Method of forming a thermoplastic layer on a flexible two-dimensional substrate and powder for preparing same

A method of forming a thermoplastic layer on a flexible substrate having two major opposing surfaces comprising the steps of:

• a) providing a thermoplastic powder having a melt flow index of at least 0.008 grams/10 minutes and comprising a (meth)acrylate polymer and a fluoropolymer, wherein the weight ratio of the (meth)acrylate polymer to the fluoropolymer ranges from 1:1 to 99:1;
• b) applying the powder in absence of solvents to at least one major surface of the substrate to form a particle layer;
• and
• c) subjecting the substrate of step b) to elevated heat and pressure until the powder in the particle layer is fused into a continuous layer that is bonded to the substrate, wherein the heat and pressure of step c) are applied simultaneously by passing the coated substrate through a heated nip configuration comprising a heated roll having an outer surface and a backup roll.