High weight, stretchable, and breathable fabrics 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 yarn having a ply of between 1 and 4; having a denier of about 130 to about 170; and having a filament of about 130 to about 160; comprising at least one cationic or disperse dyeable polyester, and being present in a weight percent of about 80 to about 95 percent;   a second yarn knit with the first yarn, the second yarn having a ply of between 1 and 3, having a denier of about 160 to about 500; having a filament of 1 to 2; comprising at least one thermoplastic polyurethane fiber, and being present in a weight percent of about 5 to about 20 percent, based on the total weight of the fabric.   
     
     
         2 . The weighted fabric of  claim 1 , wherein the weighted fabric has a weight basis of about 16 ounces per square yard or greater. 
     
     
         3 . The weighted fabric of  claim 1 , wherein the weighted fabric has a weight basis greater than 20 ounces per square yard. 
     
     
         4 . The weight fabric of  claim 3 , wherein weighted fabric has an air permeability of about 100 to about 120 per cu. ft. of air/min./sq. ft. of fabric. 
     
     
         5 . The weighted fabric of  claim 1 , wherein the first yarn comprises at least one cationic or disperse dyeable polyester fiber, and wherein the second yarn comprises at least one thermoplastic polyurethane fiber. 
     
     
         6 . The weighted fabric of  claim 5 , wherein the weighted fabric has a thickness of about 0.03 mm to about 0.08 mm. 
     
     
         7 . The weighted fabric of  claim 6 , wherein the weighted fabric has a structure of a double knit swiss pique having between 22 and 46 course per square inch and between 22 and 28 wales per inch. 
     
     
         8 . The weighted fabric of  claim 7 , wherein the first yarn comprises at least one cationic dyeable polyester fiber, and wherein the weighted fabric has a weight basis of about 20 ounces per square yard or greater. 
     
     
         9 . The weighted fabric of  claim 1 , wherein the first yarn comprises at least one disperse dyeable polyester fiber, and wherein the second yarn comprises at least one thermoplastic polyurethane fiber. 
     
     
         10 . The weighted fabric of  claim 9 , wherein the weighted fabric has a structure of a double knit swiss pique having between 40 and 46 course per square inch and between 22 and 28 wales per inch. 
     
     
         11 . A weighted fabric, comprising:
 a first yarn having a ply of between 2 and 4; having a denier of about 130 to about 170; and having a filament of about 130 to about 160; consisting of at least one cationic dyeable polyester, and being present in a weight percent of about 80 to about 95 percent;   a second yarn knit with the first yarn, the second yarn having a ply of between 1 and 2, having a denier of about 160 to about 360; having a filament of 1 to 2; consisting of at least one thermoplastic urethane fiber, and being present in a weight percent of about 5 to about 20 percent, based on the total weight of the fabric,   wherein the weighted fabric has a stretchability along the width of greater than 50 percent and along the length of about 10 percent to about 20 percent.   
     
     
         12 . The weighted fabric of  claim 11 , further comprise a dye configured to turn the weighted fabric black at a temperature of about 350 degrees Fahrenheit or less. 
     
     
         13 . The weighted fabric of  claim 12 , wherein the weighted fabric has a yard weight of about 20 ounces per yard or more. 
     
     
         14 . The weighted fabric of  claim 13 , wherein the weighted fabric has about 22 to 26 courses per inch, wherein the weighted fabric has about 24 to 28 wales per inch, and wherein the weighted fabric has a knitted structure of a double knit swiss pique. 
     
     
         15 . The weighted fabric of  claim 14 , wherein the weighted fabric has a stretchability along the width of about 80 percent or more. 
     
     
         16 . A weighted fabric, comprising:
 a first yarn having a ply of 2 to 4; a denier of about 150 to 170; and a filament of about 135 to 155, wherein the first yarn comprises consists of at least one disperse and/or cationic dyable polyester fibers, and wherein the first yarn is present in an amount of about 80 weight to about 90 weight percent; and   a second yarn knit with the first yarn, the second yarn having a ply of 1 or 2, a denier of about 180 to 360 and a filament of 1, wherein the second yarn consists of at least one thermoplastic polyurethane fiber, and wherein the second yarn is present in an amount of about 10 weight percent to about 20 weight percent, wherein the weight percents are based on the total weight percent of the weighted fabric,   wherein the weighted fabric has a yard weight of greater than 16 ounces per square yard,   wherein the weighted fabric has an air permeability of about 100 to about 120 cubic feet of air per minute per square foot of the weighted fabric, and   wherein the fiber has a thickness of about 0.040 mm to about 0.060 mm.   
     
     
         17 . The weighted fabric of  claim 16 , wherein the first yarn is present in an amount of about 82 weight percent to about 90 weight percent, and wherein the second yarn is present in an amount of 10 weight percent to about 18 weight percent. 
     
     
         18 . The weighted fabric of  claim 17 , wherein the first yarn comprises at least one cationic dyeable polyester, and the weighted fabric has a yard weight of greater than about 20 ounces per square yard. 
     
     
         19 . The weighted fabric of  claim 18 , wherein the weighted fabric has about 22 to 46 courses per inch, wherein the weighted fabric has about 24 to 28 wales per inch, and wherein the weighted fabric has a knitted structure of a double knit swiss pique. 
     
     
         20 . The weighted fabric of  claim 19 , wherein the weighted fabric has a stretchability along the width of greater than 25 percent and along the length of about 10 percent to about 25 percent.