Ainas Weber, Bad Neuenahr-Ahrweiler, Germany; and Thomas Heege, Düngenheim, Germany.
Assigned to Ontex BV, Buggenhout, Belgium; and Ontex Group NV, Erembodegem, Belgium.

Filed: 2/19/21
Issued: 3/4/25

A method for making an absorbent article comprising an absorbent core comprising one or more channels, the method comprising the steps of: i. providing a first endless moving surface (1) comprising a plurality of molds in the form of pockets (2), each mold comprising an insert (3) therein, wherein the molds are in fluid communication with an under-pressure source except for said insert (3) such that a suction zone is formed in areas neighboring said insert (3); ii. feeding a first nonwoven web (4) to said first endless moving surface (1) and over one or more said molds (2); iii. depositing an absorbent material, comprising cellulose fibers and/or superabsorbent polymer particles, over at least a portion of said first nonwoven web (4); iv. optionally further removing said absorbent material from areas of the first nonwoven web (4) corresponding to said insert (3); v. applying a second nonwoven web (5) directly or indirectly over the absorbent material, or folding said first nonwoven web (4), such to sandwich said absorbent material between the first nonwoven web (4) and the second nonwoven web (5) or upper and lower layers of said folded first nonwoven web (4); vi. joining said upper and lower layers together at least in the areas of the nonwoven web(s) (4, 5) corresponding to the insert (3) to form an absorbent core having one or more channels substantially free of absorbent material; vii. optionally joining an acquisition distribution layer to said absorbent core; viii. optionally laminating said absorbent core and acquisition distribution layer between a liquid pervious topsheet and a liquid impervious backsheet; characterized in that at least a portion of said insert (3) is porous and is in fluid communication with a positive pressure source and comprising the further step of blowing air out of said insert (3) such that an air cushion or air film around at least an uppermost surface (116) of said insert (3) is formed and said absorbent material is thereby forced away from areas of the first nonwoven web (4) corresponding to said insert (3).