Search

US-20260124339-A1 - DEPOSITION OF PHARMACEUTICAL INGREDIENT USING CONFINED ORGANIC PRINTING

US20260124339A1US 20260124339 A1US20260124339 A1US 20260124339A1US-20260124339-A1

Abstract

Embodiments of the disclosed subject matter provide a method of coating a surface with an active pharmaceutical ingredient, where an organic source having a first organic material may be heated to create an organic vapor, the first organic material having an active pharmaceutical ingredient. The source vapor may be transported via an inert carrier gas to a confined organic printing COP depositor in a deposition chamber. The organic vapor entrained in the inert carrier gas may be ejected from the COP depositor toward a surface to cause the first organic material to condense on the surface.

Inventors

  • Gregory McGraw
  • William T. Mayweather, III
  • Ving Jick Lee
  • Michael Hack

Assignees

  • UNIVERSAL DISPLAY CORPORATION

Dates

Publication Date
20260507
Application Date
20251031

Claims (20)

  1. 1 . A method of coating a surface with an active pharmaceutical ingredient, the method comprising: heating an organic source comprising a first organic material to create an organic vapor, the first organic material comprising an active pharmaceutical ingredient; transporting the organic vapor via an inert carrier gas to a confined organic printing (COP) depositor in a deposition chamber; ejecting the organic vapor entrained in the inert carrier gas from the COP depositor toward a surface to cause the first organic material to condense on the surface.
  2. 2 . The method of claim 1 , further comprising: mixing the source vapor with an inert host material vapor; and ejecting the inert host material vapor toward the surface to cause the first organic material to be mixed with the inert host material during deposition of the first organic material on the surface.
  3. 3 . The method of claim 1 , wherein the organic source is heated to a temperature of at least 150 C.
  4. 4 . The method of claim 1 , wherein at least a portion of the COP depositor proximal to the surface is maintained at a temperature of at least 150 C during ejection of the organic vapor toward the surface.
  5. 5 . The method of claim 4 , wherein the surface has a temperature of 15-30 C during ejection of the organic vapor toward the surface.
  6. 6 . The method of claim 1 , wherein a thickness of the organic material deposited on the surface is 1-200 nm.
  7. 7 . The method of claim 1 , wherein the surface comprises an outer surface of a plurality of granules.
  8. 8 . The method of claim 7 , further comprising agitating at least a portion of the plurality of granules during at least a portion of time that the organic vapor entrained in the inert carrier gas is ejected toward the surface.
  9. 9 . The method of claim 1 , wherein the surface comprises at least a portion of a surface of an implantable device.
  10. 10 . The method of claim 9 , wherein the surface has a critical dimension of not more than 1.0 mm.
  11. 11 . The method of claim 9 , wherein the first organic material is deposited on a first portion of the surface of the implantable device, the method further comprising: depositing a second organic material on a second portion of the surface of the implantable device via a COP depositor.
  12. 12 . The method of claim 11 , wherein the second portion does not overlap the first portion.
  13. 13 . The method of claim 9 , wherein the ejecting the organic vapor entrained in the inert carrier gas toward the surface results in a deposition pattern that exceeds an intended deposition zone by not more than about 100 μm.
  14. 14 . The method of claim 1 , wherein the surface comprises a biocompatible material.
  15. 15 . The method of claim 14 , further comprising depositing a second organic material on the first organic material deposited on the biocompatible material.
  16. 16 . The method of claim 15 , wherein the first and second organic materials form an ingestible tablet.
  17. 17 . The method of claim 15 , wherein each of the first and second organic materials is mixed with a corresponding inert host while being deposited.
  18. 18 . The method of claim 15 , further comprising selecting the amount of the first organic material, the second organic material, or a combination thereof based upon one or more attributes of a patient.
  19. 19 . The method of claim 15 , wherein the first and second organic materials are deposited in alternating layers, in a physical pattern on the biocompatible material, or a combination thereof.
  20. 20 . The method of claim 15 , further comprising depositing a third organic material on the second organic material.

Description

FIELD The present invention relates to devices and techniques for fabricating organic thin films for pharmaceuticals and prosthetics, and devices and techniques including the same. BACKGROUND Presently, thin films can provide a delivery mechanisms for drugs, which are also referred to as active pharmaceutical ingredients (APIs). Such thin films can provide controlled release after ingestion, or the thin films can be administered through transdermal, mucosal, or ocular routes. Thin film APIs are typically applied to a surface using solvent based techniques like solvent casting, flexographic printing, and inkjet printing, which can be followed by a controlled thermal or freeze-drying process. SUMMARY According to an embodiment, a method of coating a surface with an active pharmaceutical ingredient may be provided. The method may include heating an organic source comprising a first organic material to create an organic vapor, the first organic material comprising an active pharmaceutical ingredient. The source vapor may be transported via an inert carrier gas to a confined organic printing (COP) depositor in a deposition chamber. The organic vapor entrained in the inert carrier gas may be ejected from the COP depositor toward a surface to cause the first organic material to condense on the surface. In the method, the organic source may be heated to a temperature of at least 150 C. In the method, at least a portion of the COP depositor proximal to the surface may be maintained at a temperature of at least 150 C during ejection of the organic vapor toward the surface. The surface may have a temperature of 15-30 C during ejection of the organic vapor toward the surface. A thickness of the organic material deposited on the surface may be 1-200 nm. The surface may have an outer surface that has a plurality of granules. The method may include agitating the granules during at least a portion of time that the organic vapor entrained in the inert carrier gas is ejected toward the surface. The surface may have a critical dimension of not more than 1.0 mm. The surface may comprise at least a portion of a surface of an implantable device. The first organic material may be deposited on a first portion of the surface of the implantable device, and the method may include depositing a second organic material on a second portion of the surface of the implantable device via a COP depositor. The second portion may not overlap the first portion. The ejecting the organic vapor entrained in the inert carrier gas toward the surface may result in a deposition pattern that exceeds an intended deposition zone by not more than about 100 μm. The surface may be a biocompatible material. The method may include depositing a second organic material on the first organic material deposited on the biocompatible material to form an ingestible tablet. The method may include selecting the amount of the first organic material, the second organic material, or a combination thereof based upon one or more attributes of a patient. The first and second organic materials may be deposited in alternating layers, a physical pattern on the biocompatible surface, or a combination thereof. The method may include depositing a third organic material on the second organic material. The method may include measuring a fly height of the COP depositor above the biocompatible material while ejecting the organic vapor toward the surface, and may include adjusting the fly height of the COP depositor above the biocompatible material. The method may include adjusting the fly height to maintain a constant distance between an edge of the COP depositor and a closest surface of the surface and any materials deposited thereon. The method may include maintaining a temperature gradient along a runline between the organic evaporation source and the COP depositor. The method may include maintaining the deposition chamber at a pressure of [10-1000 Torr] The method may include applying a confinement flow around the COP depositor, the surface, or a combination thereof. The organic material deposited on the surface may not react chemically with any other material on the surface. According to an embodiment, a system may be provided for depositing an active pharmaceutical ingredient on a surface. The system may include a crucible storing an organic material comprising an active pharmaceutical ingredient. A first controllable heater may be configured to heat the crucible and the organic material to a temperature of about 150-200 C. A runline may be configured to transport evaporated organic material from the crucible to a confined organic printing (COP) depositor. A second controllable heater may be configured to heat the runline to a temperature of about 150-200 C. A deposition chamber may include a target holder, the target holder configured to maintain a target comprising a deposition surface at a temperature of about 15-30 C. The COP depositor may be configured to eject the organic m