Process for making an absorbent article comprising a topsheet/acquisition layer laminate

A process of making an absorbent article comprising the steps of:

• providing a liquid permeable topsheet web extending substantially continuously in a machine direction, the topsheet web having a first topsheet web surface lying substantially along a first topsheet web plane and second topsheet web surface, a liquid impermeable backsheet web extending substantially continuously in the machine direction, and an acquisition layer having left and right longitudinal edges a first acquisition layer surface and second acquisition layer surface lying substantially along a second acquisition layer plane;
• aligning the topsheet web and the acquisition layer in a face to face relationship such that the second topsheet web surface is in contact with the first acquisition layer surface;
• simultaneously mechanically deforming and combining the topsheet web together with the acquisition layer to form three-dimensional protrusions wherein the topsheet web and acquisition layer are nested together such that a majority of the three-dimensional protrusions formed in the topsheet web coincide with and fit together with a majority of the three-dimensional protrusions formed in the acquisition layer to provide a topsheet/acquisition layer laminate web having three-dimensional protrusions, wherein the topsheet/acquisition layer laminate having three dimensional protrusions is formed by interrupting the topsheet web or acquisition layer in the area of the three dimensional protrusions of the topsheet/acquisition layer laminate web such that three dimensional protrusions of the respective other non-interrupted topsheet web or acquisition layer at least partially fit together with the three dimensional protrusions of the interrupted topsheet web or acquisition layer;
• wherein a width of the acquisition layer is less than a width of the topsheet web in a cross direction;
• the topsheet/acquisition layer laminate web having a first surface comprising the second surface of the acquisition layer;
• and
• joining a portion of the backsheet web to a portion of the topsheet web of the topsheet/acquisition layer laminate web such that the first surface of the topsheet/acquisition layer laminate web is facing towards the backsheet web.