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

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

• (a) providing a liquid permeable topsheet web extending substantially continuously in a machine direction, the topsheet web having a first and second surface, a liquid impermeable backsheet web extending substantially continuously in the machine direction, an acquisition layer having a first and second surface, a dry-laid fibrous structure and a carrier layer web having a first and second surface, the topsheet web and the acquisition layer comprising fibers;
• (b) aligning the topsheet web and the acquisition layer in a face to face relationship such that the second surface of the topsheet web is in contact with the first surface of the acquisition layer;
• (c) simultaneously mechanically deforming and combining the topsheet web together with the acquisition layer to provide a topsheet/acquisition layer laminate web having three-dimensional protrusions,
• wherein the three-dimensional protrusions are formed from the fibers of the topsheet web and the acquisition layer, wherein a majority of the three-dimensional protrusions each comprises a base forming an opening, an opposed distal portion, and one or more side walls between the bases and the distal portions of the majority of the three-dimensional protrusions, wherein the base, distal portion and the one or more side walls are formed by fibers such that the majority of the three-dimensional protrusion has only an opening at the base;
• 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;
• (d) depositing the dry-laid fibrous structure on the first surface of the carrier layer web;
• and
• (e) joining a portion of the backsheet web to a portion of the topsheet web of the topsheet/acquisition layer laminate wherein the second surface of the carrier layer web is facing the topsheet/acquisition layer laminate web or the backsheet web.