Absorbent article with improved core and method of making

A method for making an absorbent article comprising the steps of:

• i. providing a pocket comprising a single porous cavity, wherein said cavity is in fluid communication with an under-pressure source;
• ii. providing a first nonwoven web in the form of a bottom layer (8) of a core wrap;
• iii. depositing said bottom layer (8) onto said pocket;
• iv. depositing a first absorbent material, comprising cellulose fibers and/or superabsorbent polymer particles, over at least a portion of a surface of said bottom layer (8);
• v. depositing an intermediate layer (9) over the first absorbent material such that said first absorbent material is sandwiched between said intermediate layer (9) and bottom layer (8);
• vi. joining said intermediate layer (9) to said bottom layer (8) at one or more first distinct positions;
• vii. depositing a second absorbent material, comprising cellulose fibers and/or superabsorbent polymer particles, over at least a portion of a said intermediate layer (9);
• viii. depositing a second nonwoven web in the form of a top layer (7) of a core wrap over the second absorbent material such that said second absorbent material is sandwiched between said intermediate layer (9) and top layer (7);
• ix. joining said intermediate layer (9) to said top layer (7) and/or bottom layer (8) at one or more second distinct positions, to form an absorbent core;
• x. optionally joining an acquisition distribution layer to the body facing surface of said top layer (7), and preferably laminating the absorbent core and the acquisition distribution layer between a liquid pervious topsheet and a liquid impervious backsheet;
• wherein the absorbent core (4) comprises no more than two compartments or clusters of absorbent material corresponding to said single cavity, and typically at most a top compartment or cluster between the top layer (7) and the intermediate layer (9);
• and a bottom compartment or cluster between the bottom layer (8) and the intermediate layer (9).