Patent ID: 8206628

Claim:
A process for making an embossed polymeric film web comprising a plurality of discrete extended elements formed integrally with said embossed web, said extended elements having open proximal portions, closed or open distal ends, and sidewalls, said extended elements being thinned at said distal ends and/or along said sidewalls, said process comprising the steps of: providing a forming structure comprising a plurality of discrete protruded elements and lands completely surrounding said discrete protruded elements, wherein said discrete protruded elements each have a diameter of less than about 500 microns; providing a compliant substrate; providing a precursor polymeric film web between said compliant substrate and said forming structure; wherein said precursor web has a melting point and comprises synthetic material, metallic material, biological material, or combinations thereof; and providing pressure between said compliant substrate and said forming structure sufficient to conform said precursor web to said discrete protruded elements of said forming structure to form said embossed polymeric film web; wherein said process is carried out at a temperature less than said melting point of said precursor web.