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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part of U.S. application Ser. No. 17/468,205, filed on Sep. 7, 2021, which claims priority to U.S. Provisional Application No. 63/075,404 filed on Sep. 8, 2020, which is incorporated by reference in its entirety.

TECHNICAL FIELD

This disclosure relates to fabrics useable in high resistance training to prepare for rigorous exercise that are high weight, stretchable, and breathable. This disclosure also relates to a method of knitting, dyeing, printing on, and finishing the same fabrics.

BACKGROUND

When training for competition, athletes typically desire to apply extra resistance during training so that performance can be improved. Weighted garments can be used that typically require the attachment of weights to the suit. The attachment of the weights to the garment is difficult, and the weights consume space on the garment, extend from the garment, and often shift when attached, all which make workouts less effective and risk injury. In addition, the attachment of the weights restrict movement and prevents the fabric of the suit from breathing, leading to uncomfortable workouts. It would therefore be desirable to have a weighted fabric that does not require the attachment of separate weights. It would also be desirable that the weighted fabric is breathable and stretchable so that it provides comfortable and balanced compression and allows for unrestricted movement.

SUMMARY

Disclosed herein are implementations of a weighted fabric and a method of construction thereof.

In one aspect, the present disclosure provides a weighted fabric that includes 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. The weight fabric further comprises 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.

In some aspects, the weighted fabric may have a weight basis of about 16 ounces per square yard or greater. The weighted fabric may have a weight basis greater than 20 ounces per square yard. The weighted fabric may have an air permeability of about 100 to about 120 per cu. ft. of air/min./sq. ft. of fabric. The first yarn may include at least one cationic or disperse dyeable polyester fiber, and wherein the second yarn comprises at least one thermoplastic polyurethane fiber. The weighted fabric may have a thickness of about 0.03 mm to about 0.08 mm. The weighted fabric may have 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. The first yarn may include 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. The first yarn may include at least one disperse dyeable polyester fiber, and wherein the second yarn comprises at least one thermoplastic polyurethane fiber. The weighted fabric may have 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.

In another aspect, this disclosure provides for a weighted fabric that includes 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. The weight fabric further includes 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. 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.

In some aspects, the weighted fabric may further include a dye configured to turn the weighted fabric black at a temperature of about 350 degrees Fahrenheit or less. The weighted fabric may have a yard weight of about 20 ounces per yard or more. The weighted fabric may have 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. The weighted fabric may have a stretchability along the width of about 80 percent or more.

In another aspect, the present disclosure provides a weighted fabric including 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 84 weight to about 92 weight percent. The weighted fabric further includes 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 8 weight percent to about 16 weight percent. The weight percents are based on the total weight percent of the weighted fabric. The weighted fabric has a yard weight of greater than 16 ounces per square yard. 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. The fiber has a thickness of about 0.040 mm to about 0.060 mm.

In some aspects, the first yarn may be present present in an amount of about 86 weight percent to about 90 weight percent, and the second yarn may be present in an amount of 10 weight percent to about 14 weight percent. The first yarn may include at least one cationic dyeable polyester, and weighted fabric may have a yard weight of greater than about 20 ounces per square yard. The weighted fabric may have about 22 to 46 courses per inch. The weighted fabric may have about 24 to 28 wales per inch. The weighted fabric may have a knitted structure of a double knit swiss pique. The weighted fabric may have a stretchability along the width of greater than 25 percent and along the length of about 10 percent to about 20 percent.

In one or more aspects, the present disclosure provides method for constructing a weighted fabric that includes knitting a first yarn on odd needles of a cylinder of a double-knit circular knit machine and knitting the first yarn on all needles of a dial of the double-knit circular knit machine. The method includes knitting a second yarn on even needles of the dial of the double-knit circular knit machine and knitting the first yarn at a first feed rate and the second yarn at a second feed rate to construct the weighted fabric. The method includes dyeing the weighted fabric and framing the weighted fabric.

In some aspects, the first yarn may include a cationic polyester yarn. The cationic polyester yarn may have 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. The second yarn may include a thermoplastic polyurethane fiber. The second yarn may have a denier of about 300 to about 400 and a filament of 1 to 3. The first feed rate may have a rate per 100 needles that is faster than a rate per 100 needles of the second feed rate. The first feed rate may have a rate of about 7 inches to about 12 inches per 100 needles, and the second feed rate may have a rate of about 5 inches to about 11 inches per 100 needles. The dyeing of the weighted fabric step may include adjusting a pH level of a dye to about 4.0 to about 5.0 and 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. The dyeing of the weighted fabric step may include applying an after clear. The step of framing the weighted fabric may include heatsetting the weighted fabric on a tenter frame at a temperature of about 300 degrees Fahrenheit to about 400 hundred degrees Fahrenheit. The step of heatsetting the weighted fabric further may include curling down the weighted fabric on the tenter frame and setting a tenter frame speed at approximately 16 yards per minute. The weighted fabric may have a yard weight of about 16 ounces to about 24 ounces per square yard. The weighted fabric may have approximately 28 wales per inch. The weighted fabric may have approximately 27 courses per inch.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to-scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity.

FIG. 1 is a flow diagram of a method of manufacturing a weighted circular-knit fabric.

FIG. 2A is a diagram of an example of a portion of a cylinder needle configuration for a weighted circular-knit fabric in accordance with embodiments of this disclosure.

FIG. 2B is a diagram of an example of a portion of a dial needle configuration for a weighted circular-knit fabric in accordance with embodiments of this disclosure.

FIG. 3A is a diagram of an example yarn path of feeds 2 and 4 shown in FIG. 2A and FIG. 2B.

FIG. 3B is a diagram of an example yarn path of feeds 1 and 3 shown in FIG. 2A and FIG. 2B.

FIG. 4 is a diagram showing example knit stiches for feeds 1 through 4.

FIG. 5 is a flow diagram of a method 100 of constructing a weighted circular-knit fabric.

FIG. 6 is a side view of a double knit swiss pique formed by a method, such as the methods described in FIGS. 1-5.

DETAILED DESCRIPTION

The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practical application. The specific embodiments of the present teachings as set forth are not intended to be exhaustive or limiting of the teachings. The scope of the teachings should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description. Unless defined otherwise, all technical and scientific terms used herein have the meaning commonly understood by a person skilled in the art.

Fabrics tend to lose stretchability as the weight of the fabric increases. The ideal fabric is configured to be heavy and maintain stretchability and breathability. The fabrics described herein are composed of a yarn that is configured to increase the weight of the overall fabric and another yarn that provides sufficient stretchability and breathability so the overall fabric can be used to improve the efficiency of workouts. In other words, the fabric is weighted so that when a user wears the fabric, the additional weight of the fabric increases resistance on the user while performing various physical exercises.

To achieve an advantageous garment for athletics and resistance training, a fabric with high weight, stretchability, and/or breathability is needed. The inventors have discovered that combinations of polyester yarns and thermoplastic urethane fibers or yarns in combination achieve desirable heavy weight fabrics with superior stretch and breathability. With the combination of heavy weight, superior stretch, and high breathability, the weighted fabric can be advantageously utilized in resistance training in preparation for athletic performance.

Since the fabric is composed of two yarns that are consistently spread out across the knit of the fabric, the user simply feels like a heavier load is being applied to the body. Unlike other devices which use weights or sand integrated with slots or pouches of fabrics, the consistently distributed yarns provide a fabric for working out that does not awkwardly bounce or pull the user in undesirable ways such that the particular exercises of the workout are interrupted. In addition, as described above, the fabric provides sufficient breathability while working out because of the configuration of the yarns and overall fabric, which provides advantages over semi-impermeable or completely impermeable workout suits. With the combination of stretchability, breathability, and increased weight, the user can have a workout with high exertion due to the weighted fabric and unhindered movement due to the stretchability, without having undesirable increased temperature from lack of breathability. In this configuration, the user can participate in a normal workout with the added advantage of increased weight resistance due to the fabric.

The weight fabric described herein may include a first and second yarns configured to provide increased stretchability and weight of the fabric. The first and second yarns may have any configuration sufficient to provide the desired properties of increased flexibility, weight, and breathability. The knit of the first and second yarns in the weight fabric may be any knit sufficient to provide great breathability, while retaining the other properties. Additionally, the fabric may contain additional finishes or components to change the outward appears or increase chemical resistance. For example, other components may be added to increase anti-microbial properties and/or UV resistance. In other examples, the weighted fabric may be subjected to a dye sublimation process that process that provides a particular pattern so that the user has a desirable outward appearance while wearing the fabric. Whether a particular dye is used may have an impact on overall stretchability or weight.

The weighted fabric may have any configuration sufficient to increase resistance as the user workouts. For example, the weighted fabric may extend from the ankles of a user, up to the neck, and down to each wrist and/or hand of the user. In other configurations, the weighted fabric may cover a single region of the body, such as a long sleeve, short sleeve, or sleeveless shirt covering the top of the body, a pair of shorts or pants covering the bottom of the body, or a pair of weighted leg or arm sleeves. The configuration may be based on the desires of the user. For example, a basketball player may desire to use a weighted arm sleeve to provide resistances while practicing shooting. In other examples, military person may desire to wear a full body suit so that while negotiating obstacles many portions of the body have increased resistance due to the fabric extending across the arms, legs, torso, and/or neck.

The first yarn used in the weighted fabric may function to provide increased flexibility and/or weight of the weighted fabric and may allow the fabric to be dyed a certain color. The first yarn may be any compound configurable as a yarn and containing ionic groups configured to bind with a dye. For example, the first yarn may be a polymer configured as a yarn that contains one or more anionic or cationic groups integrated within the polymer. For example, the first yarn may include a polyester or polyester derivative with anionic or cationic groups so that the first yarn is dyable with a dye that is cationic. The dye may be configured to change the weighted fabric to black or another non-white color. The utilization of either the dye or the cationic dyeable polyester may impact one or more properties of the weighted fabric, such as the number of courses per inch, the stretchability after heat treatment, or the overall weight of the fabric. The first yarn may be any type of polyester fiber that is then modified by an ionic group. In one example, the polyester may be modified by a salt containing sulfonic acid or a sulfonic acid derivative and an anionic sulfonate group so that polar groups are added to the polyester, which allows dying of the first yarn. The polyesters may be aliphatic or aromatic. For example, poly(ethylene terephthalate) may be used. In some examples, the first yarn may be a disperse dyeable polyester that is desirable to achieve certain colors of the weighted fabric. For example, the disperse dyeable polyester may be utilized where a white color is desirable, and the white color may be achieved using different parameters than a black color weighted fabric.

As described, the first yarn provides weight, flexibility, and/or breathability to the overall fabric when knitted with the second yarn, which provides increased weight and retains other properties, like flexibility and breathability. In some examples, the first yarn may be a blend of different types of fibers having different compositions that are braided together. In other examples, the first yarn may be composed of fibers having the same composition. The first yarn may have any ply sufficient to sufficient to knit with the second yarn. The first yarn may have a ply of about 1 to about 4. The first yarn may have any denier sufficient to knit with the second yarn and retain advantageous stretching, stability, and breathability properties. Any cationic polyester fiber that has a denier greater than 5% of 450/432 (i.e., 450 denier and 432 filaments) may be used within the first yarn. The first yarn may have a denier of about 80 to about 300. The first yarn may have any filament sufficient to form a yarn sufficient to knit with the second yarn. The first yarn may have a filament of about 120 to about 180. For example, the first yarn may include a cationic polyester fiber, which may be a 3 ply, 150 denier, 144 filament yarn from CS America, Inc.

The second yarn may be any compound sufficient to provide increased weight to the fabric while retaining flexibility and breathability properties. The second yarn may include a segmented polymer with hard and soft segments. The hard segments may impart a rigid crystalline phase and the soft segments may provide an amorphous rubbery phase. For example, the second yarn may include a thermoplastic polyurethane fiber. The thermoplastic polyurethane may be formed by any method known by the skilled artisan. For example, the thermoplastic polyurethane may be formed by bulk or radical polymerization by combining and polymerizing the ingredients and extruding the resultant polymer (i.e., the thermoplastic polyurethane) into a fiber that can be subjected to further processes to form a usable yarn, such as weaving, braiding, etc. to achieve the second yarn that is knittable with the first yarn. Regarding the ingredients, one example as to how to make the thermoplastic polyurethane is to combine a prepolymer polyol (hydroxyl group functionalized greater than or equal to 2) and a short-chain diol (e.g., butane-1,4-diol) with a diisocyanate. The diisocyanate may be aliphatic or aromatic. The short chain diol may be any diol sufficient to polymerize and form a thermoplastic polyurethane.

As described, the second yarn provides added weight to the overall fabric, while retaining advantageous properties of the overall fabric such as stretchability air permeability, and durability. In some examples, the second yarn may be a blend of different types of yarns having different compositions that are braided together. In other examples, the second yarn may be composed of fibers having the same composition. The second yarn as described herein may be comprised of a single fiber. The second yarn may have any ply sufficient to knit with the second yarn. The second yarn may have a ply of 1 to 3. The second yarn may have any denier sufficient to increase the weight of the yarn while retaining other advantageous properties of the overall fabric. The second yarn may have a denier of about 100 to about 550. The first yarn may have any filament sufficient to increase the weight of the overall fabric, while retaining stretchability, stability, and breathability properties. The first yarn may have a filament of 1 to 4. The second yarn may include a bright yarn J that is an X4zol™-J (X4J) from The Lubrizol Corporation, which, for example, may have a 360 denier and 1 filament yarn.

Yarn one or two may include one or more additives in the fibers or yarns to modify properties of the polyurethane and/or polyester. The additives may function to improve ultraviolet light resistance, elongation, impact strength, tear strength, breathability, wicking properties, or any combination thereof. In some examples, a microbial agent may be added to the fabric to prevent undesirable pathogens from propagating throughout the fabric. The microbial agent may be any compound sufficient to inhibit pathogen growth and reduce undesirable smells in the weighted fabric. For example, the microbial agent may include one or more zinc based compounds. As one example, the microbial agent may include zinc pyrithione or a residue of zinc pyrithione. The microbial agent may include one or more elements or compounds having an anionic portion. The microbial agent may be applied at any stage or step of formation of the overall fabric such that the fabric has anti-microbial properties after the final weighted fabric is formed. For example, the microbial agent may be applied during the dying process. In other examples, the microbial agent may be applied before or after the after clear application step.

The weighted fabric may have a sufficient weight to provide resistance to a user as he or she exercises. For example, the fabric may have a weight of about 15 ounces to about 30 ounces per square yard. As an example, a full body suit that utilizes the weighted fabric may weight about 5 pounds to about 20 pounds, depending on the configuration of the first and second yarns, the fit of the suit for the size of the user, or both. The weighted fabric may have any thickness that allows a user to conduct a workout without the weighted fabric inhibiting movement of the user. For example, the weighted fabric may have a thickness of about 0.01 mm to about 0.5 mm. To achieve the desired dimensions of the weighted fabric, the weighted fabric may include an amount of the first and second yarn, based on the total weight of the weighted fabric. For example, the weighted fabric may include about 50 percent to about 95 percent of the first yarn and about 5 percent to about 50 percent of the second yarn, where the percent of first and second yarns equals 100 percent. In some examples, one or more additional components or compositions, such as additional yarns, fibers, or coatings, may be applied to make up the balance of the total weight after sum of the first and second yarn. In some examples, including more of the first yarn may improve stretchability, durability, and/or stability of the overall weighted fabric. In some examples, including more of the second yarn may increase the weight of the weighted yarn because the second yarn may be considerably more dense than the first yarn. The weighted fabric may have include one or more advantageous properties due to the weave of the fabric and the combination of the first and the second yarns. For example, the weighted fabric may have superior tear resistance (abrasion), air permeability, stretchability, or some other property.

The weighted fabric may have any air permeability sufficient to allow the fabric to breath while a person is exercising. The air permeability may be impacted by the courses and/or wales per inch. For example, the air permeability may be about 100 to about 120 per cu. ft. of air/min./sq. ft. of fabric. Air permeability may be measured by techniques disclosed in the Examples or ASTM D737.

The weighted fabric may have any flexibility sufficient to allow the fabric to be utilized during resistance training. If flexibility is not sufficiently high, the user may experience discomfort while performing rigorous activity, which could decrease overall satisfaction and results during an exercise routine. Accordingly, the present inventors have discovered that utilizing the first and second yarns described herein increases weight of the fabric, which improves resistance training, and allows for desirable flexibility during complex motions. The weighted fabric may have desirable stretchability across the width and length of the weight fabric. For example, using the hand method, the weighted fabric may have a stretchability across the length of 10 percent or more, 20 percent or more, 30 percent or more, 40 percent or more, or 50 percent or more. The weighted fabric may have a stretchability across the width of 20 percent or more, 30 percent or more, 50 percent or more, 60 percent or more, 70 percent or more, or 80 percent or more. Stretchability may be measured by those techniques described in the examples or ASTM D6614/D6614M-20.

The present fabrics may additionally retains strong abrasion resistance, while retaining high weight, stretchability, and/or breathability. Abrasion is desirable to avoid breakdowns of the fabric while exercising, such as when moving on the ground or floor, grazing incidentally along the fabric, or any other exercise activity that may cause contact stress against the fabric. The abrasion may at between 60,000 and 90,000 cycles. The abrasion may meet about 75,000 cycles. The abrasion test results may be between about 2.5 and 5.5. Abrasion may be tested by the Martindale abrasion test of ASTM D4966-22.

FIG. 1 is a flow diagram of a method 100 of manufacturing a weighted circular-knit fabric. The method 100 includes a knitting stage 110. The knitting stage 110 may implement a circular double-knit machine to knit the first yarn and the second yarn to form a double-knit swiss pique fabric that provides stability, breathability, and flexibility. In an example, the circular double-knit machine may be configured with a 30 inch cylinder with 18 needles per inch. In this example, 1,680 needles may be used to fit this cut and cylinder on the double-knit machinery.

The first and second yarns may be knit as loosely as possible to maximize stretch properties of the fabric based on end use. In addition, the first and second yarns may be knitted loosely or tightly to adjust the stability of the fabric (e.g., tear resistance and abrasion properties). The feed rate of the first and second yarns may be controlled to vary the looseness of the fabric knit. In this example, the first yarn has a feed rate of that is faster than the feed rate of the second yarn. Specifically in this example, the first yarn may have a feed rate of about 7 inches to about 12 inches per 100 needles, and the second yarn may have a feed rate of about 5 inches to about 11 inches per 100 needles. In one example, the second yarn may be knit on the dial only. Tension may be minimized on the fabric in the greige by taking up the first and second yarns as loose as possible.

The method 100 includes a dyeing stage 120. The fabric may be dyed a color with any suitable fabric dye. The dye may include any cationic compound that is bindable with the first yarn that includes anionic groups integrated with the polymer (e.g., polyester). For example, the dye may include one or more of sodium sulfate, acetic acid, a dispersing agent, a liquor, a diffusion accelerator, a dye, a colorant, a pigment, or any combination thereof. The fabric may be dyed in a vertical jet at a high temperature and high pressure. The maximum temperature on this fabric in the vertical jet may be about 200 degrees Fahrenheit to about 350 degrees Fahrenheit. The high pressure may include any pressure above ambient pressure (e.g., 1 atm or about 101,000 Pa).

The dyeing stage 120 includes adjusting the pH level of the dye to about 4.0 to about 5.0. The pH level of the dye may be adjusted prior to heating and application of pressure in the dye tank. The pH levels may be maintained between about 4.0 to about 5.0 for the dye sample pH, the take-off pH check, or both. The take-off pH check may be performed just prior to removing the fabric from the dye bath to ensure that the dye bath is not on the alkaline side. If the dye bath is on the alkaline side at this stage, the dye may be pulled or stripped off of the yarn. It is preferable to dye the first yarn on the acidic side, and therefore, a pH of neutral or higher may cause the dye to peel off and create poor wash fastness.

The dyeing stage 120 may include the application of an after clear to the fabric to promote color fastness performance. After clear is a chemical process that removes the excess dye that did not bond to the first and/or second yarns (i.e. the dye removes the dye that is not bound to the first and/or second yarns). The desired color fastness performance may be based on the end use of the goods. The dyeing stage 120 may have a duration of about 5.0 hours to about 7.5 hours. Additionally, the after clear may be applied for a duration of about 15 minutes to about 1.0 hours, which may be followed by washing. In other words, the total time for applying the dye and/or the after clear may be conducted for a duration of about 5.0 to about 9.0 hours. The after clear may be any compound sufficient to wash the dye from the first and/or second yarns. For example, the after clear may include soda ash, thiourea dioxide, acetic acid, or any combination thereof.

The method 100 includes a framing stage 130. The framing stage 130 may include heatsetting the fabric on a frame. The second yarn is sensitive to temperatures above 360° F. so the fabric is generally heated at temperature below 360 degrees Fahrenheit. Accordingly, the fabrics disclosed herein may be heatset at about 360° F. or less on a tenter frame. Any type tenter frame may be used, and the tenter frame width may be varied dependent on the size or the configuration of the fabric. The tenter frame may be about 40 to about 80 inches wide. The tenter frame speed may be set to about 10 yards to about 20 yards per minute to ensure yarn and construction stability. The fabric may be curled down on the frame such that the fabric is folded upside-down. The fabric may be run dry at the tenter frame pad. In some examples, no chemical finish is applied to the fabric. The framing stage 130 may include pinning the fabric in a narrow fashion to obtain optimal stretch properties. For example, the pin marks may be within about 0.1 inches to about 0.75 inches of the edge of the fabric on both sides. Weight and stretch may be checked as the fabric is framed. In an example, the stretch may be checked using a hand stretch method or a weight.

FIG. 2A is a diagram of an example of a portion of a cylinder needle configuration for a weighted circular-knit fabric in accordance with embodiments of this disclosure. The portion of the cylinder needle configuration may be repeated as often as necessary depending on the desired fabric dimensions and limitations of the machinery. FIG. 2A shows the cylinder needle feeds 1 through 4, where X represents the first yarn, such as cationic polyester yarn have a ply of 3, a denier 150, and a filament of 144. As shown in FIG. 2A, the first yarn is knit onto each needle in feeds 1 and 3, where the needles in feeds 1 and 3 represent the odd needles of the cylinder.

FIG. 2B is a diagram of an example of a portion of a dial needle configuration for a weighted circular-knit fabric in accordance with embodiments of this disclosure. The portion of the dial needle configuration may be repeated as often as necessary depending on the desired fabric dimensions of the fabric. FIG. 2B shows the dial needle feeds 1 through 4, where X represents first yarn and Y represents the second yarn. As shown in FIG. 2B, the first yarn is knit onto each alternate needle in feeds 1 and 3, and a combination of the first and second yarns are knit onto each alternate needle in feeds 2 and 4, where the needles in feeds 2 and 4 represent the even needles of the dial.

FIG. 3A is a diagram of an example yarn path of feeds 2 and 4 shown in FIG. 2A and FIG. 2B. FIG. 3A shows the combination of the first and second yarns onto each alternate needle on the dial. In addition, FIG. 3A also shows that none of the needles of the cylinder are knit with yarns for these feeds.

FIG. 3B is a diagram of an example yarn path of feeds 1 and 3 shown in FIG. 2A and FIG. 2B. FIG. 3B shows that the first yarn is knit onto each alternate needle on the dial. In addition, FIG. 3A also shows that each of the needles of the cylinder are knit with the first yarn.

FIG. 4 is a diagram showing example knit stiches 400 for feeds 1 through 4. FIG. 4 shows that the first yarn 410 is knit onto each alternate needle on the dial for Feed 1 and Feed 3. In addition, FIG. 4 also shows that for Feed 1 and Feed 3, each of the needles of the cylinder are knit with the first yarn 410.

FIG. 4 shows that the first yarn 410 and the second yarn 420 are both knit onto each alternate needle on the dial for Feed 2 and Feed 4. In addition, FIG. 4 also shows that none of the needles of the cylinder are knit with yarns for Feed 2 and Feed 4.

FIG. 5 is a flow diagram of a method 500 of constructing a weighted circular-knit fabric. The weighted fabric may be comprised of a first yarn and a second yarn. The first yarn may include a cationic polyester yarn and the second yarn may be a thermoplastic polyurethane.

The method 500 includes a loading the first yarn 510. The first yarn may be knit on the needles of a cylinder of a circular double-knit machine. In an example, the first yarn may be knit onto alternate needles of the cylinder, for example, the odd needles of the cylinder. The first yarn may be knit on the needles of the dial of the circular double-knit machine. In an example, the first yarn may be knit onto all the needles of the dial of the circular knit machine.

The method 500 includes loading the second yarn. The second yarn may be knit on the needles of the dial of the circular double-knit machine. In an example, the second yarn may be knit on alternate needles of the circular double-knit machine, for example on the even needles of the circular double-knit machine.

The method 500 includes knitting 530 the first yarn and the second yarn to construct the weighted fabric. The first yarn and the second yarn may be knit to form a double-knit swiss pique fabric that provides stability, breathability, and flexibility. The first yarn may be knit at a first feed rate, and the second yarn may be knit at a second feed rate. In an example, the first feed rate may be about 7 inches to about 12 inches per 100 needles, and the second feed rate may be about 5 inches to about 11 inches per 100 needles.

The method 500 includes dyeing 540 the weighted fabric. Dyeing 540 the weighted fabric may include adjusting the pH level of a dye. Dyeing 540 the weighted fabric may include setting a temperature, a pressure, or both, of a vertical jet. Dyeing 540 the weighted fabric may include applying an after clear to the weighted fabric to remove excess surface dye. The pH level of the dye may be adjusted to about 4.0 to about 5.0. The temperature of the vertical jet may be set to about 230 degrees Fahrenheit to about 300 degrees Fahrenheit. The pressure of the vertical jet may be set to any pressure above ambient pressure (i.e., above 1 atmosphere or 101 kPa).

The method 500 includes framing 550 the weighted fabric. Framing 550 the weighted fabric may include heatsetting the weighted fabric on a tenter frame. Heatsetting the weighted fabric may include curling down the weighted fabric on the tenter frame. Heatsetting the weighted fabric may include setting a tenter frame speed to about 12 yards to about 18 yards per minute. The weighted fabric may be heatset at a temperature of about 300 degrees Fahrenheit to about 400 degrees Fahrenheit.

In any method described herein, the weighted fabric may be subject to an additional step of dye sublimation. Dye sublimation may be useful to print patterns onto the weighted fabric to give additional aesthetic appeal. For example, a pattern may be printed on a heat resistant transfer paper as a reverse image of the desired pattern on the weighted fabric. Then, the pattern is transferred from the transfer paper to the weighted fabric by a heat press operating at a desired temperature. The temperature may be set such that the weighted fabric is not undesirably altered due to the temperature of the heat press. For example, the heat press may be operated at a temperature of about 325 degrees Fahrenheit to about 400 degrees Fahrenheit. The heat press may also operated at a pressure sufficient to transfer the pattern from the transfer paper to the weight fabric. For example, the pressure may be about 35 psi to about 45 psi.

FIG. 6 is a side view of a weighted fabric 600 having a knit or structure of a double knit swiss pique formed by a method, such as the methods described in FIGS. 1-5. As shown, a first yarn 610 (e.g., the cationic dyeable polyester) is weaved with a second yarn 620 (e.g., thermoplastic polyurethane). In other examples, the first yarn 610 is weaved in the position of the second yarn 620 so that the orientations of the first and second yarns 610, 620 are reversed. FIG. 6 is intended as an example, and the weighted fabric 600 may have other structures or knits that form a fabric having very high density, flexibility, stability, and/or breathability. The weighted fabric 600 can have any weave or knit sufficient to improve the workout conditions of a user while wearing the weighted fabric 600.

As used herein, a yarn may be used interchangeably with a yarn, line, thread, strand, tendril, or fibril. A yarn may mean that one or more yarns are woven into a single line that is useable to form a weighted fabric. Fabric may be described as a cloth, weighted fabric, textile, or web. Residue means a portion of the compound is remaining after reaction with one or more other compounds. Any polymer described herein may be a copolymer of two or more monomers.

Any numerical values recited include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. For values which are less than one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value, and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner. Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of “about” or “approximately” in connection with a range applies to both ends of the range. Thus, “about 20 to 30” is intended to cover “about 20 to about 30”, inclusive of at least the specified endpoints. The term “consisting essentially of” to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms “comprising” or “including” to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of the elements, ingredients, components or steps. Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of “a” or “one” to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.

EXAMPLES

The following examples are provided to illustrate the disclosure, but are not intended to limit the scope thereof. All parts and percentages are by weight unless otherwise indicated.

Example 1

An example fabric was prepared using the method 100 of FIG. 1 or the method 500 of FIG. 5. The fabric has a configuration according to FIG. 6. In this example, the fabric was prepared to include a blend of cationic polyester yarns and a bright yarn J. A 3 ply, 150 denier, 144 filament yarn from CS America, Inc. was used as the cationic polyester fiber in this example, and a 360 denier, 1 filament X4J yarn from The Lubrizol Corporation was used as the bright fiber J. Properties of this example fabric are shown in Table 1 below.

	TABLE 1
	Cationic
	Poly (%)	X4J (%)	Yard Weight	Wales/in.	Courses/in	Thickness
Ex. 1	88	12	21.0	28	27	0.056 mm
			oz./sq. yard

As shown in Table 1 above, the example fabric was knit as a double-knit swiss pique. The example fabric has a measured thickness of 0.056 mm and a yard weight of 21.0 oz/sq. yard. The example fabric was constructed with 28 wales/inch and 27 courses/inch.

Testing was performed on the example fabric. The testing performed on the fabric included a wet and dry crocking test (CT), a wash fastness test (WF), and a Martindale abrasion test (AT). A stretch test was performed using a hand stretch method conducted in a Hornwood ISO 9001 laboratory. The stretch test measured the percent stretch in a length direction (1) and in a width direction (w). In addition, a wicking test was performed, and the example fabric was shown to pass wicking. The results from the testing are shown in Table 2 below.

	Cationic
	Poly (%)	X4J (%)	Stretch (l)	Stretch (w)	CT	WF	AT
Ex. 1	88	12	20%	45%	4.5	4.5	4.0

Referring to Table 2 above, the testing resulted in a 20% stretch in the length direction and a 45% stretch in the width direction. The testing also showed that the example fabric scored a 4.5 on the wet and dry crocking test, a 4.5 on the wash fastness test (which included 5 washes), and a 4.0 on the Martindale abrasion test at 75,000 cycles.

Examples 2-6

In these examples, the weighted fabric is tested for its permeability. These examples are made in the same fashion and have the same components and configuration (i.e., FIG. 6) as described in relation to Example 1. The breathability of the fabric is tested to determine how cool a user would feel while exercising with the weighted fabric. The test was performed according to ASTM D 737-18, which is considered the Standard Test Method for Air Permeability of Textile Fabrics. A higher value indicates that more air permeates through the fabric, whereas a lower value indicates that less air permeates through the fabric.

			Air Permeability (cu. ft. of
Sample	Cationic Poly (%)	X4J (%)	air/min./sq. ft. of fabric)
Ex. 2	88	12	118.4
Ex. 3	88	12	111.4
Ex. 4	88	12	104.4
Ex. 5	88	12	117.4
Ex. 6	88	12	103.3
Avg.	88	12	111.0

In these examples, it is shown that the weighted fabric has a very good air permeability. With the weight of this fabric being so heavy due to the combination of X4J and the Cationic Polymer, it would be expected that the air permeability be much less. Because the X4J is so dense (i.e., very high denier), the weave or knit of the X4J and the Cationic Polymer allows a significant amount of air to flow through the weighted fabric. Further, the X4J is a thermal regulating yarn, so compared to other fabrics of similar nature, the X4J regulates more heat and the weave will allow more air to flow through the fabric, so the user feels cooler while working out.

Examples 7-8

Examples 7 and 8 show a comparison between a black weighted fabric (Ex. 7) and a white weighted fabric (Ex. 8). Ex. 7 uses a cationic dyeable polyester which is used to have a black weighted fabric (using dye techniques described herein) and Ex. 8 uses a dispersible dyeable polyester to have a white weighted fabric, which does not need to be dyed and can be retained with its natural color. Regarding size of each yarn, both Exs. 7 and 8 used 3 ply, 150 denier, 144 filament draw polyester (82.5%) and a 2 ply, 180 denier, monofilament X4J (which is a trade name for Lubrizol's TPU)

					Courses	Wales	Weight (oz.
	Polyester (%)	X4J (%)	Stretch (l)	Stretch (w)	per inch	per inch	per sq. yard)
Ex. 7	82.5	17.5	10%	80%	24	26	18.4
Ex. 8	82.5	17.5	20%	55%	43	26	24.5

As seen above, even though Wales per inch is effectively the same, the stretch of Ex. 7 is significantly higher. Further, the courses per inch is different between Ex.7 and 8, which is why Ex. 8 is heavier.

Although features and elements are described above in particular combinations, one of ordinary skill in the art will appreciate that each feature or element can be used alone or in any combination with the other features and elements. While the disclosure has been described in connection with certain embodiments, it is to be understood that the disclosure is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.

Claims

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.