Disposable Absorbent Article Having Deployable Chassis Ears

Abstract

A simple disposable absorbent article including a chassis and an absorbent assembly. The chassis includes laterally opposing side flaps formed by laterally inwardly folded portions of the chassis and deployable chassis ears formed by other laterally inwardly folded portions of the chassis. Each chassis ear is held laterally inwardly folded until being deployed by being released and unfolded laterally outward so as to project laterally outward beyond the adjacent side flap. Fastening elements may be disposed on at least two of the chassis ears, the fastening elements being adapted for fastening the front waist region to the back waist region to encircle a waist and legs of a wearer. The chassis may be extensible. The absorbent assembly may be attached in a cruciform pattern to the chassis to allow portions of the chassis underlying the absorbent assembly and lying outside the cruciform attachment pattern to extend laterally.

1 . A disposable diaper comprising:
 a front waist region, a back waist region, a crotch region between the waist regions, a front waist edge, and a back waist edge;   a longitudinal axis extending from a midpoint of the front waist edge through the crotch region to a midpoint of the longitudinally opposed back waist edge;   a web comprising an interior surface and an exterior surface;   an absorbent assembly comprising an interior surface and an exterior surface;   wherein the web is folded at a first fold line and attached to itself forming a first hem, wherein the first hem comprises a first layer and a second layer, and wherein the second layer is disposed between the first layer and the backsheet;   wherein the web is folded at a second fold line and attached to itself forming a second hem, wherein the second hem comprises a first layer and a second layer, and wherein the second layer is disposed between the first layer and the backsheet;   wherein the web is folded over at a third fold line toward the longitudinal axis and attached to the interior surface of one or both of the web and absorbent assembly in the front and back waist regions forming a first side flap, the third fold line forming a first side edge of the diaper;   wherein the web is folded over at a fourth fold line toward the longitudinal axis and attached to the interior surface of one or both of the web and absorbent assembly in the front and back waist regions forming a second side flap, the fourth fold line forming a second side edge of the diaper;   wherein the web comprises a first frangible line extending from the distal edge of the first side flap to the proximal edge of the first side flap, and wherein the web comprises a second frangible line extending from the distal edge of the second side flap to the proximal edge of the second side flap, wherein the first and second frangible lines are laterally opposed in one of the front or back waist regions;   wherein a portion of the first side flap disposed between the first frangible line and one of the front or back waist edges forms a first chassis ear and comprises a first fastening element, and wherein a portion of the second side flap disposed between the second frangible line and one of the front or back waist edges forms a second chassis ear and comprises a second fastening element;   wherein a portion of the first side flap is attached adjacent to and along the first frangible line, and wherein a portion of the second side flap is attached adjacent to and along the second frangible line;   wherein the first side flap comprises the first hem and wherein the second side flap comprises the second hem;   wherein each of the first and second hems comprise a longitudinally extending gathering member; and   wherein the proximal edges of the first and second side flaps are disposed laterally inward of the respective side edges.   
     
     
         2 . The disposable diaper of  claim 1  wherein the web comprises altered and unaltered regions, and wherein the altered region of the web is formed by deformation. 
     
     
         3 . The disposable diaper of  claim 2  wherein the altered region of the web comprises a pattern of alternating ridges and valleys created by a deformation. 
     
     
         4 . The disposable diaper of  claim 3  wherein the ridges and valleys are generally longitudinally oriented. 
     
     
         5 . The disposable diaper of  claim 2  wherein the web comprises an altered region in at least one of the waist regions. 
     
     
         6 . The disposable diaper of  claim 5  wherein at least a portion of the diaper in one of the waist regions is laterally extensible to a maximum extensibility greater than a maximum extensibility of at least a portion of the diaper in the crotch region. 
     
     
         7 . The disposable diaper of  claim 1  wherein the side flaps are attached to the interior surface of the web in laterally opposing attachment zones immediately adjacent to the first and second side edges of the diaper, respectively. 
     
     
         8 . The disposable diaper of  claim 1  wherein the fastening elements include at least one fastening sheet attached to the exterior surface of the web. 
     
     
         9 . The disposable diaper of  claim 1  wherein the fastening elements comprise mechanical fastening elements. 
     
     
         10 . The disposable diaper of  claim 1  wherein the absorbent assembly includes a water-permeable covering sheet and an absorbent core, wherein the covering sheet is disposed on an interior face of the absorbent core and the absorbent assembly, and wherein the absorbent assembly also includes a second water-permeable covering sheet disposed on an exterior face of the absorbent core. 
     
     
         11 . The disposable diaper of  claim 1  wherein the absorbent assembly is attached to the interior surface of the web. 
     
     
         12 . The disposable diaper of  claim 1  wherein the absorbent assembly is attached to the web via an attachment pattern comprising a longitudinally extending portion disposed along the longitudinal axis and at least one laterally distal portion. 
     
     
         13 . The disposable diaper of  claim 1  wherein the absorbent assembly is attached to the web via a discontiguous attachment pattern. 
     
     
         14 . The disposable diaper of  claim 12  wherein the attachment pattern is discontiguous. 
     
     
         15 . The disposable diaper of  claim 13  wherein the attachment pattern comprises a longitudinally extending portion disposed along the longitudinal axis and at least one laterally distal portion. 
     
     
         16 . The disposable diaper of  claim 1  wherein the absorbent assembly comprises an absorbent core comprising particles of superabsorbent polymer that are contained inside pockets formed by a thermoplastic material. 
     
     
         17 . The disposable diaper of  claim 1  wherein the absorbent assembly comprises a topsheet smaller in length than the web. 
     
     
         18 . The disposable diaper of  claim 7  wherein the laterally opposing attachment zones are comprised in the front and back waist regions. 
     
     
         19 . The disposable diaper of  claim 1  wherein the absorbent assembly comprises an absorbent core comprising a layer of particles of superabsorbent polymer that are adhered to the absorbent core via adhesive. 
     
     
         20 . The disposable diaper of  claim 1  wherein the absorbent assembly comprises a first absorbent core comprising particles of superabsorbent polymer that are contained inside pockets formed by a thermoplastic material, and wherein the absorbent assembly comprises a second absorbent core comprising particles of superabsorbent polymer that are contained inside pockets formed by a thermoplastic material.