Dispensing method for producing dissolvable unit dose film constructs

1. A method for forming a dissolvable unit dose film construct, comprising:

providing a muco-adhesive composition including a muco-adhesive polymer matrix, the muco-adhesive polymer matrix comprising:

a water-soluble polymer, a water-dispersible polymer, a water-swellable polymer, or combinations thereof; and

a liquid carrier;

drying the muco-adhesive composition to remove at least a portion of the liquid carrier, forming a muco-adhesive film substrate;

forming a composition for a first active layer, the composition including a polymer matrix, the polymer matrix comprising:

a water-soluble polymer, a water-dispersible polymer, a water-swellable polymer, or combinations thereof;

an active ingredient; and

a liquid carrier,

wherein the composition for the first active layer has a viscosity of 1-300 cps at 1 sec −1 shear rate;

depositing the composition for the first active layer onto the muco-adhesive substrate as a plurality of individual volumes; and

removing the liquid carrier from the plurality of deposited individual volumes to form a plurality of first dissolvable film active layers on the muco-adhesive substrate.

2. The method of claim 1 , wherein the composition for the first active layer is deposited onto the muco-adhesive substrate as a plurality of individual volumes in the range between 0.1 μL to 5,000 μL.

3. The method of claim 2 , wherein the composition for the first active layer is deposited as a plurality of individual volumes in the range between 0.1 μL and 50 μL.

4. The method of claim 1 , wherein the viscosity of the composition for the first active layer deposited onto the muco-adhesive substrate is between 25 and 50 cps at 1 sec −1 shear rate.

5. The method of claim 1 , wherein the composition for the first active layer is at least 5% by weight solids at the time of depositing.

6. The method of claim 1 , wherein the muco-adhesive polymer matrix further includes an active ingredient.

7. The method of claim 6 , wherein the active ingredient in the muco-adhesive polymer matrix is compositionally distinct from the active ingredient in the composition for the first active layer.

8. The method of claim 1 , further including:

forming a composition for a second active layer, the composition for the second active layer comprising a polymer matrix, a water-soluble polymer, a water-dispersible polymer, a water-swellable polymer, or combinations thereof;

an active ingredient; and

a liquid carrier;

depositing the composition for the second active layer onto the muco-adhesive substrate as a plurality of individual volumes; and

removing at least a portion of the liquid carrier from the deposited individual volumes of the composition for the second active layer, forming a plurality of second dissolvable film active layers overlying the muco-adhesive substrate.

9. The method of claim 8 , wherein the plurality of second dissolvable film active layers is formed on a same side of the muco-adhesive film substrate as the plurality of first dissolvable film active layers.

10. The method of claim 9 , wherein the plurality of second dissolvable film active layers is spatially isolated from the plurality of first dissolvable film active layers on the muco-adhesive film substrate.

11. The method of claim 8 , wherein the plurality of second dissolvable film active layers is formed on an opposing side of the muco-adhesive film substrate from the plurality of first dissolvable film active layers.

12. The method of claim 8 , wherein the active ingredient of the plurality of second dissolvable film active layers is compositionally distinct from the active ingredient of the plurality of first dissolvable film active layers.

13. The method of claim 1 , wherein the polymer matrix of the muco-adhesive film substrate and the plurality of first dissolvable film active layers include at least one compositionally shared water-soluble polymer, at least one water-dispersible polymer, at least one water-swellable polymer, or combinations thereof.

14. The method of claim 8 , further including:

forming a composition for a third active layer, the composition for the third active layer comprising a polymer matrix comprising a water-soluble polymer, a water-dispersible polymer, a water-swellable polymer, or combinations thereof;

an active ingredient; and

a liquid carrier;

depositing the composition for the third active layer onto the muco-adhesive substrate as a plurality of third individual volumes; and

removing at least a portion of the liquid carrier from the deposited individual volumes of the composition of the third active layer, forming a plurality of third dissolvable film active layers overlying the muco-adhesive film substrate.

15. The method of claim 1 , wherein the muco-adhesive composition is a thixotropic paste.

16. The method of claim 1 , wherein the muco-adhesive film substrate is formed as a continuous web of film, and then is divided into smaller individual films after forming the plurality of first dissolvable film active layers on the muco-adhesive film substrate.

17. The method of claim 1 , wherein the step of depositing the composition for the first active layer comprises depositing using a jetting system.

18. The method of claim 1 , wherein the step of depositing the composition for the first active layer comprises depositing through a piezoelectric or air actuated valve.

19. The method of claim 1 , wherein the active ingredient comprises buprenorphine.

20. A method for forming a dissolvable unit dose film construct, comprising:

providing a muco-adhesive composition including a muco-adhesive polymer matrix, the muco-adhesive polymer matrix comprising:

a water-soluble polymer, a water-dispersible polymer, a water-swellable polymer, or combinations thereof; and

a liquid carrier;

drying the muco-adhesive composition to remove at least a portion of the liquid carrier, forming a muco-adhesive film substrate;

forming a composition for active layer, the composition having at least 5% by weight solids and viscosity of 1-300 cps at 1 sec −1 shear rate, the composition for the active layer comprising:

a water-soluble polymer, a water-dispersible polymer, a water-swellable polymer, or combinations thereof;

an active ingredient; and

a liquid carrier;

dispensing the composition for the active layer onto the muco-adhesive substrate via a jetting system having a piezoelectric or air actuated valve as a plurality of individual volumes each having a volume between 0.1 μL and 50 μL;

removing the liquid carrier from the plurality of deposited individual volumes to form a plurality of dissolvable film active layers on the muco-adhesive substrate; and

cutting the muco-adhesive film substrate to separate at least some of the plurality of dissolvable film active layers and thereby form individual unit doses.

21. A unit dose film construct made by the method of claim 1 .

22. The method of claim 1 , wherein the active ingredient comprises apomorphine.

23. The method of claim 1 , further including cutting the muco-adhesive film substrate to separate at least some of the plurality of first dissolvable film active layers and thereby form individual unit doses.