Rapidly disintegrating oral dissolvable film

1. A method of forming an oral dissolvable film, the method comprising:

(a) contacting water, a rapidly dissolving binder, a film forming polymer, and a moisture deterring polymer, to form a homogeneous mixture comprising a first active ingredient;

(b) extruding the homogeneous mixture onto a substrate;

(c) curing the extruded homogeneous mixture to form an orally dissolvable film matrix:

(d) after the curing of the extruded homogeneous mixture to form the orally disintegrating film matrix, impregnating, via 3D printing, a second active ingredient to the cured oral dissolvable film; and

(e) sizing the impregnated orally dissolvable film matrix to a desired surface area; wherein,

the rapidly dissolving binder comprises polyvinyl alcohol (PVA) and polyvinyl alcohol (PVA)-polyethylene glycol (PEG) copolymer;

the film forming polymer comprises hydroxypropyl methyl cellulose (HPMC);

the moisture deterring polymer comprises aminoalkyl methacrylate copolymers; and

the oral dissolvable film has a moisture content of less than 6 wt. %.

2. The method of claim 1 , wherein the second active ingredient is moisture sensitive, oxygen sensitive, pH sensitive, heat sensitive, light (UV) sensitive, or any combination thereof.

3. The method of claim 1 , wherein the homogeneous mixture in (a) further comprises aminoalkyl methacrylate copolymers.

4. The method of claim 1 , wherein the oral dissolvable film has a moisture content of less than 6 wt. % and wherein upon contact with the oral cavity, the oral dissolvable film disintegrates within 15 seconds.

5. The method of claim 1 , wherein the homogeneous mixture in (a) further comprises at least one of plasticizer, preservative, solvent, coloring agent, flavoring agent, sweetening agent, filler, bulking agent, saliva stimulating agent, stabilizing and thickening agent, gelling agent, taste masking agent, pigment, lubricant, release modifier, adjuvant, solubilizer & emulsifier, fragrance, emulsifier, surfactant, lipid, glidant, stabilizer, antioxidant, anti-tacking agent, acid, base, buffer, and humectant.

6. The method of claim 1 , wherein the oral dissolvable film has a moisture content of less than 4 wt. % and upon contact with the oral cavity, the oral dissolvable film disintegrates within 20 seconds.

7. The method of claim 1 , wherein the oral dissolvable film is non-hygroscopic, such that at a glass climatic chamber at 25° C. and at a relative humidity of 60%, the final water content on adsorption after 24 hours is less than 12 wt. %.

8. The method of claim 1 , having a content uniformity, such that among two or more samples, the amount of active ingredient ranges from 85% to 115%, with the standard deviation of less than or equal to 6%.

9. The method of claim 1 , wherein each active ingredient is independently moisture sensitive, oxygen sensitive, pH sensitive, heat sensitive, light (UV) sensitive, or any combination thereof and wherein

the moisture sensitive active ingredient comprises one or more of desmopressin (DDAVP) (D-amino D-arginine vasopressin); dronabinol ((−)-trans-Δ 9 )-tetrahydrocanniabinol; aspirin (acetylsalicylic acid); penicillin (PCN); dipyridamole; vorapaxar; procaine; atorvastatin; azithromycin; pseudoephedrine; tiagabine; acitretin; rescinnamine; lovastatin; tretinoin; isotretinoin; simvastatin; ivermectin; verapamil; oxybutynin; hydroxyurea; selegiline; esterified estrogens; tranylcypromine; carbamazepine; ticlopidine; methyldopahydro; chlorothiazide; methyldopamine; naproxen; acetaminophen; erythromycin; bupropion; rifapentine; penicillamine; mexiletine; verapamil; diltiazem; ibuprofen; cyclosporine; saquinavir; morphine; sertraline; cetirizine; N-[[2-methoxy-5-(1-methyl)phenyl]methyl]-2-(diphenylmethyl)-1-azabicylco[2.2.2]octan-3-amine; adrenaline; amiodarone hydrochloride; atropine sulphate; diazepam; ephedrine; frusemide; haloperidol; lignocaine; metoclopramide; noradrenaline; omeprazole; ondansetron; phenytoin; vercuronium; acyclovir; amoxicillin; cefotetan; cefotaxime; metronidazole; cefuroxime; flucloxacillin; bupivacaine; cilazapril; amlodipine; felodipine; fesoterodine; isradipine; nifedipine; nimodipine; nisoldipine; cyclosporine; saquinavir; itraconazole; and ketoconazole;

the oxygen sensitive active ingredient comprises one or more of dronabinol ((−)-trans-Δ 9 -tetrahydrocannabinol); epinephrine (also known as adrenalin or adrenaline); dopamine (3,4-dihydroxyphenethylamine); chlorpromazine (CPZ); captopril; azithromycin; pseudoephedrine; tiagabine; acitretin; rescinnamine; lovastatin; tretinoin; isotretinoin; simvastatin; ivermectin; verapamil; oxybutynin; hydroxyurea; selegiline; esterified estrogens; tranylcypromine; carbamazepine; ticlopidine; methyldopahydro; chlorothiazide; methyldopamine; naproxen; acetaminophen; erythromycin; bupropion; rifapentine; penicillamine; mexiletine; verapamil; diltiazem; ibuprofen; cyclosporine; saquinavir; morphine; sertraline; cetirizine; N-[[2-methoxy-5-(1-methyl)phenyl]methyl]-2-(diphenylmethyl)-1-azabicylco[2.2.2]octan-3-amine; adrenaline; amiodarone hydrochloride; atropine sulphate; diazepam; ephedrine; frusemide; haloperidol; lignocaine; metoclopramide; noradrenaline; omeprazole; ondansetron; phenytoin; vercuronium; acyclovir; amoxicillin; cefotetan; cefotaxime; metronidazole; cefuroxime; flucloxacillin; bupivacaine; methylphenidate; fesoterodine fumarate; morphine; hydromorphone; promethazine; dopamine; epinephrine; norepinephrine; esterified estrogen; ephedrine; pseudoephedrine; acetaminophen; ibuprofen; danofloxacin; erythromycin; penicillin; cyclosporine; methyldopate; cetirizine; diltiazem; verapamil; mexiletine; chlorothiazide; carbamazepine; selegiline; oxybutynin; vitamin A; vitamin B; vitamin C; L-cysteine; L-tryptophan; morphine; hydromorphone; promethazine; pseudoephedrine; tiagabine; acitretin; rescinnamine; lovastatin; tretinoin; isotretinoin; simvastatin; ivermectin; verapamil; oxybutynin; hydroxyurea; selegiline; esterified estrogens; tranylcypromine; carbamazepine; ticlopidine; methyldopahydro; chlorothiazide; methyldopa; naproxen; acetaminophen; erythromycin; bupropion; rifapentine; penicillamine; mexiletine; verapamil; diltiazem; ibuprofen; cyclosporine; saquinavir; morphine; sertraline; cetirizine; and N-[[2-methoxy-5-(1-methyl)phenyl]methyl]-2-(diphenylmethyl)-1-azabicylco[2.2.2]octan-3-amine;

the pH sensitive active ingredient comprises one or more of desmopressin (DDAVP) (D-amino D-arginine vasopressin); vitamin D3 (cholecalciferol); omeprazole; and esomeprazole;

the heat sensitive active ingredient comprises one or more of dronabinol ((−)-trans-Δ 9 -tetrahydrocannabinol); aspirin (acetylsalicylic acid); vitamin D3 (cholecalciferol); diazepam; epinephrine (also known as adrenalin or adrenaline); omeprazole; esomeprazole; and diazepam; and

the light (UV) sensitive active ingredient comprises one or more of penicillin (PCN); diazepam; tretinoin; isotretinoin; naproxen; erythromycin; diazepam; haloperidol; acyclovir; amlodipine; isradipine; nifedipine; promethazine; norepinephrine; promethazine; tretinoin; naproxen; digoxin; nitroglycerin; aminophylline; amphotericin B; chlorpheniramine maleate; chlorpromazine HCl; cisplatin; dacarbazine; diazoxide; diphenhydramine; dopamine hydrochloride; doxycycline hyclate; droperidol; epinephrine hydrochloride; fluorouracil; folic acid; furosemide; hydrocortisone; isoproterenol; levarterenol bitartrate; menadiol sodium diphosphate; methadone; morphine sulphate; naloxone; neostigmine methylsulfate; nitroprusside solution; phenylephrine hydrochloride; phytonadione; prochlorperazine edisylate; propranolol hydrochloride; streptomycin sulphate; sulfisoxazole diolamine; terbutaline; testosterone cypionate; triflupromazine hydrochloride; vinblastine; vincristine sulphate; vitamin B complex; dextroamphetamine; ciprofloxacin; clarithromycin; griseofulvin; itraconazole; ketoconazole; terbinafine; tetracycline hydrochloride; 1,4-dihydropyridines; 4-nerolidylcatechol; avobenzone; barnidipine; butyl methoxydibenzoylmethane; doxorubicin; fluoroquinolones; melatonin; naltrexone; cephalosporins; resveratrol; sericin; 3-hydroxyflavone; 4-methylbenzylidene camphor; 5-hydroxyflavones; antazoline; xylometazoline; nafazoline; ascorbic acid; carvedilol; cilnidipine; diclofenac; diflunisal; doxycycline; lansoprazole; manidipine; methotrexate; nicardipine; ofloxacin; oxolinic acid; phenylpropanoids; quercetin; ranitidine; rhein, sulfanilamide; and triprolidine.

10. The method of claim 1 , wherein less than 1 mg of the active ingredient per dosage form is impregnated to the cured oral dissolvable film.

11. The method of claim 1 , wherein the oral dissolvable film has a thickness of less than 0.120 mm.

12. The method of claim 1 , wherein the oral dissolvable film comprises a first and a second active ingredient, wherein the first and the second active ingredient are different, and wherein the second active ingredient is impregnated via 3D printing after the curing of the extruded homogeneous mixture.