Apparatus and method of manufacturing multi-piece open-back isolation garments

1 . An apparatus for manufacturing multi-piece open-back isolation garments, the apparatus comprising:

a neck cutting unit configured to cut neck openings in a continuous shoulder web;

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 underarm seams extending at substantially the same angle from a bottom edge of each of the first and second shoulder web panels to a position offset from a top edge of each of the first and second shoulder web panels, the underarm seams defining first and second wrist openings on opposing sides the continuous shoulder web;

a torso cutting unit configured to cut discrete torso web pieces from a continuous torso web;

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 the 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 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.

2 . The apparatus of claim 1 further comprising a perforation unit configured to create at least one perforation line in the torso web piece that defines at least one tie strap.

3 . The apparatus of claim 1 further comprising a folding unit positioned upstream from the torso cutting unit and configured to fold the continuous torso web in a cross-machine direction.

4 . The apparatus of claim 1 further comprising a stretch patch unit comprising:

at least one adhesive applicator configured to apply an adhesive to at least one continuous stretch patch web;

at least one slip cut unit comprising a vacuum anvil and a knife roll, the at least one slip cut unit configured to:

receive the continuous stretch patch web with adhesive applied on the vacuum anvil;

cut the continuous stretch patch web into discrete stretch patches on vacuum anvil with the knife roll; and

apply the discrete stretch patches over the neck openings on the continuous shoulder web with the vacuum anvil; and

at least one patch opening cutting unit configured to cut openings in the discrete stretch patches within the neck openings on the continuous shoulder web.

5 . The apparatus of claim 1 including a folding unit configured to fold the continuous shoulder web to create the overlapping first shoulder panels and second shoulder panels.

6 . The apparatus of claim 1 further comprising another cutting unit configured to cut discrete multi-piece open-back isolation garments from the continuous isolation garment web.

7 . The apparatus of claim 6 further comprising a multi-stage folding unit comprising at least three folding stations configured to at least tri-fold each discrete multi-piece open-back isolation garment.

8 . The apparatus of claim 1 wherein the transfer unit comprises first and second vacuum drums rotating in opposite directions.

9 . A method of manufacturing multi-piece open-back isolation garments, the method comprising:

cutting neck openings in a continuous shoulder web traveling in a machine direction;

forming a first shoulder web panel and a second shoulder web panel overlapping each other in the continuous shoulder web, the first shoulder web panel having a bottom edge offset from a bottom edge of the second shoulder web panel to create an area on the first shoulder web panel that is uncovered by the second shoulder web panel;

creating right and left underarm seams between the first and second shoulder web panels, the right and left underarm seams extending at substantially the same angle from the bottom edge of each of the first and second shoulder web panels to a position offset below a corresponding top edge of each of the first and second shoulder web panels, the underarm seams defining left and right wrist openings between the top edge of each of the first and second shoulder web panels and the corresponding underarm seam on opposing right and left sides the continuous shoulder web;

cutting a continuous torso web into a discrete torso web piece;

transferring the discrete torso web piece onto the first shoulder web panel such that a top edge of the discrete torso web piece overlaps the bottom edge of the first shoulder web panel in the area of the first shoulder web panel that is uncovered by the second shoulder web panel; and

bonding the discrete torso web piece to the first shoulder web panel in the area that is uncovered by the second shoulder web panel to create a continuous isolation garment web.

10 . The method of claim 9 further comprising cutting the continuous shoulder web into discrete shoulder web pieces to form multi-piece open-back isolation garments.

11 . The method of claim 10 folding the multi-piece open-back isolation garments in multiple stages.

12 . The method of claim 9 further comprising rewinding the continuous isolation garment web.

13 . The method of claim 9 wherein forming the first and second shoulder web panels comprises folding the continuous shoulder web.

14 . The method of claim 9 wherein forming the first and second shoulder web panels comprises bonding a first continuous shoulder web to a second continuous shoulder web.

15 . The method of claim 9 further comprising:

applying a neck stretch patch over each neck opening in the continuous shoulder web; and

cutting an opening in each neck stretch patch.

16 . The method of claim 15 further comprising:

cutting wrist openings in the continuous shoulder web;

applying a wrist stretch patch over each wrist opening in the continuous shoulder web; and

cutting an opening in each wrist stretch patch.

17 . A multi-piece garment comprising:

a shoulder web piece comprising:

a first shoulder web panel comprising:

a bottom edge; and

a pair of underarm edges extending out from the bottom edge; and

a second shoulder web panel overlapping the first shoulder web panel and comprising:

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;

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; and

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, the underarm seams extending at substantially the same angle from the bottom edges of each of the first and second shoulder web panels to a position offset from a top edge of each of the first and second shoulder web panels, the underarm seams defining first and second wrist openings on opposing sides the first and second shoulder web panels; 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; and

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.

18 . The garment of claim 17 wherein the first and second shoulder web panels are integral with each other and share a folded top edge in which the neck opening is located.

19 . The garment of claim 18 further comprising a thumb opening formed in each of the first and second sleeves adjacent the folded top edge.

20 . The garment of claim 17 wherein the first and second shoulder web panels are attached together via at least one seam formed adjacent the top edges of the first and second shoulder web panels.

21 . The garment of claim 17 wherein the torso web piece further comprises at least one perforation line defining at least one tie strap that is at least partially separable from the torso web piece.