Rapidly-orodispersible tablets having an interior cavity

A rapidly-orodispersible dosage form, comprising:

• a porous, durable container body comprising a first bound-powder material comprising an interconnected matrix of a first ingestible powder material and a first ingestible binder material, the container body having a base, a peripheral wall extending from the base and having an inner surface, an upper surface, and an external surface, the container body having one or more cavities bounded by the base and the inner surface of the peripheral wall;
• a porous, durable lidding body comprising a second bound-powder material comprising an interconnected matrix of a second ingestible powder material and second ingestible binder material, the lidding body having an undersurface configured to be positioned over the upper surface of the peripheral wall, to cover the one or more cavities and form one or more interior cavities;
• and
• a means for securing the lidding body to the peripheral wall,
• wherein
• the first ingestible powder material and the second ingestible powder material comprise independently one or more pharmaceutical excipients selected from the group consisting of:
• a binder, a disintegration agent, a dispersant, a sweetener, a glidant, a flavoring agent, a surfactant, a humectant, a preservative, an antioxidant, a solvent, and a diluent, including combinations thereof;
• and
• the first ingestible binder material and the second ingestible binder material are independently selected from the group consisting of:
• a water-soluble synthetic polymer, polyvinyl pyrrolidone, sorbitol, mannitol, xylitol, lactitol, erythritol, pregelatinized starch, modified starch, hydroxypropylmethylcellulose, spray dried lactose, fructose, sucrose, dextrose, sorbitol, mannitol, and xylitol, including combinations thereof.

A method for forming a rapidly-orodispersible container body having an empty cavity for containing a medicament, the method comprising the following steps:

• i) forming a rapidly-orodispersible container base, comprising the steps of:
• a) dispersing an ingestible build powder material into a base powder layer;
• b) dispensing a binding liquid comprising an ingestible binder material onto the base powder layer to form a first base level of a bound-powder matrix;
• and
• c) optionally repeating steps a) and b) one or more times to form a second or more base level of the bound-powder matrix, and thereby forming the container base;
• ii) forming a rapidly-orodispersible peripheral wall, comprising the steps of:
• a) dispersing an ingestible build powder material into an intermediate powder layer atop the container base;
• b) dispensing a binding liquid comprising an ingestible binder material onto a peripheral portion of the intermediate powder layer in registry with a periphery of the container base, without dispersing the binding liquid onto an interior portion of the intermediate powder layer, to form a first peripheral wall level of a bound-powder matrix that is bound to the container base, and having an interior filled with unbound build powder material;
• and
• c) optionally though preferably repeating steps d) and e) one or more times to form a second or more peripheral wall level of the bound-powder matrix, and thereby forming the peripheral wall bound to the container base;
• and
• iii) removing the unbound build powder material of the interior portion of the intermediate powder layer, thereby forming the rapidly-orodispersible container body having an empty cavity and comprising the rapidly-orodispersible container base and the rapidly-orodispersible peripheral wall.

A method for forming a rapidly-orodispersible dosage form containing a solid medicament within an interior cavity of the rapidly-orodispersible dosage form, comprising the steps of:

• (a) providing a porous, durable container body made of a first bound-powder material, the container body having a base, a peripheral wall extending from the base and having an inner surface, an upper surface, and an external surface, the container body having one or more empty cavities bounded by the base and the inner surface of the peripheral wall;
• (b) providing a porous, durable lidding body comprising a second bound-powder material;
• (c) dispensing a one or more particulate payload materials, the one or more particulate payload materials comprising a medicament, into the one or more empty cavity;
• (d) placing the lidding body onto the upper surface of the peripheral wall, to form an internal cavity containing the one or more particulate payload materials;
• and
• (e) securing the lidding body to the container body, thereby forming the rapidly-orodispersible dosage form.