Method for producing a substantially continuous, nonporous thermoplastic coating and articles constructed therefrom

1 . A method of making a laminate, said method comprising:

releasing a molten hot melt adhesive composition from a slot nozzle in the form of a substantially continuous non-porous film, said slot nozzle being free from contact with a substrate, said hot melt adhesive composition having a complex viscosity of less than 500 poise at 1000 radians/second and less than 1000 poise at 1 radian/second at 177° C.;

disposing the substantially continuous non-porous film between a nip formed by a first roller and a second roller;

contacting a first nonporous substrate with the substantially continuous non-porous film;

contacting a second substrate with the substantially continuous non-porous film; and

nipping said first substrate, said substantially continuous non-porous film and said second substrate to form a laminate that is free of entrapped air.

2 . The method of claim 1 , wherein said disposing, said contacting, and said nipping occur substantially simultaneously.

3 . The method of claim 1 , wherein at least one of said first substrate and said second substrate comprises a polymer film.

4 . The method of claim 1 , wherein at least one of said first substrate and said second substrate comprises a metal foil.

5 . The method of claim 1 , wherein at least one of said first substrate and said second substrate comprises a metallized polymer film.

6 . The method of claim 1 , wherein said first substrate and said second substrate comprise a polymer film.

7 . The method of claim 1 , wherein said first substrate and said second substrate comprise a metal foil.

8 . The method of claim 1 , wherein said first substrate comprises a polymer film and said second substrate comprise a metallized polymer film.

9 . The method of claim 1 , wherein said first substrate comprises a plane film or embossed film.

10 . The method of claim 1 , wherein said first substrate comprises a polymer film selected from the group consisting of oriented polypropylene, polyethylene, polyesters, polyacetate, nylon, cellulose acetate, and combinations thereof.

11 . The method of claim 1 , wherein said substantially continuous nonporous film has a coating weight of less than 10 g/m 2 .

12 . The method of claim 1 , wherein said hot melt adhesive composition comprises thermoplastic polymer, tackifying resin, and no greater than 40% by weight plasticizer.

13 . A method of making a laminate comprising:

releasing a hot melt adhesive composition that has been thermally made flowable from a coating device in the form of a substantially continuous nonporous film, said coating device being free from contact with a substrate or a roller,

contacting a release coated roller with said substantially continuous nonporous film;

contacting said substantially continuous nonporous film with a first nonporous substrate; and

nipping said substantially continuous nonporous film and said first substrate between a first roller and a second roller,

said substantially continuous nonporous film forming a coating on said first substrate, said coating having a coating weight less than 20 g/m 2 .

14 . The method of claim 13 , wherein said first roller is said release coated roller.

15 . The method of claim 13 , wherein contacting said substantially continuous nonporous film with a first substrate and nipping said substantially continuous nonporous film and said first substrate between a first roller and a second roller occur substantially simultaneously.

16 . The method of claim 13 further comprising contacting said substantially continuous nonporous film with a second substrate.

17 . The method of claim 16 further comprising nipping said second substrate, said substantially continuous nonporous film and said second substrate between a third roller and a fourth roller.

18 . The method of claim 17 , wherein contacting said substantially continuous nonporous film with said second substrate, and nipping said second substrate, said substantially continuous nonporous film, said first substrate between a third roller and a fourth roller occur substantially simultaneously.

19 . The method of claim 16 , wherein said first substrate and said second substrate are of a different composition.

20 . The method of claim 16 , wherein said first substrate and said second substrate are of the same composition.

21 . The method of claim 16 , wherein said first substrate comprises metal foil, metallized polymer film or polymer film, and said second substrate comprises metal foil, metallized polymer film or polymer film.

22 . The method of claim 13 , wherein said hot melt adhesive composition has a complex viscosity of less than 500 poise at 1000 radians/second and less than 1000 poise at 1 radian/second at 177° C.;

23 . The method of claim 13 , wherein said hot melt adhesive composition comprises thermoplastic polymer, tackifying resin, and no greater than 40% by weight plasticizer.

24 . The method of claim 13 , wherein said coating device comprises a slot nozzle.

25 . The method of claim 13 , wherein said first substrate comprises plane or embossed film.

26 . The method of claim 13 , wherein the first substrate comprises oriented polypropylene, polyethylene, polyesters, polyacetate, nylon, cellulose acetate and combinations thereof.

27 . The method of claim 16 , wherein said second substrate is selected from the group consisting of paper and cardboard.

28 . The method of claim 13 , wherein said continuous film has a coating weight of less than 10 g/m 2 .

29 . The method of claim 13 wherein at least one of said first roller and said second roller is heated.