Mechanisms of polymeric film formation

Polymeric films are applied to solid dosage forms for decorative, protective, and functional purposes. These films are generally applied by a spray atomization process, where the polymer is sprayed onto the solid substrate. The mechanism by which films are formed is dependent on whether the polymer is in the dissolved or dispersed state. For solutions, film formation occurs as the solvent evaporates, since the polymer chains are intimately mixed. Film formation from polymeric dispersions, however, requires the coalescence of individual polymer spheres and interpenetration of the polymer chains. Films prepared from polymeric dispersions exhibit a minimum film forming temperature and processing conditions must exceed this temperature in order to form the film. In addition, these systems generally require post-coating storage in temperature and humidity controlled environments to ensure complete polymer coalescence. Incomplete coalescence can lead to significant changes in drug release over time. This review article highlights the basic science principles involved in film formation from both polymeric solutions and dispersions and the variables that influence these film formation processes.