Radiofrequency Sintering of Lossy Coated Particles for Tablet Manufacturing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for manufacturing orally disintegrating tablets are inefficient, with high-density tablets taking up to 20-30 seconds to disintegrate and requiring complex, costly processes, while lyophilized tablets have limited drug loading and are shaped on only one face.

Innovation Solution

A process using lossy coated particles with a substrate and activator, where radiofrequency energy is applied to sinter the powder blend, concentrating the activator on the surface and improving tablet properties such as friability, mouthfeel, and disintegration speed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If compression method is used to manufacture orally disintegrating tablets, then tablet hardness is improved, but disintegration time increases to 20-30 seconds

Engineering Contradiction:

Improvetablet hardnessVSAvoiddisintegration time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent replaces the mechanical compression system with a radiofrequency heating and sintering system. The powder blend is heated to a sintering temperature where particles fuse together, creating tablet bonds without requiring high mechanical pressure. This substitution of mechanical bonding with thermal bonding enables fast disintegration while maintaining adequate hardness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of time

If lyophilization process is used, then disintegration speed is improved, but manufacturing time increases and drug loading is limited

Engineering Contradiction:

Improvedisintegration timeVSAvoidmanufacturing time

Core Design Contradiction:

Loss of timeVSProductivity

Solution Approach 1:

The patent changes the fundamental processing parameter from low-temperature lyophilization to high-temperature sintering. By heating the powder blend to sintering temperatures (typically 50-150°C above melting point of binder), the particles fuse rapidly to form tablets. This parameter change enables both fast disintegration and reduced manufacturing time compared to lyophilization.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If reduced compaction pressure is used to make softer tablets, then ease of chewing is improved, but tablet strength decreases making tablets fragile and brittle

Engineering Contradiction:

Improveease of chewingVSAvoidtablet strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent replaces mechanical compression with radiofrequency heating and sintering. The thermal energy causes particles to fuse together, creating strong bonds without requiring high mechanical pressure. This results in tablets that are soft and easy to chew yet maintain sufficient strength to handle during manufacturing and administration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Stability of the object's composition

If conventional coating method is used, then activator distribution is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveactivator distributionVSAvoidmanufacturing complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent combines the coating operation with the sintering operation into a single process step. The powder blend containing lossy coated particles is directly heated to sintering temperature, where the activator on the particle surfaces facilitates bonding. This merging eliminates separate coating and sintering steps, reducing manufacturing complexity while maintaining good activator distribution.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Results in tablets with improved friability, faster disintegration, higher active agent loading, and shorter manufacturing times compared to traditional methods, while maintaining aesthetic appeal and commercial efficiency.

Implementation Method 1

applying radiofrequency energy at frequencies from 1MHz to 100MHz to a powder blend to sinter said powder blend into said tablet

Methodology Applied

Scientific EffectRadiofrequency heating: Dielectric Heating

Implementation Method 2

the lossy coating comprises an activator that is used to sinter to particles to form the tablet. As this process concentrates the activator on the surface of the particle, the amount of activator added to the tablet can be reduced and the sintering of particles can be improved

Methodology Applied

Scientific EffectLossy coating absorption: Absorption (EM radiation)

Data Source

PatentEP3091966B1Process for making tablet using radiofrequency and lossy coated particles

Publication Date: 2019.07.31 JOHNSON & JOHNSON CONSUMER INC

AI summary

In one aspect the present invention features process for making a tablet comprising at least one pharmaceutically active agent, said method comprising the step of applying radiofrequency energy to a powder blend to sinter said powder blend into said tablet, wherein said powder blend comprises lossy coated particles and said at least one pharmaceutically active agent, wherein said lossy coated particles comprises a substrate that is at least partially coated with a lossy coating comprising at least one activator, wherein said substrate has a Q value of greater than 100 and said activator has a Q value of less than 75.