Dry liners for pipe repair and methods for manufacturing dry liners

1. A method of manufacturing a dry liner for reinforcing a pipe, the method comprising:

spirally winding, a glass fiber-reinforced, continuous material around a mandrel such that a subsequent layer of the glass fiber-reinforced, continuous material at least partially overlaps a preceding layer of the material to form an overlapping region;

affixing the subsequent layer of material to the preceding layer of material in the overlapping region;

wherein affixing the subsequent layer of material to the preceding layer of material in the overlapping region further comprises applying an adhesive between the subsequent layer of material and the preceding layer of material in the overlapping region.

2. A method of manufacturing a dry liner for reinforcing a pipe, the method comprising:

spirally winding, a glass fiber-reinforced, continuous material around a mandrel such that a subsequent layer of the glass fiber-reinforced, continuous material at least partially overlaps a preceding layer of the material to form an overlapping region;

affixing the subsequent layer of material to the preceding layer of material in the overlapping region;

wherein one or more thermoplastic fibers are attached to, or integrated with, the material in the overlapping region, and wherein affixing the subsequent layer of material to the preceding layer of material in the overlapping region further comprises at least partially melting the one or more thermoplastic fibers.

3. The method of claim 2 , wherein the one or more thermoplastic fibers includes polypropylene.

4. A method of manufacturing a dry liner for reinforcing a pipe, the method comprising:

spirally winding, a glass fiber-reinforced, continuous material around a mandrel such that a subsequent layer of the glass fiber-reinforced, continuous material at least partially overlaps a preceding layer of the material to form an overlapping region;

affixing the subsequent layer of material to the preceding layer of material in the overlapping region;

wherein a veil comprising a mixture of glass fibers and polyester fibers is attached to the glass fiber-reinforced, continuous material, and wherein affixing the subsequent layer of material to the preceding layer of material in the overlapping region further comprises at least partially melting polyester fibers of the veil.

5. The method of claim 1 wherein the adhesive includes a powder resin, a hot melt adhesive, a liquid/solvent-based spray glue, or a combination thereof.

6. The method of claim 1 , further comprising removing the dry liner from the mandrel prior to impregnating the dry liner with a resin.

7. A dry liner for use in reinforcing a pipe, the dry liner comprising:

a continuous spirally wound, glass fiber-reinforced material forming a first layer and a second layer that at least partially overlaps the first layer to form an overlapping region; and

a second material that affixes the first layer to the second layer in the overlapping region;

wherein the second material includes an adhesive applied between the first layer and the second layer in the overlapping region.

8. A dry liner for use in reinforcing a pipe, the dry liner comprising:

a continuous spirally wound, glass fiber-reinforced material forming a first layer and a second layer that at least partially overlaps the first layer to form an overlapping region; and

a second material that affixes the first layer to the second layer in the overlapping region;

wherein the second material includes a plurality of thermoplastic fibers that are melted to affix the first layer to the second layer.

9. A dry liner for use in reinforcing a pipe, the dry liner comprising:

a continuous spirally wound, glass fiber-reinforced material forming a first layer and a second layer that at least partially overlaps the first layer to form an overlapping region; and

a second material that affixes the first layer to the second layer in the overlapping region;

wherein the second material includes a veil comprising a mixture of glass fibers and polyester fibers.

10. The method of claim 2 , wherein the glass fiber-reinforced, continuous material includes a top surface and a bottom surface and wherein the one or more thermoplastic fibers are attached to the top surface.

11. The method of claim 2 , wherein the glass fiber-reinforced, continuous material includes a top surface and a bottom surface and wherein the one or more thermoplastic fibers are attached to both the top surface and the bottom surface.

12. The method of claim 2 , wherein the glass fiber-reinforced, continuous material has a width and the one or more thermoplastic fibers are positioned on, or integrated in, 5% to 50% of the width.

13. The method of claim 2 , wherein at least partially melting the one or more thermoplastic fibers precedes spirally winding, the glass fiber-reinforced, continuous material around the mandrel.

14. The method of claim 1 , further comprising applying heat, pressure, or a combination of both to the overlapping region after the adhesive is applied.

15. The method of claim 1 , wherein the glass fiber-reinforced, continuous material includes a top surface and a bottom surface and the adhesive is applied to the top surface.

16. The method of claim 4 , wherein the glass fiber-reinforced, continuous material includes a top surface and a bottom surface and the veil is attached to the top surface.

17. The method of claim 4 , wherein the veil is attached to the glass fiber-reinforced, continuous material by mechanically entangling the veil to the glass fiber-reinforced, continuous material.

18. The dry liner of claim 8 , wherein the one or more thermoplastic fibers includes polypropylene.

19. The dry liner of claim 7 , wherein the adhesive includes a powder resin, a hot melt adhesive, a liquid/solvent-based spray glue, or a combination thereof.

20. The dry liner of claim 9 , wherein the veil is mechanically entangled to the glass fiber-reinforced, continuous material.