Diclofenac sublingual spray

1. A stable sublingual spray formulation comprising

from about 20 to about 40% diclofenac, or a salt thereof;

from about 15 to about 45% water;

from about 5 to about 35% ethanol;

from about 5 to about 35% of propylene glycol; and

from about 1 to about 30% of polyethylene glycol 400.

2. The stable sublingual spray formulation of claim 1 wherein the diclofenac salt is potassium or sodium salt.

3. The stable sublingual spray formulation of claim 1 wherein the polar solvent is selected from the group consisting of water, ethanol, and a combination thereof.

4. The stable sublingual spray formulation of claim 1 wherein the co-solvent is selected from the group consisting of propylene glycol, a low molecular weight polyethylene glycol, and a combination thereof.

5. The stable sublingual spray formulation of claim 1 further comprising an excipient selected from the group consisting of one or more permeation enhancers, flavoring agents, sweeteners, sweetness enhancers, taste-masking agents, and a combination thereof.

6. The stable sublingual spray formulation of claim 5 wherein the one or more flavoring agents is peppermint oil, the one or more sweeteners is sucralose, the one or more sweetness enhancers is ammonium salt of glycyrrhizic acid, and the one or more taste-masking agents are sodium chloride and polyethoxylated castor oil.

7. The stable sublingual spray formulation of claim 1 that is capable of producing a droplet size distribution wherein greater than 98% of the composition particles are greater than 10 microns in diameter during administration.

8. The stable sublingual spray formulation of claim 1 that is capable of producing a droplet size distribution wherein

a) the mean Dv(10) is from about 10 to about 40 microns during administration;

b) the mean DV(50) is from about 50 to about 180 microns during administration; and

c) the mean DV(90) is from about 300 to about 700 microns during administration.

9. The stable sublingual spray formulation of claim 1 that is capable of producing a spray span ((Dv90−Dv10)/Dv50) of from about 1.5 to about 8.

10. The stable sublingual spray formulation of claim 1 that is capable of producing

a) a spray that has an ovality ratio of from about 1.1 to about 2;

b) a spray plume width that is from about 10 to about 50 millimeters during administration; and

c) a spray plume angle that is from about 20 to about 50 degree during administration.

11. A method of treating pain comprising administration of the stable sublingual spray formulation of claim 1 to a patient in need thereof.

12. The method of claim 11 wherein the pain is selected from the group consisting of acute migraine, osteoarthritis, rheumatoid arthritis, and inflammation associated pain.

13. The method of claim 11 wherein from about 50 to about 200 microliters (μL) of the sublingual spray formulation of claim 1 is administered to the patient.

14. A method of treating inflammation comprising administration of the stable sublingual spray formulation of claim 1 to a patient in need thereof.

15. A method of preventing crystal growth in a diclofenac sublingual spray formulation comprising adding at least 5% propylene glycol, at least 1% polyethylene glycol, and less than 50% water.

16. The stable sublingual spray formulation of claim 1 comprising

from about 20 to about 35% diclofenac, or a salt thereof.

17. The formulation of claim 16 comprising

from about 20 to about 30% diclofenac, or a salt thereof;

from about 20 to about 40% water;

from about 10 to about 30% ethanol;

from about 5 to about 25% of propylene glycol; and

from about 1 to about 20% polyethylene glycol 400.

18. The formulation of claim 16 comprising

from about 25 to about 35% water;

from about 15 to about 25% ethanol;

from about 10 to about 20% of propylene glycol; and

from about 5 to about 15% polyethylene glycol 400.