Methods for dispensing and adhering hot melt entrained polymers to substrates

A method for forming and adhering a plurality of entrained polymer structures to a single substrate sheet in an automated production process, comprising the steps of:

• a. extruding an entrained polymer composition in molten form, wherein the entrained polymer composition comprises a mixture of a base polymer and a particulate active agent;
• b. providing the single substrate sheet, which is in solid form, having a surface for receiving application of the entrained polymer composition, and
• c. applying the entrained polymer composition in molten form in a predetermined shape to the surface of the single substrate sheet to form thereon a solidified entrained polymer structure, wherein the entrained polymer composition adheres to the surface of the single substrate sheet by thermal bonding, wherein the entrained polymer structure is formed upon cooling and solidification of the entrained polymer composition, the solidified entrained polymer structure comprising an outer boundary, the surface of the single substrate sheet extending outwardly beyond the outer boundary;
• wherein the method is carried out using a hot melt dispensing apparatus comprising an extruder which conveys the entrained polymer composition in molten form to a dispenser that applies the entrained polymer composition in molten form to the surface of the single substrate sheet, the dispenser comprising a valve that alternates between a closed state and an open state so as to precisely form the entrained polymer composition in the predetermined shape, the method further comprising repeating step (c) and repeatedly alternating the valve between the closed state and the open state so as to form and adhere additional entrained polymer structures, each in the predetermined shape, to the single substrate sheet.