Absorbent articles and methods of making

A method for making an absorbent article comprising one or more channels, the method comprising the steps of:

• i. providing a mold comprising a non-porous insert therein, wherein the mold is in fluid communication with an under-pressure source except for said insert;
• ii. applying a first nonwoven web to said mold;
• iii. applying an absorbent material, comprising cellulose fibers and/or superabsorbent polymer particles, over at least a portion of said nonwoven web;
• iv. removing said absorbent material from areas of the nonwoven web corresponding to said insert;
• v. applying a second nonwoven web directly or indirectly over the absorbent material, or folding said first nonwoven web, such to sandwich said absorbent material between upper and lower core wrap layers of said nonwoven web(s);
• vi. joining said upper and lower core wrap layers together at least in the areas of the nonwoven web corresponding to the insert to form an absorbent core having one or more channels substantially free of absorbent material;
• vii. joining an acquisition distribution system to said absorbent core;
• viii. laminating said absorbent core and acquisition distribution system between a liquid pervious topsheet and a liquid impervious backsheet;
• characterized in that step vii. comprises the step of applying an adhesive pattern onto the acquisition distribution system or a skin facing surface of said upper core wrap layer and laminating said acquisition distribution system to said absorbent core wherein said adhesive pattern is positioned inboard and/or outboard of the channel(s) such that substantially no adhesive pattern overlaps with said channel(s), and wherein the acquisition distribution system comprises at least one spunbond and at least one meltblown layers, wherein at least a substantial portion of said spunbond layers are in direct contact with said absorbent core and said topsheet, and wherein the acquisition distribution system (201, 522, 622) comprises synthetic fibers, wherein said synthetic fibers are comprised at a level of greater than 80% by weight of said acquisition distribution system (201, 522, 622), and wherein said acquisition distribution system (201, 522, 622) has a basis weight of from 15 to 40 g/m2.