Active agent-containing articles, for example fibrous structures, that exhibit consumer acceptable article in-use properties, such as article peel strength, flexibility, and/or dissolvability, and methods for making same are provided.

A system for manufacturing a thermoplastic prepreg includes a double belt mechanism that is configured to compress a fiber mat, web, or mesh that is passed through the double belt mechanism, a resin applicator that is configured to apply monomers or oligomers to the fiber mat, web, or mesh, and a curing oven that is configured to effect polymerization of the monomers or oligomers and thereby form the thermoplastic polymer as the fiber mat, web, or mesh is moved through the curing oven. The double belt mechanism compresses the fiber mat, web, or mesh and the applied monomers or oligomers as the fiber mat, web, or mesh is passed through the curing oven so that the monomers or oligomers fully saturate the fiber mat, web, or mesh. Upon polymerization of the monomers or oligomers, the fiber mat, web, or mesh is fully impregnated with the thermoplastic polymer.

A method for improving the translation efficiency of fiber strength into composite strength is provided. A single unidirectional tape, single unidirectional fiber web or a stack of unidirectional web/unidirectional tape plies formed from partially oriented fibers/tapes is primed under mild conditions followed by subjecting the primed plies to an axial extension stress in the axial fiber direction of each fiber ply by passage through a compression apparatus. The axial extension stress extends the fibers, strengthening them, while also compacting the plies together and thereby forming a composite having improved strength. Production yield is improved by avoiding maximal fiber stretching and thereby avoiding typical manufacturing loss, and low weight composite armor having increased strength is achieved.

A method for improving the translation efficiency of fiber strength into composite strength is provided. A single unidirectional tape, single unidirectional fiber web or a stack of unidirectional web/unidirectional tape plies formed from partially oriented fibers/tapes is primed under mild conditions followed by subjecting the primed plies to an axial extension stress in the axial fiber direction of each fiber ply by passage through a compression apparatus. The axial extension stress extends the fibers, strengthening them, while also compacting the plies together and thereby forming a composite having improved strength. Production yield is improved by avoiding maximal fiber stretching and thereby avoiding typical manufacturing loss, and low weight composite armor having increased strength is achieved.

A textile composite comprising a meltable layer, a heat reactive material comprising a polymer resin comprising an aqueous acrylic resin, expandable graphite, and at least one flame retardant additive and an additional layer disposed on the heat reactive material so that the heat reactive material is between the meltable layer and the additional layer. This multilayer textile composite is used in a lightweight protective garment protecting the wearer against burns caused by flames and heat. A heat reactive composition comprising a polymer resin comprising as aqueous acrylic resin, expandable graphite and at least one flame retardant additive. A method of forming or manufacturing this multilayer textile comprising the step of heating the laminate to a temperature sufficient to remove at least a portion of the water from the aqueous acrylic resin of the heat reactive composition.

A textile composite comprising a meltable layer, a heat reactive material comprising a polymer resin comprising an aqueous acrylic resin, expandable graphite, and at least one flame retardant additive and an additional layer disposed on the heat reactive material so that the heat reactive material is between the meltable layer and the additional layer. This multilayer textile composite is used in a lightweight protective garment protecting the wearer against burns caused by flames and heat. A heat reactive composition comprising a polymer resin comprising as aqueous acrylic resin, expandable graphite and at least one flame retardant additive. A method of forming or manufacturing this multilayer textile comprising the step of heating the laminate to a temperature sufficient to remove at least a portion of the water from the aqueous acrylic resin of the heat reactive composition.

A laminate for use in a process for strengthening a selected area of a raw textile or manufactured textile product to enhance properties and performance. The process comprising the steps of applying a laminate trimmed to match the selected. area, then placed on the textile and heated in a hot press. The laminate can be comprised of a polymer film and a nonsolvent adhesive. The polymer film can be tailored from a blend of hard acrylic and tough poly-urethane to adjust for rigidity and strength. The adhesive can he a hot melt or pressure sensitive types as well as any type that provides a secure adhesion.

A laminate for use in a process for strengthening a selected area of a raw textile or manufactured textile product to enhance properties and performance. The process comprising the steps of applying a laminate trimmed to match the selected. area, then placed on the textile and heated in a hot press. The laminate can be comprised of a polymer film and a nonsolvent adhesive. The polymer film can be tailored from a blend of hard acrylic and tough poly-urethane to adjust for rigidity and strength. The adhesive can he a hot melt or pressure sensitive types as well as any type that provides a secure adhesion.

A process for forming a moldable, uncured nonwoven composite containing forming a outermost nonwoven layer, forming a structural nonwoven layer, needling the structural nonwoven layer and the outermost nonwoven layer together from both the outer surface of the outermost nonwoven layer and the second surface of the structural nonwoven layer, applying an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C. to the second surface of the structural nonwoven layer, and at least partially drying the uncured, wet nonwoven composite. Heat and pressure may be applied to form the moldable, uncured composite. A moldable, uncured nonwoven composite and a molded, cured nonwoven composite are also disclosed.

A process for forming a moldable, uncured nonwoven composite containing forming a outermost nonwoven layer, forming a structural nonwoven layer, needling the structural nonwoven layer and the outermost nonwoven layer together from both the outer surface of the outermost nonwoven layer and the second surface of the structural nonwoven layer, applying an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C. to the second surface of the structural nonwoven layer, and at least partially drying the uncured, wet nonwoven composite. Heat and pressure may be applied to form the moldable, uncured composite. A moldable, uncured nonwoven composite and a molded, cured nonwoven composite are also disclosed.