STABLE WOUND CARE FORMULATION

Abstract

The present invention relates to a sterile gel formulation suitable for use in filling a wound cavity and delivering an active ingredient thereto, the gel further having a pH range of 4.5 to 8.5, low bioadhesive strength and cohesive integrity and being formed from a polymer selected from among the group consisting of poly(vinyl) alcohol (PVA) polymer and a PVA-polyvinyl acetate copolymer, a cross-linker being a salt form of boron that produces borate ions in aqueous solution, at least one compound which has a beneficial effect as an active ingredient in the wound and at least one modulator, the modulator being a low molecular weight species that is capable of binding borate or PVA in aqueous solution through a mono-diol or di-diol formation and reduces the pH of PVA-borate hydrogels; wherein the gel is heat and/or gamma sterilised and contains less than 5% acetic acid and the polymer has a degree of hydrolysis of between 98% and 100% and a molecular weight of from 100,000 to 300,000 Daltons.

Claims

1. A sterile gel formulation suitable for use in filling a wound cavity and delivering an active ingredient thereto, the gel further having a pH range of 4.5 to 8.5, low bioadhesive strength and cohesive integrity and being formed from a polymer selected from among the group consisting of poly(vinyl) alcohol (PVA) polymer and a PVA-polyvinyl acetate copolymer, a cross-linker being a salt form of boron that produces borate ions in aqueous solution, at least one compound which has a beneficial effect as an active ingredient in the wound and at least one modulator, the modulator being a low molecular weight species that is capable of binding borate or PVA in aqueous solution through a mono-diol or di-diol formation and reduces the pH of PVA-borate hydrogels; wherein the polymer has a degree of hydrolysis of between 98% and 100% and a molecular weight of from 100,000 to 300,000 Daltons and wherein the gel is heat and/or gamma sterilised and contains less than 5% acetic acid.

2. A gel formulation as claimed in claim 1, wherein the gel formulation is sterilised at 121 C. for 15 minutes.

3. A gel formulation as claimed in claim 1, wherein the gel contains less than 2% acetic acid.

4. A gel formulation as claimed in claim 1, wherein the molecular weight of the polymer is from about 145 Daltons to about 200,000 Daltons.

5. A gel formulation as claimed in claim 1, wherein the amount of borate used in preparing the gel is from about 1.5 to about 3% w/w.

6. A gel formulation as claimed in claim 1, wherein the amount of modulator added in the preparation of the gel is from about 0.1 to about 5% w/w.

7. A gel formulation as claimed in claim 1, wherein the amount of polymer in the gel formulation ranges from about 8 to about 20% w/w.

8. A gel formulation as claimed in claim 1, wherein the at least one compound which has a beneficial effect as an active ingredient in the wound is a local anaesthetic.

9. A gel formulation as claimed in claim 1, wherein the at least one compound which has a beneficial effect as an active ingredient in the wound is a salt form of lidocaine .

10. A gel formulation as claimed in claim 1, wherein the at least one compound which has a beneficial effect as an active ingredient in the wound is selected from prilocaine, bupivacaine or another active ingredient that produces a conjugate acid and is stable in the presence of borate ions.

11. A gel formulation as claimed in claim 1, wherein the amount of active ingredient added in the preparation of the gel is from 0.1 to 5% w/w.

12. The gel formulation as claimed in claim 1 for use in wound protection.

13. The gel formulation as claimed in claim 1 for use in sealing a wound.

14. The gel formulation as claimed in claim 1 for use in preventing blood loss from a wound.

15. The gel formulation as claimed in claim 1 for use in the removal of debris from a wound.

16. The gel formulation as claimed in claim 1 for use in the prevention of wound infection.

17. (canceled)

18. A process for preparing the gel formulation of claim 1, comprising: (a) preparing a stock solution of polymer; (b) preparing a stock solution of cross-linker; (c) adding the active ingredient and the at least one modulator to the cross-linker solution; (d) gradually adding the solution prepared in step (c) with stirring to the solution prepared in step (a) to form a gel; (e) maintaining the resultant gel in a water-bath at 85 C. for 30 minutes; (f) stirring the gel to make it substantially homogenous ; and (g) sterilising the gel with heat or with gamma radiation.

19. The process of claim 18, wherein heat sterilisation is carried out at 121 C. for 15 minutes.

20. A patch comprising the gel formulation of claim 1 and a porous support.

21. A method of treatment of a wound, said method comprising: (a) lying the gel formulation of claim 1 to an open wound and allowing it to flow to fill the wound cavity; and (b) removing the gel formulation from the wound cavity after a predetermined period of time.

22. A method of treatment of pain in a human or animal patient, said method comprising: (a) applying the gel formulation of claim 1 to an intact skin surface in the region of the patient's body where the desired therapeutic effect is to be delivered; (b) overlying the gel formulation with a support ; and (c) removing the gel formulation from the skin surface after a predetermined period of time.

23. The method of treatment of claim 22, wherein the support is provided with adhesive for attachment to surrounding skin to restrict movement of the underlying gel formulation.

24. The method of treatment of claim 22, wherein the support is a porous support for secure attachment to the exposed surface of the applied gel formulation.

25. The method of claim 22, wherein the predetermined period of time ranges from about 10 minutes to about 4 hours.

26. The method of treatment of claim 21, wherein the predetermined period of time ranges from about 10 minutes to about 4 hours.

Description

[0053] In the drawings:

[0054] FIGS. 1A, 1B, 1C, 1D, 1E and 1F are photographs which show the appearance after 9 months of various blank PVA-THB hydrogels (i.e. not containing an active agent) according to the invention;

[0055] FIG. 2 is a graph which shows the effect of storage (0 vs 9 months) on the pH of the blank PVA-THB hydrogels according to the invention;

[0056] FIGS. 3A, 3B, 3C, 3D, 3E and 3F are graphs which show the results of stress sweep (0.1 to 100 Pa) at different frequency (0.1, 1, 10 Hz) for the fresh (0 month) and 9 month old PVA-THB hydrogels referred to in FIG. 2;

[0057] FIGS. 4A, 4B, 4C, 4D, 4E and 4F are graphs which show the effect of storage duration on storage (G) and loss (G) moduli and loss tangent (G/G) of the blank PVA-tetrahydroxyborate (THB) hydrogels according to the invention;

[0058] FIGS. 5A, 5B and 5C are combined graphs which respectively show the effect of storage duration on storage (G) moduli, loss (G) moduli and loss tangent (G/G) of the blank PVA-THB hydrogels according to the invention;

[0059] FIGS. 6A and 6B are graphs which show storage (G) and loss (G) moduli of various 9 month old blank PVA-THB hydrogels prepared according to the invention, before and after reheating;

[0060] FIGS. 7A and 7B are graphs which show storage (G) and loss (G) moduli for various lidocaine HCl loaded PVA-THB hydrogels according to the invention;

[0061] FIGS. 8A and 8B are graphs which show the effect of storage on in vitro release of lidocaine HCl from the PVA-THB hydrogels according to the invention;

[0062] FIGS. 9A and 9B are graphs which show storage (G) and loss (G) moduli for lidocaine HCl loaded PVA-THB hydrogels according to the invention; and

[0063] FIGS. 10A and 10B are graphs which show the effect of storage on in vitro release of lidocaine HCl from other PVA-THB hydrogels according to the invention.

[0064] The following description outlines that low degree of hydrolysis PVA blank hydrogels exhibit turbidity, phase separation and an acetic acid-like odour on storage. These unwanted changes cannot reversed by simple heating and mixing. Higher degree of hydrolysis (99%) PVA blank hydrogels according to the invention do not exhibit such changes.

[0065] For lidocaine HCl loaded PVA-THB hydrogels, hydrogels prepared with polymers having 99% hydrolysis are superior to lower degree of hydrolysis PVA hydrogels in almost all physicochemical properties and lidocaine HCl is generally stable in the higher degree of hydrolysis formulation at 20 C.

[0066] The effect of degree of hydrolysis on the stability of both drug loaded and placebo/blank hydrogels is unexpected. This knowledge can be used to successfully manufacture stable PVA-THB hydrogels.

EXAMPLES

[0067] Measurement of stability parameters was conducted for both Lidocaine loaded and blank (placebo) hydrogels.

Example 1: Blank PVA-THB Hydrogels

[0068] Preparation

[0069] PVA and borax were obtained from Merck (Merck Millipore Catalogue Nos. 141350-354, 141356 and 106303, respectively). PVA stock solution and 5% borax solution were prepared in advance of preparing the hydrogels.

[0070] 20% PVA stock solution sufficient to result in a final PVA concentration of 10% w/w was weighed into an empty container followed by gradual addition with stirring of 5% borax solution sufficient to result in a final borax concentration of 2.5% w/w. The resultant gel was kept in a water-bath at 85 C. for 30 minutes. After heating, the gel was stirred thoroughly to make it as homogenous as possible and poured into containers. The compositions of fresh and 9 month old blank PVA-THB hydrogels are displayed in Table 1 below.

[0071] The viscosity of the PVA in standard solution as listed under PVA type in Table 1 above (e.g. 4 mPAs, 5 mPAs, 28 mPas) is proportional to the molecular weight of the PVA chains. For example, the molecular weight of 28-99 PVA is about 145,000 Daltons.

TABLE-US-00001 TABLE 1 Batch number, storage duration, PVA type and composition of fresh and 9 month old blank PVA-THB hydrogels. Storage Batch No. condition PVA Type* PVA (% w/w) Borax (% w/w) 1 9 months 4-88 10 2.5 2 9 months 5-88 10 2.5 3 9 months 8-88 10 2.5 4 9 months 26-88 10 2.5 5 9 months 40-88 10 2.5 6 9 months 28-99 10 2.5 7 0 months 4-88 10 2.5 8 0 months 5-88 10 2.5 9 0 months 8-88 10 2.5 10 0 months 26-88 10 2.5 11 0 months 40-88 10 2.5 12 0 months 28-99 10 2.5 *viscosity in mPas (40 g/l water) - degree of hydrolysis (as named by Merck)

[0072] All 9 month old blank hydrogels prepared with lower degree of hydrolysis (PVA (4-88, 5-88, 8-88, 26-88 and 40-88)) and higher degree of hydrolysis (PVA (28-99)) were observed for colour or phase changes.

[0073] pH and Rheological Measurement

[0074] The pH, storage (G), loss (G) moduli and loss tangent of fresh and 9 month old blank PVA-THB hydrogels (Table 1) were determined. Measurements were carried out using a controlled stress rheometer (AR 1500, TA Instruments, New Castle, Del., USA) with Rheology Advantage Data Analysis Program Version 5.7.0, TA. Parallel plate geometry (20 mm, 1 mm gap) was used for the prepared hydrogels. The experimental temperature was efficiently monitored at 25 C. (0.1 C.). The rheometer instrument was programmed for set temperature (25 C.) and equilibration for 3 min. Stress sweep (0.1 to 100 Pa) was performed on all samples at three different frequencies (0.1, 1, 10 Hz) to check the linearity of stress vs. strain curve within the range studies. Frequency sweep from 0.1 to 100 Hz at constant stress of 60 Pa was also performed on each samples to find out storage (G) and loss (G) moduli.

[0075] Re-Heating Experiments and Effect of Heating Time

[0076] Some of the 9 month old hydrogels showed a turbid/opaque appearance and even de-mixing (phase separation). To check the reversibility of such changes, these 9 month old hydrogels were again heated at 85 C. for 30 minutes. Various physicochemical parameters such as storage (G), loss (G) moduli as well as hardness and compressibility were determined for the re-heated 9 month old hydrogels.

[0077] To investigate a previously observed phase change on extended heating for 88% hydrolysed PVA, 26-88 and 28-99 hydrogels were freshly prepared with different periods of heating at 85 C. (1, 2 and 3 hours). The physical form (homogenous or de-mixed) was observed after cooling to room temperature.

[0078] Results

[0079] Visual Observation

[0080] All 9 month old blank hydrogels prepared were observed for physical appearance and phase separation. The representative photographs of PVA blank hydrogels listed in Table 1 (batch numbers 1-6) are shown in FIGS. 1A-1F, respectively. Containers containing low degree of hydrolysis hydrogels were found to give off an acetic acid like odour. The odour was proportional to the degree of turbidity/phase separation. The above observations are summarised in Table 2 below.

[0081] As can be seen in Table 2 and FIG. 1, the higher degree of hydrolysis (99%) PVA (28-99) hydrogels remained clear without phase separation. These same hydrogels did not give off an acetic acid like odour. In contrast, the lower degree of hydrolysis (88%) PVA (4-88, 5-88, 8-88, 26-88 and 40-88) hydrogels showed turbidity and phase separation.

[0082] The turbidity was proportional to the molecular weight of PVA chains. 4-88, 5-88 and 8-88 hydrogels did not show phase separation but 26-88 and 40-88 hydrogels showed de-mixed phases. De-mixing was more significant with 40-88 hydrogels than with 26-88 hydrogels.

[0083] The major difference between the gels which displayed some sort of time dependent change and those which did not is the degree of hydrolysis. This suggests that the observations are attributable to the difference in the number of residual acetate groups present on the PVA chains.

[0084] Without being bound by theory, it is suggested that hydrolysis of residual acetate groups leads to the liberation of residual acetic acid groups which causes a reduction in the local pH which discourages the diol-THB interaction and encourages degradation of PVA chains. Furthermore, the resultant degraded PVA chains and disrupted interaction between the diol-groups and THB anions are thought to encourage hydrophobic interactions between non-polar regions of the polymer which could possibly be sufficient to cause the turbidity seen.

TABLE-US-00002 TABLE 2 Batch number, colour, phase condition and acetic acid like odour for the 9 month old blank PVA- THB hydrogels prepared according to Table 1. Batch No. Colour De-mixing Acetic acid like odour 1 Opaque (+) No Yes (+) 2 Turbid (++) No Yes (++) 3 Turbid (+++) No Yes (+++) 4 Turbid (++++) Yes Yes (++++) 5 Turbid (+++++) Yes Yes (+++++) 6 Clear () No No () Note: = absence of colour or odour; + = lowest colour or odour; +++++ = highest colour or odour.

[0085] pH

[0086] The pH of fresh and 9 month old hydrogels are displayed in FIG. 2 with the left hand column in each group of two columns showing the pH of the fresh hydrogel at 20 C. and the right hand columns showing the pH of the 9 month old hydrogel at 20 C. The decrease in pH is deemed to be related to the degree of hydrolysis and the molecular weight of the PVA used to prepare the gels. As can be seen from FIG. 2, the 28-99 PVA hydrogels showed the smallest decrease in pH over 9 months storage at 20 C. Again, without being bound by theory, it is suggested that the hydrolysis of residual acetate groups results in formation of acetic acid over a period of time and hence a decrease in pH.

[0087] Rheological Measurement

[0088] Stress sweep and frequency sweep were performed on blank PVA hydrogels. The main objective of stress sweep was to check the linearity of strain vs. stress curves at different frequencies (0.1 to 10 Hz used during frequency sweep). By checking the linearity over the studied frequencies it can be ascertained that the frequency measurement is carried out within the elastic limit.

[0089] The results of the stress sweep over a range of 0.1 to 100 Pa at three different frequencies (0.1, 1, 10 Hz) are graphically represented in FIGS. 3A-F, wherein a solid circle represents stress sweep for PVA hydrogel batch numbers 7, 8, 9, 10, 11 and 12, respectively, at 0.1 Hz, a solid triangle at 1 Hz and a solid square at 10 Hz, an empty circle represents stress sweep for PVA hydrogel batch numbers 1, 2, 3, 4, 13 and 6, respectively, at 1.0 Hz, an empty triangle at 1 Hz and an empty square at 10 Hz. All types of PVA-THB hydrogels showed linear strain vs. stress curve over the range of stress and frequency studied except 26-88 blank hydrogels which were 9 months old. These gels were opaque with phase separation giving rise to a turbid polymeric mass with a clear liquid on top.

[0090] For gels made with a lower degree of hydrolysis PVA, as the molecular weight (and hence the viscosity) of the PVA increased, the loss of strain after storage for 9 month tended to decrease. The loss of strain after 9 month storage was greatest for 4-88 and least for 40-88 PVA hydrogel. However, the hydrogels were still elastic (linear over the range of stress and frequency studied) after 9 month storage at 20 C., the loss of strain over a period of time indicates a decrease in elasticity of the hydrogels.

[0091] As for the higher degree of hydrolysis PVA hydrogel (i.e. 28-99, FIG. 3F), the loss of strain after 9 month storage at 20 C. was negligible or the strain was the same as the initial values. This result supports the superiority of 28-99 hydrogels over lower degree of hydrolysis PVA hydrogels.

[0092] Frequency Sweep

[0093] The effects of 9 month storage at 20 C. on storage (G), loss (G) moduli and loss tangent (G/G) for different PVA type blank hydrogels have been depicted in the individual graphs in FIGS. 4A-F and the combined graphs in FIGS. 5A-C, wherein in FIGS. 4A-F an empty circle with a solid line represents storage (G) moduli, a solid circle with a dotted line loss (G) moduli and an empty circle with a dotted line loss tangent for fresh PVA hydrogel batch numbers 7, 8, 9, 10, 11 and 12 at 20 C., respectively; an empty triangle with a solid line represents storage (G) moduli, a solid triangle with a dotted line loss (G) moduli and an empty triangle with a dotted line loss tangent for 9 month old PVA hydrogel batch numbers 1, 2, 3, 4, 13 and 6 at 20 C., respectively.

[0094] In the combined graphs shown in FIGS. 5A-C, storage (G) moduli (FIG. 5A), loss (G) moduli (FIG. 5B) and loss tangent (FIG. 5C) are represented by an empty circle with a solid line for batch number 7, an empty square with a solid line for batch number 9, a cross on a solid line for batch number 11, a solid square on a dotted line for batch number 1, a solid square on a dotted line for batch number 3 and a cross on a dotted line for batch number 13.

[0095] As seen from FIGS. 4 and 5, 4-88, 5-88, 8-88 and 26-88 PVA hydrogels showed considerable loss of storage and loss moduli. Furthermore, loss of elasticity of the hydrogels is indicated. Similarly, 40-88 PVA hydrogel also showed decrease in such property. However, the magnitude of change was less than for the 4-88, 5-88, 8-88 and 26-88 PVA hydrogels.

[0096] FIG. 4F and FIGS. 5A-C show that there was negligible change in storage and loss moduli for 28-99 PVA hydrogels. The higher stability of 28-99 gels could be due to a higher degree of hydrolysis eliminating the possibility of acetic acid formation as explained. Finally, frequency sweep experiments also proved superiority of 28-99 hydrogels over lower degree of hydrolysis PVA hydrogels.

[0097] Re-Heating Experiments and Effect of Heating Time

[0098] To check whether the turbidity, pH drop and phase separation is reversible or not, 9 month old hydrogels were again re-heated to 85 C. for 30 minutes, cooled and observed for all above parameters. In addition, storage (G) and loss (G) moduli as well as hardness and compressibility were measured for re-heated hydrogels.

[0099] In FIG. 6A, storage (G) and loss (G) moduli and loss tangents for 9 month old PVA hydrogels (batch numbers 3 and 13) are respectively represented by an empty circle, empty triangle and cross prior to heating and a solid circle, solid triangle and white on black cross after heating.

[0100] As can be seen in FIG. 6 and in Table 3 below, after re-heating the hydrogels, turbidity, phase separation, acetic acid-like odour, hardness and compressibility all increased. The phase separation cannot be reversed by reheating. Storage (G) and loss (G) moduli for 8-88 hydrogels slightly decreased (by 101 fold). However, G and G increased 105 fold for 40-88 hydrogels after re-heating. Loss tangent increased for both hydrogels 101 and 105 fold for 8-88 and 40-88 hydrogels, respectively. This suggests that re-heating caused the hydrogels to become more solid. This is even more evident from increase in hardness and compressibility values of re-heated hydrogels. The increase in hardness and compressibility was much higher for 40-88 hydrogels compared to 8-88 hydrogels.

[0101] All of the above observations suggest that the temperature is a major factor for the stability of the low degree of hydrolysis (88%) PVA hydrogels. The instability (in terms of colour, pH drop, acetic acid-like odour generation) caused by temperature is not reversible through reheating. A possible reason for such behaviour could be that the presence of acetic acid may accelerate PVA degradation.

[0102] To further investigate these findings, additional blank hydrogels were prepared as per the composition displayed in Table 4 below with different heating times at 85 C. Two PVA hydrogels were prepared (26-88 and 28-99) by heating at 85 C. for 1, 2 and 3 hr.

[0103] Table 4 below shows that higher degree of hydrolysis (99%) PVA hydrogels (28-99) are stable without any turbidity, acetic acid-like odour and phase separation even after 3 hr heating. However, the lower degree of hydrolysis (88%) PVA hydrogels (26-88) were not stable after heating for 3 hr at 85 C. They exhibited a slight acetic acid-like odour after 2 hr heating and complete phase separation with strong acetic acid-like odour after 3 hr heating. This set of experiments further confirmed that low degree of hydrolysis (88%) PVA hydrogels (26-88) are susceptible to higher temperature. In addition, all above experiments once again proved superiority of higher degree of hydrolysis (99%) PVA hydrogels as they are stable without noticeable change in physicochemical properties. 28-99 PVA have negligible amounts (<1%) of acetate groups which practically eliminates the possibility of hydrolysis over a period of time. The resultant 28-99 hydrogels are the same as that of fresh hydrogels in various physicochemical properties even after 9 months and did not show any substantial change after heating for 3 hours.

TABLE-US-00003 TABLE 3 Batch number, PVA type, composition, colour, phase condition and acetic odour on 9 month old blank PVA-THB hydrogels (PVA 10% w/w and Borax 2.5% w/w) Batch Storage PVA Re- De- Acetic acid Hardness Compressibility No. duration Type heating Colour mixing like odour (N) (N .Math. sec) 3 9 months 8-88 Turbid No Yes 0.68 10 0.70 0.04 (++) () (+) 3 9 months 8-88 Yes Turbid Yes Yes 0.71 0.03 0.72 0.02 (+++) (+) (++) 13 9 months 40-88 Turbid Yes Yes 11.45 1.51 10.10 1.64 (++++) (+++) (+++) 13 9 months 40-88 Yes Turbid Yes Yes 19.77 2.33 17.13 1.54 (+++++) (+++++) (+++++) Note: = absent; + = lowest; +++++ = highest

TABLE-US-00004 TABLE 4 Effect of heating time at 85 C. on colour, phase condition and acetic odour on fresh blank PVA-THB hydrogels (PVA 10% w/w and Borax 2.5% w/w) Batch Storage PVA Heating De- Acetic acid No. duration Type time Colour mixing like odour 14 0 month 26-88 1 h Clear () No No () 14 0 month 26-88 2 h Clear () No Yes (+) 14 0 month 26-88 3 h Turbid (+++) Yes Yes (+) 15 0 month 28-99 1 h Clear () No No () 15 0 month 28-99 2 h Clear () No No () 15 0 month 28-99 3 h Clear () No No () Note: = absent; + = lowest; +++++ = highest.

Example 2: Lidocaine HCl Loaded PVA-THB Hydrogels

[0104] Stability batches were prepared as per the procedure described in EXAMPLE 1 above and the composition shown in Table 5 below. A brief description of the time points, stability condition and number of containers per condition are given in Table 6 below.

TABLE-US-00005 TABLE 5 Compositions of lidocaine HCl loaded PVA-THB stability hydrogels Lidocaine Batch PVA PVA Borax Mannitol Lidocaine HCl No. Type (% w/w) (% w/w) (% w/w) (% w/w) (% w/w) 16 28-99 12 2.5 2.6 4 4.93 17 28-99 12 2.5 2.6 4 4.93 18 4-88 17 2 0.475 4 4.93 19 4-88 17 2 0.475 4 4.93

TABLE-US-00006 TABLE 6 Stability plan with stability condition, time points (M = month(s)) and testing performed Total Batch Stability containers/ No. condition Position Initial 1 M 2 M 3 M 6 M Res. 1 condition 16 30 2 C./ upright 6*, 6*, 6*, 6*, 6*, 1 12 65 5% RH 1# 1# 1# 1# 1# 17 20 C./ upright 6*, 6*, 6*, 6*, 6*, 1 12 RH uncontrolled 1# 1# 1# 1# 1# 18 30 2 C./ upright 6*, 6*, 6*, 6*, 6*, 1 12 65 5% RH 1# 1# 1# 1# 1# 19 20 C./ upright 6*, 6*, 6*, 6*, 6*, 1 12 RH uncontrolled 1# 1# 1# 1# 1# *Multiple testing carried out on the same sample at different time points #Gel samples tested only once at the time point specified

[0105] Tests carried out: Weight change *, pH *, Lidocaine Assay #, Rheology #, Hardness and compressibility *, In vitro release study

[0106] The 28-99 PVA hydrogels (batch numbers 16 and 17 in Table 5 above) were evaluated for various parameters up to 6 months storage. The same parameters for batch numbers 18 and 19 (4-88 PVA) up to the 3 month time point are also discussed.

[0107] Batch numbers 16 (28-99, 30 C./65 RH) and 17 (28-99, 20 C. uncontrolled RH):

[0108] The results of the stability batches are summarised in Table 7. Assay of lidocaine HCl by HPLC showed minor fluctuations (minor increases and decreases) over the 6 months of the study, with no appreciable trends. This indicates that the drug is stable in PVA-THB hydrogels over 6 months without any degradation. Weight loss was observed to increase over a period of time at both storage conditions. However, weight loss is very small and did not substantially affect the final composition of the hydrogels.

[0109] Changes in pH were negligible over the study and were typically within the error of the measurement. The hardness and compressibility of batch number 17 (28-99 PVA hydrogels at 20 C. uncontrolled RH) remains fairly consistent, in comparison to the 4-88 hydrogels, over the duration of the study.

[0110] Storage and loss moduli were determined using oscillatory rheometry. A frequency stress sweep was performed at a defined stress of 60 Pa between 0.1 and 10 Hz at 25 C. and storage (G) and loss (G) moduli are graphically presented in FIGS. 7A and 7B for batch numbers 16 and 17 above, wherein a solid line with an empty circle represents the storage (G) moduli for the fresh hydrogel, a solid line with an empty triangle represents the storage (G) moduli for the hydrogel after 1 month, with an empty square two months, empty diamond three months and a cross 6 months, a dotted line with a solid shape the loss (G)moduli, and a dotted line with an empty shape the loss tangent. As can be seen, both moduli decrease considerably at all studied stress frequencies for batch number 16 (30 C./65 RH) over one month storage while remained almost constant during 2, 3 and 6 month storage. Both storage (G) and loss (G) moduli remain fairly constant batch number 17 (20 C./RH uncontrolled) at all storage time points. All of the above observations suggest that ideal storage condition for the gels is 20 C. Storing gels above 20 C. cause decrease of storage (G) and loss (G) moduli, hardness and compressibility and pH.

[0111] In vitro release of lidocaine HCl for batch numbers 16 (30 C./65 RH) and 17 (20 C./RH uncontrolled) after 0, 3 and 6 month storage are graphically depicted in FIGS. 7A and 7B, respectively. As can be seen from the Figures, the hydrogels were stable and give the same lidocaine HCl release over 30 minutes from different gels within the 6 month period. Neither storage condition (30 C./65 RH and 20 C. uncontrolled) nor storage time (0 month to 6 month) yielded any difference in release pattern.

TABLE-US-00007 TABLE 7 Stability study results for Batch No. 16 (30 C./65 RH) and Batch No. 17 (20 C.) Batch numbers 18 (4-88, 30 C./65 RH) and 18 (4-88, 20 C. uncontrolled RH): Parameters 3 12 or 7 6 6 6 6 N > Lidocaine Weight Hardness Com Hardness Com Stability Time HCl Loss 12 or 7 (N) at (N .Math. Sec) at (N) at (N .Math. Sec) at Condition points Assay (%) pH 25 C. 25 C. 37 C. 37 C. 30 C./ 0 M 104.29 7.03 5.90 5.82 1.86 1.76 65 RH 10.07 0.02 0.43 0.32 0.13 0.13 Batch No. 16 1 M 100.30 0.12 6.98 4.53 4.54 1.68 1.58 28-99 PVA 2.61 0.02 0.02 0.24 0.22 0.11 0.09 2 M 96.63 0.21 6.75 4.74 4.56 2.23 2.07 1.59 0.16 0.06 0.38 0.41 0.14 0.15 3 M 99.74 0.23 6.81 4.95 4.73 1.67 1.54 3.16 0.17 0.03 0.19 0.26 0.14 0.14 6 M 99.05 0.30 6.88 1.67 0.17 0.01 20 C. 0 M 100.88 7.00 6.40 6.47 2.21 2.09 Batch No. 17 8.35 0.02 0.14 0.14 0.22 0.16 28-99 PVA 1 M 112.59 0.09 6.99 6.22 6.39 2.33 2.21 9.83 0.03 0.01 0.32 0.30 0.10 0.09 2 M 99.95 0.11 6.81 6.49 6.34 2.78 2.65 2.32 0.03 0.02 0.27 0.26 0.30 0.27 3 M 102.13 0.12 6.83 6.82 6.70 2.11 1.98 1.48 0.03 0.01 0.24 0.23 0.22 0.16 6 M 98.41 0.16 6.92 5.47 5.52 2.09 1.96 2.10 0.03 0.02 0.13 0.13 0.16 0.12 30 C./ 0 M 103.97 7.03 3.42 3.21 0.57 0.53 65 RH 1.23 0.02 0.21 0.21 0.08 0.09 Batch No. 18 1 M 105.42 0.09 6.90 2.35 2.18 0.33 0.29 4-88 PVA 4.32 0.04 0.04 0.21 0.20 0.03 0.03 2 M 99.96 0.17 6.87 1.14 1.06 0.25 0.22 0.37 0.05 0.02 0.04 0.05 0.03 0.03 3 M 107.55 0.21 6.73 0.95 0.88 0.21 0.20 0.93 0.04 0.02 0.02 0.02 0.02 0.02 6 M 20 C. 0 M 100.37 7.04 3.08 2.92 0.49 0.46 Batch No. 19 8.45 0.02 0.39 0.34 0.04 0.04 4-88 PVA 1 M 103.89 0.05 6.99 2.89 2.66 0.33 0.30 2.25 0.03 0.02 0.09 0.08 0.03 0.03 2 M 98.54 0.10 6.99 2.81 2.61 0.31 0.28 3.06 0.04 0.03 0.06 0.07 0.03 0.03 3 M 105.76 0.12 6.94 2.52 2.34 0.30 0.27 2.32 0.04 0.01 0.17 0.16 0.03 0.02 6 M

[0112] The results of the stability batches are summarised in Table 7. The assay of lidocaine HCl by HPLC showed minor fluctuations over the 3 month study. This indicates that the drug is stable in both 28-99 and 4-88 PVA-THB hydrogels up to 3 months without substantial degradation. Weight loss was observed to increase over a period of time at both storage conditions (20 C. uncontrolled humidity and 30 C./65 RH). The weight loss associated with 30 C./65 RH storage condition (Batch number 18) was slightly higher than that associated with 20 C. storage condition. However, the weight loss observed was very small and did not substantially affect the final composition of the hydrogels.

[0113] The pH was observed to drop over a period of time for both storage conditions. The magnitude of the reduction was greater at 30 C./65 RH compared to 20 C. The hardness and compressibility of 4-88 hydrogels (batch numbers 18 and 19) at both storage conditions continued to drop considerably over the 3 months storage. However, the magnitude of such decrease was lower at 20 C. compared to 30 C./65 RH.

[0114] Frequency sweep results for 4-88 stability batches (18 and 19) are presented in FIGS. 8A and 8B, wherein a solid line with an empty circle represents the IVR for the fresh hydrogel, a solid line with an empty triangle represents the storage (G) moduli for the hydrogel after 3 months and with an empty diamond six months. As can be seen from the Figures, both moduli decrease considerably at all studied stress frequencies for batch numbers 18 (30 C./65 RH) and 19 (20 C. uncontrolled RH) over one month storage, remained almost constant during 1-2 month storage and again decreased considerably during 2-3 month storage.

[0115] In vitro release of lidocaine HCl for batch numbers 18 (30 C./65 RH) and 19 (20 C. uncontrolled) after 0 and 3 months storage are graphically depicted in FIGS. 10A and 10B, respectively. As can be seen from these Figures, the hydrogels displayed the same lidocaine HCl release rate during the first 30 minutes over the 3 month period.

[0116] In conclusion, low degree of hydrolysis (88%) PVA blank hydrogels exhibited turbidity, phase separation and an acetic acid-like odour. The occurrence of such changes seemed to be related to the degree of hydrolysis of the PVA chains. No such changes were observed for higher degree of hydrolysis (99%) PVA blank hydrogels. Re-heating experiments confirmed that such changes for 88% hydrolysed PVA hydrogels are not reversed by simple heating and mixing. The effect of heating time while preparing fresh hydrogels, showed that temperature is the main culprit for the stability of the low degree of hydrolysis (88%) PVA hydrogels. Excessive heating at 85 C. can cause the fresh 88% hydrolysed PVA hydrogels to de-mix. It was proposed that these changes are attributed to hydrolysis of the residual acetate groups on PVA chains liberating acetic acid decreasing the pH and resulting in phase separation through an unknown mechanism. If the liberated acetic acid can cause degradation of PVA chains, the resultant degraded PVA chains and disturbed ionic interaction may precipitate the less soluble products to generate turbidity.

[0117] Lidocaine HCl is stable in both 28-99 and 4-88 PVA-THB hydrogels with no appreciable degradation. Storing gels above 20 C. caused a decrease of storage (G) and loss (G) moduli, hardness and compressibility and pH. These observations suggest that the ideal storage condition for the gels is 20 C. Overall stability results for lidocaine HCl loaded PVA-THB hydrogels showed that higher degree of hydrolysis hydrogels are superior than lower degree of hydrolysis PVA hydrogels in almost all physicochemical properties and that lidocaine HCl is generally stable in the formulation at 20 C.

Example 3Lidocaine HCl Loaded PVA-THB Hydrogels

[0118] Lidocaine loaded gels were manufactured as follows:

TABLE-US-00008 Material Grade % w/w Quantity (g) Lidocaine Hydrochloride Ph. Eur 4.94 4.94 monohydrate D-Mannitol Ph. Eur 2.00 2.00 Sodium Tetraborate decahydrate Ph. Eur 1.80 1.80 (Borax) PVA (99% hydrolysed) (20% stock Ph. Eur 12.00 60.00 solution) De-ionised Water Not 79.26 31.26 applicable Total 100.00 100.00

[0119] Borax, D-mannitol and lidocaine were weighed in individual weigh boats and these powders were added to a pre-weighed 250 ml glass jar. De-ionised water was added and the contents of the jar thoroughly mixed. 20% PVA stock solution was added, the lid was closed and the contents of the jar swirled to mix thoroughly before being brought up to final weight using de-ionised water. The jar and its contents were placed in a pre-heated 60 C. water bath and the heat turned to 85 C. The mixture was stirred periodically and once homogenous, it was maintained in the 85 C. water bath for a further 30 minutes. The suspension was brought up to final weight using de-ionised water and stirred briefly to fully absorb the water before being split into containers (20 g of gel per container) for testing.

[0120] Autoclaving was conducted using a 200 L Front Loading Steam Autoclave by Priorclave, programmed for a USP sterilisation cycle of 121 C. for 15 minutes. To ensure the water in the gels did not evaporate, the autoclave was set at 3 bar pressure.

[0121] Method of Analysis

[0122] Rheometric analysis of 10 gel samples, before and after autoclaving, was carried out using a Kinexus Pro rotational rheometer (Malvern Instruments Ltd., Worcestershire, UK). Storage modulus (G), loss modulus (G) and complex modulus (G*) were measured following an oscillation stress sweep to determine the linear viscoelastic region. The crossover modulus (where the G and G cross) was reported.

[0123] Results

[0124] The viscosity and appearance results for the gels (n=10) tested before and after autoclaving is detailed in Table 8 below.

TABLE-US-00009 TABLE 8 Viscosity and appearance results Crossover modulus (Pa) Appearance* (SD) Before After Before After autoclave autoclave autoclave* autoclave* Clear, homogenous, Clear, homogenous, 3.86E+3 4.08E+3 no air bubbles no air bubbles (228.43) (441.3) *Average of 10 results

[0125] There was no significant difference between the viscosity of the gels before and after autoclaving. Furthermore, the gels before and after autoclaving were visually equivalent.

Example 4Sterilisation Results

[0126] Lidocaine loaded gels were manufactured as above in both polypropylene and glass containers and according to the following tables:

TABLE-US-00010 TABLE 9a Comparative Lidocaine loaded gels Material Grade % w/w Quantity (g) Lidocaine Hydrochloride Ph. Eur 4.94 4.94 monohydrate Mannitol Ph. Eur 2.00 2.00 Sodium Tetraborate Ph. Eur 2.50 2.50 decahydrate (Borax) PVA (87-88% hydrolysed) Ph. Eur 16.00 16.00 De-ionised Water Not 75.26 Sufficient applicable quantity Total 100.00 100.00

TABLE-US-00011 TABLE 9b Lidocaine loaded gels according to the invention Material Grade % w/w Quantity (g) Lidocaine Hydrochloride Ph. Eur 4.94 4.94 monohydrate Mannitol Ph. Eur 2.00 2.00 Sodium Tetraborate Ph. Eur 1.80 1.80 decahydrate (Borax) PVA (99% hydrolysed) Ph. Eur 12.00 12.00 De-ionised Water Not 79.26 Sufficient applicable quantity Total 100.00 100.00

[0127] Autoclaving was conducted using a 200 L Front Loading Steam Autoclave by Priorclave, programmed for a USP sterilisation cycle of 121 C. for 15 minutes. To ensure the water in the gels did not evaporate, the autoclave was set at 3 bar pressure.

[0128] Glass and polypropylene containers are widely used packaging in autoclaves. There was no significant container effect on the stability of the gels after autoclaving.

[0129] Method of Analysis

[0130] Tackiness was assessed by touch. Prior to sterilisation the gels have no tack. Upon reduction in stability, the gels become sticky and pressing a finger onto the surface and removing it is a simple way to test tackiness. Clarity and air bubbles were assessed visually. All gels prepared were colourless and very transparent, so air bubbles were readily apparent.

[0131] Analysis of the shear modulus was carried out using a Kinexus Pro rheometer (Malvern Instruments Ltd., Worcestershire, UK) on all hydrogel formulations. Tests were carried out at 25 C.0.2 C. using 20 mm diameter stainless steel parallel plate geometry and a working gap of 1-2 mm. The linear viscoelastic region (LVR) of the PVA-borate hydrogel formulation was determined by an amplitude sweep (0.01-100% strain at a frequency of 1.0 Hz). All measurements of the shear modulus were performed within the LVR.

TABLE-US-00012 TABLE 10a Comparative Lidocaine loaded gels - polypropylene container Shear modulus Measurement taken pH Appearance Tacky (Pa) immediately before 7.30 Clear homogenous Yes 11587 sterilisation gel no air bubbles immediately once 7.07 Clear homogenous Yes 9974 cooled after 15 gel no air bubbles minutes heat sterilisation at 121 C. 8 days after 15 7.10 Clear homogenous Yes 9054 minutes heat gel no air bubbles sterilisation at 121 C. 15 days after 15 7.01 Clear homogenous Yes 8799 minutes heat gel no air bubbles sterilisation at 121 C.

TABLE-US-00013 TABLE 10b Comparative Lidocaine loaded gels - glass container Shear modulus Measurement taken pH Appearance Tacky (Pa) immediately before 7.19 Clear yes 12004 sterilisation homogenous gel no air bubbles immediately once 6.76 Clear gel Yes, increased 7987 cooled after 15 More viscous adhesive feel minutes heat than before compared to sterilisation at sterilisation pre- 121 C. sterilisation 8 days after 15 6.88 Clear gel Yes, 8045 minutes heat Increased increased sterilisation at adhesive feel adhesive feel 121 C. More viscous compared to than before pre- sterilisation sterilisation 15 days after 15 6.85 Clear gel Yes, 8101 minutes heat Increased increased sterilisation at adhesive feel adhesive feel 121 C. More viscous compared to than before pre- sterilisation sterilisation

[0132] As is clear from Tables 10a and 10b, the shear modulus of lidocaine loaded gels made from 88% hydrolysed PVA decreases upon attempted sterilisation.

TABLE-US-00014 TABLE 11a Lidocaine loaded gels according to the invention - polypropylene container Shear modulus Measurement taken pH Appearance Tacky (Pa) immediately before 6.78 Clear No 13120 sterilisation homogenous gel no air bubbles immediately once cooled 6.78 Clear No 13330 after 15 minutes homogenous heat sterilisation at gel no air 121 C. bubbles 8 days after 15 minutes 6.81 Clear No 12960 heat sterilisation at homogenous 121 C. gel no air bubbles 15 days after 15 minutes 6.74 Clear No 13440 heat sterilisation at homogenous 121 C. gel no air bubbles

TABLE-US-00015 TABLE 11b Lidocaine loaded gels according to the invention - glass container Shear modulus Measurement taken pH Appearance Tacky (Pa) immediately before 6.90 Clear No 12470 sterilisation homogenous gel no air bubbles immediately once cooled 6.84 Clear No 12840 after 15 minutes homogenous heat sterilisation at gel no air 121 C. bubbles 8 days after 15 minutes 6.78 Clear No 12780 heat sterilisation at homogenous 121 C. gel no air bubbles 15 days after 15 minutes 6.91 Clear No 12912 heat sterilisation at homogenous 121 C. gel no air bubbles

[0133] As is clear from Tables 11a and 11b, lidocaine loaded gels made from 99% hydrolysed PVA show essentially no difference in shear modulus upon heat sterilisation. Therefore gels according to the invention can be sterilised whilst gels prepared with a lower degree of hydrolysis cannot.

Example 5Treatment of Morton's Neuroma

[0134] Lidocaine loaded gel was prepared as described above in Examples 3 and 4.

[0135] A 5 g sample of lidocaine loaded gel was placed onto the foot of a patient with an underlying painful Morton's neuroma. The gel was placed onto the top of the foot adjacent the fourth toe. A gauze support (Mepore) was used to hold the gel in place for 4 hours. After this period of time, the gauze was removed and the patient did not report any sensation of pain from the neuroma.

[0136] Aspects of the present invention have been described by way of example only and it should be appreciated that additions and/or modifications may be made thereto without departing from the scope thereof as defined in the appended claims.