Development of breathable and liquid/wet bacterial penetration barrier composite laminated fabrics for surgical gown applications

Disposable surgical gowns are used to protect health care workers from microorganisms and body fluids to meet the needs of surgical applications. In addition to protection, it has a significant impact on the surgical team members’ comfort and thus, the success of the operations. In this study, a dual layer surgical gown-an outer layer of film and an inner layer of nonwoven fabric-was developed. Produced composite laminated fabrics are SMS (spunbond/meltblown/spunbond) nonwoven fabric laminated microporous polyethylene film and SMS (spunbond/meltblown/spunbond) nonwoven fabric laminated thermoplastic polyurethane films. These fabrics were compared with nonporous polyethylene film-coated SS (spunbond/spunbond) nonwoven fabric available in the local market. The study aims to investigate the effect of some structural factors of composite nonwoven laminated fabrics, including lamination process, manufacturing process, and film type; microporous or monolithic, nonwoven fabric manufacturing process, and helium atmospheric-pressure glow discharge plasma treatment, on their functional performance properties, including air permeability, water vapour permeability, hydrostatic pressure resistance, and wet bacterial penetration resistance. The results showed that the produced composite fabrics offer outstanding breathability and, thus, the surgical team members' comfort. Produced composite fabrics had no wet bacterial penetration of Staphylococcus aureus and thus contributed to the prevention of the transfer of bacterial pathogens to prevent surgical site infection or post-operative infection. Produced composite fabrics offer superior liquid barriers according to the barrier protection classification of the Association for the Advancement of Medical Instrumentation (ANSI/AAMI PB 70:12) and thus contribute to the prevention of the transfer of body fluids during surgical operations.