Seven-part garment assembly for automated bonding
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Solution Overview
Problem
Conventional disposable non-woven garments, such as isolation gowns and surgical gowns, face challenges in manufacturing efficiency and quality due to the difficulty in automated assembly of cylindrical sleeves and low fabric utilization, leading to issues like waste, low yield, and high bacterial counts.
Innovation Solution
A method for assembling a seven-part garment involves cutting out specific parts from a fabric, including a front part, two back parts, and four sleeve parts, and then bonding these parts in a specific order to form a complete garment, allowing for more efficient and automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cylindrical sleeves are manually sutured and assembled, then the garment can be formed with proper shape and structure, but the assembling efficiency is low and labor intensity is high
Solution Approach 1:
The garment is divided into seven distinct parts: front part, first back part, second back part, left sleeve upper part, left sleeve lower part, right sleeve upper part, and right sleeve lower part. This segmentation allows each part to be processed and assembled separately, enabling automated assembly while maintaining the cylindrical shape and proper structure of the sleeves.
Solution Approach 2:
The sleeve parts are pre-cut into upper and lower sections before assembly. This preliminary action allows the sleeves to be constructed in a linear sequence (upper part first, then lower part) rather than requiring complex cylindrical sewing, thereby enabling automated assembly processes.
2Loss of substance
If conventional cutting patterns are used for sleeves and body parts, then the garment can be assembled, but fabric utilization is low and waste is generated
Solution Approach 1:
The cutting pattern transitions from conventional V-shape or olive-shape sleeve joints to a seven-part linear arrangement. The front part, two back parts, and four sleeve parts are cut and arranged in a linear sequence that maximizes fabric utilization and minimizes waste, while still forming the required three-dimensional garment structure during assembly.
3Manufacturing precision
If manual suturing is used for assembling sleeves to body parts, then the garment can be constructed, but quality problems such as suturing omission, skipped stitches, and puckers occur frequently
Solution Approach 1:
By segmenting the garment into seven parts with predetermined cutting patterns, the assembly process is simplified to linear bonding operations rather than complex cylindrical suturing. This segmentation enables automated assembly equipment to achieve consistent, high-quality bonds without the defects associated with manual suturing.
Solution Approach 2:
The manual suturing process is replaced with automated bonding methods such as ultrasonic welding, hot-pressing, or adhesive bonding. These automated processes eliminate human error, skipped stitches, and puckers while maintaining or improving assembly speed and efficiency.
4Object-affected harmful factors
If manual handling and transfer among various processes are used, then the garment can be assembled, but products are easily polluted and bacteria count is high
Solution Approach 1:
Multiple parts are pre-cut and prepared in advance according to the seven-part design. This preliminary action allows for streamlined, continuous assembly processes with minimal handling and transfer between operations, thereby reducing contamination risks while maintaining manufacturing efficiency.
Solution Approach 2:
The seven-part design with predetermined cutting patterns allows the garment parts to be self-aligning during assembly, reducing the need for complex positioning and manual adjustment. This minimizes handling time and exposure to contamination while maintaining assembly speed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach improves manufacturing efficiency, reduces fabric waste, and enhances product quality by allowing for automated assembly and full utilization of fabric, while also reducing bacterial contamination.
Implementation Method 1
each of the bonding the left sleeve upper part, the bonding the right sleeve upper part, the bonding the left sleeve lower part, the bonding the right sleeve lower part, and the bonding the left side edge and the right side edge of the front part comprises one or more of suturing, ultrasonic welding, high-frequency welding, hot-pressing, and gluing
Implementation Method 2
each of the bonding the left sleeve upper part, the bonding the right sleeve upper part, the bonding the left sleeve lower part, the bonding the right sleeve lower part, and the bonding the left side edge and the right side edge of the front part comprises one or more of suturing, ultrasonic welding, high-frequency welding, hot-pressing, and gluing
Data Source
AI summary
Disclosed are a seven-part garment and a method for assembling a seven-part garment. The method includes: cutting out a front part, a first back part, a second back part, a left sleeve upper part, a left sleeve lower part, a right sleeve upper part, and a right sleeve lower part from a fabric; bonding the left sleeve upper part to a left side edge of the front part, and bonding the right sleeve upper part to a right side edge of the front part; bonding the left sleeve lower part to the first back part, and bonding the right sleeve lower part to the second back part; and flattening, stacking, and aligning the front part with the first back part and the second back part, and bonding side edges of the front part to side edges of the first back part and the second back part to form the garment.