Drug-Polymer Miscibility and the Overlap Concentration (C) as Measured by Rheology: Variation of Polymer Structure

Objectives Amorphous solid dispersions (ASDs), wherein a drug is molecularly dispersed in a polymer, can improve physical stability and oral bioavailability of poorly soluble drugs. Risk of drug crystallization is usually averted using high polymer concentrations. However, we demonstrated recently that the overlap concentration, C *, of polymer in drug melt is the minimum polymer concentration required to maintain drug in the amorphous state following rapid quench. This conclusion was confirmed for several drugs mixed with poly(vinylpyrrolidone) (PVP). Here we assess the solid-state stability of ASDs formulated with a variety of polymers and drugs and at various polymer concentrations ( C ) and molecular weights (MWs). We further test the hypothesis that degree of drug crystallization decreases with increasing C / C * and vanishes when C > C *, where C * depends on polymer MW and strength of drug-polymer interaction. Methods We test our hypothesis with ASDs consisting of ketoconazole admixed with polyacrylic acid, polymethacrylic acid and poly (methacrylic acid- co -ethyl acrylate); and felodipine admixed with PVP and poly (vinylpyrrolidone-co-vinyl acetate). Values of C * for polymers in molten drug are rheologically determined. Crystallization behavior is assessed by measuring enthalpy of fusion, ΔH f and by X-ray diffraction. Results We confirm that ΔH f / ΔH f , C = 0 = f ( C / C ∗), and essentially no crystallization occurs when C > C *. Conclusions Our findings will aid researchers in designing or selecting appropriate polymers to inhibit crystallization of poorly soluble drugs. This research also suggests that C * as determined by rheology can be used to compare drug-polymer interactions for similar molecular weight polymers. Graphical abstract