Development of tri-layer breathable fluid barrier nonwoven fabrics for surgical gown applications

In this study, tri-layer fabrics for surgical gown applications were developed using polypropylene spunbond, polypropylene melt-blown and polyester/rayon spunlace (hydro-entangled) nonwoven layers with the aid of a fusing machine and polypropylene powder as the bonding agent. Weight, thickness, bending rigidity, grab tensile properties, bursting strength, air permeability, water vapour transmission rate, hydrostatic pressure, water resistance (impact penetration test), and synthetic blood repellency of the fabrics (unfinished and finished with water repellent polymethylhydrosiloxanes solution) were measured and the data was statistically analyzed. The results showed that the finished fabric composed of the spunbond outer layer, melt-blown middle layer, and spunlace inner layer, meets the blood repellency requirements of level 4 protection according to the barrier protection classification of Association for the Advancement of Medical Instrumentation (AAMI). The other samples, i.e. untreated type of abovementioned sample and treated and untreated tri-layer of spunbond, melt-blown, spunbond samples offer level 2 protection according to AAMI classification.