MANUFACTURE OF TABLETS FROM ENERGY-APPLIED POWDER BLEND

1 . A process for making tablets comprising one or more pharmaceutically active agent(s) and one or more binder(s), said method comprising the steps of (i) applying energy to a powder blend comprising said pharmaceutically active agent(s) and said binder(s) for a sufficient period of time to activate said binder(s) within said powder blend and (ii) forming a predetermined amount of said energy-applied powder blend into said tablets, wherein said tablets have a density less than 0.8 g/cc and said tablets disintegrate in the mouth when placed on the tongue in less than about 30 seconds.

2 . The process of claim 1 , wherein said binder is a meltable material having a melting point of from about 40° C. to about 140° C. and said powder blend is exposed to said energy for a sufficient period of time to melt or soften said meltable material.

3 . The process of claim 2 , wherein said binder is an RF-meltable binder and said powder blend is exposed to RF energy for a sufficient period of time to melt or soften said meltable material.

4 . The process of claim 3 , wherein said radiofrequency energy has a frequency of from about 1 MHz to 100 MHz.

5 . The process of claim 1 , wherein said binder is water-activating binding material, said powder blend further comprises a water-containing material, and said powder blend is exposed to said energy for a sufficient period of time to heat the water-containing material above its dehydration temperature.

6 . The process of claim 1 , wherein said powder blend comprises from about 0.01 to about 30 percent, by weight, of said pharmaceutically active agent and from about 1 to about 30 percent, by weight, of said meltable binder.

7 . The process of claim 1 , wherein said binder is polyethylene glycol.

8 . The process of claim 1 , wherein said powder blend further comprises one or more carbohydrates selected from the group consisting of dextrose monohydrate, mannitol, erythritol, dextrose, lactose, sorbitol, isomalt, sucrose, dextrates and maltodextrins.

9 . The process of claim 8 , wherein said powder blend comprises from about 30 to about 95 percent, by weight, of said one or more carbohydrates.

10 . The process of claim 1 , wherein said powder blend has an average particle size of less than 500 microns.

11 . A process of claim 1 , wherein said energy-applied powder blend is cooled prior to forming said tablets.

12 . A process of claim 1 , wherein said tablets are formed within a tablet die.

13 . A process of claim 1 , wherein said energy-applied powder blend is cut to form said tablets.

14 . The process of claim 1 , wherein said tablets meet the criteria for Orally Disintegrating tablets as defined by the draft Food & Drug Administration guidance, as published April, 2007.

15 . The process of claim 1 , wherein said tablets have a hardness of less than 700 grams as measure using Texture Analyzer TA-XT2i that is fitted with a 7 millimeter diameter flat faced probe.

16 . The process of claim 1 , wherein the surface of said tablets are further exposed to infrared energy wherein the majority of the wavelength of said infrared energy from about 0.5 to about 5 micrometers.

17 . A process for making tablets comprising applying radiofrequency energy to a powder blend comprising a pharmaceutically active agent and a RF-meltable binder for a sufficient period of time to soften or melt said RF-binder and forming a predetermined amount of said energy-applied powder blend into said tablets.

18 . The process of claim 17 , wherein said tablets have a density less than 0.8 g/cc.

19 . The process of claim 15 , wherein said tablets disintegrates in the mouth when placed on the tongue in less than about 30 seconds.

20 . A tablet manufactured according to the process of claim 1 .