Coating die and method for use

1. A die for dispensing material, comprising:

a die body defining an at least one internal cavity, wherein the die body comprises a first portion and a second portion such that the first portion and the second portion together define the cavity, and an applicator slot wherein the cavity is in fluid communication with the applicator slot;

a plurality of gas relief passages in the die body simultaneously in fluid communication with the internal cavity, wherein the relief passages are adapted to vent air from the die body when the die is dispensing material; and

an insert attached to the die body in a position separate from the applicator slot, wherein the plurality of gas relief passages extend across substantially the entire width of the insert and the internal cavity.

2. The die according to claim 1 wherein the gas relief passages further comprise:

a plurality of channels.

3. The die according to claim 1 , wherein the plurality of gas relief passages are configured so as to allow egress of gas from the internal cavity while preventing substantial egress of coating material from the internal cavity.

4. The die according to claim 3 wherein the gas relief passages further comprise:

a plurality of channels.

5. A method of applying a material to a substrate, comprising the steps of:

providing a die comprising a die body having an internal cavity, an applicator slot in fluid communication with the internal cavity, a plurality of gas relief apertures in fluid communication with the cavity, and an insert attached to the die body in a position separate from the applicator slot, wherein the plurality of gas relief apertures extend across substantially the entire width of the insert and the internal cavity, and further wherein the die body comprises a first portion and a second portion such that the first portion and the second portion together define the internal cavity;

introducing the material into the internal cavity such that the material is dispensed onto the substrate through the applicator slot;

orienting the die such that the applicator slot is disposed generally downwards above the substrate; and

venting air within the die cavity simultaneously through the plurality of gas relief apertures, wherein the venting air occurs while the die is dispensing material.

6. The method according to claim 5 wherein the gas relief apertures are formed by a plurality of channels.

7. The method according to claim 5 , and further comprising:

preventing substantial egress of coating material through the gas relief apertures.

8. The method according to claim 5 further comprising:

moving the substrate relative to the applicator slot;

controlling the translation of material out of the die; and

forming discrete patches of material on the substrate.