Acedapsone is a long acting prodrug
of Dapsone, the diacetyl derivative
of diaminophenyl sulfone. It exhibits superior bioavailability compared
to the parent drug. Dapsone occupies a preeminent position in the
treatment of leprosy since the 1940s. Surprisingly no X-ray crystal
structure or polymorphs of acedapsone are reported. Five novel polymorphs
of acedapsone are reported (I–V) of which crystal forms I and
II are characterized by single X-ray diffraction. These novel polymorphs
were crystallized from solution, slow cooling of the melt, and spray-drying
of the powder. Solution crystallization afforded Acedapsone Forms
I and II. Slow cooling of the melt phase resulted in an amorphous
phase, which transformed to a new Form IV slowly at room temperature,
and then to Form III. Fast cooling or quick quench of the amorphous
solid gave Form I. Spray drying resulted in a new metastable polymorph
V, but this polymorph also converted to Form III at room temperature
after 6 h. In addition to five crystalline polymorphs of acedapsone,
an amorphous phase was also obtained from the melt. XPac analysis
of polymorphs I and II (space group P21/n and C2/c) showed
2D isostructurality, and Hirshfeld surface analysis revealed subtle
differences in the molecular environment of the two crystal structures.
The stability of five polymorphs by DSC, VT-PXRD, and upon heating
in a sealed tube suggested that the kinetic stability order is Form
I (most stable) > II > III > IV > V > amorphous (least
stable), whereas
competitive slurry and liquid-assisted grinding experiments gave the
thermodynamic stability as Form II (most stable) > I > III >
IV >
V > amorphous (least stable). Solventless methods such as quench
cooling
of the melt and holding in a sealed tube at high temperature and pressure
yielded the kinetically stable Form I. Spray drying of the powder
gave metastable Forms III and V (which transformed over time), and
slurry conditions gave the thermodynamic Form II. The pentamorphic
system follows Ostwald’s law of stages. The role of solvent
selection in the direct crystallization of Acedapsone polymorphs after
diacetylation of Dapsone is also discussed.