Abstract: A method of forming a thermoplastic layer on an adhesive layer is provided. In the steps of the method, a thermoplastic powder is provided having a melt flow index of at least about 0.008 grams/10 minutes, the powder is applied to at least one surface of the adhesive layer to form a particle layer, and the combination is then subjected to elevated heat and pressure until particle layer is fused into a continuous layer and the continuous layer is bonded to the adhesive layer.