Manufacture of water-swellable hydrophilic articles and drug delivery devices

The method for the preparation of a delivery device for the sustained release of an active agent therefrom which comprises:

• a. introducing active agent, and optionally a pharmaceutically acceptable carrier, into a cylindrically-shaped reservoir of a biocompatible, non-biodegradable water-swellable, water-insoluble, cylindrically-shaped plastic cartridge, in an amount sufficient to provide extended sustained release of the active agent, said cartridge having smooth external and internal cylindrical surfaces and a uniform thickness between said surfaces;
• b. introducing at least one polymerizable liquid monomer into the upper portion of said reservoir in an amount to close the open end of the reservoir, said polymerizable liquid monomer having an equilibrium water content value in its polymerized state which exceeds the equilibrium water content value of said plastic cartridge;
• and
• c. polymerizing said polymerizable liquid monomer to effectively seal the opening of the reservoir with a plug of water-swellable, water-insoluble polymer to form a delivery device which give a predetermined release of the active agent.

A delivery device for the sustained release of an active agent therefrom which comprises:

• a. biocompatible, non-biodegradable, water-swellable, water-insoluble, hydrophilic plastic cartridge having a cylindrically-shaped reservoir;
• b. said cartridge characterized by (i) an oval outer cylindrical shape at one end thereof;
• (ii) smooth internal and external cylindrical surfaces;
• and (iii) a uniform cylindrical wall thickness;
• c. sealant means for closure of the open end of said reservoir comprising a plug of biocompatible, non-biodegradable, water-swellable, water-insoluble, hydrophilic polymer having an equilibrium water content value greater than that of the plastic cartridge per se;
• and
• d. an active agent contained in the reservoir of the cartridge in an amount sufficient to provide a predetermined sustained release thereof over an extended period of time.