Radiofrequency Sintering of Lossy Coated Particles for Orally Disintegrating Tablets
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 involving lossy coated particles with a substrate coated in Hydrogenated Starch Hydrolysate, where radiofrequency energy is applied to a powder blend containing pharmaceutically active agents and excipients, concentrating the activator on the surface to improve sintering, disintegration speed, and drug loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional compression methods are used to make orally disintegrating tablets, then the tablets can be manufactured with standard equipment, but the tablets have high density and take 20-30 seconds to disintegrate in the mouth
Solution Approach 1:
The invention changes the physical-chemical parameters of the tablet formulation by incorporating lossy coated particles with specific Q values and using radiofrequency energy at specific frequencies to achieve rapid disintegration while controlling density through the sintering process
Solution Approach 2:
The invention replaces conventional mechanical compression with radiofrequency energy-based sintering to form tablets that disintegrate rapidly in the mouth, substituting mechanical force with electromagnetic energy for both manufacturing and functional performance
2Speed
If lyophilization process is used to make orally disintegrating tablets, then the tablets disintegrate faster due to lower density, but the manufacturing time is long and the process is complex
Solution Approach 1:
The invention replaces the long-duration lyophilization process with radiofrequency energy-based sintering that achieves rapid tablet formation and disintegration properties in a fraction of the time, substituting thermal mass transfer with dielectric heating
Solution Approach 2:
The invention changes the manufacturing parameters by using radiofrequency energy with specific Q value requirements for particles and activators, enabling fast processing while achieving the desired low-density, fast-disintegrating tablet properties
3Reliability
If uniform distribution of activator is used in the powder blend, then the mixing process is simple, but the sintering efficiency and tablet properties are inferior
Solution Approach 1:
The invention applies local quality by concentrating the activator on the surface of particles through coating, creating a non-uniform distribution where the surface has high activator concentration for effective sintering while the core maintains structural integrity
Solution Approach 2:
The invention uses composite materials by creating lossy coated particles with a core-shell structure, where the substrate particle is coated with a lossy activator material, combining the structural properties of the substrate with the sintering properties of the activator
4Strength
If high compaction pressure is used to make chewable tablets, then the tablets have sufficient hardness, but the tablets are difficult to chew and disintegrate
Solution Approach 1:
The invention changes the physical parameters of tablet formation by using radiofrequency sintering instead of high mechanical compression, achieving adequate hardness through energy-based bonding while maintaining a porous, low-density structure that enables easy chewing and rapid disintegration
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, while maintaining high hardness and oral disintegration within 60 seconds.
Implementation Method 1
applying radiofrequency energy to a powder blend comprising lossy coated particles and at least one pharmaceutically active agent to sinter said powder blend into a tablet
Implementation Method 2
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
Data Source
AI summary
In one aspect the present invention features a process for making a tablet comprising the step of applying radiofrequency energy to a powder blend comprising lossy coated particles and at least one pharmaceutically active agent to sinter said powder blend into a tablet, said lossy coated particles comprising a substrate having a Q value of greater than 100 that is at least partially coated with a lossy coating comprising Hydrogenated Starch Hydrolysate.