Bupropion hydrochloride is a marketed antidepressant. It is chemically known as (+)-2-(tert-butyiamino)-3'-chloropropiophenone hydrochloride. (See U.S. Patents 3.819.706 and 3.885.046). Also see Merck Index. Eleventh Edition, entry No. 1488.

In usage, bupropion hydrochloride is sold in the form of an instant release tablet wherein greater than 75% of bupropion hydrochloride is released from the tablet dissolution media in 45 minutes (See 1993 Physicians Desk Reference (PDR). pages 842 to 844). The PDR indicates bupropion hydrochloride as presently sold in an instant release tablet as being associated with seizures in approximately 0.4% (4/1000) patients treated at doses of up to 450 mg per day. In studies to date, the risk of seizures seem to be strongly associated, in part, with use of instant release tablets.

In order to reduce the seizure rate, it has been determined after experimentation that a controlled sustained release of bupropion hydrochloride should be employed.

Prior art with respect to this invention is to be found in U.S. Patent No. 4.687,660 which discloses controlled sustained release tablets containing bupropion hydrochloride.

The present invention provides an improved product in that it provides sustained release of the active ingredient as well as ease of manufacture over that disclosed in U.S. Patent 4,687.660.

After almost three years of work and testing, the present invention is now able to provide a controlled sustained release, sometimes also referred to as a sustained release (SR) tablet with improved properties and which has a shelf life over one year (i.e., there is less than 10% loss most preferably less than about 5% loss (breakdown), of buproprion hydrochloride) in one year of storage at room temperature 15 to 25°C (59 to 77°F) at 35 to 60% relative humidity. For example, with a tablet containing 100 mg of bupropion hydrochloride (label strength) the tablet will preferably contain no less than about 95mg of bupropion hydrochloride after one year in storage (shelf

life). As used herein, the term "tabiet" includes the term "caplet". which is the word used to describe a tablet termed substantially in the shape of a capsule.

The oral administration of the controlled release tablets of this invention to treat depression in humans will be under the jurisdiction of the physician: however, tablets for a 75kg ( 150 pound) human will ordinarily be given one to three times per day to provide a total daily dosage of 100 to 450mg per day for a time period that the human patient requires same as determined by a physician. The tablets are swallowed by the human in the normal manner with the aid of water or other liquid. The tablets herein preferably have a round biconvex shape (which is preferred): however, this may be varied depending on the creativity of the tablet designer. With the tablets of this invention it is now possible to dose one or two times per day rather than the three times a day as presently done with the currently marketed product.

The present invention provides a sustained release tablet comprising bupropion hydrochloride and hydroxypropyl methylcellulose. the amount of hydroxypropyl methylcellulose to the amount of bupropion hydrochloride being from 0.19: 1 to 1.1 :1 respectively and the tablet being capable in water of releasing from 20 to 60 percent of the total amount of bupropion hydrochloride in 1 hour, from 50 to 95 percent of the total amount of bupropion hydrochloride in 4 hours and not less than 75 percent of the total amount of bupropion hydrochloride in 8 hours. Cysteine hydrochloride or glycine hydrochloride may also be included. Cysteine hydrochloride is more preferable than glycine hydrochloride. since it unexpectedly causes less discoloration to the tablet core. The amount of bupropion hydrochloride in each tablet is typically from 25mg to 500mg, with the tablet dose being more typically 50mg, lOOmg or 150mg.

Methocel is the brand name for hydroxypropyl methylcellulose (HPMC) from Dow Chemical. Other companies also supply HPMC.

Specific embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which:-

Fig. 1 is a top view of the preferred tablet shape of this invention:

Fig. 2 is a side view of the tablet of Fig. 1 :

Fig. 3 is a sectional view taken along line 3-3 in Fig. 1 :

Fig. 4 is a graph showing plasma bupropion (as the free base) concentrations in nanograms/ml in adult male humans following a single dose of two 50mg bupropion HC1 (SR) tablets, divided by two over 24 hours from time of administration provided by the 50mg tablet example of this invention:

Fig. 5 is a graph showing plasma bupropion (as the free base ) . concentrations in nanograms/ml in adult male humans following a single dose of one 1 OOmg bupropion HC1 (SR) tablets over 24 hours provided by the lOOmg tablet example of this invention: and

Fig. 6 is a graph showing plasma bupropion (as the free base) concentrations in nanograms/ml in adult male humans following a single 150mg tablet over 24 hours provided by the 150mg (SR) tablet example of this invention.

In order to prepare the controlled sustained release (SR) tablets of this invention, particles of bupropion hydrochloride are preferably blended with microcrystalline cellulose and hydroxypropyl methylcellulose (Methocel) to form an admixture of blended powders. A 20 mesh sieve is conveniently used to screen the bupropion hydrochloride particles, cellulose particles and hydroxypropyl methylcellulose particles prior to blending the ingredients. Then the cysteine hydrochloride or glycine hydrochloride is dissolved in water to form a granulating solution. Thereafter, the granulating solution is preferably sprayed onto the blended powders, which are then dried. A lubricant such as magnesium stearate is added and intermixed (blended) with the blended powders having the granulating solution dried thereon. Other suitable fillers include the following: lactose, starch. Microcrystalline cellulose is also preferably added to the product to provide compressibility. Compression of the mixture in a punch and die is then used to form the tablet core.

Thereafter, the tablet ( sometimes referred to as the core ) is preferably film coated with a colored coating such as a Opadry Purple. Opadry Blue or Opadry White for identification, taste masking, and appearance purposes to provide a film coated tablet.

The film coating does not substantially affect the release rate of the bupropion hydrochloride from the tablet, since the coating is instant release which rapidly dissolves in the stomach. The outer film coating is typically 0.03mm to 0.10mm in thickness.

In the practice of this invention, for every pan by weight of bupropion hydrochloride. the amount of hydroxypropyl methylcellulose is 0.19 to 1.1 and more preferably 0.26 to 0.68 parts by weight and the amount of cysteine hydrochloride or giycine hydrochloride is 0.02 to 0.27 and more preferably 0.05 to 0.16 parts by weight. For example, in a tablet containing lOOmg of bupropion hydrochloride. the amount of hydroxypropyl methylcellulose is I9mg to 1 lOmg and most preferably 26.7 to 68mg and the amount of cysteine hydrochloride or glycine hydrochloride is 2.7mg to 27mg and most preferably 5mg to 16.2mg.

The surface area to volume of the non film-coated or core poπion of the tablets herein is important in maintaining the appropriate controlled sustained release rates.

The ratio of the surface area of the non film coated tablet (sometimes referred to as the core) surface area to tablet volume is preferably 3: 1 to 25: lcm'^ and more preferably 7:1 to 16:lcm ^~ l for tablets of 50. 100 and 150mg bupropion hydrochloride content. For tablets of 50mg bupropion HC1 content the ratio of the tablet surface area to tablet volume is most preferably 13: 1 to 16: lcm"^ and for the lOOmg bupropion HC1 content tablet the ratio is most preferably 9: 1 to 12: lcm"l and for the 150mg bupropion HC1 content tablet the ratio is most preferably 7:1 to 10: 1 cm" - .

The release rate of bupropion hydrochloride from the sustained release (SR) tablets disclosed (whether or not film coated) herein in distilled water is preferably as follows:

about 20% to about 60%o (most preferably 25 to 50%) in 1 hour:

about 50% to 95% (most preferably 60 to 95%) in 4 hours:

and

not less than about 75% (most preferably not less than 80%) in 8 hours. For the bupropion HC1 50mg content tablet the release rate of bupropion HC1 is preferably 30 to 50%) in 1 hour. 70 to 95% in 4 hours and not less than 80% in 8 hours. For the lOOmg bupropion HC1 content tablet the release rate is preferably 25 to 45%) in 1 hour. 60 to 85%) in 4 hours and not less than 80% in 8 hours. With the 150mg content tablet the release rate is preferably 25 to 45% in 1 hour. 60 to 75% in 4 hours and not less than 85% in 8 hours.

The test conditions and apparatus to determine the drug release (dissolution) rates of buproprion hydrochloride are as follows:

Apparatus: USP Rotating Paddle (Apparatus II):

Stirring Rate: 50 rpm:

Sample Size: a single unweighted tablet per vessel;

Temperature: 37°C ± 0.5°C

Medium for Dissolution of tablet: 900 ml of distilled water.

The test for dissolution (release rates) is performed as specified below in the U.S. Pharmacopoeia under "Drug Release" and the medium is sampled at 1. 4 and 8 hours.

Sample Preparation: Withdraw a measured portion of the dissolution medium not to exceed 10ml at each sampling point without replacement. Filter the sample through a LID X GMF 0.45 micron filter or a Zymark 10 micron filter (or equivalent).

Standard Preparation: Accurately weigh approximately 50mg of Bupropion Hydrochloride Reference Standard and transfer into 900ml volumetric flask. Dissolve in and dilute to volume with water and mix (nominal concentration: 0.0556mg bupropion hydrochloride per ml).

Instrumental Conditions:

Instrument: An appropriate HPLC equipped with a 10-μl sampling loop Column: BDS Hypersil Cl 8. 5 micron (50x4.6mm) column, or SUPELCOSIL

LC-18-DB. 3 micron (33x4.6mm), or equivalent Flow Rate: 2.0ml/min

Detection: UV. 224nm. 0.1 AUFS or an appropriate AUFS setting Mobile Phase: Methano pH 7.0 phosphate buffer ( 65:35) appropriately filtered and degassed.

Svstem Suitability Test: Replicate injections of the Standard Preparation give relative standard deviations for peak retention times and peak responses no greater than 2 percent. The tailing factor (T.USP) for the bupropion peak is not greater than 2.5.

Ph 7.0 Phosphate Buffer Preparation: Transfer 27.22g of monobasic potassium phosphate into a 1000-ml volumetric flask. Dissolve in and dilute to volume with water and mix. Transfer 250ml of this solution into a 1000-ml of 0.291 M sodium hydroxide, dilute to volume with water and mix.

Calculation

Step 1 - Determination of Bupropion Hydrochloride Concentration % Nominal Bupropion Hydrochloride (0.0556mg/ml) = SPL Pk Response ,, STD Wt _χ 900 _{x l 0} 0 STD Pk Response 900 L.S

Step II - Sampling Volume Corrections

Perform the following calculations to adjust for sample removal. (Evaporation is insignificant over an 8-hour period when using the Zymate II Automated Dissolution Testing System).

% L.S. Bupropion Hydrochloride released (50mg tablet) =

900 - nv _x % nominal bupropion hydrochloride (sample (n-l))= 900 n v ^ % nominal bupropion hydrochloride (sample (i))

900 i = 1

where n = number of previous samples taken

v = volume of sampie taken each time

These caiulations can be performed using the BASIC program "DISTAB".

The tablet also preferably includes as other ingredients, e.g.. lubricating agents for ease in manufacture and fillers for ease of manufacturing and to bulk the tablet to provide the desired size.

The tablet is also preferably coated with an instant release coating for appearance, taste masking, and product identification e.g. Opadry Purple. Blue or White, which will dissolve in the stomach and not substantially affect bupropion hydrochloride release rates and bupropion hydrochloride stability.

Hydroxypropyl Methylcellulose 2910. USP used in the examples, conforms to 28.0 to 30.00%) methoxyi substitution and 7.0 to 12.0%) hydroxypropoxyl substitution. The preferred nominal viscosity of 2% solution in water is not less than 3.000 centipoise and not more than 5.600 centipoise. It is supplied by Dow Chemical Company. Midland. MI as Methocei E4M premium CR.

Microcrystalline cellulose. NF supplied by FMC Corporation as Avicel PH 102. has an average particle size of 90 micrometers with particle size specification of 8%) > 60 mesh and 45% < 200 mesh.

Opadry^ Purple YS- 1-4845 is supplied by Colorcon. Inc.. contains FD&C Red No. 40 aluminum lake, hydroxypropyl methycellulose. titanium dioxide, polyethylene glycol. olysorbate 80. and FD&C Blue No. 2 Aluminum Lake.

OpadryR Blue YS- 1-4282 is supplied Colorcon. Inc.. contains FD&C Blue No. 1 aluminum lake, hydroxypropyl methycellulose. titanium dioxide, polyethylene glycol. and polysorbate 80.

OpadryR White YS-1-7059 is supplied by Colorcon. Inc.. contains hydroxypropyl methylcellulose. titanium dioxide, and polyethylene glycol.

Reference should now be had to Figs. 1 to 3 for a description of the preferred form of the biconvex film coated tablets of this invention which contain as the active ingredient (drug) 50mg. lOOmg or 150mg of bupropion HC1. The tablet (core) is shown at 10 and the film coating is shown at 1 1 in Fig.3

Tablets having the following dimensions as set forth below for the 50mg, lOOmg and 150mg bupropion HC1 content tablets in which the letters D (diameter), T (thickness). L (land). C (cap depth) and the R (radius of curvature of the biconvex region) are shown in Figs. 1 to 3.

50mg lOOmg 150mg

R in mm ( inches) 10.41 (.410) 12.15 (.4783 ) 15.34 (.604)

D in mm ( inches) 7.40 (.2913) 9.40 (.3701) 1 1.00 (.4331)

C in mm (inches) 0.66 (.026) 0.91 (.036) 0.99 (.039)

T in mm 3.40 4.32 4.65

L in mm (inches) 0.51 (.002) 0.076 (.003) 0.076 (.003)

Reference now should be had to Figs. 4. 5 and 6 which illustrate plasma bupropion levels, as the free base i.e. the compound bupropion itself (see the Merck Index. Eleventh Edition entry No. 1488) after oral administration to adult males (humans) of 50mg, lOOmg and 150mg bupropion HC1 film coated tablets of the examples herein. It is to be understood that because of the naure of the film coating, the release rate will be substantially the same whether or not the tablets are film-coated and. therefore, the data is also representative of non film coated tablets disclosed herein.

In particular. Fig. 4 represents plasma levels (divided by 2) of bupropion after oral dosage with two 50mg SR tablets in 21 male (human) patients 18 to 40 years of age weighing 66 to 92kg (132 to 1841bs). The maximum level shown is detected in the blood plasma at least one of the patients and the minimum being that detected in the blood plasma at least one of the patients and the mean being the average of all measurements of all participants.

The bupropion plasma levels for the 50mg tablet dosing measured over 24 hours as in this figure were done as described in the radioimmunoassay test set forth in the article Radioimmunoassay And Pharmacokinetic Profile of Bupropion In The Dog by Robert

F. Butz t al. published in the Joumai of Pharmacology and Experimental Therapeutics. Vol. 217. No. 3 (1981 ).

Fig. 5 is a repeat with respect to Fig. 4: however a single oral dose of a lOOmg SR tablet of this disclosure's example was administered to the same group of males as those tested previously in Fig. 4: however, the bupropion plasma levels were not divided in two. The plasma levels were also measured at the time intervals shown using the test procedure described in the aforementioned Butz et al. article.

Fig. 6 represents oral dosing of 24 male (human) patients, ages 20 to 39 years, weight 68 to 98kg (136 to 1961bs). Each of the males was dosed once with a 150mg bupropion HC1 SR tablet and bupropion plasma level measurements were made as shown on the piot of Fig. 6 at the time intervals shown to arrive at the maximum, minimum for any patient and the mean (average) for all patients in the test.

The measurements using the 150mg tablets of the examples were determined following the procedure described in the article entitled "Determination of Bupropion and Its Major Basic Metabolites in Plasma by Liquid Chromatography with Dual - Wavelength Ultraviolet Detection" by Thomas B. Cooper et al. published in Joumai of Pharmaceutical Sciences. Vol. 73. No. 8. August 1984. The results were not divided bv two as with the Fig. 4 results.

It should be understood that variations may occur in biological measurements from test to test. It should also be understood that the tablet measurements may change somewhat without departing from the spirit of the invention and that the tablet dimensions will also vary because of variability in materials, manufacturing processes, and tolerance achievable.

It should be understood that the outer coating on the core is preferred in this invention but is not a required feature of the invention herein.

_ . _Q _

EXAMPLE 1

Opadry Purple YS- 1-4845 16.00 20.00kg*

*Includes 25%) overage.

Purified Water. USP q.s 180.00kg

Camauba Wax. NF 0.04 0.04kg

Coating thickness*. 0.05 - 0.10mm for all tablets of the examples.

"q.s." means sufficient quantity in the examples.

TYPICAL MANUFACTURING PROCEDURE AND ASSEMBLING PROCESS

Bupropion Hydrochloride Sustained-Release Tablets. 150mg Bupropion Hydrochloride per coated Tablet.

1. Sift and blend the following: bupropion hydrochloride microcrystalline cellulose hydroxypropyl methylcellulose

2. Dissolve the cysteine hydrochloride in the purified water.

3. Spray the solution from Step 2 onto the blended powders from Step 1 using a fluid bed granuiator. Additional purified water may be used, if necessary, to obtain proper granule wetness.

4. Dry the granules.

5. Add magnesium stearate to the granules and mill.

6. Blend the milled granules.

7. Compress the granules at approximately 400. Omg or a weight equivalent to 150mg bupropion hydrochloride on a rotary press fitted with 11.0mm round punches and dies, the upper and lower punches plain.

8. Prepare a film-coating suspension of Opadry Purple YS- 1-4845 dispersed in purified water.

9. Spray the coating suspension onto the core tablets using suitable coating equipment until the desired weight gain is achieved.

10. Polish the coated tablets in the coating equipment using carnauba wax.

EXAMPLE 2

PREPARATION OF 100MG BUPROPION HC1 CONTENTS TABLETS

CORE INGREDIENTS Bupropion Hydrochloride Microcrystalline Cellulose. NF Hydroxypropyl Methylcellulose 2910. USP Cysteine Hydrochloride. USP Magnesium Stearate. NF Purified Water. USP

270.0mg

Surface Area to Volume Ratio 10.89cm- -

Volume 0.2766cm ³

S urface Area 3.013 cm ²

COATING INGREDIENTS

Opadry Blue YS- 1-4282 10.00 20.00*

*Includes 33.3% overage

Purified Water. USP q.s 180.0

Camauba Wax, NF 0.02667 .040

280.03mg Coating thickness ~ 0.05 - 0.10mm

TYPICAL MANUFACTURING PROCEDURE AND ASSEMBLING PROCESS

Bupropion Hydrochloride Sustained-Release Tablets, lOOmg Bupropion Hydrochloride Per Coated Tablet.

1. Sift and blend the following: bupropion hydrochloride microcrystalline cellulose hydroxypropyl methylcellulose.

2. Dissolve the cysteine hydrochloride in the purified water.

3. Spray the solution from Step 2 onto the blended powders from Step 1 using a fluid bed granuiator. Additional purified water may be used, if necessary, to obtain proper granule wetness.

4. Dry the granules.

5. Add magnesium stearate to the granules and mill.

6. Blend the milled granules.

U -

7. Compress the granules at approximately 270. Omg or a weight equivalent to 1 OOmg bupropion hydrochloride on a rotary press fitted with 9.4mm round punches and dies, the upper and lower punches plain.

8. Prepare a film-coating suspension of Opadry Blue. YS-1 -4282 dispersed in purified water.

9. Spray the coating suspension onto the core tablets using suitable coating equipment until the desired weight gain is achieved.

10. Polish the coated tablets in the coating equipment using carnauba wax.

EXAMPLE 3

PREPARATION OF 50MG BUPROPION HCL CONTENT TABLETS

CORE INGREDIENTS m /tablet

Bupropion Hydrochloride Microcrystalline Cellulose NF Hydroxypropyl Methylcellulose 2910. USP Cysteine Hydrochloride. USP Magnesium Stearate. NF

Purified Water. USP

Surface Area to Volume Ratio

Volume

Surface Area

COATING INGREDIENTS Opadry White YS-1 -7059 5.000 20.00* Purified Water. USP q.s 180.0 Carnauba Wax. NF 0-01333 0.040 140.0mg

*Includes 33.3% overage Coating thickness ~ 0.03 - 0.07mm

TYPICAL MANUFACTURING PROCEDURE AND ASSEMBLING PROCESS

Bupropion Hydrochloride Sustained-Release Tablets. 50mg Bupropion Hydrochloride Per Coated Tablet

1. Sift and blend the following:

bupropion hydrochloride microcrystalline cellulose hydroxypropyl methylcellulose.

2. Dissolve the cysteine hydrochloride in the purified water.

3. Spray the solution from Step 2 onto the blended powders from Step 1 using a fluid bed granuiator. Additional purified water may be used, if necessary, to obtain proper granule wetness.

4. Dry the granules.

5. Add magnesium stearate to the granules and mill.

6. Blend the milled granules.

7. Compress the granules at approximately 135. Omg or a weight equivalent to 50mg bupropion hydrochloride on a rotary press fitted with 7.4mm round punches and dies, the upper and lower punches plain.

8. Prepare a film-coating suspension of Opadry White. YS- 1-7059 dispersed in purified water.

9. Spray the coating suspension onto the core tablets using suitable coating equipment until the desired weight gain is achieved.

_.._

10. Polish the coated tablets in the coating equipment using carnauba wax.