Polyvinylpyrrolidone (PVP)-based polymers are excellent stabilizers for food supplements and pharmaceutical ingredients. However, they are highly hygroscopic. This study measured and modeled the water-sorption isotherms and water-sorption kinetics in thin PVP and PVP-co-vinyl acetate (PVPVA) films. The water sorption was measured at 25 °C from 0 to 0.9 RH, which comprised glassy and rubbery states of the polymer-water system. The sorption behavior of glassy polymers differs from that in the rubbery state. The perturbed-chain statistical associating fluid theory (PC-SAFT) accurately describes the water-sorption isotherms for rubbery polymers, whereas it was combined with the non-equilibrium thermodynamics of glassy polymers (NET-GP) approach to describe the water-sorption in the glassy polymers. Combined NET-GP and PC-SAFT modeling showed excellent agreement with the experimental data. Furthermore, the transitions between the PC-SAFT modeling with and without NET-GP were in reasonable agreement with the glass transition of the polymer-water systems. Furthermore, we obtained Fickian water diffusion coefficients in PVP and in PVPVA from the measured water-sorption kinetics over a broad range of humidities. Maxwell-Stefan and Fickian water diffusion coefficients yielded a non-monotonous water concentration dependency that could be described using the free-volume theory combined with PC-SAFT and NET-GP for calculating the free volume.

The amorphous state of an active pharmaceutical ingredient (API) enhances its water solubility compared to its crystalline state. However, it is well known that amorphous substances can absorb significant amounts of water therewith inducing API recrystallization. This work explores methods to obtain reliable information about water sorption in amorphous APIs and its modeling. Experimental water-sorption curves over a broad humidity range were obtained by measuring the mass increase of well-defined films of amorphous APIs. Water-sorption isotherms modeled using perturbed-chain statistical associating fluid theory (PC-SAFT) showed better accordance with the experimental data than those obtained using the Flory−Huggins model. Crank's diffusion equation was used to describe the water-sorption kinetics providing Fickian diffusion coefficients of water in indomethacin and in ritonavir. Stefan−Maxwell diffusion coefficients were obtained by converting Fickian diffusion coefficients using water activity coefficients obtained from PC-SAFT. Finally, the free-volume theory was applied to explain the persistent water concentration dependency of the Stefan−Maxwell diffusion coefficients.

Solvent sorption in polymers is of general interest for a wide variety of applications. It is well known that solvent sorption in polymers depends on both solvent diffusion and the slow rearrangement of the polymer, also known as polymer relaxation. This study provides a physically meaningful model approach for describing solvent diffusion in polymers, while considering relaxation in its most generalized form. A diffusion− relaxation model was created by combining the Stefan−Maxwell equations with multiple Maxwell elements. Parameter studies reveal the capability of the developed approach to describe anomalous solvent sorption behavior in polymers like sigmoidal, two-stage, pseudo-Fickian, case II, and super case II behavior. These parameter studies also provide detailed insights into the physical reasonings behind these phenomena. Moreover, to the best of our knowledge, this is the first time that first-principles modeling of multistage sorption curves is reported.

Water decreases the stability of amorphous solid dispersions (ASDs) and water sorption is, therefore, unwanted during ASD storage. This work suggests a methodology to predict the water-sorption isotherms and the water-sorption kinetics in amorphous pharmaceutical formulations like ASDs. We verified the validity of the proposed methodology by measuring and predicting the water-sorption curves in ASD films of polyvinylpyrrolidone-based polymers and of indomethacin. This way, the extent and the rate of water sorption in ASDs were predicted for drug loads of 0.2 and 0.5 as well as in the humidity range from 0 to 0.9 RH at 25 °C. The water-sorption isotherms and the water-sorption kinetics in the ASDs were predicted only based on the water-sorption isotherms and water-sorption kinetics in the neat polymer on the one hand and in the neat active pharmaceutical ingredient (API) on the other hand. The accurate prediction of water-sorption isotherms was ensured by combining the Perturbed-Chain Statistical Association Theory (PC-SAFT) with the Non-Equilibrium Thermodynamics of Glassy Polymers (NET-GP) approach. Water-sorption kinetics were predicted using Maxwell–Stefan diffusion coefficients of water in the ASDs.

Anomalous water-sorption kinetics in amorphous solid dispersions (ASDs) are caused by the slow swelling of the polymer. In this work, we used a diffusion–relaxation model with the Williams–Landel–Ferry (WLF) equation and the Arrhenius equation to predict the anomalous water-sorption kinetics in ASDs of poly(vinyl-pyrrolidone)-co-vinyl-acetate (PVPVA) and indomethacin (IND) at 25 °C. These predictions were based on the viscosities of pure PVPVA and pure IND, as well as on the water-sorption kinetics in pure PVPVA. The diffusion–relaxation model was able to predict the different types of anomalous behavior leading to a qualitative and quantitative agreement with the experimental data. Predictions and experiments indicated more pronounced anomalous two-stage water-sorption behavior in the ASDs than in pure PVPVA. This was caused by a higher viscosity of glassy ASD–water mixtures compared to glassy PVPVA–water mixtures at the same distance from their glass transition temperature. These results suggest that this ASD swells more slowly than the polymer it is composed of. The modeling approach applied in this work can be used in the future for predicting diffusion-controlled release behavior or swelling-controlled release behavior of ASDs.