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 chassis comprising:
 a liquid pervious topsheet; 
 a liquid impervious backsheet; 
 an absorbent core disposed between the topsheet and the backsheet; 
 a front region configured to be positioned on a wearer's front side; 
 a back region configured to be positioned on a wearer's back side; 
 a first side of the chassis; and 
 a second side of the chassis generally opposing the first side; 
   a first ear panel extending outwardly from the first side of the chassis in the back region, wherein the first ear panel is a discrete element and is joined to the first side of the chassis, and wherein the first ear panel comprises:
 a first nonwoven material; and 
 a second nonwoven material; 
   a first tear open tab joined to or integral with the first ear panel, wherein the first tear open tab comprises a nonwoven material;   a second ear panel extending outwardly from the second side of the chassis in the back region, wherein the second ear panel is a discrete element and is joined to the second side of the chassis, and wherein the second ear panel comprises:
 a first nonwoven material; and 
 a second nonwoven material; 
   a second tear open tab joined to or integral with the second ear panel, wherein the first and second tear open tabs generally extend toward the front region when the pull-on diaper is in use;   wherein a portion of the first ear panel overlaps the liquid impervious backsheet;   wherein a portion of the second ear panel overlaps the liquid impervious backsheet;   a first elasticized waistband in the front region; and   a second elasticized waistband in the back region, wherein a portion of the second elasticized waistband overlaps a portion of the first ear panel, and wherein a portion of the second elasticized waistband overlaps a portion of the second ear panel.   
     
     
         2 . The pull-on diaper of  claim 1 , wherein the first and second ear panels are extensible, wherein a portion of the first elasticized waistband overlaps a portion of a first leg cuff, and wherein a portion of the second waistband overlaps a portion of a second leg cuff. 
     
     
         3 . A disposable pull-on diaper comprising:
 a chassis comprising:
 a topsheet; 
 a backsheet; 
 an absorbent core disposed between the topsheet and the backsheet; 
 a front region; 
 a back region; 
 a first side of the chassis; and 
 a second side of the chassis; 
   a first extensible ear panel extending outwardly relative to the first side of the chassis in the back region, wherein the first extensible ear panel is a discrete element and is joined to the first side of the chassis, and wherein the first extensible ear panel comprises:
 a first nonwoven material; and 
 a second nonwoven material; 
   a tear open tab joined to the first extensible ear panel; and   a second extensible ear panel extending outwardly relative to the first side of the chassis in the front region, wherein the second extensible ear panel is a discrete element and is joined to the first side of the chassis, wherein the second extensible ear panel is joined to the first extensible ear panel, and wherein the second extensible ear panel comprises:
 a first nonwoven material; and 
 a second nonwoven material; 
   wherein the second extensible ear panel comprises a garment-facing surface, wherein the first extensible ear panel comprises a wearer-facing surface that faces the garment-facing surface of the second extensible ear panel, wherein the tear open tab comprises a wearer-facing surface facing the garment-facing surface of the second extensible ear panel, wherein the tear open tab has a free end positioned more proximal to the front region than the back region when the pull-on diaper is donned and comprises a nonwoven material, wherein a portion of the first extensible ear panel overlaps the liquid impervious backsheet, and wherein a portion of the second extensible ear panel overlaps the liquid impervious backsheet;   a waistband in the back region; and   wherein a portion of the waistband overlaps a portion of the first extensible ear panel.   
     
     
         4 . The pull-on diaper of  claim 3 , comprising:
 a third extensible ear panel extending outwardly relative to the second side of the chassis in the back region, wherein the third extensible ear panel is a discrete element and is joined to the second side of the chassis, and wherein the third extensible ear panel comprises:
 a first nonwoven material; and 
 a second nonwoven material; and 
   a second tear open tab joined to the second extensible ear panel;   wherein the third extensible ear panel comprises an end edge most distal from the second side of the chassis, wherein the pull-on diaper comprises a longitudinal axis, and wherein the end edge is angled respective to the longitudinal axis.   
     
     
         5 . The pull-on diaper of  claim 4 , comprising:
 a fourth extensible ear panel extending outwardly relative to the second side of the chassis in the front region, wherein the fourth extensible ear panel is a discrete element and is joined to the side of the chassis, wherein the fourth extensible ear panel is joined to third extensible ear panel, and wherein the fourth extensible ear panel comprises:
 a first nonwoven material; and 
 a second nonwoven material. 
   
     
     
         6 . The pull-on diaper of  claim 5 , wherein the fourth extensible ear panel comprises a garment-facing surface, wherein the third extensible ear panel comprises a wearer-facing surface, wherein a portion of the wearer-facing surface of the third extensible ear panel overlaps a portion of the garment-facing surface of the fourth extensible ear panel, and wherein the second tear open tab comprises a wearer-facing surface facing the garment-facing surface of the fourth extensible ear panel. 
     
     
         7 . The pull-on diaper of  claim 5 , wherein the fourth extensible ear panel comprises a garment-facing surface, and wherein the second tear open tab comprises a wearer-facing surface that overlaps a portion of the garment-facing surface of the fourth extensible ear panel. 
     
     
         8 . The pull-on diaper of  claim 4 , wherein the tear open tab has substantially the same size and shape as the second tear open tab, and wherein the second tear open has a free end positioned more proximal to the front region than the back region when the pull-on diaper is donned. 
     
     
         9 . The pull-on diaper of  claim 3 , wherein the pull-on diaper comprises a second waistband in the front region, and wherein the second waistband overlaps a portion of the second extensible ear panel. 
     
     
         10 . A disposable diaper comprising:
 a chassis comprising:
 a liquid pervious topsheet; 
 a backsheet; 
 an absorbent core disposed between the topsheet and the backsheet; 
 a front region configured to be positioned on a front side of a wearer; 
 a back region configured to be positioned on a rear side of a wearer; and 
 a side of the chassis; 
   an extensible ear panel extending outwardly from the side of the chassis in the back region, wherein the extensible ear panel is a discrete element, and wherein the extensible ear panel comprises:
 a first nonwoven material; and 
 a second nonwoven material; 
   a tear open tab extending from the extensible ear panel toward the front region when the diaper is donned;   a first elasticized waistband on a wearer-facing side of the diaper in the front region; and   a second elasticized waistband on the wearer-facing side of the diaper in the back region;   wherein a portion of the second elasticized waistband overlaps a portion of the extensible ear panel; and   wherein a portion of the first elasticized waistband overlaps a portion of a leg cuff.   
     
     
         11 . The diaper of  claim 10 , comprising:
 a second extensible ear panel extending outwardly from the side of the chassis in the front region, wherein the second extensible ear panel is a discrete element, wherein the second extensible ear panel is joined to the extensible ear panel to form a seam therebetween, and wherein the second extensible ear panel comprises:
 a first nonwoven material; and 
 a second nonwoven material; 
   wherein the tear open tab is positioned proximate to the seam   wherein the extensible ear panel comprises a wearer-facing surface, wherein the second extensible ear panel comprises a garment-facing surface, and wherein a portion of the wearer-facing surface of the extensible ear panel overlaps a portion of the garment-facing surface of the second extensible ear panel.   
     
     
         12 . The diaper of  claim 11 , wherein the tear open tab comprises a wearer-facing surface facing the garment-facing surface of the second extensible ear panel. 
     
     
         13 . The diaper of  claim 11 , wherein the tear open tab comprises a wearer-facing surface that overlaps a portion of the garment-facing surface of the second extensible ear panel. 
     
     
         14 . The diaper of  claim 10 , comprising:
 a second side of the chassis;   a second extensible ear panel extending outwardly from the second side of the chassis in the back region, wherein the second extensible ear panel is a discrete element, and wherein the second extensible ear panel comprises:
 a first nonwoven material; and 
 a second nonwoven material; and 
   a second tear open tab extending from the second extensible ear panel.   
     
     
         15 . The diaper of  claim 14 , comprising:
 a third extensible ear panel extending outwardly from the second side of the chassis in the front region, wherein the third extensible ear panel is a discrete element, wherein the third extensible ear panel is joined to second extensible ear panel to form a seam therebetween, and wherein the third extensible ear panel comprises:
 a first nonwoven material; and 
 a second nonwoven material; 
   wherein the second tear open tab is positioned proximate to the seam.   
     
     
         16 . The diaper of  claim 15 , wherein the third extensible ear panel comprises a garment-facing surface, and wherein the second tear open tab comprises a wearer-facing surface facing the garment-facing surface of the third extensible ear panel. 
     
     
         17 . The diaper of  claim 15 , wherein the third extensible ear panel comprises a garment-facing surface, and wherein the second tear open tab comprises a wearer-facing surface that overlaps a portion of the garment-facing surface of the third extensible ear panel. 
     
     
         18 . The diaper of  claim 17 , wherein the second tear open tab forms a portion of a garment-facing surface of the diaper, and wherein the second tear open tab has substantially the same shape as the tear open tab. 
     
     
         19 . The diaper of  claim 10 , wherein a portion of the extensible ear panel overlaps a portion of the backsheet. 
     
     
         20 . The diaper of  claim 10 , wherein a portion of the second elasticized waistband overlaps a portion of the leg cuff. 
     
     
         21 . The diaper of  claim 10 , wherein the tear open tab is positioned proximate to a seam formed in the extensible ear panel and a second ear panel. 
     
     
         22 . The diaper of  claim 10 , wherein the tear open tab has a free end that is positioned more proximal to the front region than the back region. 
     
     
         23 . A disposable pull-on diaper comprising:
 a chassis 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 of the chassis; 
   an extensible ear panel extending outwardly from the side of the chassis in the back region, wherein the extensible ear panel is joined to the side of the chassis and is a discrete element, and wherein the extensible ear panel comprises:
 a first nonwoven material; and 
 a second nonwoven material; 
   a tear open tab on the extensible ear panel;   wherein the tear open tab extends from the extensible ear panel toward the front region when the pull-on diaper is donned;   wherein the tear open tab has a garment-facing surface that forms a portion of a garment-facing surface of the diaper;   a waistband, wherein a portion of the waistband overlaps a portion of a leg cuff;   wherein a portion of the waistband overlaps a portion of the extensible ear panel; and   wherein a portion of the extensible ear panel overlaps the liquid impervious backsheet.   
     
     
         24 . The pull-on diaper of  claim 23 , comprising:
 a second extensible ear panel extending outwardly from the side of the chassis in the front region, wherein the second extensible ear panel is joined to the side of the chassis, wherein the second extensible ear panel is joined to the extensible ear panel to form a seam therebetween, and wherein the second extensible ear panel comprises:
 a first nonwoven material; and 
 a second nonwoven material; 
   wherein the first tear open tab is positioned adjacent to a portion of the seam.   
     
     
         25 . The pull-on diaper of  claim 24 , wherein the second extensible ear panel comprises a garment-facing surface, wherein the extensile ear panel comprises a wearer-facing surface, wherein a portion of the garment-facing surface of the second extensible ear panel overlaps with a portion of the wearer-facing surface of the extensible ear panel, and wherein the tear open tab comprises a wearer-facing surface facing the garment-facing surface of the second extensible ear panel. 
     
     
         26 . The pull-on diaper of  claim 23 , wherein the waistband is elasticized, and wherein the waistband in the back region. 
     
     
         27 . The pull-on diaper of  claim 26 , comprising a second elasticized waistband in the front region. 
     
     
         28 . The pull-on diaper of  claim 23 , wherein the waistband has a maximum lateral width, in a direction parallel to a lateral axis of the diaper, that is greater than a maximum lateral width of the absorbent core. 
     
     
         29 . The pull-on diaper of  claim 23 , wherein a portion of the waistband overlaps the absorbent core. 
     
     
         30 . The pull-on diaper of  claim 23 , wherein the tear open tab is positioned proximate to a bond site in an ear panel seam.