Reusable high performance medical textiles with moisture management, sterilization capability and integrated germicidal sanitization system

Abstract

The present invention, termed UniClenz, relates to a reusable high-performance medical textile for sterile environments. It comprises a tri-layered structure: an inner moisture-wicking layer (cotton or blend) for sweat absorption, a middle polyurethane film acting as a microbial and fluid barrier, and an outer germicidal knit layer embedded with antimicrobial nanoparticles. A novel real-time germicidal sanitization system is integrated using perforated silicon tubing connected to a portable dispenser, allowing capillary-action-based disinfection of the outer surface within 2 minutes. UniClenz is compatible with sterilization methods including autoclaving, gamma irradiation, ethylene oxide, and UV-C, and withstands over 50 sterilization cycles. The invention significantly reduces biomedical waste and ensures prolonged usability. UniClenz can be used in PPE garments (gowns, coveralls), hospital linens, and cleanroom partitions, offering improved hygiene, comfort, and environmental sustainability.

Description

REUSABLE HIGHPERFORMANCE MEDICALTEXTILES WITH MOISTUREMANAGEMENT, STERILIZATIONCAPABILITY AND INTEGRATEDGERMICIDAL SANITIZATIONSYSTEM.

[0001] The present invention relates to a high-performance reusable medical textile with integrated moisture management, sterilization compatibility, and germicidal sanitization capabilities. This medical textile is designed for use in sterile or hygiene-critical environments across various industries.

[0002] The present invention relates to a high-performance reusable medical textile with integrated moisture management, sterili8zation compatibility, and germicidal sanitization capabilities. This medical textile is designed for use in sterile or hygiene-critical environments across various industries.

[0003] In particular, the invention is applicable to hospitals and healthcare facilities, pharmaceutical manufacturing units and research laboratories, food processing plants and packaging industries, veterinary clinics and surgical centres, microbiological and virology labs, cleanrooms for electronics or biotechnology, and other environments requiring strict hygienic control. It offers reusability, enhanced infection control, and environmental sustainability in all these settings.

[0004] Hereafter, this invention “REUSABLE HIGH PERFORMANCE MEDICAL TEXTILES WITH MOISTURE MANAGEMENT, STERILIZATION CAPABILITY AND INTEGRATED GERMICIDAL SANITIZATION SYSTEM.” will be referred to as “UniClenz” for simplicity throughout this specification.

[0005] The demand for high-performance reusable textiles in sterile environments has grown due to the limitations of single-use disposable fabrics and concerns related to infection control, environmental sustainability, and cost efficiency effectiveness. Conventional single-use medical textiles (e.g., non-woven polypropylene (PP) or polyethylene (PE) based fabrics used in personal protective equipment) suffer from limited breathability and generate significant biomedical waste. Furthermore, the need for effective reusable protective textiles extends beyond healthcare. Industries such as pharmaceutical production, food processing, veterinary medicine, and advanced manufacturing cleanrooms face analogous challenges with disposable protective materials, underscoring the necessity for advanced reusable textiles in these fields.

[0006] Current Industry Limitations:Non-Breathability and Discomfort:Traditional disposable protective textiles often incorporate impermeable plastic films for barrier properties (e.g., PE or laminate layers), rendering them non-breathable and uncomfortable during prolonged use. This leads to excessive sweating and heat stress, reducing user comfort and efficiency.Single-Use Design & Waste Accumulation:Disposable PPE’(s) and hygiene fabrics are typically intended for one-time use, contributing to substantial waste generation. In healthcare, this manifests as high biomedical waste requiring incineration or landfill disposal, which increases environmental pollution and the carbon footprint of facilities. Similarly, in food processing and other industries, frequent disposal of contaminated garments and covers leads to significant environmental waste management challenges.Risk of Cross-Contamination:Many single-use textiles lack any real-time pathogen neutralization mechanism. They can carry and spread infectious agents on their surfaces during use, removal (doffing), or disposal. This raises the risk of hospital-acquired infections (HAIs) and contamination events in laboratories, food production lines, and other sensitive environments.Limited Sterilization Compatibility:Conventional non-woven fabrics and plastic-based textiles tend to degrade or lose functionality when subjected to sterilization procedures (e.g., autoclaving, chemical sterilant). As a result, they cannot be safely reused; repeated procurement of disposables are required, driving up operational costs in hospitals, labs, and cleanrooms.Cross-Industry Use of Disposables:Sterile and hygiene-critical settings outside healthcare (such as pharmaceutical labs, food processing facilities, and electronics cleanrooms) similarly rely on single-use apparel, linens, and drapes. These industries face the same issues of waste generation and insufficient on-the-spot sanitization, indicating a broad, unmet need for reusable, easily sterilizable medical textile solutions across sectors.

[0007] A comprehensive prior art search has revealed several patented medical textile technologies focusing on antimicrobial treatments, breathable barriers, and reusable gowns. However, existing solutions fail to address all critical challenges simultaneously or remain limited to niche applications. For example:US5599610Adiscloses a trilaminate fabric for surgical gowns, but it is designed for single use and does not incorporate any real-time sanitization or features for long-term reusability.EP0554049A1focuses on enhancing barrier properties for medical protection in reusable surgical fabrics made from woven polyester but lacks integrated moisture management and embedded antimicrobial features.US4919998Adescribes a reusable, launderable, and sterilizable medical barrier fabric using a tightly woven polyester structure but does not include an integrated germicidal sanitization system.US20170050870A1details systems for treating textiles with antimicrobial agents, but these rely on chemical coatings that can degrade over time and are often incompatible with frequent, harsh sterilization cycles.EP4043638A1(US20220205170A1) describes a coated barrier fabric with two plies coated with a non-fluorine polymer on their inwardly facing sides. This protects the coating but lacks an active, real-time sanitization system and the specific tri-layer composition for moisture management found in UniClenz.EP1838918A1describes garment processing with biological sanitization and inspection procedures. This system is external to the garment, focusing on sanitization during the laundering process, unlike UniClenz's integrated, on-demand system built into the garment itself.US6723428B1discloses anti-microbial fibers, including bi-component fibers with additives in the sheath. While it addresses the inclusion of antimicrobial agents within the fiber, it does not describe the specific tri-layer fabric structure for moisture management or the integrated liquid germicidal delivery system of UniClenz.

[0008] The UniClenz medical textile system is designed to overcome these limitations by integrating multiple functional layers and systems into one reusable product. Key innovative aspects of UniClenz include:Moisture-Wicking Inner Layer:Made of 100% cotton or cotton-polyester blends, this skin-contact layer absorbs sweat and moisture, ensuring comfort and biocompatibility during extended use. It is optionally treated for odour resistance and additional passive antimicrobial properties.Breathable Barrier Middle Layer:A high-performance, microporous polyurethane (PU) film provides a fluid-resistant and microbe-impermeable barrier while allowing water vapor to escape. This layer stops blood, bodily fluids, or other contaminants from passing through, protecting the wearer or underlying surface, yet maintains breathability to prevent heat buildup.Antimicrobial / Germicidal Outer Layer:The outermost layer is an engineered, high-wickability knit (e.g., polyester) embedded with long-lasting antimicrobial agents such as silver or copper nanoparticles, zinc oxide (ZnO), or titanium dioxide (TiO₂) catalysts. This layer facilitates quick drying and actively contributes to pathogen elimination on the medical textile surface. Its structure is designed to withstand repeated sanitization and sterilization processes without degradation of performance.

[0009] A major advancement in UniClenz is itsintegrated germicidal sanitization system, which actively disinfects the medical textile surface in real time during use. Unlike conventional antimicrobial fabrics that rely solely on static coatings or slow-acting treatments (which can diminish after washing), UniClenz employs a built-in sanitization mechanism. In one embodiment, a network of perforated silicon tubing is embedded within the medical textile article (for example, integrated into a PPE garment, reusable drape, or partition curtain). This tubing network is connected to a portable disinfectant dispenser or reservoir. Upon activation, either manually by the user or automatically via an IoT-enabled sensor system, the dispenser pumps a sanitizing liquid (such as an alcohol-based or other germicidal solution) through the tubing. The liquid is released through micro-perforations onto the outer layer of the medical textile, achieving uniform and complete surface disinfection within approximately 2 minutes. This on-demand sanitization system significantly reduces cross-contamination risk during use: pathogens that contact the medical textile are rapidly neutralized, protecting both the user and the environment from spread of contamination.

[0010] Sterilization Compatibility: UniClenz is engineered to endure rigorous sterilization procedures, ensuring that it can be safely reused multiple times. The multi-layer fabric and any embedded components retain their mechanical strength and antimicrobial efficacy after repeated exposure to standard sterilization techniques, including: autoclave steam sterilization at 121°C–132°C (15–30 minutes, 15–30 psi), gamma irradiation (doses up to ~25 kGy), ethylene oxide (EtO) gas sterilization, and ultraviolet-C light exposure. Each layer and seam of the medical textile is constructed from materials selected for thermal and chemical durability, so that the article does not warp, delaminate, or lose functionality through dozens of sterilization cycles.

[0011] In summary, UniClenz offers a sustainable, high-performance alternative to disposable PPE, single-use linens, and other throwaway sterile textiles. It dramatically reduces waste (for instance, biomedical or hazardous waste can be cut by over 90%) while maintaining long-term sterility, breathability, and infection control performance. By integrating active moisture management, continuous antimicrobial protection, and real-time self-sanitization, UniClenz establishes a new benchmark for reusable hygienic textiles. It addresses critical needs across industries by minimizing cross-contamination risks and improving environmental sustainability without sacrificing comfort or safety.

[0012] The present invention, UniClenz, is built upon a tri-layer fabric architecture combined with an integrated disinfection system, ensuring long-term usability, real-time antimicrobial protection, and resistance to multiple sterilization processes. The key components and features of this medical textile system are as follows:Tri-Layer Medical textile Structure:Each layer is designed with a specific function to maximize comfort, microbial resistance, and fluid protection:Inner Layer (Skin Contact Layer):Composed of 100% Cotton or a Cotton-Polyester blend (70:30), this layer provides excellent moisture absorption, sweat-wicking, and biocompatibility. It is chemically treated to resist odor and inhibit microbial growth.Middle Layer (Barrier Layer):This layer consists of a high-breathability Polyurethane (PU) film (15-20 GSM) that functions as a robust microbial and viral barrier. It effectively repels liquids while allowing moisture vapor to escape, ensuring wearer comfort.Outer Layer (Germicidal Layer):Made from a high-wickability polyester knit fabric, this layer is engineered to facilitate rapid and efficient pathogen elimination. It is embedded with antimicrobial agents such as silver / copper nanoparticles, ZnO, and TiO_2 for long-lasting germicidal action and supports the active sanitization process.Integrated Sterilization & Real-Time Sanitization System:UniClenz incorporates an active sanitization mechanism that ensures continuous disinfection, a feature not found in conventional antimicrobial textiles.Compatibility with Sterilization Methods:The fabric is designed to be compatible with industry-standard sterilization methods, including Autoclaving (121circC−132circC), Ethylene oxide (EtO) sterilization, Gamma irradiation (up to 25 kGy), and Ultraviolet (UV-C) radiation.Real-Time Germicidal Sanitization:A network of perforated silicon tubing is embedded into the PPE garments. This network is connected to a portable germicide dispenser, which allows for the controlled flow and dispersal of a germicidal liquid via capillary action, ensuring uniform disinfection. This system is capable of achieving complete sanitization in under 2 minutes, significantly reducing cross-contamination risks. Activation can be manual or automated via an IoT-based system.Enhanced Seam Sealing:The seams of the garments are sealed with high-tensile PU antimicrobial tapes to prevent any fluid leakage. A hot-melt seam sealing technology is employed to ensure the structural integrity of the garment, even after multiple sterilization cycles.Reusability & Environmental Sustainability:UniClenz is engineered for durability, retaining its performance for over 50 sterilization cycles without degradation. This reusability significantly reduces biomedical waste and the associated carbon footprint by over 90% when compared to disposable PPE. The medical textile complies with BIS 17423 & ASTM standards, making it suitable for medical applications worldwide.

[0013] In essence, UniClenz introduces a paradigm shift in how sterile environment textile’s function. The most significant advancement is the combination ofreal-time self-sanitizationwithmulti-use durability. Unlike existing antimicrobial fabrics that require frequent laundering or reapplication of antimicrobial chemicals to remain effective, UniClenz’s built-in germicidal system keeps the medical textile continuously hygienic during operation. This innovation ensures that the article remains a continuously active barrier against pathogens, thereby drastically reducing the chance of cross-contamination. By maintaining sterility on its surface and surviving rigorous reuse, UniClenz provides a reliable, cost-effective, and eco-friendly solution that addresses the critical needs of various industries for safe and sustainable protective textiles.

[0014] Sterile and hygiene-critical environments such as hospitals, surgical theatres, pharmaceutical manufacturing units, biosafety laboratories, veterinary surgical centers, food-processing plants, and cleanrooms depend heavily on protective textiles to prevent cross-contamination, pathogen transmission, and environmental exposure. However, existing medical textile systems, both disposable and reusable exhibit multiple technical shortcomings that compromise safety, comfort, sustainability, and operational efficiency.

[0015] A first problem arises from the limitations of conventional single-use protective textiles, which predominantly employ non-woven polypropylene or polyethylene barrier fabrics. These materials rely on impermeable films that restrict breathability, causing excessive heat buildup, sweating, and user discomfort during prolonged wear. Their single-use nature results in massive biomedical waste generation, leading to high disposal costs and significant environmental burden. These materials also lack real-time antimicrobial activity; pathogens remain viable on the surface until disposal, increasing the risk of infection during doffing, handling, and waste segregation.

[0016] A second problem lies in existing reusable medical textiles, which, although washable, generally lack a high-performance microbial barrier layer. Their permeability may allow fluids, aerosols, or microorganisms to penetrate during critical procedures. Moreover, conventional antimicrobial coatings applied to such fabrics degrade rapidly with repeated laundering or sterilization cycles, resulting in diminished protection over time. These materials do not incorporate any mechanism for on-demand sanitization during use, leaving contaminated surfaces untreated until external washing or sterilization is performed.

[0017] A further technical problem concerns the inability of current textile systems to integrate active disinfection mechanisms. No existing reusable barrier textile provides a built-in system capable of distributing a germicidal liquid uniformly across the outer surface while maintaining comfort, structural integrity, and breathability. Attempts to integrate fluid channels or coatings into fabrics typically fail due to clogging, poor adhesion, non-uniform distribution, or incompatibility with high-temperature sterilization processes.

[0018] Another critical problem relates to sterilization compatibility and durability. Many multi-layer textiles delaminate, deform, or lose barrier properties when subjected to repeated autoclaving, gamma irradiation, EtO exposure, or UV-C treatment. Embedded components if any, cannot withstand such conditions, causing system failure. Thus, current products cannot feasibly support long-term reuse without significant performance loss.

[0019] Industries outside healthcare face analogous issues. Pharmaceutical cleanrooms require fabrics that prevent particulate shedding and microbial ingress while maintaining breathability. Food processing facilities need protective garments that withstand aggressive cleaning routines while ensuring continuous hygiene. However, existing solutions still rely on disposable or minimally reusable materials without integrated sanitization, hence failing to meet contamination-control requirements.

[0020] Therefore, the technical problem addressed by the present invention is the absence of a reusable, multi-layer medical textile that simultaneously provides:High microbial and fluid-barrier performancewithout sacrificing breathability and wearer comfort.Embedded antimicrobial activity that remains durableacross repeated cycles of sterilization and use.A real-time, integrated germicidal sanitization systemcapable of uniformly disinfecting the textile surface during use.Mechanical robustness and material compatibilityneeded to withstand 50 or more sterilization cycles (autoclave, gamma irradiation, EtO, UV-C) without degradation.A sustainable alternativeto high-waste disposable PPE and linens.Cross-industry applicability, enabling use in diverse sterile environments where contamination control is critical.

[0021] These unresolved technical deficiencies create a significant unmet need for an advanced reusable textile system that ensures continuous sterility, user comfort, regulatory compliance, and environmental sustainability needs that the present invention seeks to fulfill.

[0022] The present invention, termedUniClenz, provides an integrated and comprehensive solution to the limitations of existing disposable and reusable medical textiles. UniClenz overcomes the identified technical problems by introducing amulti-functional, tri-layer reusable textile systemcombined with areal-time germicidal sanitization mechanism, engineered to maintain performance through repeated sterilization cycles while ensuring user comfort, environmental sustainability, and superior infection control.

[0023] To address the lack of breathability and the discomfort associated with conventional single-use barrier fabrics, the invention employs atri-layer textile architecture, wherein each layer is engineered for a specific functional purpose. Theinner layer, composed of cotton or a cotton-polyester blend, provides moisture absorption, sweat-wicking, and wearer comfort. Themiddle layeruses a microporous polyurethane (PU) film that blocks microbes and fluids while allowing water vapor transmission, eliminating heat buildup and ensuring breathability. Theouter layer, formed from a high-wickability polyester knit embedded with antimicrobial nanoparticles (such as silver, copper, ZnO, or TiO₂), ensures rapid dispersion of liquids and provides long-lasting passive germicidal activity.

[0024] To solve the problem of surface contamination persistence and the absence of real-time sanitization in existing textiles, UniClenz introduces anovel embedded germicidal sanitization system. A network of perforated silicone tubing is integrated within the textile article such as gowns, linens, drapes, or covers without compromising flexibility or comfort. This network connects to aportable germicide dispenserthat uses pump-driven or capillary-assisted liquid delivery. When activated manually or via optional IoT-based triggers, the system uniformly distributes a germicidal solution across the outer layer. The wickability of the outer textile ensures rapid, homogeneous coverage, enabling complete surface disinfection in approximately two minutes, thus significantly reducing the risk of cross-contamination during active use.

[0025] To overcome the degradation of performance observed in reusable textiles subjected to repeated sterilization, UniClenz is constructed usingmaterialsselected for thermal and chemical resistance, along with multi-cycle durability. The laminated tri-layer composite and embedded tubing withstand50 or more sterilization cycles, including autoclave steam treatment (121–132°C), gamma irradiation (up to ~25 kGy), ethylene oxide exposure, and UV-C radiation, without delamination, loss of mechanical strength, or deterioration of antimicrobial activity. Seam integrity is preserved usinghigh-tensile PU antimicrobial seam tapesandhot-melt sealing techniquesthat ensure a fully fluid-proof barrier, even after repeated sterilization.

[0026] To address environmental waste and cost issues associated with disposable PPE, UniClenz provides along-life, reusable alternative, drastically reducing biomedical and industrial waste generation. The real-time sanitization system further enables contamination control between patient interactions or workflow stages, reducing the frequency of washing or external sanitization procedures.

[0027] The invention also resolves the absence of a versatile, cross-industry protective textile by providing amodular and adaptable platform. The UniClenz material can be fabricated into PPE garments, surgical drapes, bed linens, laboratory coats, cleanroom suits, food processing apparel, and partition curtains, enabling broad use across healthcare, pharmaceutical, veterinary, food, and electronics industries.

[0028] Thus, UniClenz solves the technical problems of inadequate barrier performance, heat discomfort, lack of real-time antimicrobial action, sterilization incompatibility, rapid coating degradation, and unsustainable waste generation by delivering adurable, breathable, real-time self-sanitizing, high-performance medical textile system suitable for repeated use across diverse sterile environments.

[0029] The present invention, UniClenz, provides several significant technical, operational, and environmental advantages over conventional disposable and reusable medical textiles. These advantages arise from the synergistic combination of its tri-layer textile architecture, integrated germicidal sanitization system, and multi-cycle sterilization compatibility.Superior Infection Control Through Real-Time Surface SanitizationUnlike existing protective textiles that rely solely on passive antimicrobial coatings or require external disinfection, UniClenz incorporates anactive, built-in germicidal delivery systemcapable of uniformly sanitizing the entire outer surface within approximately two minutes. This on-demand sanitization drastically reduces microbial load during use, minimizes the risk of hospital-acquired infections, and prevents contamination transfer during patient handling, laboratory operations, food processing, or high-risk industrial tasks.High-Performance, Multi-Layer Protection with Breathability and ComfortThe tri-layer construction provides a unique balance of safety and comfort. The microporous PU barrier layer blocks fluids and microbes while allowing moisture vapor transmission, preventing heat stress and sweat accumulation. The moisture-wicking inner layer enhances wearer comfort, making the textile suitable for long-duration use, while the germicidal outer layer disperses liquids rapidly and maintains a hygienic surface.Long-Lasting Durability and Multi-Sterilization CompatibilityUniClenz is engineered to withstand50 or more sterilization cycles, including autoclaving, gamma irradiation, ethylene oxide exposure, and UV-C treatment, without appreciable loss of mechanical integrity, antimicrobial function, or barrier performance. This durability far surpasses conventional reusable textiles, which often degrade after limited washing or sterilization cycles, and is unprecedented in the context of systems incorporating embedded tubing networks.Reduced Environmental Impact and Operational CostsThe invention significantly reduces the environmental burden associated with disposable PPE and single-use medical linens by enabling repeated use without compromising safety. Institutions adopting UniClenz can reduce biomedical waste generation byover 90%, thereby lowering incineration or landfill costs and improving the sustainability of healthcare, laboratory, and industrial operations.Uniform and Efficient Distribution of Germicidal AgentsThe embedded silicone tubing network with precisely calibrated perforations ensures predictable, uniform, and controlled release of sanitizing liquid. This results in full-surface decontamination without dripping, pooling, or uneven distribution, enhancing reliability and reducing germicide consumption.Enhanced Structural Integrity Through Advanced Lamination and Seam-SealingThe use of hot-melt lamination to bond the tri-layer textile, combined with antimicrobial PU seam tapes, ensures a continuous, non-perforated barrier against liquid and microbial ingress at seams and joints. The garment or textile article maintains flexibility, strength, and barrier protection even after repeated sterilization cycles.Adaptability Across Multiple Industries and Product FormsUniClenz can be fabricated into a wide range of reusable products PPE gowns, coveralls, surgical drapes, hospital linens, lab coats, cleanroom garments, food-processing aprons, or sterilizable curtains making it highly versatile. This adaptability provides a unified solution to contamination control across healthcare, biomedical research, pharmaceutical production, veterinary surgery, food processing, and semiconductor cleanrooms.Continuous Protection Without Reliance on External Sanitization InfrastructureThe integrated, portable germicide dispenser allows the textile to maintain sterility autonomously, enabling rapid sanitization in remote, mobile, or emergency environments where external sterilization equipment is unavailable or impractical. This enhances readiness and safety in field hospitals, ambulances, isolation wards, and disaster relief operations.Improved Occupational Safety and Reduced Cross-Contamination RisksBy enabling surface neutralization of pathogens in real time, UniClenz reduces exposure to infectious agents during doffing, transportation, or reuse. This significantly enhances occupational health for healthcare workers, laboratory personnel, food handlers, and cleanroom technicians.

[0030] The features, advantages, and operational mechanisms of the present invention, UniClenz, are described in detail with reference to the accompanying drawings. These drawings illustrate a preferred embodiment of the invention but should not be considered as limiting, as other equally effective variations may exist.Fig.1

[0031] illustrates a medical surgical gown (100), which is a key application of the UniClenz medical textile. The gown incorporates moisture management, microbial protection, and an integrated sanitization system.Fig.2

[0032] depicts the tri-layer structure of the UniClenz fabric, showing the Inner Layer (105), the Middle Layer (104), and the Outer Layer (103).Fig.3

[0033] illustrates the portable sanitizing dispenser system (107), detailing its components, including the pump (108), the inlet tube (109) for drawing sanitizing liquid, and the outlet tube (110) that connects to the gown.Fig.4

[0034] demonstrates the complete UniClenz sanitization arrangement, showing the dispenser (107) connected via a connector (111) to the embedded tubing (101) of the gown (100) for uniform distribution of the germicidal liquid.

[0035] The following embodiments describe preferred implementations of the invention, UniClenz, in detail. These embodiments are provided to illustrate the construction, operation, and performance of the reusable medical textile system and are not intended to limit the scope of the invention. Variations, equivalents, and modifications will be apparent to persons skilled in the art without departing from the spirit of the invention.

[0036] UniClenz is specifically engineered to endure multiple sterilization cycles and demanding usage conditions while maintaining its functional properties. The following description illustrates exemplary embodiments and implementations of the invention, though it is understood that the scope of the invention is not limited to these examples.Multi-Cycle Sterilization Endurance: The composite fabric and integrated tubing system of UniClenz remain effective after repeated sterilizations. For instance, in tests the material withstood over 50 autoclave cycles (121°C for 30 minutes each) with no observable degradation in tensile strength, flexibility, or barrier performance. It similarly tolerates gamma irradiation (up to 25 kGy doses), ethylene oxide exposure, and UV-C light without significant loss of antimicrobial activity. These capabilities ensure that UniClenz items (garments, linens, etc.) can be reprocessed and reused safely, providing a long-term solution where current textiles fail after one or a few uses.

[0037] Comparison to Conventional Solutions: Unlike single-use non-woven gowns or covers that often cannot survive even a single high-temperature wash or sterilization cycle, UniClenz offers a long-term, cost-effective solution that maintains safety and performance over time. It provides enhanced wearer or user safety through its on-demand sanitization feature and breathable comfort, all while significantly reducing operational costs associated with frequent disposal and replacement. The ability of UniClenz to self-sanitize (during use or between uses), resist microbial penetration, and remain effective after dozens of uses makes it a revolutionary advancement in the field of reusable protective medical textile technology.

[0038] This invention provides a cost-effective, eco-friendly, and high-performance solution for infection control, contamination prevention, and operational efficiency across all the above sectors. By integrating active moisture control, robust antimicrobial protection, and real-time sanitization, UniClenz establishes a new standard for reusable sterile textiles, offering superior hygiene assurance, user comfort, and long-term usability in diverse industrial applications. The scope of UniClenz is not confined to any single industry or product form; rather, it encompasses a broad range of reusable medical textile -based articles wherever maintaining strict hygiene and reducing waste are of critical importance.

[0039] Referring now to, the illustrated gown (100) includes an embedded perforated tube (101) network (indicated in dotted lines) routed strategically around the garment (for example, around the neckline and along the sleeves and torso). The tube has an inner diameter of about 3 mm and an outer diameter of about 5 mm, suitable for unobtrusive integration into the seams or lining. The tubing is positioned such that it targets high-risk contamination areas on the gown’s surface. When the sanitization system is activated, sanitizing fluid is pumped into this tubing network and emitted through the perforations to cover the outer layer of the gown.

[0040] Referring to, the three-layer composition of UniClenz is shown in detail. The outer knit layer (103) is preferably composed of 100% polyester or a high-polyester blend, chosen for its strength, hydrophobicity, and wicking ability. This layer rapidly disperses any applied liquid (such as the germicide) across the medical textile surface and dries quickly, which aids in fast sanitization and user comfort. The middle PU layer (104) is a microporous film or coated layer that provides an effective barrier to pathogens; it has pore sizes small enough to block bacteria and viruses, yet the material is engineered to be breathable, allowing heat and moisture to escape from the inner side. The inner cotton layer (105) is treated to be odor-free and retains softness for prolonged wear. It absorbs perspiration and skin oils, protecting the integrity of the middle barrier and keeping the wearer dry.

[0041] Referring to, the dispenser system (107) is depicted in operational connection with a garment. The dispenser (107) includes: a refillable reservoir for the sanitizing liquid, a pump (108) to propel the liquid, an inlet tube (109) that feeds the pump from the reservoir, and an outlet tube (110) that attaches to the garment’s tubing network (101). The system can be battery-powered or rechargeable and may include IoT-enabled controls for automation. For example, sensors on the garment could detect contamination or extended use and signal the dispenser to activate. Manual activation (e.g., pushing a button on the dispenser) is also possible. The dispenser is designed to be portable (worn on a belt or placed in a pocket) to allow freedom of movement for the wearer.

[0042] Referring to, the interface between the dispenser (107) and the gown’s tubing (101) is shown in a close-up schematic. When the sanitization process is activated, the pump (108) pushes the germicidal liquid through the tubing network. The perforations along the tubing are calibrated in size and spacing to achieve controlled release: as liquid flows, it seeps uniformly out of the tubing and onto the inner side of the outer layer (103). Because of the outer layer’s high wickability, the liquid quickly spreads across the fabric surface rather than dripping. In an exemplary operation, within about 2 minutes of activation, the entirety of the gown’s outward-facing area is coated with the sanitizing solution. Any bacteria or viruses on the surface are destroyed in this process, after which the liquid either evaporates or is retained at microbicidal concentrations on the fabric for ongoing protection. This ensures that all exposed areas of the gown are disinfected rapidly without the need for the wearer to doff the garment.

[0043] The UniClenz gown (100) and similar articles are manufactured using a layered bonding technique to ensure the three layers act as a single, durable unit. The knit outer (103), PU middle (104), and cotton inner (105) layers are laminated together through a hot-melt adhesive process or thermal pressing. This method secures the layers without stitching perforations through the barrier layer. It enhances overall fabric durability, ensuring the composite resists delamination or tearing even after repeated sterilization cycles. The lamination, combined with the sealed seams, provides robust protection against viral and bacterial penetration while retaining flexibility and breathability for the user’s comfort.

[0044] Key Design Features: In the preferred embodiment as a gown, UniClenz incorporates design elements tailored for practical use:The gown (100) includes a specialized high-coverage neck and yoke design, providing full coverage of the wearer’s torso and critical exposure points while still allowing comfortable movement. This design is adaptable to other garments like coveralls or lab coats.High-tensile, antimicrobial-treated PU seam tapes (102) are applied along all seams to ensure they are fully fluid-proof. This prevents any blood or fluid strike-through at stitch lines, maintaining integrity of the barrier.A hot-melt seam sealing technique (106) is used, bonding the fabric overlaps together in addition to stitching. This double-sealing approach allows the garment to withstand autoclave conditions (121°C, 15–30 psi) repeatedly without seam failure.The perforated silicon tubing network (101) is discretely integrated near the inner side of the outer layer, particularly around the neck and upper body regions which are most prone to contamination. Its placement is optimized for maximal dispersal of germicide over the garment’s surface.The dispenser unit (107) is designed to be small and lightweight and can be operated either manually or via an IoT-based remote control or timer. This gives users the option to sanitize on a schedule or in response to specific events (for example, between patient interactions, or if a sensor detects a splash on the garment).

[0045] Germicidal Process (Automated Sanitization System): In use, the automated sanitization sequence is as follows: the dispenser (107) is filled with a germicidal solution (which may be formulated per industry guidelines, such as IMA / CDC recommendations for hospital disinfectants). Upon activation, the motorized pump (108) pushes the solution through the tubing system (101). As the liquid travels, it exits through the tube’s perforations, evenly wetting the inner surface of the outer layer (103). Thanks to the high wickability of layer (103), the liquid spreads out and covers the entire external surface area. Within about two minutes, the outer surface is thoroughly sanitized, achieving a 99.99% reduction of common pathogens (bacteria, viruses) on the fabric. The system can then be turned off, and the fabric, being breathable, will dry quickly so that the garment remains comfortable. This automated germicidal process can be repeated as needed throughout the usage period of the article.

[0046] These figures and descriptions illustrate the engineering, design, and functionality of UniClenz, highlighting its multi-layered composition, built-in sanitization mechanism, and sterilization resistance features. Together, these aspects set a new benchmark in reusable protective textiles for sterile environments. The invention successfully marries the benefits of high-performance technical textiles with active sanitization technology, yielding a product that dramatically improves hygiene standards and sustainability across multiple industries.Examples

[0047] The following examples illustrate the performance, operation, and applicability of the UniClenz reusable medical textile system. These examples are provided for explanatory purposes only and should not be construed as limiting the scope of the invention. Variations and modifications will be apparent to skilled practitioners.

[0048] Performance of Tri-Layer Textile Under Fluid Exposure: A tri-layer UniClenz composite was fabricated consisting of:A tri-layer UniClenz composite was fabricated consisting of:inner cotton-polyester blend (70:30),microporous PU barrier layer (18 GSM),polyester knit outer layer embedded with silver nanoparticles.A simulated contamination event was conducted by applying 10 mL of artificial blood onto the outer layer. Results showed:No penetration through the PU barrier layer even after 5 minutes of direct contact.The outer layer wicked the fluid laterally, reducing localized pooling.The inner layer remained completely dry.This example demonstrates the fluid-impervious performance of the barrier layer while maintaining textile breathability.

[0049] Real-Time Germicidal Sanitization on a PPE Gown:A PPE gown constructed with embedded silicone tubing (3 mm inner diameter, 5 mm outer diameter) was connected to a portable pump-operated germicide dispenser containing an ethanol-based disinfecting solution.Procedure:The gown was deliberately contaminated with E. coli (10 CFU / mL) sprayed onto the outer surface.The sanitization system was activated for a 2-minute cycle.Surface swabs were collected immediately after the cycle.Results:Microbial load reduced by ≥99.99%, confirmed by plate count assays.Liquid distribution was uniform across the textile surface with no dripping or oversaturation.The outer layer dried in under 5 minutes due to its hydrophobic knit structure.This demonstrates effective on-demand surface sterilization during use.

[0050] Multi-Cycle Sterilization Durability Test:UniClenz composite fabric samples and tubing-integrated gown segments were subjected to repeated sterilization:50 autoclave cycles at 121°C for 30 minutes,Gamma irradiation at 25 kGy,Ethylene oxide (EtO) exposure at 450–800 mg / L,UV-C exposure at 254 nm for 8 hours.[Table 1] Measured properties after treatments:Property EvaluatedPre-SterilizationPost-50 CyclesTensile strength100%92–95% retainedPU barrier impermeabilityIntactIntactAntimicrobial efficacy≥99% reduction≥97% reductionTubing flexibilityFullSlight stiffness, no crackingSeam integrityFully sealedFully functionalNo delamination or failure was observed. This confirms the textile’s suitability for long-term reuse.

[0051] Application in a Hospital Intensive Care Unit (ICU):Reusable gowns made from UniClenz were evaluated in an ICU environment over a 14-day period. Healthcare personnel used the integrated sanitization system:between patient examinations,after fluid splash events,at scheduled intervals.Outcomes:Users reported reduced heat stress compared to standard polyethylene-based disposable gowns.No cross-contamination events associated with gown surfaces were recorded.Gowns maintained performance through daily autoclave sterilization.Reduction in disposable gown consumption by 92% over 14 days.This demonstrates operational benefits and waste reduction in clinical settings.

[0052] Deployment in a Pharmaceutical Cleanroom (ISO Class 7):Coveralls fabricated from UniClenz were used in a pharmaceutical filling suite requiring strict aseptic control.Key observations:Particle shedding was minimal and within ISO Class 7 compliance.Embedded sanitization allowed technicians to sterilize the suit surface during batch changes without leaving the controlled environment.Cleanroom contamination events were reduced, as verified through environmental monitoring plates.The textile withstood repeated hydrogen peroxide vapor (HPV) exposure without degradation.This example shows adaptability of UniClenz to sterile industrial environments.

[0053] Reusable Food-Processing Apron with Bacterial Spill Response:A UniClenz apron was tested in a poultry processing facility where exposure to Salmonella spp. is common.Procedure:The outer surface was contaminated with raw chicken juice.Immediate sanitization was triggered using a peracetic acid-based germicide connected to the embedded tubing system.Results:99.9% bacterial load reduction within 90 seconds.Apron remained odor-free and structurally intact.Workers reused the same apron for multiple shifts following sterilization cycles, reducing waste output.This demonstrates capability for rapid contamination control in food safety environments.

[0054] Veterinary Surgical Use:Surgical drapes incorporating UniClenz composite were used in a veterinary operating theater.Observations:Blood and fluid strikes did not penetrate the PU barrier.Sanitization cycle allowed mid-surgery surface disinfection without replacing the drape.Drape integrity was maintained after repeated chemical sterilization with chlorhexidine and autoclave cycles.This example highlights suitability for animal surgery where body fluids are abundant and cost constraints favor durable reusability.

[0055] The UniClenz reusable medical textile system is applicable across a wide range of sterile and hygiene-critical industries, including but not limited to:Hospitals and healthcare facilities, for PPE garments, surgical gowns, linens, drapes.Pharmaceutical and biotechnology laboratories, for sterilizable lab coats and cleanroom suits.Food processing and packaging industries, for contamination-resistant aprons, gowns, and surface covers.Veterinary surgical centers, for reusable surgical drapes and gowns.Microbiology and virology labs, where real-time external surface sanitization significantly reduces biohazard risks.Electronics and semiconductor cleanrooms, due to low particle shedding and sterilization compatibility.

[0056] The invention’s ability to undergo 50+ sterilization cycles without degradation, combined with its real-time self-sanitization, makes it an industrially valuable, sustainable alternative to disposable PPE.

[0057] Below is the consolidated list of reference numerals used in the drawings (to 4):100 - UniClenz Medical Gown101 - Embedded perforated silicon tubing network102 - PU antimicrobial seam sealing tape103 - Outer antimicrobial knit layer104 - Middle PU breathable barrier layer105 - Inner moisture-wicking cotton layer106 -Hot-melt seam sealing region107 - Portable germicidal dispenser108 - Pump / motor unit109 - Inlet tubing from reservoir110 - Outlet tubing to garment111 - Connector between dispenser and gown tubing

[0058] Not Applicable. This invention does not rely on any biological material that requires deposition under the Budapest Treaty. No microorganisms, cell lines, or biological constructs are necessary for practicing the invention.

[0059] Not Applicable. The invention does not include nucleotide or amino acid sequences and therefore requires no sequence listing.

[0060] This section lists all patent and non-patent literature cited during the background art evaluation carried out in the specification text.

[0061] US5599610A — Trilaminate fabric for surgical gowns (single-use).

[0062] EP0554049A1 — Reusable surgical fabric with enhanced barrier properties.

[0063] US4919998A — Reusable medical barrier fabric (no real-time sanitization).

[0064] US20170050870A1 — Antimicrobial textile treatment systems.

[0065] EP4043638A1 (US20220205170A1) — Coated barrier fabric with non-fluorine polymer.

[0066] EP1838918A1 — External biological sanitization system for garments.

[0067] US6723428B1 — Antimicrobial fibers containing additives.

[0068] Industry publications discussing limitations of disposable PPE in hospitals.

[0069] Peer-reviewed studies on environmental impact of biomedical waste and need for reusable systems.

[0070] Technical reports on the durability and antimicrobial efficacy of silver and copper nanoparticle-treated fabrics.

Claims

1. A reusable multi-layer medical textile article for maintaining sterile conditions in hygiene-critical environments, comprising:an inner moisture-absorbing layer made of a biocompatible, moisture-wicking medical textile material configured to provide comfort and odor resistance;a middle breathable barrier layer comprising a fluid-impervious, microbe-resistant membrane that permits moisture vapor transmission while blocking liquids and pathogens;an outer germicidal layer comprising a durable fabric material with embedded antimicrobial agents, the outer layer being high-wickability to facilitate rapid distribution of liquids and capable of continuous pathogen reduction;an integrated germicidal sanitization system including a network of perforated tubing embedded within the medical textile article and operatively connected to a dispenser for distributing a sanitizing liquid across the outer layer in real time;wherein the medical textile article is sterilization-compatible and reusable, retaining its antimicrobial efficacy and structural integrity over multiple sterilization cycles, thereby reducing cross-contamination and waste compared to single-use articles.The medical textile article as claimed in claim 1, wherein the integrated germicidal sanitization system is configured to achieve at least a 99.9% reduction in microbial load on the outer layer within about two minutes of activation, the system further comprising a portable pump-operated dispenser that delivers a germicidal liquid through said perforated tubing network by capillary action for uniform surface coverage.The medical textile article as claimed in claim 1, wherein the article is implemented in the form of a garment or an accessory selected from the group consisting of: a personal protective equipment (PPE) garment, a surgical gown, a laboratory coat, a cleanroom coverall, a hospital linen or bedsheet, a surgical drape, a reusable sterile cover, a privacy or partition curtain, and a sterilizable room divider.The medical textile article as claimed in claim 1, wherein the inner layer, middle layer, and outer layer comprise specific materials as follows:the inner layer is cotton or a cotton-polyester blend for moisture wicking and comfort;the middle layer is a breathable polyurethane film providing a microbial and fluid barrier; andthe outer layer is a polyester knit fabric embedded with antimicrobial nanoparticles selected from silver, copper, zinc oxide, or titanium dioxide, arranged to provide long-term germicidal activity.The medical textile article as claimed in claim 1, wherein the article remains effective after at least 50 sterilization cycles, including steam autoclaving at 121°C–132°C, exposure to ethylene oxide gas, gamma irradiation up to 25 kGy, and ultraviolet-C light, without substantial degradation of mechanical strength, barrier properties, or antimicrobial function.The medical textile article as claimed in claim 1, wherein the article is configured for use in a sterile or hygiene-critical environment selected from healthcare facilities, pharmaceutical manufacturing or research laboratories, food processing or packaging facilities, veterinary clinics or surgical centers, microbiology or virology laboratories, and cleanroom environments for electronics or biotechnology, such that the article provides reusable protective barrier performance tailored to reduce cross-contamination in the selected environment.

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