc and hydrochloric acid, iron and acetic acid, or any other suitable metal reducing agents; reacting with a reducing agent, such as lithium aluminum hydride, diborane, sodium borohydride in acidic conditions, sodium dihydro-bis(2- methoxyethoxy) aluminate solution (VITRIDE ® ); and catalytic hydrogenation in the presence of catalysts such as RaneyTM nickel, palladium on carbon, rhodium, or the like; combinations thereof; or any other suitable reducing techniques.
  • a reducing agent such as lithium aluminum hydride, diborane, sodium borohydride in acidic conditions, sodium dihydro-bis(2- methoxyethoxy) aluminate solution (VITRIDE ® )
  • VTRIDE ® sodium dihydro-bis(2-
  • Suitable solvents that may be used include, but are not limited to, alcohol solvents, ketone solvents, aromatic hydrocarbon solvents, hydrocarbon solvents, halogenated hydrocarbon solvents, ester solvents, ether solvents, polar aprotic solvents, water, or any mixtures thereof.
  • Step c) may be carried out at suitable temperatures less than about 150°C, less than about 100°C, less than about 60°C, less than about 40°C, or any other suitable temperatures.
  • suitable times for completing the reaction in step c) depend on temperature and other conditions and may be generally less than about 15 hours, less than about 10 hours, less than about 5 hours, less than about 2 hours, less than about 30 minutes, or any other suitable times. Longer times also are useful.
  • the resulting compound of Formula XI may be recovered using any methods known in the art. For example, it may be isolated by a method that includes but is not limited to, filtration by gravity or suction, centrifugation, slow evaporation, or the like.
  • the product of step c) may be directly used in step d) without further isolation or after conventional work-up, such as, for example, quenching the reaction mixture with a quenching agent and extracting the product into a solvent.
  • Step d) involves optionally converting the resulting irans-isomer of Formula XI, or mixture of c/s-isomer of Formula XII and irans-isomer of Formula XI enriched with irans-isomer of Formula XI, to a pharmaceutically acceptable salt thereof.
  • Step d) may be carried out using any processes known in the art. For example, step d) may be carried out by reacting with a pharmaceutically acceptable acid in a suitable solvent, to obtain the corresponding acid addition salt.
  • Step d) may be carried out in a suitable solvent, such as, for example, alcohol solvents, ketone solvents, aromatic hydrocarbon solvents, hydrocarbon solvents, halogenated hydrocarbon solvents, ester solvents, ether solvents, polar aprotic solvents, nitrile solvents, water, any mixtures thereof; or any other suitable solvents.
  • a suitable solvent such as, for example, alcohol solvents, ketone solvents, aromatic hydrocarbon solvents, hydrocarbon solvents, halogenated hydrocarbon solvents, ester solvents, ether solvents, polar aprotic solvents, nitrile solvents, water, any mixtures thereof; or any other suitable solvents.
  • the salt of irans-isomer of Formula XI, or mixture of a salt of c/s-isomer of Formula XII and salt of irans-isomer of Formula XI enriched with salt of irans- isomer of Formula XI, resulting from step d) may be isolated as a crystalline compound, a solvate, an amorphous compound, or a mixture thereof, as desired.
  • the salt of a irans-isomer of Formula XI, or a mixture of salts of a c/s- isomer of Formula XII and a irans-isomer of Formula XI enriched with salt of trans- isomer of Formula XI, resulting from step d) may be isolated using any processes known in the art. For example, it may be isolated by a method that includes filtration by gravity or suction, centrifugation, slow evaporation, or drying, which may be suitably carried out using techniques including tray drying, vacuum drying, air drying, fluidized bed drying, spin flash drying, flash drying, spray drying, thin film drying, freeze drying, or the like, at atmospheric pressure or under reduced pressure.
  • the isolated, solid salt of a trans- somer of Formula XI, or mixture of salts of c/s-isomer of Formula XII and frans-isomer of Formula XI enriched with salt of frarjs-isomer of Formula XI, may carry a portion of occluded mother liquor containing higher levels of impurities. If desired the isolated solid may be washed with a solvent to wash out the mother liquor.
  • the isolated solid may be dried. This drying may be carried out in a tray dryer, vacuum oven, air oven, fluidized bed dryer, spin flash dryer, flash dryer, rotary dryer, cone dryer, rotary cone dryer or the like. Drying may be carried out at temperatures less than about 100°C, less than about 60°C, less than about 40°C, or any other suitable temperatures, at atmospheric pressure or under reduced pressure, and in the presence or absence of an inert atmosphere such as nitrogen, argon, neon, or helium. The drying may be carried out for any desired time period to achieve the desired quality of the product, such as, for example, about 1 to about 15 hours, or longer.
  • processes of the present application provide asenapine maleate having purity by HPLC which is essentially pure, substantially pure, or even pure.
  • processes of the present application provide asenapine maleate substantially free of one or more of its corresponding impurities.
  • polymorphism The occurrence of different crystal forms (polymorphism) is a property of some molecules and molecular complexes.
  • a single molecule may give rise to a variety of solids having distinct physical properties such as melting point, X-ray diffraction pattern, infrared absorption fingerprint, and NMR spectrum. This variation in solid forms may be significant and may result in differences with respect to bioavailability, stability, and other differences for formulated pharmaceutical products.
  • polymorphic forms can vary in their physical properties, regulatory authorities require that efforts shall be made to identify all polymorphic forms, e.g., crystalline, amorphous, solvated, etc., of new drug substances.
  • polymorphs are distinct solids sharing the same molecular formula yet having distinct advantageous and/or disadvantageous physical properties compared to other forms in the polymorph family.
  • One of the most important physical properties of pharmaceutical polymorphs is their solubility.
  • polymorphic forms for a given compound cannot be predicted, and there are no "standard" procedures that can be used to prepare polymorphic forms of a substance.
  • new forms of a pharmaceutically useful compound may provide an opportunity to improve the performance characteristics of pharmaceutical products.
  • discovery of additional polymorphic forms, including solvate polymorphs may help in the identification of the polymorphic content of a batch of an active pharmaceutical ingredient. For example, in some cases, different forms of the same drug can exhibit very different solubility and dissolution rates.
  • Crystalline forms are characterized by scattering techniques, e.g., x-ray diffraction powder pattern, by spectroscopic methods, e.g., infra-red, 13 C nuclear magnetic resonance spectroscopy, and by thermal techniques, e.g., differential scanning calorimetry or differential thermal analysis.
  • the compound of this invention is best characterized by the X-ray powder diffraction pattern determined in accordance with procedures that are known in the art. For a discussion of these techniques see J. Haleblian, J. Pharm. Sci. 1975 64:1269-1288, and J. Haleblian and W. McCrone, J. Pharm. Sci. 1969 58:91 1 -929.
  • a polymorphic form may be described by reference to patterns, spectra, or other graphical data as "substantially” as shown or depicted in a drawing, or by one or more data points. It will be appreciated that patterns, spectra, and other graphical data can have minor shifts in their positions, relative intensities, or other values due to a number of factors known to those of skill in the art. For example, in the crystallographic and powder X-ray diffraction arts, some variations in peak positions or the relative intensities of one or more peaks of a pattern can occur because of, without limitation, the equipment used, the sample preparation protocol, preferred packing and orientations, the radiation source, operator error, method and length of data collection, and the like.
  • a diffraction angle (2 ⁇ ) in powder X-ray diffractometry may have a permissible variation in the range of ⁇ 0.2°. Therefore, the aforementioned diffraction angle values should be understood as including values in the range of about ⁇ 0.2°. Accordingly, the present invention includes not only crystals whose peak diffraction angles in powder X-ray diffractometry completely coincide with each other, but also crystals whose peak diffraction angles coincide with each other with a permissible variation of about ⁇ .0.2°.
  • the phrase "having a diffraction peak at a diffraction angle (2 ⁇ ⁇ 0.2°) of 7.9°” means “having a diffraction peak at a diffraction angle (2 ⁇ ) of 7.7° to 8.1 °".
  • the intensities of peaks in the x-ray powder diffraction patterns of different batches of a compound may vary slightly, the peaks and the peak locations are characteristic for a specific polymorphic form.
  • the relative intensities of the PXRD peaks can vary depending on the sample preparation technique, crystal size distribution, various filters used, the sample mounting procedure, and the particular instrument employed. Moreover, instrument variation and other factors can affect the 2-theta values. Moreover, new peaks may be observed or existing peaks may disappear, depending on the type of the machine or the settings (for example, whether a Ni filter is used or not).
  • compositions comprising a stable, polymorphically pure monoclinic form of asenapine maleate, together with at least one pharmaceutically acceptable excipient.
  • compositions comprising a stable, polymorphically pure microcrystalline monoclinic form of asenapine maleate, together with at least one pharmaceutically acceptable excipient.
  • Asenapine maleate together with at least one pharmaceutically acceptable excipient of the present application may be formulated as: solid oral dosage forms such as, but not limited to: powders, granules, pellets, tablets, and capsules; liquid oral dosage forms such as but not limited to syrups, suspensions, dispersions, and emulsions; and injectable preparations such as but not limited to solutions, dispersions, and freeze-dried compositions.
  • Solid oral dosage forms such as, but not limited to: powders, granules, pellets, tablets, and capsules
  • liquid oral dosage forms such as but not limited to syrups, suspensions, dispersions, and emulsions
  • injectable preparations such as but not limited to solutions, dispersions, and freeze-dried compositions.
  • Formulations may be in the forms of immediate release, delayed release, or modified release.
  • immediate release compositions may be conventional, dispersible, chewable, mouth dissolving, or flash melt preparations
  • modified release compositions may comprise hydrophilic or hydrophobic, or combinations of hydrophilic and hydrophobic, release rate controlling substances to form matrix, reservoir, or combinations of matrix and reservoir systems.
  • the compositions may be prepared using any techniques such as direct blending, dry granulation, wet granulation, and extrusion and spheronization.
  • Compositions may be presented as uncoated, film coated, sugar coated, powder coated, enteric coated, and modified release coated.
  • DMF N,N-dimethyl formamide
  • HPLC high pressure liquid chromatography
  • An "alcohol solvent” is an organic solvent containing a carbon bound to a hydroxyl group.
  • Alcohol solvents include, but are not limited to, methanol, ethanol, 2-nitroethanol, 2-fluoroethanol, ' 2,2,2-trifluoroethanol, hexafluoroisopropyl alcohol, ethylene glycol, 1 -propanol, 2-propanol (isopropyl alcohol), 2-methoxyethanol, 1 -butanol, 2- butanol, i-butyl alcohol, t-butyl alcohol, 2-ethoxyethanol, diethylene glycol, 1 -, 2-, or 3-pentanol, neo-pentyl alcohol, t-pentyl alcohol, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether, cyclohexanol, benzyl alcohol, phenol, glycerol, Ci-6alcohols, or the like.
  • Alkoxy- refers to the group R-O- where R is an alkyl group, as defined below.
  • exemplary d-C 6 alkoxy- groups include, but are not limited to, methoxy, ethoxy, n-propoxy, 1 -propoxy, n-butoxy, and t-butoxy.
  • An alkoxy group can be unsubstituted or substituted with one or more of the following groups: halogen, hydroxyl, CrC 6 alkoxy-, H 2 N-, (Ci-C 6 alkyl)amino-, di(Ci-C 6 alkyl)amino-, (Cr C 6 alkyl)C(0)N(Ci-C 3 alkyl)-, (C C 6 alkyl)carboxyamido-, HC(O)NH-, H 2 NC(O)-, (C C 6 alkyl)NHC(O)-, di(Ci-C 6 alkyl)NC(0)-, NC-, C C 6 alkoxy-, HO 2 C-, (d- C6alkoxy)carbonyl-, (Ci-C 6 alkyl)C(O)-, C 6 -Ci 4 aryl-, CrCgheteroaryl-, C3- Cscycloalkyl-, CrC 6 haloalkyl-
  • Alkyl- refers to a hydrocarbon chain that may be a straight chain or branched chain, containing the indicated number of carbon atoms, for example, a CrCi 0 alkyl- group may have from 1 to 10 (inclusive) carbon atoms in it. In the absence of any numerical designation, “alkyl” is a chain (straight or branched) having 1 to 6 (inclusive) carbon atoms in it.
  • CrC 6 alkyl- groups include, but are not limited to, methyl, ethyl, propyl, butyl, pentyl, hexyl, isopropyl, isobutyl, sec-butyl, tert-butyl, isopentyl, neopentyl, and isohexyl.
  • An alkyl- group can be unsubstituted or substituted with one or more of the following groups: halogen, H 2 N-, (C C 6 alkyl)amino-, di(CrC 6 alkyl)amino-, (Ci-C 6 alkyl)C(O)N(C r Caalkyl)-, (CrC 6 alkyl)carboxyamido-, HC(O)NH-, H 2 NC(0)-, (Ci-C 6 alkyl)NHC(0)-, di(C C 6 alkyl)NC(0)-, NC-, hydroxyl, Ci-C 6 alkoxy-, C C 6 alkyl-, HO 2 C-, (C C6alkoxy)carbonyl-, (CrC6alkyl)C(0)-, C6-Ci 4 aryl-, CrCgheteroaryl-, C3- Cscycloalkyl-, CrC 6 haloalkyl-, amino(Ci-C
  • Aromatic hydrocarbon solvent refers to a liquid, unsaturated, cyclic, hydrocarbon containing one or more rings which has at least one 6-carbon ring containing three double bonds. It is capable of dissolving a solute to form a uniformly dispersed solution.
  • aromatic hydrocarbon solvent include, but are not limited to, benzene toluene, ethylbenzene, m-xylene, o- xylene, p-xylene, indane, naphthalene, tetralin, trimethylbenzene, chlorobenzene, fluorobenzene, trifluorotoluene, anisole, C6-C-i 0 aromatic hydrocarbons, or mixtures thereof.
  • Aryl- refers to an aromatic hydrocarbon group.
  • Examples of an C6- Ci 4 aryl- group include, but are not limited to, phenyl, 1 -naphthyl, 2-naphthyl, 3- biphen-1 -yl, anthryl, tetrahydronaphthyl, fluorenyl, indanyl, biphenylenyl, and acenaphthenyl.
  • An aryl group can be unsubstituted or substituted with one or more of the following groups: d-Cealkyl-, halogen, haloalkyl-, hydroxyl, hydroxyl(C C 6 alkyl)-, H 2 N-, amino(C C 6 alkyl)-, di(C C 6 alkyl)amino-, HO 2 C-, (C C 6 alkoxy)carbonyl-, (CrC 6 alkyl)carboxyl-, di(CrC 6 alkyl)amido-, H 2 NC(O)-, (d- Cealky amido-, or 0 2 N-.
  • (Aryl)alkyl- refers to an alkyl group, as defined above, wherein one or more of the alkyl group's hydrogen atoms have been replaced with an aryl group as defined above.
  • C 7 -Ci 0 (Aryl)alkyl- moieties include benzyl, 1 -phenylethyl, 2- phenylethyl, 3-phenylpropyl, 2-phenylpropyl, or the like.
  • An (aryl)alkyl group can be unsubstituted or substituted with one or more of the following groups: halogen, H 2 N-, hydroxyl, (Ci-C 6 alkyl)amino-, di(C C 6 alkyl)amino-, (C C 6 alkyl)C(O)N(Ci - C 3 alkyl)-, (CrC 6 alkyl)carboxyamido-, HC(O)NH-, H 2 NC(0)-, (C C 6 alkyl)NHC(0)-, di(C C 6 alkyl)NC(0)-, NC-, hydroxyl, Ci-C 6 alkoxy-, C C 6 alkyl-, HO 2 C-, (C C6alkoxy)carbonyl-, (CrC 6 alkyl)C(0)-, C6-Ci 4 aryl-, CrCgheteroaryl-, C 3 -C 8 cyclo alkyl-, d-Cehaloalky
  • “Ester solvents” include, but are not limited to, ethyl acetate, n-propyl acetate, n-butyl acetate, isobutyl acetate, t-butyl acetate, ethyl formate, methyl acetate, methyl propanoate, ethyl propanoate, methyl butanoate, ethyl butanoate, C 3-6 esters, or the like.
  • ether solvent is an organic solvent containing an oxygen atom -O- bonded to two other carbon atoms.
  • “Ether solvents” include, but are not limited to, diethyl ether, diisopropyl ether, methyl t-butyl ether, glyme, diglyme, tetrahydrofuran, 2-methyltetrahydrofuran, 1 ,4-dioxane, dibutyl ether, dimethylfuran, 2-methoxyethanol, 2-ethoxyethanol, anisole, C 2- 6ethers, or the like.
  • Ketone solvents include, but are not limited to, acetone, ethyl methyl ketone, diethyl ketone, methyl isobutyl ketone, C3- 6 ketones, or the like.
  • Halo or halogen refers to fluorine, chlorine, bromine, or iodine.
  • halogenated hydrocarbon solvent is an organic solvent containing a carbon bound to a halogen.
  • Halogenated hydrocarbon solvents include, but are not limited to, dichloromethane, 1 ,2-dichloroethane, trichloroethylene, perchloroethylene, 1 ,1 ,1 -trichloroethane, 1 ,1 ,2-trichloroethane, chloroform, carbon tetrachloride, or the like.
  • hydrocarbon solvent refers to a liquid, saturated hydrocarbon, which may be linear, branched, or cyclic. It is capable of dissolving a solute to form a uniformly dispersed solution.
  • hydrocarbon solvent include, but are not limited to, n-pentane, isopentane, neopentane, n-hexane, isohexane, 3- methylpentane, 2,3-dimethylbutane, neohexane, n-heptane, isoheptane, 3- methylhexane, neoheptane, 2,3-dimethylpentane, 2,4-dimethylpentane, 3,3- dimethylpentane, 3-ethylpentane, 2,2,3-trimethylbutane, n-octane, isooctane, 3- methylheptane, neooctane, cyclo
  • microcrystalline refers to a crystalline solid that comprises particles having size distributions where d(90) is less than or equal to about 50 ⁇ , about 45 ⁇ , about 35 ⁇ , about 25 ⁇ , about 15 ⁇ , or about 5 ⁇ .
  • micronization refers to the process of reducing the average diameter of a solid material's particles. The term micronization is used when the particles that are produced are only a few micrometers in diameter.
  • Techniques that may be used for micronization include, without limitation sifting, milling using mills, such as, for example, ball, roller, impact, or hammer mills; or jet mills, including, for example, air jet mills or jet pulverizers, or any other conventional techniques.
  • a “nitrile solvent” is an organic solvent containing a cyano -(C ⁇ N) bonded to another carbon atom.
  • “Nitrile solvents” include, but are not limited to, acetonitrile, propionitrile, C 2-6 nitriles, or the like.
  • An "organic base” is an organic compound, which acts as a base.
  • bases include, but are not limited to, triethylamine, diisopropylamine, Hunig's base, DABCO, triethanolamine, tributylamine, pyridine, lutidine, 4-dimethylamino pyridine (DMAP), diethanolamine, 4-methylmorpholine, dimethylethanolamine, tetra methylguanidine, morpholine, imidazole, 2- methylimidazole, 4-methy!imidazole, tetra methylammonium hydroxide, tetraethylammonium hydroxide, N-methyl-1 ,5,9-triazabicyclo[4.4.0]decene, 1 ,8- diazabicyclo[5.4.0]undec-7-ene (DBU), dicyclo hexylamine, and picoline.
  • DMAP 4-dimethylamino pyridine
  • DMAP 4-methylamin
  • compositions include, but are not limited to, those capable of making water-soluble and water-insoluble salts, such as the acetate, 4-acetylaminobenzoate, ascorbate, benzenesulfonate, benzoate, bicarbonate, bisulfate, bitartrate, borate, butyrate, camsylate (camphorsulfonate), carbonate, citrate, clavulariate, dihydrochloride, diphosphate, edisylate (camphorsulfonate), esylate (ethanesulfonate), formate, fumarate, gluceptate (glucoheptonate), gluconate, glucuronate, glutamate, glycolate, hexafluorophosphate, hexylresorcinate, hydrobromide, hydrochloride, hydroxynaphthoate, 1 -hydroxy-2-naphthoate, 3-hydroxy-2-naphtho
  • a "polar aprotic solvent” has a dielectric constant greater than 15 and is at least one selected from the group consisting of amide-based organic solvents, such as ⁇ , ⁇ -dimethylformamide (DMF), ⁇ , ⁇ -dimethylacetamide (DMA), N- methylpyrrolidone (NMP), formamide, acetamide, propanamide, hexamethyl phosphoramide (HMPA), and hexamethyl phosphorus triamide (HMPT); nitro- based organic solvents, such as nitromethane, nitroethane, nitropropane, and nitrobenzene; pyridine-based organic solvents, such as pyridine and picoline; sulfone-based solvents, such as dimethylsulfone, diethylsulfone, diisopropylsulfone, 2-methylsulfolane, 3-methylsulfolane, 2,4-dimethylsulfolane, 3,4-dimethy sul
  • D(10), D(50), and D(90) values are useful ways for indicating a particle size distribution.
  • D(90) refers to at least 90 volume percent of the particles having a size smaller than the said value.
  • D(10) refers to 10 volume percent of the particles having a size smaller than the said value.
  • D(50) refers to 50 volume percent of the particles having a size smaller than the said value.
  • Methods for determining D(10), D(50), and D(90) include laser diffraction, such as using equipment from Malvern Instruments Ltd. of Malvern, Worcestershire, United Kingdom.
  • HPLC is High Pressure Liquid Chromatography.
  • enriched should be understood to mean that the products obtainable in accordance with the process of present application have a higher content of one isomer, relative to the isomeric content of same isomer in a mixture before reacting the mixture with a suitable reagent.
  • the word “pure” as used herein means that the material is at least about 99% pure. In general, this refers to purity with regard to unwanted residual solvents, reaction by-products, impurities, and unreacted starting materials. In the case of stereoisomers, “pure” as used herein also means 99% of one enantiomer or diastereomer, as appropriate. “Substantially pure” as used herein means at least about 98% pure and, likewise, "essentially pure” as used herein means at least about 95% pure.
  • polymorphically pure refers to the monoclinic crystalline form of asenapine maleate containing less than about 10%, or less than about 5%, or less than about 3%, or less than about 2%, or less than about 1 %, or less than about 0.5%, or less than about 0.1 %, or less than about 0.05%, or less than about 0.01 %, or no detectable amount, of another crystalline form, as measured by PXRD analysis.
  • stable refers to the monoclinic crystalline form of asenapine maleate being retained during particle size reduction procedures.
  • Substantially free of one or more of its corresponding impurities refers to the compound that contains less than about 2%, or less than about 1 %, or less than about 0.5%, or less than about 0.3%, or less than about 0.2%, or less than about 0.1 %, or less than about 0.05%, or less than about 0.03%, or less than about 0.01 %, by weight, of each individual
  • impurity including, without limitation, the deschloro asenapine of formula (XIII), cis asenapine of formula (XIV), tetrahydro asenapine maleate of formula (XV), amide compound of formula (XVI), n-oxide of formula (XVII), or any other drug-related or process-related impurity, and that contains a total amount of impurities of less than about 2%, or less than about 1 %, or less than about 0.5%, or less than about 0.3%, or less than about 0.2%, or less than about 0.1 %, or less than about 0.05% by weight.
  • a high performance liquid chromatography method for the analysis of asenapine maleate utilizes a C18 or equivalent column. Additional parameters are as shown in Table 4.
  • EXAMPLE 1 Preparation of 2-(4-chlorophenoxy)-benzene acetic acid. To a solution of o-chlorophenylacetic acid (330 g) in o-xylene (4000 mL) is added 4-chlorophenol (306 g), K 2 CO 3 (354 g), and copper powder (18 g) at 25-30°C. The mixture is heated at reflux for 2-3 hours and water is removed by azeotropic distillation. The reaction mixture is maintained for 1 -2 hours at 25-30°C and water (4000 mL) is added. Organic and aqueous layers are separated and the organic layer is washed with water (4000 mL).
  • EXAMPLE 2 Preparation of ethyl-N-[2-[2-(4-chlorophenoxy) phenyl] acetyl]-n-methylglycinate.
  • 2-(4-chlorophenoxy)-benzeneacetic acid 250 g
  • toluene 700 mL
  • SOCI 2 105 mL
  • DMF 20 mL
  • the solvent is evaporated under vacuum at 40-50°C to afford a residue and any residual solvent is removed by adding and evaporating toluene (2x500 mL).
  • EXAMPLE 3 Preparation of 3-(2-(4-chlorophenoxy) phenyl)-1- methylpyrrolidine-2,4-dione.
  • a suspension of potassium tert-butoxide (88 g) in toluene (1000 mL) is added a solution of ethyl-N-[2-[2-(4-chlorophenoxy)phenyl] acetyl]-N-methylglycinate (250 g) in toluene (1000 mL), under nitrogen at 15-25°C and the mixture is maintained for 12-15 hours at 25-30°C.
  • Water (3000 mL) is added and the mass is maintained for 1 -2 hours at 0-5°C. Organic and aqueous layers are separated and the organic layer is washed with water (1000 mL).
  • Aqueous layers are combined and washed with ethyl acetate (2000 mL).
  • the pH of combined aqueous layers is adjusted to 2-2.5 by addition of aqueous HCI (100 mL) at 0-5°C.
  • the solid is collected by filtration and washed with water (200 mL), then is dried to afford the crude title compound.
  • the crude compound is further purified by heating at reflux a solution of crude 3-(2-(4-chlorophenoxy)phenyl)-1 - methylpyrrolidine-2,4-dione in toluene (3600 mL) for 30-60 minutes, followed by cooling to room temperature. Solid that forms is collected by filtration, washed with hexane (500 mL), and dried to afford a purified title compound. Yield: 130 g. Purity by HPLC: 99.48%.
  • EXAMPLE 5 Preparation of cis-5-chloro-2,3,3a,12b-tetrahydro-2- methyl-1 H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1-one.
  • Magnesium (15.6 g) is added to a solution of 5-chloro-2,3-dihydro-2-methyl-1 H-dibenz[2,3;6,7]oxepino [4,5-c]pyrrol-1 -one (50 g) in methanol (3000 mL), at 25-30°C over 30-45 minutes. The mixture is heated at reflux for 30-45 minutes and, over a period of 1 -2 hours, additional portions of magnesium (4x3 g) are added at 60-65°C.
  • the mass is cooled, and water (2000 mL) and 1 N hydrochloric acid (1000 mL) are added at 0- 5°C.
  • the mixture is extracted with ethyl acetate (1000 mL).
  • Organic and aqueous layers are separated and the aqueous layer is washed with ethyl acetate (500 mL).
  • EXAMPLE 6 Preparation of trans-5-chloro-2,3,3a,12b-tetrahydro-2- methyl-1 H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1-one, or a mixture of cis-5- chloro-2,3,3a,12b-tetrahydro-2-methyl-1 H-dibenz[2,3:6,7]oxepino[4,5- c]pyrrol-1-one and trans-5-chloro-2,3,3a,12b-tetrahydro-2-methyl-1 H- dibenz[2,3:6,7] oxepino[4,5-c]pyrrol-1-one enriched with trans-5-chloro- 2,3,3a,12b-tetrahydro-2-methyl-1 H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1 -one.
  • EXAMPLE 7 Preparation of a mixture of c/s-5-chloro-2,3,3a,12b- tetrahydro-2-methyl-1 h-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1 -one and irans- 5-chloro-2,3,3a,12b-tetrahydro-2-methyl-1 H-dibenz[2,3:6,7]oxepino[4,5- c]pyrrol-1-one enriched with frans-5-chloro-2,3,3a,12b-tetrahydro-2-methyl- 1 H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1 -one.
  • EXAMPLE 8 Preparation of frans-5-chloro-2,3,3a,12b-tetrahydro-2- methyl-1 H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1-one or a mixture of c s-5- chloro-2,3,3a,12b-tetrahydro-2-methyl-1 H-dibenz[2,3:6,7]oxepino[4,5- c]pyrrol-1-one and frans-5-chloro-2,3,3a,12b-tetrahydro-2-methyl-1 H- dibenz[2,3:6,7] oxepino[4,5-c]pyrrol-1-one enriched with frans-5-chloro- 2,3,3a, 12b-tetrahydro-2-methyl-1 H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1 -one.
  • the recovered c/s-isomer (19.0 g) is reacted with 1 ,8-diazabicyclo[5.4.0]undec-7-ene (DBU) in toluene, as described above, and subsequently the separation as described above is repeated to afford a mixture of frar)s-5-chloro-2,3,3a,12b-tetrahydro-2- methyl-1 H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1 -one and c/s-5-chloro-2,3,3a,12b- tetrahydro-2-methyl-1 H-dibenz [2,3:6,7] oxepino[4,5-c]pyrrol-1 -one enriched with frans-5-chloro-2,3,3a,12b-tetrahydro-2-methyl-1 H-dibenz[2,3:6,7]oxepino[4,5- c]pyrrol-1 -one.
  • DBU 1 ,
  • EXAMPLE 9 Preparation of asenapine.
  • Aluminum chloride (4.4 g) is added to tetrahydrofuran (315 mL) at 25-30°C. The solution is cooled and lithium aluminum hydride (2.2 g) is added.
  • a solution of frans-5-chloro-2,3,3a,12b- tetrahydro-2-methyl-1 H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1 -one in tetrahydrofuran (150 mL) is added in drops at -5 to 5°C and the mixture is maintained for 15-30 minutes.
  • a 0.6N sodium hydroxide solution (75 mL) is added in drops at -5 to 5°C.
  • EXAMPLE 10 Preparation of asenapine maleate. To a solution of maleic acid (3.38 g) in isopropyl alcohol (27 mL) is added a solution of asenapine (6.3 g) in isopropyl alcohol (90 mL) and the mixture is maintained for 15-30 minutes at 60°C. The mass is then cooled to 25-30°C and seeded with asenapine maleate (50 mg). The mass is maintained for 10-15 hours at 25-30°C, then the mass is slowly allowed to cool to 0-5°C and stirred for another 1 -2 hours. The solid is separated by filtration and washed with cooled isopropyl alcohol (20 mL). The solid is vacuum dried to afford asenapine maleate. Yield: 3.95 g. Purity by HPLC: 97.72%.
  • EXAMPLE 11 Preparation of asenapine maleate monoclinic form.
  • Aluminum chloride (2.7 g) is added to tetrahydrofuran (60 mL) at 25-30°C.
  • the solution is cooled to 0-10°C and lithium aluminum hydride (1 .08 g) is added.
  • the mixture is stirred for 15-30 minutes.
  • tetrahydrofuran 120 mL is added drop-wise at 0-10°C and the mixture is maintained for 1 hour.
  • Sodium hydroxide solution (0.6N,100 mL) is added at 0- 10°C.
  • the mixture is extracted with ethyl acetate (75 mL) and layers are separated, then the aqueous layer is washed with ethyl acetate (25 mL).
  • the combined organic layer is washed with saturated brine solution (2x100 mL).
  • the organic layer is dried over anhydrous sodium sulfate (10 g) and the solvent from the organic layer is evaporated at 45°C.
  • the obtained residue is dissolved in 1 - propanol (20 mL) at 25-30°C.
  • a portion of the asenapine maleate monoclinic form is micronized, using a Midas Micronizer 50, manufactured and supplied by Microtek Engineering
  • EXAMPLE 12 Preparation of asenapine maleate monoclinic form.
  • Aluminum chloride (4.40 g) is added to tetrahydrofuran (100 mL) at 25-30°C.
  • the solution is cooled to 0-5°C and a solution of lithium aluminum hydride (1 .80 g) in tetrahydrofuran (19 mL) is added.
  • the mixture is stirred for 15-30 minutes.
  • EXAMPLE 13 Purification of asenapine maleate. Asenapine maleate (34.0 g) and 1 -propanol (170 mL) are charged into a round bottom flask and stirred for 5 minutes. The contents are heated to reflux to dissolve asenapine maleate completely. The solution is cooled to 25-35°C, seeded with asenapine maleate monoclinic form (200 mg), and the mixture is stirred at 25-35°C for 5-6 hours. The obtained solid is collected by filtration, washed with 1 -propanol (17 mL), and dried under reduced pressure at 45°C, to afford 23.0 g of the title compound. A portion of the material is micronized, using the procedure described in Example 1 1 .
  • PXRD pattern (before and after micronization): complies with reference pattern of monoclinic polymorph; purity by HPLC: 99.73%; endotherm by DSC: 145°C; weight loss by TGA: 0.15%; moisture content by KF: 0.20%;
  • EXAMPLE 14 Purification of asenapine maleate. Asenapine maleate (1 1 .0 g) and 1 -propanol (1 10 mL) are charged into a round bottom flask and stirred for 5 minutes. The mixture is heated to reflux, to dissolve asenapine maleate completely. The solution is cooled to 25-35°C and stirred for 10- 5 minutes. The mixture is further cooled to 0-5°C and stirred for 1 -2 hours. The obtained solid is collected by filtration, washed with 1 -propanol (5.5 mL), and dried under reduced pressure at 45°C, to afford 9.9 g of the title compound. PXRD: complies with a reference pattern of the monoclinic polymorph.
  • EXAMPLE 15 Preparation of asenapine maleate monoclinic form.
  • a solution of asenapine (1 1 .0 g) in 2-propanol (50 mL) is added to a solution of maleic acid (4.2 g) in 2-propanol (25 mL) at 25-30°C, then seeded with asenapine maleate monoclinic form (150 mg).
  • the mixture is stirred at 25-35°C for 14 hours, the obtained solid is collected by filtration, washed with 2-propanol (10 mL), and dried under reduced pressure at 45°C, to afford 8.52 g of the title compound.
  • EXAMPLE 16 Preparation of asenapine maleate monoclinic form. Asenapine maleate (5.0 g) and 2-propanol (50 mL) are charged into a round bottom flask and stirred for 5 minutes. The mixture is heated to reflux, to dissolve asenapine maleate completely. The solution is cooled to 25-35°C and stirred for 15-16 hours. The obtained solid is collected by filtration, washed with 2-propanol (10 mL), and dried under reduced pressure at 45°C, to afford 3.8 g of the title compound. PXRD: complies with reference pattern of the monoclinic polymorph.
  • EXAMPLE 17 Micronization of asenapine maleate monoclinic form.
  • Samples of asenapine maleate monoclinic form prepared according to the process of Example 15 and Example 16 are micronized in a Midas Micronizer 50, using nitrogen as the carrier gas at a pressure of 4-6 Kg/cm 2 , and results are shown in Table 2.
  • EXAMPLE 18 Preparation of 2-(2-(4-chlorophenoxy) phenyl) acetic acid, xylene (600 mL), potassium carbonate (53.75 g), 4-chlorophenol (46.25 g), and copper powder (2.7 g) are charged in to a round bottom flask at 25-35°C.
  • the reaction mixture is heated to reflux, maintained for 2-3 hours and simultaneously water is removed by azeotropic distillation.
  • the reaction mixture is cooled to below 90°C. Water (600 mL) is added, both layers are separated. The organic layer is washed with water (600 mL).
  • EXAMPLE 19 Preparation of ethyl-N-[2-(4-chloro-2-phenoxyphenyl)-1- oxethyl]-N-methylglycinate.
  • Ethyl acetate (125 mL) and 2-(2-(4-chlorophenoxy) phenyl) acetic acid (25 g) are charged in to a round bottom flask at 28°C.
  • 1 - Hydroxybenzotriazole 13 g is charged to the reaction mixture at 28°C and stirred for 10 minutes.
  • Triethylamine 46 mL is charged to reaction mixture at 28°C and stirred for 5 minutes.
  • EXAMPLE 20 Preparation of 3-(2-(4-chlorophenoxy) phenyl)-1- methylpyrrolidine-2,4-dione.
  • a suspension of potassium tert-butoxide (148.6 g) in toluene ( 800 mL) is added a solution of ethyl-N-[2-(4-chloro-2- phenoxyphenyl)-1 -oxethyl]-N-methylglycinate (406 g) in toluene (1800 mL) at 15°C.
  • the resultant reaction mixture maintained at 25-35°C for 16 hours.
  • Water (1800 mL) is charged to the reaction mixture and stirred for 30 minutes. The organic and aqueous layers are separated.
  • the aqueous layer is washed with ethyl acetate (2500 mL).
  • the aqueous layer is cooled to 0-5°C and cone.
  • HCI 160 mL
  • the reaction mass is maintained at 0-5°C for 1.5 hour, the obtained solid is collected by filtration, washed with water (1800 mL), and dried at 45°C.
  • the resultant compound (304 g) and toluene (3000 mL) are charged in to a round bottom flask at 25-35°C. The contents are heated to reflux and maintained for 15 minutes.
  • the reaction mass is slowly cooled to 25-35°C and maintained for 1 hour.
  • the obtained solid is collected by filtration, washed with toluene (600 mL), and dried at 65°C to afford 256 g of the title compound.
  • EXAMPLE 21 Preparation of 5-chloro-2,3-dihydro-2-methyl-1 H- dibenz[2,3;6,7]oxepino[4,5-c]pyrrol-1-one.
  • Phosphoric acid 270 g
  • phosphorous pentoxide 270 g
  • the reaction mixture temperature is allowed to 1 10°C and maintained for 2 hours.
  • 3-(2-(4-Chlorophenoxy)phenyl)-1 -methylpyrrolidine-2,4- dione (90 g) is added at 1 10°C and maintained for 24 hours. Additional
  • the reaction mixture is cooled to 25-35°C, poured in to water (4500 mL), and stirred for 15 hours.
  • the reaction mass is extracted with dichloromethane (900 mL), the layers are separated, and the aqueous layer is washed with dichloromethane (900 mL).
  • the combined organic layer is washed with water (450 mL), 5% sodium bicarbonate (450 mL), and water (450 mL).
  • the solvent from the organic layer is evaporated at 45°C.
  • Methanol (180 mL) is charged to the reaction mass and again the solvent is evaporated form the reaction mass completely at 45°C under reduced pressure.
  • Methanol (450 mL) is charged to the reaction mass and heated at reflux for 30 minutes.
  • the solution is cooled to 25-35°C and further cooled to -8 to -12°C.
  • the reaction mass is maintained at -8 to -12°C for 3 hours, the obtained solid is collected by filtration, washed with chilled methanol (90 mL), and dried at 50-60°C to afford 44 g of the title compound.
  • EXAMPLE 22 Preparation of cis-5-chloro-2,3,3a,12b-tetrahydro-2- methyl-1 H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1 -one.
  • 5-Chloro-2,3-dihydro-2- methyl-1 H-dibenz[2,3;6,7]oxepino[4,5-c]pyrrol-1 -one (100 g) and methanol (3000 mL) are charged in to a round bottom flask at 25-35°C.
  • Magnesium (8.3 g) is charged to the reaction mixture at 25-35°C. The reaction mixture is heated to reflux temperature and maintained for 20 minutes.
  • the mixture is cooled to 45°C and then magnesium (8.3 g) is charged. Again the reaction mixture temperature is increased to reflux and maintained for 20 minutes. The reaction mixture is cooled to 45°C and then magnesium (8.3 g) is charged. Remaining 6 portions of magnesium (each 8.3 g) are charged to the reaction mixture in a similar manner at 40-45°C and the reaction mixture is maintained at reflux for 15-30 minutes. Water (4500 mL) is added to the reaction mixture. The mixture is cooled to 0-10°C and cone. HCI (500 mL) is added to the reaction mixture until the pH of the reaction mixture is 1 .5.
  • the reaction mass is maintained at 0-10°C for 1 hour, the obtained solid is collected by filtration, washed with water (1000 mL), and dried at 50-60°C to afford 96.0 g of the compound.
  • the resultant compound and diethyl ether (1000 mL) are charged in to a round bottom flask. The mixture is heated to reflux and maintained for 10 minutes. The mixture is cooled to 25-35°C, further cooled to 0-5°C, and maintained for 1 -2 hours. The obtained solid is collected by filtration, washed with diethyl ether (100 mL), and dried at 50-60°C to afford 48.5 g of the title compound.
  • EXAMPLE 23 Preparation of frans-5-chloro-2,3,3a,12b-tetrahydro-2- methyl-1 H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1-one.
  • DBU 1 ,8-diazabicyclo[5.4.0]undec-7-ene
  • EXAMPLE 24 Purification of frans-5-chloro-2,3,3a,12b-tetrahydro-2- methyl-1 H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1 -one. trans-5-Chloro- 2,3,3a,12b-tetrahydro-2-methyl-1 H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrol-1 -one (20 g) and ethyl acetate (80 mL) are charged in to a round bottom flask and stirred for 5 minutes.
  • EXAMPLE 25 Preparation of asenapine maleate. Tetrahydrofuran (72 mL) and dichloromethane (8 mL) are charged in to a round bottom flask. The mixture is cooled to -10 to 5°C and aluminum chloride (4.46 g) is charged in to the mixture. A solution of lithium aluminium hydride in tetrahydrofuran (2.4 M; 19 mL) is added to the reaction mixture at -10°C to 5°C.
  • reaction mass is allowed to warm to 25-35°C, filtered, and the unwanted solid is washed with tetrahydrofuran (50 mL). Separated the organic and aqueous layers, the aqueous layer is extracted with ethyl acetate (80 mL), and the combined organic layer is washed with 30% brine solution (100 mL). The solvent from the organic layer is
  • the obtained solid is collected by filtration, washed with isopropyl alcohol (10 mL) at 0-5 ° C, and dried by suction for 15 minutes to form asenapine maleate.
  • the resultant compound is charged in to another round bottom flask containing a mixture of isopropyl alcohol (40 mL) and methanol (10 mL).
  • the reaction mixture is heated to 60-65°C, basic carbon (1 g) is added to the reaction solution at the same temperature and maintained for 10-20 minutes.
  • the reaction mass is filtered and the solid is washed with isopropyl alcohol (10 mL).
  • the resultant filtrate is charged in to another round bottom flask and maintained at 25-35°C for 2-3 hours.
  • EXAMPLE 26 Purification of asenapine maleate. Asenapine maleate (10 g) and 1 -propanol (50 ml_) are charged in to a round bottom flask and stirred for 5 minutes. The mixture is heated to 65-70°C and stirred for 15-30 minutes to dissolve asenapine maleate completely. The resultant solution is filtered at 65- 70°C and the solid is washed with 1 -propanol (10 ml_). The obtained filtrate is transferred in to another round bottom flask and slowly cooled to -5°C to -10°C over a period of 140-230 minutes.

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Cited By (10)

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WO2012123325A1 (en) 2011-03-11 2012-09-20 Medichem S.A. NEW CRYSTAL FORMS OF THE SALT OF TRANS-5-CHLORO-2-METHYL-2,3,3A,12b-TETRAHYDRO-1H-DIBENZO[2,3:6,7]OXEPINO[4,5-c]PYRROLE WITH MALEIC ACID
CN102746209A (zh) * 2012-06-20 2012-10-24 盛世泰科生物医药技术(苏州)有限公司 一种3-（2-（4-氯苯氧基）苯基）-1-甲基-2,4-二酮的合成方法
WO2012156676A1 (en) * 2011-05-18 2012-11-22 Laboratorios Lesvi S.L. Monoclinic crystalline form of asenapine maleate with a specific particle size distribution
WO2012156677A1 (en) * 2011-05-18 2012-11-22 Laboratorios Lesvi S.L. A stable micronised monoclinic form of asenapine maleate and its synthesis
EP2572703A1 (en) * 2011-09-21 2013-03-27 Hexal AG Compressed oral dosage form for asenapine maleate
CN103254201A (zh) * 2012-02-21 2013-08-21 四川科伦药物研究有限公司 一种阿塞那平的制备方法
CN103342707A (zh) * 2013-06-28 2013-10-09 甘肃皓天化学科技有限公司 用于制备阿塞纳平中间体的制备方法
CN104098580A (zh) * 2014-07-22 2014-10-15 成都百裕科技制药有限公司 一种阿塞那平关键中间体的制备方法
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US9505771B2 (en) 2011-05-18 2016-11-29 Laboratories Lesvi S.L. Stable micronised monoclin form of asenapine maleate and its synthesis
US9533994B2 (en) 2011-05-18 2017-01-03 Laboratorios Lesvi S.L. Monoclinic crystalline form of asenapine maleate with a specific particle size distribution
WO2012156676A1 (en) * 2011-05-18 2012-11-22 Laboratorios Lesvi S.L. Monoclinic crystalline form of asenapine maleate with a specific particle size distribution
WO2012156677A1 (en) * 2011-05-18 2012-11-22 Laboratorios Lesvi S.L. A stable micronised monoclinic form of asenapine maleate and its synthesis
EP2572703A1 (en) * 2011-09-21 2013-03-27 Hexal AG Compressed oral dosage form for asenapine maleate
WO2013041435A1 (en) * 2011-09-21 2013-03-28 Hexal Ag Compressed oral dosage form for asenapine maleate
CN103254201A (zh) * 2012-02-21 2013-08-21 四川科伦药物研究有限公司 一种阿塞那平的制备方法
CN103254201B (zh) * 2012-02-21 2016-04-13 四川科伦药物研究有限公司 一种阿塞那平的制备方法
CN102746209A (zh) * 2012-06-20 2012-10-24 盛世泰科生物医药技术(苏州)有限公司 一种3-（2-（4-氯苯氧基）苯基）-1-甲基-2,4-二酮的合成方法
US9597291B2 (en) 2012-12-11 2017-03-21 Alfred E. Tiefenbacher (Gmbh & Co. Kg) Orally disintegrating tablet containing asenapine
US10307400B2 (en) 2012-12-11 2019-06-04 Alfred E. Tiefenbacher (Gmbh & Co. Kg) Orally disintegrating tablet containing asenapine
CN103342707A (zh) * 2013-06-28 2013-10-09 甘肃皓天化学科技有限公司 用于制备阿塞纳平中间体的制备方法
CN103342707B (zh) * 2013-06-28 2015-09-02 甘肃皓天化学科技有限公司 用于制备阿塞纳平中间体的制备方法
CN104098580A (zh) * 2014-07-22 2014-10-15 成都百裕科技制药有限公司 一种阿塞那平关键中间体的制备方法
US11154510B2 (en) 2015-06-11 2021-10-26 Alrise Biosystems Gmbh Process for the preparation of drug loaded microparticles
US11931466B2 (en) 2015-06-11 2024-03-19 Ferring B.V. Process for the preparation of drug loaded microparticles

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US20130211099A1 (en) 2013-08-15
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WO2011159903A3 (en) 2012-05-24
AU2011268335A1 (en) 2013-01-10
EP2582704A2 (en) 2013-04-24
US8779161B2 (en) 2014-07-15

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