Cotton swimwear fabric

Abstract

The present invention proposes a swimwear fabric which is made from cotton while retaining ail the required properties of swimwear such as elasticity, high breathability and fast drying, while allows air circulation for total comfort, optimizes the moisture control, gives priority to skirt protection and contributes to the preservation of the planet's ecosystem, as the cotton is a biodegradable raw material that is returned to the earth where it is used without causing problems when it decomposes. Our goal was to create a natural swimwear fabric that meets all the specifications that a swimwear fabric should have. After a lot of research we came up with the solution of using as a raw material, yarn long staple combed cotton gaze / gassed mercerized with sewing twists which is not used to create fabric but is used only for sewing and together with natural rubber yarn l%-5% in a special fabric structure we developed. This special fabric structure eliminates the problems created by such a yam when used for fabric construction and also gives additional characteristics such as elasticity, faster passage of air for total comfort and fast drying. The result is a natural swimwear fabric that meets the specifications of the swimwears by using a specific raw material in yarn and a specific fabric structure.

Description

[0001] COTTON SWIMWFAR FABRIC

[0002] Description

[0003] The technical field that this invention is refefering to is textile fabric for swimwear with elasticity. The present invention relates to swimwear fabric which is made from cotton while retaining all the required properties of swimwear such as elasticity, high breathability and quick drying, while allows air circulation for total comfort, optimizes the moisture control, gives priority to skin protection and contributes to the preservation of the planet's ecosystem, as the cotton is a biodegradable raw material that is returned to the eart h where it is used without causing problems when it decomposes.

[0004] The invention specifically addresses the technical challenge of creating a cotton-based swimwear fabric that achieves performance characteristics previously only possible with synthetic materials, through a novel combination of specialized yarn construction and an innovative three-dimensional knitting technique.

[0005] The textile industry is already aware of the multiple benefits of natural raw materials over synthetic raw materials for the the human user and for the preservation of the ecosystem of the our planet's ecosystem. Let alone in the swimwear industry which to this day made exclusively from synthetic raw materials, except for a few exceptions that exist, but they do not meet the required characteristics that a swimsuit must have, such as elasticity, fastness, fast drying, water resistance.

[0006] The present invention aims to solve the above disadvantages by proposing a swimwear fabric which is made of cotton while maintaining all the required properties of swimwear such as elasticity, quick drying, water resistance and additionally has high breathability allowing air circulation for total comfort and moisture control optimization.

[0007] Brief description of the invention

[0008] This swimwear fabric is made from 100% long staple combed cotton gaze / gassed mercerized in a three-dimensional double-knit structure.

[0009] We have seen in another embodiment that we have better properties on ths fabric using 100% long staple combed cotton gaze / gassed mercerized with sewing twists in a three-dimensional double-knit structure.

[0010] We have seen in another embodiment that we have better properties on the fabric using 95% to 99% long staple combed cotton gaze / gassed mercerized or long staple combed cotton gaze / gassed mercerized with sewing twists and 1% to 5% natural rubber yarn in a three-dimensional double-knit structure. We have seen in another embodiment that we have again better properties on the fabric using Ne2 / 28 to Ne2 / 38 yarn count / fineness at the long staple combed cotton gaze / gassed mercerized with sewing twists yarn and Ne2 / 16 to Ne2 / 38 yarn count / fineness at the natural rubber yarn.

[0011] Also we have seen in another embodiment that we have same properties if we use instead of natural rubber yarn a synthetic rubber yarn.

[0012] The method of producing this swimwear fabric is characterized by the three-dimensional double-knit structure with the rolling needle sequence on both two needle beds of the knitting machine, the alternating needles used sequence, the neutralization of opposing forces developed from the yam with sewing twist and the specific use of Hat knitting machines gauge No 12. The three-dimensional double-knit structure specifically comprises;

[0013] Knitting machice gauge No 10 to to 16, preferable gauge No 12.

[0014] Needle arrangement; Alternating sequence on both beds

[0015] Binding points; Alternating sequence distribution every 2-8 needles

[0016] Layer separation: 0.5-3.2mm

[0017] Swimwear fabric made from yarn 95% to 99% long staple combed cotton gaze / gassed mercerized with sewing twists and 1 to 5% natural rubber yarn in a three-dimensional double-knit structure / three-dimensional double layer knitted fabric. This particular kn jetting eliminates the problems caused by such a yarn with sewing twists when used for fabric construction by neutralizing the opposing forces developed in the fabric structure using two needle beds from the knitting machine by alternating the needles used with a rolling needle sequence on both two needle beds from the knitting machine. The rolling needle sequence specifically neutralizes the opposing forces and deformation stresses from the yarn with sewing twists, which is crucial for: fabric stability during production, fabric stability after extended use, prevention of diagonal deformation and maintenance of elasticity properties.

[0018] We have seen in another embodiment that we have the desired effect on the fabric when the yarn from long staple combed cotton gaze / gassed mercerized with sewing twists is from yarn count / fineness Ne2 / 28 to Ne 2 / 38. Ne (Number English) is the standard yarn numbering system expressing the fineness of yarn, where the number represents the length of yam in hanks (840 yards) per pound. Higher Ne numbers indicate finer yarns.

[0019] We have seen in another embodiment that we obtain the desired result in the fabric, when ths yarn count / fineness of the natural rubber yarn is from Ne2 / 16 to Ne2 / 38. We have seen in another embodiment that we get the same desired effect on the fabric when the rubber used is also synthetic in yarn count / fineness from Ne2 / 16 to Ne2 / 38.

[0020] Figures description

[0021] Figure 1 shows the three-dimensional double layer knitted fabric with a rolling needle sequence which is the outcome of the three-dimensional double-knit structure.

[0022] Figure 2 describes the yarns paths at the two needle beds from the knitting machine alternating the needles used with a rolling needle sequence on both two needle beds from the knitting machine.

[0023] Figure 3 shows a schematic representation of the loops.

[0024] Analytical description and experimental results

[0025] Currently, most swimwear fabrics on the market are made from synthetic materials such as polyester, nylon (polyamide), and spandex (elastane). These materials are favored for their durability, stretch, quick-drying properties, and resistance to chlorine and saltwater. However, they are not eco-friendly because they are derived from petroleum-based resources, which contribute to environmental degradation during extraction and production. Additionally, synthetic fabrics release microplastics into the water during washing, polluting marine ecosystems. These materials are also non-blodegradable, leading to long-lasting waste in landfills. From a health perspective, synthetic fabrics often contain chemical additives, such as dyes and finishing agents, which may cause skin irritation or allergies for individuals, making them less ideal for skin and body health.

[0026] Traditional Swimwear Materials and Their Problems:

[0027] 1. Environmental Impact:

[0028] Nylon: Creates nitrous oxide (310 times more potent than CO 2 as greenhouse gas) Polyester: Requires large amounts of water for cooling and uses harmful lubricants Spandex: Ranked Class E (least sustainable) in environmental benchmarks All synthetic materials release microplastics into oceans

[0029] 2. Health Concerns:

[0030] Synthetic fabrics contain "forever chemicals” that release during wear Can increase risk of skin diseases Chemicals continue releasing with each wash / dry cycle

[0031] Poor breathabshty affecting skin health

[0032] 3. Sustainability issues:

[0033] High energy consumption in production Non-biodegrsdable materials Water pollution during manufacturing

[0034] Heavy reliance on petroleum-based products

[0035] This invention relates to the development of a fabric made of natural fibres, specifically designed for applications in swimwear, combining the ecological advantages of natural materials with the functional properties that which are common to synthetic fabrics. This fabric has a high water resistance, high elasticity and fast drying, while maintaining dimensional stability and durability when used in swimming conditions. The Innovation of this invention lies in the use of specially treated natural raw materials, such as cotton (long staple combed cotton gaze / gassed mercerized with sewing twists) in combination with natural rubber. These materials are subjected to special technological knitting processes and durability tests, providing characteristics which normally the synthetic fibres have. The structure of the fabric and the knitting methods are carefully selected to ensure properties suitable for swimming use.

[0036] Raw Materials: Characteristics and Categories

[0037] Combed cotton: It is a high quality natural fibre, which is subject to a special mechanical treatment to remove the shorter fibres, increasing the durability and softness of the fabric. Combed cotton is durable and resistant to wear and tear is more durable than other varieties and ensures a high degree of durability and breathability in the finished product, while the gloss it is ideal for swimming use.

[0038] Long staple cotton: characterised by the following properties: High Durability: resists wear and tear and lasts longer. Durable and lasts longer. Silky,, smooth feel. Absorbency and Breathability : Absorbs moisture and and breathes, providing comfort. Heat and Stain Resistance: Resists heat and stain resistance. Shape Retention: Shows less shrinkage and fluffing. Natural Shine: Has a subtle shine that gives elegance. Cotton gaze / gassed mercerized : By the mercerized processing method, the cotton is chemically treated with caustic soda to increase its strength, durability and shine. This type of cotton offers increased durability and prevents overflowing in water conditions. The gaze / gassed yarn used has specially treated to reduce absorbency and increase the fabric’s resistance to tensile stress.

[0039] Natural rubber: Used in a small percentage (1-5%) to provide elasticity to the fabric. It is highly resistant to water and helps to maintain the structural integrity of the fabric even when wet. It offers dimensional stability and restores the original shape after use.

[0040] Fabric Production Process: Technologies and knit structures

[0041] The fabric is produced on STOLL CMS TC kn siting machines, which provide flexibility and precision in a wide range of knit structures and gauge. The machine gauge of the knitting machines is a measure expressing the number of needles per 1 inch of the needle bed width. The machines that was used for knitting where from gauge No. 5 to No. 14, allowing the creation of fabrics with different densities and thicknesses.

[0042] The knit structures used include:

[0043] Double and single knit structures: They offer strong durability and .stability, while they provide strength and durability, while also enhancing the elasticity of the fabric. The double-knit structure is used to create a more compact fabric with greater stability, ideal for applications that require a firm fit and durability.

[0044] Double layer knitted fabric / double-knit structure and rib structure: These structures contribute to the elasticity and durability of the fabric and faster shape recovery. Rib structure, in particular, improves elasticity, flexibility and ease of movement.

[0045] These structures enhances the ability of the fabric to adapt and retain its elasticity even after prolonged use In water.

[0046] Three-dimensional double-knit structure: An innovative technique that creates a material that maintains its stability despite repeated stresses, while the roiling needle sequence neutralizing the opposing forces developed by the sewing twists of the yarn. This arrangement is critical for preventing diagonal deformation of the fabric. Also this particular three-dimensional double-knit structure creates air gaps that allow a better breathability of the body and rapid drying of the fabric.

[0047] Experimental Tests

[0048] Initially, the use of natural rubber and synthetic rubber was tested in different percentages in the produced fabric. A percentage of l%-5% was chosen as more than 5% does not further improve the elasticity of the fabric and less than 1% reduces the desired elasticity of the fabric.

[0049] First Test Stage: 100% combed cotton

[0050] In this stage, 100' experimental tests were carried out using 100% combed cotton with knitting twists in various yam count / fineness from Ne 20 / 2 to Ne 36 / 2 with l%-5% elastic yam. The fabric structures were created with different knitting techniques, such as, double and single knit structures and rib structures in different combinations. The STOLL CMS TC from gauge No 5 to No 16 were used to produce these fabrics. Results: The elasticity of the fabric was significantly improved, although small water resistance was observed. When the fabric was wetted, the elasticity and durability of the fabric was significantly reduced, while drying was slow and the elasticity was not fully restored. The knitting machines with gauge No 5 and No 7, and the yarns counts / fineness Ne 20 / 2 to Me 26 / 2 were rejected on because the production fabric outcome of these were too thick and uncomfortable to fit. Second Test Stage: 100% Crepe Cotton

[0051] In the second stage, 80 trials were conducted with 100% crepe cotton at yarn count / fineness from Ne 28 / 2 to Me 36 / 2 and 1-5% elastic yarn. The STOLL CMS TC knitting machines from gauge No 10 to No 14 were used to produce these fabrics. Results: Ths elasticity of the fabric was further improved, while water resistance increased. The fabric retained its elasticity when the fabric was wet, although the drying time remained slow. The fabrics with yarns counts / fineness from Ne 28 / 2 to Ne32 / 2 and gauge No 14-16 were discarded due to excessive transparency when wet. Third Test Stage: 100% gaze / gassed mercerized cotton with knitting twists

[0052] In this stage, 100% gaze / gassed mercerized cotton with knitting twists was used yarns counts / fineness Ne 33 / 2 to Ne 36 / 2, with gauge No 10 and No 12 knitting machines. Results: An improvement in elasticity and water resistance, with different drying times depending on the knit stucture and the yarn count / fineness. The fabric remained stable at dimensions after repeated use, although the water resistance was not at the same level of synthetic fabrics.

[0053] Fourth Test Stage: 100% cotton gaze / gassed mercerized with sewing twists

[0054] To further improve water resistance, 100% long staple combed cotton gaze / gassed mercerized with sewing twists at yarns counts / fineness Ne 2 / 34 to Ne 2 / 36. These twists offer durability in both dry and wet conditions.

[0055] Test Parameters Definition:

[0056] Water resistance: Fabric’s ability to resist water absorption

[0057] Elasticity: Fabric’s ability to stretch and recover

[0058] Dimensional stability: Fabric's ability to maintain size and shape

[0059] Durability: Resistance to wear and deterioration under swimming conditions TWIST M EASU RE M ENTS :

[0060] This Invention's Yarn (Sewing Yarn Construction): Z twist : 800-900 TPM (20-23 TPI).

[0061] Ne 2 / 35, Strenght : 980 cN - 30 RKM, Elasticity 6.2 %

[0062] YARN SPECIFICATIONS:

[0063] A. Sewing Yarn Construction: Type: Long-staple combed cotton (ELS). Processing: gaze / gassed and mercerized. Construction: Multiple-ply sewing yarn configuration.

[0064] B.l. Critical Sewing Yarn Parameters: Twist Direction: 2 -twisting.

[0065] 800-900 TPM (20-23 TPI). Higher than standard knitting yarn.

[0066] Higher twist factor for improved strength.

[0067] Or

[0068] B.l. Critical Sewing Yarn Parameters: Twist Direction: Typically 2 / S two-stage twisting. Primary twist (single): Z direction. Final / Ply twist: S direction. Twist Multiplier: Higher than standard knitting yarn. Higher twist factor for improved strength.

[0069] C. Specific Technical Advantages: Enhanced abrasion resistance for seam durability. Improved loop formation in technical knitting. Better tensile strength for structural stability. Superior surface smoothness from gaze / gassed process.

[0070] However, it was observed that the fabric showed instability vertically due to the different twists, leading to diagonal deformation in use.

[0071] Solution to the problem: After further research, a new structure was developed 3 three-dimensional double-knit structure with a rolling needle sequence on both two needle beds of the knitting machine which neutralizing the opposing forces developed in the fabric structure caused by the yarn twists. Ensuring the stability of the fabric both during production and after extended use.

[0072] Optimal Result: Optimal fabric created with yarn count / fineness Ne 2 / 35 in knitting machine gauge No 12 and three-dimensional double-knit structure with a rolling needle sequence on both two needle beds of the knitting machine. This fabric is a form and subclass of cotton swimsuit fabric that we originally filed for a patent on July 192024 to the OBI under Case No.: 000002645 and Application No. : 20240100506.

[0073] Experimental Evaluation

[0074] All tests were carried out under real swimming conditions in salty sea and pool water, with durations ranging from 5 to 60 minutes. The results were compared with corresponding tests on synthetic swimwear fabrics, with the natural fabric approaching the characteristics of the synthetic materials, while retaining the characteristics and the ecological advantages of natural fabric.

[0075] Conclusions

[0076] This final fabric shows properties that make it an excellent alternative to synthetic materials for swimming use. The choice of natural raw materials and special knitting technology are combined to ensure durability, adaptability and performance, while offering ecologically friendly advantages. Application in swimwear could improve sustainability in production and offer a new perspective to the industry in the swimwear and sportswear sector.

[0077] TECHNICAL TERMS GLOSSARY

[0078] 1. Gauge: The number of needles per inch (as mentioned In text: gauge No. 5 to No. 16), determining fabric density and fineness.

[0079] 2. Gaze / Gassed: A process where yarn passes through a gas flame to burn off protruding fibers, creating a smoother surface (referenced in the raw materials section).

[0080] 3. Mercerized: Chemical treatment of cotton with caustic soda (as described in the raw materials section) to increase:

[0081] Strength

[0082] Durability

[0083] Shine

[0084] 4. Three-dimensional double-knit structure: As referenced throughout the text, specifically refers to:

[0085] Two separate fabric layers

[0086] Connected through specific binding points

[0087] Created using both needle beds

[0088] Using rolling needle sequence

[0089] 5. Rolling needle sequence: As mentioned in the text, refers to:

[0090] Alternating needle selection

[0091] Used on both needle beds

[0092] Neutralizes opposing forces from sewing twists

[0093] 6. Twist Direction Terminology: As mentioned in yarn specifications Z twist: Right-hand spiral twist

[0094] S twist: Left-hand spiral twist

Claims

1. Swimwear fabric with technical characteristics. Made of 100% long staple combed cotton gaze / gassed mercerized in a three- dimensional double-knit structure.

2. Swimwear fabric with technical characteristics.Made of 100% long staple combed cotton gaze / gassed mercerized with sewing twists in a three-dimensional double-knit structure,3. Swimwear fabric with technical characteristics.Made of 95% to 99% long staple combed cotton gaze / gassed mercerized or long staple combed coton gaze / gassed mercerized with sewing twists and 1% to 5% natural rubber yarn in a three-dimensional double-knit structure.

4. Swimwear fabric with technical characteristics.Made of 95% to 99% tong staple combed coton gaze / gassed mercerized or long staple combed coton gaze / gassed mercerized with sewing twists Ne2 / 28 to Ne2 / 38 yarn count / fineness and 1% to 5% natural rubber yarn in a three-dimensional double-knit structure.

5. Swimwear fabric with technical characteristics.Made of 95% to 99% tong staple combed coton gaze / gassed mercerized or long staple combed coton gaze / gassed mercerized with sewing twists Ne2 / 28 to IM®2 / 38 yarn count / fineness and 1% to 5% natural rubber yarn in Ne2 / 16 to Ne2 / 3S yam count / fineness in a three-dimensional double-knit structure.

6. Swimwear fabric with technical characteristics. Made of 95% to 99% long staple combed coton gaze / gassed mercerized or long staple combed cotton gaze / gassed mercerized with sewing twists Ne2 / 28 to Ne2 / 38 yarn count / fineness and 1% to 5% synthetic rubber yarn in Ne2 / 16 to Ne2 / 38 yarn count / fineness in a three-dimensional double-knit structure, 7. The method of producing the swimwear fabric according to claims 1-6, characterized by:The roiling needle sequence on both two needle beds from tbs kniting machine.The alternating needles used sequence.The neutralization of opposing forces developed from the yarn with sewing twist.The specific use of fiat knitting machines gauge Mol 2.

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