Multi-layer absorbent cores and methods of manufacture

A method of forming an absorbent body, the method comprising:

• moving a first covering material in a machine direction, the first covering material having a top side and a bottom side;
• moving a reinforcing material in the machine direction and combining the reinforcing material with the first covering material, the reinforcing material having a top side and a bottom side, the reinforcing material having a thickness of between 0.8 mm and 3.0 mm and a basis weight of between 25 gsm and 80 gsm;
• applying absorbent material comprising superabsorbent particles to the top side of the reinforcing material;
• moving a second covering material in the machine direction, the second covering material having a top side and a bottom side, and combining the second covering material with the first covering material and the reinforcing material to form a laminate structure of the first covering material, the reinforcing material, and the second covering material, with the first covering material disposed underneath the reinforcing material and the second covering material disposed on top of the reinforcing material;
• and
• embossing the laminate structure between a smooth roll and a pattern roll, the pattern roll comprising a plurality of discrete embossing surfaces disposed outward from an outer face of the pattern roll, the discrete embossing surfaces being round and spaced apart laterally and longitudinal across outer face of the pattern roll, wherein during embossing the embossing surfaces press the second covering material into the top side of the reinforcing material,
• wherein the laminate structure comprises greater than or equal to 90% superabsorbent material by total weight of absorbent material in the laminate structure, and
• wherein the superabsorbent material is disposed within the absorbent body at a basis weight of greater than 90 gsm and less than 350 gsm.