Microparticles with absorbed polypeptide-containing molecules formed without the use of surfactant, methods of making such microparticle compositions, and uses thereof, are disclosed. The microparticles comprise a polymer, such as a poly(.alpha.-hydroxy acid), a polyhydroxy butyric acid, a polycaprolactone, a polyorthoester, a polyanhydride, and the like. Preferred polymers are poly(D,L-lactide-co-glycolides), more preferable those having a lactide/glycolide molar ratio ranging from 40:60 to 60:40 and having a molecular weight ranging from 20,000 Daltons to 70,000 Daltons. Preferred polypeptide containing molecules are bacterial and viral antigens (including HIV antigens, meningitis B antigens, streptococcus B antigens, and Influenza A hemagglutinin antigens).

Description of the Invention

SUMMARY OF THE INVENTION

The present inventors have unexpectedly found that microparticles with adsorbed polypeptide-containing molecules can be formed in the absence of a surfactant.

For instance, according to a first aspect of the invention, a biologically active microparticle composition is provided, which comprises: (a) microparticles comprising a polymer selected from the group consisting of a poly(.alpha.-hydroxy acid), a polyhydroxy butyric acid, a polycaprolactone, a polyorthoester, a polyanhydride, and a polycyanoacrylate; and (b) a polypeptide-containing molecule, which is adsorbed to the microparticles. The composition is formed in the absence of anionic surfactant, and is preferably formed in the absence of all surfactants, including anionic, cationic, nonionic and zwitterionic surfactants.

Preferred polymers are poly(.alpha.-hydroxy acids), more preferably those selected from the group consisting of poly(L-lactide), poly(D,L-lactide) and poly(D,L-lactide-co-glycolide). More preferred are poly(D,L-lactide-co-glycolide) polymers. Preferred poly(D,L-lactide-co-glycolide) polymers are those having a lactide/glycolide molar ratio ranging from 25:75 to 75:25, more preferably 40:60 to 60:40, and having a molecular weight ranging from 10,000 to 100,000 Daltons, more preferably from 30,000 Daltons to 70,000 Daltons.

Preferred biologically active polypeptide-containing molecules include bacterial and viral antigens. HIV antigens (such as g41, gp120, gp140, p24gag and p55gag antigens), meningitis B antigens (such as meningitis B recombinant protein 287 antigen), streptococcus antigens (such as group B streptococcus antigen), and Influenza A hemagglutinin antigens are particularly preferred.

In some embodiments, the microparticle composition is provided with a further biologically active macromolecule, which may be bound or unbound to the microparticles, and may even be entrapped within the polymer. For example, the microparticle composition may be provided with an adjuvant, particularly a Th1 stimulating adjuvant. Preferred adjuvants include CpG oligonucleotides, LTK63, LTR72, MPL, aminoalkyl glucosaminide 4-phosphates (AGP's), imidazoquinoline adjuvants, lipopolysaccharide mimetic adjuvants, QS21, double-stranded RNA (dsRNA) and aluminum salts, including aluminum phosphate.

According to another aspect of the present invention, a pharmaceutically acceptable excipient is added to the above microparticle compositions.

Another aspect of the invention is directed to the delivery of a polypeptide-containing molecule to a vertebrate subject, which comprises administering to a vertebrate subject the above microparticle composition.

In other aspects of the invention, the above microparticle compositions are used in the diagnosis of diseases, in the treatment of diseases, in vaccines, and/or in raising an immune response.

For example, in an additional aspect, the invention is directed to a method for eliciting a cellular and/or humoral immune response in a vertebrate subject, which comprises administering to a vertebrate subject a therapeutically effective amount of a microparticle composition as described above.

Another aspect of the invention is directed to a method of immunization, which comprises administering to a vertebrate subject a therapeutically effective amount of the microparticle composition above.

Still other aspects of the invention are directed to methods of producing microparticles. In general, these methods comprise: (a) forming an emulsion comprising (i) a polymer selected from the group consisting of a poly(.alpha.-hydroxy acid), a polyhydroxy butyric acid, a polycaprolactone, a polyorthoester, a polyanhydride, and a polycyanoacrylate, (ii) an organic solvent, and (iii) water; followed by (b) removal of the organic solvent The method is carried out using compositions that are free of anionic surfactant, and are preferably free of all surfactant, including anionic, cationic, nonionic and zwitterionic surfactants.

Preferably, the emulsion is a water-in-oil-in-water emulsion that is formed by a process comprising: (a) emulsifying an organic phase comprising polymer and organic solvent with a first aqueous phase comprising water to form a water-in-oil emulsion; and (b) emulsifying a second aqueous phase comprising water with the emulsion formed in step (a) to form a water-in-oil-in-water emulsion. In general, these microparticle compositions are subsequently intermixed with a biologically active polypeptide-containing molecule, such as those discussed above, to produce a biologically active composition.

Although double-emulsion techniques like that above are preferred, single emulsion techniques can also be used to form the microparticle compositions of the present invention.

Still other aspects of the invention are directed to methods of producing microparticle compositions, which methods comprise: (1) forming a microparticle in an emulsification process, which microparticle comprises a polymer selected from the group consisting of a poly(.alpha.-hydroxy acid), a polyhydroxy butyric acid, a polycaprolactone, a polyorthoester, a polyanhydride, and a polycyanoacrylate; and (2) adsorbing a biologically active polypeptide-containing molecule on the surface of the microparticle. The method is carried out using compositions that are free of anionic surfactant, and are preferably free of all surfactant, including anionic, cationic, nonionic and zwitterionic surfactants.

An advantage of the present invention is that microparticle compositions for human administration, and particularly microparticle compositions for human administration that contain adsorbed polypeptide-containing molecules, can be formed without resorting to the use of surfactants. The absence of surfactants is beneficial, inter alia, because the addition of surfactants raises issues of toxicity, which issues are circumvented by the microparticle compositions of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The practice of the present invention will employ, unless otherwise indicated, conventional methods of chemistry, polymer chemistry, biochemistry, molecular biology, immunology and pharmacology, within the skill of the art. Such techniques are explained fully in the literature. See, e.g., Remington's Pharmaceutical Sciences, 18th Edition (Easton, Pa.: Mack Publishing Company, 1990); Methods In Enzymology (S. Colowick and N. Kaplan, eds., Academic Press, Inc.); Handbook of Experimental Immunology, Vols. I-IV (D. M. Weir and C. C. Blackwell, eds., 1986, Blackwell Scientific Publications); Sambrook, et al., Molecular Cloning: A Laboratory Manual (2nd Edition, 1989); Handbook of Surface and Colloidal Chemistry (Birdi, K. S., ed, CRC Press, 1997) and Seymour/Carraher's Polymer Chemistry (4th edition, Marcel Dekker Inc., 1996).

General Methods

Surprisingly, the present inventors have found that microparticles can be formed, and excellent adsorption of polypeptide-containing molecules to the microparticles can be achieved, without the use of surfactants. As a result, the microparticle/polypeptide-containing-molecule compositions of the present invention can be used as a delivery system to deliver biologically active polypeptide-containing molecules to a subject in order to prophylactically or therapeutically treat and/or diagnose a wide variety of diseases. While not wishing to be bound by theory, it is believed that the polymer materials used in connection with the present invention (e.g., PLG) typically have negatively charged groups, which give the microparticles of the present invention a net negative charge. This net negative charge leads to inter-microparticle repulsion, stabilizing the microparticles upon their formation. Moreover, this charge also attracts positively charged regions of the polypeptide-containing molecules, improving the adsorption of the polypeptide-containing molecules to the microparticles.

Many exemplary embodiments within the present patent application are directed to compositions containing microparticles with adsorbed polypeptide-containing molecules.

The present invention can be used in connection with the delivery of a wide variety of macromolecules including, but not limited to, pharmaceuticals such as antibiotics and antiviral agents, nonsteroidal antiinflammatory drugs, analgesics, vasodilators, cardiovascular drugs, psychotropics, neuroleptics, antidepressants, antiparkinson drugs, beta blockers, calcium channel blockers, bradykinin inhibitors, ACE-inhibitors, vasodilators, prolactin inhibitors, steroids, hormone antagonists, antihistamines, serotonin antagonists, heparin, chemotherapeutic agents, antineoplastics and growth factors, including but not limited to PDGF, EGF, KGF, IGF-1 and IGF-2, FGF, polynucleotides which encode therapeutic or immunogenic proteins, immunogenic proteins and epitopes thereof for use in vaccines, hormones including peptide hormones such as insulin, proinsulin, growth hormone, GHRH, LHRH, EGF, somatostatin, SNX-111, BNP, insulinotropin, ANP, FSH, LH, PSH and hCG, gonadal steroid hormones (androgens, estrogens and progesterone), thyroid-stimulating hormone, inhibin, cholecystokinin, ACTH, CRF, dynorphins, endorphins, endothelin, fibronectin fragments, galanin, gastrin, insulinotropin, glucagon, GTP-binding protein fragments, guanylin, the leukokinins, magainin, mastoparans, dermaseptin, systemin, neuromedins, neurotensin, pancreastatin, pancreatic polypeptide, substance P, secretin, thymosin, and the like, enzymes, transcription or translation mediators, intermediates in metabolic pathways, immunomodulators, such as any of the various cytokines including interleukin-1, interleukin-2, interleukin-3, interleukin-4, and gamma-interferon, antigens, and adjuvants.

The present invention is particularly well suited for the delivery of polypeptide-containing molecules to a subject. In some particularly preferred embodiments, the polypeptide-containing molecules are polypeptide antigen molecules. One advantage of microparticles with adsorbed polypeptide antigen molecules is their demonstrated ability to generate cell-mediated immune responses in a vertebrate subject. Thus, in addition to a conventional antibody response, the system herein described can provide for, e.g., the association of the expressed antigens with class I MHC molecules such that an in vivo cellular immune response to the antigen of interest can be mounted which stimulates the production of CTLs to allow for future recognition of the antigen. Furthermore, the methods may elicit an antigen-specific response by helper T-cells. Accordingly, the methods of the present invention will find use with any polypeptide-containing molecule for which cellular and/or humoral immune responses are desired, preferably antigens derived from viral and bacterial pathogens that may induce antibodies, T-cell helper epitopes and T-cell cytotoxic epitopes. Such antigens include, but are not limited to, those encoded by human and animal viruses and can correspond to either structural or non-structural proteins.

Hence, the ability of the antigen/microparticles of the invention to elicit a cell-mediated immune response against a selected antigen provides a powerful tool against infection by a wide variety of pathogens. Accordingly, the antigen/microparticle compositions of the present invention can be incorporated into vaccine compositions.

The microparticles of the present invention are particularly useful for immunuization against intracellular viruses which normally elicit poor immune responses. For example, the present invention will find use for stimulating an immune response against a wide variety of polypeptides from the herpes virus family, including proteins derived from herpes simplex virus (HSV) types 1 and 2, such as HSV-1 and HSV-2 glycoproteins gB, gD and gH; antigens derived from varicella zoster virus (VZV), Epstein-Barr virus (EBV) and cytomegalovirus (CMV) including CMV gB and gH; and antigens derived from other human herpes viruses such as HHV6 and HHV7. (See, e.g. Chee et al., Cytomegaloviruses (J. K. McDougall, ed., Springer-Verlag 1990) pp. 125-169, for a review of the protein coding content of cytomegalovirus; McGeoch et al., J. Gen. Virol. (1988) 69:1531-1574, for a discussion of the various HSV-1 encoded proteins; U.S. Pat. No. 5,171,568 for a discussion of HSV-1 and HSV-2 gB and gD proteins and the genes encoding therefor; Baer et al., Nature (1984) 310:207-211, for the identification of protein coding sequences in an EBV genome; and Davison and Scott, J Gen. Virol. (1986) 67:1759-1816, for a review of VZV.)

Antigens from the hepatitis family of viruses, including hepatitis A virus (HAV), hepatitis B virus (HBV), hepatitis C virus (HCV), the delta hepatitis virus (HDV), hepatitis E virus (HEV) and hepatitis G virus (HGV), can also be conveniently used in the techniques described herein. By way of example, the viral genomic sequence of HCV is known, as are methods for obtaining the sequence. See, e.g., International Publication Nos. WO 89/04669; WO 90/11089; and WO 90/14436. The HCV genome encodes several viral proteins, including E1 (also known as E) and E2 (also known as E2/NSI) and an N-terminal nucleocapsid protein (termed "core") (see, Houghton et al., Hepatology (1991) 14:381-388, for a discussion of HCV proteins, including E1 and E2). Each of these proteins, as well as antigenic fragments thereof, will find use in the present composition and methods.

Similarly, the sequence for the .delta.-antigen from HDV is known (see, e.g., U.S. Pat. No. 5,378,814) and this antigen can also be conveniently used in the present composition and methods. Additionally, antigens derived from HBV, such as the core antigen, the surface antigen, sAg, as well as the presurface sequences, pre-S1 and pre-S2 (formerly called pre-S), as well as combinations of the above, such as sAg/pre-S1, sAg/pre-S2, sAg/pre-S1/pre-S2, and pre-S1/pre-S2, will find use herein. See, e.g., "HBV Vaccines--from the laboratory to license: a case study" in Mackett, M. and Williamson, J. D., Human Vaccines and Vaccination, pp. 159-176, for a discussion of HBV structure; and U.S. Pat. Nos. 4,722,840, 5,098,704, 5,324,513, incorporated herein by reference in their entireties; Beames et al., J. Virol. (1995) 69:6833-6838, Birnbaum et al., J. Virol. (1990) 64:3319-3330; and Zhou et al., J. Virol. (1991) 65:5457-5464.

Antigens derived from other viruses will also find use in the compositions and methods of the present invention, such as without limitation, proteins from members of the families Picomaviridae (e.g., polioviruses, etc.); Caliciviridae; Togaviridae (e.g., rubella virus, dengue virus, etc.); Flaviviridae; Coronaviridae; Reoviridae; Bimaviridae; Rhabodoviridae (e.g., rabies virus, etc.); Filoviridae; Paramyxoviridae (e.g., mumps virus, measles virus, respiratory syncytial virus, etc.); Orthomyxoviridae (e.g., influenza virus types A, B and C, etc.); Bunyaviridae; Arenaviridae; Retroviradae (e.g., HTLV-I; HTLV-II; HIV-I (also known as HTLV-II, LAV, ARV, hTLR, etc.)), including but not limited to antigens from the isolates HIV.sub.IIIb, HIV.sub.SF2, HIV.sub.LAV, HIV.sub.LA1, HIV.sub.MN); HIV-1.sub.CM235, HIV-1.sub.US4; HIV-2; simian immunodeficiency virus (SIV) among others. Additionally, antigens may also be derived from human papillomavirus (HPV) and the tick-borne encephalitis viruses. See, e.g. Virology, 3rd Edition (W. K. Joklik ed. 1988); Fundamental Virology, 2nd Edition (B. N. Fields and D. M. Knipe, eds. 1991), for a description of these and other viruses.

More particularly, the gp 120 or gp 140 envelope proteins from any of the above HIV isolates, including members of the various genetic subtypes of HIV, are known and reported (see, e.g., Myers et al., Los Alamos Database, Los Alamos National Laboratory, Los Alamos, N. Mex. (1992); Myers et al., Human Retroviruses and Aids, 1990, Los Alamos, N. Mex.: Los Alamos National Laboratory; and Modrow et al., J Virol. (1987) 61:570-578, for a comparison of the envelope sequences of a variety of HIV isolates) and antigens derived from any of these isolates will find use in the present methods. Furthermore, the invention is equally applicable to other immunogenic proteins derived from any of the various IIV isolates, including any of the various envelope proteins such as gp160 and gp41, gag antigens such as p24gag and p55gag, as well as proteins derived from the pol and tat regions.

Influenza virus is another example of a virus for which the present invention will be particularly useful. Specifically, the envelope glycoproteins HA and NA of influenza A are of particular interest for generating an immune response. Numerous HA subtypes of influenza A have been identified (Kawaoka et al., Virology (1990) 179:759-767; Webster et al., "Antigenic variation among type A influenza viruses," p. 127-168. In: P. Palese and D. W. Kingsbury (ed.), Genetics of influenza viruses. Springer-Verlag, New York). Thus, proteins derived from any of these isolates can also be used in the compositions and methods described herein.

The compositions and methods described herein will also find use with numerous bacterial antigens, such as those derived from organisms that cause diphtheria, cholera, tuberculosis, tetanus, pertussis, meningitis, and other pathogenic states, including, without limitation, Bordetella pertussis, Neisseria meningitides (A, B, C, Y), Neisseria gonorrhoeae, Helicobacter pylori, and Haemophilus influenza. Hemophilus influenza type B (HIB), Helicobacter pylori, and combinations thereof. Examples of antigens from Neisseria meningitides B are disclosed in the following co-owned patent applications: PCT/US99/09346; PCT IB98/01665; and PCT IB99/00103. Examples of parasitic antigens include those derived from organisms causing malaria and Lyme disease.

Additional antigens, which are not necessarily exclusive of those listed elsewhere in this application, include the following: A protein antigen from N. meningitidis serogroup B, such as those in Refs. 1 to 7 below. an outer-membrane vesicle (OMV) preparation from N. meningitidis serogroup B, such as those disclosed in Refs. 8, 9, 10, 11 etc. below. a saccharide antigen from N. meningitidis serogroup A, C, W135 and/or Y, such as the oligosaccharide disclosed in Ref. 12 below from serogroup C (see also Ref. 13). a saccharide antigen from Streptococcus pneumnoniae (e.g. Refs. 14, 15, 16). an antigen from N. gonorrhoeae (e.g., Refs. 1, 2, 3). an antigen from Chlamydia pneumoniae (e.g., Refs. 17, 18, 19, 20, 21, 22, 23). an antigen from Chlamydia trachomatis (e.g. Ref. 24). an antigen from hepatitis A virus, such as inactivated virus (e.g., Refs. 25, 26). an antigen from hepatitis B virus, such as the surface and/or core antigens (e.g., Refs. 26, 27). an antigen from hepatitis C virus (e.g. Ref. 28). an antigen from Bordetella pertussis, such as pertussis holotoxin (PT) and filamentous haemaglutinin (FHA) from B. pertussis, optionally also in combination with pertactin and/or agglutinogens 2 and 3 (e.g., Refs. 29 & 30). a diphtheria antigen, such as diphtheria toxoid (e.g., chapter 3 of Ref. 31) e.g. the CRM.sub.197 mutant (e.g., Ref. 32). a tetanus antigen, such as a tetanus toxoid (e.g., chapter 4 of Ref. 31). a protein antigen from Helicobacter pylori such as CagA (e.g. Ref. 33), VacA (e.g. Ref. 33), NAP (e.g. Ref. 34), HopX (e.g. Ref. 35), HopY (e.g. Ref. 35) and/or urease. a saccharide antigen from Haemophilus influenzae B (e.g. Ref. 13). an antigen from Porphyramonas gingivalis (e.g. Ref. 36). polio antigen(s) (e.g. Refs. 37, 38) such as IPV or OPV. rabies antigen(s) (e.g. Ref. 39) such as lyophilized inactivated virus (e.g. Ref. 40, Rabavert.TM.). measles, mumps and/or rubella antigens (e.g., chapters 9, 10 and 11 of Ref. 31). influenza antigen(s) (e.g. chapter 19 of Ref. 31), such as the haemagglutinin and/or neuraminidase surface proteins. an antigen from Moraxella catarrhalis (e.g., Ref. 41). an antigen from Streptococcus agalactiae (Group B streptococcus) (e.g. Refs. 42, 43) an antigen from Streptococcus pyogenes (Group A streptococcus) (e.g. Refs. 43, 44, 45). an antigen from Staphylococcus aureus (e.g. Ref. 46). compositions comprising one or more of these antigens.

Where a saccharide or carbohydrate antigen is used, it is preferably conjugated to a carrier protein in order to enhance immunogenicity (e.g. Refs. 47 to 56). Preferred carrier proteins are bacterial toxins or toxoids, such as diphtheria or tetanus toxoids. The CRM.sub.197 diphtheria toxoid is particularly preferred. Other suitable carrier proteins include N. meningitidis outer membrane protein (e.g. Ref. 57), synthetic peptides (e.g. Refs. 58, 59), heat shock proteins (e.g. Ref. 60), pertussis proteins (e.g. Refs. 61, 62), protein D from H. Influenzae (e.g. Ref. 63), toxin A or B from C. difficile (e.g. Ref. 64), etc. Where a mixture comprises capsular saccharides from both serogroups A and C, it is preferred that the ratio (w/w) of MenA saccharide:MenC saccharide is greater than 1 (e.g. 2:1, 3:1, 4:1, 5:1, 10:1 or higher). Saccharides from different serogroups of N. meningitidis may be conjugated to the same or different carrier proteins.

Any suitable conjugation reaction can be used, with any suitable linker where necessary.

Toxic protein antigens may be detoxified where necessary (e.g. detoxification of pertussis toxin by chemical and/or means (Ref. 30).

See: International patent application 99/24578 (Ref. 1); International patent application WO99/36544 (Ref. 2); International patent application WO99/57280 (Ref. 3); International patent application WO00/22430 (Ref. 4); Tettelin et al., (2000) Science 287:1809-1815 (Ref. 5); International patent application WO96/29412 (Ref. 6); Pizza el al. (2000) Science 287:1816-1820 (Ref. 7); International patent application PCT/IB01/00166 (Ref. 8); Bjune et al. (1991) Lancet 338(8775):1093-1096 (Ref. 9); Fukasawa et al. (1990) Vaccine 17:2951-2958 (Ref. 10); Rosenqvist et al. (1998) Dev. Biol. Stand. 92:323-333 (Ref. 11); Costantino et al. (1992) Vaccine 10:691-698 (Ref. 12); Costantino et al. (1999) Vaccine 17:1251-1263 (Ref. 13); Watson (2000) Padiatr Infect Dis J 19:331-332 (Ref. 14); Rubin (2000) Pediatr Clin North Am 47:269-285, v (Ref. 15); Jedrzejas (2001) Microbiol Mol Biol Rev 65:187-207 (Ref. 16); International patent application filed on Jul. 3rd, 2001 claiming priority from GB-0016363.4 (Ref. 17); Kalman et al. (1999) Nature Genetics 21 :385-389 (Ref. 18); Read et al. (2000) Nucleic Acids Res 28:1397-406 (Ref. 19); Shirai et al. (2000) J. Infect. Dis. 181(Suppl 3):S524-S527 (Ref. 20); International patent application WO99/27105 (Ref. 21); International patent application WO00/27994 (Ref. 22); International patent application WO00/37494 (Ref. 23); International patent application WO99/28475 (Ref. 24); Bell (2000) Pediat-Infect Dis J 19:1187-1188 (Ref. 25); Iwarson (1995) APMIS 103:321-326 (Ref 26); Gerlich et al. (1990) Vaccine 8 Suppl:S63-68 & 79-80 (Ref. 27); Hsu et al. (1999) Clin Liver Dis 3:901-915 (Ref. 28); Gustafssonetal. (1996) N. Engl. J. Med. 334:349-355 (Ref. 29); Rappuoli et al. (1991) TIBTECH 9:232-238 (Ref. 30); Vaccines (1988) eds. Plotkin & Mortimer. ISBN 0-7216-1946-0 (Ref. 31); Del Guidice et al. (1998) Molecular Aspects of Medicine 19:1-70 (Ref. 32); International patent application WO93/18150 (Ref. 33); International patent application WO99/53310 (Ref. 34); International patent application WO98/04702 (Ref. 35); Ross et al. (2001) Vaccine 19:4135-4142 (Ref. 36); Sutter et al. (2000) Pediatr Clin North Am 47:287-308 (Ref. 37); Zimmerman & Spann (1999) Am Fam Physicial 59:113-118, 125-126 (Ref. 38); Dreesen (1997) Vaccine 15 Suppl:S2-6 (Ref. 39); MMWR Morb Mortal Wkly Rep 1998 January 16;47(1):12, 19 (Ref. 40); McMichael (2000) Vaccine 19 Suppl 1:S 101-107 (Ref. 41); Schuchat (1999) Lancet 353(9146):51-6 (Ref. 42); GB patent applications 0026333.5, 0028727.6 & 0105640.7 (Ref. 43); Dale (1999) Infect Dis Clin North Am 13:22743, viii (Ref. 44); Ferretti et al. (2001) PNAS USA 98:4658-4663 (Ref. 45); Kuroda et al. (2001) Lancet 357(9264):1225-1240; see also pages 1218-1219 (Ref. 46); Ramsay et al. (2001) Lancet 357(9251):195-196 (Ref 47); Lindberg (1999) Vaccine 17 Suppl 2:S28-36 (Ref. 48); Buttery & Moxon (2000) J R Coll Physicians London 34:163-168 (Ref. 49); Ahmad & Chapnick (1999) Infect Dis Clin North Am 13:113-133, vii (Ref. 50); Goldblatt (1998) J. Med. Microbiol. 47:563-567 (Ref. 51); European patent 0 477 508 (Ref. 52); U.S. Pat. No. 5,306,492 (Ref. 53); International patent application WO98/42721 (Ref. 54); Conjugate Vaccines (eds. Cruse et al.) ISBN 3805549326, particularly vol. 10:48-114 (Ref. 55); Hermanson (1996) Bioconjugate Techniques ISBN: 0123423368 & 012342335X (Ref. 56); European patent application 0372501 (Ref. 57); European patent application 0378881 (Ref 58); European patent application 0427347 (Ref. 59); International patent application WO93/17712 (Ref. 60); International patent application WO98/58668 (Ref. 61); European patent application 0471177 (Ref. 62); International patent application WO00/56360 (Ref. 63); international patent application WO00/61761 (Ref. 64).

Where diphtheria antigen is included in the composition it is preferred also to include tetanus antigen and pertussis antigens. Similarly, where a tetanus antigen is included it is preferred also to include diphtheria and pertussis antigens. Similarly, where a pertussis antigen is included it is preferred also to include diphtheria and tetanus antigens.

It is readily apparent that the present invention can be used to deliver a wide variety of polypeptide-containing molecules and hence to treat and/or diagnose a large number of diseases. In some embodiments, the polypeptide-containing-molecule/microparticle compositions of the present invention can be used for site-specific targeted delivery. For example, intravenous administration of the polypeptide-containing-molecule/microparticle compositions can be used for targeting the lung, liver, spleen, blood circulation, or bone marrow.

The adsorption of polypeptide-containing molecules to the surface of the adsorbent microparticles occurs via any bonding-interaction mechanism, including, but not limited to, ionic bonding, hydrogen bonding, covalent bonding, Van der Waals bonding, and bonding through hydrophilic/hydrophobic interactions.

Biodegradable polymers for manufacturing microparticles for use with the present invention are readily commercially available from, e.g., Boehringer Ingelheim, Germany and Birmingham Polymers, Inc., Birmingham, Ala. For example, useful polymers for forming the microparticles herein include homopolymers, copolymers and polymer blends derived from the following: polyhydroxybutyric acid (also known as polyhydroxybutyrate); polyhydroxy valeric acid (also known as polyhydroxyvalerate); polyglycolic acid (PGA) (also known as polyglycolide): polylactic acid (PLA) (also known as polylactide); polydioxanone; polycaprolactone; polyorthoester; and polyanhydride. More preferred are poly(.alpha.-hydroxy acid), such as poly(L-lactide), poly(D,L-lactide) (both known as "PLA" herein), poly(hydoxybutyrate), copolymers of D,L-lactide and glycolide, such as poly(D,L-lactide-co-glycolide) (designated as "PLG" herein) or a copolymer of D,L-lactide and caprolactone. Particularly preferred polymers for use herein are PLA and PLG polymers. These polymers are available in a variety of molecular weights, and the appropriate molecular weight for a given use is readily determined by one of skill in the art. Thus, e.g., for PLA, a suitable molecular weight will be on the order of about 2000 to 5000. For PLG, suitable molecular weights will generally range from about 10,000 to about 200,000, preferably about 15,000 to about 150,000.

If a copolymer such as PLG is used to form the microparticles, a variety of lactide:glycolide molar ratios will find use herein and the ratio is largely a matter of choice, depending in part on the coadministered polypeptide-containing molecule and the rate of degradation desired. For example, a 50:50 PLG polymer, containing 50% D,L-lactide and 50% glycolide, will provide a fast resorbing copolymer while 75:25 PLG degrades more slowly, and 85:15 and 90:10, even more slowly, due to the increased lactide component. It is readily apparent that a suitable ratio of lactide:glycolide is easily determined by one of skill in the art based, for example, on the nature of the antigen and disorder in question. Degradation rate of the microparticles of the present invention can also be controlled by such factors as polymer molecular weight and polymer crystallinity. PLG copolymers with varying lactide:glycolide ratios and molecular weights are readily available commercially from a number of sources including from Boehringer Ingelheim, Germany and Birmingham Polymers, Inc., Birmingham, Ala. Some exemplarly PLG copolymers include: (a) RG 502, a PLG having a 50:50 lactide/glycolide molar ratio and a molecular weight of 12,000 Da; (b) RG 503, a PLG having a 50:50 lactide/glycolide molar ratio and a molecular weight of 34,000 Da; (c) RG 504, a PLG having a 50:50 lactide/glycolide molar ratio and a molecular weight of 48,000 Da, (d) RG 752, a PLG having a 75:25 lactide/glycolide molar ratio and a molecular weight of 22,000 Da; and (e) RG 755, a PLG having a 75:25 lactide/glycolide molar ratio and a molecular weight of 68,000 Da. PLG polymers can also be synthesized by simple polycondensation of the lactic acid component using techniques well known in the art, such as described in Tabata et al., J. Biomed. Abater. Res. (1988) 22:837-858. Presently preferred PLG copolymers are those having a molar lactide/glycolide ratio ranging from 25:75 to 75:25, more preferably 40:60 to 60:40, and having a molecular weight ranging from 10,000 to 100,000 Daltons, more preferably from 20,000 Daltons to 70,000 Daltons.

The microparticles are prepared using any of several methods well known in the art. For example, in some embodiments, double emulsion/solvent evaporation techniques, such as those described in U.S. Pat. No. 3,523,907 and Ogawa et al., Chem Pharm. Bull. (1988) 36:1095-1103, can be used herein to make the microparticles. These techniques involve the formation of a primary emulsion consisting of droplets of polymer solution, which is subsequently mixed with a continuous aqueous phase containing a particle stabilizer/surfactant.

In other embodiments, microparticles can also be formed using spray-drying and coacervation as described in, e.g., Thomasin et al., J. Controlled Release (1996) 41:131; U.S. Pat. No. 2,800,457; Masters, K. (1976) Spray Drying 2nd Ed. Wiley, New York; air-suspension coating techniques, such as pan coating and Wurster coating, as described by Hall et al., (1980) The "Wurster Process" in Controlled Release Technologies. Methods, Theory, and Applications (A. F. Kydonieus, ed.), Vol. 2, pp. 133-154 CRC Press, Boca Raton, Fla. and Deasy, P. B., Crit. Rev. Ther. Drug Carrier Syst. (1988) S(2):99-139; and ionic gelation as described by, e.g., Lim et al., Science (1980) 210:908-910.

In preferred embodiments, a modified water-in-oil-in-water (w/o/w) solvent evaporation technique can be used to form the microparticles. Techniques of this type have been described, for example, in O'Hagan et al., Vaccine (1993) 11:965-969, PCT/US99/17308 (WO 00/06123) to O'Hagan et al., and Jeffery et al., Pharm. Res. (1993) 10:362. These techniques, however, are modified for use in connection with the present invention. Specifically, distinct from these techniques, the w/o/w emulsions of the present invention are preferably formed in the absence of surfactants (including detergents, dispersing agents, suspending agents and emulsion stabilizers).

More specifically, a particular polymer of interest such as PLG, is dissolved in an organic solvent, such as ethyl acetate, dimethyl chloride (also called methylene chloride and dichloromethane), acetonitrile, acetone, chloroform, and the like. The polymer will typically be provided in about a 1-30%, preferably about a 2-15%, more preferably about a 3-10% and most preferably, about a 4-6% solution, in organic solvent. The polymer solution is then combined with a first volume of an aqueous solution and emulsified to form an o/w emulsion. The aqueous solution can be, for example, deionized water, normal saline, or a buffered solution such as phosphate-buffered saline (PBS) or a sodium citrate/ethylenediaminetetraacetic acid (sodium citrate/ETDA) buffer solution. The latter solutions can (a) provide a tonicity, i.e., osmolality, that is essentially the same as normal physiological fluids and (b) maintain a pH compatible with normal physiological conditions. Alternatively, the tonicity and/or pH characteristics of the compositions of the present invention can be adjusted after microparticle formation and prior to administration.

Preferably, the volume ratio of polymer solution to aqueous solution ranges from about 5:1 to about 20:1, and is more preferably about 10:1. Emulsification is preferably conducted using any equipment appropriate for this task, and is typically a high-shear device such as, e.g., an homogenizer.

A volume of the o/w emulsion is then preferably combined with a larger second volume of aqueous solution, which can also be, for example, deionized water, normal saline, or a buffered solution. The ratio of the second volume of aqueous solution to the volume of the o/w emulsion typically ranges from about 2:1 to 10:1, and is more typically about 4:1. The mixture is then homogenized to produce a w/o/w double emulsion. Organic solvents are then evaporated.

The formulation parameters can be manipulated to allow the preparation of small microparticles on the order of 0.2 .mu.m (200 nm) to larger microparticles 50 .mu.m or even larger. See, e.g., Jeffery et al., Pharm. Res. (1993) 10:362-368; McGee et al., J. Microencap. (1996). For example, reduced agitation results in larger microparticles, as does an increase in internal phase volume and an increase in polymer concentration. Small particles are produced by increased agitation as well as low aqueous phase volumes and low polymer concentration.

One preferred apparatus for performing the above steps is schematically illustrated in FIG. 1 (see Original Patent). Referring now to FIG. 1, a manufacturing tank assembly, generally designated by the numeral 102, is shown. The tank assembly 102 is designed to be a "closed system," such that an aseptic environment is maintained during processing. All pieces of equipment and parts are preferably selected to be clean-in-place and autoclavable. All filters 104a-d are preferably fluoropolymer filters such as Super-Cheminert.TM. all-fluoropolymer filters from Pall Corporation. Initially, an aqueous solution, such as a deionized water 106 and an organic polymer solution, such as a solution of PLG in methylene chloride 108, are filtered and fed into tank 110 where they are continuously mixed with mixer 112. The mixture is then fed through an in-line homogenizer 114 (e.g., a high speed, high shear autoclavable in-line homogenizer such as the Kinematica MT 5000), forming an o/w emulsion. The emulsion is cooled, for example by a water-cooled condenser 116, after emerging from the in-line homogenizer 114, whereupon it is returned to the tank 110. After the contents are emulsified to the desired extent, additional aqueous solution, such as deionized water 106, is added to the tank 110, whereupon a w/o/w emulsion is formed by again feeding the contents through the in-line mixer 114. The resulting w/o/w emulsion is purged with nitrogen via distributor 119 to remove the organic solvent. The nitrogen-laden solvent vapor is filtered and cooled in a condenser 120, capturing the solvent in container 122. Where the emulsion is somewhat unstable, it may be desirable to remove the solvent concurrently with in-line mixing.

Particle size can be determined by, e.g., laser light scattering, using for example, a spectrometer incorporating a helium-neon laser. Generally, particle size is determined at room temperature and involves multiple analyses of the sample in question (e.g., 5-10 times) to yield an average value for the particle diameter. Particle size is also readily determined using scanning electron microscopy (SEM).

Following preparation, microparticles can be stored as is or lyophilized for future use. In order to adsorb polypeptide-containing molecules to the microparticles, the microparticle preparation can be simply mixed with the polypeptide-containing molecule of interest and the resulting formulation can again be lyophilized prior to use.

Typically, polypeptide-containing molecules are added to the microparticles to yield microparticles with adsorbed polypeptide-containing molecules having a polypeptide-containing molecule to microparticle weight-to-weight ratio of from about 0.0001:1 to 0.25:1, more typically 0.001:1 to 0.1:1, even more typically 0.05:1 to 0.01:1. The polypeptide-containing-molecule content of the microparticles can be determined using standard techniques.

In addition to microparticles with adsorbed polypeptide-containing molecules, the compositions of the present invention can also include a variety of other macromolecules (including additional polypeptide-containing molecules, pharmaceuticals, polynucleotides, hormones, enzymes, transcription or translation mediators, metabolic pathway intermediates, immunomodulators, antigens, adjuvants or combinations thereof.) For example, the microparticles of the present invention may have additional macromolecules entrapped or encapsulated within them, adsorbed on their surfaces, or included in solution or in suspension. Particularly preferred additional macromolecules are adjuvants.

Once the microparticles with adsorbed polypeptide-containing molecules are produced, they are formulated into pharmaceutical compositions, including vaccines, to treat and/or diagnose a wide variety of disorders, as described above. The compositions will generally include one or more pharmaceutically acceptable excipients. For example, vehicles such as water, saline, glycerol, polyethylene glycol, hyaluronic acid, ethanol, etc. may be used. Other excipients, such as wetting or emulsifying agents, biological buffering substances, and the like, may be present in such vehicles. A biological buffer can be virtually any substance which is pharmacologically acceptable and which provides the formulation with the desired pH, i.e., a pH in the physiological range. Examples of buffer solutions include phosphate buffered saline (PBS), Tris buffered saline, Hank's buffered saline, and the like. Other excipients known in the art can also be introduced into the final dosage form, including binders, disintegrants, fillers (diluents), lubricants, glidants (flow enhancers), compression aids, colors, sweeteners, preservatives, suspensing/dispersing agents, film formers/coatings, flavors and printing inks.

Adjuvants may be used to enhance the effectiveness of the pharmaceutical compositions. The adjuvants may be administered concurrently with the microparticles of the present invention, e.g., in the same composition or in separate compositions. Alternatively, the adjuvant may be administered prior or subsequent to the microparticle compositions of the present invention. In some embodiments, the adjuvant, such as an immunological adjuvant, may be encapsulated in the microparticle. Adjuvants, just as any macromolecule, may be encapsulated within the microparticles using any of the several methods known in the art. See, e.g., U.S. Pat. No. 3,523,907; Ogawa et al., Chem. Pharm. Bull. (1988) 36:1095-1103; O'Hagan et al., Vaccine (1993) 11:965-969 and Jefferey et al., Pharm. Res. (1993) 10:362. Alternatively, some adjuvants, particularly polypeptide-containing adjuvants, may be adsorbed on the microparticle as described above.

Immunological adjuvants include, but are not limited to: (1) aluminum salts (alum), such as aluminum hydroxide, aluminum phosphate, aluminum sulfate, etc.; (2) other oil-in water emulsion formulations (with or without other specific immunostimulating agents such as muramyl peptides (see below) or bacterial cell wall components), such as for example (a) MF59 (International Publication No. WO90/14837; Chapter 10 in Vaccine design: the subunit an adjuvant approach, Eds. Powell & Newman, Plenum Press 1995), containing 5% Squalene, 0.5% Tween 80, and 0.5% Span 85 (optionally containing various amounts of MTP-PE (see below), although not required) formulated into submicron particles using a microfluidizer such as Model 110Y microfluidizer (Microfluidics, Newton, Mass.), (b) SAF, containing 10% Squalane, 0.4% Tween 80, 5% pluronic-blocked polymer L121, and thr-MDP (see below) either microfluidized into a submicron emulsion or vortexed to generate a larger particle size emulsion, and (c) Ribi.TM. adjuvant system (RAS), (Ribi Immunochem, Hamilton, Mont.) containing 2% Squalene, 0.2% Tween 80, and one or more bacterial cell wall components from the group consisting of monophosphorylipid A (MPL), trehalose dimycolate (TDM), and cell wall skeleton (CWS), preferably MPL+CWS (Detox.TM.) (for a further discussion of suitable submicron oil-in-water emulsions for use herein, see commonly owned, patent application Ser. No. 09/015,736, filed on Jan. 29, 1998); (3) saponin adjuvants, such as Quil A, or QS21 (e.g., Stimulon.TM. (Cambridge Bioscience, Worcester, Mass.)) may be used or particles generated therefrom such as ISCOMs (immunostimulating complexes), which ICOMS may be devoid of additional detergent e.g., WO00/07621; (4) Complete Freunds Adjuvant (CFA) and Incomplete Freunds Adjuvant (IFA); (5) cytokines, such as interleukins (e.g. IL-1, IL-2, IL-4, IL-5, IL-6, IL-7, IL-12 (WO99/44636), etc.), interferons (e.g. gamma interferon), macrophage colony stimulating factor (M-CSF), tumor necrosis factor (TNF), etc.; (6) monophosphoryl lipid A (MPL) or 3-O-deacylated MPL (3dMPL) e.g. GB-2220221, EP-A-0689454, optionally in the substantial absence of alum when used with pneumococcal saccharides e.g. WO00/56358; (7) combinations of 3dMPL with, for example, QS21 and/or oil-in-water emulsions, e.g., EP-A-0835318, EP-A-0735898, EP-A-076123 1; (8) oligonucleotides comprising CpG motifs (Roman et al., Nat. Med., 1997, 3, 849-854; Weiner et al., PNAS USA, 1997, 94, 10833-10837; Davis et al., J Immunol. 1988, 160, 870-876; Chu et al., J. Exp. Med., 1997, 186, 1623-1631; Lipford et al., Eur. J. Immunol. 1997, 27, 2340-2344; Moldoveanu et al., Vaccine, 1988, 16, 1216-1224, Krieg et al., Nature, 1995, 374, 546-549; Klinman et al., PNAS USA, 1996, 93, 2879-2883: Ballas et al., J. Immunol., 1996, 157, 1840-1845; Cowdery et al., J. Immunol., 1996, 156, 45704575; Halpern et al., Cell. Immunol., 1996, 167, 72-78; Yamamoto et al., Jpn. J. Cancer Res., 1988, 79, 866-873; Stacey et al., J. Immunol, 1996, 157,2116-2122; Messina et al., J. Immunol, 1991, 147, 1759-1764; Yi et al., J. Immunol., 1996, 157, 4918-4925; Yi et al., J. Immunol., 1996, 157, 5394-5402; Yi et al., J. Immunol., 1998, 160, 47554761; and Yi et al., J. Immunol., 1998, 160, 5898-5906; International patent applications WO96/02555, WO98/16247, WO98/18810, WO98/40100, WO98/55495, WO98/37919 and WO98/52581) i.e. containing at least one CG dinucleotide, with 5 methylcytosine optionally being used in place of cytosine; (9) a polyoxyethylene ether or a polyoxyethylene ester e.g. WO99/52549; (10) a polyoxyethylene sorbitan ester surfactant in combination with an octoxynol (WO01/21207) or a polyoxyethylene alkyl ether or ester surfactant in combination with at least one additional non-ionic surfactant such as an octoxynol (WO01/21152); (11) a saponin and an immunostimulatory oligonucleotide (e.g., a CpG oligonucleotide) (WO00/62800); (12) an immunostimulant and a particle of metal salt e.g. WO00/23105; (13) a saponin and an oil-in-water emulsion e.g. WO99/11241; (14) a saponin (e.g. QS21)+3dMPL+IL-12 (optionally+a sterol) e.g. WO98/57659; (15) detoxified mutants of a bacterial ADP-ribosylating toxin such as a cholera toxin (CT), a pertussis toxin (PT), or an E. coli heat-labile toxin (LT), particularly LT-K63 (where lysine is substituted for the wild-type amino acid at position 63) LT-R72 (where arginine is substituted for the wild-type amino acid at position 72), CT-S 109 (where serine is substituted for the wild-type amino acid at position 109), and PT-K9/G129 (where lysine is substituted for the wild-type amino acid at position 9 and glycine substituted at position 129) (see, e.g., International Publication Nos. WO93/13202 and WO92/19265); (16) aminoalkyl glucosaminide 4-phosphates (AGP's), see, e.g., Johnson, D. A. et al.; Bioorg. Med. Chem. Lett., 1999 Aug. 2; 9(15):2273-8, (17) imidazoquinolines such as imiquimod (R-837) and resiquimod (R-848), see, e.g., Vasilakos, J. P. et al.; Cell. Immunol. 2000 Aug. 25; 204(l):64-74, (18) lipopolysaccharide mimetics, including non-saccharide phospholipids (e.g., simplified lipid A analogs lacking a disaccharide) described in Hawkins, L. D. et al; J. Pharmacol. Exp. Ther., 2002 February; 300(2):655-61, and (19) other substances that act as immunostimulating agents to enhance the effectiveness of the composition.

Muramyl peptides include, but are not limited to, N-acetyl-muramyl-L-threonyl-D-isoglutamine (thr-MDP), N-acteyl-nomuramyl-L-alanyl-D-isogluatme (nor-MDP), N-acetylmuramyl-L-alanyl-D-isogluatminyl-L-alanine-2-(1'-2'-dipalmitoyl-s- n-glycero-3-huydroxyphosphoryloxy)-ethylamine (MTP-PE), etc.

For additional examples of adjuvants, see Vaccine Design:, The Subunit and the Adjuvant Approach, Powell, M. F. and Newman, M. J, eds., Plenum Press, 1995)

The compositions will comprise a "therapeutically effective amount" of the polypeptide-containing molecule (as well as any other macromolecule) of interest. That is, a sufficient amount of the polypeptide-containing molecule will be included to treat or diagnose a condition of interest. The exact amount necessary will vary, for example, depending on the subject being treated; the age and general condition of the subject to be treated; the severity of the condition being treated; in the case of an immunological response, the capacity of the subject's immune system to synthesize antibodies; the degree of protection desired and the particular polypeptide-containing molecule selected and its mode of administration, among other factors. An appropriate effective amount can be readily determined by one of skill in the art. Thus, a "therapeutically effective amount" will typically fall in a relatively broad range that can be determined through routine trials. For example, where the macromolecule is a polypeptide antigen, an effective dose will typically range from about 1 .mu.g to about 100 mg, preferably from about 5 .mu.g to about 1 mg, more preferably about 5 .mu.g to about 100 .mu.g and most preferably about 5 .mu.g to about 50 .mu.g of the antigen delivered per dose.

Once formulated, the compositions of the invention can be administered parenterally, e.g., by injection. The compositions can be injected either subcutaneously, intraperitoneally, intravenously or intramuscularly. Other modes of administration include nasal, mucosal, rectal, vaginal, oral and pulmonary administration, suppositories, and transdermal or transcutaneous applications.

Dosage treatment may be a along a single dose schedule or a multiple dose schedule. A multiple dose schedule is one in which a primary course of administration may be with 1-10 separate doses, followed by other doses given at subsequent time intervals, chosen to maintain and/or reinforce the therapeutic response, for example at 1-4 months for a second dose, and if needed, a subsequent dose(s) after several months. The dosage regimen will also, at least in part, be determined by the need of the subject and be dependent on the judgment of the practitioner.

Furthermore, if prophylactic treatment is desired, for example, in vaccines, compositions of the present invention are generally administered prior to primary infection with the pathogen of interest. If therapeutic treatment is desired, e.g., the reduction of symptoms or recurrences, the compositions of the present invention are generally administered subsequent to primary infection.
 

Claim 1 of 41 Claims

1. A microparticle composition comprising: (a) microparticles comprising a polymer selected from the group consisting of a poly(.alpha.-hydroxy acid), a polyhydroxy butyric acid, a polycaprolactone, a polyorthoester, a polyanhydride, and a polycyanoacrylate; and (b) a polypeptide-containing molecule adsorbed to the microparticles, wherein the microparticle composition is formed in the absence of surfactant and wherein the microparticles do not contain entrapped or encapsulated polypeptide-containing molecules.

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