CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This application claims priority from U.S. Provisional Patent Application Serial Number 62848685 (hereinafter US62848685), which was filed on May 16, 2019 and U.S. Non- Provisional (Utility) Patent Application Serial Number 16/830561 (hereinafter US16/830561), which was filed on 26 March 2020. The entire content of US62848685 and US 16/830561 is incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] The present application relates to crystalline forms of irinotecan free base and processes of making thereof.

[0003] Irinotecan is [l,4'-bipiperidine]-T-carboxylic acid, (4S)-4, ll-diethyl-3,4, 12,14- tetrahydro-4-hydroxy-3,14-dioxo-lH-pyrano[3',4':6,7]indolizi no[l,2-b]quinolin-9-yl ester, having the following formula:

[0004] Unlike irinotecan hydrochloride, iriontecan in the form of free base has not been known to exist in different crystal forms. There is a need in the art for a stable, well-defined crystalline irinotecan free base, which may be conveniently used as an active pharmaceutical ingredient in the preparation of a pharmaceutical composition comprising irinotecan free base, and simple processes for preparing such a polymorph.

SUMMARY OF THE INVENTION

[0005] A first object of the present invention is to provide a crystalline form of iriontecan free base denominated as iriontecan base crystalline form S 1 in the present application.

[0006] Irinotecan base crystalline form S 1 is characterized by a powder x-ray diffraction pattern with peaks at about 8.7±0.2, 13.1±0.2, 14.5±0.2, 17.4±0.2, 18.4±0.2, 20.9±0.2, 24.0±0.2 and 27.5±0.2 degrees two-theta.

[0007] The crystalline form S 1 may be prepared by a process comprising steps of:

neutralizing an irinotecan acetic acid salt with sodium bicarbonate solution in dichloromethane to obtain a first mixture comprising an organic layer; filtering the first mixture; separating the organic layer from the first mixture; concentrating the separated organic layer; adding ethanol to the concentrated organic layer to precipitate the crystalline form SI and obtain a second mixture; isolating the crystalline form SI from the second mixture; washing the isolated the crystalline form S I with ethanol; and then drying the crystalline form SI.

[0008] A second object of the present invention is to provide another crystalline form of iriontecan free base denominated as iriontecan base crystalline form S2 in the present application.

[0009] Irinotecan base crystalline form S2 of is characterized by a powder x-ray diffraction pattern with peaks at about 7.1 ±0.2, 10.6±0.2, 12.4±0.2, 20.6±0.2, 21.6±0.2 and 24.2±0.2 degrees two-theta.

[0010] The crystalline form S2 may be prepared by a process comprising steps of:

dissolving irinotecan free base in dichloromethane at an elevated temperature to obtain an irinotecan free base solution; adding ethanol and then ethyl acetate to the irinotecan free base solution to precipitate the irinotecan free base and obtain a suspension. The precipitated crystalline form S2 is isolated from the suspension and washed with ethyl acetate and then dried.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Fig. 1 illustrates a powder X-ray diffraction pattern of crystalline irinotecan free base form S I.

[0012] Fig. 2 illustrates a TGA thermogram for crystalline form SI irinotecan free base.

[0013] Fig. 3 illustrates a DSC thermogram for crystalline form SI irinotecan free base.

[0014] Fig. 4 illustrates a powder X-ray diffraction pattern of crystalline irinotecan free base form S2.

[0015] Fig. 5 illustrates a TGA thermogram for crystalline irinotecan free base form S2.

[0016] Fig. 6 illustrates a DSC thermogram for crystalline form S2 irinotecan free base.

[0017] Fig. 7 illustrates the overlay powder X-ray diffraction patterns of crystalline form S3 irinotecan free base at different humidity conditions.

DETAIFED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0018] The present application provides several crystalline forms of irinotecan free base, i.e., Forms SI -S3.

[0019] In accordance with one embodiment, crystalline form SI of irinotecan free base is characterized by a powder x-ray diffraction pattern with peaks at about 8.7±0.2, 13.1±0.2, 14.5±0.2, 17.4±0.2, 18.4±0.2, 20.9±0.2, 24.0±0.2 and 27.5±0.2 degrees two-theta; preferably, form S 1 is further characterized by a powder x-ray diffraction pattern with peaks at about

10.9±0.2, 11.6±0.2, 15.2±0.2, 16.4±0.2, 16.7±0.2, 18.0±0.2, 18.8±0.2, 19.4±0.2, 20.2±0.2, 21.7±0.2, 22.4±0.2, 22.5±0.2, 24.6±0.2, 26.2±0.2 and 31.3±0.2 degrees two-theta. As a preferred embodiment, the crystalline form S 1 is preferably characterized by a powder X-ray diffraction pattern as substantially depicted in Fig. 1.

[0020] The crystalline form SI may be characterized by a weight loss of about 3.1% at a temperature up to 150°C, as determined by thermal gravimetric analysis (“TGA”). The crystalline form SI may be further characterized by data selected from a group consisting of: an endothermic peak at 50-150°C, an endothermic peak followed by an exothermic peak at 150— 200°C, and two endothermic peaks with onset temperatures at 231.2°C and 239.5°C, as determined by differential scanning calorimetry (“DSC”)· Typically, the crystalline form SI of irinotecan free base provided in the present application is a monohydrate form and preferably has a -3.5% of water content, as analyzed by Karl Fischer titration (“KF”).

[0021] In accordance with a second embodiment, crystalline form S2 of irinotecan free base is characterized by a powder x-ray diffraction pattern with peaks at about 7.1±0.2, 10.6±0.2, 12.4±0.2, 20.6±0.2, 21.6±0.2 and 24.2±0.2 degrees two-theta.; preferably, form S2 is further characterized by a powder x-ray diffraction pattern with peaks at about 12±0.2, 14.3±0.2, 15.6±0.2, 17.3±0.2, 19.0±0.2, 23.2±0.2 and 24.8±0.2 degrees two-theta. As a preferred embodiment, the crystalline form S2 is preferably characterized by a powder X-ray diffraction pattern as substantially depicted in Fig. 4.

[0022] The crystalline form S2 may be characterized by a weight loss of about 1.1% at a temperature up to 150°C, as determined by thermal gravimetric analysis (“TGA”). The crystalline form S2 may be further characterized by data selected from a group consisting of an endothermic peak with the onset temperature at 111 °C and an endothermic peak with maximum temperature at 235.7°C.

[0023] Experimental Methodology [0024] X-ray Powder Diffraction Anaylsis

X-ray Powder Diffraction patterns were collected on a Bruker AXS D8 diffractometer using Cu Kal radiation (40 kV, 40 mA), 0-20 goniometer, and divergence of 10 mm slits, a Ge monochromator and LynxEye detector. The representative PXRD pattern was

collected under ambient condition.

The details of the scanning parameters are:

Angular range: 5-40°

Step size: 0.02°

Scan speed: 0.6 sec/step.

[0025] Thermogravimetric Analysis (TGA)

TGA data was collected on a TA instrument Q500 TGA. Each sample (15-20 mg) was loaded onto a pre-tared platinum crucible and the balance and furnace were purged with nitrogen prior to the analysis with a flow rate set as 40±5 and 60±5 mL/min, respectively.

The heating process was programmed to start at the ambient temperature and stop at

300°C with a 10°C/min ramp.

[0026] Differential Scanning Calorimetry (DSC)

DSC data was collected on a TA Instrument MDSC Q200. Each sample (2-5 mg) was loaded onto a hermetic pan and the analysis was carried out under a constant flow of nitrogen (60 mL/min). The heating process was programmed to start from 30°C with a 10°C/min ramp and stop at 270°C, respectively. EXAMPLES

[0027] The following examples are provided to illustrate, but not to limit, the present invention.

Example 1

[0028] The preparation of the crystalline form SI of irinotecan free base

[0029] Irinotecan.HOAc (150 g) and dichloromethane (1300 mL, 8.7 vol) were added to a 3L flask at 20-30°C. Water (150 mL, 1 vol) and 5% sodium bicarbonate (600 mL, 4 vol) were added to neutralization to form an organic layer, which was then separated. The separated organic layer was washed with water (1500 mL, 10 vol) and then concentrated to about 600 mL. Ethanol (1650 mL, 11 vol) was added to the organic layer at 30-40°C to obtain a mixture. The mixture was concentrated to about 1500 mL and then cooled to 20-30°C and stirred at this temperature for 1 hr to obtain a suspension, which was then filtered to obtain a wet cake. The wet cake was dried to afford irinotecan free base form SI (120.3 g).

[0030] The PXRD characteristics of the crystalline form S 1 of irinotecan free base are reflected in the following table:

Example 2

[0031] The preparation of the crystalline form S2 of irinotecan free base

[0032] Irinotecan free base (10.5 g) and dichloromethane (104 mL, 10 vol) were added to a 500mL flask at room temperature (20-30°C) to obtain a first mixture. Ethanol (32 mL, 3 vol) was added to the mixture at 35-45°C followed by ethyl acetate (52 mL, 5 vol) to obtain a second mixture. The second mixture was concentrated to about 140 mL (13 vol), and then ethyl acetate (63 mL, 6 vol) was added at 35-45°C to obtain a third mixture. The third mixture was concentrated to cloud, held for lhr to obtain a slurry mixture. The slurry mixture was concentrated to about 140 mL (13 vol) to obtain a fourth mixture. After holding for lhr, the fourth mixture was cooled to 20-30°C and filtered to obtain a wet cake. The wet cake was washed with ethyl acetate (52 mL, 5 vol) then dried to afford irinotecan free base form S2 (7.65 g)·

[0033] The PXRD characteristics of the crystalline form S2 of irinotecan free base are reflected in the following table:

Example 3

[0034] The preparation of the crystalline form S3 of irinotecan free base

[0035] Irinotecan free base (119 g) and dichloromethane (1600 mL, 13.5 vol) were added to a 3L flask at room temperature (20-30°C) to obtain a first suspension mixture. Water (120 mL, 1 vol) and 5% sodium bicarbonate (480 mL, 4 vol) were added to the first mixture at room temperature. The suspension was filtered, and then the phases were allowed to separate, and an organic layer was saved. Water (600 mL, 5 vol) was added, and the phases were allowed to separate, and the organic layer was saved. The organic layer was concentrated to about 430 mL (3.6 vol). Ethyl acetate (1440 mL, 12 vol) was added to the concentrated organic layer at 25-35°C to obtain a second mixture. The second mixture was concentrated to about 1665 mL (14 vol) then cooled to 15-25°C to obtain a slurry mixture. The slurry mixture was filtered, and a wet cake was obtained and dried under the nitrogen to afford irinotecan free base form S3 (98.04 g). The Lorm S3 was studied by using variable humidity x-ray powder diffraction (VH-XRPD) to investigate the humidity effect on XRPD pattern (Pig 7). When the sample was exposed at 5-40% RH, no significant change in diffraction peaks was observed. Once the sample was exposed at higher than 60%RH, the diffraction peaks changed, indicating that the humidity had impact on the diffraction peaks. The changes in diffraction peaks are reversible with the humidity being changed.