An improved wet processing method for producing improved terry fabrics is provided. Woven fabric is treated based on enzymatic treatment process including de-sizing using optimized dosage of predetermined de-sizing ingredients, washed and bio-washed using optimized dosage of bio-washing ingredients. Enzyme treated fabric is pre-treated and subjected to hot air beat-up process comprising mechanically treating pre-treated fabric with optimized hot air beat-up parameters. Air is blown onto pre-treated fabric from both directions for predetermined duration and at predetermined frequency causing to and fro movement of fabric in tumbling chambers of tumbling machine resulting in an instantaneous impact produced on every pile loop of pre-treated fabric such that fibers rearrange in a path of least resistance to produce relaxed, open and aligned fiber structure in the fabric. Mechanically treated hot air-beaten up fabric is dyed and includes finishing the dyed fabric with softener and subjected to tumbling using optimized finishing parameters.

A sterile knitted fabric is provided. The sterile knitted fabric is made by the following steps: First, a plurality of nano far infrared antibacterial yarns and a plurality of bamboo charcoal hollow yarns are provided. Next, the nano far infrared antibacterial yarns are interwoven with the bamboo charcoal hollow yarn by a circular knitting machine to form a grey fabric. Next, the grey fabric is through a scouring process to form a scoured fabric. Next, the scoured fabric is through a setting process. The scoured fabric is moved 25 meters per minute for the setting process.

A sterile knitted fabric is provided. The sterile knitted fabric is made by the following steps: First, a plurality of nano far infrared antibacterial yarns and a plurality of bamboo charcoal hollow yarns are provided. Next, the nano far infrared antibacterial yarns are interwoven with the bamboo charcoal hollow yarn by a circular knitting machine to form a grey fabric. Next, the grey fabric is through a scouring process to form a scoured fabric. Next, the scoured fabric is through a setting process. The scoured fabric is moved 25 meters per minute for the setting process.

Solid-state branching and/or crosslinking of aliphatic polyamide or polyester articles is achieved using a topical approach. A surface of the article is coated with a composition that includes a polyene and a free radical initiator. The article and applied coating are then heated to induce branching and/or crosslinking in the polyamide or polyester. This is performed below the crystalline melting temperature of the polyamide or polyester, or in the case of a fabric, below the melting temperature of the fibers in the fabric. Fabrics treated in this manner exhibit reduced or even no dripping in vertical flame tests.

Solid-state branching and/or crosslinking of aliphatic polyamide or polyester articles is achieved using a topical approach. A surface of the article is coated with a composition that includes a polyene and a free radical initiator. The article and applied coating are then heated to induce branching and/or crosslinking in the polyamide or polyester. This is performed below the crystalline melting temperature of the polyamide or polyester, or in the case of a fabric, below the melting temperature of the fibers in the fabric. Fabrics treated in this manner exhibit reduced or even no dripping in vertical flame tests.

A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.

A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.

According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.

According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.

A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.