Field of the Invention This invention relates to new pharmaceutical compositions, their use as medicaments and particularly to their administration to the lung to treat lung diseases.

Background and Prior Art

Administration of biologically-active compounds to the lungs is a challenging and complicated endeavour. Active ingredients need to be formulated in a form that is not only suitable for inhalation, but also for loading into, and administration from, an inhalation device, with a view to enabling efficacy either on a topical basis, or to allow for systemic absorption into plasma following deposition, in the lung.

In this respect, compared to traditional drug delivery systems, inhaled drug delivery systems present many more difficulties, as the respiratory system is so complex. For therapeutic efficacy, inhaled active ingredients must not only be efficiently deposited in the right part(s) of the airway, but must also be in a form in which they are able to exert their therapeutic action.

In the upper lung, the epithelia of the lung comprise a periciliary layer of cells with a luminal mucus layer on top of the cell layer. Any bioactive compound needs to traverse the mucus layer to get into the cell layer.

In the alveoli in the lower lung, the cell layer is in an aqueous phase and covered by pulmonary surfactant. A bioactive compound needs to traverse the surfactant layer to get to the cell layer underneath.

The mucus layer and the surfactant layer are composed of different materials and thus permeation through these layers requires different properties. Therefore, the site of deposition is expected to influence the rate and extent of absorption of a bioactive compound in the lung. Dissolution of bioactive compounds in the mucus or surfactant layer is important for therapeutic effect. Compounds having a lower solubility and/or dissociation constant are less effective in the lung because of low drug exposure. Conversely, low solubility of compounds can be used to prolong drug action because of a longer retention time in the lung.

In case of pulmonary disorders, the epithelia of the lung may present differently to healthy tissue and provide a further rate limiting step for a therapeutic effect. Further, as with all modes of drug delivery, effectiveness is based on a combination of dissolution rate and lung mucosal permeation rate and efficiency.

Particle size or diameter of either the active ingredient itself or the composition containing it must be below 6 pm in order to reach the lower lung. In this respect, it is critical that disaggregation and/or dispersion of the active ingredients (or compositions comprising them) following administration (e.g. after actuation of an inhalation device) takes place to ensure effective delivery of the drug to the lung.

The deposition of inhaled particles is strongly influenced by a number of parameters that include mass median aerodynamic diameter (MMAD), density and shape of particles and hygroscopicity of particles. A widely-accepted notion is that for efficient deposition, the MMAD should be in the range of 1 and 5 pm. Smaller sized particles are likely to be exhaled and larger sized particles are deposited in the upper airways. Preferably, monodispersed particles are used having a narrow particle size distribution.

Suitable pharmaceutical compositions for pulmonary delivery preferably have a controlled particle size and sharp and controllable particle size distribution (PSD), which is beneficial for precise lung deposition. Particle size influences the deposition of particles in the different areas in the lung.

There is the added complication that deposition of a compound in the different regions of the lungs may also be affected by disorders that give rise to inferior lung function. For example, in case of asthma, more drug is deposited in the upper lung compared to healthy volunteers. This results in less drug being deposited in the lower lung and therefore absorbed through the air-blood barrier in the alveoli, which reduces the systemic effect of the drug.

Pharmaceutical compositions that may be employed to carry active ingredients also need to be biocompatible, which means preferably biodegradable and soluble.

Suitable pharmaceutical composition for pulmonary delivery of drugs or bioactive compounds include dry powder compositions. Such compositions are often limited to the use of crystalline drugs, because oily or amorphous compounds are extremely difficult to formulate into a dry powder that can be used for consistent and invariable dosing.

It is also advantageous if the composition is not sensitive to humidity because that may cause the composition to aggregate and affect the deposition pattern of particles.

Inhalation devices that are typically employed to administer active compounds to the lung include metered dose inhalers (MDIs), dry powder inhalers (DPIs) and soft mist inhalers (SMIs). DPIs may be divided into low, medium and high resistant DPIs.

The efficiency of DPIs, for example, is affected by two main forces 1) an inspiration air flow (IAF), which depends on a flow generated by the patient, and 2) a turbulence produced by the device.

A balance between these two forces is important for optimal performance of a device. If the IAF is too low, most of the drug is lost in the upper lung, i.e. the throat and the trachea. On the other hand, with most DPI-administered formulations, if the IAF is too high, more drug may be delivered in the lower lung (the bronchi and alveoli), but in a manner where there is often poor disaggregation of particles, and therefore dispersion of the drug in the lung.

Typical fixed-dose drug combinations for pulmonary delivery require powder homogeneity to deliver a uniform dose of drug to patients. This is often attempted by a simple blend of micronized drugs with coarse carrier particles. In a MDI, the pharmaceutical composition is typically present in a liquid form, as a solution or suspension in a propellant, such as a hydrocarbon, a fluorocarbon or a hydrogen-containing fluorocarbon. In such systems, it is often difficult to prevent dissolution of a bioactive compound from the particle or to prevent leakage of the compound from the drug-containing particle.

Typically, solvents and/or surfactants are employed with a view to imparting stability to the suspension of drug particles. The compound needs to have a low solubility in the solvents that are used.

UK patent application GB 2355711 discloses a method for the preparation of particles, whereby the particles are sized during the manufacturing of the particles.

International patent application WO 2008/150537 discloses a preparation method of porous silica particles for use in chromatography. The particles may be sized prior to use. Loading of particles with a bioactive compound for use in drug delivery is neither mentioned nor suggested.

Patlolla et a/, J. Control Release, 144, 233 (2010) discloses the encapsulation of celecoxib in nanostructured lipid carrier nanoparticles and their nebulization prior to administration to mice. US patent application US 2003/0211035 A1 describes the attachment or encapsulation of a biomedical functional material (such as a bioactive agent ligand) to polymeric microspheres. Contreras et al, Mol. Pharm., 12, 2642 (2015) evaluates the difference between oral and pulmonary administration of porous particles formed by spray drying a solution of rifampicin and L-leucine) to guinea pigs. Ungaro et al, Eur. J. Pharm. Sci., 41, 60 (2010) describes the gas-foamed porous particles based on poly(lactic- co-glycolic) acid as pulmonary drug delivery carriers. Okumu et at., Pharm. Res., 19, 1009 (2002) discloses the administration of a pulmonary delivery system comprising to the lungs by generating fine aerosols of a liquid formulation of prodrugs. None of these documents disclose the use of silica particles for pulmonary drug delivery.

The use of porous materials for potential delivery of active ingredients to the lung has been disclosed. For example, US patents US 6,254,854, US 6,740,310 and US 7,435,408 all disclose polymeric materials, such as polyanhydrides and copolymers poly(lactic acid) grafted to amino acids; and international patent application WO 03/043586 discloses polymeric nanoparticles. Tartula et al ( J . Drug Target., 19, 900 (2011)), Li et al ( Nanomedicine , 11, 1377 (2015) and Wang et al, Nanoscale Research Letters, 12, 66 (2017)) disclose mesoporous silica nanoparticles for inhaled delivery of drugs. Finally, international patent application WO 03/011251 discloses mesoporous silicon carriers for pulmonary delivery.

Particles comprising nanoporous (mesoporous) silica materials have been disclosed for use in general pharmaceutical and cosmetic applications in inter alia international patent application WO 2012/035074. Here, poorly soluble active ingredients are incorporated within nanopore channels of the silica particles. The use of similar particles with a specific particle size distribution for delivery of active ingredients to the respiratory tract are disclosed in international patent application WO 2018/202818. See also international patent applications WO 2019/211624 and WO 2020/095042.

We have found that, by changing the process described in one or more of the above-mentioned patent applications to remove from pre-loaded silica particles a greater proportion of fine particulates, we have been able to obtain deagglomerated, free-flowing silica particles. This finding was very surprising, but is expected to be a significant advantage insofar as delivery of active ingredients to the lung is concerned.

Disclosure of the Invention

According to the invention, there is provided a pharmaceutical composition suitable for administration to the lung, which composition comprises a plurality of particles, which particles comprise or consist of one or more active ingredients that is/are suitable for delivery to the lung, and which particles have:

(a) a mass median aerodynamic diameter (MMAD) and/or a mean (or absolute) particle size, that is/are that is between about 0.95 pm and about 6.05 pm; and

(b) a geometric standard deviation (GSD) that is no more than 1.33, which compositions are hereinafter referred to as 'compositions of the invention'. In compositions of the invention, mean particle sizes may be presented as weight-, number-, or volume-, based mean diameters. As used herein, the term 'weight based mean diameter' will be understood by the skilled person to include that the average particle size is characterised and defined from a particle size distribution by weight, i.e. a distribution where the existing fraction (relative amount) in each size class is defined as the weight fraction, as obtained by e.g. sieving (e.g. wet sieving). The term 'volume based mean diameter' is similar in its meaning to weight based mean diameter, but will be understood by the skilled person to include that the average particle size is characterised and defined from a particle size distribution by volume, i.e. a distribution where the existing fraction (relative amount) in each size class is defined as the volume fraction, as measured by e.g. laser diffraction. As used herein, the term 'number based mean diameter' will be understood by the skilled person to include that the average particle size is characterised and defined from a particle size distribution by number, i.e. a distribution where the existing fraction (relative amount) in each size class is defined as the number fraction, as measured by e.g. microscopy. Other instruments that are well known in the field may be employed to measure particle size, such as equipment sold by e.g. Malvern Instruments, Ltd (Worcestershire, UK), Sympatec GmbH (Clausthal- Zellerfeld, Germany) and Shimadzu (Kyoto, Japan).

Mass median aerodynamic diameter (MMAD) will be understood by those skilled in the art to mean the diameter at which 50% of the particles by mass are larger and 50% are smaller over the total delivered dose as determined by any approved device, usually a cascade impactor such as a NGI, Andersen or Marple Miller impactor (see e.g. US Pharmacopeia at <601>; and/or www.uspbpep.com/usp31/v31261/usp31nf26sl_c601.asp). MMAD may be readily determined by those skilled in the art, for example by plotting on log probability paper the percentages of mass that is less than the stated aerodynamic diameters versus the aerodynamic diameters. The MMAD is taken as the intersection of the line with the 50% cumulative percent.

Particle sizes and/or MMADs of the particles may be varied depending on the preferred and/or intended site of delivery of the active ingredient. Particle sizes and/or MMADs that may be mentioned is/are between about 1 pm and about 5.50 pm. However, it is preferred that the particle size and/or MMAD of particles in compositions of the invention is between about 1.05 pm (e.g. about 1.5 pm) and about 5.0 pm, such as up to about 4.4 pm, for example up to about 3.0 pm, and for example specifically about 1.6 pm, about 1.7 pm, about 2.9 pm, about 2.8 pm, about 2.7 pm, about 2.6 pm, about 2.5 pm, about 2.4 pm, or about 2.3 pm preferably between about 1.8 pm and about 2.2 pm, such as 1.9 pm or about 2.1 or about 2.0 pm. This will mean that particles will tend to deposit primarily in the bronchioli.

GSD will be understood by those skilled in the art to be a measure of the spread of an aerodynamic particle size distribution. It is typically calculated as follows as:

(d9o/dlo) ^1/2 wherein d9o and dio represent the diameters at which 90% and 10%, respectively, of the aerosol mass are contained, in diameters less than these diameters.

It is preferred that the GSD of particles in compositions of the invention is about less than 1.32, such as less than 1.28 or less than 1.25, including less than 1.23. less than about 1.22, and even less than about 1.21, about 1.20, about 1.19, about 1.18, about 1.17, about 1.16, about 1.15, about 1.14, about 1.13, about 1.12, about 1.11, about 1.10, about 1.09, about 1.08, about 1.07, about 1.06 or about 1.05 or less.

Other parameters that may be used to define particles include mass density and the fine particle fraction (FPF). The FPF is the proportion of particles that are deposited in lungs which is typically taken as below 5pm. Preferred FPFs are at least about 50%, including at least about 60%, such as at least about 75% (e.g. at least about 80%), including at least about 85%, e.g. at least about 90%, such as at least about 95%, at least about 98%, and up to at least about 99%, at least about 99.9% or about 100%.

Thus, compositions of the invention comprise or consist of particles that are very small, but have a well-defined particle size distribution. Compositions of the invention may be manufactured in numerous ways, for example as described hereinafter. However they are manufactured, it is essential that they are separated and classified into the particle size ranges disclosed herein by an appropriate process known to those skilled in the art.

In this respect, particles may be separated using cyclonic separation, by way of an air classifier, sedimentation, force-field fractionation, and/or by sieving using one or more sieves or filters to obtain particles within the desired size ranges. However, we have found that particles within the desired size ranges are preferably obtained by elutriation, for example as described hereinafter.

Elutriation is a process for separating particles based on their size, shape and density, using flowing liquid in a direction opposite to the direction of sedimentation. The smaller particles rise to the top (overflow) because their terminal sedimentation velocities are lower than the velocity of the rising fluid.

The unexpected observation that is associated with the present invention arises from the fact that, typically, micronized particles, that is particles with mean PSD below about 10 pm, would be expected to exhibit significant particle aggregation.

This is a well-known phenomenon in particle and powder processing. Aggregation is caused by numerous attractive (ubiquitous) forces, such as van der Waals forces and/or electrostatic interactions. In many cases, particle aggregation causes unwanted problems such as poor handling and flowability and sticking to containers.

Particles within the size range mentioned herein are also often prone to aggregation in air due to the large surface area to volume ratio.

In view of the above, particle aggregation is a serious hurdle for pulmonary delivery, given that the particle size is critical to ensure correct distribution of the particles in the lung. Aggregation of particles would be expected to lead to accumulation in the throat and upper airways thereby limiting the effectiveness of the formulation. Additionally, aggregation of particles or sticking of particles in the capsules during inhalation is a severe limitation. Given that, in the field of inhalation of dry powders, active ingredients are typically administered in the form of micronized particles (of a size between about 1 pm and about 6 pm). The problem of aggregation is typically solved by either suspending micronized particles of active ingredient in a propellant (e.g. HFA), sometimes with other excipients, such as mannitol, lactose, sorbitol, etc.) in an MDI requiring actuation, or by blending such micronized particles of active ingredient with an inactive excipient of larger particle size (e.g. mannitol or lactose), inside a capsule, which is then pre-loaded or manually loaded into a DPI, whereupon inhalation de-aggregates the medication particles and disperses them within the airways.

Furthermore, although monodisperse porous particles within this size range may be made on a bench scale by various routine methods, such as precipitation, seeded and controlled growth, emulsification and microfluidics techniques, it is very difficult or very costly to manufacture porous particles on a larger, industrially-relevant scale with a perfectly uniform particle size without the creation of fine particles or sub-micron particles. Spray drying is technique that is used on an industrial scale but this produces particles with a broad particle size distribution and creates fine particles.

As described hereinafter, we have previously found that, when small amounts of pre-loaded particles of a size that might be considered to be suitable for inhalation were investigated, as expected, the particles aggregated and had poor flow properties. When attempts were made to use common excipients that are normally employed to reduce particle aggregation, such as lubricants, the flow properties of the particles did not improve.

We have now surprisingly found that producing particles with a well-defined particle size distribution by the substantial removal of fines from those particles to provide particles with the MMADs and/or particle sizes and GSDs as hereinbefore defined, results in particles that do not aggregate in the expected (and previously observed) manner. This renders them of potential utility for pulmonary delivery.

According to a further aspect of the invention, there is provided a pharmaceutical composition suitable for administration to the lung, which composition consists essentially of a plurality of particles, which particles comprise or consist of one or more active ingredient that is suitable for delivery to the lung, and which particles have:

(a) a MMAD, and/or a mean (or an absolute) particle size, that is/are between about 0.95 pm and about 6.05 pm; and

(b) a GSD that is no more than 1.33.

In this context, the phase 'consisting essentially of includes that the composition of the invention is substantially free of any excipients that are added and either do act, or are intended to act, as a lubricant. Thus, the phrase 'consisting essentially of includes that the composition comprises less that about 1%, such as less than about 0.5%, including less than about 0.1%, or less than about 0.01%, or even less than about 0.001%, of such excipients by total weight of a composition of the invention.

The aforementioned observation is a surprise because, previously in the field of powders comprising small particles (e.g. microparticles), those skilled in the art have typically added smaller particles in order to improve flowability. In addition to lubricants that are often employed, smaller particles of e.g. colloidal silica or silica nanoparticles have been added to particulate compositions with a view to reducing the contact area between primary microparticles and so to improve the flowability of those primary particles as a powder (see, for example, Yang et al, Powder Technology, 158, 21 (2005)). That we have been able to prevent aggregation by removing smaller particles in the form of fines was completely unexpected.

The process described herein allows for the removal of fines, and thereafter the production of compositions of the invention on an industrial scale, which compositions are provided in the form of handleable powders that can be administered to patients using conventional devices in a manner that provides effective therapy in a reproducible manner, in view of the fact that aggregation is not a problem.

As described hereinafter, the unexpected finding was observed for mesoporous silica 'carrier' particles within the pores of which it is intended to load active ingredients that are suitable for delivery to the lung, as described in international patent application WO 2019/202818. It is important to note however that the inventive finding is not restricted to such use and can apply to any particles that are employed in inhalation technology, and as such may apply to particulate excipients that are employed in the delivery of dry powders to the lung, as well as to active ingredients per se. Hence, as hereinbefore defined, compositions of the invention may comprise or consist of one or more active ingredients that is/are suitable for delivery to the lung in the form of a dry powder.

Dry powders are typically administered to the lung by employing one or more of the devices mentioned hereinbefore (MDIs, SMIs and DPIs).

When compositions of the invention comprise one or more active ingredients that is/are suitable for delivery to the lung, they may further comprise excipients that may be termed 'carrier particles', which carrier particles are associated in some way with said active ingredient in a pulmonary drug delivery composition.

Such excipient and/or carrier particles that may be employed in compositions of the invention may thus comprise one or more of the materials that are presently employed in the delivery of active ingredients to the lung in the form of dry powders. Such materials may be presented in the form of a simple and/or random mixture with active ingredients, as part of an interactive mixture, in which, for example, smaller particles of active ingredients are adhered to carrier particle surfaces, and/or as porous materials, in which active ingredients are loaded into the pores of such particles.

In this respect, excipients that are typically employed in MDI inhalation technology, in which active ingredients administered as a pressurized suspension of micronized particles distributed in a propellant (e.g. HFA) include mannitol, lactose, sorbitol, etc.). In DPI inhalation technology, active ingredients are administered in the form of micronized drug particles, either alone or blended with inactive excipient of larger particle size (e.g. mannitol or lactose), inside a capsule, which may be pre-loaded or manually loaded into a device. Inhalation from a DPI may de-aggregate the medication particles and disperse them within the airways. However, it is preferred that, in compositions of the invention, active ingredient(s) is/are loaded into the pores of amorphous nanoporous (mesoporous) silica particles.

Such silica particles of the compositions of the invention may also have a mass density that is less than about 0.6 g/cm ³ , such as about 0.4 g/cm ³ , for example between about 0.15 and about 0.35 g/cm ³ .

The silica particles that may be employed in compositions of the invention may have a pore size that is between about 1 nm (e.g. about 2 nm) and about 100 nm (e.g. about 50 nm). Porous silica particles preferably have an average pore size that is in the range of about 2 nm (e.g. about 3 nm, such as about 4 nm, including about 5 nm and about 8 nm) up to about 30 nm (e.g. about 20 nm, such as about 16 nm (e.g. about 15 nm), including about 13 nm, such as about 12 nm (e.g. about 10 nm). Specific average pore sizes that may be mentioned include about 4.5 nm, about 5.0 nm, about 5.5 nm, about 6.5 nm, about 7.0 nm, about 7.5 nm, about 8.0 nm, about 8.5 nm, about 9.0 nm, about 9.5 nm, about 10 nm, about 11 nm, about 12 nm, about 13 nm, or about 14 nm. Such particles may also possess a pore volume that is between about 0.05 cm ³ /g, such as about 0.08 cm ³ /g, including about 0.09 cm ³ /g (e.g. about 0.1 cm ³ /g, such as about 0.2 cm ³ /g, or about 2 cm ³ /g) and about 3 cm ³ /g, such as about 2.5 cm ³ /g, including about 2.0 cm ³ /g (e.g. about 1.5 cm ³ /g or about 1.0 cm ³ /g), and/or may preferably possess a surface area that is in the range of about 35 m ² /g, e.g. about 40 m ² /g or about 50 m ² /g (such as about 100 m ² /g, including about 150 m ² /g or about 200 m ² /g) up to about and about 1,200 m ² /g, such as about 450 m ² /g, including about 350 m ² /g, e.g. about 300 m ² /g. All of these parameters may be determined by routine techniques, such as nitrogen adsorption isotherm (Brunauer, Emmett and Teller (BET)), mercury inclusion, and Barrett, Joyner and Halenda (BJH), methods.

Shapes of the mesoporous silica particles may be controlled by the process of manufacture. Shape may be important for the incorporation and dissolution of the active ingredient. Thus, although silica particles may potentially be any shape (e.g. gyroids, rods, fibres, pseudo-spheres, cylinders, core-shells) in compositions of the invention, they are preferably essentially spherical. By "essentially spherical", we mean that they may possess an aspect ratio smaller than about 20, more preferably less than about 10, such as less than about 4, and especially less than about 2, and/or may possess a variation in radii (measured from the centre of gravity to the particle surface), in at least about 90% of the particles that is no more than about 20% of the average value, such as no more than about 10% of that value, for example no more than about 5% of that value.

Porous silica particles may be loaded with one or more active ingredients by any suitable process known to those skilled in the art. For example, particles may be loaded by way of a solvent evaporation technique, for example as described hereinafter, impregnation, for example using a melt, use of supercritical CO2, shear mixing, co-grinding, spray-drying or freeze-drying. Well known equipment, such as a fluidized bed may be used. A preferred technique is solvent evaporation.

Alternatively, active ingredients may be manufactured as nanocrystals and adsorbed onto silica particles.

Loading the active ingredient into silica particles means that it is loaded into the nanopores of the particles. It is preferred that the pores of the silica particles are loaded, such that between about 0.1 and about 60%, preferably up to about 50%, such as up to about 45%, including up to about 40%, such as up to about 35% or up to about 30%, including up to about 25% (e.g. about 20%, or about 10%) of the total weight of the loaded particles is active ingredient and, optionally, other pharmaceutical excipients, diluents or additives. In the alternative, it is preferred that up to about 60%, including up to about 70%, or up to about 80%, such as up to about 90%, e.g. up to about 100% of the pores of the silica particles are loaded with active ingredient and, optionally, other pharmaceutical excipients, diluents or additives. The entire mass of active ingredient does not have to be loaded into the pores of the particles and may otherwise be attached to the surfaces of the particle.

Active ingredients may be loaded into such silica particles in a manner that is independent of the morphology of the drug compound. Crystalline, oily and amorphous compounds may be attached to, or loaded into, the particles.

In this respect, active ingredients may be presented within the pores of the particles of compositions of the invention in an essentially crystalline state. By 'essentially crystalline', we mean that the active ingredient is at least about 95%, such as at least about 98%, for example at least about 99%, e.g. at least about 99.5%, and preferably at least about 99.9%, such as at least about 99.99%, crystalline, which may be detected by standard techniques, such as PXRD.

Alternatively, the active ingredient may be presented within the pores of the particles of compositions of the invention in an essentially amorphous state. By 'essentially amorphous', we mean that the active ingredient is no more than about 5%, such as no more than about 2%, for example no more than about 1%, e.g. no more than about 0.5%, and preferably no more than about 0.1% crystalline, which, again, may be detected by standard techniques, such as PXRD.

Presenting active ingredient in a crystalline or in an amorphous state within the pores of the particles of compositions of the invention means that the latter are capable of delivering a consistent and/or uniform dose of active ingredient, which is independent of solubility, after administration to the lung. We have found that, by incorporating active ingredient into the pores of the particles of the compositions of the invention, the active ingredient may remain in the same physical state (e.g. crystalline or amorphous), during and after manufacture, under normal storage conditions, and during use.

In addition to the fact that it is often preferred to present active ingredients in an amorphous form to enhance dissolution and/or systemic absorption, one of the biggest challenges facing pharmaceutical formulators in the field of drug delivery to the lung is that the adhesion of microparticulate active ingredients to a carrier in, say, a DPI device is highly influenced by crystallinity, which can change over time.

In particular, active ingredient can be transformed from one solid state form to another, resulting in changes in adhesive forces, which will, in turn, affect the performance of the formulation to be inhaled.

To solve this problem, formulators have often presented microparticulate active ingredients in a crystalline form in such prior art formulations. This has often led to difficulties in achieving reproducibly, because micronization or milling are often used to reduce particle size of the active ingredient, which can lead to high energy particles in amorphous form.

Thus, the loading of active ingredients into the pores of the silica particles in accordance with the invention can physically stabilize the drug in an essentially crystalline and/or or an essentially amorphous form, and prevents it from undergoing solid state transformation, such that the physio-chemical properties of the drug do not change over time.

Regardless of what the composition of the invention comprises or how it is manufactured, the active ingredient can be stored in the form, or as part, of a composition of the invention, optionally in admixture with pharmaceutically acceptable carriers, diluents or adjuvants, under normal storage conditions, with an insignificant degree of solid state transformation (e.g. crystallisation, recrystallisation, loss of crystallinity, solid state phase transition, hydration, dehydration, solvatisation or desolvatisation). In addition to this the active ingredient may be stored in this form under normal storage conditions, with an insignificant degree of chemical degradation or decomposition.

Examples of 'normal storage conditions' include temperatures of between minus 80 and plus 50°C (preferably between 0 and 40°C and more preferably ambient temperature, such as between 15 and 30°C), pressures of between 0.1 and 2 bars (preferably atmospheric pressure), relative humidities of between 5 and 95% (preferably 10 to 60%), and/or exposure to 460 lux of UV/visible light, for prolonged periods (i.e. greater than or equal to six months). Under such conditions, active ingredient may be found to be less than about 15%, more preferably less than about 10%, and especially less than about 5%, solid-state transformed. The skilled person will appreciate that the above-mentioned upper and lower limits for temperature and pressure represent extremes of normal storage conditions, and that certain combinations of these extremes will not be experienced during normal storage (e.g. a temperature of 50°C and a pressure of 0.1 bar).

We prefer that the amorphous porous silica particles are biodegradable mesoporous silica. The term 'biodegradable' means that the silica particles are dissolvable. Accordingly, a preferred embodiment of the invention is that the silica is a synthetic amorphous silica.

In order to be completely dissolvable, the silica particles of the compositions of the invention must be amorphous and therefore entirely non-crystalline (and remain so under normal storage conditions as hereinbefore defined), by which we mean that no crystallinity is detectable by standard techniques, such as PXRD.

Amorphous silica is less sensitive to humidity when compared to dry crystalline powder compositions that are typically used in pulmonary delivery of active ingredients.

Amorphous silica particles may be manufactured by processes known in the art. In one embodiment, porous particles may be manufactured by cooperative self- assembly of silica species and organic templates such as cationic surfactants such as alkyltrimethylammonium templates with varying carbon chain lengths, and counterions such as cetyltrimethylammonium chloride (CTA+CI- or CTAC) or cetyltrimethylammonium bromide (CTA+Br- or CTAB), or non-ionic species such as diblock and triblock polymer species, such as copolymers of polyethylene oxide and polypropylene oxide for example Pluronic 123 surfactant.

The formation of mesoporous silica particles occurs following the hydrolysis and condensation of silica precursors which can include alkylsilicates such as tetraethylorthosilcate (TEOS) or tetramethylorthosilicate (TMOS) in solution or sodium silicate solution. The mesoporous silica particle size can be controlled by adding suitable additive agents, e.g. inorganic bases, alcohols including methanol, ethanol, propanol, and other organic solvents, such as acetone, which affect the hydrolysis and condensation of silica species.

Pore size may not only be influenced by hydrothermal treatment of the reaction mixture such as heating up to 100°C or even above and also with the addition of swelling agents in the form of organic oils and liquids that expand the surfactant micelle template, but also, after condensation of the silica matrix, removing the templating surfactant by calcination typically at temperatures from about 500°C to about 650°C, or alternatively from 650°C up to about 750°C, in each case for e.g. several hours. Calcination at the higher of the above two temperature ranges not only burns away the organic template resulting in a porous matrix of silica (which the lower of the above two temperature ranges will also achieve), but also creates particles with one or more of the smaller average pore sizes mentioned hereinbefore (e.g. about 2 nm to about 14 nm, about 3 nm to about 13 nm and/or about 4 nm to about 12 nm (e.g. about 10 nm)), pore volumes (e.g. about 0.05 cm ³ /g to about 2.5 cm ³ /g, including about 0.08 cm ³ /g (e.g. about 0.09 cm ³ /g) up to about 2.5 cm ³ /g, including about 2 cm ³ /g (e.g. about 1.5 cm ³ /g, such as 1.0 cm ³ /g)), and/or surface areas mentioned herein (e.g. about 35 m ² /g to about 450 m ² /g, and/or about 50 m ² /g (e.g. about 100 m ² /g, including about 200 m ² /g) and about 400 m ² /g, such as about 350 m ² /g)). The template may alternatively be removed by extraction and washing with suitable solvents such as organic solvents or acidic of basic solutions.

In another embodiment, the porous silica particles may be manufactured by a sol-gel method comprising a condensation reaction between a silica precursor solution, such as sodium silicate or an aqueous suspension of silica nanoparticles as an emulsion, in either case with a non-miscible organic solution (such as benzyl alcohol), an oil, or a liquid polymer. In this process, droplets are formed by, for example, stirring or spraying the solution. Gelation of the silica may be carried out by means of changing pH, which may be carried out during or after the condensation step, and/or evaporation of the aqueous phase.

The porosity of the particles here are formed either by exclusion due to the presence of the non-miscible secondary phase or by the jamming of the silica nanoparticles during evaporation.

Such particles may further be treated by washing to remove the non-miscible secondary phase and heating to induce condensation of the silica matrix. Furthermore, the particles may be treated by calcination as hereinbefore described to strengthen the silica matrix.

In another embodiment, the porous particles may be manufactured as porous glass through a process of phase separation in borosilicate glasses (such as Si02-B203-Na20), followed by liquid extraction of one of the formed phases through the sol-gel process, or simply by sintering glass powder. During a thermal treatment, typically between 500°C and 760°C, an interpenetration structure is generated, which results from a spinodal decomposition of the sodium-rich borate phase and the silica phase.

The porous particles may also be manufactured using a fumed process. In this method, fumed silica is produced by burning silicon tetrachloride in an oxygen- hydrogen flame producing microscopic droplets of molten silica which fuse into amorphous silica particles in three-dimensional secondary particles which then agglomerate into tertiary particles. The resulting powder has an extremely low bulk density and high surface area.

The silica particles may be modified prior to separation according to size and/or prior to loading with active ingredient.

Surface modifying may include chemical surface modifying, e.g. etching. This results in an altered surface of the silica particles and may be useful to prevent to particles from aggregating, whilst not having an influence on the dissolution rate of the active ingredient compound from the particles.

Alternatively, or in addition, a further step of surface modifying the particles by coating after manufacturing and/or after loading may be carried out. Coating may not only be used to assist with the adherence of a bioactive compound to the surface of particles, but may also be used to provide an electrical charge on the surface of the particles and, in doing so, further prevent aggregation of the particles.

Particles may be coated with a functionalizing agent, such as a surfactant or an amino acid selected from the group L-lysine, L-alanine, glycine, leucine and L- tyrosine. Coating may be done to block the pores in the particle or coating may be done without blocking the pores of the particle.

In particular, prior to loading with active ingredient, silica particles may be surface modified by chemical reaction of free silanol groups with a reagent that provides at least one organic group. This can be achieved by surface modification of silica particles by reaction with an alkoxysilane, and/or an alkylhalosilane, many of which are commercially available, for example as described hereinafter. These reagents are capable of forming 1 to 3 Si-O-Si links to the surface by way of a condensation reaction with surface silanol groups.

Typical functionalising reagents that may be employed to achieve this include 3-aminopropyl triethoxysilane, 3-mercaptopropyl trimethoxysilane and various PEG-silanes. A functionalising reagent that may be mentioned is an alkylhalosilane, which alkylhalosilane may be an alkylchlorosilane containing up to 4 (e.g. 3) alkyl groups, such as between 1 and 4 (e.g. 3) linear or branched C 1-24 alkyl groups, such as Ci-is alkyl groups, including Ci-io alkyl groups, e.g. a di- or tri-C alkylchlorosilane, such as tripropylchlorosilane, triethylchlorosilane or trimethylchlorosilane.

Alternative (and/or preferred) functionalising reagents include reactive species that comprise only one alkyl chain, such as alkyl esters of halocarboxylic acids (e.g. alkylchloroformates) or haloalkanes, for example as described hereinafter. Preferred reagents include those containing linear or branched Ci-24 alkyl groups, such as Ci-is alkyl groups, including Ci-10 alkyl groups, such as Ci-4 alkyl groups, e.g. methylchloroformate or methyliodide, propylchloroformate or propyl iodide or, more preferably, ethylchloroformate or ethyliodide.

Surface modifications of this type may be carried out by reacting said functionalising reagent with silica particles, optionally in the presence of an appropriate solvent (e.g. toluene or tetrahydrofuran) and/or an appropriate base (e.g. imidazole, N-methylmorpholine or sodium carbonate), for example as described hereinafter, or alternatively as described in Zhao and Li, J. Phys. Chem., 102, 1556 (1998), Taib etal, Int. J. Chem., 3, 2 (2011), or Chmielowiec and Morrow, J. Colloid Interface Sci., 94, 319 (1983).

However it is carried out, functionalisation of silica is preferably achieved with a low conversion (i.e. only functionalising a portion of the surface -OH groups). The choice of the functionalising reagent, solvent and temperature enables a functionalisation method to obtain the desired surface coverage with organic (e.g. alkyl) groups and therefore the desired properties. Longer alkyl chains (e.g. ethyl groups and higher) are expected to lower static interactions between the silica particles, and be more hydrophilic. Further, because the obtained products are known to be sensitive to hydrolysis to liberate the corresponding alcohol, functionalization with ethyl groups is preferred as it will liberate only ethanol in the body.

Further, after loading with active ingredient, the loaded silica particles may be admixed with one or more fatty acid- or lipid-based surfactants. Such admixing is preferably done by dry mixing said surfactant with said loaded particles, more preferably by way of a high energy mixing process. Appropriate high energy mixing equipment may include, for example, intensive mechanical processors (e.g. the Nobilita- 130 Unit Mechanofusion System (Hosokawa Micron Corporation, Osaka, Japan) or Laboratory Mixer Granulator P 1-6 (DIOSNA Dierks & Sohne GmbH, Osnabruck, Germany)), for example under appropriate mixing conditions, such as those described hereinafter and/or in Zhou et a/, J. Pharm. Sc/., 99, 969 (2010).

Admixing may also be achieved by other techniques known to those skilled in the art, including spraying a solution or a suspension of said surfactant onto the surfaces of said particles by a suitable means, such as using a fluidized bed and/or a jet mill.

The term 'fatty acid- or lipid-based surfactant' will be understood to include any surfactant comprising a long (Cs-24) hydrocarbon chain. Surfactants comprising such hydrocarbon chains are or may be derived from oilseeds (e.g. palm, palm kernel, coconut, etc.), and may be saturated, branched, linear and/or aromatic. Surfactants based on lipids or fatty acids may be non-ionic, but are preferably ionic.

Ionic surfactants may include those with a cationic head group (e.g. primary, secondary, or tertiary amines; primary and secondary amines and quaternary ammonium salts); Zwitterionic (amphoteric) surfactants (e.g. sultaines, betaines and phospholipids); but more preferably include anionic surfactants, such as salts of sulfate esters (e.g. ammonium lauryl sulfate and sodium lauryl sulfate), sulfonate esters and phosphate esters or, more preferably, carboxylate esters. Anionic surfactants based on carboxylate esters include carboxylate salts (soaps), which surfactants comprises an alkali, or an alkaline earth, metal ion (e.g. sodium, potassium, calcium or magnesium) and one or more fatty acid chain with at least 10, such as at least 12, including at least 14, such as at least 16, carbon atoms. Preferred specific anionic surfactants in this class include sodium stearate, sodium lauroyl sarcosinate and carboxylate-based fluorosurfactants, such as perfluorononanoate and perfluorooctanoate. However, we prefer that the surfactant that is employed in compositions of the invention is magnesium stearate.

The amount of surfactant that may be employed in compositions of the invention is in the range of about 0.1% to about 12% by weight of the composition, such as about 0.2% to about 11%. Preferred amounts are in the range of about 1%, such as about 2%, including about 3%, up to about 10% by weight of the composition. Specific amounts that may be included are thus about 0.5%, about 1.0%, about 1.5%, about 2.0%, about 2.5%, about 3.0%, about 3.5%, about 4.0%, about 4.5%, about 5.0%, about 5.5%, about 6.0%, about 6.5%, about 7.0%, about 7.5%, about 8.0%, about 8.5%, about 9.0%, about 9.5%, about 10.0% and about 10.5%.

According to a further aspect of the invention there is a provided a process for the production of a composition of the invention, which process comprises separating particles by an appropriate method as described herein to obtain particles having an MMAD and a GSD within the ranges specified herein.

According to a yet further aspect of the invention there is a provided a process for the production of a composition of the invention that comprises mesoporous silica particles, which process comprises:

(a) forming mesoporous silica particles by an appropriate method, e.g. as described herein;

(b) optionally, calcining said silica particles at a temperature of between about 500°C and about 600°C, or about 650°C and about 750°C, in order to provide particles having relevant pore sizes, pore volumes, and/or surface areas, within the ranges described herein;

(c) separating said silica particles by an appropriate method, e.g. as described herein, so as to obtain silica particles having an MMAD, and/or a mean (or absolute) particle size, and a GSD within the ranges specified herein;

(d) optionally surface modifying said silica particles by chemical reaction of the particles and in particular the free surface silanol groups with a reagent that provides at least one organic group, as described hereinbefore;

(e) loading the obtained silica particles with one or more active ingredients as described herein; and

(f) optionally, admixing the loaded particles from step (e) with a fatty acid- or lipid-based- surfactant as described herein.

The process described herein for production of compositions of the invention has the advantage that it allows the production of particles with sizes that enable better control of the site of deposition of the particles in the lung, so enabling accurate tailoring of site-specific lung delivery (e.g. improved delivery to the deep lung) compared to prior art inhalation formulations comprising other drugs. The process described herein also reduces manufacturing costs compared to processes in which separation is conducted after loading particles with a bioactive compound, and, as described hereinbefore, is a scalable process. This may improve the yield and efficiency of the manufacturing process. The process also potentially provides for a higher drug loading of the bioactive compounds in final dosage forms comprising compositions of the invention.

Compositions of the invention are useful as medicaments/pharmaceuticals. Their unexpectedly good flow properties renders them suitable for pulmonary delivery.

Compositions of the invention may be used to deliver a wide variety of active ingredients that are suitable for administration, and/or it desirable to administer, to the lung.

In this respect, active ingredients include biologically-, pharmaceutically- and/or medicinally-active compounds that have a therapeutic or a prophylactic effect on a disease, including those diseases mentioned hereinafter. Active ingredients may thus comprise one or more antiallergic agent, bronchodilator, pulmonary lung surfactant, analgesic, antibiotic, anti infective, leukotriene inhibitor or leukotriene antagonist, antihistamine, antiinflammatory agent, antineoplastic agent, anticancer agent, anticholinergic, anaesthetic, antitubercular, cardiovascular agent, 32-adrenergic receptor agonist, corticosteroid, nonsteroidal, anti-inflammatory agent, antibiotic, anticholinergic agent, antiviral agent, mucolytic agent, prostacyclin, beta-blocker, anti- infective agent, smoking cessation agent, angiotensin II receptor antagonist, enzyme, steroid, genetic material, viral vector, antisense agent, protein or peptide (such as a tripeptide, a growth factors or an oligonucleotide), or a combination thereof.

Examples of 32-adrenergic receptor agonists include formoterol, salbutamol, pirbuterol, metaproterenol sulfate, clenbuterol, metaproterenol, terbutaline, salmeterol, pirbuterol, procaterol, reproterol, bitolterol, fenoterol, tulobuterol and atenolol. Examples of corticosteroids include beclomethasone, ciclesonide, budesonide, fluticasone, funisolide, fluocotin butyl, triamcinolone acetonide and mometasone. Examples of nonsteroidal anti-inflammatory agents include cromolyn sodium, nedocromil, amlexanox and diclofenac (sodium). Examples of antibiotics include tobramycin, colistin, aztreonam and tobramycin. Examples of anticholinergics include tiotropium bromide, ipratropium bromide, enalaprilat and enalapril. Examples of antiviral agents include zanamivir, ribavirin, ipratropium bromide and particularly remdesivir. Examples of mucolytics include N-acetyl cysteine. Examples of leukotriene receptor antagonists include pranlukast. Examples of prostacyclin analogues include iloprost. Examples of beta-blockers include metoprolol and propranolol. Examples of anti- infective agents include pentamidine. Examples of smoking cessation agents include nicotine. Examples of anesthetics include sevoflurane, desflurane, enflurane, halothane and isoflurane. Examples of anti-cancer agents include gefitinib, dasatinib, imatinib and bosutinib.

The active ingredient may also be selected from the group felodipine, indapamide, itraconazole, losartan, quetiapine, clofazimine, OSU-03021 and folic acid.

Combinations of any of the above active ingredient may be employed. Depending upon the active ingredient(s) that is/are employed, compositions of the invention find utility in the pulmonary treatment of various disorders, including local and/or systemic disorders of the respiratory system and/or lungs. Such disorders may include one or more of infection, inflammation, COPD, asthma, tuberculosis, severe acute respiratory syndrome, respiratory syncytial virus, influenza, smallpox, drug resistant respiratory infection and/or cancer.

In this respect, there is provided a composition of the invention for use in the treatment of a respiratory disorder by pulmonary administration as well as the use of a composition of the invention for the manufacture of a medicament for the treatment of a respiratory disorder by pulmonary administration.

According to a further aspect of the invention there is provided a method of treatment of respiratory disorder, which method comprises the pulmonary administration of a pharmacologically-effective amount of an active ingredient that is useful in the treatment of said respiratory disorder in the form of a composition of the invention to a patient in need of such treatment.

'Patients' include mammalian (particularly human) patients. Human patients include both adult patients as well as paedeatric patients, the latter including patients up to about 24 months of age, patients between about 2 to about 12 years of age, and patients between about 12 to about 16 years of age. Patients older than about 16 years of age may be considered adults for purposes of the present invention. These different patient populations may be given different doses of active ingredient.

Active ingredients may be administered in the form of racemates, single enantiomers and/or pharmaceutically-acceptable salts.

Pharmaceutically-acceptable salts of active ingredients include base addition salts and preferably acid addition salts. Such salts may be formed by conventional means, for example by reaction of a free acid or, preferably, free base form of an active ingredient with one or more equivalents of an appropriate acid or base as appropriate, optionally in a solvent, or in a medium in which the salt is insoluble, followed by removal of said solvent, or said medium, using standard techniques (e.g. in vacuo, by freeze-drying or by filtration). Salts may also be prepared by exchanging a counter-ion of an active ingredient in the form of a salt with another counter-ion, for example using a suitable ion exchange resin.

Pulmonary delivery means compositions of the invention are adapted for delivery to the lungs by direct inhalation, and thereby giving rise to either the direct topical treatment by the aforementioned lung diseases, or systemic absorption of active ingredients through lung mucosa.

Administration of active ingredient is preferably intermittent. The mode of administration may also be determined by the timing and frequency of administration, but is also dependent, in the case of the treatment of the relevant condition, on its severity.

Compositions of the invention may also impart, or may be modified to impart, an immediate, or a modified, release of active ingredients.

Compositions of the invention may be combined with other excipients that are well known to those skilled in the art for pulmonary delivery of active ingredients. For example, optional excipients may include propellants; surfactants, such as poloxamers; sugars or sugar alcohols, such as lactose, glucose, mannitol or trehalose; lipids, such as DPPC, DSPC, DMPC, cholesterol; amino acids, such as leucine or trileucine; cyclodextrins, hydroxypropylated chitosan, poly-lactic-co-glycolic acid (PLGA); antioxidants; humidity regulators and the like, though such are by no means essential. Indeed, we have found that, in the pulmonary delivery of compositions of the invention, fewer additional excipients are needed, which may reduce cost of manufacture.

Inhalation devices that may be employed to administer compositions of the invention to the lung include MDIs, SMIs and DPIs, including low, medium and high resistant DPIs.

Compositions of the invention may form stable compound suspensions when suspended in solvents that are typically employed in MDIs. Loaded silica particles in particular may be well-dispersed in different solvents and may be further modified to prevent dissolution or leakage of drug into the solvent before delivery to the target site or lung. In view of the fact that, as mentioned hereinbefore, compositions of the invention have unexpectedly good flow properties, this minimizes the need for disaggregation of the particles by increased IAF and turbulence produced by the inhalation device. This in turn improves the balance between the two forces discussed hereinbefore, and thus improves delivery of active ingredients to the lower lung without loss of drug in the upper lung. This further reduces the dependence on the inhalation device that is employed.

According to a further aspect of the invention, there is further provided a drug delivery device adapted for delivery of active ingredients to the lung, which delivery device comprises a composition of the invention.

The delivery device may be a MDI, a DPI or a SMI. When used in, in particular, a MDI, the composition of the invention is optionally mixed with a propellant, which propellant has a sufficient vapour pressure to form aerosols upon activation of the delivery device. The propellant may be selected from the group a hydrocarbon, a fluorocarbon, a hydrogen-containing fluorocarbon and a mixture thereof.

The above-mentioned excipients may be commercially-available or otherwise are described in the literature, for example, Remington The Science and Practice of Pharmacy, 19th ed., Mack Printing Company, Easton, Pennsylvania (1995) and the documents referred to therein, the relevant disclosures in all of which documents are hereby incorporated by reference. Otherwise, the preparation of suitable pulmonary formulations may be achieved non-inventively by the skilled person using routine techniques.

Similarly, the amount of active ingredient in the formulation will depend on the severity of the condition, and on the patient, to be treated, but may be determined by the skilled person.

Pharmaceutically-acceptable salts, and doses, of active ingredients useful in composition of the invention include those that are known in the art and described for the drugs in question to in the medical literature, such as Martindale - The Complete Drug Reference (35 ^th Edition) and the documents referred to therein, the relevant disclosures in all of which documents are hereby incorporated by reference.

Doses may be split into multiple individual doses per day. Inhaled doses may be given between once and six, such as four times daily, preferably three times daily and more preferably twice daily. Alternatively, inhaled doses may be given between once and four times weekly, for example every other day.

In any event, the medical practitioner, or other skilled person, will be able to determine routinely the actual dosage, which will be most suitable for an individual patient, depending on the severity of the condition and route of administration. The above-mentioned dosages are exemplary of the average case; there can, of course, be individual instances where higher or lower dosage ranges are merited, and such are within the scope of this invention.

The dose administered to a mammal, particularly a human, in the context of the present invention should be sufficient to affect an appropriate response (e.g. a reduction in symptoms) in the mammal (e.g. human) over a reasonable timeframe (as described hereinbefore). One skilled in the art will recognize that the selection of the exact dose and composition and the most appropriate delivery regimen will also be influenced by inter alia the pharmacological properties of the formulation, the nature, stage and severity of the condition being treated, and the physical condition and mental acuity of the recipient, as well as the age, condition, body weight, sex and response of the patient to be treated, and the stage/severity of the disease, as well as genetic differences between patients.

Wherever the word 'about' is employed herein, for example in the context of absolute numbers (e.g. ages) and relative numbers (e.g. multiples), amounts, i.e. absolute amounts such as sizes (aerodynamic diameters, particle sizes and pore sizes), doses, weights or concentrations of (e.g. active) ingredients, pore volumes, particle surface areas, particle densities, temperatures, patient populations or time periods or frequencies; or relative amounts including percentages, standard deviations and aspect ratios, it will be appreciated that such variables are approximate and as such may vary by ±10%, for example ±5% and preferably ±2% (e.g. ±1%) from the actual numbers specified. In this respect, the term 'about 10%' means e.g. ± 10% about the number 10, i.e. between 9% and 11%.

In addition to the advantages mentioned hereinbefore, compositions of the invention may provide for an improved drug loading for the reasons described hereinbefore. This enables high quantities/doses of bioactive compound to be presented in dosage forms comprising compositions of the invention, and also efficient delivery of such higher doses to the desired site in the lung in a consistent/uniform manner. This in turn means that the frequency of dosing may be reduced, so increasing the effectiveness and efficiency of treatment as well as reducing costs of healthcare.

Furthermore, improved efficiency of deposition of active ingredient in the lung in view of the low amount of aggregation of particulates allows for more efficient and more precise lung delivery, and thus an improved therapeutic effect.

Homogeneity in terms of both particle size and drug distribution within the composition may also be improved by compositions of the invention.

If desired, compositions of the invention that comprise mesoporous silica particles may include additional bioactive compounds, which may also be loaded into those particles without substantial loss of material. This may be useful in e.g. co-therapy as described hereinbefore, and moreover may further reduce cost of manufacture.

In the case of compositions of the invention comprising mesoporous silica particles, such compositions also have the advantage that the dissolution kinetics of the active is largely independent of particle size, morphology of the compound and site of delivery in the lung. Adjusting pore size may thus be employed to tailor drug dissolution kinetics, but the dissolution kinetics of the drug will be independent of the will be independent of the position of the particles in the lung.

The uses/methods described herein may otherwise have the advantage that, in the treatment of the conditions for which the aforementioned active ingredients are known for, compositions of the invention may be more convenient for the physician and/or patient than, be more efficacious than, be less toxic than, have a broader range of activity than, be more potent than, produce fewer side effects than, or that it may have other useful pharmacological properties over, similar methods (treatments) known in the prior art.

The invention is illustrated, but in no way limited, by the following examples, in which Figures 1 and 2 are light microscope images showing silica particles produced according to a prior art method (Figure 1) and according to the method of the invention (Figure 2); and Figures 3 and 4 are MMAD distributions of silica particles loaded with remdesivir and clofazimine, respectively.

Examples

Comparative Example 1 Silica Particle Manufacture I

Pluronic 123 (triblock co-polymer, E020P070E020, Sigma-Aldrich; 4 g; templating agent) and 1,3,5-trimethylbenzene (TMB; mesitylene, Sigma- Aldrich; 3.3 g; swelling agent) were dissolved in 127 mL of distilled H2O and 20 mL of hydrochloric acid (HCI, 37%, Sigma-Aldrich) while stirring at room temperature for 3 days.

The solution was preheated to 40°C before adding 9.14 mL of tetraethyl orthosilicate (TEOS; Sigma-Aldrich). The mixture was stirred for another 10 minutes at a speed of 500 rpm, then kept at 40°C for 24 hours, and then hydrothermally treated in the oven at 100°C for another 24 hours. Finally, the mixture was filtered, washed and dried at room temperature.

The product was calcined to remove the surfactant template and swelling agent. The calcination was conducted by heating to 600°C with a heating rate of 1.5°C/min and kept at 600°C for 6 hours, followed by cooling to ambient conditions. The resultant product was a white powder comprising porous silica particles. Comparative Example 2 Silica Particle Manufacture II

A dispersion (14 wt%) of silica nanoparticles (10 nm) in water (pH 9) (400 mL) was poured into benzyl alcohol (800 mL) warmed to 50°C and stirred at 300 rpm with an overhead stirrer (Silverson, UK) for 20 minutes.

A drop of acetic acid was added and vacuum (200 bar) was applied during heating at 80°C to remove the aqueous phase. The resulting particles were collected by filtration and washing with acetone.

The product was calcined by heating to 600°C with a heating rate of 1.5°C/min and kept at 600°C for 6 hours, followed by cooling to ambient conditions. The resultant product was a white powder comprising porous silica particles in the size range 2 to 4 microns measured by scanning electron microscope (JEOL, Japan) and by electrical sensing zone method (Elzone, Micromeretics USA). The particles were further treated by refluxing in ammonium hydroxide overnight followed by filtering and refluxing in nitric acid overnight and finally filtered and washed in water and oven dried at 80°C.

Comparative Example 3 Nanoporous Silica Particle Properties I

Two porous silica particle types with different porosities and densities (1.2 mL/g and 0.9 mL/g, and 0.18 mg/mL and 0.33 mg/mL, respectively) were prepared essentially as described in Comparative Example 1 and/or Comparative Example 2, and were characterised to determine their MMAD, GSD and GPS (mean particle size) using an 8-Stage Cascade Impactor (Marple), as shown in Table 1 below.

Table 1

By optical observation, it could be seen that, in small quantities, the above particles aggregated and had poor flow properties. Attempts were made to reduce particle aggregation for formulation by using the well-known glidant magnesium stearate. This is an approved excipient for inhalation products. The particles were mechanically mixed with magnesium stearate (Sigma) at several different weight ratios in the range 1-5% magnesium stearate, but the flow properties of the particles did not improve.

Comparative Example 4

Nanoporous Silica Particles and Associated Properties II

A similar batch of silica particles was made by essentially the same process as described in Comparative Example 3 above and were characterised to determine their GSD and GPS using an 8-Stage Cascade Impactor (Marple), as shown in Table 2 below.

Table 2

A light microscopy image of these particles is shown in Figure 1

Example 1 Manufacture of a Composition of the Invention I

Silica compositions prepared essentially as described in Comparative Example 1, Comparative Example 2, Comparative Example 3 and/or Comparative Example 4 above were fractionated into tight particle sizes in which fine particles were removed through elutriation.

A conical stainless steel funnel 17 L was used. 200 g of silica particles were added as a slurry in methanol to the elutriation funnel. Methanol was pumped into the funnel through the bottom inlet tube using an HPLC pump (Aglient) at a flow rate of 1 mL/min until the funnel was full and the methanol drained out of the top outlet tube. The flow rate was increased to 1.2 mL/min and maintained at fixed flow until particles emerged through the outlet.

The particle size was measured using Elzone/Electric Sensing Zone (Micromeritics, USA). The flow was maintained at a fixed flow until no further particle sizes were detected coming from the outlet (typically from one day to several days).

The flow rate was increased systematically in increments of 0.2 mL/min and the particles emerging from the outlet tube were measured for particle size. The elutriation continued until a particle sizes of 2 pm was reached. The residue particles were collected by filtration and dried overnight in an oven at 40°C. The collected particles were measured for particle size The particles that were collected had a mean particle size of 3.7 pm measured by optical microscopy (Nikon) and Electric Sensing Zone (Micromeritics, USA) and GSD of 1.25.

The removal of fine particles by this technique led to particulate compositions that were free flowing and easier to handle.

In particular, shaking powders in a vial gave rise to particles that were more discrete and did not aggregate to the same degree as corresponding particles in which fines had not been removed, not only by visual observation of the vials, but also by optical microscopy, after sprinkling particles onto a microscope slide.

A standard Next Generation Impactor (NGI; Copley Scientific, UK) test was conducted, in which an impactor was employed that is specifically designed to characterise the flow properties of inhaled and nasal products. In such an apparatus, particles are sized by successively increasing the velocity of the air stream, forcing though a series of nozzles containing progressively reducing jet diameters and collecting resultant samples from each stage in a series of collection cups. This showed that 12% (by weight) of the powder was caught in the cup corresponding to the 'throat', signifying a fine particle fraction of 88%, compared to 20% and higher caught in the cup corresponding to the throat from corresponding particles in which fines had not been removed. An active ingredient, such as any of those mentioned hereinbefore, e.g. clofazimine, is encapsulated into the porous silica particles described above in the same manner as described in Example 1 above.

Example 2

Manufacture of a Composition of the Invention II

A similar batch of silica particles was made by essentially the same process as described in Example 1 above. The silica particles were characterised to determine their GSD and GPS using an 8-Stage Cascade Impactor (Marple), as shown in Table 3 below.

Table 3

A light microscopy image of these particles is shown in Figure 2. When compared to the image shown in Figure 1 (Comparative Example 4), it is clearly visible that these particles have a much more 'even' particle size distribution with considerably less fines in the mix.

Again, the removal of fine particles led to particulate compositions that were free flowing and easier to handle. An active ingredient, such as any of those mentioned hereinbefore, e.g. clofazimine, is encapsulated into the porous silica particles described above in the same manner as described in Example 1 above.

Example 3 Remdesivir-Loaded Silica Particles

Remdesivir (150 mg; Adooq Biosciences, USA) was dissolved in ethanol (50 mL) in a round bottom flask, at 40°C while sonicating over 5 minutes. Porous silica particles (750 mg; made by essentially the same process as described in Example 1 above) were added the remdesivir solution and sonicated for 5 minutes. The flask was connected to a rotary evaporator and mixed at 40°C at 100 rpm for 10 minutes. After this, a vacuum was applied at a pressure of 120 mbar and evaporation conducted for about an hour until the solvent was fully removed.

The loaded particles were transferred to a crucible and dried in oven at 40°C under vacuum overnight. The remdesivir loading was calculated as 16% by weight.

MMAD measurements were carried out in a Next Generation Impactor (Copley Scientific, UK) with a flow rate of 60 L/minute and pressure drop of approximately 4 kPa using standard Pharmacopoeia conditions, fitted with USP throat and pre-separator.

Loaded silica particles were filled into single use capsules by hand to a fill weight of approximately 10 mg and fitted into a Breezehaler. Particle size distribution calculations were obtained from API concentration measured by HPLC analysis using acetone as solvent.

The MMAD distribution is shown in Figure 3.

Example 4

Clofazimine-Loaded Silica Particles

Essentially the same procedure as that described in Example 3 above was repeated using clofazimine (750 mg; Santa Cruz Biotechnology, Germany), dissolved in acetone (150 mL) and 6.75 g of porous silica particles to yield clofazimine-loaded particles with a loading calculated as 15% by weight.

MMAD measurements were carried out as described in Example 3 above and the distribution is shown in Figure 4. Example 5

Budesonide-Loaded Silica Particles

Essentially the same procedure as that described in Example 3 above was repeated using budesonide (300 mg), dissolved in acetone (30 mL) and 1.5 g of porous silica particles to yield the title product.

MMAD measurements were carried out as described in Example 3 above using ethanol/water (50:50) as eluent in the HPLC analysis.