Material having a substance protected by deformable standoffs and method of making

A method of making a material having a substance protected from inadvertent contact with an external surface until said material is deformed, said method comprising the steps of:

• a) coating a forming surface with a first substance;
• b) introducing a piece of material having a first side and a second side onto said forming surface such that said first side is in contact with said first substance on said forming surface, said first substance preferentially adhering to said first side of said piece of material;
• and
• c) forming said piece of material to create a three dimensional structure having a plurality of hollow protrusions spaced apart by valleys, said first substance being transferred from said forming surface into said three dimensional structure accurately registered with said three dimensional structure by using a common transfer and forming surface.

A method of making a material having a substance protected from inadvertent contact with an external surface until said material is deformed, said method comprising the steps of:

• a) coating a forming screen with a first substance, said forming screen having a top surface and a plurality of recesses therein, said coating step applying said first substance to said top surface without bridging said recesses;
• b) introducing a piece of material having a first side and a second side onto said forming screen such that said first side is in contact with said first substance on said top surface of said forming screen, said first substance preferentially adhering to said first side of said piece of material;
• and
• c) forming said piece of material to create a plurality of hollow protrusions extending from said first side into said recesses of said forming screen, said plurality of hollow protrusions being spaced apart by valleys into which said first substance is transferred from said forming screen, said plurality of hollow protrusions being accurately registered with said first substance by use of a common transfer and forming surface, said piece of material having a plurality of depressions on said second side corresponding to said plurality of hollow protrusions.

A method of making a material having a substance protected from inadvertent contact with an external surface until said material is deformed, said method comprising the steps of:

• a) coating top surfaces of pins extending from a forming plate with a first substance, said pins being separated from each other by spaces, said coating step applying said first substance to said top surfaces of said pins without bridging across said spaces;
• b) introducing a piece of material having a first side and a second side onto said pins such that said first side is in contact with said first substance on said top surface of said pins, said first substance preferentially adhering to said piece of material;
• and
• c) forming over said pins of said forming plate said piece of material to create a plurality of hollow protrusions extending from said second side, said plurality of hollow protrusions having insides registered with said pins which have discrete spots of said first substance thereon, said piece of material having an interconnected valley formed on said second side corresponding to said spaces between said pins.