AU719463B2 - Method for producing a continuous thermoplastic coating and articles constructed therefrom - Google Patents

Description

*48465DIV DP:MN P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant: H B FULLER LICENSING FINANCING, INC Actual Inventor(s): Werenicz, Harald; Wittkopf, Thomas; Voss, Gerhard; Remmers, Peter; Katsaros, Mark; Polance, Robert; Kroll, Mark.

Address for Service: COLLISON CO.,117 King William Street, Adelaide, S.A. 5000 Invention Title: METHOD FOR PRODUCING A CONTINUOUS THERMOPLASTIC COATING AND ARTICLES CONSTRUCTED THEREFROM The following statement is a full description of this invention, including the best method of performing it known to me/us: 1A METHOD FOR PRODUCING A CONTINUOUS THERMOPLASTIC COATING AND ARTICLES CONSTRUCTED THEREFROM Field of the Invention This invention relates to a non-contact coating method for producing a continuous coating and articles constructed therefrom. This invention further relates to a method for producing a textile material with a moistureimpermeable barrier layer and to a method for producing a moistureabsorbing article of hygiene which has such a barrier layer. This invention particularly relates to a textile material and hygienic disposable articles comprising a body fluid impermeable barrier layer which can be produced from said coating method. Preferably, the thermoplastic composition used in S. the coating method for producing the barrier layer exhibits certain rheological 1bi characteristics.

Background of the Invention eo 15 For various applications, materials are required which are impermeable to liquids such as water and body fluids, but at the same time have a textile character which is as close as possible to materials without the impermeability Scharacteristics. One example of such application is hygienic articles such as disposable diapers, feminie napkins, panty liners, surgical drapes, bed pads, and the like. Such hygienic articles often have a substantial absorption capacity. To ensure that the liquid which is to be absorbed does not reach articles of clothing, such hygienic articles customarily have a continuous layer of a body fluid impermeable film on their garment facing side. Since touching this film material is an unwelcome sensation for a number of users, it has been suggested to cover the outward side of the film with a thin layer of textile material so that the article has a textile feel also on its exterior surface.

EP-A-O 187 728 teaches a disposable diaper with a barrier layer in the form of a plastic material film, typically consisting of a polyolefin, a polyacrylate, of PVC, nylon or other thermoplastic material. The barrier film is laminated, adhered or 11 S 2 welded onto a thin nonwoven layer, which makes it necessary to prepare the film laminate off-line. As an alternative, it is suggested that the plastics material of the file is to be extrusion coated onto the non-woven. The laminate, thus formed, is then used as the outermost material layer in such a way that the film layer is on the inside, so that the outer nonwoven layer provides the desired exterior texture. This production method is rather expensive. Highly polymeric plastic materials such as polyethylene, polypropylene, polyacrylate and so on, have low melt flow indices and can (if at all) only be processed into impermeable films on very sophisticated 1 0 machinery. This would also be true for the suggested direct extrusion coating which does not appear to have been reduced to practice yet. Separately producing the film, with subsequent laminating onto the nonwoven, is even more inefficacious in view of the additional production step required.

0S -SUS patents 4,692,161 and 4,627,847 teach a leakage waist barrier for the S 1 5 edge of an absorbent hygienic article provided by coating a hotmelt adhesive onto the edge area of a nonwoven sheet material. Depending on the actual type of application, this hotmelt adhesive can also serve a constructive function, in combination with its function as a barrier, in that it can adhere the nonwoven to other materials of the hygienic article. The hotmelt is to be 20 coated in a conventional matter by slot nozzle coating, transfer coating, spray coating or other such methods. The above-mentioned US patents indicate that the hotmelt coating must have a minimum thickness of 25[tm, preferable at least 75[tm, so that a continuous closed barrier layer is achieved.

Conventional slot nozzle coatings on uneven substrates such as nonwovens 0' 25 are typically done by keeping the slot nozzle in permanent contact with the substrate such that the nozzle lies on the substrate during the coating. It is unproblematic to coat hotmelt adhesives onto uneven substrates with slot nozzles or spray coating methods, provided that only a discontinuous coating is required such as for constructive applications wherein the coating weight of 3 0 the hotmelt ranges from about 3 g/m 2 to about 10 g/m 2 If, however, a continuous layer is to be created, this can 3 only be done using these customary coating methods if the coating weight of the hotmelt is greater than about 30 g/m 2 Such high coating weights are expensive. Furthermore, direct coating with a slot nozzle provides substantial mechanical and thermal stresses on the coated substrates, especially since the slot nozzle is heated during coating. Therefore, ver sensitive substrates such as nonwovens made of very fine or low melting point fibres cannot always be coated with hotmelt from a slot nozzle in a customary manner without damaging the substrate. Such problems cannot be overcome when coating with heated coating rollers or spray coating with heated airstreams.

The high coating weights of this prior art lead to increased stiffness of the coated substrate, thus impairing the textile character.

Similar problems occur in the production of hygienic articles and in other areas, such 15 as fabric production, wherein the resulting materials are required to exhibit liquid impermeability, especially body fluid impermeability, with textile character which is as unimpaired as possible. This is especially pertinent for improving the comfort of the user. Presently, in such technical fields, production methods utilizing preformed laminated films are preferred.

ooo* S20 Therefore, there remains a need for a non-contact method capable of producing a =o o continuous coating layer having low coating weights.

Oleo Summary of Invention A method of coating a thermoplastic composition from a coating device onto a substrate, said method comprising the steps of: making said thermoplastic composition flowable; advancing said substrate along a path; dispensing a continuous film of said thermoplastic compositions from _said coating device; suspending said film of said composition being dispensed between said coating device and said substrate prior to contacting said film with said advancing substrate; wherein the complex viscosity of the thermoplastic composition at the coating temperature is less than 500 poise at 1,000 radians/sec and ranges from 100 to 1000 poise at 1 radian/sec.

The invention further provides a method for producing a moisture-absorbing hygienic article comprising at least one structural element of absorbent

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o go o material, at least one moisture-impermeable, water vapor-permeable inner barrier layer substantially covering the absorbent element and at least one outer layer of textile material which is bonded to the barrier layer on one face, characterized in that for forming the inner barrier layer, a thermoplastic composition is coated as a continuous closed film from a coating device onto the textile material of the outer layer without the coating device contacting the textile material.

The invention is also characterized by a disposable hygienic article, including a first layer, which is a body fluid permeable substrate, and a second layer 10 which is a body fluid impermeable barrier layer formed by the method of any Sone of claims 11 to 14.

600*06 S"Brief Description of the Drawing Figure 1 depicts the method of the present invention wherein a continuous thermoplastic coating is formed and adhered to a carrier substrate.

Detailed Description of the Drawing 6 ooO• Substrate 1 travels past a series of idle rollers to ensure the web is in proper alignment prior to approaching the coating device At start up the coating device is initially in contact with the substrate to adhere the leading edge of the coating to the substrate. As substrate 1 is advanced by the drive rolls the coating device is removed from substrate 1 at a distance most often ranging from about 0.5 mm to about 20 mm, depending on the properties of the thermoplastic composition being coating. Substrate 2 is optionally adhered to the coating surface by means of a nip roll In the preferred embodiment, substrate 2 may be any substrate present in a hygienic article such as an absorbent, elastomeric strands or webs, tissue, films, coverstock materials such as nonwoven or perforated polyethylene, we well as any material that is not necessarily in the form of a web such as superabsorbent polymer.

Detailed Description of the Invention In the method of the present invention, a melted hotmelt adhesive, preferably substantially air-free is released from a coating or release device in such a way that it exits the device S* O S 6 as a continuous film. A typical example for this is a slot nozzle, as it has previously been used for coating in direct contact with a substrate. Thus, melt coating devices which are already at hand can be reset for use according to the invention in that the slot nozzle is lifted off the substrate and is adjusted to have a suitable distance from the substrate.

When the viscous but flowable molten adhesive leaves the coating device, it does not contact the substrate immediately, but rather travels for a distance as a continuous coating film suspended above the substrate without touching either the device or the substrate. The distance between the coating device 1 0 and the substrate ranges from about 0.5 mm to about 20 mm. It is possible that at suitable machine speed settings, and with specific adhesives or other coating materials, the distance can be even greater than 20 mm. The distance is largely dictated by the viscosity and open time of the thermoplastic composition being coated. It is surmised that the thermoplastic composition 1 5 cools sufficiently in its suspended state such that it has built in viscosity and cohesive strength to the extent that the filaments or fibres present on the substrate surface cannot penetrate the coating, yet the thermoplastic composition is molten or soft enough to adequately adhere to the substrate.

:It has been shown to be especially advantageous, that the coating layer 2 0 contacts the substrate in a substantially horizontal direction rather than in a vertical direction. To realise this advantage, a roller can be provided in the path of movement of the substrate to give the substrate a substantially vertical, 2 upward direction, as the substrate passes the coating device. Additionally, the coating device, such as a slot nozzle, can be provided substantially horizontally beside the roller so that the coating travels from the side towards the surface of the substrate.

The diameter of the coating role is preferably about 15 mm to about 50 mm in diameter with the nozzle slightly above the centre of the coating roll such that the angle at which the thermoplastic coating contacts the substrate is less than 3 0 about 600 as the substrate is moving away form the nozzle. The coating head is adjusted by one of ordinary skill in the art to optimise for even flow and distribution of the thermoplastic coating over the entire width of the application.

Thereafter, the sufficiently cooled coating contacts the substrate surface and adheres to the surface without deeply penetrating into the substrate. When the substrate is preferably a textile material such as a nonwoven, the thus produced material comprises the textile substrate layer and a coating, preferably a hotmelt barrier layer. If the thermoplastic coating is of such a composition that it substantially detackifies after sufficient cooling, the laminate of the coated substrate, thus formed, can be rolled up and stored.

The laminate can then be used at some later time, eg as a body fluid impermeable backsheet having improved tactile quality in a disposable hygienic article. The laminate can be bonded by any suitable bonding technique including ultrasonic boding, heat welding, or more commonly adhesive boding.

Preferably, the coating of the barrier layer is done "inline" immediately before 0any further processing of the thus produced coated textile laminate. In such a case, the surface of the barrier layer which is pointing away from the substrate and is still sufficiently tacky can be used for a constructive adhesion step and therefore can also serve to bond the coated textile material to other elements of a hygienic article. Other elements that could by simultaneously bonded in this manner during the formation of the barrier layer include absorbent, superabsorbent polymer, elastomeric strands or webs, tissue, films, as well as various permeable coverstock material such as nonwoven or perforated films.

Since the hotmelt coating can be provided at extremely low temperatures, materials can also be provided with barrier layers which are too sensitive mechanically and/or thermally for customary coating methods.

Such sensitive materials include low gauge polyethylene materials, low basis weight nonwovens and the like. A substantial advantage of the invention is that continuous, sufficiently impermeable barrier layers can be made from hotmelts at very low coating weights. Even with customary commercially available hotmelts, closed barrier layers can be produced at coating weight of not more than 30 g/m 2 and generally, it is easily possible to achieve coating weights between 10 g/m 2 and 20 g/m 2 and most preferably less than 10 g/m 2 As previously stated, the prior art coating of hotmelts according to customary methods for forming edge leakage barriers, as in US patent 4,692,161, requires area weights of about 70 g/m 2 to create the preferred film thickness of around 75 Rm. At thickness of 25 tm, the suggested minimum according to this art, the contact-coated layer is perforated by substrate fibre, and is not closed.

The very thin barrier layers which can be produced according to the invention Sodo not only contribute to the economical advantages of the inventive method, but also make it possible to achieve a very much reduced stiffness of the material, which thus comes much closer, in its properties, to a textile material 15 which is not provided with a barrier layer at all.

The Thermoplastic Composition *69* As previously mentioned, uncompounded thermoplastic materials such as polyolefines, especially polyethylene, polypropylene, amorphous polyolefins such as Vestoplast 703® (Huls) and the like, may be suitable thermoplastic materials for the coating method of the present invention. However, hotmelt adhesives are preferred due to the ability to independently tailor the viscoelastic properties, open time, tack, and various other properties. Hotmelt adhesives commonly have melt flow indices required for such processing already at very low temperatures. Typical hotmelts are fluid enough for such processing at temperatures ranging from about 600 to 1100 C.

More preferably, the thermoplastic composition exhibits certain rheological characteristics such that a continuous, especially a body fluid impermeable coating can be produced at coating weights of less than about 30 g/m 2 In general, the rheological properties preferably fall within a rheological window 3 0 wherein the complex viscosity at high shear rates (1,000 rad/sec) is less than about 500 poise and the complex viscosity at low shear rates 1 rad/sec) is between about 100 and about 1,000 poise. In other words, preferable thermoplastic compositions exhibit Newtonian regions at low shear rates and shear thinning at higher shear rates. Thermoplastic compositions having wide windows of application are those in which the composition exhibits the appropriate rheological properties at a variety of application settings, particularly low temperatures. Narrow application windows are those in which the rheological parameters are only met under very specific conditions. Amorphous polyolefins based hotmelt adhesives such as Lunatack® D-8370 Fuller Company) tend to exhibit relatively flat viscosity curves at low shear rates (less than about 10 rad-sec) and consequently relatively wide application windows. Block copolymer based hotmelt adhesives tend to exhibit particularly steep viscosity profiles causing very narrow application windows.

SData generated that supports this rheological window is depicted-in Table 1.

15 The test procedures used to.determine the rheological data.aredescribed in detail hereinafter.

The applicants surmise that the high shear information relates to the processing conditions at the slot die exit. A composition with too high of a complex viscosity at 1,000 radians/sec would require excessive pump pressure to exit the coating device. A die with a shim gap larger than 3 mm could be used to process these materials but a higher coating weight may result.

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The low shear information relates to the settling of the coating on the substrate during the time it is suspended above the substrate. If the low shear value is too high, the coating may not adhere adequately to the substrate and/or the thermoplastic composition builds up at the nozzle causing a streaked, discontinuous coating. If the low shear viscosity is too low, the coating may seep into the substrate, causing poor barrier properties.

Extensional viscosity, which was not measured can also strongly influence the melt strength. Higher levels of branching or the addition of a small concentration of a high molecular weight material can strongly influence the melt strength. More preferred, are compositions that meet the target rheological parameters at low application temperatures of less than about 125°C, most preferably less than about 110°C.

Accordingly, many known hotmelt adhesive compositions are well suited for use in the coating method of this invention. Hotmelt adhesives typically comprise at least one thermoplastic polymer, at least one plasticiser and at least one tackifying resin. Preferably, such suitable hotmelts comprise up to by weight of thermoplastic polymer, up to 40% by weight of a plasticizer and up to 70% by weight of tackifying resin.

With respect to the thermoplastic polymer, atactic polyalphaolefins such as S 1 0 Vestoplast® 708 (Huls) and synthetic rubbers such as S-EB-S block 00 copolymers have been found to be especially suited, particularly those as Sused in hotmelt adhesives such as Lunatack® D-3964 B. Fuller). Further, "however, also other thermoplastic polymers are suitable, such as ethylene- "vinylacetate copolymers or other synthetic rubbers as available in commerce 1 5 under the trade names Kraton®, Solprene®, and Stereon®.

Plasticizers and tackifying resins used in hotmelt adhesives are known. Oils such as naphthenic oils are preferred plasticizers. As for tackifying resins, those resins already known for such purposes are generally suitable, especially hydrocarbon resins, ester resins and other such compatible resins.

2 0 The components are mixed and processed in a known manner to prepare the hotmelts which can be used according to this invention.

With suitable hotmelts, such as those described in DE-A-41 21 716, it is also possible to make materials which are impermeable to liquid water, yet water vapor permeable rendering the coating "breathable".

In addition to commonly known hotmelt adhesives, thermoplastic compositions comprising a water soluble, saline (body fluid) insoluble copolyester such as Eastman AQ 1350®, commercially available from Eastman, are also particularly useful for creating barrier films that are impervious to body fluid, yet readily water soluble. This feature is of particular 3 0 interest for creating flushable and compostable disposable hygienic products.

Furthermore, there may be applications wherein water permeability 11 is desired. Accordingly, this coating method may also be suitable for coating water permeable, water soluble and/or biodegradable thermoplastic materials.

Hereinafter, the invention will be further depicted by the following non-limiting examples.

Embodiment example 1: Several hotmelts which slightly differ from each other in composition were formulated in the following composition ranges: 10 20 25% napthenic oil 40% atactic polyolefin(s) 35 45% hydrocarbon resin Embodiment example 2: 1 5 Several hotmelts were formulated within the following range limits: 20% SIS-block copolymer 25% napthenic oil 65% ester resin 20 Embodiment example 3: As a commercially available hotmelt adhesive, the "Lunatack D 8370" product was used, which is available from H. B. Fuller GmbH. This is a hot-melt adhesive comprising about 35% polyolefine, about 40% hydrocarbon resin with a cyclopentadiene component, about 15% polyisobutylene and about 25 10% naphtheric oil.

Testing Procedure The hotmelts according to embodiment examples 1 through 3 were placed in a customary processing machine provided with a slot nozzle such as Nordson EP 51. The slot nozzle was provided horizontally facing a roller over which a 3 0 polypropylene nonwoven was led in an upward direction. The distance between the slot nozzle and the substrate was 2 mm, at a nozzle slot length of mm. The web speed of the nonwoven was 25 m/min. At a system pressure of about 53 bar and a release temperature of the 12 hot-melt of approximately 1000C, the hotmelt was coated onto the substrate, where it formed a closed barrier layer. Immediately thereafter, the thus coated substrate was adhered to a customary absorptive body (tissue). In each case, a reliable adhesive bond between substrate and tissue was provided, and in each case, the hotmelt barrier layer formed between the tissue and the substrate was found to be completely liquid-impermeable. Processing was without any problems. The coating weight was an average of 21 g/m 2 At corresponding fine adjustment of release temperature of hotmelt, system pressure, distance between slot nozzle and substrate, machine speed etc.

etc., it was systematically possible to form water-tight closed barrier layers at °area weights of less than 20 g/m 2 on this substrate.

•00 0 Examples 4-16: 0 Table 1 depicts rheological data on Examples 4 through 16. Column 2 of 0 Table 1 depicts the reference temperature for the rheological parameters as well as the coating application temperature for each sample. Table 2 depicts the chemical description of examples 4 through 9 as well as the coating parameters for those examples in which a continuous coating resulted. A Y 'consistent continuous coating was not able to be produced with samples 4 Io through to 9 at the temperature indicated in Column 2. The applicants surmise that the inability to produce a continuous coating is due to the complex viscosity being greater than about 1000 poise at about 1 rad/sec By comparing examples 5 with 14 and 4 with 10, the complex viscosity at 1 rad/sec can be forced into the rheological window by increasing the temperature. By comparing example 7 with 16, the applicants have demonstrated the relatively narrow rheological window of Lunatack® D-3964.

At 900C D-3964 exhibits too high of a complex viscosity at 1 rad/sec. At 1100C D3964 exhibits to low of a complex viscosity at 1 rad/sec, causing the material to soak into the substrate. The applicants surmise a temperature exists between 900C and 1100C wherein D-3964 would produce a continuous coating. However, a thermoplastic composition exhibiting such a narrow rheological window would have little chance of commercial success.

13 Example 14 exhibits the utility of blending a thermoplastic composition that does not meet the rheological window with another material such that the resulting composition is useful for producing a continuous coating. In this particular example, since D-3964 exhibits too low of a complex viscosity at 1 rad/sec, it is blended with a material to raise the complex viscosity at 1 rad/sec such that the blend exhibits the preferable rheological properties.

Alternatively, examples exhibiting too high of a complex viscosity at 1 rad/sec, such as examples 4 through 9 can be blended with compatible materials to lower the complex viscosity such that the blended material may be coated at the preferable application temperature of less than 125C.

°o0. Examples 4 through 16 were tested in a similar manner as Examples 1 3.

o*o. The application conditions and rheological data of the adhesive compositions are depicted in Table 1. A system pressure ranging fromabout 40 to about S° bar was obtained during coating of examples 10 through 16.

i The rheological data was generated from a dynamic mechanical spectrometer such as aRheometric Scientific RDS 7700 (10,000 g/cm transducer, 10 g/cm 0 >10,000 g/cm torque). A master curve of G' (shear storage modulus), G" *°.41(shear loss moulus) and complex viscosity as a function of frequency was O obtained through time temperature superposition. During testing the sample was loaded at the upper test temperature between 50 mm diameter parallel *"--plate discs with a 1 to 2 mm gap. After allowing the sample temperature to stabilise for at least 10 minutes, a frequency sweep was performed from about 0.1 to about 100 radians per second. Upon the completion of the frequency sweep, the sample temperature was lowered to the next temperature and the procedure repeated. The strain amplitude was adjusted to improve the resolution and ranged from about 20% to about 40%. After the frequency sweep was completed at the final, lowest temperature, time-temperature superposition was used to overlay the data into a single master curve at the application temperature. If the actual coating temperature was not one of the actual temperatures tested, the Williams, Landel, Ferry (WLF) (Ferry, J.D.

14 \Iiscoelastic Properties of Polymers, 3rd Ed., Wiley: NY, 1980) equation was used to obtain the master curve.

06 ~3 S S S S 9 *5 *9 a a aes .9 a, t *5 S S S Sb a S S S 6 5 9 S .ae 54. 595 5 Example Temp. Complex Complex GS Crossover Tan delta @1 Slope Visc -!FContinuous Viscosity 1 Vsoty 1 rad/sec Frequency rad/sec 1/1000 Coating rad/sec (poise rad/sec (poise) (ye/m) rasc rad/sec Formed (dyns/c 2 (ad/ec)yes/no 4 125 15000 100 1 -0000 1 11 150 no 90 10000 300 3000 300 13 33 no 6 120 4500 1500 300 1000 30 4.5 no 7 90 3000 .100 400 50 7 30 not tested 8 110 2000 500 700 10000 3 4 no 9 140 1000 500 50 >1000 70 2 no 160 200 200 5 >1000 4 1.25 yes 11 125 800 100 5000 20 1 8 yes 12 125 800 100 100 1000 10 8 yes 13 125 300 50 200 1 1 6 not tested 14 110 300 50 20 7000 20 6 yes .128 100 80 10 1000 10 1.25 yes 16 110 100 13.5 18 100 25 128. Ino 0 'S '304 4 090* oo or 4, 4 *0a @9 ~9g boo 09 4~ 4 S 0 44 0 0 4 0 0 0 JO rig 049 0 Example Tradename(s) Chemical Description Coating Sped Permeability cm 3 Of HO Weight M/MIN pressure 4 347-BD-1 9 atactic polyolefin hotmelt adhesive (HMA) Fuller) 0-3964 10% SEBS block copolymer/hydrocarbon Vestoplast® 750 resin/napthenic oil HMA atactic polyolefin 6 Eastman AQ® 1350 water dispersible copolyester (WO 95/1 8191) 7 D-3964 SEBS block copolymer/hydrocarbon resin/napthenic oil HMA 8 NP-2085 (HBF) urethane 9 Eastman AQ® 1350 See Example 9 Eastman AQ® 1350 See Example 9 11 Vestoplast® 703 atactic polyolefin 22 (Huls) 12 347-BD-33 (HBF) actactic polyolfin HMA 1 0 30 100 1 3 Vestoplast® 703 atactic polyolefin Fischer Tropsch wax Paraflint H4 1 4 0-3964 10% SEBS block copolymer/hydrocarbon 9-11 34 Vestoplast 750 resin/napthenic oil HMA atactic polyolef in D-8370 atactic polyolefin HMA 1 2 30 46 16 D-3964 See Example 10 8 30 17 Vestoplast® 750 See Example 13 15-16 Wax

Claims (13)

1. A method of coating a thermoplastic composition from a coating device onto a substrate, said method comprising the steps of: making said thermoplastic composition flowable; advancing said substrate along a path; dispensing a continuous film of said thermoplastic compositions from said coating device; suspending said film of said composition being dispensed between said coating device and said substrate prior to contacting said film with said advancing substrate; wherein the complex viscosity of the thermoplastic composition at the coating temperature is less than 500 poise at 1,000 radians/sec and ranges from 100 to 1000 poise at 1 radian/sec.

S2. A method according to claim 1, wherein said substrate is a textile material. eeoc

3. A method according to claim 1, wherein the coating device is spaced from the path of the substrate at a distance between about 0.5 to about 20 mm.

4. A method according to claim 3, wherein the distance between the coating =device and the substrate is less than about 10 mm.

5. A method according to claim 1, wherein the coating device is a slot nozzle.

6. A method according to claim 5, wherein said slot nozzle has a shim gap of less than 5 mm.

7. A method according to claim 1, wherein the substrate is directed substantially vertically immediately after passing the coating device. 18

8. A method according to claim 1, wherein the thermoplastic composition is dispensed onto the substrate such that the coating weight is less than about g/m 2

9. A method according to claim 1, wherein the thermoplastic composition is coated at a rate of at least about 200 metres/min.

The method according to claim 1, wherein the thermoplastic composition is released from the coating device at a temperature of less than about 1600C.

11. The method according to claim 1, wherein the thermoplastic composition is released from the coating device at a temperature of less than about 125°C.

12. The method according to claim 1, wherein the thermoplastic composition is released from the coating device at a temperature of less than about 1100C. S•

13. A method of coating a hot melt adhesive from a coating device onto a substrate, said method comprising the steps of: 1 5 making said hot melt adhesive flowable; S"advancing said substrate along a path; dispensing a continuous film of said hot melt adhesive from said coating device; a suspending said film of said composition being dispensed between 20 said coating device and said substrate prior to contacting said film with said advancing substrate; wherein the complex viscosity of the hot melt adhesive at the coating temperature is less than 500 poise at 1,000 radians/sec and ranges from 100 to 1000 poise at 1 radian/sec. Dated this 8th day of March 2000 H B FULLER LICENSING FINANCING, INC R By their Patent Attorneys COLLISON CO