MXPA99007653A - Disposable absorbent article with folded ear panels and method of making same - Google Patents

Abstract

The present invention relates to a means of reproducibly and consistently folding the ear panels on disposable absorbent articles in order to simplify and accelerate the diaper opening process for the user, reduce the risk of potential injury to the end user and wearer caused by clipped ear panels, and create for packaging purposes, a more aesthetically satisfying arrangement in the disposable diaper pack. In another aspect of the invention, a method for the making of a disposable absorbent diaper, which incorporates the folding of the ear panels, is outlined.

Description

DISPOSABLE ABSORBENT ARTICLE WITH FOLDED EAR PANELS AND METHOD OF ELABORATION OF THE SAME FIELD OF THE INVENTION The present invention relates to a superior manner of folding the ear panels onto the disposable absorbent articles. In particular, attention is directed towards disposable diapers.

BACKGROUND OF THE INVENTION Disposable absorbent articles, in particular, disposable diapers, are well-known articles of manufacture that are designed to be used primarily by infants and people suffering from incontinence. These diapers are worn around the user's lower torso and are intended to absorb and contain urine and other bodily discharges, thus preventing staining, wetting or similar contamination of items (eg, clothing, sheets) to other people, etc.), who may be in contact with this diaper during use. Obtaining a new disposable diaper, the user normally unfolds the diaper from the folded and packed configuration to a semi-folded configuration, located the ear panels provided with the tape tab fastening devices and open outward of the diaper to a split configuration that It allows the user to adjust and fasten the diaper around the user's waist to effect a lateral closure. In the bent and semi-bent configurations, the ear panels are typically located adjacent to the back waist region of the diaper, resulting in tape tab fastening devices that are in a position that, either, do not facilitate easy access to the user or that pose a risk to the user or even to the user due to the close nature of the ear panels. The tracking tends to occur during the fabrication of the cutting phase as a result of the casual arrangement of the ear panels in the chassis assembly. The prior art does not reveal any particularly pertinent information on the subject of bending the ear panels in disposable absorbent articles such as diapers. For example, U.S. Patent No. 3,863,637 focuses on the folding of a diaper. In particular, the diaper is longitudinally folded in a configuration that in cross section resembles the Greek symbol sigma on one side of the longitudinal centerline of the diaper and a reverse sigma on the opposite side of the diaper. The diaper has a rectangular outline with adhesive strips which are provided on the opposite corners of one end of a diaper. Due to the rectangular shape of the diaper, the problem of the bending of the ear is not simply encountered. In contrast, U.S. Patent No. 4,050,462 mentions the bending of the ear panels. The document describes how a diaper according to the teachings of the invention can be folded and adapted for packaging. The foreshortening of the narrow crotch section as a result of the presence of the elastics makes the diaper double over itself transversely in the middle, thus allowing the ear panels to extend outward on the edges of the crotch. the waistband sections are easily folded inwards. European patent EP 0 452 951 B1 describes the folding of the side sections on a training pants for the purpose of facilitating the packaging. In particular, the document relates to a training pant having a front portion, a back portion and side sections connecting both portions together. The side sections extend from the waist opening towards the respective leg openings and are folded along the center line of the training pants extending in the longitudinal direction, such that they are placed between the front portion and the back portion of the training pants. ConcurrentlyOther disposable diaper products on the market reveal a random disposition regarding the bending of the ear panels and in addition, the tight ear panels which are very prevalent. This is more pronounced within the disposable diaper packs when opening. As a result of prior attempts of the prior art, it has been recognized by those skilled in the art that it would be desirable to provide a means for repulsively and consistently bending ear panels in disposable diapers in order to simplify and accelerate the diaper opening process by the user, reducing the risk of potential damage to the end users and the use caused by the tight ear panels, and creating for packaging purposes, an aesthetically satisfactory disposition within the disposable diaper package. The solution is found to make the ear panels that are multiply bent to create a configuration that exposes the tape tab fastening devices of the ear panels to the user when the diaper has been opened in a half-open configuration and that does not reveal the severed ears. It has now been discovered that the benefits of the present invention range from an easy one-step opening action to the diaper and the tape tab fastening device.; even a product with a superior and increased appearance due to the clean, controlled and consistent manner of the bending of the ear panel; even a product that is extremely benevolent to the user and does not cause harm to either the buyer or the user; to a product that confers a high level of satisfaction and safety to the user, and even a disposition that is more about a first impact when the user opens the package of disposable diapers to obtain a diaper. In addition, the inclusion of the bending procedure in the current production lines is complete. In fact, the bending procedure results in increased reliability, simplification of the process and allows the elimination of the use of static load equipment, which poses a safety risk to operators.

BRIEF DESCRIPTION OF THE INVENTION In one aspect of the present invention, there is disclosed a disposable absorbent article having a front waist region and a posterior waist region, a chassis assembly comprising a liquid permeable top sheet and a liquid impermeable back sheet attached to the top sheet; an absorbent core placed between the top sheet and the back sheet; and a pair of ear panels in the posterior waist region. The ear panels comprise a tape tab fastening device comprising a joint area and a functional area. Each of the ear panels is folded back on itself, at least the width of the attachment area of the tape retention device subsequently folded forward on itself at least once the width of the area of attachment of the tape tab fastening device. The part of the ear panel after forward folding that does not comprise the attachment area of the tape tab fastening device is arranged in a configuration partially overlapping the attachment area of the tape tab fastening device. In a preferred embodiment of the present invention, each of the ear panels is bent forward on themselves, at twice the width of the attachment area of the tape tab fastening device. The ear panels may be either unitary, with the rear waist region of the diaper or joined along a seam line thereto. In another aspect of the present invention, a method for making a disposable diaper with the features described above is described. The steps comprise providing a disposable diaper; folding each of the ear panels back on itself, to at least the area of attachment of the tape tab fastening device; folding each of the ear panels forward on themselves at least once the width of the attachment area of the tape tab fastening device; folding each part of the ear panels after forward folding that do not comprise the attachment area of the tape tab fastening device in a configuration that partially overlaps the attachment area of the tape tab fastening device. In another preferred embodiment of the present invention, the ear panels are joined along a seam line to the posterior waist region before the forward bending step occurs.

BRIEF DESCRIPTION OF THE DRAWINGS It is believed that the invention will be better understood from the following description in combination with the accompanying drawings, in which: Figure 1 is a plan view of a disposable diaper embodiment of the present invention having portions cut away for reveal the underlying structure with the outer surface of the diaper facing the observer; Figure 2A is a cross-sectional view through line A-A in Figure 1 of the preferred embodiment of the disposable diaper; Figure 2B is a continuation of Figure 2A after the ear panel has been folded back on itself; Figure 2E is a continuation of Figure 2B after the ear panel has been bent forward on itself at least once the width of the attachment area of the fastening device.

Figure 3A is a preferred embodiment of the present invention and is a continuation of Figure 2C. In this embodiment, the ear panel has been bent forward on itself, at twice the width of the attachment area of the tape tab fastening device; Figure 3B is a continuation of Figure 3A and shows the fully folded configuration of the ear panel.

DETAILED DESCRIPTION OF THE INVENTION As used herein, the term "disposable absorbent article" refers to articles that absorb and contain body exudates., and more specifically refers to articles that are placed against or close to the body of the user to absorb and contain the various exudates discharged from the body, and which are intended to be discarded after a single use (ie, these are not intended to be washed or otherwise restored or reused), and, preferably to be recycled, composted or otherwise disposed of in an environmentally compatible manner. As used herein, the term "diaper" refers to a garment generally worn by infants or incontinence sufferers that is pulled up between the legs and fastened around the user's waist, the term "panel" is used herein, to designate an area or element of the waist or diaper feature. (Although a panel is typically a different area or element, a panel may overlap a bit with an adjacent panel). As used herein the term "attached" encompasses configurations by which one element is directly secured to another element by attaching the element directly to the other element and configurations by which the element is indirectly secured to the other element by fixing the element to a member or intermediate members which in turn are fixed to the other element. Figure 1 is a plan view of the diaper 20 of the present invention in its flat, non-contracted state (i.e., with the contraction induced by the elastic pulled outward) with parts of the structure that are cut out to more clearly show the construction of the diaper 20 and with the part of the diaper 20 that gives away from the wearer, the external surface facing towards the observer. As shown in Figure 1, the diaper 20 has a generally T-shape and comprises a chassis assembly 22 comprising a liquid-permeable top sheet 24, a liquid-impermeable back sheet 26, attached to the top sheet 24, a core absorbent 28 located between the top sheet 24 and the back sheet 26; extendable leg folds 30 each comprising a leg flap panel 31 and one or more elastic members elastic threads 54 operatively attached to the leg flap panel 31; an extensible rear waist feature 32 comprising a central waistband panel 34, a pair of ear panels 36, each comprising a tape tab fastening device 37, and a hip panel 38; a clamping member for the tape tab fastening device 37; and a front waist extensible feature 42 comprising a front waist panel 43. Each of the panels may be a separate member attached to the entire diaper structure or may be unitary with the diaper 20 in which they comprise an extension of other elements of the diaper, such as the top sheet 24, the back sheet 26, or both. In the embodiment shown in Figure 1, all of the panels except for the panels except for the ear panels 36 comprise an extension of the top sheet 24 and the back sheet 26. The ear panels 36 comprise a separate member attached to the ear. central waistband panel 34 and at least a portion of hip panel 38. In addition, any or all of the panels may be extensible. The chassis panel 22 is typically non-extensible in order to maintain the integrity of the absorbent core 28 during use, although it may be made extensible such as by being formed as a film web in the form of SELF structural elastic as described in FIG. present, preferably the expandable panels comprise a SELF frame. The use of an SELF weft allows the strength / extension properties of each of the panels to be specifically designed to maximize the fit and containment of the diaper with a minimum amount of materials (no conventional elastic materials are needed). As is evident from Figure 1, the diaper 20 is provided with a closure system comprising a tape tab fastening device 37 and a tie member 41 for adjusting the diaper 20 on the wearer. The tape tab fastening device 37 comprises a joining area 39 and a functional area (not shown), and the lacing area, preferably a reinforcing strip 41, or the alternative, a part of the back sheet 26, placed in the front waist region 45 of the diaper 20. The bonding area 39 is the area on the tape tab fastening device 37 which is attached to the ear panel 36 and the functional area is the area on the fastening device. of tape tab 37 on which the functional elements are located to allow engagement with the tie-down member on the front waist region 45 of the diaper. The functional elements can adopt a number of configurations such as the adhesive fastening elements, mechanical fastening element, a combination of adhesive fastening elements and mechanical fastening elements or any other means as is known to the man skilled in the art. The diaper of Figure 1 has an inner surface (not shown), an outer surface 44 (facing the viewer in Figure 1), opposite the inner surface, a front waist region 45, a rear waist region 46 opposite to the front waist region 45, and a periphery that is defined by the outer edges of the diaper 20, in which the longitudinal edges are designated 47 and the end edges are designated 48. Although the person skilled in the art will recognize that a diaper is usually described in terms of having a pair of waist regions and a crotch region between the waist regions; in this application; for simplicity of terminology the diaper is described as having only waist regions, each of the waist regions including a part of the diaper that would typically be designated as part of the crotch region. The inner surface of the diaper 20 comprises that part of the diaper 20 which is placed adjacent the wearer's body during use (i.e., the inner surface is generally formed by at least a portion of the topsheet 24 and other components attached to the sheet upper 24). The external surface 44 cises that part of the diaper 20 that is positioned away from the wearer's body (i.e., the outer surface 44 is generally formed by at least a portion of the back sheet 26, and other cnents attached to the back sheet 26). The front waist region 45 and the rear waist region 46 extend, respectively, from the end edges 48 of the periphery to the lateral center line 49 of the diaper 20. The lateral direction (x direction or width), is defined as the direction parallel to the lateral center line 49 of the diaper 20; the longitudinal direction (direction y or length), which is defined as the direction parallel to the longitudinal center line 50; and the axial direction (z direction or thickness, being defined as the direction extending through the thickness of the diaper 20). Figure 1 shows a preferred embodiment of the diaper 20 in which the topsheet 24 and backsheet 26 have length and width dimensions generally greater than those of the absorbent core 28. The backsheet 26 and the topsheet 24 extend beyond the edges of the absorbent core 28 to form in this manner certain of the panels and portions of the periphery of the diaper. The periphery defines the outer perimeter or, in other words, the edges of the diaper 20. The periphery cises the longitudinal edges 47 and the end edges 48. The chassis assembly 22 (chassis panel of the diaper 20) is shown in Figure 1 as cising the main chassis portion of the diaper 20. The chassis assembly 22 cises at least one absorbent core 28 preferably an outer cover layer cising the top sheet 24 and the back sheet 26. In this manner, the chassis assembly 22 cises the main structure of the diaper with other features added to form the csite structure of the diaper. An example of the chassis assembly of the present invention is described in U.S. Patent No. 3,860,003. The absorbent core 28 may be any absorbent means that is capable of absorbing and retaining liquids such as urine and other certain exudates from the body. The absorbent core 28 has a garment surface, a body surface, side edges 57, and waist edges 56. The absorbent core 28 can be manufactured in a wide variety of sizes and shapes (e.g., rectangular, hourglass , T-shaped, asymmetrical, etc.), and from a wide variety of liquid absorbent materials commonly used in disposable diapers and other absorbent articles such as crushed wood pulp, which is generally referred to as air felt. Examples of other suitable absorbent materials include accreted cellulose wadding, meltblown polymers including coform, crosslinked cellulose fibers, tissue, including tissue wraps and tissue laminates, absorbent sponge absorbent foams, superabsorbent polymers, gelling absorbent materials, or any other material equivalent or combinations of materials. The configuration and construction of the absorbent core 28 may also be varied (eg, the absorbent core 28 may have varying gauge zones, a hydrophilic gradient, a superabsorbent gradient, or acquisition zones of lower average density and lower average basis weight; understand one or more layers or structures). However, the total absorbent capacity of the absorbent core 28 must be ctible with the design load and intended use of the diaper 20. In addition, the size and absorbent capacity of the absorbent core 28 can be varied to encss users ranging from infants to Adults. A useful absorbent structure such as the absorbent core 28 of the present invention which has achieved wide acceptance and commercial success is described in U.S. Patent No. 4,610,678, U.S. Patent No. 4,673,402; United States Patent No. 4,888,231; U.S. Patent No. 5,147,345; U.S. Patent No. 5,102,597 and U.S. Patent No. 4,834,735 also disclose absorbent structures that are useful in the present invention. The absorbent core 28 is preferably the double layer absorbent structure described in U.S. Patent No. 5,234,423. The backsheet is positioned adjacent the garment surface of the absorbent core 28 and is preferably attached thereto by attachment means (not shown) such as those well known in the art. For example, the backsheet 26 can be secured to the absorbent core 28 by a continuous uniform adhesive layer, a patterned adhesive layer, or an array of separate lines, coils, or dots of adhesives. The adhesives that have been found to be satisfactory are manufactured by Tredegar Corporation of Terre Haute, IN and marketed as P8863. The attachment means will preferably comprise an open-pattern network of filaments of adhesive as described in HL-1258. The attachment means preferably will comprise an open-pattern network of filaments of adhesive as described in U.S. Patent No. 4,573,986. An exemplary attachment means of an open-pattern network of filaments comprises several lines of twisted adhesive filaments. in a spiral pattern as illustrated by the apparatus and methods shown in U.S. Patent No. 3,911, 173; U.S. Patent No. 4,785,996 and U.S. Patent No. 4,842,666. Alternatively, the joining means may comprise heat bonds, pressure joints, heat / pressure joints, ultrasonic joints, mechanical dynamic joints, or any other suitable joining means or combinations of these joining means as are known in the art. technique. The backsheet 26 is impervious to liquids (eg, urine), and is preferably manufactured from a thin plastic film, although other flexible liquid impervious materials may also be used. As used herein, the term "flexible" refers to materials that are docile and will readily conform to the contour and general shape of the human body. The backsheet 26 prevents the exudates absorbed and contained within the absorbent core 28 from wetting articles that are in contact with the diaper 20 such as sheets and undergarments. The backsheet 26 may thus comprise a woven or non-woven material, polymeric films, such as thermoplastic, polyethylene or polypropylene films or composite materials such as a film-coated nonwoven material.

Preferably, the backsheet is a thermoplastic film having a thickness of from about 0.0112 mm to about 0.051 mm. The backsheet 26 preferably comprises a mixed polyethylene film of approximately 0.025 mm as manufactured by Tredegar Corporation of Terre Haute, IN., And marketed as P8863. The topsheet 24 is positioned adjacent to the body surface of the absorbent core 28 and is preferably attached to it and to the backsheet 26 by attachment means (not shown) such as those known in the art. Suitable attachment means were described with respect to the attachment of the backsheet 26 to the absorbent core 28. In a preferred embodiment of the present invention the topsheet 24 and the backsheet 26 are directly bonded together at the periphery of the diaper and they are indirectly joined together by attaching them directly to the absorbent core 28 by the joining means (not shown). The topsheet 24 is docile, soft-feeling, and non-irritating to the user's skin, in addition, the topsheet 24 is permeable to liquid allowing liquids (eg, urine) to easily penetrate through its thickness. A suitable top sheet can be manufactured from a wide range of materials, such as porous foams, cross-linked foams, plastic films with openings, or woven or non-woven webs of natural fibers (e.g., wood or cotton fibers), synthetic fibers (for example, polyester or polypropylene fibers), or a combination of natural and synthetic fibers. Preferably, the topsheet 24 is made of a hydrophobic material to isolate the wearer's skin from the liquids that have passed through the topsheet 24 and which are contained in the absorbent core 28 (i.e., prevent rewetting). If the topsheet 24 of a hydrophobic material is made, at least the top surface thereof is treated to be hydrophilic, so that the liquids will transfer through the topsheet 24 more rapidly. This decreases the likelihood that the body exudates will flow out of the topsheet 24 instead of being drawn through the topsheet 24 and absorbed by the absorbent core 28. The topsheet 24 can be made hydrophilic by treating it with a surfactant. . Suitable methods for treating the topsheet 24 with a surfactant include spraying the material with a surfactant and immersing the material in the surfactant. A more detailed discussion of this treatment and hydrophilic ability is contained in U.S. Patent No. 4,988,344. The diaper 20 preferably further comprises extendable leg cuffs 30 to provide improved containment of liquids and other exudates from the body. Each extensible leg fold 30 may comprise several different embodiments to reduce leakage of body exudates in the leg regions.

(The leg fold can be and is sometimes also referred to as leg bands, leg flaps, barrier folds or elastic folds). U.S. Patent No. 3,860,003 discloses a disposable diaper which provides a collapsible leg opening having a leg flap and one or more elastic members to provide an elasticized leg fold (gusset fold).

U.S. Patent No. 4,909,803 discloses a disposable diaper having upstanding elasticated fins (leg cuffs), to improve the containment of the leg regions. U.S. Patent No. 4,695,278 discloses a disposable diaper having double folds including a gusset fold and a barrier fold. U.S. Patent No. 4,695,278 discloses a disposable diaper or incontinence garment having sidewall leakage protection channels configured to contain the free liquids within the garment. United States Patent No. 4No. 704,115 discloses an absorbent article having leg cuffs having a relatively low final contact force at relatively high elongations achieved, for example, by the material with low contact force differential. U.S. Patent No. 4,087,255 discloses an absorbent article having bent barrier folds with the distant orifice positioned outward from the proximal edge in one waist region and inward in the other to provide the best fit around the hip / settlement. Although each extendable leg fold 30 can be configured to be similar to any of the leg bands, leg flaps, barrier folds or elastic folds described above, as shown in Figure 1, each extendable leg fold 30 comprises the leg flap panel 31 extending laterally outwardly from the chassis panel 22, the side edge 52 of the absorbent core 28 and one or more elastic members, elastic threads 54, operatively joined to the leg flap panel 31, such as described in U.S. Patent No. 3,860,003.

The diaper 20 further comprises extensible waist features that provide improved fit and containment. The extensible waist features at least extend longitudinally outwardly of the chassis assembly, preferably one of the respective waist edge 56 of the absorbent core 28, and generally form at least a portion of the end edge 48 of the diaper 20. In this way , in the embodiment shown in Figure 1, the extensible rear waist feature 32 comprises that portion of the diaper 20 extending from the waist edge 56 of the absorbent core 28 in the rear waist region 46 toward the end edge 48 of the diaper 20 Although a disposable diaper 20 of the present invention is constructed with an expandable waist feature disposed in each waist region (a waist feature 32 and an extensible front waist feature 42), the discussion will focus on diapers having different for each extensible waist feature. At a minimum, it is preferable that the diaper 20 has at least one of the extendable waist characteristics constructed in accordance with the present invention, more preferably at least the rear extendable waist feature 32. The features can be constructed as a separate element. attached to the chassis assembly 22 or as an extension of other diaper elements (i.e., unitary). The waist characteristics will be described with respect to the preferred embodiments, in which certain parts or panels comprise an extension of other diaper elements such as the backsheet 26, the topsheet 24, or both and other parts or panels comprise an element separate attached to other parts or panels of the waist feature or other diaper panels. The extensible rear waist feature 32 provides an expandable member that provides a more comfortable and contoured fit by initially comfortably adjusting the diaper to the wearer and holding this adjustment throughout the time of use much later when the diaper has been loaded with the exudates since the posterior extensible posterior waist feature allows the diaper to expand and, preferably, contract. In addition, the extensible posterior waist feature develops and maintains the forces of use (tensions) that increase the tensions developed and maintained by the closure system, to maintain the diaper on the wearer and that increase the diaper fit around the waist of the diaper. user, the extensible rear waist feature 32 further provides for greater effective application of the diaper since, even if the diapering person pulls to one side (the ear panel 36) of the extensible rear waist feature 32 further than the another during the application (asymmetrically), the diaper will "self-adjust" during use. As shown in Figure 1, the extensible rear waist feature 32 comprises a central waistband panel 34; a pair of ear panels 36, and a hip panel 38, in the embodiment shown in Figure 1, the hip panel 38 is disposed longitudinally outwardly of the chassis assembly 22 (the chassis panel), preferably from the waist edge 56 of the absorbent core 28, in the middle region of the middle rear waist region 46; the central waistband panel 34 is arranged longitudinally outwardly of the hip panel 38; and the side panels 36 are each disposed laterally outwardly from the central waistband panel 34 and at least a portion of the hip panel 38. As discussed hereinafter, the particular location of each panel of the rear waist feature is important for the total performance of the rear waist feature. The ear panels 36 are those parts of the rear waist feature extendable 32 extending generally outwardly from the central waistband panel 34 and at least a portion of the hip panel 38. The ear panels 36 are each an extendable member that function primarily to provide greater comfort and contour adjustment initially fitting the diaper 20 comfortably to the user in the appliqué and hold the fit throughout the time of use much later when the diaper 20 has been loaded with the exudates enlarging the circumference of the diaper 20 to the sides, fixing the rear waist region 46 to the front waist region 45 of the diaper 20 to complete a closure of the diaper 20, and distribute the forces along both of the waist and legs to transfer these forces in such a way as to exist a tight fit without irritation of the skin due to excessive forces on the legs or on the waist. The ear panels 36 also provide stretch, in the preferred embodiments, a force of contraction after extension and application. In this way, the ear panels 36 provide a greater comfortable fit and contour allowing the sides of the diaper to expand and contract. The ear panels 36 also develop and maintain the forces of use (tensions), and increase the tensions developed and maintained by the tape tab fastening device 37 and the landing or clamping member to maintain the diaper 20 on the wearer and increase the fit., the ear panels 36 help maintain the primary tension line formed by the primary clamping system; allowing the diaper to fit comfortably on the user's hips where dynamic movement exists and initially pretensioning the extensible waist feature, if provided in the diaper 20, since the diaper 20 typically stretches the ear panels 36 when the diaper is applied over the wearer such that when the ear panels 36 contract, tension is transmitted from the ear panels 36 through the tape tab fastening device 37 and the landing or binding member 41 towards the extensible front waist feature 42. The ear panels 36 further provide effective further application of the diaper 20, since even if the user pulls the ear panel 36 farther than the other during the application, the diaper will self-adjust "during use " The ear panels 36 may have a number of different sizes and shapes. For example, the ear panels 36 can each have an arcuate shape such that the forces transmitted through the ear panel 36 are along a line or area disposed at an angle with respect to the user's body to adjust the diaper in a lumbar curve of the back and allowing the tension forces (the primary tension line) to be directed down towards the abdominal crease of the user, to provide a primary, continuous tension line. Examples of these side panels are described in United States Patent Application No. 08 / 072,300; and in the United States patent application Serial No. 08 / 155,048. The ear panels 36 have a rectangular shape in Figure 1. For a "large, typical" baby diaper (8 kg to 14 kg), the ear panels 36 can, for example, have a size of approximately 63 mm in diameter. the lateral direction by approximately 57 mm in the longitudinal direction. The ear panels 36 can be constructed in a number of configurations and from a material of different numbers. Examples of diapers with elasticized side panels are disclosed in U.S. Patent No. 4,857,067; U.S. Patent No. 4,381,781; United States patent No. 4,938,753, and United States Patent No. 5,151,091. In this manner, the ear panels 36 may comprise conventional elastic or mechanically stretched laminates such as a zero tension stretch laminate or a SELF weft. The ear panels 36 may comprise a separate element attached to the rear waist feature in the central waistband panel 34 and the hip panel 38 or may be constructed as an extension of other elements such as the rear waist feature 32 or the diaper 20 such as the backsheet 26 or the topsheet 24, preferably both the topsheet 24 and the backsheet 26. In the embodiment of the present invention shown in Figure 1, the ear panels 36 each comprise a SELF screen. separate attached to the rear waist feature 32 (the central waistband panel 34 and the hip panel 38). The SELF screen of the ear panels 36 preferably comprises a laminate of two or more layers, preferably two layers; most preferably a laminate of a polyethylene blend film as sold by Clopay Corporation of Cincinnati, Ohio, as Clopay 1401 and a nonwoven web such as the P-8 material: Figure 2A is a cross-sectional view through of line AA in Figure 1 of the preferred embodiment of the disposable diaper. In greater detail, Figure 2a shows only a portion of the upper sheet 24, a portion of the back sheet 26, an ear panel 36 and a tape tab fastening device 37. The attachment area 39 of the tongue fastening device of tape 37 is visible. In the embodiment shown in Figure 2A the ear panel 36 is attached to and extends laterally outward from the rear waist region 46. In Figure 2A the ear panel 36 is attached to the back sheet 26, but can also be attached to the top sheet 24. The ear panel 36 can also be a unitary part of the disposable diaper 20. Figure 2B is a continuation of Figure 2A the ear panel 36 is folded back on itself at least the width of the bonding area 39 of the tape tab fastening device 37. The edge 40 of the bonding area 39 of the tape tab fastening device 37 can serve as a useful reference line for bending. During the process, the cutting welds (not shown) keep the folded ear panels 36 in place until the disposable diaper has been packed. In Figure 2C, the ear panel 36 is subsequently folded forward on itself, at least once the width of the bonding area 39 of the tape tab fastening device 37. Figure 3A is a preferred embodiment of the present invention and is a continuation of Figure 2C. in this preferred embodiment, the ear panel 36 is bent forward on itself at twice the width of the bonding area 39 of the tape tab fastening device 37. Figure 3B is a continuation of Figure 3A and shows the fully bent configuration of the ear panel 36, as desired by the present invention. In particular, the part T of the ear panel 36 after forward folding that does not comprise the bonding area 39 of the tape tab fastening device 37 is arranged in a configuration partially overlapping the bonding area 39 of the fastening device of the tape. tape tab 37. In another preferred embodiment of the present invention, each of the ear panels 36 are joined along a back waist joint line 46. This is apparent from Figure 1. In another aspect of the present invention, the manufacture of a disposable diaper 20 is disclosed. Figures 1, 2a, 2b, 2c, 3a and 3b are relevant. The method comprises the steps of (a) providing a diaper 20 comprising a front waist region 45 and a rear waist region 46, a chassis assembly 22 comprising an upper sheet 24 permeable to liquid and a back sheet 26 impervious to liquid attached to the upper sheet 24; an absorbent core 28 positioned between the topsheet 24 and the backsheet 26; and a pair of ear panels 36 in the rear waist region 46, the ear panels 36 comprising a tape tab fastening device 37 comprising a joint area 39 and a functional area (not shown), (b) folding each of the ear panels 36 back on itself, to at least the width of the attachment area 39 of the tape tab fastening device 37; (c) bending each of the ear panels 36 forward on itself at least once the width of the bonding area 39 of the tape tab fastening device 37; (d) folding each part of the ear panels 36 then forward of the bending which does not, comprises the attachment area 39 of the tape tab fastening device 37 in a configuration that partially overlaps the attachment area 39 of the fastening device Tape tab 37. In a preferred embodiment of the method, step (c) includes bending each of the ear panels 36 forward on themselves, at twice the width of the attachment area 39 of the fastener device. tape tab 37. In another preferred embodiment of the present invention, each of the ear panels 36 comprises a frame attached to the rear waist feature 32 and step (b) occurs prior to attachment of the ear panels 36. to the back waist region 46 of the diaper 20 at a seam 58. As used herein, the term "seam" refers to the regions where the panels extend or are attached to the chassis assembly 22 These regions can be any of several curved or straight lines, but these are not limited to lines. Therefore, these regions may comprise tabs, strips, flashing lines and the like.

Claims (9)

1. - Disposable absorbent article (20) having a front waist region (45) and a rear waist region (46), the absorbent article (20) comprising: a chassis assembly (22) comprising an upper sheet (24), liquid permeable and a backsheet (26) impervious to liquid bound with the top sheet (24); an absorbent core (28) positioned between the top sheet (24) and the back sheet (26); and a pair of ear panels (36) in said back waist region (46), each of the ear panels (36) comprising a tape tab fastening device (37), comprising a bonding area ( 39), and a functional area; characterized in that each of the ear panels (36) is folded back on itself, at least the width of the attachment area (39), of said tape tab fastening device (37); and subsequently is bent forward on itself at least once the width of said joining area (39) of said tape tab fastening device (37).

2. The disposable absorbent article (20) according to claim 1, wherein each of the ear panels (36) is folded forward on itself at twice the width of said joining area (39) of the tape retention device (37).

3. The disposable absorbent article (20) according to any of the preceding claims, wherein the portion (P) of the ear panel (36) after bending forward that does not comprise the joining area (39) of said tape tab fastening devices (37) is arranged in a configuration by partially overlapping the attachment area (39) of the fastening device of tape tab (37).

4. The disposable absorbent article (20) according to any of the preceding claims, wherein said functional area of the tape tab fastening device (37) comprises an adhesive fastening element.

5. The disposable absorbent article (20) according to any of the preceding claims, wherein the functional area of the tape tab fastening device (37) comprises a mechanical fastening element.

6. The disposable absorbent article (20) according to claim 1, wherein each of the ear panels (36) is joined along a seam line (58) to the rear waist region 46.

7. Method of making a disposable diaper (20) wherein the method comprises the steps of: a) providing a disposable diaper (20) comprising a front waist region (45) and a rear waist region (46) , a chassis assembly (22) comprising a liquid permeable top sheet (24), and a liquid impermeable back sheet (26) attached to the top sheet (24); an absorbent core (28) positioned between the top sheet (24) and the back sheet (26); and a pair of ear panels (36) in the rear waist region (46), the ear panels (36) comprising a tape tab fastening device (37) comprising a joint area (39) and a functional area; b) bending each of the ear panels (36) back on itself to at least the width of the joint area (39) of the tape tab fastening device (37); c) folding each of the ear panels (36) forward on itself at least once the width of the joint area (39), of the tape tab fastening device (37); d) folding each part (P) of the ear panels (36) after forward folding that does not comprise the attachment area (39) of the tape tab fastening device (37), to a configuration that overlaps partially the junction area (39), of! tape retention device (37).

8. The method according to claim 7, wherein step (c) includes bending each of the ear panels (36) forward on itself at twice the width of the joining area (39) of said tape tab fastening device (37).

9. The method according to claim 8, wherein step (b) occurs before joining the ear panels (36) to the rear waist region (46) in a joint line (58).