Drug delivery systems and methods for making and using the same
11737970 · 2023-08-29
Assignee
Inventors
Cpc classification
B82Y5/00
PERFORMING OPERATIONS; TRANSPORTING
A61K9/0097
HUMAN NECESSITIES
Y10S424/00
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
A61K9/16
HUMAN NECESSITIES
A61K9/00
HUMAN NECESSITIES
Abstract
During nanoscale manufacture on a substrate, payload active agents are loaded on a delivery platform, with a release layer between the delivery platform and the payload active agent and an encapsulate over the payload active agent. The combined delivery platform, release layer, active agent payload, and encapsulant form a nanoscale drug delivery vehicle for subsequent delivery to a patient. The nanoscale drug delivery vehicle is small enough to permeate through the cell and deliver the payload active agent within the cell via reducing the retaining functionality of the release layer and degrading of the encapsulant. The nanoscale drug delivery vehicle offers a series of improved features including greater control of size, shape, dosage, bioavailability, cell targeting, and release timing.
Claims
1. A method of preparing a nanoscale drug delivery vehicle for drug delivery to a patient or biological specimen, the method comprising the sequential performance of the steps of: (a) providing a substrate; (b) disposing a buffer layer onto the substrate; (c) disposing a delivery platform onto the buffer layer; (d) disposing a release layer onto the delivery platform; and (e) disposing a payload active agent onto the release layer; wherein the payload active agent, the release layer, the delivery platform, the buffer layer, and the substate are configured in vertical alignment along a vertical axis, with the payload active agent being disposed above the release layer along the vertical axis, the release layer being disposed above the delivery platform along the vertical axis, the delivery platform being disposed above the buffer layer along the vertical axis, and the buffer layer being disposed above the substrate along the vertical axis; wherein the buffer layer retains the delivery platform against the substrate; wherein the release layer retains the payload active agent against the delivery platform; wherein following the sequential performance of steps (a) through (e), the nanoscale drug delivery vehicle, comprising the delivery platform, the release layer, and the payload active agent, is prepared via releasing the delivery platform from the substrate via reducing the buffer layer’s retaining functionality via one or more of: thermal exposure, chemical exposure, sound exposure, electromagnetic field exposure, light exposure, mechanical force; and wherein following the releasing of the delivery platform from the substrate, the payload active agent is delivered in vivo to the patient or biological specimen via releasing the payload active agent from the delivery platform in vivo by reducing the release layer’s retaining functionality via one or more of: thermal exposure, chemical exposure, sound exposure, electromagnetic field exposure, light exposure, mechanical force.
2. The method of claim 1, wherein one or more of the steps of disposing the buffer layer onto the substrate, disposing the delivery platform onto the buffer layer, disposing the release layer onto the delivery platform, or disposing the payload active agent onto the release layer comprise patterning via a nanoscale manufacturing technique chosen from one or more of: direct writing, optical lithography, directed self-assembly, imprint lithography, particle beam lithography.
3. The method of claim 1, wherein the step of disposing the delivery platform onto the buffer layer is performed via one or more of nucleation deposition, atomic layer deposition, polymer spin coating, vapor deposition, plasma deposition, chemical vapor deposition, chemically assisted particle beam deposition, plasma deposition, electroplating.
4. The method of claim 1, wherein the step of disposing the payload active agent onto the release layer is performed via one or more of: nucleation deposition, atomic layer deposition, polymer spin coating, vapor deposition, plasma deposition, chemical vapor deposition, chemically assisted particle beam deposition, plasma deposition, electroplating.
5. The method of claim 1, wherein the disposing the buffer layer onto the substrate is performed via one or more of: nucleation deposition, atomic layer deposition, polymer spin coating, heating of the substrate, vapor deposition, plasma deposition, chemical vapor deposition, chemically assisted particle beam deposition, plasma deposition, electroplating.
6. The method of claim 1, wherein the buffer layer is formed of a material comprising one or more of: a metal, an oxide, a ceramic, a polymer, or combinations thereof.
7. The method of claim 1, wherein prior to the release of the delivery platform from the substrate, the delivery platform is adhered to a second object.
8. The method of claim 1, wherein the disposing of the release layer onto the delivery platform is performed via one or more of: nucleation deposition, atomic layer deposition, polymer spin coating, heating of the substrate, vapor deposition, plasma deposition, chemical vapor deposition, chemically assisted particle beam deposition, plasma deposition, electroplating.
9. The method of claim 1, wherein prior to the releasing the payload active agent from the delivery platform in vivo, the payload active agent is adhered to a second object.
10. The method of claim 1, wherein following the performance of step (e), an encapsulant is disposed over the payload active agent.
11. The method of claim 10, wherein the encapsulant is formed of a material comprising one or more of: a solvent, a polymer, a wax, a fatty acid, an amino acid, a protein, an enteric coating, a protective active agent, a shellac.
12. The method of claim 10, wherein following the disposing of the encapsulant over the payload active agent, the payload active agent is exposed from under the encapsulant by degrading the encapsulant via one or more of: thermal exposure, chemical exposure, sound exposure, electromagnetic field exposure, light exposure, mechanical force.
13. The method of claim 1, wherein the delivery platform is formed of a material comprising one or more of: a metal, an oxide, a ceramic, a polymer, or combinations thereof.
14. The method of claim 1, wherein the delivery platform is formed of a material having a patterned metastructure configured to reflect light so as to provide information.
15. The method of claim 1, wherein the material of the payload active agent and the delivery platform is patterned to define a patterned metastructure configured to reflect light so as to provide information.
16. The method of claim 1, wherein the payload active agent comprises one or more of the group of: a pharmaceutical drug, a biological molecule, a lipid, a carbohydrate, a polymer, an amino acid, a polymeric drug, a protein, a nucleic acid, a combinatorial polymer, a fatty acid, a combinatorial therapeutic, a wax, a steroid, a glyceride, a liquid, an element, a compound, an antibiotic, a vaccine, a genomic agent, a virus, mitochondria, a bacteria, a physical structure, a detergent, a lubricant, a fertilizer, a therapeutic, a nucleotide, a nucleoside, a supplement, a combinatorial medicine, a nano machine, a cosmetic, a marker, a solvent.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) These and other features and advantages of the various embodiments disclosed herein are better understood with respect to the following descriptions and drawings, in which:
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DETAILED DESCRIPTION
(8) Disclosed herein are nanoscale based drug delivery vehicles and methods for researching, developing, manufacturing, preparing, and administering the same. According to the preferred embodiment, the drug delivery platform is a nanoscale-sized structure that allows the deposit and adhesion, encapsulation, transportation, controlled release and delivery of nanoscale-size payload active agents which are medicines bound to the delivery platform by a controllable release layer for delivery in vivo or in vitro to a patient or other biological specimen.
(9) In some aspects, the nanoscale drug delivery vehicles are prepared by printing therapeutic payload active agents on nanoscale delivery platforms. In some aspects, the nanoscale drug delivery vehicles are prepared by means of three dimensional printing on delivery platforms. In some aspects, the delivery platforms are active structures (e.g., they have some therapeutic effect on their own). In some aspects, the delivery platforms improve and/or control bioavailability of therapeutics (e.g., peptide drugs, pharmaceutical drugs, biomolecules, etc.) - a key factor in drug delivery. In some embodiments, the concept disclosed herein uses surface exposure using a beam of particles to seed growth areas to custom deposit sub-30 nanometer payload active agents (e.g., therapeutics) onto sub-100 nanometer disks (e.g. platforms, platform islands, etc.) that are taken up by the cell when introduced into the body or cell transdermally, intradermally, intravenously, topical, transmucosally, orally, as a suppository, ocularly, through the respiratory system or direct surface contact, as a liquid, as a powder, a dissolvable tape, as a non-dissolvable tape, as a compact pill, as a capsule or as a combination of one or plural combination of more than one for in vitro or in vivo delivery to the body or cell. In some aspects, the disposing of the payload active agents is by means of surface nucleation deposition, atomic layer deposition, physical vapor deposition, chemical vapor deposition, evaporation deposition, plasma deposition, electroplating or chemically assisted particle beam deposition.
(10) In some aspects, the largest dimension of the deposited payload active agent is less than about 500 nm, about 100 nm, about 50 nm, about 40 nm, about 30 nm, about 20 nm, or about 10 nm in diameter, measured at the widest point. In some embodiments, the largest dimension of the delivery platform is less than about 1000 nm, about 100 nm, about 80 nm, or about 50 nm in diameter, measured at the widest point. The nanoscale drug delivery vehicles containing the payload active agent may be printed in batches of similar or dissimilar sizes, and in similar or dissimilar shapes, all of which may be seen to affect intracellular permeability, solubility and bioavailability of the nanoscale drug delivery vehicles and/or the payload active agents. The nanoscale drug delivery vehicles may be printed using techniques including, but not limited to, resist based optical lithography, direct-write particle beam lithography; imprint patterning, directed self-assembly or resistless nucleation patterning.
(11) It may be seen that one aspect of the present disclosure is that patterning of the material, including the material comprising the delivery platform and the payload active agent, at the nanoscale level, may allow the ability to create sub-wavelength surface metastructures of the payload active agent and/or the delivery platform. These patterned metastructure features allow custom or semi-custom printing of single and/or multiple reflective signatures, which may be utilized according to known and future methods of optical and/or other form of verification to allow up to patient-level verification of manufacturer origin, time, lot code and prescription, as well as to convey any and all other forms of encoded information for useful purposes throughout the manufacturing, prescribing, administering, and potentially even the post-administration process. According to various embodiments, the method of preparing the nanoscale drug delivery vehicle, including the provision of the materials used in forming the nanoscale drug delivery vehicle, and the disposing of those materials to form the components used in its manufacture, including but not limited to the substrate, the buffer layer, the release layer, the delivery platform, the payload active agent, and the encapsulant layer may be performed by various known and future developed methods, which may include but are not limited to nucleation deposition, atomic layer deposition, physical vapor deposition, chemical vapor deposition, evaporation deposition, electroplating, ink printing, chemically assisted particle beam deposition, a combination or a subset of each process with the emphasis of ambient temperature, pressure and chemical exposure for each process to avoid destroying the active agent payload.
(12) Once produced, the nanoscale drug delivery vehicle structure, which according the preferred embodiment comprises the delivery platform, the payload active agent, the release layer, and the encapsulant, may be removed from the substrate using a variety of techniques to reduce the buffer layer’s retaining functionality, which may include known and future developed methods, including but not limited to thermal exposure, chemical exposure, sound exposure, electromagnetic field exposure, light exposure, and mechanical force. For example, according to the one contemplated embodiments, the nanoscale drug delivery vehicle may be physically adhered to a second object, such as a liftoff structure, and the delivery platform of the nanoscale drug delivery platform may be released from the substrate via physical force. According to other embodiments, release of the nanoscale drug delivery platform from the substrate may be achieved via the buffer layer being dissolved in a solution, transferring the nanoscale drug delivery vehicle structures to the solution. According to further embodiments, the nanoscale drug delivery vehicle may be release from the substrate according and be collected in an evaporated dry powder form. However, it may be seen that once released from the substrate, the nanoscale drug delivery vehicles may be collected in any known or future developed form in which nanoscale structures are collected, and as such may be packaged, administered, or otherwise further manipulated in known or future developed ways.
(13) According to a preferred embodiment, the nanoscale drug delivery vehicles may be embedded within a dissolvable or non-dissolvable tape, bandage or implantable physical structure as a deliverable media. Each individual unit of a deliverable media of these types may have, for example, between hundreds of thousands to trillions of individual nanoscale drug delivery vehicles per unit. Delivery mechanisms to administer the nanoscale drug delivery vehicles may include all known or future developed methods of administration, including but not limited to administration transdermally, intradermally, intravenously, topical, transmucosal orally, as a suppository, ocular, respiratory or direct surface contact transfer, and my include all known or future forms of administrable compounds, including but not limited to liquids, powders, populated surfaces by means of a liquid or a powder, a dissolvable tape, a non-dissolvable tape, a compact pill, a capsule or a combination of one or plural combination of more than one for in vitro, or in vivo delivery to a patient or biological specimen.
(14) In some embodiments, these nanoscale drug delivery vehicles have the potential to turn molecular discoveries arising from generic and advanced therapeutic drug development into widespread benefit for patients. In some aspects, the nanoscale drug delivery vehicles offer improved delivery systems for existing drugs that can be manufactured on-demand, as a customizable, on-demand activation medical solution for each individual patient.
(15) In some embodiments, the nanoscale drug delivery vehicles may be configured to have a controlled release of one or more of the payload active agents into the patient or biological specimen to which it is or will be administered, with such controlled release being controlled by known or future developed methods that may be influenced or controlled by certain controllable aspects of the nanoscale drug delivery vehicle and the components thereof, such as shape, size, magnetic properties, electric field properties charge doping, and other aspects. It may be seen that manipulation of such aspects may affect the bioactive characteristics of the payload active agents nanoscale drug delivery vehicles, including but not limited to active or passive bioavailability. In some aspects, the release of the payload active agents loaded on the nanoscale drug delivery vehicles may allows passive or active triggered release through mechanisms based upon thermal, time, sound, light, magnetic, electric field, or radiation, all of which may affect bioavailability characteristics within the body or within the cell. In some aspects, intracellular delivery of multiple nanoscale drug delivery vehicles or their payload active agents may allow recombination or reconstruction of the payload active agents to form ideal therapeutics that are too large to permeate the cell as originally designed.
(16) In some embodiments which target efficiency in biodistribution, the nanoscale drug delivery vehicles may has dimensions of less than about 500 nm, about 200 nm, about 100 nm, about 90 nm, about 80 nm, about 70 nm, about 50 nm, about 30 nm about 10 nm, about 1 nm, or about 0.5 nm in diameter, measured at the widest point, In some aspects, the nanoscale drug delivery vehicles prepared according to the disclosed methods may be small enough to penetrate the cell wall/membrane. In some aspects, the nanoscale drug delivery vehicles and/or payload active agents prepared by the disclosed methods are variously configured to improve bioavailability, require lower doses than conventional forms of drugs via conventional methods of administration, and to selectively target delivery zones within the body.
(17) In some embodiments, the nanoscale drug delivery vehicles are prepared using “direct-write” technologies, massively parallel particle beam printing technologies, optical lithography printing technologies, nano imprint technologies, directed self-assembly (DSA) technologies or a combination of one or more of these technologies. However, it may be seen that the nanoscale drug delivery vehicles may be formed according to other known and future developed methods of preparation. According to one particular embodiment, a method of preparing a nanoscale drug delivery vehicles is contemplated in which a beam technology it utilized, which may be seen to result in high speed, high resolution (resistless) pattern processing for heterogeneous patterned deposits. According to the preferred embodiment, the nanoscale drug delivery vehicles may be prepared according to the systems and methods for operation of the various embodiments of the direct-write and particle beam printing technologies disclosed in the following U.S. Pat., the disclosure of each of which are hereby incorporated by reference: 7,259,373; 7,993,813; 7,501,644; 7,495,244; 7,507,960; and 7,659,526.
(18) In some embodiments, the nanoscale drug delivery vehicles prepared using the methods disclosed herein may fully customize the delivery platform, the payload active agent, or both for generic or patient specific application. In some aspects, one or more materials can be used as a platform (e.g., scaffold, support, matrix, platform, etc.) or buffer to result in positive or negative adhesive. In some embodiments, one or more of the payload active agents can be formed having a patterned metastructure. In some embodiments, by leveraging the ability to make unique “direct-write” sub-100 nanometer structures, using the chemical purity of the semiconductor industry, and new beam technologies for high speed, high resolution (resistless) pattern processing, the high volume of personally customized nanoscale drug delivery vehicles may be achieved.
(19) In some embodiments, the nanoscale drug delivery vehicles may be manufactured by a simple selective pattern nucleation of the materials combined with encapsulating and followed by release of nanoscale drug delivery vehicles from the substrate. In some embodiments, the methods for selective pattern nucleation of the materials cannot be performed using semiconductor techniques due to the chemical and/or thermal exposure related to the resist-based fabrication. In some embodiments, resist-based fabrication would destroy the payload active agent. In some embodiments, the method for selective pattern nucleation of the material may be gentle and ambient process to avoid damaging the payload active agent or reducing their therapeutic functionality. In some embodiments, the highspeed beam and patterned processing technology can be used for manufacturing both the material of the delivery platform and of the payload active agents. In some embodiments, these nanoscale drug delivery vehicle design leverages commercial semiconductor process design software and design rule to create and design new drugs and combinations of therapeutics, supplements, genomics, and active delivery machines
(20) According to certain aspect of the present disclosure, the nanoscale drug delivery vehicles and/or the components thereof may be manufactured using ion, neutron, electron or photon beam technology, herein referred to “beam technology.” It may be seen that beam technology may enables the high volume printing of the seed layer for growing one or more components of the structure of the nanoscale drug delivery vehicle. In some embodiments, the beam technology is comprised of a unique high speed ion optic, parallel beam optic or stencil projection particle beam optic that delivers spatially and temporally resolved, highly controlled, and highly repetition beam packets that improve spatially resolved interaction at the pattern seeding surface.
(21) In some embodiments, the technology disclosed herein can leverage the maturity and flexibility of direct-write semiconductor lithography with custom 3D print nano-scaled medication preparation as a new form of customizable drug manufacturing technology. In some embodiments, the techniques described herein create a low-cost manufacturing process. In some embodiments, the fabrication can be used with computer-aided-design (CAD) information to provide 2D and 3D printed medicine allowing customizability. In some embodiments, the processes allow available-on-demand medication that can be stored in raw material and/or that can be offered at lower cost handling of bio material. In some contemplated embodiments, the nanoscale drug delivery vehicles may enable transport of drug payload active agents through the cell membranes and into the cell cytoplasm offering improved bioavailability and bio-distribution. In some embodiments, the nanoscale drug delivery vehicle and/or the components thereof, such as the delivery platform, may be formed of metal composites which can be selected, sized and conjured in order to selectively target certain organs. In some embodiments, selective targeting can be performed by adding targeting molecules to the disclosed nanoscale drug delivery vehicles. In some embodiments, selective targeting can allow improved delivery for a range of applications such as, for example, but without limitation, binding polymers to calcium for bone cancer treatment, cure infections of burn victims, or treating renal and liver failure.
(22) 3D printing has recently taking a lead role as a potential solution for future manufacturing of solid, physical and functional objects. However, there are still many problems and limitations to the technology for high resolution and high throughput manufacturing. Current limitations of the technology bar the manufacturing of hybrid materials (customizable, multi-materials, alloys and compounds), require touch (finishing) labor, and display insufficient purity for drug manufacturing and limited resolution derived from the thermal dynamics of the writing beam that creates a weld (heat) pool around the 3D feature exposure. In some embodiments, the techniques disclosed herein address those limitations.
(23) In some embodiments, formation of surface metastructures as flat lens reflective optics can be created by the nanoscale drug delivery vehicle structure, including but not limited to the metastructure of the delivery platform or the payload active agent. It may thus be seen that these metastructures may be configured in order to convey information, which may be harnessed in order to, for example but without limitation, provide custom trusted and patient verifiable anti-counterfeit signatures.
(24) In some embodiments, the nanoscale drug delivery vehicles are manufactured by direct write ion exposure to seed the surface substrate or delivery platform. In some embodiments, after direct write ion exposure, heterogeneous nucleation deposition is performed. In some embodiments, the process is performed by disposing a releasable buffer layer (such as an oxide or resist) on the substrate, which may be, in the exemplary embodiment, a silicon wafer. In some embodiments, delivery platforms are then disposed onto the substrate. In some embodiments, a wide range of elements, metals, composites, and alloys, can be used to form the delivery platform of the nanoscale drug delivery vehicle. In some embodiments, these delivery platforms, may be, including but without limitation, gold, aluminum, titanium, titanium dioxide, copper or zinc oxide. It may thus also be seen that the material of the delivery platform itself may also provide natural or dual function antibiotic properties, such as for example the recognized antimicrobial properties of copper. In some embodiments, the sites for the delivery platforms are exposed as circular or otherwise defined shapes on the substrate (oval, rectangular, polygonal, triangular, etc.). In some embodiments, the substrate is placed in a nucleation chamber for parallel nucleation by means of a carrier gas and de-absorption of a metal on the buffer layer. In some embodiments, the process can then be repeated with various buffers and payload layers using a variety of chemicals which are then coated with a protective layer to form an encapsulant, allowing a 2D or 3D build of material, hybrid material, systems or combinations plus a protective coating used during travel from the substrate to the delivery mechanism, with example aspects, but not limited to mechanisms as a liquid, a powder, a dissolvable tape, a non-dissolvable tape, a compact pill, a capsule or a combination of one or plural combination of more than one., invitro or invivo to the body or host cell.
(25) In some embodiments, the delivery mechanism is a liquid, a powder, a dissolvable tape, a non-dissolvable tape, a compact pill, a capsule or a combination of one or plural combination of more than one.
(26) In some embodiments, the substrate is a semiconductor wafer, including but not limited to silicon, gallium arsenide, sapphire and other common wafer materials. In some embodiments, the substrate is a less common wafer like substance, including a metal, an alloy, glass, quartz, or combinations of common and less common materials.
(27) In some embodiments, because the disclosed methods can involve a direct write process, each nanoscale drug delivery vehicle or group of nanoscale drug delivery vehicles can be custom fabricated specifically for a patient or group of patients to maximize a unique biodistribution for that patient or group of patients.
(28) In some embodiments, features of the presently disclosure allow the ability to both research and manufacture high volumes of high purity, highly potent and freshly manufactured on demand personalized drugs, hybrid drugs, custom deliverable medicines, supplements, vaccines, therapeutics or combinatorial generic medicines. Some embodiments permit clinicians or researchers to explore nanotoxicology, genomics, proteomics, lipid or polymer-based nanoparticles, carrier-mediated chemotherapeutic agents, selective active or passive delivery methods, antibiotics, nano based anti-cancer and anti-aging agents. In some embodiments, features of this new technology allow improvement of biodistribution, delivery of personalized pharmacokinetics medicine, exploration of pharmacodynamics, and how they relate to improved bioavailability by drug delivery within the cell.
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(35) A wide variety of variations are possible. Components may be added, removed or reordered. Different components may be substituted out. The arrangement and configuration may be different. Similarly, processing steps may be added or removed, or reordered.
(36) Those skilled in the art will appreciate that the methods and designs described above have additional applications and that the relevant applications are not limited to those specifically recited above. Also, the present invention may be embodied in other specific forms without departing from the essential characteristics as described herein. The embodiments described above are to be considered in all respects as illustrative only and not restrictive in any manner.
(37) It will further be appreciated that applications for this disclosure are virtually unlimited. Described above are a small number of high leveraged nanomedicine applications to demonstrate the potential of this disclosure, particularly for controlled delivery of protein and lipid loaded nanomedicines. A wide variety of other application are possible. It will be further appreciated that the majority of the disclosed method steps can also be performed via existing resist based semiconductor patterning using optical lithography. This may be seen as equivalent to present day technology and may greatly reduce the risk of various steps.
(38) Although this disclosure is generally in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present disclosure extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the disclosure and obvious modifications and equivalents thereof. In addition, while several variations of the various embodiments disclosed herein have been shown and described in detail, other modifications, which are within the scope of this disclosure, will be readily apparent to those of skill in the art. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes. Thus, it is intended that the scope of the present disclosure should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.