"Fabric, particularly for a swixnsuit"

[0001] The present invention generally relates to the field of fabrics for jumpsuits and swimsuits for competitive sports and, particularly, to a swimsuit fabric.

[0002] Swimsuits and related elasticized fabrics are known, which are typically achieved by weaving single-filament elastic threads and by subsequently filling or soaking the fabric with a rubber solution, such as to obtain a thin impermeable layer contributing to an improved water- repellency of the swimsuit.

[0003] The known swimsuit fabrics, particularly competition swimsuits, while being satisfactory as regards stretchability thereof (meant as the tensile elongation ability) , have some "technical-mechanical" drawbacks which are perceived as prejudicial to the sports performance, therefore hardly acceptable by competition swimmers. [0004] These drawbacks relate in particular to fabric high weight, a too low spring force (elastic module) thereof, and fabric impermeability and water-repellency, which tends to rapidly decrease after some uses, for example in salt or chlorinated water.

[0005] Therefore, object of the present invention is to provide a fabric, particularly for swimsuit, and a method for the manufacturing thereof, having such features as to

obviate at least some of the drawbacks cited with reference to the prior art .

[0006] Within the scope of the main object, a particular object of the present invention is to propose a fabric having a high . lightness, preferably up to 100g/m ² and lower, such as to afford the "second skin" effect, which provides an almost complete freedom of movement to the agonistic swimmer and, at the same time, a high adhesion and covering of large body surfaces, which decrease the hydrodynamic resistance ("glide" effect) .

[0007] A further object of the present invention is to provide a fabric combining a high elastic elongation ability with a high spring force, adapted to compress the athlete's muscles during competitions, in order to avoid the lactic acid build-up and reduce flabby movements of the swimmer's fabrics, which could increase his/her hydrodynamic resistance, thus decreasing sports performance .

[0008] A further object of the present invention is to provide a fabric having a high impermeability and water- repellency also after a relatively long period of use of the swimsuit .

[0009] A further object of the present invention is to propose a fabric having an improved soft-touch, in the sense of a silky, but at the same time technical "hand",

such as to further increase the second, skin effect. [0010] These and other objects are achieved by a fabric, particularly for a competition swimsuit, comprising: - a plain weave interlacement of warp threads and weft threads , in which said warp thread comprises a first base thread with four elastic polyurethane filaments, and a first added thread having a plurality of non-elastic polyamide fibres, said first base thread and said first added thread being mutually coupled in a coiled or twisted manner in order to create said warp thread, in which said weft thread comprises a second base thread with four elastic polyurethane filaments, and a second added thread having a plurality of non-elastic polyamide fibres, said second base thread and said second added thread being mutually coupled in a coiled or twisted manner in order to create said weft thread, in which the first added thread fibre count is lower than the second added thread fibre count, and the average diameter of the first added thread individual fibres is above than the average diameter of the second added thread individual fibres .

[0011] In order to better understand the invention, and appreciate the advantages thereof, some exemplary, non- limiting embodiments will be described herein below, with

reference to the annexed drawings, in which: [0012] Fig. 1 is a schematic view of a fabric according to an embodiment of the invention;

[0013] Fig. 2 is an enlarged schematic view of the detail II in Fig. 1;

[0014] Fig. 3 is an enlarged schematic view of the detail III in Fig. 1;

[0015] Fig. 4 illustrates a swimsuit made of the fabric according to an embodiment of the invention. [0016] With reference to the Figures, a fabric, particularly for a competition swimsuit, is generally indicated with the reference numeral 1.

[0017] The fabric 1 comprises a plain weave interlacement of warp threads 2 and weft threads 3. The warp thread 2 comprises a first base thread 4 with four elastic polyurethane filaments, and a first added thread 5 with a plurality of non-elastic polyamide fibres 6. The first base thread 4, and the first added thread 5, are mutually coupled in a coiled or twisted manner in order to create the warp thread 2.

[0018] Similarly, the weft thread ^' 3 comprises a second base thread 7 with four elastic polyurethane filaments, and a second added thread 8 having a plurality of non-elastic polyamide fibres 9, and the second base thread 7 and the second added thread 8 are also mutually coupled in a coiled

or twisted manner in order to create the weft thread 3. [0019] In accordance with an aspect of the invention, the first added thread 5 fibre count 6 is lower than the second added thread 8 fibre count 9, and the average diameter of the first added, thread 5 individual fibres 6 is above than the average diameter of the second added thread 8 individual fibres 9.

[0020] In accordance with an embodiment, the first base thread 4 (warp) , and the second base thread 7 (weft) , have a mass which is expressed as dtex and is essentially equal. By way of advantageous example, the first base thread 4 may have a mass, which is expressed as dtex, within the range of from 35 dtex to 55 dtex, and the second base thread 7 may have a mass, which is expressed as dtex, within the range of from 35 dtex to 55 dtex. Advantageously, each of the first base thread and the second base thread has a mass, which is expressed as dtex, within the range of from 42 dtex to 46 dtex, preferably of about 44 dtex. [0021] In accordance with an embodiment, each of the first base thread 4 (warp) , and the second base thread 7 (weft) , has a round cross-section.

[0022] The second added thread 8 individual fibres (weft) can be microfibres, while the first added thread 5 individual fibre 6 (warp) are conventional fibres having a weight, expressed as dtex, which is at least double, preferably at

least three-fold, than the weight of the second added thread individual microfibres.

[0023] In accordance with an embodiment, the first added thread 5 (warp) comprises 5 to 10 fibres having a preferably irregular cross-section, with a total weight, expressed as dtex, of from 15 dtex to 30 dtex, preferably seven fibres 6 with a total weight of about 22 άtex [0024] The second added thread 8 (weft) can comprise 15 to 25 fibres with a total weight, expressed as dtex, of from 15 dtex to 30 dtex, preferably about 20 microfibres with a total weight of about 20 dtex.

[0025] Advantageously, the first base thread 4 (warp) is coil wound by the first added thread 5, so as to obtain a warp thread having a weight of from 30 dtex to 38 dtex, preferably of about 34 dtex.

[0026] The second base thread 7 (weft) can be also coil wound by the second added thread 8, so as to obtain a weft thread having a weight of from 27 dtex to 35 dtex, preferably of about 31 dtex. [0027] The fabric 1 is advantageously so configured and treated as to have a thread count of from 75 to 85 threads/cm in the weft, and from 75 to 85 threads/cm in the warp. According to a preferred embodiment, the thread count is about 76 threads/cm in the weft and 78 threads/cm in the warp.

[0028] According to a further embodiment, the fabric 1 is provided with a polytetrafluoroethylene soaking and/or coating which, beside impermeabilizing the individual threads, is so configured as to create impermeable barriers between two adjacent threads, respectively. This can be achieved through an extraordinarily high density of PTFξ in the bath in which the fabric 1 is treated, so as to obtain PTFE bridges between adjacent threads. [0029] The fabric according to the embodiments hereto described can be achieved by the following method.

[0030] The warp thread is achieved by coil winding the first added thread around the first base thread and, similarly, the weft thread is achieved by coil winding the second added thread around the second base thread. [0031] Subsequently, a raw fabric is made by plain weave interlacement of 40 threads/cm - 48 threads/cm, preferably 44 threads/cm in the warp with 36 threads/cm - 44 threads/cm, preferably 40 threads/cm in the weft. [0032] The raw fabric will be then cleaned by rinsing it in a detergent-containing-aqueous solution bath. In this manner, spinning and weaving oils, and a number of impurities embedded in the fabric and threads during the previous processing steps, are removed. [0033] Subsequently, the cleaned raw fabric is subjected to a dimensionally stabilizing and density increase to a value

ranging between 90 g/m2 and HO g/m2 by heating (thermofixing) through exposure of the fabric to a temperature ranging between 160 ⁰ C and 230 ⁰ C, preferably about 197 ⁰ C, and concomitant monitoring of the fabric mass per area unit-. Thermofixing occurs, for example, by application of aqueous vapour to the fabric, and monitoring can be carried out by means of a control device determining the . fabric areal mass based on the principle of gamma- particle adsorption. [0034] The cleaned and stabilized fabric can be then dyed in a dyeing bath for a time period ranging from 5 to 7 hours, preferably 6 hours. The use of premetallized dyes turned out to be advantageous in order to improve the feel of the fabric "technicity" (particularly as regards the sense of touch, therefore the "second skin" feeling of the athlete) . [0035] After dyeing, the dyed fabric is dried to a temperature within the range of from 85 ⁰ C to 120 ⁰ C, preferably of about 110 ⁰ C. [0036] The quality control for the fabric can occur through an inspection light box.

[0037] With reference to the increase of the fabric impermeability and water-repellency, the following method has been selected and defined, after a number of experimental tests: [0038] The fabric is immersed in a polytetrafluoroethylene

solution bath, preferably in a solution of 85 g Oleofobol 7 ₇ 52® per litre - 110 g Oleofobol 7752 ^® per litre, preferably about 100 g Oleofobol 7752 ^® per litre (the Oleofobol 7752 ^® product is commercialized by the CIBA company.) Subsequently, the PTFE- and water-impregnated fabric is squeezed between a pair of nipping and squeezing rolls in order to remove the excess PTFE. Finally, the fabric is dried and heated in order to complete the PTFE polymerization. To these aims, the fabric is exposed to a temperature within the range of from 180 ⁰ C to 200 ⁰ C, preferably of about 19O ⁰ C, for a time period of about 20 seconds .

[0039] The thus-obtained fabric can be cut and sewn, welded, or glued in order to manufacture a swimsuit 10 as illustrated, for example, in Fig. 4.

[0040] The fabric 1 and, therefore, the swimsuit 10 made of the fabric 1 , have a number of advantages .

[0041] The fabric 1 has a high thread count, a lightness of about 100g/m ² (while the known swimsuit fabrics weigh about 130 g/m ² ) , a high elasticity in terms of elongation ability

(up to 65% elongation in the weft and to 100% elongation in the warp) , an exceptional spring force, excellent impermeability and water-repellency, and soft-touch. This affords an improved fitting of the swimsuit or garment made of the fabric 1, since the fabric follows the body

movements, adhering to the skin without interfering with the freedom of movement .

[0042] Furthermore, an improved compression of the athlete's muscle under strain is achieved. Compared to the values found in the .known fabrics, the fabric spring force

(elastic module) , therefore the muscle compression is increased of about 50%.

[0043] Finally, the fabric 1 affords excellent hydrodynamic features, thus increasing the "glide" effect of the swimmer in the water.