Patent Description:
Isolation garments are useful in protecting the individuals wearing them from hostile environments. For example, hospital staff, patients, and visitors may wear isolation garments to avoid exposure to blood, other body fluids, and infectious materials or to protect patients, especially those with weakened immune systems, from infection. Also, individuals working in industrial facilities may wear isolation garments to prevent contact with hazardous chemicals. However, isolation garments may be worn in other conditions as well, especially in light of requirements imposed by some jurisdictions to prevent exposure to coronavirus disease <NUM> (COVID-<NUM>). As an example, hair dressers or barbers may be required to wear isolation garments during their appointments.

Manufacturers produce isolation garments using a variety of different methods. In one method, an automated system combines material webs to construct a portion of an isolation garment. However, the product produced by the automated system does not include sleeves and is not folded. Thus, the isolation garments are finished by hand, with sleeves being sown onto the initial product and then folded for packaging. This method results in a slow production speed and involves a high level of manual labor input.

Another method involves producing isolation garments using a sequential or non-continuous operation. That is, cutting the material webs, combining the webs, and folding of the webs are all performed at different stations. Therefore, the isolation garments must be constantly transferred between the stations in their various stages of production. Further, the combining of the webs and the folding and packaging of the resulting isolation garments is performed by hand. As such, this method is also slow and requires much manual labor.

Still another method that involves a high degree of manual input is one in which an individual cuts the shape of isolation garments out of one material web or out of a stack of material webs. The rest of the material web is discarded as scrap. Thereafter, the material webs are bonded, folded, and packaged manually. The end result is a plurality of isolation garments produced by a slow, manual method that produces a large amount of wasted raw material.

<CIT>), which discloses the preamble of claim <NUM>, discloses an article for clothing particularly a blouse, dress or shirt for limited use, which is made from foldable sheet material, e.g. paper, and consists of (a) an upper part comprising the shoulders, sleeves and neck opening and formed by folding the sheet material, aligning the edges with each other and fixing these edges to close the sleeve, and (b) a lower part forming the body part, open at the bottom and formed by folding a sheet of material and aligning the edges.

<CIT>), which discloses the preamble of claim <NUM>, discloses a disposable protection gown provided to prevent the contact of clothes and the body of a user when wearing or taking off the gown, by cutting a shoulder unit when pulling a chest part. Such a disposable protection gown comprises a front side covering unit, a shoulder unit, a head inserting unit, a sleeve unit, a waist string, and a cut-out line. The head inserting unit is formed on the center where the front side covering unit and the shoulder unit contact with each other. The sleeve unit is produced by extending the side of the front side covering unit and the shoulder unit. The cut-out line is formed from the head inserting unit, and crosses the shoulder unit.

It would therefore be desirable to provide an apparatus and method of manufacturing isolation garments that can produce isolation garments quickly and do not depend on a high level of manual input or result in a large amount of raw material scrap.

In accordance with one aspect of the invention, an apparatus for manufacturing multi-piece open-back isolation garments includes a neck cutting unit configured to cut neck openings in a continuous shoulder web and a first bonding unit configured to create underarm seams between first shoulder web panels and second shoulder web panels overlapping each other in the continuous shoulder web. The apparatus also includes a torso cutting unit configured to cut discrete torso web pieces from a continuous torso web and a transfer unit configured to transfer the discrete torso web pieces onto the first shoulder web panels of the continuous shoulder web such that a top edge of each discrete torso web piece overlaps a bottom edge of the first shoulder web panels in an area of the first shoulder web panels that is uncovered by the second shoulder web panels. In addition, the apparatus includes a second bonding unit configured to bond the discrete torso web pieces to the first shoulder web panels in the area uncovered by the second shoulder web panels to create a continuous isolation garment web.

In accordance with another aspect of the invention, a method of manufacturing multi-piece open-back isolation garments includes cutting neck openings in a continuous shoulder web traveling in a machine direction and forming first shoulder web panels and second shoulder web panels overlapping each other in a continuous shoulder web, the first and second shoulder web panels having respective bottom edges offset from each other to create an area on the first shoulder web panel that is uncovered by the second shoulder web panel. The method additionally includes creating underarm seams between the first and second shoulder web panels and cutting a continuous torso web into discrete torso web pieces.

Furthermore, the method includes transferring the discrete torso web pieces onto the first shoulder web panels such that a top edge of each discrete torso web piece overlaps the bottom edge of the first shoulder web panels in the area of the first shoulder web panel that is uncovered by the second shoulder web panels and bonding the discrete torso web pieces to the first shoulder web panels in the area that is uncovered by the second shoulder web panels to create a continuous isolation garment web.

In accordance with yet another aspect of the invention, a multi-piece garment includes a shoulder web piece having a first shoulder web panel and second shoulder web panel overlapping the second shoulder web panel. The first shoulder web panel includes a bottom edge and a pair of underarm edges extending out from the bottom edge, and the second shoulder web panel includes a bottom edge offset from the bottom edge of the first shoulder web panel to create an area on first shoulder web panel that is uncovered by the second shoulder web panel and a pair of underarm edges extending out from the bottom edge of the second shoulder web panel and substantially aligned with the pair of underarm edges of the first shoulder web panel. The shoulder web piece further includes a pair of underarm seams joining the first and second shoulder web panels at adjacent underarm edges of the first and second shoulder web panels to form first and second sleeves in the shoulder web piece and a neck opening formed in the first and second shoulder web panels across from the bottom edges of the first and second shoulder web panels. The multi-piece garment also includes a torso web piece comprising a top edge overlapping the bottom edge of the first shoulder web panel of the shoulder web piece in the area uncovered by the second shoulder web panel of the shoulder web piece, the torso web piece attached to the first shoulder web panel via a seam positioned between the top edge of the torso web piece and the bottom edge of the first shoulder web panel.

Various other features and advantages of the present invention will be made apparent from the following detailed description and the drawings.

The drawings illustrate embodiments presently contemplated for carrying out the invention.

Embodiments of the present invention provide for an apparatus and method of manufacturing multi-piece open-back isolation garments. In executing the method of manufacturing, the apparatus utilizes a series of cutting, folding, bonding, and transfer units. These units operate together to create discrete torso web pieces from a continuous torso web, combine the discrete torso pieces with at least one continuous shoulder web, cut the combined torso and shoulder web structure to form the multi-piece open-back isolation garments, and fold or roll up the multi-piece open-back isolation garments for packaging. The multi-piece open-back isolation garments may be used in a variety of environments such as, for example, as isolation gowns in medical environments, as an alternative to coveralls in industrial environments, and any other environments in which isolation from potentially hazardous or unclean materials or other individuals is desired. Thus, while referred to hereafter as "isolation gowns," it is contemplated that the garments described herein may be manufactured for use outside of the healthcare industry.

Referring to <FIG>, a rear view of a multi-piece open-back isolation gown <NUM> is shown, according to an embodiment of the invention. Isolation gown <NUM> includes a torso web piece <NUM> and a shoulder web piece <NUM>. Torso and shoulder web pieces <NUM>, <NUM> may include nonwoven materials, woven materials, films, foams, and/or composites or laminates of any of these material types. Torso web piece <NUM> includes a top edge <NUM>, a bottom edge <NUM>, and left side and right side edges <NUM>, <NUM> extending between top and bottom edges <NUM>, <NUM>. However, in various embodiments, torso web piece <NUM> may have a different shape resulting in a different number and arrangement of edges. Torso web piece <NUM> further includes two optional tie straps <NUM>, <NUM> along left and right side edges <NUM>, <NUM>. Tie straps <NUM>, <NUM> may be separated from the rest of torso web piece <NUM> along perforation lines <NUM>, <NUM> spaced apart from left and right side edges <NUM>, <NUM>, respectively, but remain integrated with torso web piece <NUM> adjacent top edge <NUM>. Tie straps <NUM>, <NUM> may then be pulled back by a wearer of isolation gown <NUM> in order to keep isolation gown <NUM> close to the wearer and further prevent contact with possibly unsafe substances.

While <FIG> shows torso web piece <NUM> with two tie straps <NUM>, <NUM> extending down to bottom edge <NUM> at side edges <NUM>, <NUM>, torso web piece <NUM> may include different tie strap configurations resulting from different perforation line configurations. As a non-limiting example, perforation lines <NUM>, <NUM> may stop short of bottom edge <NUM> and extend away from side edges <NUM>, <NUM>, respectively, before extending down to bottom edge <NUM> such that tie straps <NUM>, <NUM> are lengthened along bottom edge <NUM> as shown in <FIG>. As another non-limiting example, perforation lines <NUM>, <NUM> may be arranged on torso web piece <NUM> such that tie straps <NUM>, <NUM> extend down side edges <NUM>, <NUM> and then wind back up toward top edge <NUM> in order to lengthen tie straps <NUM>, <NUM> as shown in <FIG>. As yet another non-limiting example, perforation lines <NUM>, <NUM> may be replaced by at least one perforation line <NUM> extending along torso web piece <NUM> near bottom edge <NUM> in order to perforate a single tie strap along bottom edge <NUM> as shown in <FIG>. In that case, the single tie strap may be completely separable from torso web piece <NUM> such that wearers of isolation gown <NUM> can wrap the separated tie strap around their waists and tie it in position. In yet other alternative embodiments, tie straps may be omitted from the integrated structure of the multi-piece open-back isolation gown <NUM> entirely and separately packaged with gown <NUM>.

Shoulder web piece <NUM> of isolation gown <NUM> includes overlapping front and rear shoulder web panels <NUM>, <NUM>. In multi-piece open-back isolation gowns <NUM> of <FIG>, front and rear shoulder web panels <NUM>, <NUM> share a folded top edge <NUM>. However, front and rear shoulder web panels <NUM>, <NUM> may also be formed from two discrete shoulder web panels with separate top edges (not shown) in an alternative embodiment. In that case, shoulder web piece <NUM> would include a seam (not shown) between shoulder web panels <NUM>, <NUM> adjacent the two top edges. Regardless, top edge <NUM> includes a substantially centralized neck opening <NUM>.

Shoulder web piece <NUM> may also include one or multiple optional neck perforation lines <NUM> that extend down from neck opening <NUM> on rear shoulder web panel <NUM> such that a wearer of isolation gown <NUM> is able to tear out a portion of rear shoulder web panel <NUM> to make neck opening <NUM> larger or to completely tear rear shoulder web panel <NUM> apart. Tearing apart rear shoulder web panel <NUM> may aid wearer in removing isolation gown <NUM> without being contaminated by a substance that landed on isolation gown <NUM> during a medical procedure or industrial activity, as non-limiting examples. A larger neck opening <NUM> may make a wearer more comfortable while wearing isolation gown <NUM>. In addition, shoulder web piece <NUM> may also include optional thumb slits or holes <NUM>, referred to hereafter as thumb openings <NUM>, along top edge <NUM> in order to allow wearers of isolation gown <NUM> to insert their thumbs therethrough and have greater control over the movement of isolation gown <NUM>.

Front shoulder web panel <NUM> includes a front bottom edge <NUM> and two front underarm edges <NUM> extending from front bottom edge <NUM> toward top edge <NUM>, and rear shoulder web panel <NUM> includes a rear bottom edge <NUM> and two rear underarm edges <NUM> extending from rear bottom edge <NUM> toward top edge <NUM> at approximately the same angle as front underarm edges <NUM>. Shoulder web piece <NUM> includes underarm seams <NUM> joining front and rear shoulder web panels <NUM>, <NUM> at adjacent front and rear underarm edges <NUM>, <NUM> in order to create left and right sleeves <NUM>, <NUM> having respective left and right wrist openings <NUM>, <NUM> defined between underarm seams <NUM> and top edge <NUM>. While depicted as being circular in shape, wrist openings <NUM>, <NUM> may be square, rectangular, triangular or other shapes as dictated by design specifications.

Front and rear underarm edges <NUM>, <NUM> are substantially aligned with each other. However, front bottom edge <NUM> is offset from rear bottom edge <NUM>. That is, front bottom edge <NUM> is farther away from top edge <NUM> than rear bottom edge <NUM>. The offset between front bottom edge <NUM> and rear bottom edge <NUM> creates an area <NUM> of front shoulder web panel <NUM> that is uncovered by second shoulder web panel <NUM> where a seam <NUM> is formed between torso web piece <NUM> and front shoulder web panel <NUM> of shoulder web piece <NUM> to attach torso and shoulder web pieces <NUM>, <NUM> together. Underarm seams <NUM> and seam <NUM> may be created using a variety of different bonding techniques that attach together two or more material layers such as thermal, ultrasonic, pressure, or adhesive bonding techniques and various other forms of bonding known in the industry.

Referring now to <FIG> and <FIG>, isolation gowns <NUM>, <NUM> are illustrated, according to alternative embodiments of the invention. Isolation gowns <NUM>, <NUM> differ from isolation gown <NUM> by incorporating alternative shoulder web pieces <NUM>, <NUM> in place of shoulder web piece <NUM> shown in <FIG>. Isolation gowns <NUM>, <NUM> are illustrated as including torso web piece <NUM> having the tie strap configuration of <FIG>, but it is contemplated that other embodiments may include any of the alternative tie strap configurations illustrated in <FIG>. Since shoulder web pieces <NUM>, <NUM> are arranged similarly to shoulder web piece <NUM> of <FIG>, like elements in shoulder web pieces <NUM>, <NUM> are numbered identically to corresponding elements in shoulder web piece <NUM>. The only differences between shoulder web piece <NUM> of <FIG> and shoulder web pieces <NUM>, <NUM> are the arrangement of wrist openings <NUM>, <NUM> in sleeves <NUM>, <NUM>, the addition of a neck stretch patch <NUM> over neck opening <NUM> in front and rear shoulder web panels <NUM>, <NUM>, and the addition of wrist stretch patches <NUM> over wrist openings <NUM>, <NUM> in lieu of optional thumb openings <NUM>.

In shoulder web piece <NUM> of <FIG>, wrist openings <NUM>, <NUM> are located along the top edge <NUM>. Neck stretch patch <NUM> is folded over top edge <NUM> across neck opening <NUM>, and wrist stretch patches <NUM> are folded over top edge <NUM> across wrist openings <NUM>, <NUM>. In shoulder web piece <NUM> of <FIG>, wrist openings <NUM>, <NUM> are located in front shoulder web panel <NUM> between top edge <NUM> and underarm seams <NUM>. Neck stretch patch <NUM> is folded over top edge <NUM> across neck opening <NUM>, and wrist stretch patches <NUM> are positioned over wrist openings <NUM>, <NUM> on front shoulder web panel <NUM>. Thus, the difference between shoulder web piece <NUM> of <FIG> and shoulder web piece <NUM> of <FIG> is the location of wrist openings <NUM>, <NUM> and wrist stretch patches <NUM>. However, in each of shoulder web pieces <NUM>, <NUM>, neck and wrist stretch patches <NUM>, <NUM> function in the same way, as described below with respect to <FIG>.

Referring to <FIG>, a top view of neck stretch patch <NUM> and wrist stretch patches <NUM> of shoulder web pieces <NUM>, <NUM> of <FIG> and <FIG> are illustrated in relation to a continuous shoulder web <NUM> including neck opening <NUM> and wrist openings <NUM>, <NUM> of shoulder web pieces <NUM>, <NUM> of <FIG> and <FIG> during the manufacturing process for isolation gowns <NUM>, <NUM>, according to an embodiment of the invention. Neck stretch patch <NUM> includes a neck opening <NUM> therein smaller than neck opening <NUM> in front and rear shoulder web panels <NUM>, <NUM> shown in phantom. Similarly, each wrist stretch patch <NUM> includes a wrist opening <NUM> therein smaller than wrist openings <NUM>, <NUM>, which are shown in phantom. Neck and wrist stretch patches <NUM>, <NUM> are made of a stretchable material such as, for example, an elastic film, elastic adhesive, elastic composite, or elastic laminate. Since neck and wrist stretch patches <NUM>, <NUM> are stretchable, a wearer's neck and hands may still fit through the smaller neck and wrist holes <NUM>, <NUM>, respectfully. Thereafter, neck and wrist stretch patches <NUM>, <NUM> contract onto the wearer's neck and wrists to create seals that may additionally protect against potentially hazardous, infectious, or unclean materials entering isolation gown <NUM>. As such, the inclusion of neck and wrist stretch patches <NUM>, <NUM> are beneficial to wearers of isolation gown <NUM>.

Referring now to <FIG>, an isolation gown <NUM> is illustrated, according to another embodiment of the invention. Isolation gown <NUM> includes an alternative shoulder web piece <NUM> in place of shoulder web piece <NUM> shown in <FIG>. Isolation gown <NUM> is illustrated as including torso web piece <NUM> having the tie strap configuration of <FIG>, but it is contemplated that other embodiments may include any of the alternative tie strap configurations illustrated in <FIG>. Since shoulder web piece <NUM> is arranged similarly to shoulder web pieces <NUM>, <NUM>, <NUM> of <FIG>, <FIG>, and <FIG>, like elements in shoulder web piece <NUM> are numbered identically to corresponding elements in shoulder web pieces <NUM>, <NUM>, <NUM>. Like shoulder web pieces <NUM>, <NUM> of <FIG> and <FIG>, shoulder web piece <NUM> differs from shoulder web piece <NUM> of <FIG> in the application of neck stretch patch <NUM> over neck opening <NUM>.

However, shoulder web piece <NUM> differs from shoulder web pieces <NUM>, <NUM> (<FIG> and <FIG>) in that shoulder web piece <NUM> includes a different configuration of wrist stretch patches <NUM> applied over corresponding wrist openings <NUM> in sleeves <NUM>, <NUM>. Wrist stretch patches <NUM> are folded over top edge <NUM> across wrist openings <NUM>, with wrist openings <NUM> provided facing the right and left edges of sleeves <NUM>, <NUM>. During the manufacturing process, wrist stretch patches <NUM> and wrist openings <NUM> are positioned to span two adjacent isolation gowns <NUM>, as explained with respect to <FIG> below.

Referring to <FIG>, a top view of neck stretch patch <NUM> and wrist stretch patches <NUM> of shoulder web piece <NUM> of <FIG> are illustrated in relation to a continuous shoulder web <NUM> including neck opening <NUM> and wrist openings 52of shoulder web piece <NUM> of <FIG> during the manufacturing process for isolation gown <NUM>, according to an embodiment of the invention. Neck stretch patch <NUM> is arranged in the same manner as shown in <FIG>, with neck opening <NUM> smaller than neck opening <NUM> in front and rear shoulder web panels <NUM>, <NUM>. Like neck and wrist stretch patches <NUM>, wrist stretch patches <NUM> may be made of a stretchable material such as, for example, an elastic film, elastic adhesive, elastic composite, or elastic laminate. After wearers of isolation gown <NUM> insert their heads and hands through the stretchable material of neck and wrist stretch patches <NUM>, <NUM>, respectively, neck and wrist stretch patches <NUM>, <NUM> contract onto their necks and wrists to create seals to provide more protection from the intrusion of possibly hazardous, infection, or unclean materials into isolation gown <NUM>.

In addition, the size of wrist stretch patches <NUM> provides an advantage during manufacturing. More specifically, as shown in <FIG>, a length <NUM> of wrist stretch patches <NUM> is equal to that of neck stretch patch <NUM>. As such, wrist stretch patches <NUM> of <FIG>, wrist stretch patches <NUM> may be applied to front and rear shoulder web panels <NUM>, <NUM> with the same machine as that used to apply neck stretch patches <NUM>. This will be discussed in further detail with respect to <FIG> below.

Referring now to <FIG>, portions of an exemplary manufacturing line <NUM> for manufacturing multi-piece open-back isolation gowns <NUM> and associated production flow <NUM> is illustrated, according to an embodiment of the invention. <FIG> illustrates the machinery in manufacturing line <NUM> for performing a method of manufacturing multi-piece open-back isolation gowns <NUM>. <FIG> illustrates how webs may be manipulated and combined into multi-piece open-back isolation gown <NUM> of <FIG> including shoulder web piece <NUM> in manufacturing line <NUM>. <FIG> illustrates how webs may be manipulated to create shoulder web pieces <NUM>, <NUM> of <FIG> and <FIG>, respectively, in manufacturing line <NUM>. <FIG> illustrates how webs may be manipulated to create shoulder web piece <NUM> of <FIG> in manufacturing line <NUM>. As such, like elements in <FIG> and <FIG> are numbered identically to corresponding elements in <FIG>.

Referring to <FIG> and <FIG>, manufacturing line <NUM> includes a torso web piece section <NUM> that forms torso web pieces <NUM>, a shoulder web piece section <NUM> that forms one of shoulder web pieces <NUM>, <NUM>, <NUM>, <NUM>, and an isolation gown section <NUM> that forms multi-piece open-back isolation gowns <NUM>, <NUM>, <NUM>, <NUM> from torso web piece <NUM> and one of shoulder web pieces <NUM>, <NUM>, <NUM>, <NUM>. In general, manufacturing line <NUM> performs operations along a machine direction <NUM>, but also performs operations in a cross-machine direction <NUM> that is perpendicular to machine direction <NUM>. In order to facilitate the formation of torso web pieces <NUM>, a continuous torso web <NUM> is fed into torso web piece section <NUM> in machine direction <NUM>. Continuous torso web <NUM> may be fed into torso web piece section <NUM> via a turnbar infeed process during which continuous torso web <NUM> is unwound from a roll (not shown).

Continuous torso web <NUM> is then directed past at least one roller <NUM> to an optional perforation unit or apparatus <NUM> including a rotary anvil <NUM> aligned with a rotary knife roll <NUM> having one or more knives <NUM>. Each knife <NUM> may be positioned within an insert (not shown) on rotary knife roll <NUM> and arranged to align with a corresponding insert (not shown) inset within rotary anvil <NUM> during operation of perforation unit <NUM>. Perforation unit <NUM> may be included in order to cut perforation lines in continuous torso web <NUM> in order to define one or more tie straps. As a non-limiting example, perforation unit <NUM> may be configured to cut perforation lines <NUM>, <NUM> in continuous torso web <NUM> in order to define tie straps <NUM>, <NUM>, as shown in <FIG>. While tie straps <NUM>, <NUM> are shown in <FIG> in the configuration of gown <NUM> of <FIG>, perforation unit <NUM> may be configured to create tie straps in any of the alternative configurations shown in <FIG>. In yet other embodiments, perforation unit <NUM> may be a cutting unit that cuts tie straps off of continuous torso web <NUM> for reattachment to torso web pieces <NUM> later in manufacturing line <NUM>. Further, tie straps may also be made offline from a web separate from continuous torso web <NUM> and attached to torso web pieces <NUM> in manufacturing line <NUM> or packaged as unattached strips with completed gowns <NUM>, <NUM>, <NUM>, <NUM>.

After passing through perforation unit <NUM>, continuous torso web <NUM> is folded in cross-machine direction <NUM> by a folding unit or apparatus <NUM> to make torso web pieces <NUM> easier to manipulate once they are separated from continuous torso web <NUM>. Folding unit <NUM> may include belts, rotary wheels, discs, rollers, fixed rods or plates of various shapes (flat or three-dimensional) and/or other known folding technologies. As shown in <FIG>, the fold in continuous torso web <NUM> is slightly off center such that bottom edge <NUM> on continuous torso web <NUM> is folded toward, but spaced apart from, top edge <NUM> on continuous torso web <NUM>. The spacing between top and bottom edges <NUM>, <NUM> of continuous torso web <NUM> aids in bonding discrete torso web pieces <NUM>, as will be described in more detail below with respect to isolation gown section <NUM> of manufacturing line <NUM>.

Once continuous torso web <NUM> is folded, it is fed to a torso cutting unit or apparatus <NUM>, such as a rotary die, knife roll with rotary anvil, laser technology, ultrasonic technology, or other known cutting means, for cutting discrete torso web pieces <NUM> from continuous torso web <NUM>. Cutting unit <NUM> is shown in <FIG> with the same components as perforation unit <NUM> including rotary anvil <NUM> aligned with rotary knife roll <NUM> having one or more knives <NUM>. However, in cutting unit <NUM>, each knife <NUM> on rotary knife roll <NUM> is configured to completely separate discrete torso web pieces <NUM> rather than create perforation lines. This is shown most clearly in <FIG> by way of cut line <NUM> separating one discrete torso web piece <NUM> from continuous torso web <NUM> after being folded. While <FIG> illustrates cutting unit <NUM> after folding unit <NUM> in manufacturing line <NUM>, the locations of the folding and cutting units <NUM>, <NUM> may be switched such that cutting unit <NUM> cuts discrete torso web pieces <NUM> from continuous torso web <NUM> and then folding unit <NUM> folds discrete torso web pieces <NUM> rather than continuous torso web <NUM>. Regardless, all resulting folded discrete torso web pieces <NUM> are re-pitched in a re-pitching unit or apparatus <NUM> in order to create separation between them for their placement onto a continuous shoulder web <NUM>, as explained in more detail below with respect to isolation gown section <NUM>. Re-pitching unit <NUM> may include rotary or linear servo/electro-magnetic technology, mechanical cams, speed mis-match between adjacent units, and/or other known re-pitching technologies. While a single re-pitching unit <NUM> is shown, alternate embodiments may include multiple re-pitching units positioned before and/or after transfer unit <NUM> to re-pitch the discrete torso web pieces <NUM> prior to transfer to continuous shoulder web <NUM>.

As shown in <FIG> and <FIG>, shoulder web piece section <NUM> operates simultaneously with torso web piece section <NUM>. To begin, at least one continuous shoulder web <NUM> is fed into shoulder web piece section <NUM> of manufacturing line <NUM> in machine direction <NUM>. Continuous shoulder web(s) <NUM> may be fed into shoulder web piece section <NUM> via a turnbar infeed process during which continuous torso web <NUM> is unwound from a roll (not shown) and directed past at least one roller <NUM>. Shoulder web piece section <NUM> will be in one of two different configurations <NUM>, <NUM> for processing continuous shoulder webs <NUM>. In configuration <NUM>, a single continuous shoulder web <NUM> is provided, folded, and bonded together. In alternative configuration <NUM>, two separate continuous shoulder webs 120a, 120b are provided and bonded together.

Initially, regarding configuration <NUM>, continuous shoulder web <NUM> is directed to a die and/or perforation unit or apparatus <NUM>, such as a rotary die, knife roll with rotary anvil, laser technology, ultrasonic technology, or other known cutting means. In <FIG>, die and/or perforation unit <NUM> includes rotary anvil(s) <NUM> and rotary knife roll(s) <NUM> with one or more knives <NUM>. Die and/or perforation unit <NUM> is configured to cut neck openings <NUM> in continuous shoulder web <NUM> and may optionally cut perforation lines <NUM> and thumb openings <NUM> in continuous shoulder web <NUM>, as shown in <FIG>. Thus, die and/or perforation unit <NUM> may be considered a neck cutting unit <NUM> or a neck and perforation cutting unit <NUM>. In one embodiment, die and/or perforation unit <NUM> includes a single rotary anvil <NUM>/rotary knife roll <NUM> pair with knives <NUM> configured to cut neck openings <NUM>, perforation lines <NUM>, and thumb openings <NUM>. In such an embodiment, die and/or perforation unit <NUM> may be cammed to create neck openings <NUM>, perforation lines <NUM>, and thumb openings <NUM> at the desired spacing. In an alternate embodiment, die and/or perforation unit <NUM> includes two or more separate rotary anvil <NUM>/rotary knife roll <NUM> pairs, spaced in the machine direction <NUM>, for cutting neck openings <NUM>, perforation lines <NUM>, and thumb openings <NUM>. Any or all of the separate rotary anvil <NUM>/rotary knife roll <NUM> pairs may be cammed. Thereafter, continuous shoulder web <NUM> may pass through an optional stretch patch unit <NUM>. Stretch patch unit <NUM> may be used to apply neck stretch patches <NUM> of <FIG>, wrist stretch patches <NUM> of <FIG>, and/or wrist stretch patches <NUM> of <FIG> when forming shoulder web piece <NUM> of <FIG>, shoulder web piece <NUM> of <FIG>, or shoulder web piece <NUM> of <FIG>.

<FIG> illustrates that at least one continuous stretch patch web <NUM> may be fed into stretch patch unit <NUM>. This may be done via a turnbar infeed process during which each continuous stretch patch web <NUM> is unwound from a roll (not shown). The number of continuous stretch patch webs <NUM> supplied to stretch patch unit <NUM> depends, at least in part, on whether different size stretch patches are necessary to create shoulder web pieces <NUM>, <NUM>, <NUM>. Each continuous stretch web <NUM> is passed by an adhesive applicator <NUM> that applies adhesive to continuous stretch web <NUM>. Thereafter, each continuous stretch web <NUM> is directed to a slip cut unit or apparatus <NUM> for the creation of stretch patches such as, for example, neck stretch patches <NUM>, wrist stretch patches <NUM>, and/or wrist stretch patches <NUM>.

Slip cut unit <NUM> includes a rotary vacuum anvil <NUM> and rotary knife roll <NUM> including one or more knives <NUM>. Continuous stretch patch web <NUM> is fed at a relatively low speed along rotary vacuum anvil <NUM>, which is moving at a relatively higher surface speed and upon which continuous stretch patch web <NUM> is allowed to "slip. " Each knife <NUM>, which is preferably moving at a surface velocity similar to that of rotary vacuum anvil <NUM>, cuts off a segment of continuous stretch patch web <NUM> against rotary vacuum anvil <NUM> to create discrete stretch patches (not shown in <FIG>), which, as stated above, may correspond to neck stretch patches <NUM>, wrist stretch patches <NUM>, and/or wrist stretch patches <NUM>. Once cut, each discrete stretch patch is held by a vacuum drawn through holes (not shown in <FIG>) in rotary vacuum anvil <NUM> as it is carried at the speed of rotary vacuum anvil <NUM> downstream to a transfer point <NUM> where it is transferred onto continuous shoulder web <NUM> with the adhesive from adhesive applicator <NUM> contacting continuous shoulder web <NUM>. A roller <NUM> is positioned across from rotary vacuum anvil <NUM> such that continuous shoulder web <NUM> with the discrete stretch patches thereon passes through a nip <NUM> between rotary vacuum anvil <NUM> and roller <NUM> in order to press the stretch patches onto continuous shoulder web <NUM>.

Once the stretch patches have been applied to continuous shoulder web <NUM>, continuous shoulder web <NUM> passes through one or more die units or apparatuses <NUM> including rotary anvil <NUM> and rotary knife roll <NUM> with one or more knives <NUM>. The configuration of knives <NUM> on rotary knife roll <NUM> of die unit(s) <NUM> is designed to cut neck and/or wrist openings in the stretch patches. As such, die unit(s) <NUM> may be considered patch opening cutting unit(s) <NUM>. For example, die unit(s) <NUM> may be configured to cut neck openings <NUM> in neck stretch patch <NUM> of <FIG> and/or wrist openings <NUM> in wrist stretch patches <NUM> of <FIG>. Non-limiting examples of how stretch patches <NUM>, <NUM>, and <NUM> may be applied to continuous shoulder web <NUM> by slip cut unit <NUM> and cut by die unit(s) <NUM> in stretch patch unit <NUM> will be described below with respect to <FIG> and <FIG>.

After passing through stretch patch unit <NUM> or, if stretch patch unit <NUM> is not included, after passing through die and/or perforation unit <NUM>, continuous shoulder web <NUM> is folded in cross-machine direction <NUM> by a folding unit or apparatus <NUM>. Folding unit <NUM> may include belts, rotary wheels, discs, rollers, fixed rods or plates of various shapes (flat or three-dimensional) and/or other known folding technologies. As shown most clearly in <FIG>, the fold in continuous shoulder web <NUM> is performed to define front and rear shoulder web panels <NUM>, <NUM> of in <FIG>, <FIG>, and <FIG> with folded top edge <NUM>. As such, the fold created by folding unit <NUM> is slightly off-center in order to create area <NUM> of front shoulder web panel <NUM> that is uncovered by rear shoulder web panel <NUM>.

Once folded, continuous shoulder web <NUM> passes through bonding unit or apparatus <NUM>. In <FIG>, bonding unit <NUM> is shown as an ultrasonic bonding unit <NUM> including a rotary anvil <NUM> and an ultrasonic fixed blade horn or sonotrode <NUM> that cooperate to create underarm seams in continuous shoulder web <NUM>. As shown in <FIG>, the underarm seams may be, for example, underarm seams <NUM> shown in shoulder web pieces <NUM>, <NUM>, <NUM>, <NUM> of <FIG>, <FIG>, and <FIG>. However, bonding unit <NUM> may alternatively include components for creating the underarm seams via a different bonding technique such as, for example, thermal, pressure, or adhesive bonding techniques or various other forms of bonding known in the industry. Regardless of which type of bonding technique is utilized by bonding unit <NUM>, both folding unit <NUM> and bonding unit <NUM> may be positioned downstream in manufacturing line <NUM> such as, for example, in isolation gown section <NUM>.

If configuration <NUM> of shoulder web piece section <NUM> is used in manufacturing line <NUM> instead of configuration <NUM>, shoulder web piece section <NUM> will receive two continuous shoulder webs 120a, 120b. In the same manner as in configuration <NUM>, each continuous shoulder web 120a, 120b will pass through separate die and/or perforation units <NUM> to create neck openings <NUM> and/or optional perforations <NUM> and thumb openings <NUM>. Thereafter, the two continuous shoulder webs 120a, 120b are laid on top of each other and passed through a bonding unit or apparatus <NUM>. Like bonding unit <NUM>, bonding unit <NUM> is shown in <FIG> as including rotary anvil <NUM> and sonotrode <NUM> for performing ultrasonic bonding, but may include equipment for performing another bonding technique such as, for example, thermal, pressure, or adhesive bonding. However, in addition to creating underarm seams in continuous shoulder webs 120a, 120b, bonding unit <NUM> also creates a top seam (not shown) adjacent to top edges (not shown) of continuous shoulder webs 120a, 120b. The result of the bonding is that the combined front and rear continuous shoulder webs 120a, 120b are arranged similarly to continuous shoulder web <NUM> of configuration <NUM>, but with the inclusion of the seam between front and rear continuous shoulder web panels 120a, 120b. As such, the combined front and rear continuous shoulder webs 120a, 120b will be referred to as continuous shoulder web <NUM>.

As illustrated by <FIG> and <FIG>, after torso web piece section <NUM> and shoulder web piece section <NUM> have completed their operations, torso web pieces <NUM> and continuous shoulder web <NUM> are provided by torso and shoulder web piece sections <NUM>, <NUM>, respectively, to isolation gown section <NUM>. Isolation gown section <NUM> includes a torso web piece transfer unit or apparatus <NUM> including two vacuum transfer drums or rolls <NUM>, <NUM>. In each of vacuum transfer drums <NUM>, <NUM>, a vacuum drawn through holes (not shown) to carry torso web pieces <NUM> and transfer them to continuous shoulder web <NUM>. More specifically, vacuum transfer drum <NUM> receives torso web pieces <NUM> from torso web piece section <NUM> and carries them in a clockwise direction <NUM> until they reach vacuum transfer drum <NUM>, at which point, vacuum transfer drum <NUM> releases torso webs <NUM> and vacuum transfer drum <NUM> carries them in a counterclockwise direction <NUM> to continuous shoulder web <NUM>. Torso web pieces <NUM> are positioned on continuous shoulder web <NUM> such that top edge <NUM>, and not bottom edge <NUM>, of each torso web piece overlaps bottom edge <NUM> of front shoulder panel <NUM> in area <NUM> of front shoulder panel <NUM> uncovered by rear shoulder panel <NUM>. While torso web piece transfer unit <NUM> is shown in <FIG> as transferring torso web pieces <NUM> to continuous shoulder web <NUM> either after or before continuous shoulder web <NUM> passes through folding and bonding units <NUM>, <NUM>, torso web piece transfer unit <NUM> may transfer torso web pieces <NUM> at various points upstream in configurations <NUM>, <NUM> of shoulder web piece section <NUM>.

In an alternative embodiment, transfer unit <NUM> may be in the form of a unit that takes the place of vacuum rolls <NUM>, <NUM>. The unit may be in the form of a cam-based system (not shown) in which a plurality of vacuum pucks (not shown) may re-pitch and/or rotate discrete torso web pieces <NUM> and place them onto continuous shoulder web <NUM>. The unit may also be a track-based system (not shown) in which a plurality of vacuum pucks (not shown) on a track re-pitch and/or rotate discrete torso web pieces <NUM> and place them onto continuous shoulder web <NUM>. In the track-based system, the vacuum pucks may be controlled individually by separate drive elements on the track and could then be more easily reconfigured electronically as necessary. In the case where transfer unit <NUM> is the cam-based or track-based system, discrete torso web pieces <NUM> may optionally be folded by a folding unit (not shown) before being carried by transfer unit <NUM>. In embodiments where transfer unit <NUM> incorporates re-pitching functionality, re-pitching unit <NUM> may be omitted. Alternate embodiments may include multiple re-pitching units positioned before and/or after transfer unit <NUM> to re-pitch the discrete torso web pieces <NUM> prior to transfer to continuous shoulder web <NUM>.

As explained above, once torso web pieces <NUM> are placed onto continuous shoulder web <NUM>, continuous shoulder web <NUM> may then be passed through folding and bonding units <NUM>, <NUM> if it has not already passed through folding and bonding units <NUM>, <NUM> in configuration <NUM> of shoulder web piece section <NUM>. Next, torso web pieces <NUM> and continuous shoulder web <NUM> are bonded together in a bonding unit <NUM>. In the illustrated embodiment, bonding unit <NUM> includes a rotary anvil <NUM> and sonotrode <NUM> for ultrasonic bonding. However, as similarly explained above with respect bonding units <NUM>, <NUM>, bonding unit <NUM> may include components for performing another type of bonding like thermal or pressure bonding, as non-limiting examples. In yet other embodiments, bonding unit <NUM> is an adhesive applicator that places a strip of adhesive (not shown) on continuous shoulder web <NUM> or on each torso web piece <NUM> before each torso web piece <NUM> is positioned on continuous shoulder web <NUM> to bond discrete torso web pieces <NUM> to continuous shoulder web <NUM>. As shown in <FIG>, regardless of the technique used to bond torso web pieces <NUM> and continuous shoulder web <NUM>, bonding unit <NUM> bonds torso web pieces <NUM> to continuous shoulder web <NUM> to create seam <NUM> between torso web piece <NUM> and front shoulder web panel <NUM> in area <NUM> of front shoulder web panel <NUM> uncovered by rear shoulder web panel <NUM>. In embodiments that bond with adhesive, isolation gown section <NUM> may include nip rollers (not shown) that press torso web pieces <NUM> and continuous shoulder web <NUM> together at the adhesive strip.

After torso web pieces <NUM> and continuous shoulder web <NUM> are bonded together, the combined structure may be considered as a continuous isolation garment web - referred to hereafter as isolation gown web <NUM>. Continuous isolation gown web <NUM> is directed to a die unit or apparatus <NUM> including rotary anvil <NUM> and rotary knife roll <NUM> with one or more knives <NUM> configured to cut out the excess underarm material <NUM> from continuous shoulder web material <NUM> below underarm seams <NUM> in front and rear shoulder panels <NUM>, <NUM> and create underarm edges <NUM>, <NUM> in front and rear shoulder panels <NUM>, <NUM>, respectively. Die unit <NUM> may also be configured to separate continuous isolation gown web <NUM> into discrete multi-piece open-back isolation gowns <NUM>, <NUM>, <NUM>, <NUM> including torso web piece <NUM> and shoulder web piece <NUM>, <NUM>, <NUM>, <NUM>, respectively, at cut lines <NUM>. <FIG> illustrates isolation gowns <NUM> with torso web piece <NUM> and shoulder web pieces <NUM>, as similarly shown in <FIG>. Alternatively, die unit <NUM> may create cut lines <NUM> as perforation lines <NUM> when it is desired to package continuous isolation gown web <NUM> in a roll from which an individual may tear discrete isolation gowns <NUM> as needed.

Once die unit <NUM> has removed excess underarm material <NUM> and/or cut continuous isolation gown web <NUM> into discrete isolation gowns <NUM>, <NUM>, <NUM>, <NUM>, continuous isolation gown web <NUM> or discrete isolation gowns <NUM>, <NUM>, <NUM>, <NUM> are folded in cross direction <NUM> by a folding unit or apparatus <NUM>, which may include belts, rotary wheels, discs, rollers, fixed rods or plates of various shapes (flat or three-dimensional) and/or other known folding technologies. While <FIG> illustrates that folding unit <NUM> folds torso web pieces <NUM> over shoulder web pieces <NUM>, folding unit <NUM> may instead fold shoulder web pieces <NUM> over torso web pieces <NUM>. In an alternative embodiment, not forming part of the claimed invention, folding unit <NUM> is positioned upstream of die unit <NUM>. After passing through die unit <NUM> and folding unit <NUM>, discrete isolation gowns <NUM>, <NUM>, <NUM>, <NUM> pass through a multi-stage folding unit or apparatus <NUM>. As non-limiting examples, not forming part of the claimed invention, multi-stage folding unit <NUM> may include multiple folding stations such as, for example, three tuckers (not shown) or multiple pairs of rotating folding blades (not shown) that perform a tri-fold operation on each isolation gown <NUM> to make them ready for packaging, as shown in <FIG>. While a tri-fold configuration is described herein, it is contemplated that multi-stage folding unit <NUM> may be configured to create any number of folds in each isolation gown <NUM>, <NUM>, <NUM>, <NUM> to create the desired package shape. However, if continuous isolation gown web <NUM> has not been separated into discrete isolation gowns <NUM>, <NUM>, <NUM>, <NUM>, continuous isolation gown web <NUM> may be fed into a rewinder (not shown) and rolled up or rewound for packaging in an isolation gown web dispenser (not shown) from which discrete isolation gowns <NUM> may be torn, as described above.

Referring now to <FIG>, a simplified view of a stretch patch unit or apparatus <NUM> along with a corresponding processing flow <NUM> is illustrated, according to an embodiment of the invention. Stretch patch unit <NUM> may be used as stretch patch unit <NUM> in <FIG> to place neck stretch patches <NUM> and wrist stretch patches <NUM> on continuous shoulder web <NUM> for creating shoulder web pieces <NUM>, <NUM> shown in <FIG> and <FIG>. While not depicted in the simplified view shown in <FIG>, it will be understood that stretch patch unit <NUM> includes adhesive applicators <NUM>, slip cut units <NUM>, and die units <NUM> shown in stretch patch unit <NUM> of <FIG> as necessary to perform stretch patch operations.

Referring now to <FIG> and <FIG> together as appropriate, two continuous wrist stretch patch webs <NUM> and one continuous neck stretch patch web <NUM> are fed into stretch patch unit <NUM>, and adhesive applicators <NUM> apply adhesive to webs <NUM>, <NUM>. After adhesive is applied, separate slip cut units <NUM> cut discrete wrist stretch patches <NUM> and discrete neck stretch patches <NUM> from continuous wrist and neck stretch patch webs <NUM>, <NUM>, respectively, and place them over wrist openings <NUM>, <NUM> and neck opening <NUM>, respectively. Next, one or more die units <NUM> cut wrist openings <NUM> and neck openings <NUM> in wrist stretch patches <NUM> and neck stretch patches <NUM>, respectively. Thereafter, continuous shoulder web <NUM> will continue on to folding and bonding units <NUM>, <NUM> of configuration <NUM> of shoulder web piece section <NUM> shown in <FIG>. Folding and bonding units <NUM>, <NUM> will perform the folding and bonding operations described above with respect to <FIG> and <FIG> to form shoulder web pieces <NUM>, <NUM> shown in <FIG> and <FIG>.

Referring now to <FIG>, a simplified view of a stretch patch unit or apparatus <NUM> along with a corresponding process flow <NUM> is illustrated, according to another embodiment of the invention. Like stretch patch unit <NUM>, stretch patch unit <NUM> may be used as stretch patch unit <NUM> in <FIG>. However, stretch patch unit <NUM> is used to place neck stretch patches <NUM> and wrist stretch patches <NUM> on continuous shoulder web <NUM> for creating shoulder web piece <NUM> shown in <FIG>. While not depicted in the simplified view shown in <FIG>, it will be understood that stretch patch unit <NUM> includes adhesive applicators <NUM>, slip cut units <NUM>, and die units <NUM> shown in stretch patch unit <NUM> of <FIG> as necessary to perform stretch patch operations.

Referring now to <FIG> and <FIG> together as appropriate, stretch patch unit <NUM> utilizes a single continuous stretch patch web <NUM> due to the fact that neck stretch patches <NUM> and wrist stretch patches <NUM> have the same length <NUM>, as shown in <FIG>. Continuous stretch patch web <NUM> passes under adhesive applicator <NUM>, which applies adhesive thereto. Then, slip cut unit <NUM> cuts discrete neck stretch patches <NUM> and discrete wrist stretch patches <NUM> from continuous stretch patch web <NUM>. Each discrete neck stretch patch <NUM> is placed over one neck opening <NUM> and every discrete wrist stretch patch <NUM> is placed over one wrist opening <NUM>. Thereafter, one or more die units <NUM> cut neck opening <NUM> in neck stretch patches <NUM> inside of neck opening <NUM>. A given wrist stretch patch <NUM> is divided in half downstream in isolation gown section <NUM> by die unit <NUM> and thus forms the right and left wrist portions of two adjacent gowns <NUM>. Having passed through die unit(s) <NUM>, continuous shoulder web <NUM> will continue on to folding and bonding units <NUM>, <NUM> of configuration <NUM> of shoulder web piece section <NUM> shown in <FIG>. Folding and bonding units <NUM>, <NUM> will perform the folding and bonding operations described above with respect to <FIG> and <FIG> to form shoulder web pieces <NUM> shown in <FIG>.

Beneficially, embodiments of the invention include an apparatus and method of manufacturing multi-piece open-back isolation garments having a torso web piece and a shoulder web piece. In manufacturing the shoulder web pieces, front and rear shoulder panels are formed by either folding one continuous shoulder web and bonding the overlapping shoulder web layers or by bonding two continuous shoulder webs together. At the same time, discrete torso web pieces are cut from a continuous torso web by a cutting unit. A transfer unit transfers the discrete torso web pieces onto the continuous shoulder web such that top edges of the discrete torso web pieces overlap a bottom edge of the front shoulder web panels of the continuous shoulder web in an area that is uncovered by the rear shoulder web. Thereafter, the discrete torso web pieces are bonded to the front shoulder web panel of the continuous shoulder web in the area uncovered by the rear shoulder web to form a continuous multi-piece open-back isolation garment web which may be rewound into a roll or cut to form discrete isolation garments for folding and packaging. The manufacturing of the multi-piece open-back isolation garments can quickly produce the isolation garments without manual input and with only a small amount of scrap material. The formation of the torso web pieces does not result in any scrap material, and the formation of the shoulder web pieces results in only minimal scrap material from cutting neck and wrist openings and excess underarm material.

Therefore, according to one embodiment of the invention, an apparatus for manufacturing multi-piece open-back isolation garments includes a neck cutting unit configured to cut neck openings in a continuous shoulder web and a first bonding unit configured to create underarm seams between first shoulder web panels and second shoulder web panels overlapping each other in the continuous shoulder web. The apparatus also includes a torso cutting unit configured to cut discrete torso web pieces from a continuous torso web and a transfer unit configured to transfer the discrete torso web pieces onto the first shoulder web panels of the continuous shoulder web such that a top edge of each discrete torso web piece overlaps a bottom edge of the first shoulder web panels in an area of the first shoulder web panels that is uncovered by the second shoulder web panels. In addition, the apparatus includes a second bonding unit configured to bond the discrete torso web pieces to the first shoulder web panels in the area uncovered by the second shoulder web panels to create a continuous isolation garment web.

According to another embodiment of the present invention, a method of manufacturing multi-piece open-back isolation garments includes cutting neck openings in a continuous shoulder web traveling in a machine direction and forming first shoulder web panels and second shoulder web panels overlapping each other in a continuous shoulder web, the first and second shoulder web panels having respective bottom edges offset from each other to create an area on the first shoulder web panel that is uncovered by the second shoulder web panel. The method additionally includes creating underarm seams between the first and second shoulder web panels and cutting a continuous torso web into discrete torso web pieces. Furthermore, the method includes transferring the discrete torso web pieces onto the first shoulder web panels such that a top edge of each discrete torso web piece overlaps the bottom edge of the first shoulder web panels in the area of the first shoulder web panel that is uncovered by the second shoulder web panels and bonding the discrete torso web pieces to the first shoulder web panels in the area that is uncovered by the second shoulder web panels to create a continuous isolation garment web.

According to yet another embodiment of the present invention, a multi-piece garment includes a shoulder web piece having a first shoulder web panel and second shoulder web panel overlapping the second shoulder web panel. The first shoulder web panel includes a bottom edge and a pair of underarm edges extending out from the bottom edge, and the second shoulder web panel includes a bottom edge offset from the bottom edge of the first shoulder web panel to create an area on first shoulder web panel that is uncovered by the second shoulder web panel and a pair of underarm edges extending out from the bottom edge of the second shoulder web panel and substantially aligned with the pair of underarm edges of the first shoulder web panel. The shoulder web piece further includes a pair of underarm seams joining the first and second shoulder web panels at adjacent underarm edges of the first and second shoulder web panels to form first and second sleeves in the shoulder web piece and a neck opening formed in the first and second shoulder web panels across from the bottom edges of the first and second shoulder web panels. The multi-piece garment also includes a torso web piece comprising a top edge overlapping the bottom edge of the first shoulder web panel of the shoulder web piece in the area uncovered by the second shoulder web panel of the shoulder web piece, the torso web piece attached to the first shoulder web panel via a seam positioned between the top edge of the torso web piece and the bottom edge of the first shoulder web panel.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims.

Claim 1:
An apparatus for manufacturing multi-piece open-back isolation garments, the apparatus comprising:
a neck cutting unit (<NUM>) configured to cut neck openings in a continuous shoulder web;
a first bonding unit (<NUM>) configured to create underarm seams between first shoulder web panels and second shoulder web panels overlapping each other in the continuous shoulder web;
a torso cutting unit (<NUM>) configured to cut discrete torso web pieces from a continuous torso web;
characterized in further comprising
a transfer unit (<NUM>) configured to transfer the discrete torso web pieces onto the first shoulder web panels of the continuous shoulder web such that a top edge of each discrete torso web piece overlaps a bottom edge of the first shoulder web panels in an area of the first shoulder web panels that is uncovered by the second shoulder web panels; and
a second bonding unit (<NUM>) configured to bond the discrete torso web pieces to the first shoulder web panels in the area uncovered by the second shoulder web panels to create a continuous isolation garment web.