FIELD OF THE INVENTION
[001] The present invention generally relates to inherent infection control textiles
(yarns and fabrics) and their method of manufacturing. More particularly, the present invention
relates to inherent infection control yarn which provides protection against bacteria and fungi
and may be used for variety of applications including but not limited to medical use such as in
hospitals and also find its utility in sports, kids clothing, hotels, railways etc.
BACKGROUND OF THE INVENTION
[002] Cotton is one of the most popular fibre used in the textile industry. Fabrics made
from 100 % cotton fibres are non‐allergenic, soft and easy to care for. Because of all these
properties, cotton is used for making a variety of fabrics such as towels, clothing, bed sheets,
blankets, denims, socks, caps, gloves, undergarments and the like.
[003] Further, cotton fibre is highly absorbent and absorbs moisture readily, which
makes cotton clothes comfortable in hot weather. However, fabrics made from cotton have
various disadvantages. One of the serious disadvantages of such fabric is their inability to dry
rapidly. Although these fabrics are good at absorbing moisture, it also takes a lot of time before
they dry out. As they remain wet for longer duration, they become permeable to various
microorganisms like bacteria and fungi. Further, there are many places where the permeability
of cotton fabric to micro‐organisms is quite high and is therefore a major concern. Examples of
the same being wearers/users in healthcare‐related workplaces like hospitals or users in public
transportation like railways and airlines wherein towels, blankets and bed sheets are communal
and are not washed regularly, and furthermore sports apparels which absorb sweat and remain
moist for longer time.
[004] To address these problems many different approaches have been explored to
manufacture fabric which resist microbial contamination. One such technique includes applying
an antimicrobial composition to a yarn. Although this technique is very commonly used, the
limitation being, the chemical treatment using antimicrobial composition can be toxic or may get
washed away during domestic or industrial laundering or multiple washing.
[005] Further, other modifications to this technique have also been proposed. One
such method involves the use of silver metal, wherein nanosilverpaticles of less than 100 nm in
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diameter are coated on the fibrous material. However, since silver metal is used; fabric obtained
using this technology becomes comparatively expensive.
[006] Another technique involves the use of bamboo fibres as anti‐bacterial textiles;
however, these are not efficient as infection control textiles. Further, there is a possibility of
migration of surface fibres due to abrasion, pilling after repeated use while manufactured using
conventional ring spinning technology.
[007] Accordingly, there persists a need for inherent and durable infection control
textile which is simple in manufacturing, non‐toxic and simultaneously without using any
chemicals.
[008] Furthermore, these exists a need to uniquely manufacture yarns for textiles
having antimicrobial properties throughout the life of the fabric.
SUMARY OF THE INVENTION
[009] In view of the foregoing disadvantages inherent in the prior‐art, the general
purpose of the present invention is to provide infection control textiles (yarns and fabrics) to
include advantages of the prior art and to overcome the drawbacks inherent in the prior art and
offering some added advantages.
[0010] The principal object of the embodiments herein of the present invention is to
provide a yarn which presents protection against infections caused by microorganisms such as
bacteria and fungi.
[0011] Another object of the embodiments herein of the present invention is to provide
a yarn which presents protection against infections caused by microorganisms such as bacteria
and fungi throughout the life of the fabric.
[0012] Yet another object of the embodiments herein of the present invention is to
provide a yarn which is simple in manufacturing.
[0013] Yet another object of the embodiments herein of the present invention is to
provide a yarn which may be prepared without using chemicals and is non‐toxic.
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[0014] These and other objects of the present invention have been fulfilled by preparing
an infection control yarn.
[0015] The infection control yarn of the present invention comprises an inner layer and
an outer layer, wherein the inner layer has base member, a first sheath and a second sheath.
The inner and the outer layer are made of a unique combination of the antimicrobial staple
fibres and antimicrobial filament fibres, blended with natural and synthetic fibres. By modifying
the specific ratio of this unique combination of antimicrobial staple fibres and filaments; the
specific antimicrobial component in the final yarn may be obtained as per the requirement.
[0016] These together with other aspects of the invention, along with the various
features of novelty that characterize the invention herein will be better appreciated and
understood when considered in conjunction with the following description and the
accompanying drawings. It should be understood, however, that the following descriptions,
while indicating preferred embodiments and numerous specific details thereof, are given by
way of illustration and not of limitation. Many changes and modifications can be made within
the scope of the exemplary embodiments herein without departing from the spirit thereof, and
the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF FIGURES
[0017] While the specification concludes with claims that particularly point out and
distinctly claim the invention, it is believed that the advantages and features of the present
invention will become better understood with reference to the following more detailed
description of expressly disclosed exemplary embodiments taken in conjunction with the
accompanying figures. The figures and detailed description which follow are intended to be
merely illustrative of the expressly disclosed exemplary embodiments and are not intended to
limit the scope of the present invention as set forth in the appended claims.
[0018] This invention is illustrated in the accompanying figures, throughout which like
reference letters indicate corresponding parts in the various figures. The embodiments herein
will be better understood from the following description with reference to the drawings, in
which:
[0019] Figure 1 shows an inner layer comprising a base member, first sheath and
second sheath wherein base member and first sheath form a core and is covered by second
sheath; and
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[0020] Figure 2 is a final structure of the yarn wherein inner layer arrangement of
Figure 1 is kept inside and the outer layer of antimicrobial filament fibres is wrapped or ring
spun on an outer side.
DETAILED DESCRIPTION OF INVENTION
[0021] The exemplary embodiments herein and the various features and advantageous
details thereof are explained more fully with reference to the non‐limiting embodiments that
are illustrated in the accompanying figures and detailed in the following description.
Descriptions of well‐known components and processing techniques are omitted so as to not
unnecessarily obscure the embodiments herein. Also, the various embodiments described
herein are not necessarily mutually exclusive, as some embodiments may be combined with
one or more other embodiments to form new embodiments. The term “or” as used herein,
refers to a non‐exclusive or, unless otherwise indicated. The examples used herein are
intended merely to facilitate an understanding of ways in which the embodiments herein may
be practiced and to further enable those skilled in the art to practice the embodiments
herein. Accordingly, the examples should not be construed as limiting the scope of the
embodiments herein.
[0022] Thus in accordance with the present invention, an infection control yarn which
exhibits antimicrobial properties throughout the life of the fabric and method for making such
yarn is provided.
[0023] The infection control yarn of the present invention includes an inner layer and
an outer layer. More specifically, inner layer has base member and first sheath which forms
the core of the yarn. The inner layer further comprises a second sheath covering the core of
the yarn.
[0024] In the embodiments provided herein, first and the second sheath are made of
natural and synthetic fibres blended with antimicrobial staple fibres and the base member
and outer layer is made of antimicrobial filament fibres.
[0025] The antimicrobial staple and filament fibres used, are the substrates to which
antimicrobial agents have been incorporated into the fibers, rendering a product that kills or
inhibits the growth of microorganisms whereas synthetic or natural fibres includes fibres of
cotton yarn, non‐woven cotton, cotton wool, linen, silk, wool, nylon, polyester, acrylic,
viscose, polypropylene, aramid or any other blended or synthetic fibre.
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[0026] In the preferred embodiment, the natural fibre used in the invention is cotton
and the content of antimicrobial staple and filament fibres in the yarn contributes to 10 to
100 % based on the weight of the yarn. Further, the inner layer may be wrapped or helically
covered with antimicrobial filament fibres on the outer side.
[0027] Antimicrobial fibres have long been used to prepare antimicrobial fabrics,
however, inventors have found that the use of combination of antimicrobial staple fibres and
antimicrobial filament fibres have its own advantage and forms one of the critical feature of
the invention. Since the antimicrobial staple fibres and antimicrobial filament fibres are used
in the specific ratio in the yarn, by modifying this specific ratio; antimicrobial component in
the final yarn could be obtained as per the requirement; which is unattainable by the
conventional methods currently present in the art.
[0028] Still further, the unique way of forming the yarn having inner layer of base
member, first sheath and the second sheath and finally covering the inner layer by an outer
layer in the invention provide a tight twist to the yarn and prevents migration of surface
fibres. Thus, the fabric remains durable and can be used for longer duration.
[0029] In another embodiment, the method for manufacturing an infection control yarn
involves preparing an inner layer having base member, first sheath and second sheath
wherein base member and first sheath together form the core.. The core is covered with a
second sheath thereby configuring an inner layer of the yarn, and enclosing the inner layer of
the yarn with a outer layer.
[0030] The base member and outer layer is made of anti‐microbial filament fibres and
first sheath and second sheath is made of natural and synthetic fibres blended with
antimicrobial staple fibres
[0031] The antimicrobial action of the yarn occurs when microbes such as bacteria and
fungi come in contact with the surface of the fabric. The antimicrobial agents penetrate the
cell wall of the microbe and disrupt key cell functions so the microbe cannot grow or
reproduce. Thus, growth is disrupted, and the microbes are finally reduced.
[0032] Further, yarn prepared according to the invention has antibacterial and
antifungal effects against broad spectrum of bacteria and fungi, such as Escherichia coli,
Methicillin resistant, Chlamydia trachomatis, Providenciastuartii, Vibrio vulnificus,
Pneumobacillus, Nitrate‐negative bacillus, Staphylococcus aureus, Candida albicans, Bacillus
cloacae, Bacillus allantoides, Morgan's bacillus (Salmonella morgani), Pseudomonas
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maltophila, Pseudomonas aeruginosa, Neisseria gonorrhoeae, Bacillus subtilis, Bacillus
foecalisalkaligenes, Streptococcus hemolyticus B, Citrobacter, and Salmonella paratyphi C;
and more particularly against Staphylococcus aureus and Klebsiella pneumonia.
[0033] The infection control yarn of the present invention may be used to fabricate
towels, clothing, bed sheets, blankets, medical robes, denims, socks, caps, gloves and
undergarmentsandexhibits antimicrobial properties throughout the life of fabric and is nontoxic
and safe for humans.
The following examples are illustrative, and should not be viewed as limiting the scope of the
present invention. Reasonable variations, such as those occur to reasonable artisan, may be
made herein without departing from the scope of the present invention.
METHOD STEPS FOR MANUFACTURING AN INFECTION CONTROL YARN
Method for manufacturing an infection control yarn comprises preparing an inner layer
having a base member, covering the base member with a first sheath to form a core. A second
sheath made of natural and synthetic fibres blended with antimicrobial staple fibres, thereby
configuring an inner layer of the yarn, and enclosing the inner layer of the yarn with an outer
layer of anti‐microbial filament fibres.
EXAMPLE 1: ANTIMICROBIAL CONTENT IN THE YARN
a. Base member–Antibacterial filament‐9 tex
b. First sheath roving (cotton blended with antibacterial staple fibres)‐35tex
c. second sheath roving ‐35tex
d. Wrapping antibacterial filament‐ 9 tex
Total tex of final yarn – 93
Total antibacterial component in the final yarn‐ 25
% antibacterial component in the final yarn‐ 27 %
EXAMPLE 2: ANTIMICROBIAL CONTENT IN THE YARN
a. Base member–Antibacterial filament‐9 tex
b. First sheath roving (cotton blended with antibacterial staple fibres)‐65 tex
c. Second sheath roving ‐65 tex
d. Wrapping antibacterial filament‐ 9 tex
Total tex of final yarn – 155
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Total antibacterial component in the final yarn‐ 31
% antibacterial component in the final yarn‐ 20 %
ANTIMICROBIAL ACTIVITY OF INFECTION CONTROL YARN
The infection control yarn of the present invention was examined for the antimicrobial activity
particularly for their activity against Staphylococcus aureus and Klebsiella pneumonia. The
antimicrobial activity of the yarn after repeated washes was also tested.
EXPERIMENTAL: ANTIMICROBIAL TEST OF THE WOVEN FABRIC AFTER 50 WASHES:
Purpose: Determination of Antimicrobial Activity of the woven fabric after 50 washes.
Method: Antimicrobial Activity was determined by AATCC 100 – 2012 method
Test Inoculum used were:
1. Staphylococcus aureus ATCC 6538 (1 x 105 CFU/ml)
2. Klebsiellapneumoniae ATCC 4352 (1.5 x 105 CFU/ml)
Additional Test Information:
1. Sample size: 4.8cm
2. No. of swatches used: 4
3. Inoculum Carrier: Phosphate Buffered water
4. Neutraliser: DE broth
Sample
Identification
Test
Culture
No. of Bacteria per sample
(CFU/sample)
Percentage
Reduction of
Microorganism
(R)
Inoculated
Sample
at 0 hours (B)
Inoculated
Sample
at 24 hours (A)
AFTER 50
WASH
Staph. Aureus 1.2 x 105 3 x 103 97.50%
K. pneumonia 1.4 x 105 3.2 x 103 97.71%
RESULT:
Fabric showed 97.50% and 97.71% antimicrobial activity towards Staphylococcus aureus and
Klebsiellapneumoniae respectively when analyzed as per AATCC 100 ‐ 2012 test Method.
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A) ANTIMICROBIAL TEST OF THE WOVEN FABRIC AFTER 75 WASHES:
Purpose: Determination of Antimicrobial Activity of the woven fabric after 75 washes
Method: Antimicrobial Activity was determined by AATCC 100 method
Test Inoculum used were:
1. Staphylococcus aureus ATCC 6538 (1 x 105 CFU/ml)
2. Klebsiellapneumoniae ATCC 4352 (1.5 x 105 CFU/ml)
Additional Test Information:
1. Sample size: 4.8cm
2. No. of swatches used: 4
3. Inoculum Carrier: Phosphate Buffered water
4. Neutraliser: DE broth
Sample
Identification
Test
Culture
No. of Bacteria per sample
(CFU/sample)
Percentage
Reduction of
Microorganism
(R)
Inoculated Sample
at 0 hours (B)
Inoculated
Sample
at 24 hours (A)
AFTER 75
WASH
Staph. aureus 1.5 x 105 2 x 104 86.67 %
K. pneumoniae 1.0 x 105 1.0 x 104 90.0 %
RESULT: Fabric showed 86.67% and 90% antimicrobial activity towards Staphylococcus aureus
and Klebsiellapneumoniae respectively when analyzed as per AATCC 100 test Method.
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We Claim:
Claim 1. An infection control yarn having antimicrobial properties comprising:
an inner layer having
a base member,
a first sheath covering the base member to form a core of the yarn, and
a second sheath covering the core of the yarn,
wherein said base member is made of antimicrobial filament fibres and
said first sheath and second sheath is made of natural and synthetic fibres blended with
antimicrobial staple fibres; and
an outer layer enclosing the inner layer,
wherein the outer layer is made of anti‐microbial filament fibres, and
wherein the infection control properties of the yarn is achieved by uniquely
mixing antimicrobial filament fibres with natural and synthetic fibres blended with antimicrobial
staple fibres.
Claim 2. The infection control yarn as claimed in claim 1, wherein said natural and synthetic
fibres is selected from the group consisting of cotton yarn, non‐woven cotton, cotton wool,
linen, silk, wool, nylon, polyester, acrylic, viscose, polypropylene, aramid or any other blended
or synthetic fibre.
Claim 3. The infection control yarn as claimed in claim 1, wherein said outer layer is wrapped
or helically covered around the inner layer.
Claim 4. The infection control yarn as claimed in claim 1, wherein said content of antimicrobial
staple and filament fibres in the yarn is about 10 to 100 % based on the weight of the yarn.
Claim 5. The infection control yarn as claimed in claim 1, wherein said antimicrobial properties
includes inhibition against growth of bacteria and fungi.
Claim 6. The infection control yarn as claimed in claim 1, wherein said antimicrobial properties
includes not less than 95 % inhibition against growth of bacteria and fungi after 50 washes.
Claim 7. The infection control yarn as claimed in claim 1, wherein said antimicrobial properties
includes not less than 85 % inhibition against growth of bacteria and fungi after 75 washes.
Claim 8. The infection control yarn as claimed in claim 1, wherein said yarn is used to fabricate
towels, clothing bed sheets, blankets, medical robes, denims, socks, caps, undergarments.
Claim 9. A method for manufacturing an infection control yarn comprising:
providing a base member of anti‐microbial filament fibres;
covering the base member with a first sheath made of natural and synthetic fibres
blended with antimicrobial staple fibres, to form a core of the yarn;
covering the core of the yarn with a second sheath made of natural and synthetic fibres
blended with antimicrobial staple fibres, configuring an inner layer of the yarn; and
enclosing the inner layer of the yarn with a outer layer anti‐microbial filament fibres.