Aerosol generating article equipped with a capsule

Abstract

An aerosol generating article (10) is provided for generating an inhalable aerosol when heated. The aerosol generating article (10) comprises a capsule (14;114). The capsule (14;114) comprises a capsule outer wall (20) defining an internal cavity (22). The capsule (14;114) also comprises a first aerosol generating substrate (24;124) within the internal cavity (22) of the capsule (14;114). The capsule (14;114) also comprises at least one of an aerosol former, a flavoring agent, and a second aerosol generating substrate provided inside the capsule outer wall (20), on the surface of the capsule outer wall (20), or both inside and on the surface of the capsule outer wall (20). An aerosol generating system (2000;3000) is also provided, comprising an aerosol generating article (10) and an aerosol generating device (200, 300) equipped with a heating element (240, 340) configured to heat the aerosol generating article (10). A method for manufacturing a capsule (14) is also provided.

Description

Technical Field

[0001] The present invention relates to an aerosol-generating article comprising an aerosol-generating substrate and adapted to generate an inhalable aerosol upon heating. The present invention also relates to an aerosol-generating system comprising the aerosol-generating article and a method of manufacturing a capsule.

Background Art

[0002] Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco-containing substrate, is heated rather than burned are known in the art. Typically, in such heated smoking articles, the aerosol is generated by transferring heat from a heat source to a physically separated aerosol-generating substrate or material, which may be in contact with the heat source, within the heat source, around the heat source, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and entrained in the air drawn through the aerosol-generating article. The released compounds condense as they cool to form an aerosol.

[0003] Numerous prior art documents disclose aerosol-generating devices for consuming aerosol-generating articles. Such devices include, for example, electrically heated aerosol-generating devices in which an aerosol is generated by heat transfer from one or more electric heater elements of the aerosol-generating device to the aerosol-generating substrate of the heated aerosol-generating article. For example, electrically heated aerosol-generating devices have been proposed that comprise internal heater blades adapted to be inserted into the aerosol-generating substrate.

[0004] The use of aerosol-generating articles in combination with external heating systems is also known. For example, International Publication 2020 / 115151 describes the provision of one or more heating elements arranged around the aerosol-generating article when the aerosol-generating article is received in a cavity of an aerosol generator. Alternatively, an inductively heatable aerosol-generating article comprising an aerosol-generating substrate and a susceptor disposed within the aerosol-generating substrate is proposed in International Publication 2015 / 176898. [Overview of the project] [Problems that the invention aims to solve]

[0005] Certain types of aerosol-generating substrates containing nicotine and relatively high aerosol-forming content, such as nicotine-containing gels and films, are known. These substrates are typically very stable during storage and, advantageously, deliver nicotine to consumers very consistently upon heating. They also, advantageously, can generate aerosols at lower temperatures than other solid substrates. However, the use of this type of aerosol-generating substrate can also present problems. Relatively high aerosol-forming content increases the risk of aerosol-forming leakage from the substrate during storage and use. Furthermore, certain substrates, such as gel compositions, generally melt upon heating of the aerosol-generating substrate within the aerosol generator during use. Consequently, the viscosity of the gel composition increases significantly, making it more difficult to control the movement of the gel composition, particularly to retain it within the aerosol-generating article. Leakage of aerosol-forming or molten gel composition from the aerosol-generating article is undesirable because it can leak into the heating chamber of the aerosol generator and contaminate the aerosol generator. Leakage of aerosol-forming or gel composition can also be potentially unpleasant for consumers. When an aerosol-generating article is heated by an external heating system, such as one or more heating elements arranged around the periphery of the article, another problem may arise: a short delay may occur after the heater is activated until the aerosol-generating substrate is heated sufficiently to generate aerosols. Furthermore, when an aerosol-generating article is heated by an internal heating system, such as an internal heater blade inserted into the aerosol-generating substrate, aerosol generation may decrease as the aerosol-generating substrate is depleted.

[0006] Therefore, it is desirable to provide a novel aerosol generating article having an arrangement that provides improved retention of the aerosol generating substrate within the aerosol generating article during storage and use. It is even more desirable to provide such aerosol generating articles that enable efficient heating of the aerosol generating substrate so that aerosols can be generated from the aerosol generating substrate in an efficient and consistent manner. It is even more desirable to provide aerosol generating articles that provide improved quantity and quality of aerosols generated by the aerosol generating article, while also improving the consistency and duration of aerosol generation. [Brief explanation of the drawing]

[0007] [Figure 1] Figure 1 shows a schematic side cross-sectional view of an aerosol generating article according to the present invention. [Figure 2] Figure 2 shows a schematic side cross-sectional view of a capsule suitable for use with the aerosol-generating article shown in Figure 1. [Figure 3] Figure 3 shows a schematic side cross-sectional view of an alternative capsule suitable for use with the aerosol-generating article shown in Figure 1. [Figure 4a] Figure 4a shows a schematic side cross-sectional view of the first embodiment of the aerosol generation system according to the present invention. [Figure 4b] Figure 4b shows a schematic side cross-sectional view of a second embodiment of the aerosol generation system according to the present invention. [Figure 5a] Figure 5a shows a graph of the aerosols generated against time in the aerosol generation system shown in Figure 4a. [Figure 5b] Figure 5b shows a graph of the aerosol generation system shown in Figure 4b against time. [Modes for carrying out the invention]

[0008] This disclosure relates to an aerosol generating article for generating an inhalable aerosol upon heating. The aerosol generating article may comprise a capsule. The capsule may comprise a capsule wall defining an internal cavity. The capsule may comprise a first aerosol generating substrate within the internal cavity. The capsule may comprise at least one of an aerosol former, a flavoring agent, and a second aerosol generating substrate provided inside the capsule wall, on the surface of the capsule wall, or both inside and on the surface of the capsule wall.

[0009] The present invention provides an aerosol generating article for generating an inhalable aerosol upon heating. The aerosol generating article comprises a capsule. The capsule comprises a capsule outer wall defining an internal cavity. The capsule comprises a first aerosol generating substrate within the internal cavity. The capsule comprises at least one of an aerosol former, a flavoring agent, and a second aerosol generating substrate provided inside the capsule outer wall, on the surface of the capsule outer wall, or both inside and on the surface of the capsule outer wall.

[0010] As used herein, the term “aerosol-generating article” is used herein to refer to an article that heats an aerosol-generating substrate to produce an inhalable aerosol and deliver it to a consumer.

[0011] As used herein, the term "aerosol-generating substrate" means a substrate that has the ability to generate aerosols by releasing volatile compounds upon heating.

[0012] As used herein, the term "aerosol generator" refers to a device comprising a heater element that interacts with an aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

[0013] As used herein, the term “longitudinal direction” refers to the direction corresponding to the main longitudinal axis of the aerosol generating article, extending between the upstream and downstream ends of the aerosol generating article. As used herein, the terms “upstream” and “downstream” describe the relative position of elements (or parts of elements) of the aerosol generating article with respect to the direction in which aerosols are transported through the aerosol generating article during use. During use, air is drawn through the aerosol generating article in the longitudinal direction. The term “transverse direction” refers to the direction perpendicular to the longitudinal axis. Any reference to “cross-section” of the aerosol generating article or its components refers to the cross-section unless otherwise specified. The term “length” means the dimension of a component of the aerosol generating article in the longitudinal direction. For example, this may be used to indicate the dimension of a capsule in the longitudinal direction.

[0014] As used herein, the term “solid” refers to an aerosol-generating substrate that, rather than being a liquid or gas, retains its shape and becomes low enough to form at room temperature. The term “solid” encompasses gel materials and compositions.

[0015] Advantageously, providing an aerosol generating article having a capsule containing a first aerosol generating substrate within an internal cavity defined by the outer wall of the cavity provides a highly effective method for retaining the first aerosol generating substrate in place within the aerosol generating article during storage and use. This configuration is particularly beneficial for aerosol generating substrates having a relatively high aerosol-forming content, such as aerosol generating films and gel compositions of the types described below. Encapsulating the first aerosol generating substrate within a capsule prevents leakage of the aerosol-forming material from the first aerosol generating substrate during storage or use. Furthermore, if the first aerosol generating substrate melts upon heating, as in the case of many gel compositions, the molten substrate can be effectively retained within the capsule. Thus, leakage of the aerosol-forming material or the first aerosol generating substrate from the aerosol generating article during use can be substantially prevented, and as a result, the risk of contamination of the aerosol generating device is advantageously minimized.

[0016] Advantageously, providing a capsule containing at least one of an aerosol-forming agent, a flavoring agent, and a second aerosol-generating substrate provided inside the capsule wall, on the surface of the capsule wall, or both inside and on the surface of the capsule wall may provide an enhanced effect in addition to the aerosol generated by heating the first aerosol-generating substrate within the capsule's internal cavity. Advantageously, at least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate may result in at least one of the following: an increase in the overall amount of aerosol generated, an increase in the density of the aerosol, and an increase in the amount of activator in the aerosol, such as nicotine, the aerosol-forming agent, or the flavoring agent. Advantageously, the aerosol generated by at least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate may have a taste or properties complementary to the aerosol generated by the first aerosol-generating substrate within the capsule's internal cavity. The resulting improved aerosol can then be delivered to the consumer.

[0017] Advantageously, in configurations where the aerosol generating article is heated from the outside, for example by passing it through one or more heating elements arranged around its periphery, the aerosol generated by at least one of the aerosol maker, flavoring agent, and second aerosol generating substrate, provided inside the capsule wall, on the surface of the capsule wall, or both inside and on the surface of the capsule wall, can result in faster aerosol generation. Specifically, at least one of the aerosol maker, flavoring agent, and second aerosol generating substrate can result in aerosol generation at the start of the experience, even if the first aerosol generating substrate in the capsule's internal cavity is not yet sufficiently heated to generate the aerosol itself. Subsequently, once the first aerosol generating substrate in the capsule's internal cavity is sufficiently heated, the aerosol generated by the first aerosol generating substrate in the internal cavity can replace the aerosol generated by at least one of the aerosol maker, flavoring agent, and second aerosol generating substrate. Therefore, advantageously, at least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate may reduce or eliminate the delay between the operation of the external heating element and aerosol generation, and may also improve the consistency and duration of aerosol generation, while increasing the total amount and quality of aerosols generated by the aerosol-generating article. This results in an improved user experience.

[0018] Advantageously, in a configuration in which an aerosol-generating article, such as an internal heater blade inserted into the capsule, is internally heated, the aerosols generated by at least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate provided inside the capsule wall, on the surface of the capsule wall, or both inside and on the surface of the capsule wall, can improve the duration of aerosol generation. For example, when the aerosol-generating article is internally heated, at least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate may be heated after the first aerosol-generating substrate in the internal cavity of the capsule. This can increase the total time of aerosol generation because at least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate may continue to generate aerosols even after the first aerosol-generating substrate in the internal cavity has been depleted. Therefore, advantageously, providing at least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate inside the capsule wall, on the surface of the capsule wall, or both inside and on the surface of the capsule wall may increase not only the duration and consistency of aerosol generation but also the total amount of aerosol generated. This results in an improved user experience.

[0019] In embodiments in which the capsule includes a second aerosol-generating substrate, the second aerosol-generating substrate may be the same as the first aerosol-generating substrate. The second aerosol-generating substrate may be different from the first aerosol-generating substrate. In a particularly preferred embodiment, the capsule includes both the first and second aerosol-generating substrates, each of which contains nicotine. The second aerosol-generating substrate may contain tobacco powder. The capsule does not have to contain flavoring agents. In other words, the capsule does not have to contain flavoring agents.

[0020] The capsule may have an inner coating on at least a portion of the inner surface of the outer wall of the capsule. The inner coating of the capsule may contain at least one of an aerosol former, a flavoring agent, and a second aerosol generating substrate.

[0021] Advantageously, providing an inner coating on at least a portion of the inner surface of the capsule outer wall can prevent contamination of at least one of the aerosol former, flavorant, and second aerosol generating substrate of the inner coating during handling of the capsule.

[0022] The inner coating of the capsule may be provided on substantially the entire inner surface of the capsule outer wall. The inner coating of the capsule may be provided only on a portion of the inner surface of the capsule outer wall. The inner coating of the capsule may be provided only on a portion of the inner surface of the capsule outer wall that extends parallel to the longitudinal axis of the aerosol generating article.

[0023] The inner coating of the capsule may have a thickness of 0.1 micrometer or more, 0.2 micrometer or more, 0.5 micrometer or more, 1 micrometer or more, 5 micrometer or more, 10 micrometer or more, 50 micrometer or more, 0.1 millimeter or more, 0.15 millimeter or more, or 0.2 millimeter or more.

[0024] The inner coating of the capsule may have a thickness of 1 millimeter or less, 0.75 millimeter or less, 0.5 millimeter or less, 0.4 millimeter or less, or 0.2 millimeter or less.

[0025] The inner coating of the capsule may have a thickness of 50 micrometers to 1 millimeter, 0.1 millimeter to 0.75 millimeter, 0.1 millimeter to 0.5 millimeter, 0.1 millimeter to 0.4 millimeter, 0.1 millimeter to 0.2 millimeter, 0.15 millimeter to 0.5 millimeter, 0.2 millimeter to 0.4 millimeter, or 0.1 millimeter to 0.2 millimeter.

[0026] The inner coating of the capsule may have a mass of 0.05 micrograms or more, 0.1 micrograms or more, 0.2 micrograms or more, 0.3 micrograms or more, 0.4 micrograms or more, 0.5 micrograms or more, 0.6 micrograms or more, 0.7 micrograms or more, 0.8 micrograms or more, 0.9 micrograms or more, 1 microgram or more, 10 micrograms or more, 50 micrograms or more, 100 micrograms or more, 0.15 milligrams or more, 0.2 milligrams or more, 0.25 milligrams or more, 0.5 milligrams or more, 1 milligram or more, or 1.5 milligrams or more.

[0027] The inner coating of the capsule may have a mass of 2 milligrams or less, 1.5 milligrams or less, 1 milligram or less, 0.5 milligrams or less, 0.25 milligrams or less, or 0.2 milligrams or less.

[0028] The inner coating of the capsule may have a mass of 0.1 to 2 milligrams, 0.15 to 1.5 milligrams, 0.2 to 1 milligram, or 0.25 to 0.5 milligrams.

[0029] At least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate may be dispersed within the outer wall of the capsule. At least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate may be uniformly dispersed throughout substantially the entire outer wall of the capsule.

[0030] At least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate may be dispersed only on a portion of the capsule's outer wall. At least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate may be dispersed only on a portion of the capsule's outer wall parallel to the long axis of the capsule.

[0031] The capsule may contain at least one of an aerosol-forming agent, a flavoring agent, and a second aerosol-generating substrate dispersed within the inner coating on at least a portion of the inner surface of the outer wall of the capsule, and within the outer wall of the capsule.

[0032] The capsule may comprise a second aerosol-generating substrate dispersed within the capsule's outer wall and within an inner coating on at least a portion of the inner surface of the capsule's outer wall. The second aerosol-generating substrate, which may be provided within the inner coating on at least a portion of the inner surface of the capsule's outer wall and dispersed within the capsule's outer wall, may contain nicotine.

[0033] As described above, the capsule may include an inner coating on at least a portion of the inner surface of the outer wall of the capsule, and the inner coating may include at least one of an aerosol former, a flavoring agent, and a second aerosol generating substrate.

[0034] The inner coating may contain, on a dry weight basis, 5% by weight or more of aerosol-forming material, 10% by weight or more of aerosol-forming material, 15% by weight or more of aerosol-forming material, 20% by weight or more of aerosol-forming material, 25% by weight or more of aerosol-forming material, 30% by weight or more of aerosol-forming material, 35% by weight or more of aerosol-forming material, 40% by weight or more of aerosol-forming material, 45% by weight or more of aerosol-forming material, 50% by weight or more of aerosol-forming material, 60% by weight or more of aerosol-forming material, or 70% by weight or more of aerosol-forming material.

[0035] The inner coating may contain, on a dry weight basis, 80% by weight or less of aerosol-forming material, 75% by weight or less of aerosol-forming material, 70% by weight or less of aerosol-forming material, 60% by weight or less of aerosol-forming material, 50% by weight or less of aerosol-forming material, 40% by weight or less of aerosol-forming material, 30% by weight or less of aerosol-forming material, 25% by weight or less of aerosol-forming material, 20% by weight or less of aerosol-forming material, 15% by weight or less of aerosol-forming material, or 10% by weight or less of aerosol-forming material.

[0036] The inner coating consists of 5% to 80% by weight of aerosol-forming material, 10% to 80% by weight of aerosol-forming material, 15% to 80% by weight of aerosol-forming material, 20% to 80% by weight of aerosol-forming material, 25% to 80% by weight of aerosol-forming material, 30% to 80% by weight of aerosol-forming material, and 35% to 80% by weight of aerosol-forming material, based on dry weight. - Cent aerosol formers, 40% to 80% by dry weight aerosol formers, 5% to 60% by dry weight aerosol formers, 10% to 60% by dry weight aerosol formers, 15% to 60% by dry weight aerosol formers, 20% to 60% by dry weight aerosol formers, 25% to 60% by dry weight aerosol formers, 30% by dry weight aerosol formers Aerosol formers of 1-60% by weight, based on dry weight; aerosol formers of 35-60% by weight, based on dry weight; aerosol formers of 40-60% by weight, based on dry weight; aerosol formers of 5-40% by weight, based on dry weight; aerosol formers of 10-40% by weight, based on dry weight; aerosol formers of 15-40% by weight, based on dry weight; aerosol formers of 20-40% by weight, based on dry weight. It may also contain 25% to 40% by weight of aerosol-forming material, 30% to 40% by weight of aerosol-forming material on a dry weight basis, 35% to 40% by weight of aerosol-forming material on a dry weight basis, 5% to 20% by weight of aerosol-forming material on a dry weight basis, 10% to 20% by weight of aerosol-forming material on a dry weight basis, 15% to 20% by weight of aerosol-forming material on a dry weight basis, or about 20% by weight of aerosol-forming material on a dry weight basis.

[0037] Suitable aerosol-forming materials for inclusion in the inner coating are known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, propylene glycol, 1,3-butanediol, and glycerol), esters of polyhydric alcohols (such as glycerol mono-, di-, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dodecanedioic acid and dimethyl tetradecanedioic acid).

[0038] The inner coating preferably contains glycerol as an aerosol-forming agent.

[0039] The inner coating consists of glycerol of 5% to 80% by weight, 10% to 80% by weight, 15% to 80% by weight, 20% to 80% by weight, 25% to 80% by weight, 30% to 80% by weight, 35% to 80% by weight, and 40% to 80% by weight, based on dry weight. On a dry weight basis, 5% to 60% glycerol, 10% to 60% glycerol, 15% to 60% glycerol, 20% to 60% glycerol, 25% to 60% glycerol, 30% to 60% glycerol, 35% to 60% glycerol, 40% to 60% glycerol, 5% to 40% glycerol, 10% to It may contain 40% by weight glycerol, 15% to 40% by weight glycerol on a dry weight basis, 20% to 40% by weight glycerol on a dry weight basis, 25% to 40% by weight glycerol on a dry weight basis, 30% to 40% by weight glycerol on a dry weight basis, 35% to 40% by weight glycerol on a dry weight basis, 5% to 20% by weight glycerol on a dry weight basis, 10% to 20% by weight glycerol on a dry weight basis, 15% to 20% by weight glycerol on a dry weight basis, or about 20% by weight glycerol on a dry weight basis.

[0040] The inner coating of the capsule does not need to contain tobacco in any substantial way.

[0041] The inner coating of the capsule may contain one or more flavoring agents selected from menthol, mint such as peppermint and spearmint, chocolate, licorice, citrus and other fruit flavors, gamma octalactone, vanillin, ethyl vanillin, breath freshener flavoring agents, spice flavoring agents such as cinnamon, methyl salicylate, linalool, bergamot oil, geranium oil, lemon oil, ginger oil, and tobacco flavor, tea flavor, wine flavor, berry flavor, coffee flavor, acid, alcohol, ester, aldehyde, ketone, pyrazine, lactic acid, sucrose and other sweeteners, quinine, other bitter compounds, and combinations or blends thereof.

[0042] The inner coating may contain 0.1% or more by weight of flavoring agents on a dry weight basis, 1% or more by weight of flavoring agents on a dry weight basis, 2% or more by weight of flavoring agents on a dry weight basis, or 5% or more by weight of flavoring agents on a dry weight basis.

[0043] The inner coating may contain flavorings of 10% by weight or less, 5% by weight or less, 2% by weight or less, or 1% by weight or less, based on dry weight.

[0044] The inner coating may contain 0.1% to 10% by weight of flavorings on a dry weight basis, 1% to 10% by weight of flavorings on a dry weight basis, 2% to 10% by weight of flavorings on a dry weight basis, 5% to 10% by weight of flavorings on a dry weight basis, 0.1% to 5% by weight of flavorings on a dry weight basis, 1% to 5% by weight of flavorings on a dry weight basis, 2% to 5% by weight of flavorings on a dry weight basis, 0.1% to 2% by weight of flavorings on a dry weight basis, or 0.1% to 1% by weight of flavorings on a dry weight basis.

[0045] The inner coating of the capsule may contain a second aerosol-generating substrate. The second aerosol-generating substrate of the inner coating may contain nicotine.

[0046] As used herein, the term "nicotine" is used to mean nicotine, nicotine base, or nicotine salt.

[0047] In embodiments in which the second aerosol-generating substrate of the inner coating comprises a nicotine base or a nicotine salt, the amounts of nicotine listed herein are, respectively, the amount of free base nicotine or the amount of protonated nicotine.

[0048] The second aerosol-generating substrate of the inner coating may contain natural or synthetic nicotine.

[0049] Nicotine may contain one or more nicotine salts. One or more nicotine salts may be selected from a list consisting of nicotine lactate, nicotine citrate, nicotine pyruvate, nicotine beetartrate, nicotine benzoate, nicotine pectinate, nicotine alginate, and nicotine salicylate.

[0050] Nicotine may include tobacco extract.

[0051] The inner coating may contain at least 0.5% by weight nicotine, at least 1% by weight nicotine, or at least 2% by weight nicotine, on a dry weight basis.

[0052] The inner coating may contain nicotine of 10% by weight or less, 8% by weight or less, or 6% by weight or less, on a dry weight basis.

[0053] The inner coating may contain 0.5% to 10% by weight nicotine, 1% to 8% by weight nicotine, or 2% to 6% by weight nicotine, on a dry weight basis.

[0054] The second aerosol-generating substrate of the inner coating may contain one or more carboxylic acids.

[0055] Advantageously, a nicotine salt can be produced by including one or more carboxylic acids in the second aerosol-generating substrate.

[0056] One or more carboxylic acids of the second aerosol-generating substrate of the inner coating may be selected from the group consisting of acids, benzoic acid, fumaric acid, and levulinic acid, and preferably one or more carboxylic acids are selected from the group consisting of lactic acid and levulinic acid.

[0057] Advantageously, the inventors discovered that lactic acid and levulinic acid are particularly good carboxylic acids for producing nicotine salts.

[0058] The inner coating may contain 0.5% by weight or more of carboxylic acid, 1% by weight or more of carboxylic acid, or 2% by weight or more of carboxylic acid, on a dry weight basis.

[0059] The inner coating may contain carboxylic acid at a dry weight of 15% by weight or less, carboxylic acid at a dry weight of 10% by weight or less, or carboxylic acid at a dry weight of 5% by weight or less.

[0060] The inner coating may contain 0.5% to 15% by weight of carboxylic acid on a dry weight basis, 1% to 10% by weight of carboxylic acid on a dry weight basis, 2% to 5% by weight of carboxylic acid on a dry weight basis, 0.25% to 3.5% by weight of carboxylic acid on a dry weight basis, 0.5% to 3% by weight of carboxylic acid on a dry weight basis, or 1% to 2.5% by weight of carboxylic acid on a dry weight basis.

[0061] The inner coating may include a second aerosol generating substrate in the form of an aerosol generating film containing a cellulose-based film-forming agent, nicotine, and an aerosol-forming agent. The aerosol generating film of the inner coating may further contain a cellulose-based reinforcing agent. Preferably, the aerosol generating film of the inner coating may further contain 30% by weight or less of water.

[0062] As used herein, the term “film” is used to describe a solid layered element having a thickness less than its width or length. A film may be self-supporting. In other words, a film may have cohesive and mechanical properties that allow it to be separated from a support surface, even if it is obtained by casting a film-forming formulation onto a support surface. Alternatively, a film may be placed on a support or sandwiched between other materials. This can enhance the mechanical stability of the film.

[0063] The aerosol-forming content of the inner coating aerosol-generating film may be within the range defined above for the second aerosol-generating substrate. Preferably, the inner coating aerosol-generating film contains, on a dry weight basis, preferably at least 40 weight percent of aerosol-forming, more preferably at least 50 weight percent of aerosol-forming, more preferably at least 60 weight percent, and more preferably at least 70 weight percent of aerosol-forming. The inner coating aerosol-generating film may contain up to 80 weight percent of aerosol-forming, on a dry weight basis. The aerosol-forming in the inner coating aerosol-generating film is preferably glycerol.

[0064] The term "cellulose-based film-forming agent" is used to describe cellulose polymers that have the ability to form continuous films, either on their own or in the presence of an auxiliary thickener.

[0065] Preferably, the cellulosic film-forming agent for the inner coating is selected from the group consisting of hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethyl methylcellulose (HEMC), hydroxyethylcellulose (HEC), hydroxypropylcellulose (HPC), and combinations thereof.

[0066] More preferably, the cellulosic film-forming agent for the inner coating is selected from the group consisting of hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), and combinations thereof.

[0067] In a particularly preferred embodiment, the cellulosic film-forming agent for the inner coating is HPMC.

[0068] The inner coating aerosol-generating film may have a cellulosic film-forming agent content of 10% to 40% by weight, 15% to 35% by weight, or 20% to 30% by weight, on a dry weight basis.

[0069] The inner coating aerosol-generating film preferably further contains a cellulose-based reinforcing agent. Preferably, the cellulose-based reinforcing agent for the inner coating is selected from the group consisting of cellulose fibers, microcrystalline cellulose (MCC), cellulose powder, and combinations thereof.

[0070] The inner coating aerosol-generating film may contain a cellulosic reinforcing agent of 0.5% to 40% by weight, 5% to 30% by weight, or 10% to 25% by weight, based on dry weight.

[0071] The inner coating aerosol-generating film may further contain carboxymethylcellulose, preferably sodium carboxymethylcellulose.

[0072] The inner coating aerosol-generating film may have a carboxymethylcellulose content of 1% to 15% by weight, 2% to 12% by weight, or 4% to 10% by weight on a dry weight basis.

[0073] The nicotine content of the inner coating aerosol-generating film may be within the range defined above for the inner coating itself.

[0074] The inner coating aerosol-generating film may be a substantially tobacco-free aerosol-generating film.

[0075] In preferred embodiments, the inner coating aerosol generating film contains an acid. More preferably, the inner coating aerosol generating film contains one or more organic acids. Even more preferably, the inner coating aerosol generating film contains one or more carboxylic acids. In particularly preferred embodiments, the acid is lactic acid, benzoic acid, fumaric acid, or levulinic acid.

[0076] The inner coating aerosol-generating film preferably contains 0.25% to 3.5% by weight of acid, 0.5% to 3% by weight of acid, or 1% to 2.5% by weight of acid on a dry weight basis.

[0077] The inner coating aerosol-generating film may have a thickness of 50 micrometers to 1 millimeter, 0.1 millimeters to 0.75 millimeters, 0.1 millimeters to 0.5 millimeters, 0.1 millimeters to 0.4 millimeters, 0.1 millimeters to 0.2 millimeters, 0.15 millimeters to 0.5 millimeters, 0.2 millimeters to 0.4 millimeters, or 0.1 millimeters to 0.2 millimeters.

[0078] The inner coating aerosol-generating film may optionally be provided on a suitable carrier element.

[0079] The inner coating may include a second aerosol-generating substrate in the form of a gel composition comprising nicotine, at least one gelling agent, and an aerosol-forming agent. Preferably, the gel composition of the inner coating is substantially tobacco-free.

[0080] The preferred weight range of nicotine in the inner coating gel composition is the same as that defined above in relation to the aerosol generating film.

[0081] The inner coating gel composition preferably contains, on a dry weight basis, at least 40 weight percent of aerosol-forming material, at least 50 weight percent of aerosol-forming material, more preferably at least 60 weight percent, and more preferably at least 70 weight percent of aerosol-forming material. The inner coating gel composition may contain up to 80 weight percent of aerosol-forming material on a dry weight basis. The aerosol-forming material in the inner coating gel composition is preferably glycerol.

[0082] The inner coating gel composition preferably contains at least one gelling agent. Preferably, the inner coating gel composition contains a total amount of gelling agents in the range of about 0.4% to about 10% by weight, or about 0.5% to about 8% by weight, or about 1% to about 6% by weight, or about 2% to about 4% by weight, or about 2% to about 3% by weight, on a dry weight basis.

[0083] The term "gelling agent" refers to a compound that, when added homogeneously to a mixture of 50% water and 50% glycerol in an amount of approximately 0.3% by weight, forms a solid medium or supporting matrix, leading to a gel. Examples of gelling agents for the inner coating include, but are not limited to, hydrogen-linked gelling agents and ionic-linked gelling agents.

[0084] The term "hydrogen bond crosslinking gelling agent" refers to a gelling agent that forms non-covalent or physical crosslinks via hydrogen bonds.

[0085] The inner coating gel composition may contain one or more of the following: galactomannan, gelatin, agarose, konjac gum, or agar, and may also contain a hydrogen bonding crosslinking gelling agent. It is preferable that the hydrogen bonding crosslinking gelling agent contains agar.

[0086] The term "ionic crosslinking gelling agent" refers to a gelling agent that forms non-covalent or physical crosslinks via ionic bonding.

[0087] The inner coating gel composition may contain an ion-crosslinking gelling agent, which may include low acylgellan, pectin, kappacarragenan, iotacarragenan, or alginate. The ion-crosslinking gelling agent preferably contains low acylgellan.

[0088] The gelling agent of the inner coating may contain one or more biopolymers. The biopolymers may be formed from polysaccharides.

[0089] Examples of biopolymers include gellan gum (natural gellan gum, low-acyl gellan gum, high-acyl gellan gum, and low-acyl gellan gum are preferred), xanthan gum, alginate (alginic acid), agar, and guar gum. The inner coating gel composition may preferably contain xanthan gum. The inner coating gel composition may contain two biopolymers. The inner coating gel composition may contain three biopolymers. The inner coating gel composition may contain two biopolymers in substantially equal weights. The inner coating gel composition may contain three biopolymers in substantially equal weights.

[0090] The inner coating gel composition may further contain a thickening agent. The thickening agent, combined with hydrogen-bonding crosslinking gelling agents and ion-crosslinking gelling agents, surprisingly appears to support the solid culture medium and maintain the gel composition even when it contains high levels of glycerol.

[0091] The term "thickener" refers to a compound that, when uniformly added in an amount of 0.3 weight percent to a mixture of 50 weight percent water / 50 weight percent glycerol at 25°C, increases viscosity without causing gel formation, causing the mixture to remain in a fluid state or to stay fluid.

[0092] The inner coating gel composition preferably contains a thickening agent in an amount of about 0.2% to about 5% by weight, or about 0.5% to about 3% by weight, or about 0.5% to about 2% by weight, or about 1% to about 2% by weight, on a dry weight basis.

[0093] The thickener in the inner coating gel composition may contain one or more of the following: xanthan gum, carboxymethylcellulose, microcrystalline cellulose, methylcellulose, gum arabic, guar gum, lambda carrageenan, or starch. It is preferable that the thickener in the inner coating gel composition contains xanthan gum.

[0094] The inner coating gel composition may further contain divalent cations. Preferably, the divalent cations include calcium ions such as calcium lactate in solution. Divalent cations (such as calcium ions) can assist in gel formation in compositions containing gelling agents, such as ion-crosslinking gelling agents. Ionic effects may assist in gel formation. Divalent cations may be present in the inner coating gel composition in an amount ranging from about 0.1 to about 1 weight percent, or about 0.5 weight percent, on a dry weight basis.

[0095] The inner coating gel composition may further contain an acid. The acid may contain a carboxylic acid. The carboxylic acid may contain a ketone group. Preferably, the carboxylic acid may contain a ketone group having less than 10 carbon atoms, such as levulinic acid or lactic acid, or less than 6 carbon atoms or less than 4 carbonate atoms. Preferably, this carboxylic acid has three carbon atoms (such as lactic acid).

[0096] The inner coating gel composition preferably contains water. The inner coating gel composition becomes more stable when it contains water.

[0097] Preferably, the inner coating gel composition contains about 8% to about 32% by weight of water, or about 15% to about 25% by weight of water, or about 18% to about 22% by weight of water, or about 20% by weight of water.

[0098] As described above, at least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate may be dispersed within the outer wall of the capsule.

[0099] It will be understood that at least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate that may be dispersed within the outer wall of the capsule may be the same as or different from at least one of the aerosol-forming agent, flavoring agent, and second aerosol-generating substrate of the inner coating of the capsule described above.

[0100] The capsule may contain an aerosol-forming material dispersed within the capsule wall. The aerosol-forming material within the capsule wall may include an aerosol-forming material selected from at least one of polyhydric alcohols, esters of polyhydric alcohols, and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids. The polyhydric alcohol that may be dispersed within the capsule wall may be selected from at least one of triethylene glycol, propylene glycol, 1,3-butanediol, and glycerol, and preferably the aerosol-forming material within the capsule wall contains glycerol. The aerosol-forming material within the capsule wall may include an ester of a polyhydric alcohol selected from at least one of glycerol monoacetate, glycerol diacetate, and glycerol triacetate. The aerosol-forming material within the capsule wall may also include an aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid selected from at least one of dimethyl dodecanediate and dimethyl tetradecanediate.

[0101] The outer wall of the capsule may contain, on a dry weight basis, 5% by weight or more of aerosol-forming material, 10% by weight or more of aerosol-forming material, 15% by weight or more of aerosol-forming material, 20% by weight or more of aerosol-forming material, 25% by weight or more of aerosol-forming material, 30% by weight or more of aerosol-forming material, 35% by weight or more of aerosol-forming material, or 40% by weight or more of aerosol-forming material.

[0102] The outer wall of the capsule may contain, on a dry weight basis, 50% by weight or less of aerosol-forming material, 40% by weight or less of aerosol-forming material, 30% by weight or less of aerosol-forming material, 25% by weight or less of aerosol-forming material, 20% by weight or less of aerosol-forming material, 15% by weight or less of aerosol-forming material, or 10% by weight or less of aerosol-forming material.

[0103] The outer shell of the capsule is composed of glycerol of 5% to 80% by weight, 10% to 80% by weight, 15% to 80% by weight, 20% to 80% by weight, 25% to 80% by weight, 30% to 80% by weight, and 35% to 80% by weight, based on dry weight. Weight percent glycerol, on a dry weight basis; 40% to 80% glycerol, on a dry weight basis; 5% to 60% glycerol, on a dry weight basis; 10% to 60% glycerol, on a dry weight basis; 15% to 60% glycerol, on a dry weight basis; 20% to 60% glycerol, on a dry weight basis; 25% to 60% glycerol, on a dry weight basis; 30% Cent-60 weight percent glycerol, on a dry weight basis; 35-60 weight percent glycerol, on a dry weight basis; 40-60 weight percent glycerol, on a dry weight basis; 5-40 weight percent glycerol, on a dry weight basis; 10-40 weight percent glycerol, on a dry weight basis; 15-40 weight percent glycerol, on a dry weight basis; 20-40 weight percent glycerol, on a dry weight basis It may also contain 25% to 40% by weight glycerol, 30% to 40% by weight glycerol on a dry weight basis, 35% to 40% by weight glycerol on a dry weight basis, 5% to 20% by weight glycerol on a dry weight basis, 10% to 20% by weight glycerol on a dry weight basis, 15% to 20% by weight glycerol on a dry weight basis, or about 20% by weight glycerol on a dry weight basis.

[0104] One or more flavoring agents may be dispersed within the outer wall of the capsule.

[0105] One or more flavoring agents inside the capsule wall may be selected from the group consisting of menthol, mint such as peppermint and spearmint, chocolate, licorice, citrus and other fruit flavors, gamma octalactone, vanillin, ethyl vanillin, breath freshener flavoring agents, spice flavoring agents such as cinnamon, methyl salicylate, linalool, bergamot oil, geranium oil, lemon oil, ginger oil, and flavor compounds selected from the group consisting of tobacco flavor, tea flavor, wine flavor, berry flavor, coffee flavor, acid, alcohol, ester, aldehyde, ketone, pyrazine, lactic acid, sucrose and other sweeteners, quinine, other bitter compounds, and combinations or blends thereof.

[0106] The outer wall of the capsule does not necessarily have to contain tobacco. In other words, the tobacco may not be dispersed within the outer wall of the capsule.

[0107] The capsule may include a second aerosol-generating substrate dispersed within the outer wall of the capsule. The second aerosol-generating substrate may contain nicotine.

[0108] The second aerosol-generating substrate within the outer wall of the capsule may contain natural or synthetic nicotine.

[0109] The second aerosol-generating substrate within the capsule wall may contain one or more nicotine salts. One or more nicotine salts of the second aerosol-generating substrate within the capsule wall may be selected from the list consisting of nicotine lactate, nicotine citrate, nicotine pyruvate, nicotine beetartrate, nicotine benzoate, nicotine pectinate, nicotine alginate, and nicotine salicylate.

[0110] The nicotine in the second aerosol-generating substrate within the outer wall of the capsule may contain tobacco extract.

[0111] The outer wall of the capsule may contain at least 0.5% by weight of nicotine, at least 1% by weight of nicotine, or at least 2% by weight of nicotine, on a dry weight basis.

[0112] The outer wall of the capsule may contain nicotine of 10% by weight or less, 8% by weight or less, or 6% by weight or less, on a dry weight basis.

[0113] The outer wall of the capsule may contain 0.5% to 10% by weight of nicotine, 1% to 8% by weight of nicotine, or 2% to 6% by weight of nicotine, on a dry weight basis.

[0114] The second aerosol-generating substrate within the outer wall of the capsule may contain one or more carboxylic acids.

[0115] Advantageously, a nicotine salt can be produced by including one or more carboxylic acids in the second aerosol-generating substrate.

[0116] The second aerosol-generating substrate within the outer wall of the capsule may contain one or more carboxylic acids selected from the group consisting of acids, benzoic acid, fumaric acid, and levulinic acid, preferably one or more carboxylic acids selected from the group consisting of lactic acid and levulinic acid.

[0117] As mentioned above, advantageously, the inventors have discovered that lactic acid and levulinic acid are particularly good carboxylic acids for producing nicotine salts.

[0118] The outer wall of the capsule may contain 0.5% by weight or more of carboxylic acid, 1% by weight or more of carboxylic acid, or 2% by weight or more of carboxylic acid, on a dry weight basis.

[0119] The outer wall of the capsule may contain 15% by weight or less of carboxylic acid, 10% by weight or less of carboxylic acid, or 5% by weight or less of carboxylic acid, on a dry weight basis.

[0120] The outer wall of the capsule may contain, on a dry weight basis, 0.5% to 15% by weight of carboxylic acid, 1% to 10% by weight of carboxylic acid, 2% to 5% by weight of carboxylic acid, 0.25% to 3.5% by weight of carboxylic acid, 0.5% to 3% by weight of carboxylic acid, or 1% to 2.5% by weight of carboxylic acid.

[0121] The capsule outer wall may be formed of any suitable material. Preferably, the capsule outer wall is formed of an impermeable material, and most preferably, an impermeable polymer material. This ensures that air does not pass through the capsule outer wall except through holes specifically provided for airflow during use. Therefore, the airflow through the capsule during use can be effectively controlled.

[0122] The outer wall of the capsule may be formed from a porous material.

[0123] The capsule outer wall may contain polymeric or cellulosic materials. For example, the capsule outer wall may be made of one or more nicotine-compatible polymers, including medical-grade polymers such as ALTUGLAS® medical resin polymethyl methacrylate (PMMA), Chevron Phillips K-Resin® styrene-butadiene copolymer (SBC), Arkema specialty performance polymers Pebax®, Rilsan®, and Rilsan® Clear, DOW (Health+®) low-density polyethylene (LDPE), DOW® LDPE91003, DOW® LDPE91020 (MFI2.0; density 923), ExxonMobil® polypropylene (PP) PP1013H1, PP1014H1, and PP9074MED, and Trinseo CALIBRE® polycarbonate (PC) 2060-SERIES.

[0124] Alternatively, the capsule wall may be formed from one or more materials selected from polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), gelatin, and hydroxypropyl methylcellulose (HPMC).

[0125] In embodiments where the capsule wall is intended to be penetrated by a heating element or penetrating element within the aerosol generator, as described below, the capsule wall should be formed of a penetrating or fragile material. The upstream end wall of the capsule may optionally have one or more weak lines or weak regions positioned to facilitate the insertion of a heating element through the capsule wall during use.

[0126] The capsule exterior wall may further include an external covering on at least a portion of its outer surface. Naturally, the external covering may have the same or different properties as the internal covering.

[0127] Advantageously, providing an external covering on at least a portion of the outer surface of the capsule's outer wall can prevent contamination or damage to the capsule during handling.

[0128] As described above, the capsule contains a first aerosol-generating substrate within the internal cavity of the capsule. The first aerosol-generating substrate within the internal cavity of the capsule may be provided in any suitable form.

[0129] The first aerosol-generating substrate within the internal cavity of the capsule may be a solid first aerosol-generating substrate. Preferably, the capsule contains multiple particles of the solid first aerosol-generating substrate. For example, the capsule may contain multiple beads, pellets, granules, flakes, fragments, or flakes of the first aerosol-generating substrate.

[0130] In certain embodiments, the maximum dimension of each particle is preferably at least 0.05 mm, more preferably at least 0.1 mm, more preferably at least 0.15 mm, more preferably at least 0.2 mm, more preferably at least 0.25 mm, more preferably at least 0.5 mm, more preferably at least 0.75 mm, and more preferably at least 1 mm. The maximum dimension of each particle is preferably 10 mm or less, more preferably 9 mm or less, more preferably 8 mm or less, more preferably 6 mm or less, and more preferably 5 mm or less. Providing relatively large particles within these ranges may be preferable when holes are provided in the capsule wall for forming air intakes and outlets, as described below. The relatively large maximum dimension of the particles then ensures that the particles are not lost through the holes in the capsule wall.

[0131] The maximum dimension of a particle corresponds to its maximum outer diameter. If the particle is substantially spherical, the maximum dimension of the particle corresponds to its diameter.

[0132] In these embodiments, the capsule preferably contains at least two particles of the first aerosol generating substrate, more preferably at least five particles of the first aerosol generating substrate, more preferably at least ten particles of the first aerosol generating substrate, more preferably at least 20 particles of the first aerosol generating substrate, and more preferably at least 30 particles of the first aerosol generating substrate. The capsule may contain up to 200 particles.

[0133] In other embodiments, the first solid aerosol-generating substrate may be in the form of a powder having more smaller particles. For example, in such embodiments, the powder may be formed from particles having a D50 particle size of 50 to 80 micrometers, 50 to 75 micrometers, 55 to 75 micrometers, 55 to 70 micrometers, or 60 to 70 micrometers.

[0134] As used herein, the term "D50 particle size" refers to the median particle size of a particulate material or powder. The D50 particle size is the particle size that divides the distribution in half, with half of the particles being larger than the D50 particle size and the other half being smaller than the D50 particle size. The particle size distribution can be determined by laser diffraction. For example, the particle size distribution can be determined by laser diffraction using a Malvern Mastersizer 3000 laser diffraction particle size analyzer, according to the manufacturer's instructions.

[0135] The powder may be formed from particles having a D95 particle size of 80 to 130 micrometers, 90 to 125 micrometers, 100 to 120 micrometers, or 110 to 120 micrometers.

[0136] As used herein, the term "D95 particle size" means a particle size in which 95 percent of the mass of particles have a particle size smaller than this value.

[0137] The powder may be formed from particles having a maximum diameter of 50 to 250 micrometers, 80 to 225 micrometers, or 100 to 125 micrometers.

[0138] In embodiments where the capsule contains multiple particles, the mass of each particle is preferably at least 0.05 micrograms, more preferably at least 0.1 micrograms, more preferably at least 0.2 micrograms, more preferably at least 0.3 micrograms, more preferably at least 0.4 micrograms, more preferably at least 0.5 micrograms, more preferably at least 0.6 micrograms, more preferably at least 0.7 micrograms, more preferably at least 0.8 micrograms, more preferably at least 0.9 micrograms, more preferably at least 1 microgram, more preferably at least 10 micrograms, more preferably at least 100 micrograms, more preferably at least 200 micrograms, more preferably at least 500 micrograms, and more preferably at least 1 milligram. The mass of each particle is preferably 600 milligrams or less, more preferably 500 milligrams or less, more preferably 400 milligrams or less, more preferably 300 milligrams or less, more preferably 200 milligrams or less, more preferably 100 milligrams or less, more preferably 50 milligrams or less, and more preferably 10 milligrams or less.

[0139] Alternatively, the first solid aerosol-generating substrate may be in the form of one or more sheets. As used herein, the term “sheet” refers to a thin layer-like element having a width and length substantially greater than its thickness.

[0140] One or more sheets as described herein may be crimped, folded, gathered, and pleated. One or more sheets may be cut into strands.

[0141] The first aerosol generating substrate preferably contains nicotine. More preferably, the first aerosol generating substrate contains nicotine and an aerosol-forming agent, but can take various different forms.

[0142] The first aerosol generating substrate may contain at least 15 weight percent of aerosol forming material on a dry weight basis. Preferably, the first aerosol generating substrate contains at least 20 weight percent of aerosol forming material on a dry weight basis, more preferably at least 25 weight percent of aerosol forming material, more preferably at least 30 weight percent of aerosol forming material, more preferably at least 35 weight percent of aerosol forming material, more preferably at least 40 weight percent of aerosol forming material, more preferably at least 45 weight percent of aerosol forming material, and more preferably at least 50 weight percent of aerosol forming material.

[0143] Preferably, the first aerosol generating substrate comprises 80% by weight or less of an aerosol forming material, more preferably 75% by weight or less of an aerosol forming material, and more preferably 70% by weight or less of an aerosol forming material, on a dry weight basis.

[0144] For example, the first aerosol generating substrate may have an aerosol-forming content of 15% to 80% by weight of aerosol-forming material, 20% to 80% by weight of aerosol-forming material, 25% to 80% by weight of aerosol-forming material, 30% to 80% by weight of aerosol-forming material, 35% to 80% by weight of aerosol-forming material, 40% to 80% by weight of aerosol-forming material, 30% to 75% by weight of aerosol-forming material, 35% to 75% by weight of aerosol-forming material, 40% to 75% by weight of aerosol-forming material, 45% to 75% by weight of aerosol-forming material, 40% to 70% by weight of aerosol-forming material, or 50% to 70% by weight of aerosol-forming material, on a dry weight basis.

[0145] In certain preferred embodiments, the aerosol-forming content of the first aerosol-generating substrate may be 40% to 80% by weight of aerosol-forming materials, or 45% to 75% by weight of aerosol-forming materials, or 50% to 70% by weight of aerosol-forming materials, on a dry weight basis. In such embodiments, the aerosol-forming content of the first aerosol-generating substrate is therefore relatively high.

[0146] Suitable aerosol-forming materials for inclusion in the first aerosol-generating substrate are known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, propylene glycol, 1,3-butanediol, and glycerol), esters of polyhydric alcohols (such as glycerol mono-, di-, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dodecanediic acid and dimethyl tetradecanediic acid).

[0147] The first aerosol generating substrate preferably contains glycerol as an aerosol forming body.

[0148] For example, the first aerosol-generating substrate may have a glycerol content of 15% to 80% by weight, or 20% to 80% by weight, or 25% to 80% by weight, or 30% to 75% by weight, or 35% to 75% by weight, or 40% to 70% by weight, or 45% to 70% by weight, or 50% to 70% by weight, on a dry weight basis.

[0149] The first aerosol-generating substrate may contain nicotine. As used herein, the term "nicotine" is used to mean nicotine, nicotine base, or nicotine salt. In embodiments in which the first aerosol-generating substrate contains a nicotine base or nicotine salt, the amounts of nicotine listed herein are, respectively, amounts of free base nicotine or amounts of protonated nicotine.

[0150] The first aerosol-generating substrate within the capsule's internal cavity may contain natural or synthetic nicotine. The nicotine may include one or more nicotine salts. These nicotine salts may be selected from a list consisting of nicotine lactate, nicotine citrate, nicotine pyruvate, nicotine beetartrate, nicotine benzoate, nicotine pectinate, nicotine alginate, and nicotine salicylate. The nicotine may also contain tobacco extracts.

[0151] The first aerosol generating substrate preferably contains at least 0.5 weight percent of nicotine on a dry weight basis. The first aerosol generating substrate more preferably contains at least 1 weight percent of nicotine on a dry weight basis. The first aerosol generating substrate is even more preferably containing at least 2 weight percent of nicotine on a dry weight basis. In addition, or alternatively, the first aerosol generating substrate preferably contains less than 10 weight percent of nicotine on a dry weight basis. The first aerosol generating substrate is even more preferably containing less than 8 weight percent of nicotine on a dry weight basis. The first aerosol generating substrate is even more preferably containing less than 6 weight percent of nicotine on a dry weight basis.

[0152] For example, the first aerosol generating substrate may contain 0.5% to 10% by weight of nicotine, or 1% to 8% by weight of nicotine, or 2% to 6% by weight of nicotine, on a dry weight basis.

[0153] The first aerosol-generating substrate may contain one or more carboxylic acids. Advantageously, the inclusion of one or more carboxylic acids in the first aerosol-generating substrate allows for the formation of nicotine salts.

[0154] One or more carboxylic acids may include one or more of lactic acid and levulinic acid. Advantageously, the inventors have found that lactic acid and levulinic acid are particularly good carboxylic acids for producing nicotine salts.

[0155] The first aerosol generating substrate preferably contains at least 0.5 weight percent of carboxylic acid on a dry weight basis. The first aerosol generating substrate more preferably contains at least 1 weight percent of carboxylic acid on a dry weight basis. The first aerosol generating substrate more preferably contains at least 2 weight percent of carboxylic acid on a dry weight basis.

[0156] In addition, or alternatively, the first aerosol-generating substrate may contain less than 15 weight percent of carboxylic acid on a dry weight basis. More preferably, the first aerosol-generating substrate contains less than 10 weight percent of carboxylic acid on a dry weight basis. More preferably, the first aerosol-generating substrate contains less than 5 weight percent of carboxylic acid on a dry weight basis. For example, the first aerosol-generating substrate may contain 0.5 to 15 weight percent of carboxylic acid on a dry weight basis, 1 to 10 weight percent of carboxylic acid on a dry weight basis, 2 to 5 weight percent of carboxylic acid on a dry weight basis, 0.25 to 3.5 weight percent of carboxylic acid on a dry weight basis, 0.5 to 3 weight percent of carboxylic acid on a dry weight basis, or 1 to 2.5 weight percent of carboxylic acid on a dry weight basis.

[0157] The first aerosol-generating substrate does not necessarily have to contain tobacco.

[0158] In certain preferred embodiments, the first aerosol generating substrate may be in the form of an aerosol generating film comprising a cellulosic film-forming agent, nicotine, and an aerosol-forming agent. The aerosol generating film of the first aerosol generating substrate may contain glycerol. The aerosol generating film of the first aerosol generating substrate may have a glycerol content of at least 40 weight percent on a dry weight basis. The aerosol generating film of the first aerosol generating substrate within the internal cavity of the capsule may further contain a cellulosic reinforcing agent.

[0159] The aerosol-generating film of the first aerosol-generating substrate within the internal cavity of the capsule may further contain water, preferably 30% by weight or less.

[0160] The aerosol-forming material content of the aerosol-generating film of the first aerosol-generating substrate may be within the range defined above for the first aerosol-generating substrate.

[0161] The term "cellulose-based film-forming agent" is used to describe cellulose polymers that have the ability to form continuous films, either on their own or in the presence of an auxiliary thickener.

[0162] Preferably, the cellulosic film-forming agent of the first aerosol-generating substrate is selected from the group consisting of hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethyl methylcellulose (HEMC), hydroxyethylcellulose (HEC), hydroxypropylcellulose (HPC), and combinations thereof.

[0163] More preferably, the cellulosic film-forming agent of the first aerosol-generating substrate is selected from the group consisting of hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), and combinations thereof.

[0164] In a particularly preferred embodiment, the cellulosic film-forming agent of the first aerosol-generating substrate is HPMC.

[0165] The aerosol-generating film of the first aerosol-generating substrate may have a cellulosic film-forming agent content of 10% to 40% by weight, or 15% to 35% by weight, or 20% to 30% by weight, on a dry weight basis.

[0166] The aerosol-generating film of the first aerosol-generating substrate preferably further contains a cellulosic reinforcing agent. Preferably, the cellulosic reinforcing agent is selected from the group consisting of cellulose fibers, microcrystalline cellulose (MCC), cellulose powder, and combinations thereof.

[0167] The aerosol-generating film of the first aerosol-generating substrate may have a cellulosic reinforcing agent content of 0.5% to 40% by weight, or 5% to 30% by weight, or 10% to 25% by weight, on a dry weight basis.

[0168] The aerosol-generating film of the first aerosol-generating substrate may further contain carboxymethylcellulose, preferably sodium carboxymethylcellulose.

[0169] The aerosol-generating film of the first aerosol-generating substrate may have a carboxymethylcellulose content of 1% to 15% by weight, or 2% to 12% by weight, or 4% to 10% by weight, on a dry weight basis.

[0170] The nicotine content of the aerosol-generating film of the first aerosol-generating substrate may be within the range defined above for the first aerosol-generating substrate within the internal cavity of the capsule.

[0171] The aerosol-generating film of the first aerosol-generating substrate may be a substantially tobacco-free aerosol-generating film.

[0172] In preferred embodiments, the aerosol-generating film of the first aerosol-generating substrate contains an acid. More preferably, the aerosol-generating film of the first aerosol-generating substrate contains one or more organic acids. Even more preferably, the aerosol-generating film of the first aerosol-generating substrate contains one or more carboxylic acids. In particularly preferred embodiments, the acid is lactic acid, benzoic acid, fumaric acid, or levulinic acid.

[0173] The aerosol-generating film of the first aerosol-generating substrate preferably contains 0.25% to 3.5% by weight of acid, or 0.5% to 3% by weight of acid, or 1% to 2.5% by weight of acid, on a dry weight basis.

[0174] The aerosol-generating film of the first aerosol-generating substrate may have a thickness of 50 micrometers to 1 millimeter, 0.1 millimeters to 1 millimeter, 0.1 millimeters to 0.75 millimeters, 0.1 millimeters to 0.5 millimeters, 0.1 millimeters to 0.4 millimeters, 0.1 millimeters to 0.2 millimeters, 0.15 millimeters to 0.5 millimeters, 0.2 millimeters to 0.4 millimeters, or 0.1 millimeters to 0.2 millimeters. In a particularly preferred embodiment, a layer of the film-forming composition of the first aerosol-generating substrate having a thickness of about 50 micrometers to 400 micrometers, more preferably about 100 micrometers to 200 micrometers, is formed inside the internal cavity of the capsule.

[0175] The aerosol-generating film of the first aerosol-generating substrate may be provided on a suitable carrier element.

[0176] The first aerosol generating substrate may include a gel composition comprising nicotine, at least one gelling agent, and an aerosol forming agent. Preferably, the gel composition of the first aerosol generating substrate is substantially free of tobacco.

[0177] The preferred weight range of nicotine in the gel composition of the first aerosol generating substrate may be the same as that defined above in relation to the aerosol generating film of the first aerosol generating substrate.

[0178] The first aerosol-generating substrate gel composition preferably contains at least 50 weight percent of aerosol-forming material, more preferably at least 60 weight percent, and more preferably at least 70 weight percent, on a dry weight basis. The first aerosol-generating substrate gel composition may contain up to 80 weight percent of aerosol-forming material, on a dry weight basis. The aerosol-forming material in the first aerosol-generating substrate gel composition is preferably glycerol.

[0179] The gel composition of the first aerosol generating substrate preferably contains at least one gelling agent. Preferably, the gel composition of the first aerosol generating substrate contains a total amount of gelling agent in the range of about 0.4% to about 10% by weight, or about 0.5% to about 8% by weight, or about 1% to about 6% by weight, or about 2% to about 4% by weight, or about 2% to about 3% by weight, on a dry weight basis.

[0180] Examples of gelling agents for the first aerosol-generating substrate include, but are not limited to, hydrogen-bonding crosslinking gelling agents and ion-crosslinking gelling agents.

[0181] The hydrogen-bonding crosslinking gelling agent of the first aerosol-generating substrate may contain one or more of galactomannan, gelatin, agarose, konjac gum, or agar. It is preferable that the hydrogen-bonding crosslinking gelling agent contains agar.

[0182] The ion-crosslinking gelling agent of the first aerosol-generating substrate may include low-acylgelane, pectin, kappa-carrageenan, iota-carrageenan, or alginate. Preferably, the ion-crosslinking gelling agent may include low-acylgelane.

[0183] The gelling agent of the first aerosol generating substrate may contain one or more biopolymers. The biopolymers may be formed from polysaccharides.

[0184] Examples of the first aerosol-generating substrate biopolymer include gellan gum (natural gellan gum, low-acyl gellan gum, high-acyl gellan gum, and low-acyl gellan gum are preferred), xanthan gum, alginate (alginic acid), agar, and guar gum. The composition may preferably contain xanthan gum. The first aerosol-generating substrate composition may contain two biopolymers. The first aerosol-generating substrate composition may contain three biopolymers. The first aerosol-generating substrate composition may contain two biopolymers in substantially equal weights. The first aerosol-generating substrate composition may contain three biopolymers in substantially equal weights.

[0185] The gel composition of the first aerosol-generating substrate may further contain a thickening agent. The thickening agent, combined with a hydrogen-bonding crosslinking gelling agent and an ionic crosslinking gelling agent, surprisingly appears to support the solid culture and maintain the gel composition of the first aerosol-generating substrate within the internal cavity of the capsule, even when the gel composition contains high levels of glycerol.

[0186] Preferably, the gel composition of the first aerosol generating substrate contains a thickener in the range of about 0.2% to about 5% by weight, or about 0.5% to about 3% by weight, or about 0.5% to about 2% by weight, or about 1% to about 2% by weight, on a dry weight basis.

[0187] The thickener of the first aerosol generating substrate may contain one or more of the following: xanthan gum, carboxymethylcellulose, microcrystalline cellulose, methylcellulose, gum arabic, guar gum, lambda carrageenan, or starch. It is preferable that the thickener contains xanthan gum.

[0188] The gel composition of the first aerosol generating substrate may further contain divalent cations. Preferably, the divalent cations of the first aerosol generating substrate include calcium ions such as calcium lactate in solution. Divalent cations (such as calcium ions) can assist in gel formation of compositions containing gelling agents, such as ion-crosslinking gelling agents. Ionic effects may assist in gel formation. Divalent cations may be present in the gel composition of the first aerosol generating substrate in an amount ranging from about 0.1 to about 1 weight percent, or about 0.5 weight percent, on a dry weight basis.

[0189] The gel composition of the first aerosol generating substrate may further contain an acid. The acid may contain a carboxylic acid. The carboxylic acid may contain a ketone group. Preferably, the carboxylic acid may contain a ketone group having less than 10 carbon atoms, such as levulinic acid or lactic acid, or less than 6 carbon atoms or less than 4 carbonate atoms. Preferably, this carboxylic acid has three carbon atoms (such as lactic acid).

[0190] Preferably, the gel composition of the first aerosol-generating substrate contains some water. The gel composition of the first aerosol-generating substrate is more stable when the composition contains some water.

[0191] Preferably, the gel composition of the first aerosol generating substrate contains about 8 to 32 weight percent of water, or about 15 to 25 weight percent of water, or about 18 to 22 weight percent of water, or about 20 weight percent of water.

[0192] The capsule is preferably spherical-cylindrical in shape, with the cylindrical portion defined by a cylindrical wall and each end of the cylindrical portion having rounded hemispherical end walls. This type of capsule is commonly used in the pharmaceutical industry. Alternatively, the capsule may be spherical or oval in shape.

[0193] The capsule is preferably a two-part capsule having two separate parts that fit together to close the capsule and hold its contents. The two separate parts may be fitted together by friction without adhesive. Alternatively, the two parts may be sealed together using adhesive. The two separate parts may have one or more different sizes and shapes from each other.

[0194] The capsule preferably comprises a first part and a second part, the second part having a smaller outer diameter than the first part so that the end of the second part can be inserted into the open end of the first part to close the capsule. When the capsule is mounted within a hollow tubular element, the second part of the capsule is preferably provided downstream of the first part.

[0195] In these embodiments, the outer diameters of the first and second parts of the capsule may be fitted such that only the second part of the capsule can be received within the hollow tubular element. The outer diameter of the first part of the capsule is fitted to be larger than the inner diameter of the hollow tubular element, so that the first part of the capsule is not received within the hollow tubular element and remains outside the hollow tubular element at its upstream end. Preferably, the second part of the capsule is held within the hollow tubular element by friction fitting. The first part prevents the capsule from being further pushed into the hollow tubular element.

[0196] Alternatively, in such embodiments, the capsule may be completely inserted into a hollow tubular element, and the outer diameters of the first and second parts of the capsule may be fitted such that the outer diameter of the second part is smaller than the inner diameter of the hollow tubular element. This provides space between the second part of the capsule and the wall of the hollow tubular element, allowing airflow around the second part of the capsule. Such arrangement may be beneficial in embodiments where it is desirable to position the air outlet on the cylindrical wall of the capsule, as described below. The outer diameter of the first part of the capsule is preferably fitted so that the first part of the capsule is held in place within the hollow tubular article by friction fitting. Alternatively, the first part of the capsule may be held in place by a suitable adhesive. Either of these arrangements preferably substantially prevents airflow around the first part of the capsule downstream of the second part of the capsule.

[0197] The internal cavity of the capsule preferably has a volume of at least 250 cubic millimeters, which corresponds to 0.25 milliliters. This corresponds to the internal volume or capacity of the capsule. The internal cavity of the capsule preferably has a volume of at least 400 cubic millimeters (0.4 milliliters), more preferably at least 500 cubic millimeters (0.5 milliliters), and more preferably at least 600 cubic millimeters (0.6 milliliters). The internal cavity of the capsule may be less than 2000 cubic millimeters (2 milliliters), or less than 1500 cubic millimeters (1.5 milliliters), or less than 1000 cubic millimeters (1 milliliter). For example, standard capsule sizes 000, 00, 0, 0, 1, 2, and 3 may be preferred.

[0198] The capsule preferably has a length of at least 10 millimeters, more preferably at least 12 millimeters, more preferably at least 15 millimeters, and more preferably at least 18 millimeters. The capsule length is preferably less than 30 millimeters, more preferably less than 28 millimeters, and more preferably less than 25 millimeters. For example, the capsule length may be 10 to 30 millimeters, or 12 to 28 millimeters, or 15 to 25 millimeters, or 18 to 25 millimeters. The capsule length may also be about 20 millimeters.

[0199] Preferably, the capsule has a maximum diameter of at least 5 mm, more preferably at least 5.5 mm, more preferably at least 6 mm, and more preferably at least 6.5 mm. Preferably, the maximum diameter of the capsule is less than 9 mm, more preferably less than 8.5 mm, more preferably less than 8 mm, and more preferably less than 7.5 mm. For example, the maximum diameter of the capsule may be between 5 mm and 9 mm, or between 5.5 mm and 8.5 mm, or between 6 mm and 6 mm, or between 6.5 mm and 7.5 mm. The maximum diameter of the capsule may be about 7 mm.

[0200] As described above, the first aerosol generating substrate in the internal cavity of the capsule may be a solid first aerosol generating substrate. The internal cavity of the capsule preferably contains at least 50 milligrams of the first aerosol generating substrate, more preferably at least 100 milligrams of the first aerosol generating substrate, and more preferably at least 150 milligrams of the first aerosol generating substrate. The internal cavity may contain up to 1000 milligrams of the first aerosol generating substrate, or up to 750 milligrams of the first aerosol generating substrate, or up to 500 milligrams of the first aerosol generating substrate, or up to 250 milligrams of the first aerosol generating substrate. For example, the internal cavity of the capsule may contain 50 milligrams to 1000 milligrams of the first aerosol generating substrate, or 100 milligrams to 750 milligrams of the first aerosol generating substrate, or 150 milligrams to 500 milligrams of the first aerosol generating substrate, or 150 milligrams to 250 milligrams of the first aerosol generating substrate.

[0201] The density of the first aerosol-generating substrate within the capsule's internal cavity may correspond to at least 0.1 milligrams / cubic millimeter of the internal cavity. This corresponds to the total mass of the first aerosol-generating substrate divided by the total volume of the internal cavity. Preferably, the density of the first aerosol-generating substrate in the internal cavity of the capsule corresponds to 0.12 milligrams / cubic millimeter of the internal cavity, more preferably at least 0.15 milligrams / cubic millimeter of the internal cavity, more preferably at least 0.18 milligrams / cubic millimeter of the internal cavity, more preferably at least 0.2 milligrams / cubic millimeter, more preferably at least 0.22 milligrams / cubic millimeter, more preferably at least 0.25 milligrams / cubic millimeter, more preferably at least 0.28 milligrams / cubic millimeter, more preferably at least 0.3 milligrams / cubic millimeter, more preferably at least 0.32 milligrams / cubic millimeter, more preferably at least 0.35 milligrams / cubic millimeter, more preferably at least 0.38 milligrams / cubic millimeter, and more preferably at least 0.4 milligrams / cubic millimeter.

[0202] Preferably, the density of the first aerosol-generating substrate in the internal cavity of the capsule may correspond to less than 2 milligrams / cubic millimeter of the internal cavity, more preferably less than 1.9 milligrams / cubic millimeter of the internal cavity, more preferably less than 1.8 milligrams / cubic millimeter, more preferably less than 1.7 milligrams / cubic millimeter, more preferably less than 1.6 milligrams / cubic millimeter, more preferably less than 1.5 milligrams / cubic millimeter, more preferably less than 1.4 milligrams / cubic millimeter, more preferably less than 1.3 milligrams / cubic millimeter, more preferably less than 1.2 milligrams / cubic millimeter, more preferably less than 1.1 milligrams / cubic millimeter, or less than 1 milligram / cubic millimeter. For example, the density of the first aerosol-generating substrate within the capsule's internal cavity is 0.1 mg / m³ to 2 mg / m³, or 0.12 mg / m³ to 1.9 mg / m³, or 0.15 mg / m³ to 1.8 mg / m³, or 0.18 mg / m³ to 1.7 mg / m³, or 0.2 mg / m³ to 1.6 mg / m³, or 0.22 mg / m³ to 1.5 mg / m³, or 0. This may correspond to 25 milligrams / cubic millimeter to 1.4 milligrams / cubic millimeter, or 0.28 milligrams / cubic millimeter to 1.3 milligrams / cubic millimeter for internal cavities, or 0.3 milligrams / cubic millimeter to 1.2 milligrams / cubic millimeter for internal cavities, or 0.32 milligrams / cubic millimeter to 1.1 milligrams / cubic millimeter for internal cavities, or 0.35 milligrams / cubic millimeter to 1 milligram / cubic millimeter for internal cavities, or 0.38 milligrams / cubic millimeter to 1 milligram / cubic millimeter for internal cavities, or 0.4 milligrams / cubic millimeter to 1 milligram / cubic millimeter for internal cavities.

[0203] The filling rate of the capsule's internal cavity with the first aerosol-generating substrate is preferably at least 50 percent, more preferably at least 60 percent, and more preferably at least 70 percent. The filling rate is preferably less than 90 percent. The filling rate corresponds to the proportion of the capsule's internal cavity occupied by the first aerosol-generating substrate. It may be advantageous to retain some empty space within the internal cavity to allow airflow through the cavity and to enable uniform heating of the first aerosol-generating substrate.

[0204] The capsule may comprise at least one susceptor within its internal cavity. The capsule may comprise a single susceptor element within its internal cavity, or one of several susceptor particles within its internal cavity. The several susceptor particles may include a susceptor material, but may not include an aerosol-generating substrate.

[0205] The capsule may be adapted so that one or more airflow paths are provided through the capsule during heating. This may allow aerosols generated from the capsule to be drawn out through the aerosol generating article and delivered to the consumer. The capsule may be sealed and airtight in the initial stage so that when the aerosol generating article is inserted into the aerosol generating device, airflow paths are created, for example, through the insertion of an internal heating element or by penetrating elements that penetrate the outer wall of the capsule and any covering present thereon.

[0206] Alternatively, and more preferably, the capsule may be provided with at least one air intake and at least one air outlet within the outer wall of the capsule. The at least one air intake and at least one air outlet may define one or more airflow paths through the internal cavity of the capsule. The at least one air outlet may be provided downstream of the at least one air intake.

[0207] The capsule preferably has multiple air intakes. For example, the capsule may have 2 to 6 air intakes, or 4 to 5 air intakes.

[0208] The capsule preferably has multiple air outlets. For example, the capsule may have 2 to 6 air outlets. The number of air outlets may be the same as or different from the number of air intakes. It may be advantageous to provide more air outlets than air intakes because the air outlets need to allow aerosols generated inside the capsule to escape from the capsule into the hollow tubular element.

[0209] The number and size of the air intakes and air outlets may be adjusted to control the airflow through the capsule and the draw resistance (RTD) of the aerosol-generating article. In certain embodiments, the capsule provides the primary source of RTD within the article, and therefore the overall RTD of the aerosol-generating article is likely to be highly dependent on the RTD of the capsule.

[0210] Each air intake and outlet is preferably in the form of a hole passing through the outer wall of the capsule. Each hole is preferably spherical, but other shapes may also be appropriate. The diameter of each hole should be large enough, for example, that the hole cannot be easily blocked by dust. However, the diameter of each hole should also be adapted according to the shape and properties of the first aerosol generating substrate in the internal cavity of the capsule, so that the first aerosol generating substrate in the internal cavity of the capsule is not lost from the internal cavity through the hole.

[0211] Each hole forming the air intake or air outlet preferably has a diameter of at least 0.2 mm, more preferably at least 0.25 mm, more preferably at least 0.3 mm, more preferably at least 0.35 mm, more preferably at least 0.4 mm, and more preferably at least 0.5 mm. The diameter of each hole may be less than 2 mm, or less than 1.8 mm, or less than 1.7 mm, or less than 1.6 mm, or less than 1.5 mm, or less than 1.4 mm, or less than 1.3 mm, or less than 1.2 mm, or less than 1.1 mm, or less than 1 mm, or less than 0.9 mm, or less than 0.8 mm. For example, the diameter of each hole may be 0.2 mm to 2 mm, or 0.25 mm to 1.8 mm, or 0.3 mm to 1.6 mm, or 0.35 mm to 1.4 mm, or 0.4 mm to 1.2 mm, or 0.45 mm to 1 mm, or 0.5 mm to 0.9 mm, or 0.5 mm to 0.8 mm.

[0212] If multiple air intakes or outlets are provided, each hole should be spaced sufficiently apart so that its presence does not adversely affect the structural integrity of the capsule. For example, it is preferable that the holes be spaced at least 1 millimeter apart from each other.

[0213] At least one air outlet is preferably located at least 5 millimeters downstream of at least one air intake, more preferably at least 8 millimeters downstream of at least one air intake, and more preferably at least 10 millimeters downstream of at least one air intake. This spacing allows for maximizing the length of the airflow path through the capsule.

[0214] Preferably, at least one air outlet is located at the downstream end of the capsule. If the capsule has a conventional capsule shape with an elongated cylindrical body and rounded end walls, it is preferable that at least one air outlet is provided on the downstream end wall.

[0215] At least one air intake may be located at the upstream end of the capsule. For example, if the capsule has the conventional capsule shape as described above, at least one air intake may be provided on the upstream end wall. However, it may be advantageous to position at least one air intake at a certain distance downstream of the upstream end. For example, at least one air intake may be provided at least 2 millimeters downstream of the upstream end of the capsule, or at least 3 millimeters downstream of the upstream end of the capsule, or at least 4 millimeters downstream of the upstream end of the capsule, or at least 5 millimeters downstream of the upstream end of the capsule. If multiple air intakes are provided, all air intakes should be provided at least this distance from the upstream end, even when the position of the air intakes along the length of the capsule changes.

[0216] The capsule may comprise a cylindrical wall and rounded end walls at the upstream and downstream ends of the cylindrical wall (as in conventional capsule shapes), and at least one air intake may be advantageously provided in the cylindrical wall downstream of the upstream end wall.

[0217] Positioning at least one air intake away from the upstream end of the capsule may be particularly beneficial when the first aerosol-generating substrate within the capsule's internal cavity is in the form of the aforementioned gel composition, or any other type of substrate that melts or becomes more viscous upon heating. At least one air intake away from the upstream end of the cavity where molten substrate may accumulate ensures that the risk of the first aerosol-generating substrate leaking from the capsule is minimized. The risk of the air intake being blocked by the first aerosol-generating substrate is also reduced.

[0218] The aerosol generating article may include a hollow tubular element. Preferably, the hollow tubular element extends to the downstream end of the aerosol generating article. The capsule may be mounted inside the hollow tubular element. The capsule may be mounted at the upstream end of the hollow tubular element.

[0219] The hollow tubular element may have a ventilation zone that allows outside air to enter the aerosol-generating article. The ventilation zone may be provided downstream of the downstream end of the capsule. The ventilation zone may include at least one ventilation hole. The ventilation zone may include multiple holes through the hollow tubular element.

[0220] The capsule may be mounted within a hollow tubular element, in particular when at least one air intake is provided on the cylindrical wall of the capsule, such that at least one air intake is not covered or blocked by the wall of the hollow tubular element. There are various suitable ways to achieve this, as described below.

[0221] The hollow tubular element may have one or more holes extending through its peripheral wall, positioned to coincide with one or more air intakes on the capsule. In such an arrangement, air can pass from outside the hollow tubular element through its peripheral wall into at least one air intake.

[0222] The capsule may be mounted within a hollow tubular element such that a portion of the capsule extends from the upstream end of the hollow tubular element, thereby positioning at least one air intake on the outside of the hollow tubular element. Preferably, at least 20 percent of the length of the capsule protrudes from the hollow tubular element, and more preferably at least 30 percent. Preferably, 50 percent or less of the length of the capsule protrudes from the hollow tubular element. Thus, the majority of the capsule is within the hollow tubular element so that the capsule can be held firmly in place. The hollow tubular element may have a flange or projection extending inward from its inner surface at the downstream end of the capsule to prevent the capsule from being pushed further downstream into the hollow tubular element. For example, the hollow tubular element may have an annular flange extending from its inner surface.

[0223] The capsule may be provided with an outer diameter smaller than the inner diameter of the hollow tubular element. This arrangement provides a space between the outer surface of the capsule and the inner surface of the hollow tubular element so that air can pass between the capsule and the hollow tubular element to at least one air intake. It may be necessary to block the airflow from the upstream end of the hollow tubular element to at least one air outlet within the capsule wall. In this way, the main airflow path is clearly defined through the capsule and not around the outside. This can be achieved, for example, by providing an annular sealing ring around the capsule within the hollow tubular element, sealing the space between the capsule and the inner surface of the hollow tubular element at a position downstream of at least one air intake. The annular sealing ring also advantageously helps to hold the capsule in place within the hollow tubular element.

[0224] The outer diameter of the capsule is preferably at least 0.2 millimeters smaller than the inner diameter of the hollow tubular element, more preferably at least 0.5 millimeters smaller, and more preferably at least 0.8 millimeters smaller. The outer diameter of the capsule may be up to 2 millimeters smaller than the inner diameter of the hollow tubular element.

[0225] The inner surface of a hollow tubular element may be corrugated at its upstream end to define a plurality of axial channels arranged circumferentially so as to substantially coincide with at least one air intake. In such an arrangement, air can enter the hollow tubular element through the axial channels defined by the corrugated surface and pass along the capsule to at least one air intake. Preferably, the hollow tubular element is corrugated only along a portion of its length from the upstream end, and not along its entire length. Therefore, it is preferable that the axial channels extend to a position upstream of at least one air outlet so that there is no airflow from the upstream end of the hollow tubular element to at least one air outlet. In this way, the main airflow path is clearly defined through the capsule and not around the outside.

[0226] As described above, the capsule containing the first aerosol generating substrate may be mounted inside a hollow tubular element. The hollow tubular element provides the main structural element of the aerosol generating article. Preferably, the hollow tubular element extends to the downstream end of the aerosol generating article.

[0227] As used herein, the term “hollow tubular element” generally refers to an elongated element that defines a lumen or channel along its longitudinal axis. In particular, the term “tubular” is used below with respect to a tubular element having a substantially cylindrical cross-section and defining at least a channel extending between the upstream and downstream ends of the tubular element. However, naturally, alternative shapes (e.g., alternative cross-sectional shapes) of tubular segments may be possible.

[0228] The hollow tubular element may have a capsule containing a first aerosol-generating substrate attached to its upstream end, as described above. Furthermore, the hollow tubular element may define an empty cavity downstream of the capsule, extending along part or all of the length of the hollow tubular element. The empty cavity may extend all the way from the capsule to the downstream end of the aerosol-generating article. Thus, the aerosol-generating article may be formed using only two elements: the capsule and the hollow tubular element. Alternatively, one or more filter segments may be provided within the hollow tubular element at their downstream end, as will be described in more detail below.

[0229] The empty cavity that can be defined within the hollow tubular element downstream of the capsule preferably has a length of at least 10 millimeters, more preferably at least 12 millimeters, and more preferably at least 14 millimeters. The length of the empty cavity may be up to 40 millimeters, or up to 30 millimeters, or up to 25 millimeters. For example, the empty cavity may have a length of 10 to 40 millimeters, or 12 to 30 millimeters, or 14 to 25 millimeters.

[0230] Preferably, the hollow tubular element has a total length of at least 25 mm, more preferably at least 28 mm, more preferably at least 30 mm, more preferably at least 32 mm, and more preferably at least 34 mm. The length of the hollow tubular element may be less than 50 mm, or less than 48 mm, or less than 45 mm, or less than 42 mm, or less than 40 mm. For example, the total length of the hollow tubular element may be 25 mm to 50 mm, or 28 mm to 48 mm, or 30 mm to 45 mm, or 32 mm to 42 mm, or 34 mm to 40 mm.

[0231] The hollow tubular element may have an outer diameter of 5 mm to 12 mm, for example, 5 mm to 10 mm, or 6 mm to 8 mm. The hollow tubular element may have an outer diameter of 7.2 mm ± 10 percent.

[0232] The inner diameter of the hollow tubular element is preferably constant along the length of the hollow tubular element. The lumen or cavity of the hollow tubular segment may have any cross-sectional shape. The lumen of the hollow tubular segment may have a circular cross-sectional shape.

[0233] Preferably, the inner diameter of the hollow tubular element is at least 5 mm, more preferably at least 5.5 mm, more preferably at least 6 mm, and more preferably at least 6.5 mm. Preferably, the inner diameter of the hollow tubular element is less than 9 mm, more preferably less than 8.5 mm, more preferably less than 8 mm, and more preferably less than 7.5 mm. For example, the inner diameter may be between 5 mm and 9 mm, or between 5.5 mm and 8.5 mm, or between 6 mm and 6 mm, or between 6.5 mm and 7.5 mm. The inner diameter may be about 7 mm.

[0234] The hollow tubular element preferably has a wall thickness of at least 100 micrometers, more preferably at least 150 micrometers, more preferably at least 200 micrometers, more preferably at least 250 micrometers, and more preferably at least 500 micrometers. The wall thickness of the hollow tubular element may be less than 2 millimeters, preferably less than 1.5 millimeters, and even more preferably less than 1.25 mm. The wall thickness of the hollow tubular element may be less than 1 millimeter. For example, the wall thickness of the hollow tubular element may be 100 micrometers to 2 millimeters, or 150 micrometers to 1.5 millimeters, or 200 micrometers to 1.25 millimeters, or 250 micrometers to 1 millimeter, or 500 micrometers to 1 millimeter.

[0235] The hollow tubular segment may include a paper-based material. The hollow tubular segment may include at least one layer of paper. The paper may be very rigid paper. The paper may be crimped paper, such as crimped heat-resistant paper or crimped sulfuric acid paper. Advantageously, the crimped paper may form one or more airflow channels extending around the outside of the capsule. One or more airflow channels may be particularly advantageous in embodiments in which the capsule has at least one of an air intake and an air outlet on the cylindrical wall of the capsule.

[0236] Preferably, the hollow tubular element is formed from cardboard. The hollow tubular element may be a cardboard tube. Advantageously, cardboard is a cost-effective material that provides a balance between being deformable to provide ease of inserting articles into the aerosol generator and being rigid enough to provide proper engagement of articles with the inside of the device. Thus, the cardboard tube may provide adequate resistance to deformation or compression during use.

[0237] The hollow tubular segment may be a paper tube. The hollow tubular segment may be a tube formed from spirally wound paper. The hollow tubular segment may be formed from multiple layers of paper. The paper may have a basis weight of at least about 50 grams per square meter, at least about 60 grams per square meter, at least about 70 grams per square meter, or at least about 90 grams per square meter.

[0238] The hollow tubular segment may contain polymer materials. For example, the hollow tubular segment may contain a polymer film. The polymer film may contain a cellulose film. The hollow tubular segment may contain low-density polyethylene (LDPE) or polyhydroxyalkanoate (PHA) fibers. The hollow tube may contain cellulose acetate tow.

[0239] If the hollow tubular segment contains cellulose acetate tow, the cellulose acetate tow may have about 2 to about 4 deniers per filament and about 25 to about 40 total deniers.

[0240] Hollow tubular elements are preferably provided with a negligible level of drawdown resistance (RTD). The term “negligible level of RTD” is used to describe an RTD of less than 1 mmH2O per 10 mm length hollow tubular segment or hollow tubular element, preferably less than 0.4 mmH2O per 10 mm length hollow tubular segment or hollow tubular element, and more preferably less than 0.1 mmH2O per 10 mm length hollow tubular segment or hollow tubular element.

[0241] The RTD of the hollow tubular element is preferably about 10 mmH2O or less. More preferably, the RTD of the hollow tubular element is about 5 mmH2O or less. Even more preferably, the RTD of the hollow tubular element is about 2.5 mmH2O or less. Even more preferably, the RTD of the hollow tubular element is about 2 mmH2O or less. Even more preferably, the RTD of the hollow tubular element is about 1 mmH2O or less.

[0242] The RTD of the hollow tubular element may be at least 0 mmH2O, or at least about 0.25 mmH2O, or at least about 0.5 mmH2O, or at least about 1 mmH2O.

[0243] The RTD of the hollow tubular element may be about 0 mmH2O to about 10 mmH2O, preferably about 0.25 mmH2O to about 10 mmH2O, preferably about 0.5 mmH2O to about 10 mmH2O. The RTD of the hollow tubular element may be about 0 mmH2O to about 5 mmH2O, preferably about 0.25 mmH2O to about 5 mmH2O, preferably about 0.5 mmH2O to about 5 mmH2O. The RTD of the hollow tubular element may be about 1 mmH2O to about 5 mmH2O. The RTD of the hollow tubular element may be about 0 mmH2O to about 2.5 mmH2O, preferably about 0.25 mmH2O to about 2.5 mmH2O, more preferably about 0.5 mmH2O to about 2.5 mmH2O. The RTD of the hollow tubular element may be about 0 mmH2O to about 2 mmH2O, preferably about 0.25 mmH2O to about 2 mmH2O, and more preferably about 0.5 mmH2O to about 2 mmH2O. The RTD of the hollow tubular element is preferably about 0 mmH2O.

[0244] The aerosol-generating article may further comprise a downstream filter segment mounted within a hollow tubular element at the downstream end of the hollow tubular element. The downstream filter segment may extend to the downstream end of the hollow tubular element. The downstream end of the downstream filter segment may define the downstream end of the aerosol-generating article. Including the downstream filter segment within the hollow tubular element may be useful in providing the aerosol-generating article with a desired level of RTD (Ready-to-Dose).

[0245] The downstream filter segment may be located downstream of the capsule, and preferably, the capsule and the downstream filter segment are separated by a gap in the longitudinal direction such that a cavity is defined between them. The downstream filter segment is preferably located at least 5 millimeters downstream from the downstream end of the capsule, more preferably at least 8 millimeters downstream, more preferably at least 10 millimeters downstream, and more preferably at least 15 millimeters downstream. The downstream filter segment is preferably located less than 30 millimeters downstream from the downstream end of the capsule, and more preferably less than 25 millimeters downstream. The distance defined between the downstream end of the capsule and the downstream filter segment corresponds to the length of the cavity between the capsule and the downstream filter segment.

[0246] The downstream filter segment is preferably a solid plug, which may also be described as a "plain" plug and is non-tubular. Therefore, the filter segment preferably has a substantially uniform cross-sectional area.

[0247] The downstream filter segment is preferably formed of a fibrous filter material. The fibrous filter material may be for filtering aerosols generated from a first aerosol generating substrate and at least one of an aerosol former, flavoring agent, and second aerosol generating substrate provided inside the capsule wall, on the surface of the capsule wall, or both inside and on the surface of the capsule wall. Suitable fibrous filter materials will be known to those skilled in the art. Particularly preferably, at least one downstream filter segment includes a cellulose acetate filter segment formed from cellulose acetate tow.

[0248] The downstream filter segment may optionally contain flavoring agents, which can be provided in any preferred form. For example, the downstream filter segment may comprise one or more capsules, beads, or granules of the flavoring agent, or threads or filaments filled with one or more flavoring agents.

[0249] The downstream filter segment preferably has a low particle filtration efficiency.

[0250] The downstream filter segment preferably has an outer diameter approximately equal to the inner diameter of the hollow tubular element, so that the downstream filter segment is held within the hollow tubular element by friction fitting.

[0251] Preferably, the outer diameter of the downstream filter segment is 5 mm to 12 mm, more preferably 6 mm to 10 mm, and more preferably 7 mm to 8 mm.

[0252] Unless otherwise specified, the draw resistance (RTD) of a component or aerosol-generating article shall be measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of the component. The terms “pressure drop” or “draw resistance” of a component or article may also refer to “resistance to draw.” These terms generally refer to the fact that the measurement in accordance with ISO 6565-2015 is successfully performed under a test of a volumetric flow rate of 17.5 ml per second at the output or downstream end of the measured component, at a temperature of 22 degrees Celsius, a pressure of 101 kPa (approximately 760 Torr), and a relative humidity of 60%. The conditions for smoking and the specifications of the smoking machine are presented in ISO standard 3308 (ISO 3308:2000). The atmosphere for adjustment and testing is presented in ISO standard 3402 (ISO 3402:1999).

[0253] The draw-out resistance (RTD) of the downstream filter segment may be at least 0 mmH2O, or at least 3 mmH2O, or at least 6 mmH2O.

[0254] The RTD of the downstream filter segment may be 12 mmH2O or less, or 11 mmH2O or less, or 10 mmH2O or less.

[0255] As described above, the downstream filter segment may be formed from a fibrous material. The downstream filter segment may be formed from a porous material. The downstream filter segment may be formed from a biodegradable material. The downstream filter segment may be formed from a cellulose material such as cellulose acetate. For example, the downstream filter segment may be formed from a bundle of cellulose acetate fibers having 10 to 15 denier per filament. For example, the downstream filter segment may be formed from a relatively low-density cellulose acetate tow, such as cellulose acetate tow containing fibers of 12 denier per filament.

[0256] The downstream filter segment may be formed from a polylactic acid-based material. The downstream filter segment may also be formed from a bioplastic material, preferably a starch-based bioplastic material. The downstream filter segment may be manufactured by injection molding or extrusion molding. Bioplastic materials are advantageous because they can provide a downstream filter segment structure that is easy and inexpensive to manufacture, with a specific complex cross-sectional profile that may include multiple relatively large airflow channels extending through the downstream filter segment material, providing suitable RTD properties.

[0257] The length of the downstream filter segment may be at least 5 millimeters, or at least 8 millimeters, or at least 10 millimeters. The length of the downstream filter segment may be less than 20 millimeters, or less than 15 millimeters, or less than 12 millimeters. For example, the length of the downstream filter segment may be between 5 millimeters and 20 millimeters, or between 8 millimeters and 15 millimeters, or between 8 millimeters and 12 millimeters, or between 10 millimeters and 12 millimeters.

[0258] The downstream filter segment may be provided downstream of the hollow tubular element. The downstream filter segment may extend between the hollow tubular element and the downstream end of the aerosol-generating article. The downstream filter segment may be connected to the hollow tubular element by a chipping wrapper.

[0259] The overall RTD of an aerosol-generating article may be at least 1 milliH2O. For example, the overall RTD of an aerosol-generating article may be at least 2 milliH2O, at least 3 milliH2O, at least 4 milliH2O, at least 5 milliH2O, at least 6 milliH2O, at least 7 milliH2O, at least 8 milliH2O, at least 9 milliH2O, at least 10 milliH2O, at least 15 milliH2O, at least 20 milliH2O, at least 30 milliH2O, at least 40 milliH2O, or at least 50 milliH2O.

[0260] The overall RTD of an aerosol-generating article may be 180 mmH2O or less. For example, the overall RTD of an aerosol-generating article may be 170 mmH2O or less, 160 mmH2O or less, 150 mmH2O or less, or 140 mmH2O or less.

[0261] The overall RTD of an aerosol-generating article may range from 1 mmH2O to 180 mmH2O. For example, the overall RTD of an aerosol-generating article may range from 5 mmH2O to 170 mmH2O, 10 mmH2O to 160 mmH2O, 20 mmH2O to 150 mmH2O, or 50 mmH2O to 140 mmH2O.

[0262] The aerosol-generating article may have an overall length of at least 40 millimeters, or at least 50 millimeters, or at least 60 millimeters.

[0263] The total length of the aerosol-generating article may be 90 millimeters or less, or 85 millimeters or less, or 80 millimeters or less.

[0264] The total length of the aerosol generating article is preferably 40 mm to 70 mm, more preferably 45 mm to 70 mm. The total length of the aerosol generating article is preferably 40 mm to 60 mm, more preferably 45 mm to 60 mm. The total length of the aerosol generating article is preferably 40 mm to 50 mm, more preferably 45 mm to 50 mm. The total length of the aerosol generating article may be about 45 mm.

[0265] The aerosol-generating article may have an outer diameter of at least 5 millimeters, at least 6 millimeters, or at least 7 millimeters.

[0266] The aerosol-generating article may have an outer diameter of approximately 12 mm or less, approximately 10 mm or less, or approximately 8 mm or less.

[0267] The aerosol-generating article may have an outer diameter of about 5 mm to about 12 mm, preferably about 6 mm to about 12 mm, more preferably about 7 mm to about 12 mm. The aerosol-generating article may have an outer diameter of about 5 mm to about 10 mm, preferably about 6 mm to about 10 mm, more preferably about 7 mm to about 10 mm. The aerosol-generating article may have an outer diameter of about 5 mm to about 8 mm, preferably about 6 mm to about 8 mm, more preferably about 7 mm to about 8 mm. The aerosol-generating article may have an outer diameter of less than 7 mm.

[0268] The outer diameter of an aerosol-generating article may be substantially constant along its entire length. Alternatively, different parts of the aerosol-generating article may have different outer diameters.

[0269] The present invention also relates to an aerosol generating system comprising the aerosol generating article according to the present invention described above, and an aerosol generating device equipped with a heating element configured to heat the aerosol generating article.

[0270] As described above, during use, at least one of the aerosol-forming material on the outer wall of the capsule, the flavoring agent, and the second aerosol-generating substrate may be heated before the first aerosol-generating substrate in the internal cavity of the capsule. Alternatively, during use, at least one of the aerosol-forming material on the outer wall of the capsule, the flavoring agent, and the second aerosol-generating substrate may be heated after the first aerosol-generating substrate in the internal cavity of the capsule.

[0271] The aerosol generator has a distal end and an oral end. The aerosol generator may include a body. The body or housing of the aerosol generator may define a device cavity at the oral end of the device for removably receiving an aerosol generating article. The aerosol generator may include a heating element or heater for heating a first aerosol generating substrate and at least one of an aerosol forming agent, a flavoring agent, and a second aerosol generating substrate provided inside the capsule wall, on the surface of the capsule wall, or both inside and on the surface of the capsule wall.

[0272] The device cavity may also be called the heating chamber of the aerosol generator. The device cavity may extend between a distal end and a mouth (or proximal) end. The distal end of the device cavity may be a closed end, and the mouth (or proximal) end may be an open end. The aerosol generating article may be inserted into the device cavity or heating chamber through the open end of the device cavity. The device cavity may be cylindrical in shape to accommodate the same shape as the aerosol generating article.

[0273] The expression "internal acceptance" may refer to the fact that a component or element is fully or partially accepted within another component or element. For example, the expression "an aerosol-generating article is accepted within the device cavity" means that the aerosol-generating article is fully or partially accepted within the device cavity of the aerosol-generating article. When an aerosol-generating article is accepted within the device cavity, the aerosol-generating article may be in contact with the distal end of the device cavity. When an aerosol-generating article is accepted within the device cavity, the aerosol-generating article may be substantially close to the distal end of the device cavity. The distal end of the device cavity may be defined by an end wall.

[0274] The length of the cavity in the device may be 15 mm to 80 mm, or 20 mm to 70 mm, or 25 mm to 60 mm, or 25 mm to 50 mm.

[0275] The length of the cavity in the device may be 25 to 29 millimeters, 26 to 29 millimeters, or 27 to 28 millimeters.

[0276] When an aerosol-generating article is received within the device cavity, it is preferable that the capsule be completely within the device cavity to optimize the heating of the first aerosol-generating substrate and at least one of the aerosol-forming material, flavoring agent, and second aerosol-generating substrate provided within the capsule wall, on the surface of the capsule wall, or both within and on the surface of the capsule wall. Therefore, it is preferable that the length of the device cavity be longer than the length of the capsule.

[0277] The diameter of the device cavity may be 4 mm to 10 mm. The diameter of the device cavity may be 5 mm to 9 mm. The diameter of the device cavity may be 6 mm to 8 mm. The diameter of the device cavity may be 6 mm to 7 mm.

[0278] The diameter of the device cavity may be substantially the same as, or greater than, the diameter of the aerosol generating article. The diameter of the device cavity may be the same as the diameter of the aerosol generating article in order to establish a tight fit with the aerosol generating article. The cross-sectional shape of the device cavity may be substantially the same as the cross-sectional shape of the aerosol generating article. The device cavity may have a substantially circular cross-section.

[0279] The device cavity may be configured to establish a tight fit with the aerosol generating article received within the device cavity. A tight fit may refer to a sliding fit. The aerosol generating device may have a peripheral wall. Such peripheral wall may define a device cavity or a heating chamber. The peripheral wall defining the device cavity may be configured to engage in a tight fit with the aerosol generating article received within the device cavity such that, when received within the device, there is substantially no gap or empty space between the peripheral wall defining the device cavity and the aerosol generating article.

[0280] Such airtight fittings can establish an airtight fit or configuration between the device cavity and the aerosol-generating article received therein.

[0281] In such an airtight configuration, there is virtually no gap or empty space between the peripheral wall defining the device cavity and the aerosol-generating article through which air flows.

[0282] A tight fit with the aerosol-generating article may be established along the entire length of the device cavity or along a portion of the length of the device cavity.

[0283] The heating element may be any suitable type of heating element.

[0284] The heating element may be an external heating element that heats the capsule and its contents from the outside. Such an external heating element may surround the aerosol generating article when inserted into or received within the aerosol generating device. The heating element may be provided around the periphery of the device cavity such that the heating element at least partially surrounds the capsule when the aerosol generating article is received within the device cavity.

[0285] Alternatively, the heating element may be an internal heating element that heats the capsule and its contents internally. The heating element may be provided within the device cavity so that it is inserted into the capsule when the aerosol-generating article is received into the device cavity. The heating element may be an elongated heater blade or pin adapted to be inserted into the capsule to heat the capsule and its contents internally. The heating element may penetrate the capsule when the aerosol-generating article is received into the device cavity. The heating element may penetrate the upstream end of the capsule when the aerosol-generating article is received into the device cavity. One or more weak lines or weak regions may be provided on the upstream end of the capsule, which may be configured to break when the heating element penetrates into the upstream end of the capsule when the aerosol-generating article is received into the device cavity.

[0286] Advantageously, by providing one or more weak lines or weak regions at the upstream end of the capsule, configured to be ruptured when a heating element penetrates into the upstream end of the capsule, it is possible to ensure that the capsule does not substantially move relative to one or both of the hollow tubular element and the aerosol-generating article when the aerosol-generating article is received in the device cavity.

[0287] The heater may comprise at least one heating element. The at least one heating element can be any suitable type of heating element. In some embodiments, the device comprises only one heating element. In some embodiments, the device comprises multiple heating elements.

[0288] The heating element may be a resistance heating element.

[0289] Suitable materials for forming the resistive heating element include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide, etc.), carbon, graphite, metals, metal alloys, and composite materials made of ceramic materials and metal materials. Such composite materials may include doped ceramics or may include undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel, iron, cobalt, stainless steel-based superalloys, Timetal (registered trademark), and iron-manganese-aluminum-based alloys.

[0290] In some embodiments, the resistive heating element comprises one or more stamped portions of an electrically resistive material (such as stainless steel). Alternatively, at least one resistive heating element may include a heating wire or filament (e.g., a wire of Ni—Cr (nickel-chromium), platinum, tungsten or an alloy).

[0291] In some embodiments, the heating element includes an electrically insulated substrate, and at least one resistive heating element is provided on the electrically insulated substrate.

[0292] The electrically-insulated substrate can include any suitable material. For example, the electrically-insulated substrate can include one or more of paper, glass, ceramic, an anodized metal, a coated metal, and polyimide. The ceramic can include mica, alumina (Al2O3) or zirconia (ZrO2). The electrically-insulated substrate preferably has a thermal conductivity of about 40 watts / meter kelvin or less, preferably about 20 watts / meter kelvin or less, and ideally about 2 watts / meter kelvin or less.

[0293] The heater may include a heating element including a rigid electrically-insulated substrate having one or more conductive tracks or wires disposed on its surface. The size and shape of the electrically-insulated substrate can be such as to allow direct insertion into the capsule. If the electrically-insulated substrate is not sufficiently rigid, the heating element may include further reinforcement means. The current can pass through one or more conductive tracks to heat the heating element and at least one of the first aerosol-generating substrate, an aerosol former, a flavorant, and the second aerosol-generating substrate provided within, on the surface of, or both within and on the surface of the capsule outer wall.

[0294] In some embodiments, the heater comprises an induction heating arrangement. The induction heating device can comprise an inductor coil and a power supply configured to provide a high-frequency oscillating current to the inductor coil. As used herein, a high-frequency oscillating current means an oscillating current having a frequency of from about 500 kHz to about 30 MHz. The heater can advantageously comprise a DC / AC inverter for converting a DC current supplied by a DC power supply into an alternating current. The inductor coil can be arranged to generate a high-frequency oscillating electromagnetic field when receiving the high-frequency oscillating current from the power supply. The inductor coil can be arranged to generate a high-frequency oscillating electromagnetic field within the device cavity. In some embodiments, the inductor coil can substantially surround the device cavity. The inductor coil can extend at least partially along the length of the device cavity.

[0295] The heater may include an induction heating element. The induction heating element may be a susceptor element. The susceptor element may be positioned such that when an aerosol generating article is received in the cavity of the aerosol generator, the oscillating electromagnetic field generated by the inductor coil induces a current within the susceptor element, thereby heating the susceptor element. In these embodiments, the aerosol generator is preferably capable of generating a fluctuating electromagnetic field having a magnetic field strength (H-field strength) of 1 to 5 kiloamperes / meter (kA / m), preferably 2 to 3 kA / m, for example, about 2.5 kA / m. The electrically operated aerosol generator is preferably capable of generating a fluctuating electromagnetic field having a frequency of 1 to 30 MHz, for example, 1 to 10 MHz, for example, 5 to 7 MHz.

[0296] In these embodiments, the susceptor element may be located in contact with the first aerosol generating substrate. In some embodiments, the susceptor element is located within the aerosol generating device. In these embodiments, the susceptor element may be located within a cavity. The aerosol generating device may include only one susceptor element. The aerosol generating device may comprise multiple susceptor elements. In some embodiments, the susceptor element is preferably arranged to heat the outer wall of the capsule and any covering present thereon.

[0297] In embodiments where the capsule of the aerosol-generating article includes a susceptor, it is preferable that the inductor coil is arranged to heat the susceptor of the capsule.

[0298] In some embodiments, the aerosol generator may comprise at least one resistance heating element and at least one induction heating element. In some embodiments, the aerosol generator may comprise a combination of a resistance heating element and an induction heating element.

[0299] The aerosol generator may further include a controller. During use, the heater may be controlled to operate within a specified operating temperature range below the maximum operating temperature. The operating temperature range within the heating chamber (or device cavity) is preferably about 150°C to about 300°C. The operating temperature range of the heater may be about 150°C to about 250°C.

[0300] The aerosol generator may be equipped with a power supply. The power supply may be a DC power supply. In some embodiments, the power supply is a battery. The power supply may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery (e.g., lithium cobalt, lithium iron phosphate, or lithium polymer battery). However, in some embodiments, the power supply may be another form of charge storage device, such as a capacitor. The power supply may require recharging and may have a capacity that allows for sufficient energy storage for one or more user operations, such as one or more aerosol generation experiences.

[0301] The aerosol generator may include a penetration device for penetrating the capsule when the aerosol generating article is inserted into the device cavity. As described above, penetration of the capsule may be necessary to establish one or more airflow paths through the capsule.

[0302] The aerosol generator may include airflow channeling extending between a channel inlet and a channel outlet. The airflow channel may be configured to establish fluid communication between the inside of the device cavity and the outside of the aerosol generator. The airflow channel of the aerosol generator may be defined within the housing of the aerosol generator to enable fluid communication between the inside of the device cavity and the outside of the aerosol generator. When an aerosol-generating article is received in the device cavity, the airflow channel may be configured to provide air flowing into the article to deliver the generated aerosol to a user who inhales it from the mouth end of the article.

[0303] The airflow channels of the aerosol generator may be defined within or by the peripheral walls of the housing of the aerosol generator. In other words, the airflow channels of the aerosol generator may be defined within the thickness of the peripheral walls, by the inner surfaces of the peripheral walls, or a combination of both. The airflow channels may be partially defined by the inner surfaces of the peripheral walls, or partially defined within the thickness of the peripheral walls. The inner surfaces of the peripheral walls define the periphery of the device cavity.

[0304] The present invention also relates to a method for manufacturing capsules within an aerosol-generating article. The method includes providing a capsule outer wall that defines an internal cavity. The method also includes applying an inner coating to at least a portion of the inner surface of the capsule outer wall. The method further includes forming at least one of an air intake and an air outlet by penetrating the capsule outer wall after the application of the inner coating.

[0305] Advantageously, applying the inner coating before penetrating the outer wall of the capsule ensures that the inner coating does not cover at least one of the air intake and air outlet.

[0306] The capsule may contain any of the optional or preferred features described above with respect to the aerosol generating article of the present invention.

[0307] The capsule wall may be perforated by any suitable method to form at least one of an air intake and an air outlet. For example, at least one of the air intake and air outlet may be provided by laser perforation. Alternatively, or additionally, at least one of the air intake and air outlet may be provided by penetrating the capsule wall by mechanical force, such as by mechanical clamping of the capsule wall. The capsule may be heated to facilitate the perforation process.

[0308] The method may further include providing a first aerosol-generating substrate within the internal cavity of the capsule. The first aerosol-generating substrate may include any of the preferred or optional features of the first aerosol-generating substrate described above with respect to the aerosol-generating article of the present invention.

[0309] The method may further include providing the capsule as a two-part capsule in the form of two separate parts.

[0310] The method may further include joining two separate parts together by friction fitting and / or adhesive, the two separate parts being joined together after applying an inner coating to at least a portion of the inner surface of the outer wall of the capsule and after providing a first aerosol generating substrate within the internal cavity of the capsule.

[0311] The inner coating applied to at least a portion of the inner surface of the outer wall of the capsule may include at least one of an aerosol-forming agent, a flavoring agent, and a second aerosol-generating substrate. The inner coating may have any of the preferred or optional features described above with respect to the aerosol-generating article of the present invention.

[0312] The method may also include further steps relating to the manufacture of an aerosol-generating article. For example, the method may further include the step of providing a hollow tubular structure and inserting a capsule at least partially into the hollow tubular element to form an aerosol-generating article. Naturally, the aerosol-generating article of the method may be the same aerosol-generating article described in other sections of this application, and may have one or more features of the aerosol-generating articles described therein.

[0313] When the capsule is at least partially inserted into a hollow tubular element to form an aerosol-generating article, the hollow tubular element can at least partially overlap with the position of at least one of the air inlet and the air outlet within the capsule outer wall. In such embodiments, the hollow tubular element may be penetrated using the same or different methods to form at least one of the air inlet and the air outlet within the wall of the hollow tubular element and to penetrate the capsule outer wall. At least one of the air inlet and the air outlet of the capsule outer wall can at least partially overlap with at least one of the air inlet and the air outlet of the wall of the hollow tubular element. At least one of the air inlet and the air outlet of the capsule outer wall can completely overlap with at least one of the air inlet and the air outlet of the wall of the hollow tubular element. The capsule outer wall may be penetrated after the capsule is at least partially inserted into the hollow tubular element such that both the capsule outer wall and the wall of the hollow tubular element are penetrated simultaneously.

[0314] When the capsule is at least partially inserted into a hollow tubular element to form an aerosol-generating article, the hollow tubular element does not have to overlap with the position of at least one of the air inlet and the air outlet within the capsule outer wall. In such embodiments, only the capsule outer wall may be penetrated to form at least one of the air inlet and the air outlet.

[0315] [Examples] The following provides a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more of the features described above, for example, any one or more of the features of another example, embodiment, or aspect described herein.

[0316] Example 1: An aerosol-generating article for generating an inhalable aerosol upon heating, the aerosol-generating article comprising a capsule comprising a capsule outer wall defining an internal cavity, The first aerosol generating substrate inside the capsule's internal cavity, An aerosol generating article comprising a capsule containing at least one of an aerosol-forming agent, a flavoring agent, and a second aerosol-generating substrate, provided inside the outer wall of the capsule, on the surface of the outer wall of the capsule, or both inside and on the outer wall of the capsule. Example 2: The aerosol generating article according to Example 1, wherein the capsule has an inner coating on at least a portion of the inner surface of the outer wall of the capsule, and the inner coating comprises at least one of an aerosol forming body, a flavoring agent, and a second aerosol generating substrate. Example 3: The aerosol-generating article according to Example 2, wherein the inner coating of the capsule is provided on substantially the entire inner surface of the outer wall of the capsule. Example 4: The aerosol-generating article according to Example 2, wherein the inner covering of the capsule is provided only on a portion of the inner surface of the outer wall of the capsule, and optionally, the inner covering of the capsule is provided only on a portion of the inner surface of the outer wall of the capsule that extends parallel to the longitudinal axis of the capsule. Example 5: An aerosol generating article according to any one of Examples 2 to 4, wherein the inner coating of the capsule has a thickness of 0.1 micrometers or more, optionally 0.2 micrometers or more, optionally 0.5 micrometers or more, optionally 1 micrometer or more, optionally 5 micrometers or more, optionally 10 micrometers or more, optionally 50 micrometers or more, optionally 0.1 millimeters or more, optionally 0.15 millimeters or more, or optionally 0.2 millimeters or more. Example 6: An aerosol generating article according to any one of Examples 2 to 5, wherein the inner coating of the capsule has a thickness of 1 mm or less, optionally 0.75 mm or less, optionally 0.5 mm or less, optionally 0.4 mm or less, optionally 0.2 mm or less, optionally 0.15 mm or less, optionally 0.1 mm or less, optionally 50 micrometers or less, optionally 10 micrometers or less, optionally 5 micrometers or less, optionally 1 micrometer or less, optionally 0.5 micrometers or less, optionally 0.2 micrometers or less, or optionally 0.1 micrometers or less. Example 7: An aerosol generating article according to any one of Examples 2 to 6, wherein the inner coating of the capsule has a mass of 0.05 micrograms or more, optionally 0.1 micrograms or more, optionally 0.2 micrograms or more, optionally 0.3 micrograms or more, optionally 0.4 micrograms or more, optionally 0.5 micrograms or more, optionally 0.6 micrograms or more, optionally 0.7 micrograms or more, optionally 0.8 micrograms or more, optionally 0.9 micrograms or more, optionally 1 microgram or more, optionally 10 micrograms or more, optionally 50 micrograms or more, optionally 100 micrograms or more, optionally 0.15 milligrams or more, optionally 0.2 milligrams or more, optionally 0.25 milligrams or more, optionally 0.5 milligrams or more, optionally 1 milligram or more, or optionally 1.5 milligrams or more. Example 8: An aerosol generating article according to any one of Examples 2 to 7, wherein the inner coating of the capsule has a mass of 2 milligrams or less, optionally 1.5 milligrams or less, optionally 1 milligram or less, or optionally 0.5 milligrams or less, optionally 0.25 milligrams or less, optionally 0.2 milligrams or less, optionally 0.15 milligrams or less, optionally 100 micrograms or less, optionally 50 micrograms or less, optionally 10 micrograms or less, optionally 1 microgram or less, optionally 0.9 micrograms or less, optionally 0.8 micrograms or less, optionally 0.7 micrograms or less, optionally 0.6 micrograms or less, optionally 0.5 micrograms or less, optionally 0.4 micrograms or less, optionally 0.3 micrograms or less, optionally 0.2 micrograms or less, optionally 0.1 micrograms or less, or optionally 0.05 micrograms or less. Example 9: An aerosol generating article according to any one of Examples 2 to 8, wherein the inner coating of the capsule contains an aerosol-forming material. Example 10: The aerosol generating article according to Example 9, wherein the inner coating of the capsule contains, optionally, 5% by weight or more of an aerosol-forming material on a dry weight basis, 10% by weight or more of an aerosol-forming material on a dry weight basis, optionally, 15% by weight or more of an aerosol-forming material on a dry weight basis, optionally, 20% by weight or more of an aerosol-forming material on a dry weight basis, optionally, 25% by weight or more of an aerosol-forming material on a dry weight basis, optionally, 30% by weight or more of an aerosol-forming material on a dry weight basis, optionally, 35% by weight or more of an aerosol-forming material on a dry weight basis, optionally, 40% by weight or more of an aerosol-forming material on a dry weight basis, optionally, 45% by weight or more of an aerosol-forming material on a dry weight basis, optionally, 50% by weight or more of an aerosol-forming material on a dry weight basis, optionally, 60% by weight or more of an aerosol-forming material on a dry weight basis, or optionally, 70% by weight or more of an aerosol-forming material on a dry weight basis. Example 11: The aerosol generating article according to Example 9 or 10, wherein the inner coating of the capsule comprises, optionally, 80% by weight or less of an aerosol-forming material on a dry weight basis, 75% by weight or less of an aerosol-forming material on a dry weight basis, 70% by weight or less of an aerosol-forming material on a dry weight basis, 60% by weight or less of an aerosol-forming material on a dry weight basis, 50% by weight or less of an aerosol-forming material on a dry weight basis, 40% by weight or less of an aerosol-forming material on a dry weight basis, 30% by weight or less of an aerosol-forming material on a dry weight basis, 25% by weight or less of an aerosol-forming material on a dry weight basis, 20% by weight or less of an aerosol-forming material on a dry weight basis, 15% by weight or less of an aerosol-forming material on a dry weight basis, or 10% by weight or less of an aerosol-forming material on a dry weight basis. Example 12: An aerosol generating article according to any one of Examples 9 to 11, wherein the inner coating of the capsule comprises an aerosol-forming body selected from at least one of polyhydric alcohols, esters of polyhydric alcohols, and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids. Example 13: The aerosol generating article according to any one of Examples 9 to 12, wherein the aerosol forming material of the inner coating of the capsule contains a polyhydric alcohol selected from at least one of triethylene glycol, propylene glycol, 1,3-butanediol, and glycerol, and preferably the aerosol forming material of the inner coating of the capsule contains glycerol. Example 14: An aerosol generating article according to any one of Examples 9 to 13, wherein the aerosol-forming material of the inner coating of the capsule contains an ester of a polyhydric alcohol selected from at least one of glycerol monoacetate, glycerol diacetate, and glycerol triacetate. Example 15: An aerosol generating article according to any one of Examples 9 to 14, wherein the aerosol-forming material of the inner coating of the capsule comprises an aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid selected from at least one of dimethyl dodecanediate and dimethyl tetradecanediate. Example 16: The inner coating of the capsule may consist of 5% to 80% glycerol by dry weight, optionally 10% to 80% glycerol by dry weight, optionally 15% to 80% glycerol by dry weight, optionally 20% to 80% glycerol by dry weight, optionally 25% to 80% glycerol by dry weight, or optionally 30% to 80% glycerol by dry weight. Optionally, 35% to 80% glycerol by dry weight, optionally, 40% to 80% glycerol by dry weight, optionally, 5% to 60% glycerol by dry weight, optionally, 10% to 60% glycerol by dry weight, optionally, 15% to 60% glycerol by dry weight, optionally, 20% to 60% glycerol by dry weight, optionally Based on dry weight, 25% to 60% glycerol, optional; based on dry weight, 30% to 60% glycerol, optional; based on dry weight, 35% to 60% glycerol, optional; based on dry weight, 40% to 60% glycerol, optional; based on dry weight, 5% to 40% glycerol, optional; based on dry weight, 10% to 40% glycerol, optional; based on dry weight, Based on quantity, 15% to 40% by weight glycerol; optionally, based on dry weight, 20% to 40% by weight glycerol; optionally, based on dry weight, 25% to 40% by weight glycerol; optionally, based on dry weight, 30% to 40% by weight glycerol; optionally, based on dry weight, 35% to 40% by weight glycerol; optionally, based on dry weight, 5% to 20% by weight glycerol; optionally, based on dry weight,An aerosol-generating article according to any one of Examples 9 to 15, comprising 10% to 20% by weight glycerol, optionally 15% to 20% by weight glycerol on a dry weight basis, or optionally about 20% by weight glycerol on a dry weight basis. Example 17: An aerosol-generating article according to any one of Examples 2 to 16, wherein the inner coating of the capsule is substantially free of tobacco. Example 18: An aerosol generating article according to any one of Examples 1 to 17, wherein the inner coating of the capsule contains a second aerosol generating substrate. Example 19: The aerosol generating article according to Example 18, wherein the second aerosol generating substrate of the inner coating of the capsule contains nicotine. Example 20: The aerosol-generating article according to Example 19, wherein the inner coating of the capsule contains, on a dry weight basis, at least 0.5 weight percent nicotine, optionally, at least 1 weight percent nicotine, on a dry weight basis, or optionally, at least 2 weight percent nicotine, on a dry weight basis. Example 21: The aerosol-generating article according to Example 19 or 20, wherein the inner coating of the capsule contains nicotine at a dry weight of 10% by weight or less, optionally 8% by weight or less, or optionally 6% by weight or less, of nicotine on a dry weight basis. Example 22: The aerosol generating article according to any one of Examples 18 to 21, wherein the inner coating of the capsule contains one or more carboxylic acids, and optionally, one or more carboxylic acids are selected from the group consisting of acids, benzoic acid, fumaric acid, and levulinic acid, preferably, one or more carboxylic acids are selected from the group consisting of lactic acid and levulinic acid. Example 23: The aerosol generating article according to Example 22, wherein the inner coating of the capsule contains 0.5% by weight or more of carboxylic acid on a dry weight basis, optionally 1% by weight or more of carboxylic acid on a dry weight basis, or optionally 2% by weight or more of carboxylic acid on a dry weight basis. Example 24: The aerosol-generating article according to Example 22 or 23, wherein the inner coating of the capsule contains 15% by weight or less of a carboxylic acid on a dry weight basis, optionally 10% by weight or less of a carboxylic acid on a dry weight basis, or optionally 5% by weight or less of a carboxylic acid on a dry weight basis. Example 25: An aerosol generating article according to any one of Examples 2 to 24, wherein the inner coating of the capsule comprises a second aerosol generating substrate, the second aerosol generating substrate is in the form of an aerosol generating film, and optionally the aerosol generating film comprises a cellulose-based film-forming agent, nicotine, and an aerosol-forming agent. Example 26: The aerosol generating article according to Example 25, wherein the aerosol generating film covering the inside of the capsule contains glycerol, and optionally the aerosol generating film has a glycerol content of at least 40 weight percent on a dry weight basis. Example 27: The aerosol generating article according to Example 25 or 26, wherein the cellulose-based film-forming agent for the aerosol generating film covering the inside of the capsule is selected from the group consisting of hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethyl methylcellulose (HEMC), hydroxyethylcellulose (HEC), hydroxypropylcellulose (HPC), and combinations thereof, preferably the cellulose-based film-forming agent is selected from the group consisting of hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), and combinations thereof, and more preferably the cellulose-based film-forming agent is hydroxypropyl methylcellulose (HPMC). Example 28: An aerosol generating article according to any one of Examples 25 to 27, wherein the aerosol generating film covering the inside of the capsule contains, on a dry weight basis, 10% to 40% by weight of a cellulose-based film-forming agent, optionally, 15% to 35% by weight of a cellulose-based film-forming agent, or optionally, 20% to 30% by weight of a cellulose-based film-forming agent. Example 29: The aerosol generating article according to any one of Examples 25 to 28, wherein the aerosol generating film covering the inside of the capsule further contains water, preferably the aerosol generating film contains 30% by weight or less of water. Example 30: The aerosol generating article according to any one of Examples 25 to 29, wherein the aerosol generating film covering the inside of the capsule further comprises a cellulosic reinforcing agent, and optionally, the cellulosic reinforcing agent is selected from the group consisting of cellulose fibers, microcrystalline cellulose (MCC), cellulose powder, and combinations thereof. Example 31: The aerosol generating article according to Example 30, wherein the aerosol generating film covering the inside of the capsule contains 0.5% to 40% by weight of a cellulose-based reinforcing agent on a dry weight basis, optionally 5% to 30% by weight of a cellulose-based reinforcing agent on a dry weight basis, or optionally 10% to 25% by weight of a cellulose-based reinforcing agent on a dry weight basis. Example 32: The aerosol generating article according to any one of Examples 25 to 31, wherein the aerosol generating film covering the inside of the capsule further contains carboxymethylcellulose, and preferably the carboxymethylcellulose is sodium carboxymethylcellulose. Example 33: The aerosol generating article according to Example 32, wherein the aerosol generating film covering the inside of the capsule contains 1% to 15% by weight of carboxymethylcellulose on a dry weight basis, optionally 2% to 12% by weight of carboxymethylcellulose on a dry weight basis, or optionally 4% to 10% by weight of carboxymethylcellulose on a dry weight basis. Example 34: An aerosol generating article according to any one of Examples 25 to 33, wherein the aerosol generating film covering the inside of the capsule has a thickness of 50 micrometers to 1 millimeter, optionally 0.1 to 0.75 millimeters, optionally 0.1 to 0.5 millimeters, optionally 0.1 to 0.4 millimeters, optionally 0.1 to 0.2 millimeters, optionally 0.15 to 0.5 millimeters, optionally 0.2 to 0.4 millimeters, or optionally 0.1 to 0.2 millimeters. Example 35: An aerosol generating article according to any one of Examples 2 to 34, wherein the inner coating of the capsule comprises a second aerosol generating substrate, and the second aerosol generating substrate is in the form of a gel composition comprising an aerosol forming body and at least one gelling agent. Example 36: The aerosol-generating article according to Example 35, wherein the gel composition of the inner coating of the capsule contains glycerol, and optionally, the gel composition of the inner coating has a glycerol content of at least 40% by weight on a dry weight basis. Example 37: The aerosol generating article according to Example 35 or 36, wherein the gel composition for the inner coating of the capsule contains a total amount of gelling agent on a dry weight basis of 0.4 to 10 percent by weight, 0.5 to 8 percent by weight, optionally 1 to 6 percent by weight, optionally 2 to 4 percent by weight, or optionally 2 to 3 percent by weight. Example 38: The aerosol generating article according to any one of Examples 35 to 37, wherein the gel composition of the inner coating of the capsule contains a hydrogen bonding crosslinking gelling agent, and optionally the hydrogen bonding crosslinking gelling agent contains one or more of galactomannan, gelatin, agarose, konjac gum, or agar, preferably the hydrogen bonding crosslinking gelling agent contains agar. Example 39: The aerosol generating article according to any one of Examples 35 to 38, wherein the gel composition of the inner coating of the capsule contains an ion crosslinking gelling agent, optionally comprising one or more of low acylgerane, pectin, kappacarragenan, iotacarragenan, or alginate, and preferably comprising low acylgerane as the hydrogen bonding crosslinking gelling agent. Example 40: The aerosol generating article according to any one of Examples 35 to 39, wherein the gelling agent of the gel composition of the inner coating of the capsule comprises one or more biopolymers, optionally comprising gellan gum, xanthan gum, alginate (alginic acid), agar, guar gum, and preferably comprising xanthan gum. Example 41: An aerosol generating article according to any one of Examples 35 to 40, wherein the gel composition of the inner coating of the capsule contains a thickener, and optionally the gel composition contains the thickener in an amount of 0.2% to 5% by weight on a dry weight basis, optionally 0.5% to 3% by weight on a dry weight basis, optionally 0.5% to 2% by weight on a dry weight basis, or optionally 1% to 2% by weight on a dry weight basis. Example 42: The aerosol generating article according to Example 41, wherein the thickening agent of the gel composition coating the inside of the capsule comprises one or more of xanthan gum, carboxymethylcellulose, microcrystalline cellulose, methylcellulose, gum arabic, guar gum, lambda carrageenan, or starch, preferably the thickening agent comprises xanthan gum. Example 43: An aerosol generating article according to any one of Examples 35 to 42, wherein the gel composition of the inner coating of the capsule contains a divalent cation. Example 44: The aerosol generating article according to any one of Examples 35 to 43, wherein the gel composition of the inner coating of the capsule further contains water, optionally comprising 8 to 32 weight percent water, optionally 15 to 25 weight percent water, optionally 18 to 22 weight percent water, or optionally about 20 weight percent water. Example 45: An aerosol generating article according to any one of Examples 1 to 44, wherein at least one of an aerosol-forming agent, a flavoring agent, and a second aerosol-generating substrate is dispersed within the outer wall of the capsule, and optionally, at least one of the aerosol-forming agent, a flavoring agent, and a second aerosol-generating substrate is uniformly dispersed substantially throughout the outer wall of the capsule. Example 46: The aerosol generating article according to Example 45, wherein the second aerosol generating substrate is dispersed within the outer wall of the capsule. Example 47: The aerosol generating article according to Example 46, wherein the second aerosol generating substrate dispersed within the outer wall of the capsule contains nicotine. Example 48: The aerosol generating article according to Example 46 or 47, wherein the second aerosol generating substrate dispersed within the outer wall of the capsule contains one or more carboxylic acids. Example 49: The aerosol generating article according to Example 48, wherein one or more carboxylic acids of the second aerosol generating substrate dispersed within the outer wall of the capsule are selected from the group consisting of acids, benzoic acid, fumaric acid, and levulinic acid, and preferably, one or more carboxylic acids of the second aerosol generating substrate dispersed within the outer wall of the capsule are selected from the group consisting of lactic acid and levulinic acid. Example 50: An aerosol-generating article according to any one of Examples 45 to 49, wherein the outer wall of the capsule is substantially free of tobacco. Example 51: An aerosol generating article according to any one of Examples 45 to 50, wherein the aerosol-forming material is dispersed within the outer wall of the capsule. Example 52: The aerosol generating article according to Example 51, wherein the aerosol-forming material dispersed within the outer wall of the capsule comprises an aerosol-forming material selected from at least one of polyhydric alcohols, esters of polyhydric alcohols, and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids. Example 53: The aerosol generating article according to Example 51 or 52, wherein the aerosol-forming material dispersed within the outer wall of the capsule contains a polyhydric alcohol selected from at least one of triethylene glycol, propylene glycol, 1,3-butanediol, and glycerol, and preferably the aerosol-forming material dispersed within the outer wall of the capsule contains glycerol. Example 54: The aerosol generating article according to any one of Examples 51 to 53, wherein the aerosol-forming body dispersed within the outer wall of the capsule contains an ester of a polyhydric alcohol selected from at least one of glycerol monoacetate, glycerol diacetate, and glycerol triacetate. Example 55: The aerosol generating article according to any one of Examples 51 to 54, wherein the aerosol-forming body dispersed within the outer wall of the capsule comprises an aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid selected from at least one of dimethyl dodecanediate and dimethyl tetradecanediate. Example 56: An aerosol generating article according to any one of Examples 45 to 55, wherein one or more flavoring agents are dispersed within the outer wall of the capsule. Example 57: An aerosol generating article according to any one of Examples 1 to 56, wherein the capsule is located within an inner coating on at least a portion of the inner surface of the outer wall of the capsule, and comprises at least one of an aerosol-forming body, a flavoring agent, and a second aerosol-generating substrate dispersed within the outer wall of the capsule. Example 58: The aerosol generating article according to Example 57, wherein the capsule comprises a second aerosol generating substrate dispersed within the outer wall of the capsule, and within the inner coating on at least a portion of the inner surface of the outer wall of the capsule, and optionally the second aerosol generating substrate contains nicotine. Example 59: An aerosol-generating article according to any one of Examples 1 to 58, wherein the outer wall of the capsule is formed of an impermeable material. Example 60: An aerosol generating article according to any one of Examples 1 to 59, wherein the outer wall of the capsule is formed of a porous material. Example 61: An aerosol-generating article according to any one of Examples 1 to 60, wherein the outer wall of the capsule contains a polymer material or a cellulose-based material. Example 62: The aerosol generating article according to Example 61, wherein the outer wall of the capsule contains one or more of the following: polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), gelatin, and hydroxypropyl methylcellulose (HPMC). Example 63: The aerosol-generating article according to Example 61 or 62, wherein the outer wall of the capsule comprises one or more medical-grade polymers optionally selected from ALTUGLAS® medical resin polymethyl methacrylate (PMMA), Chevron Phillips K-Resin® styrene-butadiene copolymer (SBC), Arkema specialty performance polymers Pebax®, Rilsan®, and Rilsan® Clear, DOW (Health+®) low-density polyethylene (LDPE), DOW® LDPE91003, DOW® LDPE91020 (MFI2.0; density 923), ExxonMobil® polypropylene (PP) PP1013H1, PP1014H1, and PP9074MED, and Trinseo CALIBRE® polycarbonate (PC) 2060-SERIES. Example 64: An aerosol-generating article according to any one of Examples 1 to 63, wherein the outer wall of the capsule is formed of a punctureable or fragile material. Example 65: An aerosol generating article according to any one of Examples 1 to 64, wherein the upstream end of the outer wall of the capsule includes one or more weak lines or weak regions. Example 66: An aerosol generating article according to any one of Examples 1 to 65, wherein the capsule has an external coating on at least a portion of the outer surface of the outer wall of the capsule. Example 67: An aerosol generating article according to any one of Examples 1 to 66, wherein the first aerosol generating substrate in the internal cavity of the capsule is a solid first aerosol generating substrate. Example 68: The aerosol generating article according to Example 67, wherein the capsule contains a plurality of particles of a solid first aerosol generating substrate within an internal cavity. Example 69: The aerosol-generating article according to Example 68, wherein a plurality of particles of a solid first aerosol-generating substrate comprise at least one of a plurality of beads, pellets, granules, flakes, fragments, or flaks. Example 70: The aerosol generating article according to Example 68 or 69, wherein the particles of the first solid aerosol generating substrate in the internal cavity of the capsule each have a maximum dimension of 0.05 mm or more, optionally 0.1 mm or more, optionally 0.15 mm or more, optionally 0.2 mm or more, optionally 0.25 mm or more, optionally 0.5 mm or more, optionally 0.75 mm or more, or optionally 1 mm or more. Example 71: An aerosol generating article according to any one of Examples 68 to 70, wherein the particles of the first solid aerosol generating substrate in the internal cavity of the capsule each have a maximum dimension of 10 mm or less, optionally 9 mm or less, optionally 8 mm or less, optionally 6 mm or less, or optionally 5 mm or less. Example 72: An aerosol generating article according to any one of Examples 68 to 71, wherein the number of particles of the first solid aerosol generating substrate in the internal cavity of the capsule is 2 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, or optionally 30 or more. Example 73: An aerosol generating article according to any one of Examples 68 to 72, wherein the number of particles of the first solid aerosol generating substrate in the internal cavity of the capsule is 200 or less. Example 74: The aerosol generating article according to Example 68, wherein the first solid aerosol generating substrate in the internal cavity of the capsule is in the form of a powder. Example 75: The aerosol generating article according to Example 74, wherein the powder is in the form of particles having a D50 particle size of 50 to 80 micrometers, optionally 50 to 75 micrometers, optionally 55 to 75 micrometers, optionally 55 to 70 micrometers, or optionally 60 to 70 micrometers. Example 76: The aerosol generating article according to Example 74 or 75, wherein the powder is in the form of particles having a D95 particle size of 80 to 130 micrometers, optionally 90 to 125 micrometers, optionally 100 to 120 micrometers, or optionally 110 to 120 micrometers. Example 77: An aerosol-generating article according to any one of Examples 74 to 76, wherein the powder is in the form of particles having a maximum diameter of 50 to 250 micrometers, optionally 80 to 225 micrometers, or optionally 100 to 125 micrometers. Example 78: The aerosol generating article according to Example 67, wherein the first solid aerosol generating substrate is in the form of one or more sheets, and optionally one or more sheets are crimped, folded, assembled, and pleated, and optionally one or more sheets are cut into strands. Example 79: An aerosol generating article according to any one of Examples 68 to 78, further comprising at least one susceptor within the internal cavity of the capsule. Example 80: The aerosol generating article according to Example 79, wherein the capsule comprises a single susceptor element within the internal cavity of the capsule, or one of a plurality of susceptor particles within the internal cavity, and the plurality of susceptor particles comprises a susceptor material and does not contain an aerosol generating substrate. Example 81: An aerosol generating article according to any one of Examples 1 to 80, wherein the first aerosol generating substrate in the internal cavity comprises an aerosol forming body. Example 82: The aerosol generating article according to Example 81, wherein the first aerosol generating substrate in the internal cavity comprises, optionally, 15% by weight or more of aerosol-forming material on a dry weight basis, 20% by weight or more of aerosol-forming material on a dry weight basis, 25% by weight or more of aerosol-forming material on a dry weight basis, 30% by weight or more of aerosol-forming material on a dry weight basis, 35% by weight or more of aerosol-forming material on a dry weight basis, 40% by weight or more of aerosol-forming material on a dry weight basis, 45% by weight or more of aerosol-forming material on a dry weight basis, 50% by weight or more of aerosol-forming material on a dry weight basis, 60% by weight or more of aerosol-forming material on a dry weight basis, or 70% by weight or more of aerosol-forming material on a dry weight basis. Example 83: The aerosol generating article according to Example 81 or 82, wherein the first aerosol generating substrate in the internal cavity comprises, optionally, an aerosol forming body of 80 weight percent or less on a dry weight basis, an aerosol forming body of 75 weight percent or less on a dry weight basis, or optionally, an aerosol forming body of 70 weight percent or less on a dry weight basis. Example 84: An aerosol generating article according to any one of Examples 81 to 83, wherein the first aerosol generating substrate in the internal cavity comprises an aerosol-forming body selected from at least one of polyhydric alcohols, esters of polyhydric alcohols, and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids. Example 85: The aerosol generating article according to any one of Examples 81 to 84, wherein the aerosol-forming body of the first aerosol-generating substrate in the internal cavity contains a polyhydric alcohol selected from at least one of triethylene glycol, propylene glycol, 1,3-butanediol, and glycerol, and preferably the aerosol-forming body of the first aerosol-generating substrate in the internal cavity contains glycerol. Example 86: The aerosol generating article according to any one of Examples 81 to 85, wherein the aerosol forming body of the first aerosol generating substrate in the internal cavity comprises an ester of a polyhydric alcohol selected from at least one of glycerol monoacetate, glycerol diacetate, and glycerol triacetate. Example 87: The aerosol generating article according to any one of Examples 81 to 86, wherein the aerosol-forming body of the first aerosol-generating substrate in the internal cavity comprises an aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid selected from at least one of dimethyl dodecanediate and dimethyl tetradecanediate. Example 88: An aerosol generating article according to any one of Examples 81 to 83, wherein the first aerosol generating substrate in the internal cavity comprises, optionally, 15% to 80% by weight of glycerol on a dry weight basis, 20% to 80% by weight of glycerol on a dry weight basis, Optionally, 25% to 80% by weight of glycerol on a dry weight basis, Optionally, 30% to 75% by weight of glycerol on a dry weight basis, Optionally, 35% to 75% by weight of glycerol on a dry weight basis, Optionally, 40% to 70% by weight of glycerol on a dry weight basis, Optionally, 45% to 70% by weight of glycerol on a dry weight basis, or Optionally, 50% to 70% by weight of glycerol on a dry weight basis. Example 89: An aerosol generating article according to any one of Examples 1 to 88, wherein the first aerosol generating substrate in the internal cavity contains nicotine. Example 90: The aerosol generating article according to Example 89, wherein the first aerosol generating substrate in the internal cavity contains, on a dry weight basis, at least 0.5 weight percent of nicotine, optionally at least 1 weight percent of nicotine, on a dry weight basis, or optionally at least 2 weight percent of nicotine. Example 91: The aerosol generating article according to Example 89 or 90, wherein the first aerosol generating substrate in the internal cavity contains 10% by weight or less of nicotine on a dry weight basis, optionally 8% by weight or less of nicotine on a dry weight basis, or optionally 6% by weight or less of nicotine on a dry weight basis. Example 92: The aerosol generating article according to any one of Examples 1 to 91, wherein the first aerosol generating substrate in the internal cavity comprises one or more carboxylic acids, and optionally, one or more carboxylic acids are selected from the group consisting of acids, benzoic acid, fumaric acid, and levulinic acid, preferably, one or more carboxylic acids are selected from the group consisting of lactic acid and levulinic acid. Example 93: The aerosol generating article according to Example 92, wherein the first aerosol generating substrate in the internal cavity contains 0.5% by weight or more of carboxylic acid on a dry weight basis, optionally 1% by weight or more of carboxylic acid on a dry weight basis, or optionally 2% by weight or more of carboxylic acid on a dry weight basis. Example 94: The aerosol generating article according to Example 92 or 93, wherein the first aerosol generating substrate in the internal cavity contains 15% by weight or less of a carboxylic acid on a dry weight basis, optionally less than 10% by weight of a carboxylic acid on a dry weight basis, or optionally less than 5% by weight of a carboxylic acid on a dry weight basis. Example 95: An aerosol generating article according to any one of Examples 92 to 94, wherein the first aerosol generating substrate in the internal cavity contains, optionally, 0.5 to 15 weight percent of carboxylic acid on a dry weight basis, 1 to 10 weight percent of carboxylic acid on a dry weight basis, optionally, 2 to 5 weight percent of carboxylic acid on a dry weight basis, optionally, 0.25 to 3.5 weight percent of carboxylic acid on a dry weight basis, optionally, 0.5 to 3 weight percent of carboxylic acid on a dry weight basis, or optionally, 1 to 2.5 weight percent of carboxylic acid on a dry weight basis. Example 96: An aerosol generating article according to any one of Examples 1 to 95, wherein the first aerosol generating substrate in the internal cavity is substantially free of tobacco. Example 97: An aerosol generating article according to any one of Examples 1 to 96, wherein the first aerosol generating substrate in the internal cavity of the aerosol generating film optionally comprises a cellulose-based film-forming agent, nicotine, and an aerosol-forming agent. Example 98: The aerosol generating article according to Example 97, wherein the aerosol generating film in the internal cavity contains glycerol, and optionally the aerosol generating film has a glycerol content of at least 40 weight percent on a dry weight basis. Example 99: The aerosol generating article according to Example 97 or 98, wherein the cellulose-based film-forming agent of the aerosol-generating film in the internal cavity is selected from the group consisting of hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethyl methylcellulose (HEMC), hydroxyethylcellulose (HEC), hydroxypropylcellulose (HPC), and combinations thereof, preferably the cellulose-based film-forming agent is selected from hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), and combinations thereof, and more preferably the cellulose-based film-forming agent is hydroxypropyl methylcellulose (HPMC). Example 100: An aerosol generating article according to any one of Examples 97 to 99, wherein the aerosol generating film in the internal cavity contains, on a dry weight basis, 10% to 40% by weight of a cellulose-based film-forming agent, optionally, 15% to 35% by weight of a cellulose-based film-forming agent, or optionally, 20% to 30% by weight of a cellulose-based film-forming agent. Example 101: The aerosol generating article according to any one of Examples 97 to 100, wherein the aerosol generating film in the internal cavity further contains water, preferably the aerosol generating film contains 30% by weight or less of water. Example 102: The aerosol generating article according to any one of Examples 97 to 101, wherein the aerosol generating film in the internal cavity further contains a cellulosic reinforcing agent, and optionally the cellulosic reinforcing agent is selected from the group consisting of cellulose fibers, microcrystalline cellulose (MCC), cellulose powder, and combinations thereof. Example 103: The aerosol generating article according to Example 102, wherein the aerosol generating film in the internal cavity contains 0.5% to 40% by weight of a cellulose-based reinforcing agent on a dry weight basis, optionally 5% to 30% by weight of a cellulose-based reinforcing agent on a dry weight basis, or optionally 10% to 25% by weight of a cellulose-based reinforcing agent on a dry weight basis. Example 104: The aerosol generating article according to any one of Examples 97 to 103, wherein the aerosol generating film in the internal cavity further contains carboxymethylcellulose, and preferably the carboxymethylcellulose is sodium carboxymethylcellulose. Example 105: The aerosol generating article according to Example 104, wherein the aerosol generating film in the internal cavity contains 1% to 15% by weight of carboxymethylcellulose on a dry weight basis, optionally 2% to 12% by weight of carboxymethylcellulose on a dry weight basis, or optionally 4% to 10% by weight of carboxymethylcellulose on a dry weight basis. Example 106: An aerosol generating article according to any one of Examples 97 to 105, wherein the aerosol generating film in the internal cavity has a thickness of 50 micrometers to 1 millimeter, optionally 0.1 millimeters to 1 millimeter, optionally 0.1 millimeters to 0.75 millimeters, optionally 0.1 millimeters to 0.5 millimeters, optionally 0.1 millimeters to 0.4 millimeters, optionally 0.1 millimeters to 0.2 millimeters, optionally 0.15 millimeters to 0.5 millimeters, optionally 0.2 millimeters to 0.4 millimeters, or optionally 0.1 millimeters to 0.2 millimeters. Example 107: An aerosol generating article according to any one of Examples 97 to 106, wherein an aerosol generating film in an internal cavity is provided on a carrier element. Example 108: An aerosol generating article according to any one of Examples 1 to 107, wherein the first aerosol generating substrate in the internal cavity comprises a gel composition containing at least one gelling agent. Example 109: The aerosol generating article according to Example 108, wherein the gel composition of the first aerosol generating substrate in the internal cavity contains a total amount of gelling agent of 0.4 to 10 percent by dry weight, 0.5 to 8 percent by dry weight, optionally 1 to 6 percent by dry weight, optionally 2 to 4 percent by dry weight, or optionally 2 to 3 percent by dry weight, on a dry weight basis. Example 110: The aerosol generating article according to Example 108 or 109, wherein the gel composition of the first aerosol generating substrate in the internal cavity comprises a hydrogen bonding crosslinking gelling agent, optionally comprising one or more of galactomannan, gelatin, agarose, konjac gum, or agar, preferably comprising agar as the hydrogen bonding crosslinking gelling agent. Example 111: The aerosol generating article according to any one of Examples 108 to 110, wherein the gel composition of the first aerosol generating substrate in the internal cavity comprises an ion crosslinking gelling agent, optionally comprising one or more of low acylgerane, pectin, kappacarragenan, iotacarragenan, or alginate, and preferably comprising low acylgerane as the hydrogen bonding crosslinking gelling agent. Example 112: The aerosol generating article according to any one of Examples 108 to 111, wherein the gelling agent of the gel composition of the first aerosol generating substrate in the internal cavity comprises one or more biopolymers, optionally comprising gellan gum, xanthan gum, alginate (alginic acid), agar, guar gum, and preferably comprising xanthan gum. Example 113: The aerosol generating article according to any one of Examples 108 to 112, wherein the gel composition of the first aerosol generating substrate in the internal cavity contains a thickener, and optionally the gel composition contains the thickener in an amount of 0.2% to 5% by weight on a dry weight basis, optionally 0.5% to 3% by weight on a dry weight basis, optionally 0.5% to 2% by weight on a dry weight basis, or optionally 1% to 2% by weight on a dry weight basis. Example 114: The aerosol generating article according to Example 113, wherein the thickener of the gel composition of the first aerosol generating substrate in the internal cavity comprises one or more of xanthan gum, carboxymethylcellulose, microcrystalline cellulose, methylcellulose, gum arabic, guar gum, lambda carrageenan, or starch, preferably the thickener comprises xanthan gum. Example 115: An aerosol generating article according to any one of Examples 108 to 114, wherein the gel composition of the first aerosol generating substrate in the internal cavity contains a divalent cation. Example 116: An aerosol-generating article according to any of Examples 1 to 115, wherein the internal cavity has a volume of 250 cubic millimeters or more, optionally 400 cubic millimeters or more, optionally 500 cubic millimeters or more, or optionally 600 cubic millimeters or more. Example 117: An aerosol-generating article according to any of Examples 1 to 116, wherein the internal cavity has a volume of 2000 cubic millimeters or less, optionally 1500 cubic millimeters or less, or optionally 1000 cubic millimeters or less. Example 118: An aerosol generating article according to any of Examples 1 to 117, wherein the capsule has a length of 10 mm or more, optionally 12 mm or more, optionally 15 mm or more, or optionally 18 mm or more. Example 119: An aerosol generating article according to any of Examples 1 to 118, wherein the capsule has a length of 30 mm or less, optionally 28 mm or less, or optionally 25 mm or less. Example 120: An aerosol generating article according to any of Examples 1 to 119, wherein the capsule has a maximum diameter of 5 mm or more, optionally 5.5 mm or more, optionally 6 mm or more, or optionally 6.5 mm or more. Example 121: An aerosol generating article according to any of Examples 1 to 120, wherein the capsule has a maximum diameter of 9 mm or less, optionally 8.5 mm or less, optionally 8 mm or less, or optionally 7.5 mm or less. Example 122: An aerosol generating article according to any of Examples 1 to 121, wherein the capsule has one of the shapes of a spherical cylinder, a sphere, or an egg shape. Example 123: The aerosol generating article according to any of Examples 1 to 122, wherein the capsule is a two-part capsule in the form of two separate parts, optionally the two separate parts are joined together by either or both of friction fitting and adhesive, optionally one of the two separate parts defines the upstream end of the capsule and the other of the two separate parts defines the downstream end of the capsule, and optionally the two separate parts have one or more of different sizes and shapes from each other. Example 124: An aerosol generating article according to any one of Examples 1 to 123, wherein the internal cavity contains 50 milligrams or more of a first aerosol generating substrate, optionally 100 milligrams or more of a first aerosol generating substrate, or optionally 150 milligrams or more of a first aerosol generating substrate. Example 125: An aerosol generating article according to any one of Examples 1 to 124, wherein the internal cavity contains a first aerosol generating substrate of 1000 milligrams or less, optionally a first aerosol generating substrate of 750 milligrams or less, optionally a first aerosol generating substrate of 500 milligrams or less, or optionally a first aerosol generating substrate of 250 milligrams or less. Example 126: An aerosol generating article according to any of Examples 1 to 125, wherein the total mass of the first aerosol generating substrate divided by the volume of the internal cavity is 0.1 milligrams / cubic millimeter or more, optionally 0.12 milligrams / cubic millimeter or more, optionally 0.15 milligrams / cubic millimeter or more, optionally 0.18 milligrams / cubic millimeter or more, optionally 0.2 milligrams / cubic millimeter or more, optionally 0.22 milligrams / cubic millimeter or more, optionally 0.25 milligrams / cubic millimeter or more, optionally 0.28 milligrams / cubic millimeter or more, optionally 0.3 milligrams / cubic millimeter or more, optionally 0.32 milligrams / cubic millimeter or more, optionally 0.35 milligrams / cubic millimeter or more, optionally 0.38 milligrams / cubic millimeter or more, or optionally 0.4 milligrams / cubic millimeter or more. Example 127: An aerosol generating article according to any of Examples 1 to 126, wherein the total mass of the first aerosol generating substrate divided by the volume of the internal cavity is 2 milligrams / cubic millimeter or less, optionally 1.9 milligrams / cubic millimeter or less, optionally 1.8 milligrams / cubic millimeter or less, optionally 1.7 milligrams / cubic millimeter or less, optionally 1.6 milligrams / cubic millimeter or less, optionally 1.5 milligrams / cubic millimeter or less, optionally 1.4 milligrams / cubic millimeter or less, optionally 1.3 milligrams / cubic millimeter or less, optionally 1.2 milligrams / cubic millimeter or less, optionally 1.1 milligrams / cubic millimeter or less, or optionally 1 milligrams / cubic millimeter or less. Example 128: An aerosol generating article according to any of Examples 1 to 127, wherein the first aerosol generating substrate in the internal cavity fills 50 percent or more of the internal cavity's volume, optionally 60 percent or more of the internal cavity's volume, or optionally 70 percent or more of the internal cavity's volume. Example 129: An aerosol generating article according to any of Examples 1 to 128, wherein the first aerosol generating substrate in the internal cavity fills 90 percent or less of the volume of the internal cavity. Example 130: An aerosol generating article according to any one of Examples 1 to 129, wherein the capsule further comprises at least one air intake and at least one air outlet on the outer wall of the capsule, and the at least one air intake and at least one air outlet define one or more airflow paths through an internal cavity. Example 131: The aerosol generating article according to Example 130, wherein at least one air outlet is provided downstream of at least one air intake. Example 132: The aerosol-generating article according to Example 130 or 131, wherein at least one air intake port of the outer wall of the capsule is provided at the upstream end of the capsule. Example 133: The aerosol generating article according to Example 130 or 131, wherein at least one air intake port on the outer wall of the capsule is provided at least 2 millimeters downstream from the upstream end of the capsule, optionally at least 3 millimeters downstream from the upstream end of the capsule, optionally at least 4 millimeters downstream from the upstream end of the capsule, or optionally at least 5 millimeters downstream from the upstream end of the capsule. Example 134: An aerosol-generating article according to any one of Examples 130 to 133, wherein at least one air outlet of the outer wall of the capsule is provided at the downstream end of the capsule. Example 135: The aerosol generating article according to any one of Examples 130 to 134, wherein at least one air intake port on the outer wall of the capsule is provided at least 5 millimeters downstream from at least one air intake port, optionally at least 8 millimeters downstream from at least one air intake port, or optionally at least 10 millimeters downstream from at least one air intake port. Example 136: An aerosol generating article according to any one of Examples 130 to 135, wherein the capsule is equipped with multiple air outlets, optionally the capsule is equipped with 2 to 6 air outlets, and optionally the capsule is equipped with 4 to 5 air outlets. Example 137: An aerosol generating article according to any one of Examples 130 to 136, wherein the capsule has the same number of air intake ports as the number of air outlets. Example 138: An aerosol generating article according to any one of Examples 130 to 136, wherein the capsule has more air outlets than air intakes. Example 139: An aerosol generating article according to any one of Examples 130 to 138, wherein at least one air intake is provided on the cylindrical wall of the capsule. Example 140: The aerosol generating article according to any one of Examples 130 to 139, wherein each of at least one air intake and at least one air outlet is in the form of a hole passing through the outer wall of the capsule, preferably each hole being circular. Example 141: An aerosol generating article according to any one of Examples 130 to 140, wherein each hole forming at least one air intake and at least one air outlet has a diameter of 0.2 mm or more, optionally 0.25 mm or more, optionally 0.3 mm or more, optionally 0.35 mm or more, optionally 0.4 mm or more, or optionally 0.5 mm or more. Example 142: An aerosol generating article according to any one of Examples 130 to 141, wherein each hole forming at least one air intake and at least one air outlet has a diameter of 2 mm or less, optionally 1.8 mm or less, optionally 1.6 mm or less, optionally 1.4 mm or less, optionally 1.2 mm or less, optionally 1 mm or less, optionally 0.9 mm or less, or optionally 0.8 mm or less. Example 143: An aerosol generating article according to any one of Examples 130 to 142, wherein each hole forming at least one air intake or at least one air outlet is separated from each other by a gap of at least 1 millimeter. Example 144: An aerosol generating article according to any one of Examples 1 to 143, wherein the aerosol generating article comprises a hollow tubular element, preferably the hollow tubular element extending to the downstream end of the aerosol generating article. Example 145: The aerosol generating article according to Example 144, wherein the capsule is mounted inside a hollow tubular element, and optionally the capsule is mounted on the upstream end of the hollow tubular element. Example 146: An aerosol-generating article according to Example 144 or 145, wherein a tubular element defines an empty cavity downstream of the capsule. Example 147: The aerosol generating article according to Example 146, wherein the empty cavity has a length of 10 mm or more, optionally the empty cavity has a length of 12 mm or more, and optionally the empty cavity has a length of 14 mm or more. Example 148: The aerosol generating article according to Example 146 or 147, wherein the empty cavity has a length of 40 mm or less, optionally the empty cavity has a length of 30 mm or less, and optionally the empty cavity has a length of 40 mm or less. Example 149: An aerosol generating article according to any one of Examples 144-148 and any one of Examples 130-143, wherein the capsule protrudes from the upstream end of a hollow tubular element such that at least one air intake is located outside the hollow tubular element. Example 150: An aerosol generating article according to any one of Examples 144 to 149, wherein 20 percent or more of the length of the capsule protrudes from a hollow tubular element, or optionally, 30 percent or more of the length of the capsule protrudes from a hollow tubular element. Example 151: An aerosol-generating article according to any one of Examples 144 to 150, wherein 50 percent or less of the length of the capsule protrudes from a hollow tubular element. Example 152: An aerosol generating article according to any one of Examples 144 to 151, wherein the hollow tubular element has a length of 25 mm or more, optionally 28 mm or more, optionally 30 mm or more, optionally 32 mm or more, or optionally 34 mm or more. Example 153: An aerosol generating article according to any one of Examples 144 to 152, wherein the hollow tubular element has a length of 50 mm or less, optionally 48 mm or less, optionally 45 mm or less, optionally 42 mm or less, or optionally 40 mm or less. Example 154: An aerosol generating article according to any one of Examples 144 to 153, wherein the hollow tubular element has an outer diameter of 5 mm to 12 mm, optionally 5 mm to 10 mm, or optionally 6 mm to 8 mm. Example 155: An aerosol generating article according to any one of Examples 144 to 154, wherein the hollow tubular element has an inner diameter of 5 mm or more, optionally 5.5 mm or more, optionally 6 mm or more, or optionally 6.5 mm or more. Example 156: An aerosol generating article according to any one of Examples 144 to 155, wherein the hollow tubular element has an inner diameter of 9 mm or less, optionally 8.5 mm or less, optionally 8 mm or less, or optionally 7.5 mm or less. Example 157: An aerosol generating article according to any one of Examples 144 to 156, wherein the hollow tubular element has a wall thickness of 100 micrometers or more, optionally 150 micrometers or more, optionally 200 micrometers or more, optionally 250 micrometers or more, or optionally 500 micrometers or more. Example 158: An aerosol generating article according to any one of Examples 144 to 157, wherein the hollow tubular element has a wall thickness of 2 mm or less, optionally 1.5 mm or less, optionally 1.25 mm or less, or optionally 1 mm or less. Example 159: An aerosol-generating article according to any one of Examples 144 to 158, wherein the outer diameter of the capsule is smaller than the inner diameter of the hollow tubular element, optionally, the outer diameter of the capsule is at least 0.2 mm smaller than the inner diameter of the hollow tubular element, optionally, the outer diameter of the capsule is at least 0.5 mm smaller than the inner diameter of the hollow tubular element, or optionally, the outer diameter of the capsule is at least 0.8 mm smaller than the inner diameter of the hollow tubular element. Example 160: The aerosol-generating article according to Example 159, wherein the outer diameter of the capsule is 0.2 millimeters or less smaller than the inner diameter of the hollow tubular element. Example 161: An aerosol generating article according to any one of Examples 144 to 160, wherein the capsule is mounted inside a hollow tubular element by friction fitting. Example 162: An aerosol-generating article according to any one of Examples 144 to 161, wherein the hollow tubular structure is formed from a material selected from paper, cardboard, or polymer. Example 163: An aerosol generating article according to any one of Examples 144 to 162, wherein the inner wall of a hollow tubular element includes multiple longitudinally oriented corrugations. Example 164: An aerosol generating article according to any one of Examples 144 to 163, wherein the draw-out resistance (RTD) of the hollow tubular element is 10 mmH2O or less, optionally about 5 mmH2O or less, optionally about 2.5 mmH2O or less, optionally 2 mmH2O or less, or optionally 1 mmH2O or less. Example 165: An aerosol generating article according to any one of Examples 144 to 164, wherein the draw-out resistance (RTD) of the hollow tubular element is 0 mmH2O or greater, optionally 0.25 mmH2O or greater, optionally 0.5 mmH2O or greater, or optionally 1 mmH2O or greater. Example 166: An aerosol generating article according to any one of Examples 144 to 165, further comprising a downstream filter segment mounted within a hollow tubular element at the downstream end of the hollow tubular element. Example 167: The aerosol generating article according to Example 166, wherein the downstream filter segment extends to the downstream end of a hollow tubular element, and optionally, the downstream end of the downstream filter segment defines the downstream end of the aerosol generating article. Example 168: The aerosol generating article according to Example 166 or 167, wherein the downstream filter segment is located at least 5 millimeters downstream from the downstream end of the capsule, optionally at least 8 millimeters downstream from the downstream end of the capsule, optionally at least 10 millimeters downstream from the downstream end of the capsule, or optionally at least 15 millimeters downstream from the downstream end of the capsule. Example 169: An aerosol generating article according to any one of Examples 165 to 168, wherein the downstream filter segment is located no more than 30 millimeters downstream from the downstream end of the capsule, or optionally no more than 25 millimeters downstream from the downstream end of the capsule. Example 170: An aerosol generating article according to any one of Examples 165 to 169, wherein the downstream filter segment is formed of a fibrous filter material, and optionally, the downstream filter segment includes a cellulose acetate filter segment formed of cellulose acetate tow. Example 171: An aerosol generating article according to any one of Examples 165 to 170, wherein the downstream filter segment has an outer diameter approximately equal to the inner diameter of the hollow tubular element. Example 172: An aerosol generating article according to any one of Examples 165 to 171, wherein the outer diameter of the downstream filter segment is 5 mm to 12 mm, optionally 6 mm to 10 mm, or 7 mm to 8 mm. Example 173: An aerosol generating article according to any one of Examples 165 to 172, wherein the draw-out resistance (RTD) of the downstream filter segment is 0 mmH2O or greater, optionally 3 mmH2O or greater, or optionally 6 mmH2O or greater. Example 174: An aerosol generating article according to any one of Examples 165 to 173, wherein the draw-out resistance (RTD) of the downstream filter segment is 12 mmH2O or less, optionally 11 mmH2O or less, or optionally 10 mmH2O or less. Example 175: An aerosol generating article according to any one of Examples 165 to 174, wherein the length of the downstream filter segment is 5 millimeters or more, or optionally 8 millimeters or more, or optionally 10 millimeters or more. Example 176: An aerosol generating article according to any one of Examples 165 to 175, wherein the length of the downstream filter segment is 20 mm or less, or optionally 15 mm or less, or optionally 12 mm or less. Example 177: An aerosol-generating article according to any of Examples 1 to 176, wherein the draw-out resistance (RTD) of the aerosol-generating article is 1 mmH2O or more, optionally 2 mmH2O or more, optionally 3 mmH2O or more, optionally 4 mmH2O or more, optionally 5 mmH2O or more, optionally 6 mmH2O or more, optionally 7 mmH2O or more, optionally 8 mmH2O or more, optionally 9 mmH2O or more, optionally 10 mmH2O or more, optionally 15 mmH2O or more, optionally 20 mmH2O or more, optionally 30 mmH2O or more, optionally 40 mmH2O or more, or optionally 50 mmH2O or more. Example 178: An aerosol-generating article according to any of Examples 1 to 177, wherein the draw-out resistance (RTD) of the aerosol-generating article is 170 mmH2O or less, optionally 160 mmH2O or less, optionally 150 mmH2O or less, or optionally 140 mmH2O or less. Example 179: An aerosol generating article according to any of Examples 1 to 178, wherein the length of the aerosol generating article is 40 mm or more, optionally 50 mm or more, or optionally 60 mm or more. Example 180: An aerosol generating article according to any of Examples 1 to 179, wherein the length of the aerosol generating article is 90 mm or less, optionally 85 mm or less, or optionally 80 mm or less. Example 181: An aerosol generating article according to any of Examples 1 to 180, wherein the aerosol generating article has an outer diameter of 5 mm or more, optionally 6 mm or more, or optionally 7 mm or more. Example 182: An aerosol generating article according to any of Examples 1 to 181, wherein the aerosol generating article has an outer diameter of 12 mm or less, optionally about 10 mm or less, optionally about 8 mm or less, or optionally about 7 mm or less. Example 183: An aerosol generating article according to any of Examples 1 to 182, wherein the aerosol generating article has a constant outer diameter along its length. Example 184: Aerosol generation system, an aerosol generating article described in any of Examples 1 to 183, An aerosol generating system comprising: an aerosol generating device having a heating element configured to heat an aerosol generating article; and an aerosol generating system. Example 185: The aerosol generating system according to Example 184, wherein during use, at least one of the aerosol-forming material on the outer wall of the capsule, the flavoring agent, and the second aerosol-generating substrate is heated in front of the first aerosol-generating substrate in the internal cavity of the capsule. Example 186: The aerosol generating system according to Example 184, wherein during use, at least one of the aerosol-forming material on the outer wall of the capsule, the flavoring agent, and the second aerosol-generating substrate is heated after the first aerosol-generating substrate in the internal cavity of the capsule. Example 187: An aerosol generating system according to any one of Examples 184 to 186, wherein the aerosol generating device comprises a device cavity for receiving an aerosol generating article. Example 188: An aerosol generating system according to any one of Examples 184 to 187, wherein the heating element is a resistance heating element. Example 189: An aerosol generating system according to any one of Examples 184 to 187, wherein the heating element is a susceptor. Example 190: The aerosol generating system according to Example 189, wherein the device cavity comprises an inductor coil surrounding a susceptor. Example 191: The aerosol generating system according to any one of Examples 184 to 190, wherein the heating element is one of a blade or a pin. Example 192: An aerosol generating system according to any one of Examples 184 to 191, wherein a heating element is provided in the device cavity such that the heating element is inserted into a capsule when an aerosol generating article is received into the device cavity. Example 193: An aerosol generating system according to any one of Examples 184 to 192, wherein the heating element penetrates the capsule when the aerosol generating article is received into the device cavity. Example 194: The aerosol generating system according to Example 193, wherein the heating element penetrates the upstream end of the capsule when the aerosol generating article is received into the device cavity. Example 195: The aerosol generating system according to Example 194, wherein one or more weak lines or weak regions on the upstream end of the capsule are configured to rupture when an aerosol generating article is received into the device cavity, due to the penetration of a heating element into the upstream end of the capsule. Example 196: The aerosol generating system according to Example 195, wherein the capsule does not substantially move relative to one or both of the hollow tubular element and the aerosol generating article when the aerosol generating article is received in the device cavity. Example 197: An aerosol generating system according to any one of Examples 184 to 190, wherein a heating element is provided around the periphery of the device cavity such that the heating element at least partially surrounds the capsule when an aerosol generating article is received into the device cavity. Example 198: An aerosol generating system according to any one of Examples 184 to 197, wherein the device cavity comprises a distal end and a proximal end, the distal end of the device cavity being a closed end and the proximal end of the device cavity being an open end. Example 199: An aerosol generating system according to any one of Examples 184 to 198, wherein the cross-sectional shape of the device cavity is substantially the same as the cross-sectional shape of the aerosol generating article. Example 200: An aerosol generating system according to any one of Examples 184 to 199, wherein the apparatus cavity has a substantially circular cross-sectional area. Example 201: An aerosol generating system according to any one of Examples 184 to 200, wherein the length of the device cavity is greater than the length of the capsule. Example 202: An aerosol generating system according to any one of Examples 184 to 201, wherein the capsule is completely located within the device cavity when the aerosol generating article is received into the device cavity. Example 203: An aerosol generating system according to any one of Examples 184 to 202, wherein the apparatus cavity has a length of 15 mm to 80 mm, optionally 20 mm to 70 mm, optionally 25 mm to 60 mm, optionally 25 mm to 50 mm, optionally 25 mm to 29 mm, optionally 26 mm to 29 mm, or optionally 27 mm or 28 mm. Example 204: An aerosol generating system according to any one of Examples 184 to 203, wherein the apparatus cavity has a diameter of 4 mm to 10 mm, optionally 5 mm to 9 mm, optionally 6 mm to 8 mm, or 6 mm to 7 mm. Example 205: An aerosol generating system according to any one of Examples 184 to 204, wherein the diameter of the device cavity is greater than or equal to the outer diameter of the aerosol generating article, and optionally, the diameter of the device cavity is substantially the same as the outer diameter of the aerosol generating article. Example 206: An aerosol generating system according to any one of Examples 184 to 205, wherein the aerosol generating device further comprises a power supply. Example 207: An aerosol generating system according to any one of Examples 184 to 206, wherein the aerosol generating device further comprises a penetration device for penetrating a capsule when an aerosol generating article is inserted into the device cavity. Example 207: The aerosol generating system according to any one of Examples 184 to 206, wherein the aerosol generating device further comprises a controller. Example 208: The aerosol generating system according to Example 207, wherein the aerosol generator is controlled by a controller and configured to operate at temperatures between approximately 150 degrees Celsius and approximately 300 degrees Celsius. Example 209: A method for manufacturing capsules for aerosol-generating articles, To provide a capsule outer wall that defines the internal cavity, Applying an inner coating to at least a portion of the inner surface of the outer wall of the capsule, A method comprising forming at least one of an air intake and an air outlet by penetrating the outer wall of the capsule after the application of an inner coating. Example 210: A method for producing a capsule according to Example 209, further comprising providing a first aerosol-generating substrate into the internal cavity of the capsule. Example 211: A method for manufacturing a capsule according to Example 210, further comprising providing the capsule as a two-part capsule in the form of two separate parts. Example 212: A method for manufacturing a capsule according to Example 211, further comprising joining two separate parts together by friction fitting and / or adhesive, wherein the two separate parts are joined together after applying an inner coating to at least a portion of the inner surface of the outer wall of the capsule and after providing a first aerosol generating substrate within the internal cavity of the capsule. Example 213: A method for producing a capsule according to any one of Examples 210 to 212, wherein the inner coating applied to at least a portion of the inner surface of the outer wall of the capsule comprises at least one of an aerosol-forming agent, a flavoring agent, and a second aerosol-generating substrate. Example 214: A method for producing an aerosol generating article as described in any one of Examples 1 to 183, A method comprising a method for producing a capsule as described in any one of Examples 209 to 213. Example 215: A method for manufacturing an aerosol-generating article, To provide a capsule manufactured according to the method described in any one of Examples 209 to 213, To provide a hollow tubular element, A method comprising: inserting a capsule at least partially into a hollow tubular element to form an aerosol-generating article. Example 216: The method according to Example 215, wherein the aerosol-generating article includes any of the features of Examples 1 to 183.

[0317] The present invention will be further described with reference to the attached drawings, for illustrative purposes only.

[0318] Figure 1 shows an aerosol generating article 10 comprising a hollow tubular element 12 and a capsule 14 attached to the upstream end of the hollow tubular element 12. The aerosol generating article 10 extends from an upstream or distal end 16 substantially coinciding with the upstream end of the capsule 14 to a downstream or oral end 18 coinciding with the downstream end of the hollow tubular element 12.

[0319] The aerosol generating article 10 has an overall length of approximately 45 mm and an outer diameter of approximately 7.2 mm.

[0320] The hollow tubular element 12 is formed from a cylindrical cardboard tube with a wall thickness of approximately 0.25 millimeters. The hollow tubular element 12 defines an internal channel. The hollow tubular element 12 has a length of approximately 45 millimeters, an outer diameter of approximately 7.2 millimeters, and an inner diameter of approximately 6.7 millimeters. The capsule 14 is mounted at the upstream end within the internal channel of the hollow tubular element 12.

[0321] Figure 2 shows a more detailed view of a suitable capsule 14 for use with the aerosol generating article 10 shown in Figure 1.

[0322] Capsule 14 is a two-part capsule formed from an impermeable polymer such as HPMC. Capsule 14 has an elongated capsule (spherical cylindrical) shape with a round cross-section. The capsule comprises a capsule outer wall 20 and an inner coating 21 that covers the entire inner surface of the capsule outer wall 20. The outer wall 20 and the inner coating 21 define an internal cavity 22 containing a plurality of beads 24 of a first aerosol generating substrate, which is a solid first aerosol generating substrate containing nicotine. The inner coating contains a second aerosol generating substrate containing nicotine, an aerosol formizer, and a flavoring agent. The capsule outer wall 20 is defined by a cylindrical wall 26 and opposing hemispherical end walls 28 formed integrally with the cylindrical wall 26. Capsule 14 has a length of approximately 20 millimeters and an outer diameter of approximately 6.7 millimeters. Thus, the outer diameter of capsule 14 is similar to the inner diameter of the hollow tubular element 12, and the capsule is held within the hollow tubular element 12 by friction fitting.

[0323] The downstream filter segment 50 extends from the capsule 14 through a gap and defines an empty cavity 52 inside the hollow tubular element 12. The empty cavity 52 has a length of approximately 25 millimeters. The downstream filter segment 50 extends to the downstream end of the hollow tubular element 12, and the downstream end of the downstream filter segment 50 substantially coincides with the downstream end of the aerosol generating article 10.

[0324] The downstream filter segment 50 has a length of approximately 10 millimeters and comprises a low-density cellulose acetate filter segment. The RTD of the downstream filter segment 50 is approximately 10 mmH2O.

[0325] The capsule 14 is mounted within the hollow tubular element 12 such that approximately 30 percent of the capsule 14 extends beyond the upstream end of the hollow tubular element 12. Thus, the capsule 14 protrudes from the upstream end of the hollow tubular element 12, and the upstream end of the capsule 14 defines the upstream end 16 of the aerosol generating article 10.

[0326] The capsule has an internal volume of approximately 600 cubic millimeters and contains approximately 200 milligrams of solid primary aerosol generating substrate. Therefore, the capsule contains approximately 0.33 milligrams / cubic millimeter of primary aerosol generating substrate in its internal cavity 22.

[0327] The capsule 14 is equipped with a plurality of air outlets 30, each of which is in the form of a hole extending through the outer wall 20 of the capsule and has a diameter of approximately 0.5 millimeters. The plurality of air intakes 30 are separated by gaps in a circular formation on the upstream end wall 28 of the capsule 14.

[0328] The capsule 14 further comprises a plurality of air outlets 32, each of which extends through the outer wall 20 of the capsule and is in the form of a hole having a diameter of approximately 0.5 millimeters. The plurality of air outlets 32 are separated by gaps in a circular formation on the downstream end wall 29 of the capsule 14.

[0329] The projection of the capsule 14 from the upstream end of the hollow tubular element 12 means that the air intake 30 is located outside the hollow tubular element 12.

[0330] The air intake port 30 and the air outlet port 32 are arranged at opposing ends of the capsule 14 so as to be substantially symmetrical to each other.

[0331] The arrangement of the air intake port 30 and air outlet port 32 defines multiple airflow paths through the internal cavity 22 of the capsule 14 so that ambient air can be drawn out through the capsule 14 and in contact with the solid first aerosol generating substrate beads 24 during heating. The aerosol generated from the solid first aerosol generating substrate beads 24 as it heats up is drawn out of the capsule 14 along the hollow tubular element 12 through the air outlet port 32, together with the ambient air, to the downstream end 18 of the aerosol generating article 10.

[0332] Capsule 14 has one or more weak lines or weak regions on its upstream end (not shown), which will be described in more detail below.

[0333] Each of the beads 24 of the solid first aerosol generating substrate contained within the capsule 14 is spherical in shape with a diameter of 0.8 millimeters. The beads are formed from a gel composition having the following composition: [Table 1] JPEG2026512623000002.jpg3897

[0334] Figure 3 shows a more detailed diagram of a suitable alternative capsule 114 for use in the aerosol generating article 10 of Figure 1. Capsule 114 differs from capsule 14 in that it does not include an inner coating covering the inner surface of the capsule outer wall 120. Instead, a second aerosol generating substrate containing nicotine, an aerosol formizer, and a flavoring agent is dispersed within the capsule outer wall 120. Furthermore, capsule 114 differs from capsule 14 in that it contains multiple flakes of an aerosol generating film 124 containing a first aerosol generating substrate having the following composition: [Table 2] JPEG2026512623000003.jpg38115

[0335] Figure 4a shows an aerosol generating system 2000 according to a first embodiment of the present invention. The aerosol generating system 2000 comprises an aerosol generating article 10 as described above. The aerosol generating system 2000 further comprises an aerosol generating device 200. The aerosol generating device 200 comprises a device housing 245. The device housing 245 defines a device cavity 242 for receiving the upstream end of the aerosol generating article 10. The device cavity 242 has an inner diameter substantially corresponding to the outer diameter of the aerosol generating article 10. The aerosol generating device 200 further comprises a heater element 240 in which a heating element 240 is provided around the periphery of the device cavity 242. In this embodiment, the heating element 240 is a resistance heating element, but of course, other types of heating elements may be used. The heating element 240 surrounds a capsule 14 when the aerosol generating article 10 is received in the device cavity 242. As a result, during use, the second aerosol-generating substrate, aerosol-forming body, and flavoring agent of the inner coating 21 of the capsule 14 are heated in front of the solid first aerosol-generating substrate beads 24 in the internal cavity 22 of the capsule 14.

[0336] If the capsule 14 of the aerosol generating article 10 is replaced with capsule 114, it will be understood that, as described above, the second aerosol generating substrate, aerosol forming agent, and flavoring agent dispersed on the outer wall of capsule 114 are heated in front of the flakes 124 of the first aerosol generating substrate in the internal cavity 122 of capsule 114.

[0337] Figure 4b shows an aerosol generating system 3000 according to a second embodiment of the present invention. The aerosol generating system 3000 comprises an aerosol generating article 10 as described above. The aerosol generating system 3000 further comprises an aerosol generating device 300. The aerosol generating device 300 comprises a device housing 345. The device housing 245 defines a device cavity 342 for receiving the upstream end of the aerosol generating article 10. The device cavity 342 has an inner diameter substantially corresponding to the outer diameter of the aerosol generating article 10. The aerosol generating device 300 further comprises a heater element 340 provided within the device cavity 342 such that the heating element 340 is inserted into the capsule 14 when the aerosol generating article 10 is received within the device cavity 342. The heating element 340 penetrates the upstream end of the capsule 14 when the aerosol generating article 10 is received within the device cavity. As a result, during use, the second aerosol generating substrate, aerosol forming body, and flavoring agent of the inner coating 21 of the capsule 14 are heated after the beads 24 of the solid first aerosol generating substrate in the internal cavity 22 of the capsule 14. In this embodiment, the heating element 340 is a heater blade in the form of a susceptor element. The aerosol generator 300 further comprises an inductor coil 341 surrounding the susceptor heating element 340.

[0338] One or more weak lines or weak regions (not shown) on the upstream end of the capsule 14 are configured to break when the aerosol generating article 10 is received into the device cavity 342, by the penetration of the heating element 340 into the upstream end of the capsule 14. As a result, the capsule 14 does not substantially move relative to the hollow tubular element 12 or the aerosol generating article 10 when the aerosol generating article 10 is received into the device cavity.

[0339] If capsule 14 is replaced with capsule 114, it will be understood that, as described above, the second aerosol-generating substrate, aerosol-forming agent, and flavoring agent dispersed on the outer wall of capsule 114 are heated after the flakes 124 of the first aerosol-generating substrate in the internal cavity 122 of capsule 114.

[0340] Figure 5a is an example graph showing the amount of aerosol generated over time in an aerosol generating system 2000 according to a first embodiment of the present invention. As described above, during use, the second aerosol generating substrate, aerosol forming body, and flavoring agent of the inner coating 21 of the capsule 14 are heated in front of the solid first aerosol generating substrate beads 24 in the internal cavity 22 of the capsule 14. As a result, the aerosol provided by the coating 21 is generated more rapidly than the aerosol generated by the solid first aerosol generating substrate beads 24 in the internal cavity 22. Thus, the coating 21 of the capsule 14 reduces the delay between the operation of the heating element 240 and the subsequent aerosol generation. Furthermore, it will be understood that the coating 21 of the capsule 14 increases the total amount of aerosol generated by the aerosol generating system 2000 by providing additional aerosol to the aerosol generated by the beads 24. It will be understood that if capsule 14 is replaced with capsule 114, the graph in Figure 5a will be similar.

[0341] Figure 5b is an example graph showing the amount of aerosol generated over time in an aerosol generating system 3000 according to a second embodiment of the present invention. As described above, during use, the second aerosol generating substrate, aerosol formizer, and flavoring agent of the inner coating 21 of the capsule 14 are heated after the beads 24 of the solid first aerosol generating substrate in the internal cavity 22 of the capsule 14. As a result, the aerosol provided by the coating 21 is generated with a greater delay after the operation of the heater element 340 than the aerosol generated by the beads 24 of the solid first aerosol generating substrate in the internal cavity 22. Thus, the coating 21 of the capsule 14 extends the duration of aerosol generation by providing a boost of aerosol generated from the heating of the coating 21 when the amount of aerosol generated from the beads 24 is decreasing or depleted. Furthermore, it will be understood that the coating 21 of the capsule 14 increases the total amount of aerosol generated by the aerosol generating system 3000 by providing additional aerosol to the aerosol generated by the beads 24. It will be understood that if capsule 14 is replaced with capsule 114, the graph in Figure 5b will be similar.

[0342] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, percentages, etc., are understood to be modified in all cases by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein. Thus, in this context, the figure A is understood as A ± 10%. In this context, the figure A may be considered to include a number that falls within the general standard error of the measurement of the characteristic that figure A modifies. In some cases as used in the appended claims, the figure A may deviate by the percentages listed above, provided that the amount of deviation does not substantially affect the basic and novel characteristics of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein.

Claims

1. An aerosol generating article for generating an inhalable aerosol when heated, wherein the aerosol generating article is It is a capsule, The outer wall of the capsule defines the internal cavity, The first aerosol generating substrate in the internal cavity of the capsule, An aerosol generating article comprising a capsule containing at least one of an aerosol-forming body, a flavoring agent, and a second aerosol-generating substrate, provided inside the outer wall of the capsule, on the surface of the outer wall of the capsule, or both inside and on the outer wall of the capsule.

2. The aerosol generating article according to claim 1, wherein the outer wall of the capsule is formed of an impermeable polymer material.

3. The aerosol generating article according to claim 1 or 2, wherein at least one of the aerosol forming body, flavoring agent, and second aerosol generating substrate is dispersed within at least a portion of the outer wall of the capsule.

4. The aerosol generating article according to any one of claims 1 to 3, wherein the capsule has an inner coating on at least a portion of the inner surface of the outer wall of the capsule, and the inner coating comprises at least one of an aerosol forming body, a flavoring agent, and a second aerosol generating substrate.

5. The aerosol-generating article according to claim 4, wherein the inner coating contains 5% to 40% by weight of glycerol on a dry weight basis.

6. The aerosol generating article according to claim 4 or 5, wherein the inner coating has a thickness of 50 micrometers to 1 millimeter.

7. The aerosol generating article according to any one of claims 1 to 6, wherein the upstream end of the outer wall of the capsule includes one or more weak lines or weak regions.

8. The aerosol generating article according to any one of claims 1 to 7, wherein the first aerosol generating substrate is a solid first aerosol generating substrate, and the capsule contains a plurality of particles of the solid first aerosol generating substrate.

9. The aerosol generating article according to claim 8, wherein the first solid aerosol generating substrate fills at least 50 percent of the volume of the internal cavity.

10. The aerosol generating article according to any one of claims 1 to 9, wherein the capsule comprises the second aerosol generating substrate provided inside the outer wall of the capsule, on the surface of the outer wall of the capsule, or both inside and on the outer wall of the capsule, and the second aerosol generating substrate contains nicotine.

11. The aerosol generating article according to any one of claims 1 to 10, wherein the capsule further comprises at least one air intake and at least one air outlet on the outer wall of the capsule, and the at least one air intake and at least one air outlet define one or more airflow paths through the internal cavity.

12. Aerosol generation system, an aerosol generating article according to any one of claims 1 to 11, An aerosol generating system comprising: an aerosol generating device having a heating element configured to heat the aerosol generating article; and an aerosol generating system.

13. The aerosol generating system according to claim 12, wherein the aerosol generating device further comprises a device cavity for receiving the aerosol generating article, and the heating element is provided in the device cavity such that the heating element is inserted into the capsule when the aerosol generating article is received in the device cavity.

14. The aerosol generating system according to claim 12, wherein the aerosol generating device further comprises a device cavity for receiving the aerosol generating article, and the heating element is provided around the periphery of the device cavity such that the heating element at least partially surrounds the capsule when the aerosol generating article is received in the device cavity.

15. A method for manufacturing an aerosol-generating article, To provide a capsule outer wall that defines the internal cavity, Applying a coating to at least a portion of the inner surface of the outer wall of the capsule, A method comprising forming at least one of an air intake and an air outlet by penetrating the outer wall of the capsule after the coating has been applied.

16. A method for producing a capsule according to claim 15, further comprising providing a first aerosol generating substrate into the internal cavity of the capsule.

17. A method for manufacturing a capsule according to claim 16, further comprising providing the capsule as a two-part capsule in the form of two separate parts.

18. A method for manufacturing a capsule according to claim 17, further comprising joining the two separate parts together by friction fitting and / or adhesive, wherein the two separate parts are joined together after the inner coating has been applied to at least a portion of the inner surface of the outer wall of the capsule and after the first aerosol generating substrate has been provided into the internal cavity of the capsule.

19. A method for producing a capsule according to any one of claims 15 to 18, wherein the inner coating applied to at least a portion of the inner surface of the outer wall of the capsule comprises at least one of an aerosol-forming body, a flavoring agent, and a second aerosol-generating substrate.

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