Article having a seal and process for forming the same

1. A process comprising the steps of:

(a) feeding at least two webs between a pressure source and a forming structure comprising a plurality of discrete forming elements selected from the group consisting of discrete apertures, discrete depressions, discrete protruded elements, and combinations thereof; and

(b) applying pressure from the pressure source against the webs and the forming structure sufficient to conform the at least two webs to the discrete forming elements of the forming structure to form an embossed seal comprising a plurality of concentric discrete extended elements having open proximal ends and open distal ends, wherein the discrete forming elements have a diameter of between about 50 microns to about 500 microns.

2. The process of claim 1 , wherein pressure source is a compliant substrate.

3. The process of claim 2 , wherein the compliant substrate has a Shore A hardness of about 30 durometers to about 90 durometers.

4. The process of claim 1 , comprising feeding the webs at a rate of at least about 0.1 meter per second.

5. The process of claim 1 , comprising applying pressure for a dwell time of about 0.5 milliseconds to about 50 milliseconds.

6. The process of claim 1 , wherein the temperature of the webs is from about 20° C. to about 110° C.

7. The process of claim 1 , wherein the discrete forming elements of the forming structure have an area density of at least 10 discrete forming elements per square centimeter.

8. The process of claim 1 , wherein the discrete forming elements of the forming structure having an average diameter of about 10 microns to about 5000 microns.

9. The process of claim 1 , wherein the discrete extended elements have an aspect ratio of at least about 0.2.

10. The process of claim 1 , wherein the embossed seal is free from adhesives.

11. The process of claim 1 , wherein the embossed seal is formed without fusing the webs together in a melted state.

12. The process of claim 1 , wherein the at least two webs is defined by a single polymeric web that is overlapped onto itself.

13. The process of claim 12 , wherein the single polymeric web comprises a multi-layered coextruded film.

14. A process comprising the steps of:

(a) providing a forming structure comprising a plurality of discrete protruded elements;

(b) providing a compliant substrate;

(c) making an initial contact between the forming structure and the compliant substrate;

(d) thereafter converging the forming structure and the compliant structure beyond the initial contact to define a compression distance; and

(e) feeding at least two webs between the forming structure and the compliant substrate to form an embossed seal comprising a plurality of concentric discrete extended elements;

(f) wherein the embossed seal is devoid of adhesives; and

(g) wherein the at least two webs are not melt fused together in the embossed seal;

and wherein the embossed seal comprises a plurality of concentric discrete extended elements having open proximal ends and open distal ends, wherein the discrete forming elements have a diameter of between about 50 microns to about 500 microns.

15. The process of claim 14 , wherein the compression distance is about 0.1 millimeters to about 5 millimeters.

16. The process of claim 14 , wherein the forming structure and the compliant substrate are rotating.

17. A process comprising the steps of:

(a) providing a forming structure comprising a plurality of discrete protruded elements;

(b) providing a compliant substrate;

(c) feeding a web between the forming structure and the compliant substrate to form an embossed seal comprising three overlapped portions and comprising a plurality of concentric discrete extended elements;

(d) wherein the embossed seal is devoid of adhesives; and

(e) wherein the at least two webs are not melt fused together in the embossed seal and wherein the embossed seal comprises a plurality of concentric discrete extended elements having open proximal ends and open distal ends, wherein the discrete forming elements have a diameter of between about 50 microns to about 500 microns.

18. The process of claim 17 , wherein a dwell time of the web between the forming structure and the compliant substrate is about 0.5 milliseconds to about 50 milliseconds.

19. The process of claim 17 , further comprising the step of (f) heating the web to a temperature of about 20° C. to about 110° C.

20. The Process of claim 17 , wherein the compliant substrate comprises a Shore A hardness of from about 30 to about 90 durometer.