Claims:We Claim:
1. A method for fabricating an antimicrobial layer on a fabric (100), the method comprising:
synthesizing, a concoction of a fibre-forming polymer, a polyelectrolyte, and a metal oxide in predetermined weight by volume percentage [wt/vol%];
coating, the synthesized concoction on the fabric (100) to form the antimicrobial layer (103) on the fabric.

2. The method as claimed in claim1, wherein the predetermined wt/vol% of the fibre-forming polymer is 3 wt/vol% to 9 wt/vol%, the polyelectrolyte is 3 wt/vol% to 9 wt/vol% and the metal oxide is 5 wt/vol% to 15 wt/vol%

3. The method as claimed in claim 1, wherein the fibre-forming polymer is at least one of a polycaprolactone (PCL) and polyvinylidenefluoride (PVDF).

4. The method as claimed in claim 1, wherein the polyelectrolyte is a Poly (Diallyldimethylammonium Chloride).

5. The method as claimed in claim 1, wherein the metal oxide is at least one of a copper(I) oxide (Cu2O), copper(II) oxide (CuO), silver oxide (Ag2O), iron oxide (Fe2O3), magnesium oxide (MgO), titanium oxide (TiO2), and zinc oxide (ZnO).

6. The method as claimed in claim 1, wherein the coating of the synthesized concoction on the fabric (100) is carried out by a spray coating technique.

7. The method as claimed in claim 6, wherein the coated concoction on the fabric (100) is in form of fibres.

8. A coated fabric, comprising:
a layer of fabric; and
at least one layer of concoction of a fibre-forming polymer, a polyelectrolyte and a metal oxide, wherein the at least one-layer acts as an antimicrobial layer of the coated fabric.

9. The coated fabric as claimed in claim 8, wherein the fibre-forming polymer is at least one of a polycaprolactone (PCL) and polyvinylidenefluoride (PVDF).

10. The coated fabric as claimed in claim 8, wherein the polyelectrolyte is a Poly (Diallyldimethylammonium Chloride).

11. The coated fabric as claimed in claim 8, wherein the metal oxide is at least one of a copper(I) oxide (Cu2O), copper(II) oxide (CuO), silver oxide (Ag2O), iron oxide (Fe2O3), magnesium oxide (MgO), titanium oxide (TiO2), and zinc oxide (ZnO).

12. The coated fabric as claimed in claim 8, wherein the coated concoction on the fabric (100) is in form of fibres.

13. The coated fabric as claimed in claim 8, wherein the concoction comprises the predetermined wt/vol% of the fibre-forming polymer is 3 wt/vol% to 9 wt/vol%, the polyelectrolyte is 3 wt/vol% to 9 wt/vol% and the metal oxide is 5 wt/vol% to 15 wt/vol%.
14. The coated fabric as claimed as claimed in claim 8, wherein the fabric (100) is at least one of a cotton fabric, a nylon fabric, and a polyester fabric.

15. A method for fabricating a fabric (100) with a radiation-resistant layer (102) and an antimicrobial layer (103), the method comprising:
providing a layer of the fabric;
coating at least one layer with each of a synthesized resin mixture and a synthesized concoction on a surface of the fabric (100) to obtain the fabric (100) with the radiation-resistant layer (102) and the antimicrobial layer (103).

16. The method as claimed in claim 15, wherein synthesized resin mixture is prepared by a process comprising:

dispersing a predetermined amount of particles in a water-borne polyurethane (WPU) to obtain a mixture;

sonicating the mixture for 15 mins to 20 mins to obtain the resin mixture.

17. The method as claimed in claim 15, wherein the synthesized concoction comprises mixing of a polymer, polyelectrolyte and a metal oxide in predetermined weight by volume percentage [wt/vol%].

18. The method as claimed in claim 17, wherein predetermined wt/vol% of the fibre-forming polymer is 3 wt/vol% to 9 wt/vol%, the polyelectrolyte is 3 wt/vol% to 9 wt/vol% and the metal oxide is 5 wt/vol% to 15 wt/vol%

19. The method as claimed in claim 17, wherein the fibre-forming polymer is at least one of a polycaprolactone (PCL) and polyvinylidenefluoride (PVDF).

20. The method as claimed in claim 17, wherein the polyelectrolyte is a Poly (Diallyldimethylammonium Chloride).

21. The method as claimed in claim 17, wherein the metal oxide is one of a copper(I) oxide (Cu2O), copper(II) oxide (CuO), silver oxide (Ag2O), iron oxide (Fe2O3), magnesium oxide (MgO), titanium oxide (TiO2), and zinc oxide (ZnO).

22. The method as claimed in claim 16, wherein the particles are at least one of a graphite nanoplatelets (GNP) and a carbon nanotube (CNT).

23. The method as claimed in claim 16, wherein the particles are dispersed in the water-borne polyurethane (WPU) with a composition ranging from 6 phr to 10 phr.

24. The method as claimed in claim 15, wherein the coating of resin mixture on the surface the fabric (100) is carried out by a film applicator.

25. The method as claimed in claim 15, wherein the coating of synthesized concoction on the fabric (100) surface is carried out by a spray coating.

26. The method as claimed in claim 25, wherein the spray coating forms fibre formation on the fabric.

27. The method as claimed in claim 15, wherein the fabric (100) is at least one of a cotton fabric, a nylon fabric, and a polyester fabric.

28. A fabric (100), comprising: a coating of at least one layer of each of a synthesized resin mixture and a synthesized concoction on the fabric surface to obtain the fabric (100) with the radiation-resistant layer (102) and the antimicrobial layer (103).

29. A laminate comprising one or more layers of fabric (100) as claimed in claim 28 stacked in a predetermined order.
, Description:TECHNICAL FIELD
Present disclosure relates in general to a field of material science. Particularly, but not exclusively, the present disclosure relates to field of manufacturing of polymers and composite. Further, embodiments of the disclosure discloses a laminate and a method for fabrication of the laminate to include a coating of radiation resistant layer and an antimicrobial layer.

BACKGROUND OF THE DISCLOSURE
Radiations of any kind are harmful to all living beings. While naturally emitting radiations such as sun’s rays are mostly blocked off by the earth’s ozone layer, other sources of radiations emitted from man-made devices are still a major concern. Researchers have been working on developing materials which can shield such radiations more specifically electromagnetic radiations. Medical devices have been actively used in healthcare industry. These medical devices emit strong electric and magnetic radiations (i.e. electromagnetic) from devices such as X-ray, laser, ultrasound, infrared, ultraviolet etc. These electric and magnetic disturbances, if not controlled, can be harmful to living beings and environment. Such radiations can also interfere in the smooth operation of other medical devices which can lead to malfunctioning of medical devices. Thus, it may compromise with patient’s health and lead to jeopardy. Therefore, it is required to fabricate materials that can curb the emission of electromagnetic radiations emanating from such medical devices and/or shield other sensitive devices that may come in contact with such electromagnetic radiations. Conventionally, several polymer-based nanocomposites have been developed and used in healthcare industries to shield from the electromagnetic radiations. Such nanocomposites with radiation resistant properties, are synthesized by incorporating various particles/nanoparticles inside a polymeric matrix. These particles/nanoparticles are ultra-fine particles which can be both electrically conducting and magnetic in nature. Thus, such nanocomposites provide an ability to shield electromagnetic radiations. Hence, such polymeric nanocomposites find applications in different fields where electromagnetic radiations are emitted. Moreover, some inherent advantages of using such polymeric nanocomposite materials are their lightweight bulk, ease of processibility/machinability, and low cost.
However, in a healthcare setup, radiation may not be the only cause of concern. Since the healthcare setup sees many footfalls a day, the risk of microbes and viruses leading to an outbreak is ever looming. Microbes are a major concern in a healthcare setup and these microbes are infectious and causes diseases that afflict people. Even otherwise, in the day to day life, people may come in contact with other living beings which may have been infected by such disease causing microbes. Thus, there is a risk of spreading of such infectious diseases as well. In recent times, due to unprecedented advent of the SARS-COV-2 virus, there is a sharp rise in worldwide COVID related cases which is highly infectious. Based on some research work, it is clear that, the COVID virus can be active on surfaces of objects and walls for long periods of time. The COVID virus also gets transmitted when a person comes in contact with such infested object surfaces or any other infected person. Thus, disease can spread at a rapid rate. Therefore, it is required to fabricate materials which can kill the microbes and thus curb the spread of infectious diseases. Conventionally, spraying techniques have been used on the contaminated surroundings to kill the microbes and thereby controlling the spread of infectious diseases. Although spraying is quite useful, but the sprayed chemicals can have an adverse health effects on people and the animals around where inhalation of such disinfectants is harmful. Moreover, spraying is a costly activity and not feasible for large areas such as a healthcare setup.
The present disclosure is directed to overcome one or more limitations stated above or any other limitation associated with the prior arts.

SUMMARY OF THE DISCLOSURE
One or more shortcomings of the prior art are overcome by method and a product as claimed and additional advantages are provided through the method as described in the present disclosure.

Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the present disclosure, a method for fabricating an antimicrobial layer on a fabric is disclosed. The method of fabrication comprises, synthetization of a concoction. The concoction comprises of three main compositions including a fibre-forming polymer, a polyelectrolyte, and a metal oxide. A predetermined weight by volumes percentage (wt/vol%) of the fibre-forming polymer, the polyelectrolyte and the metal oxide is involved in synthesis of the concoction. The synthesized concoction is then coated on the surface of a fabric to form an antimicrobial layer on the fabric.
In an embodiment, predetermined wt/vol% of the fibre-forming polymer includes 3 wt/vol% to 9 wt/vol%, the polyelectrolyte is 3 wt/vol % to 9 wt/vol % and the metal oxide is 5 wt/vol% to 15 wt/vol%.

In an embodiment, the fibre-forming polymer is at least one of a polycaprolactone (PCL) and polyvinylidenefluoride (PVDF).

In an embodiment, the polyelectrolyte is a Poly (Diallyldimethylammonium Chloride).
In an embodiment, the metal oxide is at least one of a copper(I) oxide (Cu2O), copper(II) oxide (CuO), silver oxide (Ag2O), iron oxide (Fe2O3), magnesium oxide (MgO), titanium oxide (TiO2), and zinc oxide (ZnO).

In an embodiment, the coating of the synthesized concoction on the fabric is carried out by a spray coating technique.

In an embodiment, the coated concoction on the fabric is in form of fibres.

In another non-limiting embodiment of the present disclosure, a coated fabric is disclosed. The coated fabric comprises a layer of a fabric and at least one layer of concoction of a fibre-forming polymer, a polyelectrolyte and a metal oxide, wherein the at least one-layer acts as an antimicrobial layer of the coated fabric.

In an embodiment, the fibre-forming polymer, is at least one of a polycaprolactone (PCL) and polyvinylidenefluoride (PVDF).

In an embodiment, the polyelectrolyte is a Poly (Diallyldimethylammonium Chloride).
In an embodiment, the metal oxides can be at least one of a copper(I) oxide (Cu2O), copper(II) oxide (CuO), silver oxide (Ag2O), iron oxide (Fe2O3), magnesium oxide (MgO), titanium oxide (TiO2), and zinc oxide (ZnO).
In an embodiment, the coated concoction on the fabric is in form of fibres.

In an embodiment, predetermined wt/vol% of the fibre forming polymer includes 3 wt/vol% to 9 wt/vol%, the polyelectrolyte is 3 wt/vol% to 9 wt/vol% and the metal oxide is 5 wt/vol% to 15 wt/vol%.

In an embodiment, the coated fabric is at least one of a cotton fabric, a nylon fabric, and a polyester fabric.

In another non-limiting embodiment of the present disclosure, a method for fabricating a fabric with a radiation-resistant layer and an antimicrobial layer is disclosed. The method of fabrication involves providing a layer of the fabric. Followed by coating at least one layer with each of a synthesized resin mixture and a synthesized concoction on a surface of the fabric to obtain the fabric with the radiation-resistant layer and the antimicrobial layer.
In an embodiment, the synthesized resin mixture is prepared by the process comprising the steps of dispersing a predetermined amount of particles in a water-borne polyurethane (WPU) to obtain a mixture. The resin mixture so obtained is sonicated for 15 minutes to 20 minutes to obtain the resin mixture.

In an embodiment, the synthesized concoction comprises mixing of a polymer, polyelectrolyte and a metal oxide in predetermined wt/vol%.

In an embodiment, the predetermined wt/vol% of the fibre-forming polymer is 3 wt/vol% to 9 wt/vol%, the polyelectrolyte is 3 wt/vol% to 9 wt/vol% and the metal oxide is 5 wt/vol% to 15 wt/vol%.

In an embodiment, the fibre-forming polymer is at least one of polycaprolactone (PCL) and polyvinylidenefluoride (PVDF).

In an embodiment, the polyelectrolyte is a Poly (Diallyldimethylammonium Chloride).

In an embodiment, the metal oxide is at least one of a copper(I) oxide (Cu2O), copper(II) oxide (CuO), silver oxide (Ag2O), iron oxide (Fe2O3), magnesium oxide (MgO), titanium oxide (TiO2), and zinc oxide (ZnO).

In an embodiment, the particles are at least one of a graphite nanoplatelets (GNP) and a carbon nanotube (CNT).
In an embodiment, the particles are dispersed in the water-borne polyurethane (WPU) with a composition ranging from 6 phr to 10 phr.
In an embodiment, the coating of resin mixture on the surface the fabric is carried out by a film applicator.

In an embodiment, the coating of synthesized concoction on the fabric surface which is carried out by a spray coating.

In an embodiment, the spray coating forms fibre formation on the fabric.

In an embodiment, the fabric is at least one of a cotton fabric, a nylon fabric, and a polyester fabric.

In another non-limiting embodiment of the present disclosure, a fabric is disclosed. The fabric comprises a coating of at least one layer of each of a synthesized resin mixture and a synthesized concoction on the fabric surface to obtain the fabric with the radiation-resistant layer and the antimicrobial layer.

In another non-limiting embodiment of the present disclosure, a laminate comprising one or more layers of fabric is disclosed.

It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES
The novel features and characteristics of the disclosure are set forth in the appended description. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiments when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

Figures.1a and 1b illustrates a schematic view of a fabric and a fabric coated with an antimicrobial layer and a radiation-resistant layer on a fabric according to an exemplary embodiment of the present disclosure.

Figures.2a and 2b illustrates a schematic view of a fabric and a fabric coated with a radiation-resistant layer on a fabric according to an exemplary embodiment of the present disclosure.

Figure.3 illustrates a cross-sectional layout of the laminate with the antimicrobial layer and the radiation resistant layer, according to an exemplary embodiment of the present disclosure.

Figure.4 is a flowchart illustrating a method of fabricating a coated fabric with an antimicrobial layer, according to an exemplary embodiment of the present disclosure.

Figure.5 is a flowchart illustrating a method of fabricating a fabric with a radiation-resistant layer and an antimicrobial layer, according to an exemplary embodiment of the present disclosure.

Figure.6 illustrates a graph of Alternating Current (AC) conductivity versus frequency for a laminate, according to an exemplary embodiment of the present disclosure.

Figure.7 illustrates a graph of Electromagnetic Interference (EMI) shielding effectiveness versus frequency for a laminate, according to an exemplary embodiment of the present disclosure.

Figure.8 illustrates pictorial representation captured during testing of the plaque assay to detect the antimicrobial activity of fabricated samples.

Figure 8a represents sample A which contains PCL reacted against bacteriophage with contact time of 2 hours during an experimental test.
Figure 8b represents sample B which contains PCL+PDDA reacted against bacteriophage with contact time of 2 hours during an experimental test.

Figure 8c represents sample C which contains PCL+PDDA+Cu2O reacted against bacteriophage with contact time of 2 hours during an experimental test.

Figure 8d represents sample D which contains PCL+PDDA+CuO reacted against bacteriophage with contact time of 2 hours during an experimental test.

Figures.9a, 9b and 9c illustrates digital photographs of laminates pasted on to different substrates in an experimental setup, according to an exemplary embodiment of the present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION
The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the description of the disclosure. It should also be realized by those skilled in the art that such equivalent methods do not depart from the scope of the disclosure. The novel features which are believed to be characteristic of the disclosure, as to method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the disclosure.

The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusions, such that a method that comprises a list of acts does not include only those acts but may include other acts not expressly listed or inherent to such method. In other words, one or more acts in a method proceeded by “comprises… a” does not, without more constraints, preclude the existence of other acts or additional acts in the method.

Embodiments of the present disclosure discloses a method for fabricating an antimicrobial layer on a fabric and a coated fabric. Further embodiments also discloses the method for fabricating a laminate that includes both the antimicrobial layer and the radiation resistant layer. Radiations of any kind are harmful to all living beings. While naturally emitting radiations such as sun rays are mostly blocked off by the earth’s ozone layer, other sources of radiations emitted from man-made devices are still a major concern. Researchers have been working on developing materials which can shield such radiations more specifically electromagnetic radiations. Medical devices have been actively used in healthcare industry. These medical devices emit strong electric and magnetic radiations (i.e. electromagnetic) from devices such as X-ray, laser, ultrasound, infrared, ultraviolet etc. These electric and magnetic disturbances, if not controlled, can be harmful to humans and environment. Therefore, it is of paramount importance to fabricate materials that can curb the emission of electromagnetic radiations. However, in a healthcare setup, radiations may not be the only cause of concern. The healthcare setups sees many footfalls a day and risk of microbes and viruses leading to an outbreak is ever looming. Microbes are a major concern in a healthcare setup and these microbes are infectious and causes diseases that afflict people. Even otherwise, in the day to day life, people may come in contact with other people and animals which may have been infected by such disease causing microbes. Thus, there is a risk of spreading of such infectious diseases as well. In recent times, due to unprecedented advent of the SARS-COV-2 virus, there is a sharp rise worldwide in COVID related cases which is highly infectious. Based on some research work, it is clear that, the COVID virus can be active on surfaces of objects and walls for long periods of time. The COVID virus also gets transmitted when a person touches such infested object surfaces. Thus, disease can spread at a rapid rate. Therefore, it is required to fabricate materials that can kill the microbes and thus curb the spread of infectious diseases.
Further, it would be very beneficial if a single material can be fabricated, having both the properties i.e. the radiation shielding property as well as antimicrobial property.
According to various embodiment of the disclosure, a method for fabricating an antimicrobial layer on a fabric is disclosed. The method comprises synthesizing of a concoction, wherein the concoction may be formulated to have an antimicrobial activity to curb growth of microbes. In an embodiment, the concoction may comprise of three major compositions such as a fibre forming polymer, a polyelectrolyte, and a metal oxide. The concoction is formed by mixing these three major compositions in a predetermined weight by volume percentage [wt/vol%]. Once the concoction is prepared based on required wt/vol%, the concoction may be coated on to the surface of a fabric by a coating technique including but not limiting to spray coating. In an embodiment, the coating of this concoction onto the fabric confers antimicrobial properties to the coated fabric.
In an embodiment, the coated fabric comprises a layer of fabric and at least one layer of concoction of a fibre-forming polymer, a polyelectrolyte and metal oxide. The at least one-layer of concoction acts as the antimicrobial layer, thus providing antimicrobial property to the coated fabric.
As used herein, the term “antimicrobial” refers to agents having the ability to kill or inhibit/slow growth of a wide range of microorganisms including but not limiting to bacteria, viruses, algae, protozoans and fungi (such as mold and mildew). Accordingly, the antimicrobial layer of the present disclosure is capable of killing or inhibiting growth of various microbes such as gram-positive & gram-negative bacteria, viruses, algae, protozoans, fungi etc.

As used herein, the term “radiation-resistant” refers to the ability to shield the radiations such as medical X-rays, gamma rays, infrared rays, ultraviolet rays etc. emitted by the various medical devices which can cause malfunctioning of the other medical devices and may be harmful for users.

As used herein, the term “sonication” refers to the process of applying sound energy to agitate particles in a liquid for homogeneous dissolution. Ultrasonic frequencies (>20 kHz) are usually used, so the process is also known as ultrasonication. The process of sonication can be conducted using either an ultrasonic bath or an ultrasonic probe sonicator.

In an embodiment, the synthetization of the concoction which is finally spray coated on fabric comprises the steps of dissolving 0.6 g of a polycaprolactone (PCL) in 10 ml of dichloromethane (DCM) to obtain a mixture. Further, 2 ml of a Poly (Diallyldimethylammonium Chloride) [also termed as PDDA in the specification] is added to the obtained mixture. A mixture consisting of 10 mg of copper oxide dispersed in 1 ml of ethanol is further added to the previously obtained mixture. The copper oxide is added in form of nanoparticles. The concoction so obtained confers antimicrobial property to the coated fabric.

Referring now to figures 1-5, which discloses a method for fabricating a fabric with a radiation-resistant layer and an antimicrobial layer. The method comprises the steps of providing a layer of the fabric and coating at least one layer with each of a synthesized resin mixture and a synthesized concoction of a fibre-forming polymer, a polyelectrolyte and metal oxide in predetermined wt/vol% on a surface of the fabric to obtain the fabric with the radiation-resistant layer and the antimicrobial layer. In an embodiment, the resin mixture may be obtained by a dispersion of a predetermined amount of particles in the range 6 phr to 10 phr in a water-borne polyurethane (WPU) to obtain a mixture. The particles mixed in the water-borne polyurethane (WPU) are at least one of a graphite nanoplates (GNP) and a carbon nanotube (CNT). This mixture is then subjected to sonicating for about 15 to 20 minutes, to obtain a homogenous resin mixture. Sonication is a technique that uses sound energy to agitate particles in a given solution to obtain a homogeneous dispersion. In another embodiment, the synthetization of the concoction involves a mixing of predetermined wt/vol% of three major compositions i.e. a fibre-forming polymer, a polyelectrolyte, and a metal oxide.

In an embodiment, the fibre-forming polymer is at least one of a polycaprolactone (PCL) and polyvinylidenefluoride (PVDF) mixed in the wt/vol% ranging from 3 wt/vol% to 9 wt/vol%.

In an embodiment, the polyelectrolyte is at least one of a Poly (Diallyldimethylammonium Chloride) mixed in the wt/vol% ranging from 3 wt/vol% to 9 wt/vol%.

In an embodiment, the metal oxide is at least one of a copper(I) oxide (Cu2O), copper(II) oxide (CuO), silver oxide (Ag2O), iron oxide (Fe2O3), magnesium oxide (MgO), titanium oxide (TiO2), and zinc oxide (ZnO) mixed in the wt/vol% ranging from 5 wt/vol% to 15 wt/vol%. Therefore, the concoction thus obtained is then coated on the surface of the fabric. The coating of the concoction is carried out using the spray coating method. During the spray coating, the solvent in the concoction vaporises due to high air pressure involved during spray coating process. Thus the concoction gets deposited on the fabric surface in the form of fibers. In an embodiment, the coated fabric confers to radiation shielding property as well as antimicrobial activity.

Figure 1a illustrates a fabric on which the radiation resistant layer and an antimicrobial layer is being fabricated. In an embodiment, the method for fabrication of the antimicrobial layer on the fabric comprises synthesisation of a concoction. The concoction is prepared by mixing the predetermined wt/vol% of the fibre-forming polymer in the range of 3 wt/vol% to 9 wt/vol%, the polyelectrolyte in the range of 3 wt/vol% to 9 wt/vol% and the metal oxide in the range of 5 wt/vol% to 15 wt/vol%. The concoction so obtained is coated on the surface of the fabric (100) as shown in figure 1a.

Figure 1b represents a fabric comprising a coating of at least one layer of a synthesized resin mixture and a synthesized concoction on the fabric surface. In an embodiment, the method for fabrication of a fabric with the radiation resistant layer (102) and antimicrobial layer (103) as shown in figure 1b comprises the steps of synthetization of a resin mixture and a concoction. The resin mixture is obtained by dispersing predetermined amount of graphite nanoplates (GNP) in the range 6 phr to 10 phr in water-borne polyurethane (WPU) to obtain a mixture. The mixture so obtained is subjected to sonication for 15 to 20 minutes to obtain the resin mixture. This resin mixture is coated on the fabric (100) to obtain the fabric with GNP layer (102) (henceforth referred to as CF/GNP). Further, a layer of synthesized concoction of a polycaprolactone (PCL), Poly (Diallyldimethylammonium Chloride) and copper oxide is applied over the cotton fabric coated with graphite nanoplates (GNP) layer (102). Thus a cotton fabric with both a radiation resistant layer (102) and an antimicrobial layer (103) (henceforth referred to as CF/CNP/AML, where AML refers the antimicrobial layer) is obtained as shown by figure 1b. In an embodiment, during spray coating of the concoction, the solvent in the concoction vaporises due to high air pressure involved and the concoction gets deposited on the fabric surface in the form of fibers.

Now referring to Figure 2a and 2b, which discloses a method for fabricating a fabric with a radiation-resistant layer. The method comprises the steps of providing a layer of the fabric and coating with a resin mixture. The coating of the resin mixture confers the radiation-resistant properties to the fabric. In an embodiment, the resin mixture is obtained by dispersion of a predetermined amount of particles in the range 6 phr to 10 phr in a water-borne polyurethane (WPU) to obtain a mixture. The particles mixed in the water-borne polyurethane (WPU) are at least one of a graphite nanoplates (GNP) and a carbon nanotube (CNT). The mixture so obtained is then subjected to sonicating for 15 to 20 minutes to obtain a homogenous resin mixture. Sonication is a technique that uses sound energy to agitate particles in a given solution to obtain a homogeneous dispersion. The resin mixture is then coated on to the surface of the fabric by using a film applicator. Thus the fabric acquires radiation-resistant property.

In an embodiment, the units used for resin mixture is parts per hundred resin (phr). The synthesis of the resin mixture involves the dispersion of a predetermined amount of particles in a water-borne polyurethane (WPU) to obtain a mixture. About 800 mg of particles are dispersed in 10 g of resin which is called as 8 phr.

Now referring to Figure 3, which illustrates a cross-sectional layout of a laminate. The laminate consists of layers of a fabric, a radiation-resistant layer and an antimicrobial layer.

According to various embodiments, the radiation-resistant layer (102) and the antimicrobial layer (103) can be coated and stacked on the fabric (100) in any order depending on the requirements. For instance, the first layer on the fabric may be the antimicrobial layer (103) in one particular application. In another application, the first layer on the fabric may be the radiation resistant layer (102). However, the order of the stacking of the antimicrobial layer (103) and the radiation-resistant layer (102) can be changed depending on the requirement of the application.

Now referring to Figure 4, which illustrates a flowchart disclosing a method for fabricating the antimicrobial layer on the fabric. The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method. Additionally, individual blocks may be deleted from the methods without departing from the scope of the subject.

The method for fabrication of the antimicrobial layer on the fabric comprises synthesis of the concoction having antimicrobial properties. At block (104), a predetermined wt/vol% of the fibre-forming polymer in the range of 3 wt/vol% to 9 wt/vol%, the polyelectrolyte in the range of 3 wt/vol% to 9 wt/vol% and the metal oxide in the range of 5 wt/vol% to 15 wt/vol% is mixed to form the concoction. At block (105), the concoction so obtained is coated on the surface of the fabric by a known spray coating method, to form the antimicrobial layer. In an embodiment, once the fabric is spray coated or coated by any other coating techniques is allowed to dry at room temperature for a predetermined time period. In an embodiment, during spray coating of the concoction, the solvent in the concoction vaporises due to high air pressure involved and the concoction gets deposited on the fabric surface in the form of fibers. Lastly, at block (106), the coated fabric with antimicrobial properties is obtained.

Now referring to Figure 5, which illustrates a flowchart of a method for fabricating an antimicrobial layer and a radiation-resistant layer on the fabric.

The method comprises steps of providing a layer of fabric as shown by block (107). This layer of the fabric is then coated with at least one layer with each of a synthesized resin mixture and a synthesized concoction of a fibre-forming polymer, a polyelectrolyte and a metal oxide on the surface of the fabric as indicated by block (108). In an embodiment, the resin mixture is obtained by dispersing graphite nanoplates (GNP) in water-borne polyurethane(WPU) followed by sonication. Sonication is a commonly used technique for obtaining homogeneous dispersions. The resin mixture so obtained is coated on the fabric to confer radiation resistant properties. The synthesisation of the concoction involves a mixing of a predetermined wt/vol% of polycaprolactone (PCL) in the range 3 wt/vol% to 9 wt/vol%, Poly (Diallyldimethylammonium Chloride) in the range 3 wt/vol% to 9 wt/vol% and copper oxide in the range 5 wt/vol% to 15 wt/vol% . The concoction so obtained is coated on the fabric and allowed to dry at room temperature for a predetermined time period. Later the fabric so coated confers to antimicrobial properties.

Figure.6 illustrates a graph of Alternating Current (AC) conductivity versus frequency graphs of the laminate obtained as a result of the experiment. The frequency of the AC is in the range of 10-1 Hz to 107 Hz. The graph line with square dots illustrates a laminate having only radiation-resistant layer (i.e. CF/GNP). The graph line with round dots represents a laminate having both the radiation-resistant layer and the antimicrobial layer (i.e. CF/CNP/AML). It is evident from the graphs that the conductivity of the laminate with both the antimicrobial layer and the radiation-resistant layer (i.e. CF/CNP/AML) is less than that of the laminate with only radiation resistant layer (i.e. CF/GNP) as the graph line with round dots lies below the graph line with square dots. The antimicrobial layer acts as an insulator. Thus, the presence of electrically insulating antimicrobial layer between two layers of conductive coating in case of the laminate having both the radiation-resistant layer and the antimicrobial layer poses hinderance to the bulk conductivity. Therefore, the conductivity value is less in case of the laminate with both the antimicrobial layer and the radiation-resistant layer in comparison to the laminate having only the radiation-resistant layer. The conductivity values of both the laminates remains nearly unchanged as the frequency is increased up to 103 Hz. However, the conductivity value shows a significant increase with the increase in frequency values beyond 103 Hz, for both the laminates as shown by the graphs.

Figure.7 illustrates a graph of Electromagnetic Interference( EMI) shielding effectiveness versus frequency, obtained as a result of an experiment. The graph line with round dots represents a laminate having only radiation-resistant layer (i.e. CF/GNP). The graph line with square dots represents a laminate having both the radiation-resistant layer and the antimicrobial layer (i.e. CF/CNP/AML). In an embodiment, the radiation shielding properties of the laminates (i.e. CF/GNP and CF/CNP/AML) are measured in X-band in frequency range 8.2GHz -12.4 GHz. It is evident from the graph that the laminate with only radiation resistant layer(i.e. CF/GNP) shows a shielding effectiveness of -15 dB to -20 dB. Such shielding effectiveness is a useful requirement of a commercial radiation shielding material. On the incorporation of the antimicrobial layer (i.e. CF/CNP/AML), there is a noticeable decrease in shielding effectiveness because of the insulating nature of the antimicrobial layer. In some experiments, the shielding effectiveness value can be easily modified by changing the stacking order of the laminates thereby the value can be reached to much above -20dB. In an embodiment, the shielding effectiveness value can be further modified by stacking multiple layers of the same laminate.

Figure.9 illustrates digital photographs of laminates pasted on to the different surfaces to demonstrate the potential applications of laminates. The laminates produced by the method of in the present disclosure may be used to cover the entire surfaces such as the surface of a window pane, surface of an entire wall, partition walls, etc. The laminates may also be used to manufacture floor/wall tiles with the laminates pasted on the surface. Thus the laminates will provide the radiation-resistance to the window panes, walls, floor etc which also curb the growth of the disease spreading microbes.

Figure 9a indicate a laminate pasted on the surface of a window pane. The laminate may be further used to cover the entire surface of the window panes.

Figure 9b indicate a laminate pasted on the surface of a wall. The laminate can be further used to cover the entire surface of the wall.

Figure 9c indicate a laminate pasted on the surface of floor/wall tile. The laminate can be further used to manufacture such tiles having the radiation-resistant and antimicrobial properties.

Experiment and Test Study:
Now referring to figure.8 illustrating the pictorial representation to showcase the plaque assay to detect the antimicrobial activity of fabricated samples as a part of the experiment. Four samples were made and referred to as sample A, B, C and D, respectively. Sample A consists of only Polycaprolactone (i.e. Sample A: PCL) in the antimicrobial layer. Sample B consists of a combination of Polycaprolactone and Poly (Diallyldimethylammonium Chloride) (i.e. Sample B: PCL+PDDA) in the antimicrobial layer. Sample C consists of a combination of Polycaprolactone, Poly (Diallyldimethylammonium Chloride) and copper (II) oxide (i.e. Sample C : PCL+PDDA+Cu2O. Finally, Sample D consists of a combination of Polycaprolactone, Poly (Diallyldimethylammonium Chloride) and copper (I) oxide (i.e. Sample D: PCL+PDDA+CuO). The prepared samples A, B, C and D are evaluated for the antimicrobial activities against bacteriophage with contact time of 2 hours. It is evident from the figure that all the samples showed formation of plaques. It can be observed that sample C and sample D showed a smaller number of formation of plaques. This can be attributed to the copper oxides present in the antimicrobial layers of sample C and sample D. The copper oxide provide strong antimicrobial activity to the samples C and sample D. Further, Sample C showed much smaller number of plaques compared to sample D. This shows that the sample C is having the most suitable combination for ascertaining the antimicrobial properties.

Table 1 illustrates four different kinds of samples A, B, C and D prepared as a part of the experiment. The as prepared samples (i.e. Sample A: PCL, Sample B: PCL+PDDA, Sample C: PCL+PDDA+Cu2O, and Sample D: PCL+PDDA+CuO) are used to study the antimicrobial activity in different embodiments of the present disclosure. It is evident from Table 1 that sample C (~40 plaques) displayed a smaller number of plaques followed by sample D (~50 in comparison to sample B and sample A wherein more than half of the bacterial culture was eaten by the virus. Indicated Mask sample C and mask sample D has the potential of killing virus within a contact time of 2 hours in comparison to the control sample.

Two laminates were taken as a part of experimental study to evaluate the radiation-resistant properties. One, where there is no antimicrobial layer (henceforth referred to as CF/GNP) but has graphite nanoplatelets (GNP) coated on its inner surface (hence can shield Electromagnetic radiations) and the other one with the antimicrobial layer (henceforth referred to as CF/CNP/AML, where AML refers the antimicrobial layer) to study and compare the differences.

The room temperature Alternating Current (AC) conductivity of the fabrics has been measured using an Alpha-A analyser (Novocontrol, Germany) in a broad frequency range of 10-1 to 107 Hz. Small square-shaped pieces of the fabric (1 cm × 1 cm) has been used for conductivity studies. The fabrics are characterized for microwave shielding using Vector Network Analyzer (VNA) from Keysight Technologies by the use of waveguides in the X band. The setup has been calibrated by TRL (i.e. through, reflect and line). The S (i.e. conductivity) parameters as obtained from the VNA are used to back-calculate the total shielding effectiveness and the respective contributions of reflection and absorption.

For the evaluation of antimicrobial activity, 2 % Luria broth agar (15 ml each) has been poured in 100 ml Petri dishes and allowed to solidify before experimenting. Each mask sample has been cut into a circular piece (1cm diameter). Thus four samples A, B, C and D (i.e. Sample A: PCL, Sample B: PCL+PDDA, Sample C: PCL+PDDA+Cu2O, and Sample D: PCL+PDDA+CuO) are obtained to study the effect of an individual element of the concoction. The antimicrobial studies are carried out for three different samples along with the control as shown in figures 7a to 7b.

10µl of M13 P1 bacteriophage (1012 pfu/ml) has been spotted and incubated for 2 hours (i.e. contact time) at humidified conditions. 10ml hot 0.7% agar medium in 50 ml tubes has been distributed during the incubation period. After 2 hours of contact duration, the sample has been vortexed in 500µl phosphate buffer saline (PBS) for 2 minutes to obtain the laminate extract. The extract is then added in the 10 ml 0.7% agar tubes, subsequently, 100µl saturated bacterial culture (E. coli) solution is added to the tubes, vortexed for 30 seconds, and poured onto the 2% solidified agar plate. Finally, it is incubated at 37°C in the incubator for 24 hours and then imaged. One plate is kept as negative control only with bacteriophage.

Results:
1. Conductivity and EMI (Electromagnetic Interference) Shielding properties of the laminates:
The charge transport properties of the two laminates (i.e. CF/GNP and CF/CNP/AML) are measured at room temperature over a frequency ranging from 107 to 10-1 Hz. It is noticed that both the laminates prepared tend to percolate, showing frequency independent conductivity (characteristic of DC conductivity). It is worth noticing that the conductivity of the laminates with antimicrobial layer is less than that of control sample (as seen in Figure-5). This is because of the electrically insulating antimicrobial layer between two layers of conductive coating (GNP) thereby posing a hindrance to its bulk conductivity.

The electromagnetic radiation shielding properties of the prepared laminates as measured in the X-band (8.2-12.4 GHz). The trend in increase of the values tend to correlate well with the conductivity values of the laminates as discussed above. The neat laminate (i.e., without antimicrobial layer) shows a shielding effectiveness of -20 dB which matches the market requirement of shielding materials when it comes to commercializing such shields. On the incorporation of the antimicrobial layer, there is a slight decrease in shielding effectiveness because of the presence of an insulating layer (similar to conductivity results). Also, by changing the concentration of graphite nanoplatelets (GNP) and by changing the stacking order of the laminates, the values can be easily modified to reach much above -20 dB. Hence, the values shown here are just representative to demonstrate the ability of the laminates to shield Electromagnetic interference (EMI).

2. Antimicrobial properties of laminates:
All the samples (i.e. Sample A: PCL, Sample B: PCL+PDDA, Sample C: PCL+PDDA+Cu2O, and Sample D: PCL+PDDA+CuO) shows plaques. The sample C and sample D shows a smaller number of plaques formation as evident from figure 8. The Sample C shows approximately 40 plaques while sample D displayed approximately 50 plaques. Indicated Mask sample C and mask sample D has the potential of killing virus within a contact time of 2 hours in comparison to the control. This can be attributed to the presence of copper oxide in the antimicrobial layer of the sample C and sample D. The copper oxide provides antimicrobial activity to the sample C and sample D.

The antimicrobial activities of the prepared samples are evaluated against bacteriophage, a small-sized virus that possesses single-stranded RNA. Bacteriophage suspension in buffer has been inoculated on the different samples, with a contact time of 2 hours, and phages were then evaluated by plaque assay. The images of the plates with plaques are shown in Figure 7. The figures 7a, 7b, 7c, and 7d clearly reveals that there is a significant decrease in number of plaques after the exposure to Cu2O and CuO containing samples (i.e. Sample C and Sample D). This demonstrates their strong antimicrobial activity. While on the other hand in case of pure PCL and PCL-PDDA systems (i.e. Sample A and Sample B) shows minimal activity i.e. higher plaques are observed showing that virus has eaten most of the bacteria.

Table 1
Samples PFU at 0hr (B) PFU at 2hr (A) Log reduction (Log B/A)
PFU Log PFU Log 2hr
Control 1.0x1012 12 1.0x1012 12 0
Mask A 380 2.5 9.5
Mask B 180 2.25 9.75
Mask C 42 1.5 10.5
Mask D 50 1.69 10.31

Based on the above results, it is proposed that the contact of virus with the surface of mask based on copper compounds causes the denaturation or degradation of biomolecules particularly protein in viruses, which results in their inactivation. Thus the sample C and sample D showed higher antimicrobial activity in comparison to sample A and sample B.

In an embodiment, the laminates as disclosed in the present disclosure can be used to cover the surfaces of the walls, window panes, housing of the medical devices etc. in the healthcare setup thereby preventing the spread of infectious diseases.

In an embodiment, the laminates installed in the health care setups provides radiation shielding to emitted radiations by medical devices, and these laminates in-turn prevents malfunctioning of other medical devices in the vicinity and also provides radiation shielding to the users.

In some instances, water droplets or splashes of water may contact the laminate disclosed in the present disclosure, these water droplets or splashes of water may penetrate the laminate. As the water droplets are absorbed or penetrate the laminate, any viruses or microbes residing in such droplets of water may be killed due to the antiviral property of the laminate.

In an embodiment, the laminates may be manufactured in an economical way thereby avoiding expensive spray disinfectant techniques that are conventionally followed.

Equivalents:

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Referral Numerals:

Referral Numeral Description
100 Fabric surface
102 Radiation-resistant layer
103 Antimicrobial layer
1a Fabric
1b Fabric with radiation-resistant layer and antimicrobial layer
2a Fabric
2b Fabric with radiation-resistant layer