Flufenamic acid (FFA) is a highly
polymorphic drug molecule with
nine crystal structures reported in the Cambridge Structural Database.
This study explores the use of synchrotron X-ray powder diffraction
combined with differential scanning calorimetry to study crystallization
and polymorphic phase transitions upon heating FFA–polymer
amorphous solid dispersions (ASDs). Ethyl cellulose (EC, 4 cp) and
hydroxypropylmethylcellulose (HPMC) grades with different viscosities
and substitution patterns were used to prepare dispersions with FFA
at 5:1, 2:1, 1:1, and 1:5 w/w drug/polymer ratios by quench cooling.
We employed a 6 cp HPMC 2910 material and two HPMC 2208 samples at
4000 and 100 000 cp. Hyphenated X-ray diffraction (XRD)–differential
scanning calorimetry (DSC) studies show that the 6 and 100 000
cp HPMCs and 4 cp EC polymers can stabilize FFA form IV by inhibiting
the transition to form I during heating. It appears that the polymers
stabilize FFA in both amorphous and metastable forms via a combination
of intermolecular interactions and viscosity effects. Increasing the
polymer content of the ASD also inhibits polymorphic transitions,
with drug/polymer ratios of 1:5 w/w resulting in FFA remaining amorphous
during heating. The comparison of FFA ASDs prepared with different
samples of HPMCs and ECs suggests that the chemical substitution of
the polymer (HPMC 2208 has 19–24% methoxy groups and 4–12%
hydroxypropyl groups, while HPMC 2910 has 28–30% methoxy groups
and 7–12% hydroxypropyl groups) plays a more significant role
in directing polymorphic transitions than the viscosity. A previously
unreported polymorph of FFA was also noted during heating but its
structure could not be determined.