Patent ID: 7658811

Claim:
A process of manufacturing a stretch composite, said method comprising the steps of: a) providing a first substrate, said substrate moving in a machine direction, wherein said substrate has opposing first and second surfaces; b) providing a letterpress adhesive application system, said letterpress adhesive application system comprising a pattern roll and an applicator roll, each of said rolls having an exterior surface with a roll surface temperature, a portion of said exterior surface of said pattern roll comprising a predetermined pattern of raised surface elements; c) depositing a molten, non-adhesive, elastomeric composition onto the exterior surface of said applicator roll, said composition having an application temperature, said application temperature being greater than said pattern roll surface temperature and a peel force of less than about 3 N/cm; d) transferring a portion of said composition from said applicator roll to a distal surface of said raised elements so as to surface coat said raised elements wherein said composition cohesively fails such that a portion of said composition also remains on said applicator roll; and e) cooling said transferred portion to a temperature between said application temperature and said pattern roll surface temperature causing a cohesive strength of said composition to increase such that said cohesive strength is greater than said peel force; and f) contacting said first surface of said substrate and said surface coated raised elements and substantially completely transferring said elastomeric composition from said distal surface of said raised surface elements to said first surface.