Weighted circular-knit fabric and method of making the same

Abstract

Disclosed herein are implementations of a weighted fabric and a method of construction thereof. The method for constructing the weighted fabric includes loading a first yarn on a cylinder of a double-knit circular knit machine. The method includes loading the first yarn on a dial of the double-knit circular knit machine. The method includes loading a second yarn on the dial of the double-knit circular knit machine. The method includes knitting the first yarn and the second yarn to construct the weighted fabric. The first yarn may be knitted at a first feed rate. The second yarn may be knitted at a second feed rate. The first feed rate may be greater than the second feed rate. The method may include dyeing the weighted fabric. The method may include framing the weighted fabric.

What is claimed is: 
     
         1 . A weighted fabric, comprising:
 a first fiber having a ply of between about 1 and about 4; a denier of about 130 to about 170; and a filament of about 130 to about 160;   a second fiber knit with the first fiber, the second fiber having a denier of about 300 to about 500 and a filament of 1 to 3.   
     
     
         2 . The weighted fabric of  claim 1 , wherein the weighted fabric has a yard weight of about 16 ounces to about 24 ounces per square yard. 
     
     
         3 . The weighted fabric of  claim 1 , wherein the first fiber includes a cationic dyeable polyester. 
     
     
         4 . The weighted fabric of  claim 3 , wherein the first fiber includes one or more anionic compounds. 
     
     
         5 . The weighted fabric of  claim 1 , wherein the second fiber includes a thermoplastic polyurethane fiber. 
     
     
         6 . The weighted fabric of  claim 1 , wherein the weighted fabric has a thickness of about 0.03 mm to about 0.08 mm. 
     
     
         7 . The weighted fabric of  claim 1 , wherein the weighted fabric has a structure of a double knit swiss pique. 
     
     
         8 . A method for constructing a weighted fabric, the method comprising:
 knitting a first yarn on odd needles of a cylinder of a double-knit circular knit machine;   knitting the first yarn on all needles of a dial of the double-knit circular knit machine;   knitting a second yarn on even needles of the dial of the double-knit circular knit machine;   knitting the first yarn at a first feed rate and the second yarn at a second feed rate to construct the weighted fabric;   dyeing the weighted fabric; and   framing the weighted fabric.   
     
     
         9 . The method of  claim 8 , wherein the first yarn includes a cationic polyester yarn. 
     
     
         10 . The method of  claim 9 , wherein the cationic polyester yarn has a ply of about 1 to about 4; a denier of about 130 to about 170; and a filament of about 130 to about 160. 
     
     
         11 . The method of  claim 8 , wherein the second yarn includes a thermoplastic polyurethane fiber. 
     
     
         12 . The method of  claim 11 , wherein the second yarn has a denier of about 300 to about 400 and a filament of 1 to 3. 
     
     
         13 . The method of  claim 11 , wherein the first feed rate has a rate per 100 needles that is faster than a rate per 100 needles of the second feed rate. 
     
     
         14 . The method of  claim 13 , wherein the first feed rate has a rate of about 7 inches to about 12 inches per 100 needles, and wherein the second feed rate has a rate of about 5 inches to about 11 inches per 100 needles. 
     
     
         15 . The method of  claim 8 , wherein dyeing the weighted fabric comprises:
 adjusting a pH level of a dye to about 4.0 to about 5.0;   setting a temperature of a vertical jet to about 230 degrees Fahrenheit to about 300 degrees Fahrenheit and a pressure of the vertical jet to greater than 101,000 Pa; and   applying an after clear.   
     
     
         16 . The method of  claim 8 , wherein framing the weighted fabric comprises:
 heatsetting the weighted fabric on a tenter frame at a temperature of about 300 degrees Fahrenheit to about 400 hundred degrees Fahrenheit.   
     
     
         17 . The method of  claim 16 , wherein heatsetting the weighted fabric further comprises:
 curling down the weighted fabric on the tenter frame; and   setting a tenter frame speed at approximately 16 yards per minute.   
     
     
         18 . The weighted fabric of  claim 8 , wherein the weighted fabric has a yard weight of about 16 ounces to about 24 ounces per square yard. 
     
     
         19 . The weighted fabric of  claim 8 , wherein the weighted fabric has approximately 28 wales per inch. 
     
     
         20 . The weighted fabric of  claim 8 , wherein the weighted fabric has approximately 27 courses per inch.