Disposable pull-on garment having improved protection against red marking and method for making the same

Abstract

The present disclosure is directed, in part, to a disposable garment having a front region, a back region, and a crotch region extending between the front region and the back region. The disposable garment comprises a chassis in the front region, the back region, and the crotch region. The chassis comprises a liquid pervious topsheet, a liquid impervious backsheet, and an absorbent core disposed between the topsheet and the backsheet. The disposable garment comprises a pair of ear panels extending laterally outward from the chassis in the front region or the back region, a seam panel extending laterally outward from at least one of the ear panels, and a tab formed with the seam panel and extending laterally outward from the seam panel.

What is claimed is: 
     
         1 . A disposable pull-on diaper comprising:
 a liquid pervious topsheet;   a liquid impervious backsheet;   an absorbent core disposed between the topsheet and the backsheet;   a front region;   a back region;   a side;   a first extensible ear panel extending outwardly from the side in the front region, wherein the first extensible ear panel is a discrete element and is joined to the side, wherein the first extensible ear panel comprises:
 a first nonwoven material; 
 a second nonwoven material; and 
 an apertured film positioned at least partially intermediate the first and second nonwoven materials; 
   a second extensible ear panel extending outwardly from the side in the back region, wherein the second extensible ear panel is a discrete element and is joined to the side, wherein the second extensible ear panel comprises:
 a first nonwoven material; 
 a second nonwoven material; and 
 an apertured film positioned at least partially intermediate the first and second nonwoven materials; 
   a butt seam joining the first and second extensible ear panels to form a leg opening;   an elasticized waistband in the front region;   a first leg cuff; and   a second leg cuff;   wherein a first portion of the elasticized waistband overlaps a first portion of the first leg cuff; and   wherein a second portion of the elasticized waistband overlaps a first portion of the second leg cuff.   
     
     
         2 . The pull-on diaper of  claim 1 , wherein the butt seam comprises a pattern of heat or pressure welds. 
     
     
         3 . The pull-on diaper of  claim 1 , wherein the butt seam comprises a pattern of ultrasonic welds. 
     
     
         4 . The pull-on diaper of  claim 1 , comprising a second side, and wherein the pull-on diaper comprises:
 a third extensible ear panel extending outwardly from the second side in the front region, wherein the third extensible ear panel is a discrete element and is joined to the second side, and wherein the third extensible ear panel comprises:
 a first nonwoven material; 
 a second nonwoven material; and 
 an apertured film positioned at least partially intermediate the first and second nonwoven materials; 
   a fourth extensible ear panel extending outwardly from the second side in the back region, wherein the fourth extensible ear panel is a discrete element and is joined to the second side, and wherein the fourth extensible ear panel comprises:
 a first nonwoven material; 
 a second nonwoven material; and 
 an apertured film positioned at least partially intermediate the first and second nonwoven materials; and 
   a second butt seam joining the third and fourth extensible ear panels to form a second leg opening.   
     
     
         5 . The pull-on diaper of  claim 4 , wherein the second butt seam comprises a pattern of heat or pressure welds. 
     
     
         6 . The pull-on diaper of  claim 4 , wherein the second butt seam comprises a pattern of ultrasonic welds. 
     
     
         7 . The pull-on diaper of  claim 1 , comprising a second elasticized waistband in the back region. 
     
     
         8 . The pull-on diaper of  claim 7 , wherein a first portion of the second elasticized waistband overlaps a second portion of the first leg cuff, and wherein a second portion of the second elasticized waistband overlaps a second portion of the second leg cuff. 
     
     
         9 . The pull-on diaper of  claim 7 , wherein a portion of the elasticized waistband overlaps a portion of the first extensible ear panel, and wherein a portion of the second elasticized waistband overlaps a portion of the second extensible ear panel. 
     
     
         10 . The pull-on diaper of  claim 1 , wherein a portion of the backsheet overlaps with a portion of the first extensible ear panel. 
     
     
         11 . The pull-on diaper of  claim 1 , wherein a portion of the backsheet extends into the first extensible ear panel. 
     
     
         12 . The pull-on diaper of  claim 11 , wherein a portion of the backsheet extends into the second extensible ear panel. 
     
     
         13 . The pull-on diaper of  claim 12 , wherein the first portion of the first leg cuff overlaps a portion of the first extensible ear panel. 
     
     
         14 . A disposable diaper comprising:
 a liquid pervious topsheet;   a liquid impervious backsheet;   an absorbent core disposed between the topsheet and the backsheet;   a front region;   a back region; and   a side;   a discrete first ear panel extending outwardly from the side in the front region, wherein the first ear panel comprises:
 a first nonwoven material; 
 a second nonwoven material; and 
 a perforated film positioned at least partially intermediate the first and second nonwoven materials; 
   a discrete second ear panel extending outwardly from the side in the back region, wherein the second ear panel comprises:
 a first nonwoven material; 
 a second nonwoven material; and 
 a perforated film positioned at least partially intermediate the first and second nonwoven materials; 
   a butt seam joining the discrete first and second ear panels to form a leg opening; and   an elasticized waistband on a wearer-facing surface of the diaper;   wherein a portion of the elasticized waistband overlaps either a portion of the discrete first ear panel or a portion of the discrete second ear panel; and   wherein a portion of the elasticized waistband overlaps a portion of a leg cuff, and wherein the portion of the leg cuff overlaps either a portion of the discrete first ear panel or a portion of the discrete second ear panel.   
     
     
         15 . The diaper of  claim 14 , wherein the butt seam comprises a pattern of heat or pressure welds or a pattern of ultrasonic welds. 
     
     
         16 . The diaper of  claim 14 , comprising a second elasticized waistband on a wearer-facing surface of the diaper. 
     
     
         17 . The diaper of  claim 14 , comprising a second side, and wherein the diaper comprises:
 a discrete third ear panel extending outwardly from the second side in the front region, wherein the third ear panel comprises:
 a first nonwoven material; 
 a second nonwoven material; and 
 a perforated film positioned at least partially intermediate the first and second nonwoven materials; 
   a discrete fourth ear panel extending outwardly from the second side in the back region, wherein the fourth ear panel comprises:
 a first nonwoven material; 
 a second nonwoven material; and 
 a perforated film positioned at least partially intermediate the first and second nonwoven materials; and 
   a second butt seam joining the discrete third and fourth extensible ear panels to form a second leg opening; and   a second elasticized waistband on the wearer-facing surface of the diaper.   
     
     
         18 . The diaper of  claim 17 , wherein the second butt seam comprises a pattern of heat or pressure welds or a pattern of ultrasonic welds. 
     
     
         19 . The diaper of  claim 14 , wherein a portion of the liquid impervious backsheet extends to a portion of the first ear panel. 
     
     
         20 . The diaper of  claim 14 , wherein a portion of the liquid impervious backsheet overlaps with a portion of the first ear panel. 
     
     
         21 . The diaper of  claim 17 , wherein the discrete first and third ear panels have substantially the same size and shape. 
     
     
         22 . The diaper of  claim 17 , wherein the discrete second and fourth ear panels have substantially the same size and shape. 
     
     
         23 . The diaper of  claim 14 , comprising an acquisition/distribution core positioned over the absorbent core. 
     
     
         24 . The diaper of  claim 14 , comprising a second leg cuff, wherein the elasticized waistband overlaps a portion of the second leg cuff. 
     
     
         25 . A disposable pull-on diaper comprising:
 a liquid pervious topsheet;   a liquid impervious backsheet;   an absorbent core disposed between the topsheet and the backsheet;   a front region;   a back region;   a side;   a first extensible ear panel extending outwardly relative to the side in the front region, wherein the first extensible ear panel is a discrete element and is joined to the side, wherein the first extensible ear panel comprises:
 a first nonwoven material; 
 a second nonwoven material; and 
 an apertured or perforated material positioned at least partially intermediate the first and second nonwoven materials; 
   a second extensible ear panel extending outwardly relative to the side in the back region, wherein the second extensible ear panel is a discrete element and is joined to the side, wherein the second extensible ear panel comprises:
 a first nonwoven material; 
 a second nonwoven material; and 
 an apertured or perforated material positioned at least partially intermediate the first and second nonwoven materials; and 
   a butt seam joining the first and second extensible ear panels to form a leg opening;   a first elasticized waistband in the front region; and   a second elasticized waistband in the back region;   wherein a portion of the backsheet extends to the first extensible ear panel; and   wherein a portion of the backsheet extends to the second extensible ear panel.   
     
     
         26 . The pull-on diaper of  claim 25 , wherein a portion of the first elasticized waistband overlaps a portion of the first extensible ear panel, and wherein a portion of the second elasticized waistband overlaps a portion of the second extensible ear panel. 
     
     
         27 . The pull-on diaper of  claim 25 , comprising a leg cuff, wherein a portion of the first elasticized waistband overlaps a portion of the leg cuff. 
     
     
         28 . The pull-on diaper of  claim 27 , comprising a second leg cuff, wherein a portion of the second elasticized waistband overlaps a portion of the second leg cuff. 
     
     
         29 . A disposable pull-on diaper comprising:
 a topsheet;   a backsheet;   an absorbent core disposed between the topsheet and the backsheet;   a front region;   a back region;   a side;   a discrete first extensible ear panel extending outwardly from the side in the front region, wherein the discrete first extensible ear panel is joined to the side, wherein the first extensible ear panel comprises:
 a first nonwoven material; 
 a second nonwoven material; and 
 an apertured or perforated material positioned at least partially intermediate the first and second nonwoven materials; 
   a discrete second extensible ear panel extending outwardly from the side in the back region, wherein the discrete second extensible ear panel is joined to the side, wherein the second extensible ear panel comprises:
 a first nonwoven material; 
 a second nonwoven material; and 
 an apertured or perforated material positioned at least partially intermediate the first and second nonwoven materials; 
   a butt seam comprising a plurality of bonds joining the discrete first and second extensible ear panels to form a leg opening; and   an elasticized waistband on a wearer-facing surface of the diaper, wherein the elasticized waistband overlaps a portion of the discrete first extensible ear panel or a portion of the discrete second extensible ear panel;   wherein the backsheet extends to the first extensible ear panel.   
     
     
         30 . The pull-on diaper of  claim 29 , wherein the elasticized waistband is in the front region, and wherein a portion of the elasticized waistband overlaps a first portion of a leg cuff.