Sailcloth with high 1% warp and high warp efficiency and method of making same

A woven sailcloth comprising warp yarns and fill yarns weaved in a plain weave in which the fill yarns are pre-crimped, and in which the ratio of fill yarn count to warp yarn count is about 1.1:1 to about 1.8:1 and the ratio of warp yarn density to fill yarn density is about 1.2:1 to about 1.9:1, wherein the woven sailcloth has a 1% warp of at least about 125 and/or a warp efficiency of at least about 17.

A woven sailcloth having a weight of at least about 7 and comprising warp yarns and fill yarns in which the ratio of fill yarn count to warp yarn count is about 1.1:1 to about 1.8:1 and the ratio of warp yarn density to fill yarn density is about 1.2:1 to about 1.9:1, wherein the fill yarns are pre-crimped, and wherein the woven sailcloth has a 1% warp of at least about 125, a warp efficiency of at least about 17, a 1% warp to 1% fill ratio of at least about 4:1, a 1% fill to 1% bias ratio of less than about 1:1, a 1% warp:1% fill to 1% fill:1% bias ratio of at least about 1:1, a 10 lb. warp to 10 lb. fill ratio of less than about 0.5:1, a 10 lb. fill to 10 lb. bias ratio of at least about 1:1, and a 10 lb. warp:10 lb. fill to 10 lb. fill:10 lb. bias ratio of less than about 0.5:1.

A method of making a woven sailcloth comprising warp yarns and fill yarns, which method comprises weaving warp yarns and fill yarns in a plain weave in which the fill yarns are pre-crimped, and in which the ratio of fill yarn count to warp yarn count is about 1.1:1 to about 1.8:1 and the ratio of warp yarn density to fill yarn density is about 1.2:1 to about 1.9:1, whereupon a woven sailcloth comprising warp yarns and fill yarns is made.

A method of making a sail, which method comprises assembling panels of sailcloth comprising warp yarns and fill yarns in which the fill yarns are pre-crimped, and in which the ratio of fill yarn count to warp yarn count is about 1.1:1 to about 1.8:1 and the ratio of warp yarn density to fill yarn density is about 1.2:1 to about 1.9:1, wherein (i) at least one panel of sailcloth has a 1% warp of at least about 125 and/or a warp efficiency of at least about 17 and (ii) the at least one panel of sailcloth is assembled into the sail with load paths oriented along its warp yarns, whereupon a sail is made.

A method of making a sail, which method comprises assembling panels of sailcloth, at least one panel of which is woven sailcloth comprising warp yarns and fill yarns weaved in a plain weave in which the fill yarns are pre-crimped, and in which the ratio of fill yarn count to warp yarn count is about 1.1:1 to about 1.8:1 and the ratio of warp yarn density to fill yarn density is about 1.2:1 to about 1.9:1, wherein the woven sailcloth has a 1% warp of at least about 125 and/or a warp efficiency of at least about 17, whereupon a sail is made.

A method of making a sail, which method comprises assembling panels of sailcloth having a weight of at least about 7 comprising warp yarns and fill yarns in which the fill yarns are pre-crimped, and in which the ratio of fill yarn count to warp yarn count is about 1.1:1 to about 1.8:1 and the ratio of warp yarn density to fill yarn density is about 1.2:1 to about 1.9:1, wherein (i) at least one panel of sailcloth has at least one of a 1% warp to 1% fill ratio of at least about 4:1, a 1% fill to 1% bias ratio of less than about 1:1, a 1% warp:1% fill to 1% fill:1% bias ratio of at least about 1:1, a 10 lb. warp to 10 lb. fill ratio of less than about 0.5:1, a 10 lb. fill to 10 lb. bias ratio of at least about 1:1, a 10 lb. warp:10 lb. fill to 10 lb. fill:10 lb. bias ratio of less than about 0.5:1 and (ii) the at least one panel of sailcloth is assembled into the sail with load paths oriented along its warp yarns, whereupon a sail is made.

A method of making a sail, which method comprises assembling panels of sailcloth, at least one of which is a panel of woven sailcloth having a weight of at least about 7 and comprising warp yarns and fill yarns weaved in a plain weave in which the fill yarns are pre-crimped, and in which the ratio of fill yarn count to warp yarn count is about 1.1:1 to about 1.8:1 and the ratio of warp yarn density to fill yarn density is about 1.2:1 to about 1.9:1, wherein the woven sailcloth has a 1% warp of at least about 125, a warp efficiency of at least about 17, and at least one of a 1% warp to 1% fill ratio of at least about 4:1, a 1% fill to 1% bias ratio of less than about 1:1, a 1% warp:1% fill to 1% fill:1% bias ratio of at least about 1:1, a 10 lb. warp to 10 lb. fill ratio of less than about 0.5:1, a 10 lb. fill to 10 lb. bias ratio of at least about 1:1, and a 10 lb. warp:10 lb. fill to 10 lb. fill:10 lb. bias ratio of less than about 0.5:1, whereupon a sail is made.