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 garment is 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 garment 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 an isolation garment out of one material web or out 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.

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.

<CIT>) discloses an article for clothing, particularily 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.

In accordance with one aspect of the invention, an apparatus for manufacturing multi-piece closed-back isolation garments includes a slitting unit configured to cut and separate a continuous cover strip segment from a continuous shoulder web, at least one die unit configured to cut a neck opening in the continuous shoulder web, and a first folding unit configured to fold a second shoulder web panel of a continuous shoulder web over a first shoulder web panel of the continuous shoulder web and create an area on the first shoulder web panel that is uncovered by the second shoulder web panel. The apparatus further includes a first bonding unit configured to bond the first shoulder web panel to the second shoulder web panel, a first adhesive applicator configured to apply a first adhesive strip to the uncovered area of the first shoulder web panel, and a perforation unit configured to cut a perforation line in a continuous torso web to define a first tie strap. In addition, the apparatus includes a second folding unit configured to fold the continuous torso web into a tube, a cutting unit configured to cut a torso web piece from the folded continuous torso web, and a transfer unit configured to transfer a torso web piece having a substantially tubular shape onto the first adhesive strip. The apparatus also includes a second adhesive applicator configured to apply a second adhesive strip to attach the continuous cover strip segment to the torso web piece and second shoulder web panel and forming a continuous isolation garment web and at least one other adhesive applicator configured to attach a second tie strap to the torso web piece of the continuous isolation garment web.

In accordance with another aspect of the invention, a method of manufacturing multi-piece closed-back isolation garments includes slitting a continuous cover strip segment from a continuous shoulder web using a slitting unit, cutting neck openings in the continuous shoulder web using a die unit, and overlapping first and second shoulder web panels of the continuous shoulder web to create an area in the first shoulder web panels that is uncovered by the second shoulder web panel. Furthermore, the method includes bonding the first and second shoulder web panels with a first bonding unit, applying a first adhesive strip on the continuous shoulder web in the uncovered area of the first shoulder web panel, and cutting a perforation line in the continuous torso web to define an integrated continuous tie strap. The method also includes folding a continuous torso web to form a tube, cutting a torso web piece from the folded continuous torso web, and transferring, with a transfer unit, a torso web piece having a substantially tubular shape onto the first adhesive strip such that a top edge of the torso web piece overlaps the bottom edge of the first shoulder web panel. Additionally, the method includes attaching the continuous cover strip segment to the torso web piece and second shoulder web panel with a second adhesive strip to form a continuous isolation garment web and adhesively attaching a second tie strap to the torso web piece of the continuous isolation garment web.

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 closed-back/tube-style 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 torso web pieces from at least one continuous torso web, combine the discrete torso pieces with a continuous shoulder web, and cut and fold the combined torso and shoulder web structure to form the multi-piece closed-back isolation garments, and fold or roll up the multi-piece closed-back isolation garments for packaging. The multi-piece closed-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>, rear, right side, and rear perspective views of a multi-piece closed-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. In <FIG>, torso web piece <NUM> is shown as a single torso web panel that has been folded. Folded torso web piece <NUM> includes a top edge <NUM>, a bottom edge <NUM>, folded left side and right side edges <NUM>, <NUM>, and overlapping left and right side panel edges <NUM>, <NUM>, where panel edges <NUM>, <NUM> are named for their locations prior to folding torso web piece <NUM>. Edges <NUM>, <NUM>, <NUM>, <NUM> define front and rear surfaces <NUM>, <NUM> of torso web piece <NUM>. Right side panel edge <NUM> is folded over left side panel edge <NUM> by an overlapping distance <NUM>. However, in various embodiments, left side panel edge <NUM> may be folded over right side panel edge <NUM> by overlapping distance <NUM>. In either case, torso web piece <NUM> has a substantially tubular shape. Further, in other embodiments, torso web piece <NUM> may also be formed of two separate torso web panels (not shown). In that case, the two torso web panels would be bonded at their side edges to create side seams (not shown). The side seams may be created using a variety of different bonding techniques that attach together two or more material layers such as sonic, thermal, ultrasonic, pressure, or adhesive bonding techniques and various other forms of bonding known in the industry.

Torso web piece <NUM> further includes two optional tie straps <NUM>, <NUM>. Tie strap <NUM> is positioned along right side panel edge <NUM>. When in use, tie strap <NUM> will be separated from torso web piece <NUM> along perforation line <NUM>, but remain integrated with torso web piece <NUM> adjacent top edge <NUM>. Tie strap <NUM> is positioned on rear surface <NUM> of torso web piece <NUM> along folded right side edge <NUM> and is coupled to rear surface <NUM> via top and bottom adhesive strips <NUM>, <NUM> adjacent to folded right side edge <NUM> and may be a strip of web material cut from torso web piece <NUM> before folding. When in use, tie strap <NUM> will be separated from torso web piece <NUM> at bottom adhesive strip <NUM> and remain connected to torso web at top adhesive strip <NUM>. Bottom adhesive strip <NUM> may be omitted in some embodiments. Tie straps <NUM>, <NUM> may be tied around 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.

Shoulder web piece <NUM> of isolation gown <NUM> includes overlapping front and rear shoulder web panels <NUM>, <NUM>. In isolation gown <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 discrete shoulder web panels with separate top edges (not shown). In that case, shoulder web piece <NUM> would include a seam (not shown) between shoulder web panels <NUM>, <NUM> adjacent the two top edges. The seam between the two top edges may be created by a bonding technique such as, for example, sonic, thermal, ultrasonic, pressure, or adhesive bonding. Regardless, top edge <NUM> includes a substantially centralized neck opening <NUM>.

Shoulder web piece <NUM> may also include one or more perforation line(s) <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 apart 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> in approximately the same pattern as front underarm edges <NUM>. Shoulder web piece <NUM> includes underarm seams or bond patterns <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>. Underarm seams <NUM> may be created by a bonding technique such as sonic, thermal, ultrasonic, pressure, or adhesive bonding, as non-limiting examples.

Front and rear underarm edges <NUM>, <NUM> are substantially aligned with each other and joined to one another by bond patterns <NUM>. 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> on an interior surface <NUM> of front shoulder web panel <NUM> that is uncovered by second shoulder web panel <NUM> where torso web piece <NUM> is attached to front shoulder web panel <NUM> by an adhesive strip <NUM>. That is, torso web piece <NUM> is positioned on front shoulder web panel <NUM> such that top edge <NUM> of torso web piece <NUM> extends beyond and overlaps front bottom edge <NUM> and adhesive strip <NUM>, but is positioned adjacent and does not overlap rear bottom edge <NUM>.

Isolation gown <NUM> further includes a cover strip segment <NUM>, which may be formed of the same types of material as torso and shoulder web pieces <NUM>, <NUM>. Cover strip segment <NUM> includes upper adhesive strips <NUM>, <NUM> and lower adhesive strips <NUM>, <NUM> positioned thereon. Cover strip segment <NUM> is positioned over rear shoulder web panel <NUM> and rear surface <NUM> of torso web piece <NUM> such that upper adhesive strip <NUM> bonds cover strip segment <NUM> to rear shoulder web panel <NUM> and lower adhesive strip <NUM> bonds cover strip segment <NUM> to rear surface <NUM> of torso web piece <NUM>. In other words, cover strip segment <NUM> is used to couple together rear shoulder web panel <NUM> of shoulder web piece <NUM> and rear surface <NUM> of torso web piece <NUM>. Additionally, cover strip segment <NUM> may optionally include a perforation line <NUM> formed as an extension of perforation line <NUM> in rear shoulder web panel <NUM> to aid a wearer of isolation gown <NUM> in removing isolation gown <NUM>.

Referring now to <FIG> and <FIG>, portions of an exemplary manufacturing line <NUM> for manufacturing multi-piece closed-back isolation gowns 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 closed-back isolation gowns such as, for example, isolation gown <NUM> of <FIG>. The production flow <NUM> of <FIG> illustrates how webs may be manipulated and combined into multi-piece closed-back isolation gown <NUM> of <FIG> in manufacturing line <NUM>. As such, like elements in <FIG> are numbered identically to corresponding elements in <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 shoulder web pieces <NUM>, and an isolation gown section <NUM> that forms multi-piece closed-back isolation gown <NUM> from torso web piece <NUM> and shoulder web piece <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> at least one continuous torso web <NUM> including a continuous left side panel edge <NUM> and a continuous right side panel edge <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) and directed past at least one roller <NUM>. Torso web piece section <NUM> will be in one of two configurations <NUM>, <NUM> for processing continuous torso webs <NUM>. In configuration <NUM>, a single continuous torso web <NUM> is provided and folded. In configuration <NUM>, two separate continuous torso webs <NUM> are provided and bonded together.

Initially, regarding configuration <NUM>, continuous torso web <NUM> is directed to an optional slitting unit <NUM>. Slitting unit or apparatus <NUM> may include one or more knives or slitters (not shown) configured to cut at least one slit <NUM> in continuous torso web <NUM> in order to create one or more separated continuous tie strap webs <NUM> from continuous torso web <NUM>. Thereafter, each separated continuous tie strap web <NUM> is directed away from continuous torso web <NUM> via one or more tie strap roller(s) <NUM>. In alternative embodiments, continuous tie strap web <NUM> may be fed via a material roll (not shown) separate from continuous torso web <NUM>, in which case slitting unit <NUM> may be omitted. Meanwhile, continuous torso web <NUM> may pass through 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 include an ultrasonic assembly in lieu of knife roll <NUM> to create areas of weakness in the material in an alternative embodiment. Perforation unit <NUM> may be included in order to cut one or more perforation lines <NUM> in continuous torso web <NUM> in order to define one or more integral continuous tie strap webs <NUM>. When continuous torso web <NUM> is cut later on in torso web piece section <NUM>, perforation lines <NUM> may become perforation line <NUM> in <FIG> and <FIG>.

Once separated continuous tie strap webs <NUM> and integral continuous tie strap webs <NUM> have been formed, continuous torso web <NUM> is directed to a folding unit <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 and is configured to fold continuous torso web <NUM> in cross-direction <NUM> at each of continuous left and right side panel edges <NUM>, <NUM> such that continuous right side panel edge <NUM> is folded over continuous left side panel edge <NUM>, as shown in <FIG>. In other words, folding over continuous left side panel edge <NUM> occurs before folding over continuous right side panel edge <NUM>. However, in various embodiments, left side panel edge <NUM> may be folded over right side panel edge <NUM>. Regardless, in folding continuous torso web <NUM>, continuous folded left and right side edges <NUM>, <NUM> are formed.

If configuration <NUM> of torso web piece section <NUM> is used in manufacturing line <NUM> instead of configuration <NUM>, torso web piece section <NUM> will receive two continuous torso webs 518a, 518b in machine direction <NUM>. Since configuration <NUM> utilizes two continuous torso webs 518a, 518b rather than a single continuous torso web <NUM>, continuous torso webs 518a, 518b may be much narrower than continuous torso web <NUM> such as, for example, approximately half the width of continuous torso web <NUM>. Like continuous torso web <NUM> in configuration <NUM>, continuous torso web 518a may be directed to an optional slitting unit <NUM> including more knives or slitters (not shown) configured to cut at least one slit <NUM> in continuous torso web 518a in order to create one or more separated continuous tie strap webs <NUM> from continuous torso web 518a. Thereafter, each separated continuous tie strap web <NUM> is directed away from continuous torso web 518a via one or more tie strap roller(s) <NUM>.

Continuous torso web 518a is laid over continuous web 518b, and continuous torso webs 518a, 518b pass through a 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 side seams (not shown) in continuous torso webs 518a, 518b. However, bonding unit <NUM> may alternatively include components for creating the side seams via a different bonding technique such as, for example, sonic, thermal, pressure, or adhesive bonding techniques or various other forms of bonding known in the industry. After passing through bonding unit <NUM>, bonded continuous torso webs 518a, 518b are referred to as continuous torso web <NUM>.

Regardless of whether torso web piece section <NUM> includes configuration <NUM> or configuration <NUM>, the resulting continuous torso web <NUM> is directed to a tie strap attachment unit or apparatus <NUM>. Tie strap attachment unit <NUM> is configured to apply adhesive to continuous torso web <NUM> and place any continuous tie strap webs <NUM> onto the adhesive to attach continuous tie strap webs <NUM> to continuous torso web <NUM>. Thereafter, continuous torso web <NUM> passes through a 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 from continuous torso web <NUM> at a cut line <NUM>, as shown in <FIG>. As a non-limiting example, these discrete torso web pieces may be in the form of torso web pieces <NUM> of <FIG>, as shown in <FIG>. 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>, <NUM>, <NUM> rather than create perforation lines.

After discrete torso web pieces <NUM> are cut from continuous torso web <NUM>, discrete torso web pieces <NUM> may be processed by a number of optional units or apparatus to fold and/or rearrange discrete torso web pieces <NUM> for placement onto a continuous shoulder web <NUM>. More specifically, torso web piece section <NUM> may include an optional re-pitching unit or apparatus <NUM> configured to create a gap between adjacent discrete torso web pieces <NUM> in machine direction <NUM>, one or more optional folding units or apparatuses <NUM> configured to bi-fold or tri-fold discrete torso web pieces <NUM>, and/or an optional rotational unit or apparatus <NUM> configured to rotate discrete torso web pieces <NUM> by approximately <NUM> degrees, as shown in <FIG> as a non-limiting example. Alternatively, the re-pitching, folding, and rotating of discrete torso web pieces <NUM> may be performed by a single unit or apparatus, as discussed in more detail below with respect to isolation gown section <NUM>. In yet other embodiments, re-pitching unit <NUM> may be positioned downstream of folding unit(s) <NUM> such that the folding operation is performed prior to re-pitching.

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 shoulder 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 and processed. In alternative configuration <NUM>, two separate front and rear continuous shoulder webs 555a, 555b are provided, processed, and bonded together.

Initially, regarding configuration <NUM>, continuous shoulder web <NUM> is directed to a slitting unit or apparatus <NUM> including rotary anvil <NUM> and rotary knife roll <NUM> with one or more knives <NUM>. Slitting unit <NUM> is configured to form a slit <NUM> in continuous shoulder web <NUM> in order to form a continuous cover strip segment <NUM>. When continuous cover strip segment <NUM> is cut later on in isolation gown section <NUM>, continuous cover strip segment <NUM> will become a plurality of discrete cover strip segments <NUM>, as shown in <FIG>. Continuous cover strip segment <NUM> is then directed away from continuous shoulder web <NUM> via one or more rollers <NUM>. However, in various embodiments, continuous cover strip segment <NUM> may be supplied as a separate web or cut from web other than continuous shoulder web <NUM>. If continuous cover strip segment <NUM> is not cut from continuous shoulder web <NUM>, continuous shoulder web <NUM> may be narrower. Regardless, an optional perforation unit <NUM> may be used to create one or more perforation lines <NUM> (<FIG> and <FIG>) in continuous cover strip segment <NUM>.

Meanwhile, continuous shoulder web <NUM> is directed to a die and/or perforation unit or apparatus <NUM> including 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 neck perforation line(s) <NUM> and thumb openings <NUM> in continuous shoulder web <NUM>, as shown in <FIG>. 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>, neck perforation line(s) <NUM>, and thumb openings <NUM>. In such an embodiment, die and/or perforation unit <NUM> may be cammed to create neck openings <NUM>, neck perforation line(s) <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>, neck perforation line(s) <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> enters a folding unit <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. 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> shown mostly clearly in <FIG> with folded top edge <NUM>. As such, the fold created by folding unit <NUM> is made slightly off-center in in order to create area <NUM> uncovered by rear shoulder web <NUM>. In an alternative embodiment, folding unit <NUM> is positioned upstream of the die and/or perforation unit <NUM> that creates neck openings <NUM>. Once folded, continuous shoulder web <NUM> passes through a bonding unit or apparatus <NUM>. In <FIG>, bonding unit <NUM> is shown as an ultrasonic bonding unit <NUM> including rotary anvil <NUM> and 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> of shoulder web piece <NUM> of <FIG>. However, bonding unit <NUM> may alternatively include components for creating the underarm seams via a different bonding technique such as, for example, sonic, thermal, pressure, or adhesive bonding techniques or various other forms of bonding known in the industry.

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 front and rear continuous shoulder webs 555a, 555b that are approximately half as wide as continuous shoulder web <NUM> in configuration <NUM> (not counting continuous cover strip segment <NUM>). In the same manner as in configuration <NUM>, front and rear continuous shoulder webs 555a, 555b will pass through separate die and/or perforation units 576a, 576b, respectively. Die and/or perforation unit 576a is configured to create neck openings <NUM> and/or optional thumb openings <NUM> in front continuous shoulder web 555a. Die and/or perforation unit 576b is configured to create neck openings <NUM> and/or optional perforation line <NUM> in rear continuous shoulder web 555b. Rear continuous shoulder web 555b also passes through slitting unit <NUM> to form a slit <NUM> in rear continuous shoulder web 555b and create continuous cover strip segment <NUM>. Continuous cover strip segment <NUM> is then directed away from rear continuous shoulder web 555b via one or more rollers <NUM>. While <FIG> illustrates slitting unit <NUM> before die and/or perforation unit 576b, they may be reversed in various embodiments. Alternatively, in various embodiments, continuous cover strip segment <NUM> may be supplied as a separate web or cut from a web other than rear continuous shoulder web 555b. If continuous cover strip segment <NUM> is not cut from rear continuous shoulder web 555b, rear continuous shoulder web 555b may be narrower.

Next, front and rear continuous shoulder webs 555a, 555b are laid on top of each other and passed through a bonding unit or apparatus <NUM>. Like bonding unit <NUM> in configuration <NUM> of shoulder web piece section <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, sonic, thermal, pressure, or adhesive bonding. However, in addition to creating underarm seams in continuous shoulder webs 555a, 555b, bonding unit <NUM> also creates a top seam (not shown) adjacent to top edges (not shown) of continuous shoulder webs 555a, 555b. The result of the bonding is that the combined front and rear continuous shoulder webs 555a, 555b are arranged similarly to continuous shoulder web <NUM> of configuration <NUM>, but with the inclusion of the top seam between front and rear continuous shoulder webs 555a, 555b. As such, the combined front and rear continuous shoulder webs 555a, 555b will be referred to as continuous shoulder web <NUM>. After passing through configuration <NUM> or configuration <NUM>, continuous shoulder web <NUM> passes by an adhesive applicator <NUM>, which applies adhesive strip <NUM> in area <NUM> of front shoulder web panel <NUM> uncovered by rear shoulder web panel <NUM> shown in <FIG>.

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>. Continuous cover strip segment <NUM> is also directed to isolation gown section <NUM>. Isolation gown section <NUM> includes a torso web piece transfer unit or apparatus <NUM> configured to transfer discrete torso web pieces <NUM>, <NUM>, <NUM> in a rotational direction <NUM> (counterclockwise in <FIG> and <FIG>) such that front surface <NUM> of each discrete torso web piece <NUM>, <NUM>, <NUM> is placed onto adhesive strips <NUM> on continuous shoulder web <NUM> for attachment to continuous shoulder web <NUM>. Transfer unit <NUM> may be a separate unit from that of re-pitching unit <NUM>, folding unit <NUM>, and/or rotational unit <NUM> in the form of a vacuum drum in which a vacuum drawn through holes (not shown) in the vacuum drum carries discrete torso web pieces <NUM> and transfers them to continuous shoulder web <NUM>. However, transfer unit <NUM> may be in the form of a unit that takes the place of re-pitching unit <NUM> and/or rotational unit <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 folding unit <NUM> before being carried by transfer unit <NUM>. Discrete torso web pieces <NUM> are folded by folding unit <NUM> slightly off-center such that bottom edge <NUM> of each discrete torso web piece <NUM> is folded toward, but spaced apart from, top edge <NUM>. While <FIG>. illustrates a single re-pitching unit <NUM>, 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>.

After discrete torso web pieces <NUM> are placed onto adhesive strips <NUM> on continuous shoulder web <NUM>, an adhesive applicator <NUM> applies adhesive strips <NUM>, <NUM>, <NUM>, <NUM> onto rear surface <NUM> of discrete torso web pieces <NUM> adjacent top edge <NUM> and, optionally, onto rear shoulder web panel <NUM> adjacent bottom edge <NUM>. In an alternative embodiment, optional adhesive applicator <NUM> is provided in place of or in addition to adhesive applicator <NUM> to apply adhesive strips <NUM>, <NUM>, <NUM>, <NUM> onto continuous cover strip segment <NUM>. Next, continuous cover strip segment <NUM> is placed over adhesive strips <NUM>, <NUM>, <NUM>, <NUM> to bond together torso web pieces <NUM> and rear shoulder web panels <NUM>. Once discrete torso web pieces <NUM> and rear shoulder web panels <NUM> are bonded together, the combined structure may be considered as a continuous isolation garment web, referred to hereafter as continuous isolation gown web <NUM>. Continuous isolation gown web <NUM> is directed to 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. Folding unit <NUM> (<FIG>) may fold continuous isolation gown web <NUM> by folding discrete torso web pieces <NUM> in cross-machine direction <NUM> over a portion of continuous shoulder web <NUM> as shown in <FIG>. In other embodiments, folding unit <NUM> may alternatively fold discrete torso web pieces <NUM> under continuous shoulder web <NUM> or fold continuous shoulder web <NUM> over or under discrete torso web pieces <NUM>.

Upon completion of the folding, continuous isolation gown <NUM> passes through a die unit or apparatus <NUM> including rotary anvil <NUM> and rotary knife roll <NUM> with one or more knives <NUM>. Die unit <NUM> is configured to cut out excess underarm and cover strip material and wrist cutouts <NUM> from continuous shoulder web <NUM> in front and rear shoulder web panels <NUM>, <NUM> and create underarm edges <NUM>, <NUM> in front and rear shoulder web panels <NUM>, <NUM>, respectively. Die unit <NUM> may also be configured to separate continuous isolation gown web <NUM> into discrete multi-piece closed-back/tube-style isolation gowns <NUM> including respective torso web pieces <NUM> and shoulder web pieces <NUM> at cut lines <NUM>. In the illustrated embodiment die unit <NUM> is positioned downstream from folding unit <NUM>. In an alternative embodiment, die unit <NUM> may be positioned upstream of folding unit <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 material and wrist cutouts <NUM> and/or cut continuous isolation gown web <NUM> into discrete isolation gowns <NUM>, discrete isolation gowns <NUM> pass through a multi-stage folding unit or apparatus <NUM>. As non-limiting examples, 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 the isolation gown <NUM> to create the desired folded product shape for packaging. However, if continuous isolation gown web <NUM> has not been separated into discrete isolation gowns <NUM>, multi-stage folding unit <NUM> may instead be a rewinder for rolling up continuous isolation gown web <NUM> for packaging in an isolation gown web dispenser (not shown) from which discrete isolation gowns <NUM> may be torn, as described above.

Beneficially, embodiments of the invention include an apparatus and method of manufacturing multi-piece closed-back isolation gowns having a torso web piece and a shoulder web piece. In manufacturing the torso web pieces, either a single continuous torso web is folded or two continuous torso webs are bonded together. In manufacturing the shoulder web pieces, front and rear shoulder web 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. 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 with an adhesive strip. Thereafter, a continuous cover strip segment is applied to couple the discrete torso web pieces and continuous shoulder web to form a continuous multi-piece closed-back isolation gown web which may be would into a roll or cut to form discrete isolation gowns for folding and packaging. The manufacturing of the multi-piece closed-back isolation gowns can quickly produce the isolation gowns 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 closed-back isolation garments includes a slitting unit configured to cut and separate a continuous cover strip segment from a continuous shoulder web, at least one die unit configured to cut a neck opening in the continuous shoulder web, and a first folding unit configured to fold a second shoulder web panel of a continuous shoulder web over a first shoulder web panel of the continuous shoulder web and create an area on the first shoulder web panel that is uncovered by the second shoulder web panel. The apparatus further includes a first bonding unit configured to bond the first shoulder web panel to the second shoulder web panel, a first adhesive applicator configured to apply a first adhesive strip to the uncovered area of the first shoulder web panel, and a perforation unit configured to cut a perforation line in a continuous torso web to define a first tie strap. In addition, the apparatus includes a second folding unit configured to fold the continuous torso web into a tube, a cutting unit configured to cut a torso web piece from the folded continuous torso web, and a transfer unit configured to transfer a torso web piece having a substantially tubular shape onto the first adhesive strip. The apparatus also includes a second adhesive applicator configured to apply a second adhesive strip to attach the continuous cover strip segment to the torso web piece and second shoulder web panel and forming a continuous isolation garment web and at least one other adhesive applicator configured to attach a second tie strap to the torso web piece of the continuous isolation garment web.

According to another embodiment of the present invention, a method of manufacturing multi-piece closed-back isolation garments includes slitting a continuous cover strip segment from a continuous shoulder web using a slitting unit, cutting neck openings in the continuous shoulder web using a die unit, and overlapping first and second shoulder web panels of the continuous shoulder web to create an area in the first shoulder web panels that is uncovered by the second shoulder web panel. Furthermore, the method includes bonding the first and second shoulder web panels with a first bonding unit, applying a first adhesive strip on the continuous shoulder web in the uncovered area of the first shoulder web panel, and cutting a perforation line in the continuous torso web to define an integrated continuous tie strap. The method also includes folding a continuous torso web to form a tube, cutting a torso web piece from the folded continuous torso web, and transferring, with a transfer unit, a torso web piece having a substantially tubular shape onto the first adhesive strip such that a top edge of the torso web piece overlaps the bottom edge of the first shoulder web panel. Additionally, the method includes attaching the continuous cover strip segment to the torso web piece and second shoulder web panel with a second adhesive strip to form a continuous isolation garment web and adhesively attaching a second tie strap to the torso web piece of the continuous isolation garment web.

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 invention is defined by the claims, and may include other examples that occur to those skilled in the art.

Claim 1:
An apparatus for manufacturing multi-piece closed-back isolation garments, the apparatus comprising:
at least one die unit (<NUM>) configured to cut a neck opening in the continuous shoulder web;
a first bonding unit (<NUM>) configured to bond the first shoulder web panel to the second shoulder web panel;
the apparatus being characterized in further comprising:
a slitting unit (<NUM>) configured to cut and separate a continuous cover strip segment from a continuous shoulder web;
a first folding unit (<NUM>) configured to fold a second shoulder web panel of the continuous shoulder web over a first shoulder web panel of the continuous shoulder web and create an area on the first shoulder web panel that is uncovered by the second shoulder web panel;
a first adhesive applicator (<NUM>) configured to apply a first adhesive strip to the uncovered area of the first shoulder web panel;
a perforation unit (<NUM>) configured to cut a perforation line in a continuous torso web to define a first tie strap;
a second folding unit (<NUM>) configured to fold the continuous torso web into a tube;
a cutting unit (<NUM>, <NUM>) configured to cut a torso web piece from the folded continuous torso web;
a transfer unit (<NUM>) configured to transfer the torso web piece having a substantially tubular shape onto the first adhesive strip;
a second adhesive applicator (<NUM>, <NUM>) configured to apply a second adhesive strip to attach the continuous cover strip segment to the torso web piece and second shoulder web panel and forming a continuous isolation garment web; and
at least one other adhesive applicator (<NUM>) configured to attach a second tie strap to the torso web piece of the continuous isolation garment web.