Pipe liner and method of making and installing the same

1. An eversion liner for lining a pipe, the liner comprising:

an outer impermeable portion having an interior, the outer impermeable portion comprising a fluid-impermeable material;

inner and outer strength portions, the outer strength portion being located in the interior of the outer impermeable portion, each of the inner and outer strength portions having an interior, each of the inner and outer portions being arranged to form a respective longitudinally extending tube and comprising strengthening fibers, each of the inner and outer portions having a width and opposite first and second longitudinal edge margins spaced apart along the width, at least one of the inner and outer strength portions comprising strength material including chopped strands of fiber gathered into bundles, the bundles being oriented generally parallel to one another and distributed along said at least one of the inner and outer strength portions, each of the bundles extending in a direction from the first longitudinal edge margin to the second longitudinal edge margin of said at least one of the inner and outer strength portions, the first and second longitudinal edge margins of said at least one of the inner and outer portions being positioned adjacent one another and being attached to one another at a seam; and

a middle portion having an interior, the middle portion comprising felt, the middle portion being located in the interior of the outer strength portion, the inner strength portion being located in the interior of the middle portion

the outer impermeable portion, the inner and outer strength portions and the middle portion being arranged in layers and formed into a liner tube having a longitudinal axis, the seam joining the first and second longitudinal edge margins of said at least one of the inner and outer strength portions extending parallel to the longitudinal axis, said at least one of the inner and outer strength portions being configured for being stretched radially from a first external diameter to a second external diameter larger than the first external diameter, the seam being constructed to hold the first longitudinal edge margin from moving in a circumferential direction relative to the second longitudinal edge margin as the liner tube is stretched radially from the first external diameter to the second external diameter.

2. An eversion liner as set forth in claim 1 , wherein the chopped strands of fiber are arranged to strengthen the liner in a hoop direction of the liner tube.

3. An eversion liner as set forth in claim 1 , wherein the chopped strands of fiber extend generally parallel to the width of said at least one of the inner and outer strength portions.

4. An eversion liner as set forth in claim 1 , wherein said at least one of the inner and outer strength portions further comprises an inner felt layer and an outer felt layer, the chopped strands of fiber being sandwiched between the inner and outer felt layers.

5. An eversion liner as set forth in claim 4 , wherein the inner and outer felt layers are needle punched to the chopped strands of fiber.

6. An eversion liner as set forth in claim 4 , wherein one of the inner and outer felt layers is flame bonded to the middle portion.

7. An eversion liner as set forth in claim 1 , wherein said at least one of the inner and outer strength portions further comprises continuous strands of fiber distributed along said at least one of the inner and outer strength portions, the continuous strands of fiber being oriented parallel to one another and transverse to the chopped strands of fiber.

8. An eversion liner as set forth in claim 1 , wherein said at least one of the inner and outer strength portions further comprises a mat of random oriented chopped fibers.

9. An eversion liner as set forth in claim 1 , wherein the longitudinal edge margins of said at least one of the inner and outer strength portions are positioned in overlapping engagement to form an overlap portion having a width, the eversion liner being configured to be everted into a host pipe such that the at least one of the inner and outer strength portions expands from a first diameter to a larger second diameter without decreasing the width of the longitudinal overlap portion.

10. An eversion liner as set forth in claim 9 , wherein the longitudinal overlap portion of has a width of at least about 3.8 cm.

11. An eversion liner as set forth in claim 1 , wherein the seam comprises stitching.

12. An eversion liner as set forth in claim 1 , wherein said at least one of the inner and outer strength portions further comprises a reinforcing strip, the reinforcing strip extending along the longitudinal overlap portion and being attached to said at least one of the inner and outer strength portions at locations adjacent each of the first and second longitudinal edge margins.

13. An eversion liner as set forth in claim 1 , wherein the middle portion comprises a plurality of discrete felt layers.

14. An eversion liner as set forth in claim 13 , wherein each of the discrete felt layers is flame bonded to an adjacent one of the other discrete felt layers.

15. An eversion liner as set forth in claim 1 , wherein the middle portion comprises a number of discrete felt layers in an inclusive range of from 1 to 5 discrete felt layers.

16. An eversion liner as set forth in claim 1 , wherein the fluid-impermeable material comprises coated felt.

17. An eversion liner as set forth in claim 1 , wherein said at least one of the inner and outer strength portions includes both of the inner and outer strength portions.

18. An eversion liner as set forth in claim 1 wherein said at least one of the inner and outer strength portions is formed of a single sheet of unitary strength material.

19. A method of manufacturing a liner for lining a pipe, the method comprising:

providing a first strength layer comprising strengthening fibers;

providing at least one felt layer;

providing a second strength layer comprising strengthening fibers; and

providing an impermeable layer;

wherein at least one of the steps of providing the first strength layer and providing the second strength layer comprises:

providing strength material comprising chopped strands of fiber gathered into bundles, the bundles being oriented generally parallel to one another and distributed along the strength material, each of the bundles extending in a direction from a first longitudinal edge margin to a second longitudinal edge margin of the strength material;

forming a liner tube having a longitudinal axis from the first strength layer, said at least one felt layer, the second strength layer and the impermeable layer such that the second strength layer is located inward of the impermeable layer, said at least one felt layer is located inward of the second strength layer and the first strength layer is located inward of said at least one felt layer; and

joining first and second longitudinal edge margins of the strength material forming at least one of the first strength layer and the second strength layer together at a seam extending parallel to the longitudinal axis of the liner tube, the seam being constructed to hold the first longitudinal edge margin from moving in a circumferential direction relative to the second longitudinal edge margin as the liner tube is stretched radially from the first external diameter to the second external diameter.

20. The method as set forth in claim 19 wherein both of the step of providing the first strength layer and the step of providing the second strength layer comprise providing strength material comprising chopped strands of fiber gathered into bundles, the bundles being oriented generally parallel to one another and distributed along the strength material, each of the bundles extending in a direction from a first longitudinal edge margin to a second longitudinal edge margin of the strength material.