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Apparatus and methods for producing intermittent, discrete patterns of coating material, such as hot melt adhesive, onto discrete substrates or substrate areas, where the patterns have sharp, square leading and trailing edges, as well as side edges. A slot nozzle die has elongated air slots along th

Apparatus and methods for producing intermittent, discrete patterns of coating material, such as hot melt adhesive, onto discrete substrates or substrate areas, where the patterns have sharp, square leading and trailing edges, as well as side edges. A slot nozzle die has elongated air slots along the slot extrusion opening. In the operation of the apparatus, the air flow is initiated from both air slots prior to the initiation of the hot melt flow. Also, the air flow is continued beyond that point in time, when the hot melt flow ceases. The delays between the operations of the air flow and the hot melt flow are on the order of micro seconds. Coating weights down to 1 gram per square meter at about 350 meters per minute substrate speed are provided. Alternatively, the lead and lag air start and stop times on each side of the coating material are different to control the exact disposition of the square cut-on and square cut-off coating edge on the substrate.

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An apparatus for producing a coating for application to a substrate, the apparatus comprising: a body; a substantially V-shaped die mounted to the body and having a coating material passage for receiving and conducting the coating material to a die outlet; a pair of air blocks mounted to the body an

An apparatus for producing a coating for application to a substrate, the apparatus comprising: a body; a substantially V-shaped die mounted to the body and having a coating material passage for receiving and conducting the coating material to a die outlet; a pair of air blocks mounted to the body and forming respective, air passages in part with the V-shaped die, the air passages receiving process air and conducting the process air through respective air outlets on opposite sides of the die outlet and onto opposite sides of the coating material exuding from the die outlet; and an air valve mounted to the body and having a valve inlet connected to a source of process air and a valve outlet connected to one of the air passages, the air valve selectively starting and stopping the flow of process air to the one of the air passages and out of a respective air outlet.