Industrial process for preparation of clopidogrel hydrogen sulphate

Information

  • Patent Application
  • 20080097101
  • Publication Number
    20080097101
  • Date Filed
    March 04, 2005
    19 years ago
  • Date Published
    April 24, 2008
    16 years ago
Abstract
An improved process for the manufacture of Clopidogrel starting from 2-(2-thienyl) ethylamine, which eliminates the isolation of an unstable intermediate like 2-(2-thienyl) ethyl formimine by subjecting it to a one pot cyclization to get 4, 5, 6, 7-tetrahydrothieno (3,2-c) pyridine of Formula II and further reacting with halo-compound of Formula III (where X is Cl or Br) at 20 to 90° C. temperature characterized in a solvent like water and/or dichloroethane in presence of organic or inorganic bases is disclosed herein. This invention further discloses a process for resolution of racemic Clopidogrel into its optical antipodes and converting the dextroclopidogrel base into its known polymorphs namely ‘Form I’ or ‘Form II’ in solvents selected from methyl propyl ketone, methyl isopropyl ketone, diethyl ketone or their mixture thereof, mixture of ethyl acetate and methyl propyl ketone, mixture of ethyl acetate and methyl isopropyl ketone, or mixture of ethyl acetate and diethyl ketone or ethyl acetate.
Description

BRIEF DESCRIPTION OF FIGURES


FIG. 1 represents Powder X-Ray diffraction pattern (PXRD) of clopidogrel hydrogen sulphate Form I prepared according to example 7 of the present invention.



FIG. 2 represents Powder X-Ray diffraction pattern (PXRD) of clopidogrel hydrogen sulphate Form II prepared according to example 11 of the present invention.



FIG. 3 represents Differential Scanning Calorimetry record of Form I of clopidogrel hydrogen sulphate prepared according to example 7 of the present invention.



FIG. 4 represents Differential Scanning Calorimetry record of Form II of clopidogrel hydrogen sulphate prepared according to example 11 of the present invention.



FIG. 5 represents Powder X-Ray diffraction pattern (PXRD) of clopidogrel hydrogen sulphate Form I standard as given in '915 patent.



FIG. 6 represents the spectrogram obtained by Fourier Transform Infra Red spectrometry (FTIR) of clopidogrel hydrogen sulphate Form I prepared according to example 7 of the present invention



FIG. 7 represents spectrogram obtained by Fourier Transform Infra Red spectrometry (FTIR) of clopidogrel hydrogen sulphate Form II prepared according to example 11 of the present invention.



FIG. 8 represents an overlay of powder x-ray diffraction pattern (PXRD) of clopidogrel hydrogen sulphate crystalline Form I and Form II.





DETAILED DESCRIPTION OF THE INVENTION

The improved process for preparation of racemic clopidogrel, its resolution, and conversion to hydrogen sulphate salt in specific crystalline forms viz; ‘Form I’ and ‘Form II’ are described in detail with the specific embodiments/conditions here after.


It has now been found that new condition/process makes it possible to convert 2-(2-thienyl) ethylamine to 4,5,6,7-tetrahydrothieno (3,2-c) pyridine via 2-(2-thienyl) ethyl formimine in a single step in one-pot and thereby eliminating the isolation of unstable intermediate, 2-(2-thienyl) ethyl formimine, making the process industrially more feasible.


Consequently, the invention relates to an improved synthesis of Clopidogrel by reacting 2-(2-thienyl) ethylamine with paraformaldehyde in presence of dry HCl, optionally isolating the compound of Formula II, and reacting with halo-compound of Formula III (X=Cl or Br) in a single organic solvent or a combination of organic solvents and water.


Accordingly, the 2-(2-thienyl) ethylamine is reacted with paraformaldehyde in a suitable solvent selected from non-polar solvent like aliphatic and aromatic hydrocarbon solvents, chlorinated hydrocarbons like dichloroethane (EDC) etc. The reaction takes place at a temperature of 30° C. to 100° C. and the water formed as a byproduct in the reaction is removed continuously by azeotropic distillation using a Dean-Stark assembly or the like. Azeotropic distillation herein means removal of two or more solvents from a mixture of solvents that form a low boiling mixture called azeotrope by distillation at elevated temperature.


After removal of water, the intermediate 2-(2-thienyl) ethyl formimine formed in solution is in situ reacted with dry HCl gas. The dry HCl also can be advantageously introduced into reactor as a solution in a suitable organic solvent. The solvent used for this purpose include dimethyl formamide, alcoholic solvents like methanol, ethanol, isopropyl alcohol etc. The one pot conversion of 2-(2-thienyl) ethylamine takes place in a period of 4 to 8 hours. The preferred temperature for carrying out the cyclization of intermediate in presence of the acid catalyst is in the range from 60° C. to 90° C.


According to present invention, the cyclization of 2-(2-thienyl) ethyl formimine obtained takes place in-situ spontaneously in presence of acid and yields the stable intermediate 4,5,6,7-tetrahydrothieno (3,2-c) pyridine as its hydrochloride salt. The said salt precipitates from the reaction medium and conveniently isolated in substantially pure form.


The acid catalyzed cyclization of 2-(2-thienyl) ethyl formimine is preferably carried out at a temperature range of 70° C. to 75° C., for a period of 4 hours.


According to a preferred embodiment of the invention, the 4,5,6,7-tetrahydrothieno (3,2-c) pyridine as a free base or its hydrochloride salt form is reacted with a halo derivative of Formula III in organic solvent especially dichloroethane in presence of an organic base to obtain Clopidogrel. The organic base for carrying out this step of the process is selected from the group consisting of trialkyl amines such as triethylamine, trimethylamine, diisopropylethylamine and the like. The preferred base is triethylamine. The preferred halo derivative of Formula III is the bromo compound (Formula III, where X=Br).


According to the above process step of the present invention, wherein the compound III and 4,5,6,7-tetrahydrothieno (3,2-c) pyridine is reacted, the reaction is carried out at a temperature range of about 50° C. to about 80° C. for about 4 to 4.5 hours, preferably about 3.5 hours at 70° C. In this step of the process, where the acid salt of Formula II is used as reactant, then an excess amount of the base is used. This is required to neutralize the acid salt to liberate the free base of the compound of Formula II that reacts with the halo derivatives of Formula III.


In another embodiment of the invention, the process step of reaction of 4,5,6,7-tetrahydrothieno(3,2-c)pyridine with the halo compound of Formula III is carried out in a heterogeneous mixture of solvents selected from a combination of water and chlorinated hydrocarbon solvents such as dichloromethane or dichloroethane. The preferred solvent is a mixture of water and dichloroethane. The preferred ratio of water and dichloroethane is 1:0.5. A specific advantage of this reaction medium is that a phase-transfer catalyst as taught by prior patents is not required and the reaction can be performed at ambient conditions.


The base for carrying out the above process step is selected from the group consisting of inorganic bases like alkali metal carbonates. The preferred alkali metal carbonate used is sodium carbonate or potassium carbonate.


Preferably the inorganic base may be used in molar equivalent ratio relative to the halo compound of Formula III or in slight excess. In the case of reaction of acid salt of Formula II with Formula III, an excess base is used to liberate the free amine from acid salt. A preferable ratio of base used in this case ranges from 2 moles to 3 moles relative to compound of Formula II.


In this step of the process, the 4,5,6,7-tetrahydrothieno(3,2-c)pyridine or its hydrochloride salt and the inorganic base is preferably taken in water in a reaction vessel. The addition of a compound of Formula III is carried out as its solution in dichloroethane to form the heterogeneous reaction conditions. This process is particularly advantageous from the point of view of handling the halo compound of Formula III, due to its highly irritant and lachrymator properties.


According to the process of the present invention, this step is advantageously carried out at ambient temperature. Although the reaction goes faster at high temperature, to limit the impurity generation, this step is carried out at a temperature of 25° C. to 30° C. for a period of 7 to 10 hours, preferably 10 hours.


The Clopidogrel prepared following the above method is isolated by phase separation and washing the organic layer with water. The organic layer is removed by evaporation and the clopidogrel base obtained is purified in acetone by making its hydrogen sulphate salt. The pure Clopidogrel hydrogen sulphate is isolated as pure crystals from the solvent by suction filtration and drying.


According to a particularly advantageous alternative form of the present invention, the preparation of Clopidogrel may be carried out from 4,5,6,7-tetrahydrothieno (3,2-c) pyridine intermediate in the actual medium (hydrocarbon solvents) in which it is prepared in a single pot.


Consequently, according to the invention, clopidogrel is prepared by the following reactions in a single pot.

    • 1. 2-(2-thienyl)ethylamine is reacted with paraformaldehyde in suitable solvent as described earlier and removing the water formed in the reaction azeotropically.
    • 2. introducing dry HCl in the form of solution or gas and cyclizing the corresponding formimine to give 4,5,6,7-tetrahydrothieno(3,2-c)pyridine as hydrochloride salt in the reaction vessel.
    • 3. saponifying the hydrochloride salt of 4,5,6,7-tetrahydrothieno(3,2-c)pyridine of Formula II with introduction of an aqueous solution of sodium or potassium carbonate in required amounts.
    • 4. introducing halo-compound of Formula III as such or as a solution in organic solvent used for the stage 1 and reacting at a temperature of 25° C. to 30° C. for a period of 8 to 10 hours, preferably 10 hours,
    • 5. isolating the Clopidogrel base in the organic layer after phase separation and washing with water, removing the solvent by evaporation to leave Clopidogrel base as residue in the reaction vessel, and
    • 6. isolating pure Clopidogrel hydrogen sulphate by introducing acetone and conc. sulphuric acid into the reaction vessel.


The addition of Sulphuric acid is carried out preferably at a temperature of 0° C. to 25° and the addition of Sulphuric acid to the acetone solution of Clopidogrel base may be carried out in a controlled manner so as to avoid undue exothermicity with proper cooling. The hydogen sulphate salt was further treated with a base like sodium or potassium carbonate to liberate the free clopidogrel base.


The Clopidogrel base obtained by the process of the present invention is, further, resolved into it enantiomers using optically active camphorsulphonic acid. The process of resolution involves contacting Clopidogrel base with(−)camphor sulphonic acid in a mixture of polar and non-polar/weakly polar organic solvents and crystallizing the dextroisomer as a diasteriomeric salt of camphor sulphonic salt.


The solvent of choice used in preparing combination solvents is selected from acetone, dichloromethane, toluene and cyclohexane. The mixtures of solvents ideal for resolution of racemic clopidogrel are combination of acetone:dichloromethane, acetone:toluene, and acetone:cyclohexane; wherein the preferred mixtures of the solvents are combination of acetone:dichloromethane and acetone:toluene, and the most preferred mixture of the solvents is acetone:dichloromethane. This solvent combination in a preferred proportion is essential for the success of resolution in respect of yield and purity in a single crystallization step. The preferred ratio of the solvents used is 20:0.5 (10:0.25), wherein the more preferred ratio is 15:0.75 and the most preferred ratio is 10:1. It is preferable to use anhydrous levo-camphor-10-sulphonic acid and the most preferred molar ratio of camphor sulphonic acid is 1.05 to 1.1 molar equivalents relative to the racemic clopidogrel mixture. The salt formation is carried out in the temperature range of 25-35° C., preferably at 30±2° C.


The diasteriomer salt is then hydrolyzed using alkali metal carbonates such as sodium carbonate or ammonia to liberate the dextro enantiomer of Clopidogrel as free base. After hydrolysis, (+)(S) Clopidogrel base was isolated by extraction using organic solvents like dichloromethane followed by evaporation of solvent to give (+) Clopidogrel having an enantiomeric purity more than 99.5% with an yield of 76 to 80%.


Owing to the economy of the process, the unwanted isomer, (−)(R) clopidogrel camphor sulphonate salt, left behind in the mother liquor after crystallization of S-isomer is racemized and recycled. The mother liquor containing (−)(R) clopidogrel camphor sulphonate along with some amount of unrecovered S-isomer after removal of crystallization solvent is treated with NaOH in alcoholic solvents like methanol at a temperature ranging from 30 to 50° C. to obtain a 50:50 ratio of both isomers (referred as racemic mixture). After racemization, the (±) clopidogrel free base is isolated by solvent evaporation, and extraction using a mixture of dichloromethane and water. The dichloromethane layer contains the (±)clopidogrel base and aqueous layer contains the resolving agent (camphor sulphonic acid) and both are recovered and recycled. A particularly important aspect of this process of invention is that it avoids the isolation of (R) clopidogrel base from the diasteriomeric salt and directly converts it to the(±)clopidogrel base.


Finally, the dextro clopidogrel free base obtained above is converted to hydrogen sulphate salt in its two crystalline polymorphs, ‘Form I’ and ‘Form II’ by a reproducible process on large scale.


Large scale production of these two crystalline Forms according to the process described in the '915 patent resulted in Form II or a mixture or contaminated with either form at a higher percentage. Also the improved process of '443 patent application resulted in scale-up problems on large scale due to lump formation and semi-solid/sticky nature of the product at lower temperature and converts to more stable ‘Form II’. Also encountered problems in maintaining precise control of temperature at different set points as stated in the '443 patent on large scale production.


This lead us to find suitable solvents or conditions where these problems are minimized and ensure reproducibility of Form I and II, particularly Form I without contamination of other forms. This research has led to an efficient process where Form I and Form II can be produced reliably from a single solvent or mixture of solvents.


Accordingly, the present invention provides a process for preparing polymorph Form I of clopidogrel hydrogen sulphate comprising dissolving the(+)clopidogrel base in solvents like methyl propyl ketone, methyl isopropyl ketone, diethyl ketone or mixture thereof, or mixture of ethyl acetate and methyl propyl ketone or mixture of ethyl acetate and methyl isopropyl ketone, or mixture of ethyl acetate and diethyl ketone; cooling to a temperature of −10° C. to 10° C.; adding concentrated sulphuric acid (98%, d=1.84) by maintaining the temperature at in the range of −10 to 20° C.; raising to a temperature of 10° C. to 15° C. and maintaining for 5 to 7 hours; further raising to a temperature of 28° to 30° C. and maintaining for a period of 7 to 10 hours and filtering the crystals obtained.


The mixture of ketone solvents include mixture of methyl propyl ketone and methyl isopropyl ketone, mixture of methyl propyl ketone and diethyl ketone, mixture of methyl isopropyl ketone and diethyl ketone, in all proportions.


In a further embodiment, the present invention provides a process for preparing polymorph Form I of clopidogrel hydrogen sulphate from ethyl acetate comprising the steps of dissolving the(+)clopidogrel base in ethyl acetate, cooling to a temperature of 18° C., adding concentrated sulphuric acid with or without maintaining temperature at 18°, raising to a temperature of 28° to 30° C. and maintaining for a period of 7 to 10 hours and filtering the crystals obtained.


In the process, in ethyl acetate, the temperature range of 18° to 30° C. gave Form I reproducibly on a large scale. Within this temperature range an easily dispersible mass is obtained and slight imbalance of temperature is well tolerated to give Form I consistently.


In both the cases, in the process for Form I, the preferred concentration of sulphuric acid was in the range of 90% to 98% and the molar ratios were in the range of 1 to 1.1 with respect to the (+) clopidogrel base. The most preferred concentration of sulphuric acid used in the salt formation was 96%.


In a preferred embodiment of the process, the exotherm of sulphuric acid addition is controlled by cooling and maintaining the temperature in between 18° to 24° C. in case of solvent ethyl acetate; and cooling and maintaining the temperature in between −10 to 10° C. in case of solvents methyl propyl ketone, methyl isopropyl ketone, diethyl ketone or their mixture thereof, or mixture of ethyl acetate and methyl propyl ketone or mixture of ethyl acetate and methyl isopropyl ketone, or mixture of ethyl acetate and diethyl ketone.


The Form I so obtained was confirmed by PXRD, DSC and FTIR without any detectable quantity of Form II or other polymorphic Forms with respect to the standard Form I PXRD pattern as described in '915 patent.


In another aspect, Form II crystals of (+) clopidogrel hydrogen sulphate is prepared from the same solvent ethyl acetate comprising steps of dissolving (+) clopidogrel base in the solvent, heating to a temperature of 45° C., adding concentrated sulphuric acid, stirring the reaction mixture at 45° C. to 50° C. for a period of 1 hour, cooling to 30° C. and continue stirring for a period of 4 to 7 hours to effect the complete crystallization.


In the process, the preferred concentration of sulphuric acid was in the range of 90% to 98% and the molar ratios were in the range of 1.0 to 1.1 with respect to clopidogrel base. The most preferred concentration of sulphuric acid used in the salt formation was 96%.


The Form II obtained by the process of the invention was confirmed by PXRD, DSC and FTIR and found to be identical with it disclosed in the '915 patent without any detectable contamination of Form I.


In yet another aspect, Form II of clopidogrel is prepared from ethyl acetate at a lower temperature of 5° to 15° C. comprising the steps of dissolving (+) clopidogrel base in ethyl acetate at 25° to 30° C., cool to 5° to 15° C. and mixing with conc. sulphuric acid at the said temperature, maintaining the mass under stirring for a period of 8 to 10 hours at 5 to 15° C. to yield crystals of clopidogrel Form II. The crystals obtained are filtered and dried and is identified as Form II by PXRD, FTIR and DSC without detectable contamination of Form I.


To our surprise the crystal form obtained at temperature below 15° C. and above 40° C. process conditions are the stable Form II crystals, while the temperature range of 18° to 30° C. processing conditions invariably yielded crystal Form I of clopidogrel hydrogen sulphate.


In another embodiment, the present invention provides a process for the preparation of Form II crystals of clopidogrel hydrogen sulphate from isopropyl alcohol comprising steps of dissolving clopidogrel base in solvent, adding concentrated sulphuric acid at a temperature of 28° to 30° C., stirring to effect complete crystallization for a period of 12 to 15 hours, filter and dry the crystals. The crystal form is identified equivalent to Form II. This solvent system (isopropyl alcohol) is, however, known to give Form IV.


In a preferred embodiment of the process the concentrated sulphuric acid is added as a solution in isopropyl alcohol.


The present invention also provides a process for the preparation of Form II of clopidogrel hydrogen sulphate from tetrahydrofuran comprising steps of dissolving clopidogrel base in solvent, cooling the reaction mass to a temperature of 10° to 15° C.; adding concentrated sulphuric acid at a temperature of 10° to 15° C., stirring to effect complete crystallization for a period of 6 to 8 hours, filter and dry the crystals. The crystal form is identified equivalent to Form II.


The following examples further illustrate the present invention but are not construed limiting in any manner to the scope of the invention as substantially described.


EXAMPLES
Example 1
One Pot Process for 4,5,6,7-tetrahydrothieno(3,2-C)pyridine Hydrochloride

100 gm. of 2-thienylethylamine was charged in a 1 litre reaction vessel equipped with a dean stark assembly for azeotropic removal of water. Dichloroethane (600 ml.) was added and the mixture stirred for 5 minutes. 26.4 gm. paraformaldehyde was added and the reaction mass was heated to reflux. Water formed in the reaction was continuously removed. After 4 hours the reaction mass was cooled to 30° C. and 133 ml. of 6.6 N hydrochloric acid solution in dimethyl formamide was added. The reaction mass was heated to 70° C. for 4 hours. The reaction cooled to 15° C. and filtered under suction and washed with dichloroethane. The solid obtained was dried in oven at 50° C. 124 gm (90%) of 4,5,6,7-tetrahydrothieno(3,2-c)pyridine hydrochloride are obtained.


Example 2
Clopidogrel Base and Clopidogrel Hydrogen Sulphate (Dichloroethane as Solvent)

50 gm. 4,5,6,7-tetrahydrothieno(3,2-C)pyridine hydrochloride was charged in 1 litre reaction vessel. 150 ml. dichloroethane was added and stirred for 5 minutes. 75 gm. of methyl-1-bromo-(2-chlorophenyl)acetate and 80 ml. triethyl amine was added. Stirred at 25° C. for 1 hour and then heated to reflux for 4 hours. The reaction mixture cooled to room temperature and quenched in water. The organic layer was washed with water, and distilled the dichloroethane to obtain clopidogrel base as an oil.


This clopidogrel base was dissolved in 300 ml. acetone and mixed with 17.5 ml. Conc. Sulphuric acid under cooling. The precipitated pure Clopidogrel hydrogen sulphate was filtered and washed with acetone. The precipitate was dried in an oven at 50° C. and 105 gm.(88%) Clopidogrel hydrogen sulphate was obtained.


Example 3
Clopidogrel Base and Clopidogrel Hydrogen Sulphate (Water and Dichloroethane as Reaction Medium)

50 gm. of 4,5,6,7-tetrahydrothieno(3,2-C)pyridine hydrochloride was charged in 1 litre reaction vessel containing 500 ml. water and 75.4 gm. sodium carbonate and stirred for 1 hour. 75 gm. of methyl-1-bromo-(2-chlorophenyl) acetate in 250 ml. dichloroethane was added, stirred at 25° C. for 8 hours. The organic layer was separated and washed with water, and distilled the dichloroethane to obtain Clopidogrel base as an oil.


This was dissolved in acetone (300 ml.), cooled to 0-5° C. and mixed with 17.5 ml. conc. Sulphuric acid under cooling. The precipitated pure Clopidogrel hydrogen sulphate was filtered and washed with acetone. The precipitate was dried in an oven at 50° C. The 105 gm. (88%) Clopidogrel hydrogen sulphate was obtained.


Example 4
One-Pot Process for Clopidogrel Hydrogen Sulphate from Thienoethylamine

100 gm. of 2(2-thienyl)ethylamine was charged in a reaction vessel equipped with a dean-stark assembly for azeotropic removal of water. Dichloroethane (600 ml.) was added and the mixture stirred for 5 minutes. 26.4 gm. paraformaldehyde was added and the reaction mass was heated to reflux. Water formed in the reaction was continuously removed in 4 hours. The reaction mass was cooled to 30° C. and 133 ml. of 6.6 N hydrochloric acid solution in dimethyl formamide was added. The reaction mass was heated at 70° C. for 4 hours. The reaction cooled to 25° C. and an aqueous solution of sodium carbonate (prepared from 1400 ml. water and 208 gms sodium carbonate) was added. The mixture was stirred for 1 hour and a solution of 206.7 gm. of methyl-1-bromo-(2-chlorphenyl) acetate in 690 ml. dichloroethane was added. The reaction mass stirred at room temperature for 9 hours and the aqueous layer is discarded. The organic layer washed with water and dichloroethane was evaporated. To the oil left in the reaction vessel, 825 ml acetone was added and stirred for 1 hour. The mass cooled to 0 to 5° C. and 48 ml. conc. Sulphuric acid was added. The mixture was further stirred for 4 hours. The precipitated crystals filtered off under suction and the pure Clopidogrel hydrogen sulphate was dried in oven at 50° C. to get 280.5 gm (85%).


Example 5
(S)(+) Clopidogrel Base

93.0 gm (0.28 mole) of racemic base methyl-2-(2-chlorophenyl)-2-(4,5,6,7-tetrahydrothieno [3,2-c] pyridin-5-yl) acetate was charged in 550 ml mixture of acetone and dichloromethane solvent. 73.8 gm (0.31 mole) levo-camphor-10-sulphonic acid was added in the solution. The clear solution was stirred overnight at 30±2° C. and cooled the reaction mass to −2 to 3° c. The crystals obtained was filtered and washed with acetone and dried at room temperature under vacuum to give 61 gm of diateriomeric salt of (S)clopidogrel. The yield obtained is 76.0% on the basis of the starting racemate charged. The crystals have


[α]D20+25·25 (c=1.89%, methanol); HPLC (AGP(R) column) assay=99.65%.


The diasteriomeric salt (60 gm) obtained above was dissolved in 240 ml water containing 16.8 gms of Sodium bicarbonate and 240 ml ethyl acetate was added and stirred for a period of 2 hours at room temperature. The organic layer was separated and washed with water and evaporated to give 35.35 gm of (+)-(S)-Clopidogrel base as an oil.


Example 6
(S)(+) Clopidogrel Base

93.0 gm (0.28 mole) of racemic base methyl-2-(2-chlorophenyl)-2-(4,5,6,7-tetrahydrothieno [3,2-c] pyridin-5-yl) acetate is charged in 550 ml mixture of acetone and toluene. 73.8 gm (0.31 mole) levo-camphor-10-sulphonic acid is added to the solution. The clear solution is stirred overnight at 30±2° c. The reaction mass is cooled to −2 to 3° C. The crystals obtained is filtered and washed with acetone and dried under reduced pressure. The yield obtained is 80% on the basis of the starting racemate charged. The crystals have [α]D20+24.49(c=1.89%, methanol); HPLC(AGP(R) column) assay=99.285%. The camphor sulphonate salt was further cleaved to obtain (S)(+)clopidogrel base as in example 5.


Example 7

Clopidogrel base (5.79 kg) was dissolved in methyl propyl ketone (37 liter) at room temperature. This mixture was cooled to −10° C. and concentrated sulphuric acid (96%, density=1.83) was added (1.02 liter) maintaining temperature −10° to 0° C. while addition. The reaction mass was stirred for 1.0 hour and warmed slowly to 10 to 15° C. in 30 to 45 minute. The formed crystals were stirred for 7 hour. The reaction mass temperature was further raised to 28 to 30° C. and maintained for 8.0 hour. The solid obtained was filtered under suction and washed with methyl propyl ketone, and dried in oven at 48° C. for 3 hour. The solid after drying weighed 6.82 kg (90%) was Form I clopidogrel hydrogen sulphate (PXRD pattern incorporated: FIG. 1)


Example 8

Clopidogrel base (5.79 kg) was dissolved in methyl isopropyl ketone (37 liter) at room temperature. This mixture was cooled to −10° C. and concentrated sulphuric acid (96%, density=1.83) was added (1.02 liter) maintaining temperature −10° to 0° C. while addition. The reaction mass was stirred for 1.0 hour and warmed slowly to 10 to 15° C. in 30 to 45 minutes. The formed crystals were stirred for 7 hour. The reaction mass temperature was further raised to 28 to 30° C. and maintained for 8.0 hour. The solid obtained was filtered under suction and washed with methyl isopropyl ketone, and dried in oven at 48° C. for 3 hour. The solid after drying weighed 6.82 kg (90%) was Form I clopidogrel hydrogen sulphate (PXRD pattern is identical with FIG. 1).


Example 9

Clopidogrel base (5.79 kg) was dissolved in ethyl acetate (30 liter) at room temperature. This mixture was cooled to 18° C. and concentrated sulphuric acid (96%, density=1.83) was added (1.02 liter) maintaining temperature 18° to 20° C. while addition. The reaction mass was stirred for 30 minutes and warmed slowly to 28° to 30° C. in 30 to 40 minute. The formed crystals were stirred for 8 hour. The solid obtained was filtered under suction and washed with ethyl acetate, and dried in oven at 40° C. for 3 hour. The solid after drying weighed 6.7 kg (88%) was Form I clopidogrel hydrogen sulphate (PXRD pattern is identical with FIG. 1).


Example 10

Clopidogrel base (5.79 kg) was dissolved in ethyl acetate (30 liter) at room temperature. This mixture was heated to 45° C. and concentrated sulphuric acid (96%, density=1.83) was added (1.02 liter). The reaction mass was stirred for 30 minutes at 45° to 50° C. The formed crystals were cooled to 30° C. in one hour and stirred for 4 hour. The solid obtained was filtered under suction and washed with ethyl acetate, and dried in oven at 48° C. for 3 hour. The solid after drying weighed 6.5 kg (86%) and identified as pure clopidogrel hydrogen sulphate Form II ( PXRD pattern incorporated FIG. 2)


Example 11

Clopidogrel base (5.79 kg) was dissolved in ethyl acetate (30 liter) at room temperature. This mixture was cooled to 20° C. and concentrated sulphuric acid (98%, density=1.84) was added (1.02 liter). The temperature rose to 28° C. while addition and the reaction mass was stirred for 10 hour at 28° to 30° C. The solid obtained was filtered under suction and washed with ethyl acetate, and dried in oven at 40° C. for 3 hour. The solid after drying weighed 6.8 kg (89.6%) and identified as pure clopidogrel hydrogen sulphate Form I (PXRD pattern is identical with FIG. 1).


Example 12

Clopidogrel base (7.25 kg) was dissolved in isopropyl alcohol (62.5 liter) at room temperature. This mixture was maintained at 28° to 30° C. and concentrated sulphuric acid solution in isopropyl alcohol (prepared by mixing 1.14 liter concentrated sulphuric acid and 43.5 liter isopropyl alcohol) was added. The reaction mass was stirred for 12 hour at 28° to 30° C. The solid obtained was filtered under suction and washed with ethyl acetate, and dried in oven at 48° C. for 3 hours. The solid after drying weighed 7.6 kg (80%) and identified as pure clopidogrel hydrogen sulphate Form II ( PXRD pattern as in example 4).


Example 13

Clopidogrel base (5.79 kg) was dissolved in tetrahydrofuran (30 liter) at room temperature. This mixture was cooled to 10° to 15° C. and concentrated sulphuric acid (80%) solution 1.4 liter was added while maintaining the temperature under cooling. The reaction mass was stirred for 8 hour at 13° to 15° C. The solid obtained was filtered under suction and washed with tetrahydrofuran, and dried in oven at 48° C. for 3 hour. The solid after drying weighed 5.9 kg (78%) and identified as pure clopidogrel hydrogen sulphate Form II (PXRD pattern as in example 4).


Example 14

Clopidogrel base (5.79 kg) was dissolved in ethyl acetate (30 liter) at room temperature. This mixture was cooled to 5° C. and concentrated sulphuric acid (98%, density=1.84) was added (1.02 liter) while maintaining the temperature at 5° to 10° C. and the reaction mass was stirred for 3 hour at 10° to 15° C. and maintained for 10 to 12 hour at 24° C. The solid obtained was filtered under suction and washed with ethyl acetate, and dried in oven at 48° C. for 3 hour. The solid after drying weighed 6.9 kg (90%) and identified as pure clopidogrel hydrogen sulphate Form II ( PXRD pattern was identical as in example 4)


Example 15

Clopidogrel base (5.79 kg) was dissolved in ethyl acetate (30 liter) at room temperature. This mixture was cooled to 10° C. and concentrated sulphuric acid (98%, density=1.84) was added (1.02 liter) while maintaining the temperature at 10° to 15° C. and the reaction mass was stirred for 10 hour at 15° C. The solid obtained was filtered under suction and washed with ethyl acetate, and dried in oven at 48° C. for 3 hours. The solid after drying weighed 6.7 kg (89.6%) and identified as pure clopidogrel hydrogen sulphate Form II (PXRD pattern was identical as in example 4).


It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative examples and that the present invention may be embodied in other specific forms without departing from the essential attributes thereof, and it is therefore desired that the present embodiments and examples be considered in all respects as illustrative and not restrictive, reference being made to the appended claims, rather than to the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

Claims
  • 1-31. (canceled)
  • 32. A process for making clopidogrel of Formula I starting from 2-(2-thienyl)ethylamine characterized in that the said process comprising
  • 33. The process of claim 32, wherein the step i) is performed in a solvent selected from aliphatic, aromatic hydrocarbons and chlorinated hydrocarbons.
  • 34. The process of claim 33, wherein the solvent is dichloroethane.
  • 35. The process of claim 32, wherein 2-(2-thienyl)ethyl formimine is formed in-situ by effective removal of water at reflux temperature and cyclized in presence of anhydrous hydrochloric acid.
  • 36. The process of claim 32, wherein said 4,5,6,7-tetrahydrothieno(3,2-c)pyridine is formed at a temperature ranging from about 60° C. to 90° C.
  • 37. The process of claim 32, wherein step ii) is carried out in dichloroethane.
  • 38. The process of claim 32, wherein the base is selected from trialkyl amines.
  • 39. The process of claim 38, wherein the base is triethyl amine.
  • 40. The process of in claim 32, wherein step ii) takes place at a temperature of 50° C. to 80° C.
  • 41. The process of claim 32, wherein the clopidogrel is prepared in a single-pot procedure without isolation of intermediates 4,5,6,7-tetrahydrothieno(3,2-c)pyridine or its salts.
  • 42. The process of claim 32, wherein step i) takes place in the presence of an acid catalyst.
  • 43. The process of claim 42, wherein the acid catalyst is HCl.
  • 44. A process for preparation of clopidogrel of Formula I comprising the step of reacting 4,5,6,7-tetrahydrothieno(3,2-C)pyridine of formula II or its salt with a halobenzene derivative of Formula III in presence of a base in a solvent, wherein the solvent is chlorinated hydrocarbon, water or a mixture of water and hydrocarbon solvents selected from aliphatic, aromatic and chlorinated hydrocarbons.
  • 45. The process of claim 44, wherein the solvent is a combination of dichloroethane and water.
  • 46. The process of claim 44, wherein the base is sodium carbonate or potassium carbonate.
  • 47. The process of claim 44, wherein reaction is performed at a temperature of 20° C. to 40° C.
  • 48. The process of claim 44, wherein the compound of Formula III is methyl-1-bromo-(2-chlorophenyl)acetate.
  • 49. The process of claim 44, further comprising the steps of treating said clopidogrel of Formula I with levo-rotatory camphor sulphonic acid in a solvent system of polar and apolar/weakly polar solvents; and obtaining substantially pure dextrorotatory clopidogrel of Formula IA.
  • 50. The process of claim 49, wherein the solvent system is acetone and dichloromethane; acetone and toluene; or acetone and cyclohexane
  • 51. The process of claim 50, wherein the combination solvent is acetone and dichloromethane.
  • 52. The process of claim 51, wherein the ratio of acetone and dichloromethane is 10:1.0.
  • 53. A process for preparation of dextrorotatory clopidogrel or its salt comprising the step of resolving racemic clopidogrel with levo-rotatory camphor sulphonic acid in a solvent system of polar and apolar/weakly polar solvents to obtain substantially pure dextrorotatory clopidogrel of Formula IA.
  • 54. The process of claim 53, wherein the solvent system is acetone:dichloromethane, acetone:toluene, or acetone:cyclohexane.
  • 55. The process of claim 54, wherein the combination solvent is acetone:dichloromethane.
  • 56. An process for making Form I crystals of (+)-(S)-clopidogrel hydrogen sulphate of Formula IB comprising the steps of:
  • 57. The process of claims 56, wherein said mixture of ketone solvents are mixtures of methyl propyl ketone and methyl isopropyl ketone, mixture of methyl propyl ketone and diethyl ketone, or mixture of methyl isopropyl ketone and diethyl ketone.
  • 58. The process of claim 56, wherein step ii) involves cooling to a temperature range of −10 to 20° C.
  • 59. The process of claim 56, wherein step iii) is carried out while maintaining reaction solution temperature at −10 to 10° C.
  • 60. The process of claim 56, wherein the solution is seeded with Form I prior to addition of sulphuric acid.
  • 61. The process of claim 56, wherein the mixture of step iv) is maintained at a temperature range of 10° to 30° C.
  • 62. The process of claim 61, wherein the mixture of step iv) is maintained at 10° to 30° C. for 8 to 15 hours.
  • 63. The process of claim 56, wherein the solvent is methylpropyl ketone.
  • 64. The process of claim 56, wherein the solvent is methylisopropyl ketone.
  • 65. The process of claim 56, wherein the solvent is ethyl acetate-methylpropyl ketone.
  • 66. The process of claim 56, wherein the solvent is ethyl acetate-methylisopropyl ketone.
  • 67. The process of claim 56, wherein the solvent is methyl propyl ketone and methyl isopropyl ketone.
  • 68. A process for making Form I crystals of (+)-(S)-clopidogrel hydrogen sulphate of Formula IB, said process comprising: i) dissolving methyl (+)-(S)-α-(2-chlorophenyl)-4,5,6,7-tetrahydrothieno[3,2-C]pyridine-5-acetate ((+)-(S)-clopidogrel base) in ethyl acetate;ii) cooling to a temperature of 18° to 200 C;iii) mixing said cooled solution with concentrated sulphuric acid in which the temperature not exceeding 30° C.;iv) maintaining the salt mixture at 28° to 30° C. for 7 to 10 hours to effect precipitation of (+)-(S)-clopidogrel hydrogen sulphate in Form I; andv) recovering said crystals of Form I.
  • 69. The process of claim 68, wherein step iii) is carried out while maintaining the temperature at 18 to 24° C.
  • 70. The process of claim 68, wherein the strength of said sulphuric acid is about 95 to 98%.
  • 71. The process of claim 68, wherein the molar ratio of sulphuric acid used is 1.02 to 1.1 relative to (+)-(S)-clopidogrel base.
  • 72. A clopidogrel Form I prepared according to claim 1 and having the Powder X-ray diffraction pattern as substantially given in FIG. 1.
  • 73. A pharmaceutical composition characterized in that the clopidogrel prepared according to claim I and having the Powder X-ray diffraction pattern as substantially given in FIG. 1 is put into a pharmaceutically acceptable dosage form.
Priority Claims (3)
Number Date Country Kind
281/MUM/2004 Mar 2004 IN national
626/MUM/2004 Jun 2004 IN national
861/MUM/2004 Aug 2004 IN national
PCT Information
Filing Document Filing Date Country Kind 371c Date
PCT/IN05/00071 3/4/2005 WO 00 9/5/2006