Claims for Patent: 8,894,987

Summary for Patent: 8,894,987

Title:	Tamper resistant dosage forms
Abstract:	The present invention relates to pharmaceutical dosage forms, for example to a tamper resistant dosage form including an opioid analgesic, and processes of manufacture, uses, and methods of treatment thereof.
Inventor(s):	McKenna; William H. (Yonkers, NY), Mannion; Richard O. (Furlong, PA), O'Donnell; Edward P. (Basking Ridge, NJ), Huang; Haiyong H. (Princeton, NJ)
Assignee:
Application Number:	11/844,872
Patent Litigation and PTAB cases:	See patent lawsuits and PTAB cases for patent 8,894,987
Patent Claims:	1. A process of preparing a solid oral extended release pharmaceutical dosage form, comprising at least the steps of: (a) combining at least (1) at least one polyethylene oxide and (2) at least one active agent comprising oxycodone hydrochloride, to form a composition; (b) shaping the composition to form an extended release matrix formulation; and (c) curing said extended release matrix formulation comprising at least a curing step of subjecting the extended release matrix formulation to a temperature which is at least the softening temperature of said polyethylene oxide for a time period of at least about 1 minute, wherein the at least one polyethylene oxide, based on rheological measurements, has a molecular weight of approximately 4,000,000 and is at least 79% by weight of the composition; and wherein (i) wherein the cured shaped extended release formulation is flattened without breaking to no more that about 60% of its thickness before flattening, said flattened cured shaped extended release formulation has an in-vitro dissolution, when measured in a USP Apparatus 1 (basket) at 100 rpm and at 37.degree. C. in 900 ml of simulated gastric fluid having no enzymes and having 40% ethanol, wherein the percent amount of oxycodone hydrochloride release at 0.5 hours of dissolution deviates no more than about 20% points from the corresponding in-vitro dissolution of said formulation when measured in a USP Apparatus 1 (basket) at 100 rpm and at 37.degree. C., in 900 ml of simulated gastric fluid having no enzymes and having no ethanol; (ii) between 5 and 40% (by weight based upon total weight of oxycodone hydrochloride in said cured shaped extended release matrix formulation) of oxycodone hydrocodone in said cured shaped extended release matrix formulation is released after 0.5 hours, when measured in a USP Apparatus 1 (basket) at 100 rpm and at 37.degree. C. in 900 ml of simulated gastric fluid having no enzymes and having 40% or 0% ethanol; or (iii) a combination of (i) and (ii). 2. The process of claim 1, wherein in step c) the extended release matrix formulation is subjected to a temperature which is at least the softening temperature of said polyethylene oxide for a time period of at least about 5 minutes. 3. The process of claim 1, wherein in step c) the extended release matrix formulation is subjected to a temperature which is at least the softening temperature of said polyethylene oxide for a time period of at least about 15 minutes. 4. The process of claim 1, wherein in step b) the composition is shaped to form an extended release matrix formulation in the form of tablet. 5. The process of claim 4, wherein in step b) the composition is shaped by direct compression of said composition. 6. The process of claim 1, wherein in step c) the extended release matrix formulation is subjected to a temperature of at least about 60.degree. C. 7. The process of claim 6, wherein in step c) the extended release matrix formulation is subjected to a temperature of from about 62.degree. C. 8. The process of claim 6, wherein in step c) the extended release matrix formulation is subjected to a temperature of at least about 62.degree. C. for a time period of from about 1 minute to about 5 hours. 9. The process of claim 6, wherein in step c) the extended release matrix formulation is subjected to a temperature of at least about 62.degree. C. for a time period of at least about 15 minutes. 10. The process of claim 6, wherein in step c) the extended release matrix formulation is subjected to a temperature of at least about 60.degree. C. for a time period of at least about 15 minutes. 11. The process of claim 1, wherein in step c) the extended release matrix formulation is subjected to a temperature of at least about 60.degree. C. but less than about 90.degree. C. 12. The process of claim 1, wherein the curing step c) takes place in an oven with an inside temperature. 13. The process of claim 12, wherein the temperature of step c) is the target inside temperature of the oven and wherein the curing step starts when the inside temperature of the oven reaches said temperature, and the curing step ends either when the heating is stopped or at least reduced and the inside temperature of the oven subsequently drops below said temperature by more than about 10.degree. C. or below about 62.degree. C., in a plateau-like temperature profile or when the inside temperature of the oven drops below said temperature in a parabolic or triangular temperature profile. 14. The process of claim 13, wherein the temperature profile during the curing step c) shows a plateau-like form and wherein said temperature is at least about 68.degree. C. and the curing time is in the range of from about 30 minutes to about 20 hours. 15. The process of claim 1, wherein the curing step c) takes place in a convection curing device comprising an inlet air temperature, an exhaust air temperature, a temperature probe, or combination thereof. 16. The process of claim 15, wherein the temperature of step c) is defined to be the target inlet air temperature and wherein the curing step starts when the inlet air temperature reaches said temperature and the curing step ends either when the heating is stopped or at least reduced and the inlet air temperature subsequently drops below said temperature by more than about 10.degree. C. or below about 62.degree. C., in a plateau-like temperature profile or when the inlet air temperature drops below said temperature in a parabolic or triangular temperature profile. 17. The process of claim 16, wherein the temperature profile during the curing step c) shows a plateau-like form and wherein said temperature is at least about 72.degree. C. and the curing time is in the range of from about 15 minutes to about 2 hours. 18. The process of claim 15, wherein the temperature of step c) is the target exhaust air temperature and wherein the curing step starts when the exhaust air temperature reaches said temperature and the curing step ends either when the heating is stopped or at least reduced and the exhaust air temperature subsequently drops below said temperature by more than about 10.degree. C. or below about 62.degree. C., in a plateau-like temperature profile or when the exhaust air temperature drops below said temperature in a parabolic or triangular temperature profile. 19. The process of claim 18, wherein the temperature profile during the curing step c) shows a plateau-like form and wherein said temperature is at least about 68.degree. C. and the curing time is in the range of from about 1 minute to about 2 hours. 20. The process of claim 15, wherein the temperature of step c) is the target temperature of the extended release matrix formulations and wherein the curing step starts when the temperature of the extended release matrix formulations reaches said temperature and the curing step ends either when the heating is stopped or at least reduced and the temperature of the extended release matrix formulations subsequently drops below said temperature by more than about 10.degree. C. or below about 62.degree. C., in a plateau-like temperature profile or when the temperature of the extended release matrix formulations drops below said temperature in a parabolic or triangular temperature profile. 21. The process of claim 15, wherein the temperature of step c) is the target temperature measured using a temperature probe and wherein the curing step starts when the temperature measured using the temperature probe reaches said temperature and the curing step ends either when the heating is stopped or at least reduced and the temperature measured using the temperature probe subsequently drops below said temperature by more than about 10.degree. C. or below about 62.degree. C., in a plateau-like temperature profile or when the temperature measured using the temperature probe drops below said temperature in a parabolic or triangular temperature profile. 22. The process of claim 21, wherein the temperature profile during the curing step c) shows a plateau-like form and wherein said temperature is at least about 68.degree. C. and the curing time is in the range of from about 15 minutes to about 2 hours. 23. The process of claim 1, wherein the curing step c) takes place in a bed of free flowing extended release matrix formulations. 24. The process of claim 1, wherein the curing takes place in a coating pan. 25. The process of claim 1, comprising a further step of coating the cured extended release matrix formulation. 26. The process of claim 1, comprising the steps of: (a) combining at least (1) at least one polyethylene oxide and (2) oxycodone hydrochloride, to form a composition; (b) shaping said composition to form the extended release matrix formulation in the form of a tablet by direct compression; (c) curing said tablet by subjecting a bed of free flowing tablets to a temperature from about 62.degree. C. to about 90.degree. C. for a time period of at least about 1 minute in a coating pan and subsequently cooling the bed of free flowing tablets to a temperature of below about 50.degree. C.; and subsequently (d) coating the tablets in a coating pan, wherein the at least one polyethylene oxide having, based on rheological measurements, a molecular weight of approximately 4,000,000, is at least 80% by weight of the composition. 27. The process of claim 1, wherein the oxycodone hydrochloride has a 14-hydroxycodeinone level of less than about 25 ppm. 28. The process of claim 1, wherein the composition further comprises at least one polyethylene oxide having, based on rheological measurements, an approximate molecular weight of less than 1,000,000. 29. The process of claim 28, wherein the composition further comprises at least one polyethylene oxide having, based on rheological measurements, a molecular weight of from 100,000 to 900,000. 30. The process of claim 29, wherein the composition further comprises at least one polyethylene oxide having, based on rheological measurements, a molecular weight of 100,000. 31. The process of claim 1, wherein the overall content of the oxycodone hydrochloride in the composition is more than about 5% (by wt) 32. The process of claim 1, wherein the composition comprises at least about 10% (by wt) of a polyethylene oxide having, based on rheological measurements, a molecular weight of less than 1,000,000. 33. The process of claim 32, wherein in step c) the shape extended release matrix formulation is subjected to a temperature of less than about 80.degree. C. 34. The process of claim 1, wherein the curing step c) leads to a decrease in the density of the extended release matrix formulation. 35. The process of claim 1, 2, 6, 9, 15, 22, and 26, wherein the density of the cured extended release matrix formulation in comparison to the density of the uncured extended release matrix formulation decreases by at least about 0.5%. 36. A solid oral extended release pharmaceutical dosage form obtainable by a process according to claim 1-26, 27, 28-30, 31, and 32-35. 37. The solid oral extended release pharmaceutical dosage form of claim 36, wherein the density of the extended release matrix formulation is equal to or less than about 1.20 g/cm.sup.3. 38. A process of preparing a solid oral extended release pharmaceutical dosage form, comprising at least the steps of: (a) combining at least (1) at least one polyethylene oxide and (2) oxycodone hydrochloride, to form a composition; (b) shaping the composition to form an extended release matrix formulation; and (c) curing said extended release matrix formulation comprising at least a curing step of subjecting the extended release matrix formulation to a temperature which is at least the softening temperature of said polyethylene oxide for a time period of at least 5 minutes, wherein the at least one polyethylene oxide has, based on rheological measurements, a molecular weight of approximately 4,000,000 and is at least 79% by weight of the composition, and wherein said cured shaped extended release matrix formulation has a property selected from the group consisting of: (i) when the cured shaped extended release formulation is flattened without breaking to no more than about 60% of its thickness before flattening, said flattened cured shaped extended release formulation has an in-vitro dissolution, when measured in a USP Apparatus 1 (basket) at 100 rpm and at 37.degree. C. in 900 ml of simulated gastric fluid having no enzymes and having 40% ethanol, wherein the percent amount of oxycodone hydrochloride released at 0.5 hours of dissolution deviates no more than about 20% points from the corresponding in-vitro dissolution of said formulation when measured in a USP Apparatus 1 (basket) at 100 rpm and at 37.degree. C., in 900 ml of simulated gastric fluid having no enzymes and having no ethanol; (ii) between 5 and 40% (by weight based upon total weight of oxycodone hydrochloride in said cured shaped extended release matrix formulation) of oxycodone hydrocodone in said cured shaped extended release matrix formulation is released after 0.5 hours, when measured in a USP Apparatus 1 (basket) at 100 rpm and at 37.degree. C. in 900 ml of simulated gastric fluid having no enzymes and having 40% or 0% ethanol; or (iii) a combination of (i) and (ii). 39. The process of claim 38, wherein the composition is shaped to form an extended release matrix formulation in the form of tablet. 40. The process of claim 39, wherein the composition is shaped by direct compression of said composition. 41. The process of claim 38, wherein in step c) the extended release matrix formulation is subjected to a temperature of at least 60.degree. C. 42. The process of claim 41 wherein in step c) the extended release matrix formulation is subjected to a temperature of from 65.degree. C. to 90.degree. C. 43. The process of claim 41, wherein in step c) the extended release matrix formulation is subjected to a temperature at of least 60.degree. C. for a time period of at least 15 minutes. 44. The process of claim 41, wherein in step c) the extended release matrix formulation is subjected to a temperature of at least 60.degree. C. for a time period of at least 60 minutes. 45. The process of claim 38, wherein in step c) the extended release matrix formulation is subjected to a temperature of at least 60.degree. C., but less than 90.degree. C. 46. The process of claim 38, wherein the curing step c) takes place in an oven. 47. The process of claim 38, wherein the curing step c) takes place in a bed of free flowing extended release matrix formulations. 48. The process of claim 38, wherein the curing step c) takes place in a coating pan. 49. The process of claim 38, comprising a further step of coating the cured extended release matrix formulation. 50. The process of claim 49, comprising the steps of: (a) combining at least (1) at least one polyethylene oxide and (2) oxycodone hydrochloride, to form a composition; (b) shaping said composition to form the extended release matrix formulation in the form of a tablet by direct compression; (c) curing said tablet by subjecting a bed of free following tablets to a temperature from 70.degree. C. to 90.degree. C. for a time period of at least 30 minutes in a coating pan and subsequently cooling the bed of free flowing tablets to a temperature of below 50.degree. C.; and subsequently (d) coating the tablet in said coating pan, wherein the at least one polyethylene oxide has, based on rheological measurement, a molecular weight of approximately 4,000,000 and is at least 79% by weight of the composition. 51. The process of claim 38, wherein the composition further comprises at least one polyethylene oxide having, based on rheological measurements, an approximate molecular weight of less than 1,000,000. 52. The process of claim 51, wherein the composition further comprises at least one polyethylene oxide having, based on rheological measurements, a molecular weight of from 100,000 to 900,000. 53. The process of claim 51, wherein the composition further comprises at least one polyethylene oxide having, based on rheological measurements, a molecular weight of 100,000. 54. The process of claim 38, wherein the composition comprises at least one polyethylene oxide having, based on rheological measurements, a molecular weight of at least 1,000,000 and at least one polyethylene oxide having, based on rheological measurements, an approximate molecular weight of less than 1,000,000, wherein the composition comprises at least 10% (by wt) of the polyethylene oxide having, based on rheological measurements, an approximate molecular weight of less than 1,000,000. 55. The process of claim 54, wherein in step c) the extended release matrix formulation is subjected to a temperature of less than 80.degree. C. 56. A solid oral extended release pharmaceutical dosage form obtainable by the process according to any one of claims 38-50, 51-53, 54, and 55. 57. The process of claim 1, wherein in step c) the curing is conducted at atmospheric pressure. 58. The process of claim 23, wherein magnesium stearate is added during or after the curing step. 59. A solid oral extended release pharmaceutical dosage form obtainable by a process according to any one of claims 57 and 58. 60. A solid oral release pharmaceutical dosage form prepared by a process comprising at least the steps of: (a) combining at least (1) at least one polyethylene oxide and (2) at least one active agent comprising oxycodone hydrochloride, to form a composition; (b) shaping the composition to form an extended release matrix formulation; and (c) curing said extended release matrix formulation comprising at least a curing step of subjecting the shape extended release matrix formulation to a temperature which is at least the softening temperature of said polyethylene oxide for a time period of at least 1 minute, wherein the at least one polyethylene oxide, based on rheological measurements, has a molecular weight of approximately 4,000,000 and is at least 79% by weight of the composition; and wherein (i) when the cured shaped extended release formulation is flattened without breaking to no more than about 60% of its thickness before flattening, said flattened cured shaped extended release formulation has an in-vitro dissolution, when measured in a USP Apparatus 1 (basket) at 100 rpm and at 37.degree. C. in 900 ml of simulated gastric fluid having no enzymes and having 40% ethanol, wherein the percent amount of oxycodone hydrochloride released at 0.5 hours of dissolution deviates no more than about 20% points form the corresponding in-vitro dissolution of said formulation when measured in a USP Apparatus 1 (basket) at 100 rpm and at 37.degree. C., in 900 ml of simulated gastric fluid having no enzymes and having no ethanol; (ii) between 5 and 40% (by weight based upon total weight of oxycodone hydrochloride in said cured shaped extended release matrix formulation) of oxycodone hydrocodone in said cured shaped extended release matrix formulation is released after 0.5 hours, when measured in a USP Apparatus 1 (basket) at 100 rpm and at 37.degree. C. in 900 ml of simulated gastric fluid having no enzymes and having 40% or 0% ethanol; or (iii) a combination of (i) and (ii). 61. A solid oral extended release pharmaceutical dosage form according to claim 60, wherein the curing step c) comprises subjecting the shaped extended release matrix formulation to a temperature of at least 60.degree. C. for a time period of at least 5 minutes. 62. A solid oral extended release pharmaceutical dosage form according to claim 61, wherein time period is at least 15 minutes and said curing takes place in a coating pan. 63. The process of claim 1, wherein (i) when the cured shaped extended release formulation is flatted without breaking to no more than about 60% of its thickness before flattening, said flattened cured shaped extended release formulation has an in-vitro dissolution, when measured in a USP Apparatus 1 (basket) at 100 rpm and at 37.degree. C. in 900 ml of simulated gastric fluid having no enzymes and having 40% ethanol, wherein the percent amount of oxycodone hydrochloride release at 0.5 hours of dissolution deviates no more than about 20% points from the corresponding in-vitro dissolution of said formulation when measured in a USP Apparatus 1 (basket) at 100 rpm and at 37.degree. C., in 900 ml of simulated gastric fluid having no enzymes and having no ethanol. 64. The process of claim 1, wherein (ii) between 5 and 40% (by weight based upon total weight of oxycodone hydrochloride in said cured shaped extended release matrix formulation of oxycodone hydrocodone in said cured shaped extended release matrix formulation is released after 0.5 hours, when measured in a USP Apparatus 1 (basket) at 100 rpm and at 37.degree. C. in 900 ml of simulated gastric fluid having no enzymes and having 40% or 0% ethanol. 65. The process of any claims 1, 3, 6, 9, 15, 22, 31, and 50 wherein said polyethylene oxide is at least 80% by weight of the composition.