Cure-in-place pipe liner

Abstract

Provided are cure-in-place pipe (CIPP) liners for rehabilitation of damaged pipe. CIPP liners comprise a moisture barrier layer, a resin absorbent layer, and a thermosetting hot curing-resin impregnating the absorbent layer. The resin absorbent layer comprises a thermoplastic polyolefin component in an amount in the range of from 1 wt. % to 99 wt. % and a polyolefin recyclate component in an amount in the range of from 1 wt. % to 99 wt. %., wherein wt. % is based on the total weight of the thermoplastic polyolefin component and the polyolefin recyclate component.

Description

CURE-IN-PLACE PIPE LINERFIELD OF THE INVENTION

[0001] The present disclosure relates to pipe liners for in-place repair of damaged piping, including but not limited to, large diameter buried pipe such as a sewage system. More specifically, it is directed to liners for pipe rehabilitation with cure-in-place pipe lining (CIPP) technologies.BACKGROUND OF THE INVENTION

[0002] There has been much research and development by industry' to develop end-use applications that incorporate PCR resins and have quality and / or performance similar to or equal to corresponding end-use applications fabricated from virgin polymers. Existing and new environmental regulations provide continued motivation to develop suitable commercial uses of PCR resins while reducing the amount of waste plastics to landfill. Successful development of these commercial pathways will create demand for products incorporating PCR resins.

[0003] Plastic waste is typically segregated by polymer type. Recyclates of polypropylene (PP) and high density polyethylene (HDPE) typically have a low melt flow rate or a low melt index, respectively. Such high melt viscosities make these polyolefin recyclates difficult to process and limit the end-use applications in which they can be used directly. Another limitation for the use of recycled polyolefins is poor organoleptic properties, such as, but not limited to, the presence of unpleasant odors, taste, and / or unintended color coming from volatile organic compounds which may have been absorbed in these polymers during their usage. It would be desirable to have end uses for polymer recyclates where such characteristics are unimportant thus eliminating the need for processing steps to modify these characteristics.

[0004] A potential use of PCR resins is in cure-in-place pipe (CIPP) lining where organoleptic and / or optical properties of a polymer are typically not critical. CIPP lining is installed into an existing conduit either by pulling a cable secured to holes at the front end of the liner or by eversion of the liner while securing a hold-back cable to holes at the trailing end of the everting liner. CIPP is a method of lining a pipe with a hard, rigid pipe of thermosetting resin, wherein a tubular fibrous felt is immersed in the resin to form a carrier for the resin. The immersed felt and resin have an inflatable tube therein after insertion into a pipe by eversion. This tube is then inflated to shape the resin to the pipe inner surface. The resin is cured to form the hard, rigid lining pipe with the felt embedded therein.

[0005] US2014 / 0158244A1 discloses liner for CIPP rehabilitation comprising a layer of thermoplastic polymer material, a resin absorbent layer, thermosetting hot curing-resinimpregnating the absorbent layer, wherein said thermoplastic is a heterophasic polyolefin composition having flexural modulus equal to or lower than 200 MPa. The heterophasic polyolefin composition provides an impermeable inner layer to protect the thermosetting layer before, during, and after curing.

[0006] However, it would be desirable to blend the heterophasic polyolefin composition with one or more lower cost polymers if such blend had a desirable balance of properties. It would be further desirable if such one or more lower cost polymers included a PCR resin.SUMMARY OF THE INVENTION

[0007] The present disclosure relates to a pipe liner comprising a moisture barrier layer, a nonwoven absorbent layer, and a thermosetting hot curing-resin impregnating the absorbent layer. The moisture barrier layer comprises a thermoplastic polyolefin component in an amount in the range of from 1 wt. % to 99 wt. % and a polyolefin recy elate component in an amount in the range of from 1 wt. % to 99 wt. %. wherein wt. % is based on the total weight of the thermoplastic polyolefin component and the polyolefin recyclate component.

[0008] In some embodiments, the thermoplastic polyolefin component comprises: a) a first heterophasic copolymer, wherein a propylene homopolymer or a random copolymer (RACO) with ethylene is mixed with a bipolymer; b) a second heterophasic copolymer containing three components: A) a semi-crystalline propylene homopolymer, or random copolymer with ethylene or other alpha-olefins; B) a polyethylene homopolymer, or a polyethylene copolymer with 1 -butene or other alpha-olefins; and C) an elastomeric component consisting of a copolymer of propylene, ethylene, and optionally 1 -butene; or c) a combination thereof.

[0009] In some embodiments, the polyolefin recyclate comprises a polyethylene, a polypropylene, or a combination thereof.

[0010] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter, which form the subject matter of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other processes for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent processes do not depart from the spirit and scope of the invention as set forth in the appendedclaims. The novel features which are believed to be characteristic of the invention, both as to its structure and method of manufacture, together with further objects and advantages will be better understood from the following description.DETAILED DESCRIPTION OF THE INVENTION

[0011] Illustrative embodiments of the subject matter claimed below will now be disclosed. In the interest of clarity, some features of some actual implementations may not be described in this specification. It will be appreciated that in the development of any such actual embodiments, numerous implementation-specific decisions must be made to achieve the developer s specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort, even if complex and time-consuming, would be a routine undertaking for those of ordinary' skill in the art having the benefit of this disclosure.

[0012] The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary' meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than the broadest meaning understood by skilled artisans, such a special or clarifying definition will be expressly set forth in the specification in a definitional manner that provides the special or clarifying definition for the term or phrase. It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural references unless otherwise specified.

[0013] For example, the following discussion contains a non-exhaustive list of definitions of several specific terms used in this disclosure (other terms may be defined or clarified in a definitional manner elsewhere herein). These definitions are intended to clarify the meanings of the terms used herein. It is believed that the terms are used in a manner consistent with their ordinary' meaning, but the definitions are nonetheless specified here for clarify.Definitions

[0014] All concentrations herein are by weight percent (“wt. %”) unless otherwise specified.

[0015] As used herein, “about” means the stated value plus or minus the margin of error of measurement or plus or minus 10% if no method of measurement is indicated.

[0016] As used herein, “bipolymer” is a specific ty pe of copolymer that has elastomeric properties and a sufficient co-monomer content to create a partially amorphous phase, about 10%or more comonomer. A bipolymer is one component of the final polymer composition of a PP heterophasic copolymer or a rTPO.

[0017] As used herein, ‘'comprising” is to be interpreted as specifying the presence of the stated features, integers, steps, or components as referred to, but does not preclude the presence or addition of one or more features, integers, steps, or components, or groups thereof. Moreover, each of the terms “by”, '‘comprising,” “comprises”, “comprised of' “including," “includes,” "included,” “involving.” "involves,” "involved,” and “such as” are used in their open, non-limiting sense and may be used interchangeably. Further, the term “comprising” is intended to include examples and aspects encompassed by the terms “consisting essentially of’ and “consisting of.” Similarly, the term “consisting essentially of’ is intended to include examples encompassed by the term “consisting of.”

[0018] As used herein, “consisting essentially of’ excludes additional material elements, but allows the inclusions of non-material elements that do not substantially change the nature of the invention.

[0019] As used herein, “consisting of’ is closed and excludes all additional elements.

[0020] As used herein, “conversion” is used to denote the percentage of a component fed which disappears across a reactor.

[0021] As used herein, “copolymer” refers to a polyolefin polymer that contains two types of alpha-olefin monomer units.

[0022] As used herein, “eversion” refers to the process of inserting the CIPP liner by turning it inside out as it is pushed or pulled into the host pipe. Eversion is typically achieved using water or air pressure. Eversion is described in U.S. Pat. No. 5,919,327, the contents of which are fully incorporated herein by reference.

[0023] As used herein, “HDPE” means ethylene homopolymers and ethylene copolymers produced in a suspension, solution, slurry, or gas phase polymerization process and having a density in the range of 0.940 g / cm3to 0.970 g / cm3.

[0024] As used herein, “heterophasic copolymer” or “heco” refers to a reactor blend of homopolymers and / or copolymers that contains two components: A) a semi-crystalline polypropylene matrix and B) a bipolymer component. The polypropylene matrix may be a homopolymer (HOMO) PP or a random copolymer (RACO) PP of propylene with ethylene or other alpha-olefins. The bipolymer is dispersed within the semi-crystalline polypropylene matrix.

[0025] As used herein, “homopolymer” or “HOMO” refers to a polymer consisting solely or essentially of units derived from a single kind of monomer, e.g., polyethylene homopolymer is apolymer comprised solely or essentially of units derived from ethylene, and polypropylene homopolymer is a polymer comprised solely or essentially of units derived from propylene.

[0026] As used herein, “intrinsic viscosity” refers to the measure of a solute’s contribution to the viscosity of a solution. Here, the solution used is decalin at 135°C, unless otherwise specified. The ‘solute’ can be the base resin or one of the base resin's individual components or copolymers or bipolymers or the fraction of the base resin that is soluble in xylene at room temperature. Room temperature is approximately 25°C.

[0027] As used herein. “LDPE” means ethylene homopolymers and / or ethylene copolymers produced in a high pressure free radical polymerization and having a density in the range of 0.910 g / cm3to 0.940 g / cm3.

[0028] As used herein, “LLDPE” means ethylene copolymers produced in a suspension, solution, slurry, or gas phase polymerization process and having a density in the range of 0.910 g / cm3to 0.940 g / cm3.

[0029] As used herein, “MDPE” means ethylene copolymers produced in a suspension, solution, slurry, or gas phase polymerization process and having a density in the range of 0.925 g / cm3to 0.940 g / cm3.

[0030] As used herein, “melt flow rate” and “MFR” are used interchangeably to refer to the measure of the ability’ of the melt of the base resin to flow under pressure. The melt flow rate can be determined by ASTM D 1238L (“Standard Test Method for Melt Flow Rates of Thermoplastics by Extrusion Plastometer”), both of which measure the melt flow rate at 230°C and 2.16 Kg of weight. The “melt flow range” is a range of melt flow rates.

[0031] As used herein, “olefin” and alternatively referred to as “alkene,” is a linear, branched, or cyclic compound of carbon and hydrogen having at least one double bond.

[0032] As used herein, “polyolefin recyclate” means post-consumer recycled (“PCR”) polymer and / or post-industrial recycled (“PIR”) polymer. Polyolefin recyclate is derived from an end product that has completed its life cycle as a consumer item and would otherwise be disposed of as waste (e.g., a polyethylene water bottle) or from plastic scrap that is generated as waste from an industrial process.

[0033] As used herein, “polyolefin” in some embodiments is a type of polymer with the general formula (CH2CHR)nwhere R is an alkyl group, including, but not limited to LDPE, LLDPE, MDPE, HDPE, and PP. PP consists of, but is not limited to, propylene homopolymers, random copolymer, impact (heterophasic or block) copolymers and compounds thereof.

[0034] As used herein, “processability’7refers to how well a polymer composition can be formed into a film (cast, blown, water quenched or mono or biaxially oriented) of commercial quality or molded by injection, compression or rotational molding or extruded into a fiber, sheet, coating, corrugated board, profile or thermoformed or other form into an article of commercial quality at commercially acceptable rates using the equipment and conditions.

[0035] As used herein, “thermoplastic polyolefins” or “TPOs” are used to refer to polyolefins that become pliable or moldable above a specific temperature and solidify upon cooling. The terms “Reactor made thermoplastic polyolefins” or “reactor thermoplastic polyolefins” or “rTPO” are used interchangeably to refer to thermoplastic polyolefins that are made in a reactor system. The present disclosure uses tw o types of rTPOs for its foamed compositions. The first is a heterophasic copolymer having a semi-crystalline polypropylene matrix with greater than 30% bipolymer content by weight. The second rTPO has a semi- crystalline polypropylene matrix with a polyethylene homopolymer or a polyethylene copolymer with 1 -butene or other alpha olefin, and, an elastomeric component consisting of a copolymer of propylene, ethylene, and optionally 1- butene. The first and second heterophasic polymers disclosed herein are rTPOs.

[0036] As used herein, “virgin” with respect to polymers, means pre-consumer polymers. Preconsumer polymers are obtained directly or indirectly from petrochemical, bio-based renewable and advanced chemical recycled polyolefin recy elate feedstocks fed to a polymerization apparatus. Pre-consumer polyolefins can be subjected to post polymerization processes such as, but not limited to, extrusion, pelletization, visbreaking, devolatization, oligomer removal, steam treatment, compounding and / or other processing completed before the product reaches the enduse consumer. In some embodiments, virgin polymer may have a single heat history. In some embodiments, a virgin polymer has more than one heat history. In some embodiments, a virgin polymer comprises no additives. In some embodiments, a virgin polymer comprises additives.

[0037] As used herein, “a-olefin” or “alpha-olefin” means an olefin of the general formula CH2=CH — R, wherein R is a linear or branched alkyl containing from 1 to 10 carbon atoms. The a-olefin can be selected, for example, from propylene, 1-butene. 1-pentene, 1-hexene. 1-octene. 1- dodecene, and the like.

[0038] In the present description, the terms “monomer” and “comonomer” are used interchangeably. The terms mean any compound with a polymerizable moiety’ that is added to a reactor in order to produce a polymer. In those instances, in which a polymer is described as comprising one or more monomers, e.g., a polymer comprising propylene and ethylene, the polymer, of course, comprises units derived from the monomers, e.g., — CH2 — CH2 — , and not the monomer itself, e.g., CH2=CH2. For example, when a copolymer is described as having an"ethylene’’ content of 35 wt.% to 55 wt.%. it is understood that the "mer ” unit in the copolymer is derived from ethylene in the polymerization reaction and the derived units are present at 35 wt.% to 55 wt.%, based upon the weight of the copolymer.Pipe liner

[0039] Disclosed herein are pipe liners comprising a moisture barrier layer, a nonwoven absorbent layer, and a thermosetting hot curing-resin impregnating the absorbent layer. The moisture barrier layer herein comprises a blend of a thermoplastic polyolefin (TPO) and a polyolefin recyclate. The blend composition is produced by melt blending the TPO component and the polymer recyclate component in amounts sufficient to result in the blend composition having sufficient flexibility and strength to permit everting the multilayer liner into the damaged pipe that is to be rehabilitated. The blend composition further provides a moisture barrier to allow use of steam and / or hot water to cure the thermosetting hot curing-resin impregnating the absorbent layer while preventing leakage of moisture into the absorbent layer and / or leakage of the thermosetting hot curing-resin into the inner diameter of the pipe.Moisture barrier laver

[0040] The Moisture barrier layer comprises blend composition of a thermoplastic polyolefin component and a polyolefin recyclate component. The TPO component comprises one or more first heterophasic copolymers as described herein, one or more second heterophasic copolymers as described herein, or a combination thereof. In some embodiments, the blend composition comprises the thermoplastic polyolefin component in an amount in the range of from 1 wt. % to 99 wt. %, and the polymer recyclate component in an amount in the range of from 1 wt. % to 99 wt. %.

[0041] In some embodiments, the blend composition has a flexural elastic modulus (MEF) ISO 178 less than or equal to 350 MPa, less than or equal to 300 MPa, less than or equal to 250 MPa, less than or equal to 200 MPa, or less than or equal to 180 MPa. In some embodiments, the blend composition has a flexural elastic modulus greater than or equal to 40 MPa, greater than or equal to 60 MPa, greater than or equal to 80 MPa, greater than or equal to 100 MPa, or greater than or equal to 120 MPa.- TPO

[0042] In some embodiments, the TPO component comprises a first heterophasic copolymer, wherein a propylene homopolymer or a random copolymer (RACO) with ethylene is mixed with a bipolymer. In some embodiments, the TPO component comprises a second heterophasic copolymer containing three components: A) a semi-crystalline propylene homopolymer, orrandom copolymer with ethylene or other alpha-olefins; B) a polyethylene homopolymer, or a polyethylene copolymer with 1 -butene or other alpha-olefins; and, C) an elastomeric component consisting of a copolymer of propylene, ethylene, and optionally 1 -butene. In some embodiments, the TPO component comprises one of more first heterophasic copolymers, one or more second heterophasic copolymers, or a combination thereof.+ First heterophasic copolymers

[0043] A first ty pe of first heterophasic copolymer comprises:(A) from about 8 to about 25% by weight of a cry stalline polymer fraction selected from the group consisting of (i) a propylene homopolymer having solubility’ in xylene at room temperature lower than 10% by weight; and (ii) a copolymer of propylene and at least one alpha-olefin of formula H2C=CHR, where R is H or a C2-C6 linear or branched alkyl, containing at least 85% by weight of propylene, having solubility7in xy lene at room temperature lower than 15% by weight; and(B) from about 75 to about 92% by weight of an elastomeric fraction comprising(i) a first elastomeric copolymer of propylene with at least one alpha-olefin of formula H2C=CHR, where R is H or a C2-C6 linear or branched alky l, optionally containing 0.5 to 5% by weight of a diene, the first elastomeric copolymer containing from about 15 to 32% by weight alpha-olefin, and having solubility in xylene at room temperature greater than 50% by weight, the intrinsic viscosity of the xylene soluble fraction ranging from about 3.0 to 5.0 dl / g; and(ii) a second elastomeric copolymer of propylene with at least one alpha-olefin of formula H2C=CHR, where R is H or a C2-C6 linear or branched alky l, optionally containing 0.5 to 5% by weight of a diene, the second elastomeric copolymer containing more than 32% up to 45% by weight alpha-olefin, and having solubility7in xylene at room temperature greater than 80% by weight, the intrinsic viscosity of the xylene soluble fraction ranging from about 4.0 to6.5 dl / g; wherein the (b.i) / (b.ii) weight ratio ranges from about 1:5 to 5: 1.

[0044] The total weight of (A) + (B) is 100 wt. %. In further embodiments of the first type of first heterophasic copolymer has: a flexural modulus lower than 60 MPa; a Shore A hardness lower than 90; a tension set at 100% lower than 35%; a melt flow rate between 0.1 and 10 g / 10 min..wherein the melt flow rate values are measured according to ASTM D 1238; or any combination thereof.

[0045] A second type of first heterophasic copolymer comprises:(A) from about 10 to 70% by weight of a copolymer of propylene and one or more comonomers) selected from ethylene and CH2=CHR alpha-olefins where R is a 2-8 carbon alkyl, wherein the copolymer contains from about 0 to 8% of co-monomer(s); and(B) from about 30 to 90% by weight of a copolymer of ethylene and (i) propylene or (ii) CH2=CHR alpha-olefins, where R is a 2-8 carbon alkyl radical, or (iii) a combination thereof, optionally with minor amounts of a diene, with this copolymer containing from about 50% to 80% of ethylene.

[0046] The total weight of (A) + (B) is 100 wt. %. In further embodiments of the second type of first heterophasic copolymer has an intrinsic viscosity [T|] of a fraction soluble in xylene at room temperature (XS) of 1.8 dl / g or more.

[0047] A third type of first heterophasic copolymer comprises:(A) from 30% to less than 70% of a semi-crystalline polypropylene component selected from the group consisting of a propylene homopolymer, a random copolymer of propylene containing up to 8% of ethylene, a random copolymer of propylene containing up to 8% of at least one C4-C10 a-olefin, or any combination thereof, wherein the semi-crystalline polypropylene component has a monomodal molecular weight distribution; and(B) greater than 30% to about 70% of a bipolymer component of propylene and at least one co-monomer selected from ethylene and / or C4-C10 a-olefins, wherein the bipolymer itself has from about 50% to about 75% of propylene, wherein the bipolymer is partially soluble in xylene at room temperature and has an intrinsic viscosity of from about 4 to 7.5 dl / g (in decalin).

[0048] The total weight of (A) + (B) is 100 wt. %. In further embodiments of the third type of first heterophasic copolymer has: a MFR between 0.35 and 1 g / 10 min.; an intrinsic viscosity of the xylene soluble fraction from about 4 dL / g to 6 dL / g (in decalin); or a combination thereof.

[0049] A fourth type of first heterophasic copolymer comprises:(A) from about 60 to 85% by weight of a broad molecular weight distribution propylene polymer having a poly dispersity index from about 5 to 15 and melt flow rate of from about 40 to 75 g / 10 min.; and(B) from about 15 to 40% by weight of a partially xylene-soluble olefin polymer rubber consisting of a poly(ethylene-co-propylene) containing at least 65% by weight of ethylene, wherein the xylene-insoluble content of (B) is 25- 40% by weight, measured by dissolving the polymer in xylene at 135°C, cooling the solution to 25°C. allowing to settle for 30 minutes, followed by filtering.

[0050] The total weight of (A) + (B) is 100 wt. %. In further embodiments of the fourth type of first heterophasic copolymer has a MFR in the range of from 5 to 20 g / 10 min.

[0051] A fifth type of first heterophasic copolymer comprises:(A) from about 25 to 50% by weight of a crystalline propylene homopolymer with a solubility in xylene at room temperature of less than or equal to 4%, or a crystalline copolymer of propylene with ethylene or a C-i-Cs alpha-olefin having an ethylene or alpha-olefin content 0.5 to 3%, and a solubility in xylene at room temperature of from less than or equal to 4%; and(B) from about 50 to 75% by weight of a partially amorphous copolymer of ethylene with a C4-C8 alpha-olefin, wherein the alpha-olefin content is from about 10 to 20%, and the copolymer is from about 10 to 40% soluble in xylene at room temperature.

[0052] The total weight of (A) + (B) is 100 wt.+ Second heterophasic copolymers

[0053] A first type of second heterophasic copolymer comprises:(A) from about 5 to 35% by weight of a propylene-based polymer containing 90% by weight or more of propylene units and 10% by weight or less of a fraction soluble in xylene at 25 °C;(B) from about 25 to 50% by weight of an ethylene homopolymer containing 5% by weight or less of a fraction soluble in xylene at 25°C; and(C) from about 30 to 60% by weight of a copolymer of ethylene and propylene containing from about 25% to 75% by weight of ethylene units and containing from about 55% to 95% by weight of a fraction soluble in xylene at 25°C.

[0054] The total weight of (A) + (B) + (C) is 100 wt. %. In further embodiments of the first type of second heterophasic copolymer has: a total content the ethylene units (as determined byinfrared analysis) of 50% by weight or higher; a melt flow rate between 1.0 and 5.0 g / 10 min.; or a combination thereof.

[0055] A second type of second heterophasic copolymer comprises:(A) from about 5 to 35% by weight of a propylene-based polymer containing 90% by weight or more of propylene units and 10% by weight or less of a fraction soluble in xylene at 25 °C;(B) from about 25 to 50% by weight of a copolymer of ethylene and a Cs-Cs alpha-olefin containing from about 0.1% to 20% by weight of alpha-olefin units and 75% byweight or less of a fraction soluble in xylene at 25°C; and(C) from about 30 to 60% by weight of a copolymer of ethylene and propylene containing from about 25% to 75% by weight of ethylene units and containing from about 55% to 95% by weight, of a fraction soluble in xylene at 25°C.

[0056] The total weight of (A) + (B) + (C) is 100 wt. %. In further embodiments of the second type of second heterophasic copolymer has: a total content of the C3-C8 alpha-olefin units (as determined by infrared analysis) of 3% by weight or higher; a melt flow rate between 0. 1 and 6 g / 10 min.; or a combination thereof.

[0057] A third type of second heterophasic copolymer comprises:(A) from about 10 to 60% by weight of a homopolymer of propylene with isotactic index greater than 80, or a copolymer having over 85% by weight of propylene with (i) ethylene or (ii) CH2=CHR alpha-olefins, where R is a 2-8 carbon alkyl radical, or combinations of (i) and (ii);(B) from about 5 to 20% parts by weight of a copolymer fraction containing ethylene that is insoluble in xylene at ambient temperature; and(C) from about 37 to 80% by weight of a copolymer fraction of ethylene and (i) propylene or (ii) another CH2=CHR a-olefin, or combinations of (i) and (ii), and, optionally, minor portions of a diene, wherein component (C) is less than 40% byweight of ethylene, being soluble in xylene at ambient temperature, and having an intrinsic viscosity from about 1.5 to 5 dl / g.

[0058] The total weight of (A) + (B) + (C) is 100 wt. %. and the percent by weight of the sum of the (B) and (C) components with respect to the total polyolefin composition is from about 40% to 90% and the (B) / (C) weight ratio is lower than 0.4. In further embodiments of the third type of second heterophasic copolymer has a MFR in the range of from 0.35 and 35 g / 10 in.

[0059] A fourth type of second heterophasic copolymer comprises:(A) from about 5 to 35% by weight of a propylene and ethylene copolymer having 15% by weight or less of a fraction soluble in xylene at 25°C (XSA) referred to the weight of A, and having from about 0.5 wt. % to 7.0 wt. % of ethylene derived units;(B) from about 20 to 50% by weight of an ethylene homopolymer having 5% by weight or less of a fraction soluble in xylene at 25°C (XSB) referred to the weight of (B); and(C) from about 30 to 60% by weight of a terpolymer, wherein the terpolymer contains propylene, about 45% to 65% by weight of ethylene derived components, and from about 15% to 38% by weight of 1-butene derived components, wherein the terpolymer has from about 30% to 85% by weight of a fraction soluble in xylene at 25°C (XSc), the amount of ethylene units; 1-butene units and the fraction XSc being referred to the weight of (C).

[0060] The total weight of (A) + (B) + (C) is 100 wt. %. In further embodiments, the fourth type of second heterophasic copolymer has MFR in the range of from 0.8 and 20 g / 10 min.

[0061] A fifth type of second heterophasic copolymer comprises:(A) from about 5 to 35% by weight of a propylene homopolymer containing 10% by weight or less of a fraction soluble in xylene at 25°C (XSA), the amount of the fraction XS being referred to the weight of (A);(B) from about 20 to 50% by weight of an ethylene homopolymer having 5% by weight or less of a fraction soluble in xylene at 25°C (XSB) referred to the weight of (B); and(C) from about 30 to 60% by weight of a terpolymer, wherein the terpolymer contains propylene, about 45% to 65% by weight of ethylene derived components, and from about 15% to 38% by weight of 1-butene derived components, wherein the terpolymer has from about 30% to 85% by weight of a fraction soluble in xylene at 25°C (XSc), the amount of ethylene units; 1-butene units and the fraction XSc being referred to the weight of (C).

[0062] The total weight of (A) + (B) + (C) is 100 wt. %. In further embodiments, the fifth type of second heterophasic copolymer has a MFR in the range of from 0.8 to 20 g / 10 min.

[0063] In some embodiments, the first and second heterophasic compositions can be prepared by blending components (A), (B), and when present (C) in the molten state, which is to say at temperatures greater than their softening or melting point. In some embodiments, the first and second heterophasic compositions can be prepared by sequential polymerization in the presenceof a highly stereospecific Ziegler-Natta catalyst. In particular, the catalyst system used comprises (i) a solid catalytic component containing a titanium compound and an electron-donor compound, both supported on magnesium chloride, and (ii) an Al trialkyl compound and optionally an electron-donor compound. Other catalysts that may be used are metallocene-type catalysts, as described in U.S. Pat. No. 5.324,800 and EP-A-0 129 368; particularly advantageous are bridged bis-indenyl metallocenes, for instance as described in U.S. Pat. No. 5,145,819 and EP-A-0 485 823.Polyolefin recyclate

[0064] In some embodiments, the polyolefin recyclate is a polypropylene. In some embodiments, the polypropylene comprises units derived from propylene and units derived from one or more of ethylene and C4-C20 alpha-olefins or mixtures thereof. In some embodiments, the polypropylene comprises a polypropylene impact copolymer, a polypropylene random copolymer, or a combination thereof. In some embodiments, the polypropylene recyclate has a melt flow rate less than or equal to 125 dg / min. but more typically less than or equal to 35 dg / min and preferably less than or equal to 2.0 dg / min. (2.16 kg, 230°C).

[0065] Polypropylene recyclate comprises a PCR resin containing recyclates derived from propylene homopolymers and copolymers, including plastomers, having of units derived from propylene and units derived one or more of ethylene and C4-C20 alpha-olefins or mixtures thereof. Preferably, the units derived from one or more of ethylene and C4-C10 alpha-olefin comonomers are present in amounts up to 35 wt. %, based upon the total weight of the copolymer of propylene. The propylene homopolymers and copolymers can be produced using either Ziegler Natta or single-site catalysts, e.g., metallocene catalysts. The propylene homopolymers and copolymers can be produced using a gas phase process, liquid process (condensed monomer), slurry process, or solution process or combination thereof. In some embodiments, when the propylene polymer is a copolymer, it preferably contains 0.4 to 18% copolymer, more typically 2 to 6 wt. %, based upon the total w eight of the copolymer, of ethylene derived units as a comonomer.

[0066] In some embodiments, a polypropylene recyclate to be modified by the process herein comprises a polypropylene homopolymer, a random copolymer polypropylene, an impact copolymer polypropylene, or a combination thereof. In some embodiments, propylene homopolymers have an isotactic index of at least 90. In some embodiments random copolymer polypropylene comprise random copolymers of propylene and ethylene or buty lene, or random terpolymers of propylene, ethylene, butylene and hexene, wherein the maximum ethylene content, or ethylene plus alpha-olefin content, is 10% by weight, and the random copolymer polypropylene has an isotactic index of at least 80. In some embodiments, the impact copolymer polypropylenecomprises a heterophasic propylene polymer materials consisting essentially of by weight, (i) 99-55% of a polymeric material selected from the group consisting of a propylene homopolymer having an isotactic index greater than 90, and a crystalline copolymer of propylene and an alpha-olefin of the formula CH2=CHR, where R is H or a 2-6 carbon linear or branched alkyl group, having an isotactic index of at least 80, the alpha-olefin being less than 10% of the copolymer, and (ii) 1-45% of an elastomeric olefin polymer of propylene and an olefinic material selected from the group consisting of alpha-olefins of the formula CH2=CHR, where R is H or a 2-6 carbon linear or branched alkyl group, the alpha-olefin being 50-70% of the elastomeric polymer.

[0067] In some embodiments, the polyolefin recyclate is a polyethylene recyclate. In some embodiments, the polyethylene recyclate comprises units derived from ethylene and units derived from one or more of C3-C20 alpha-olefins or mixtures thereof. In some embodiments, the polyethylene recyclate comprises a high density polyethylene, a medium density' polyethylene, a low density polyethylene, a linear low density polyethylene, or a combination thereof. In some embodiments, the polyethylene recyclate has a melt index less than or equal to 160 dg / min. but more typically less than or equal to 20 dg / min. and preferably less than or equal to 2.0 dg / min. (2.16 kg, 190°C).

[0068] In some embodiments, a polyethylene recyclate to be modified by the process herein comprises a PCR resin containing recy elates derived from a low density polyethylene (LDPE), a high density' polyethylene (HDPE), a copolymer of ethylene with a C3-10 alpha-olefin, (generally referred to as linear low density polyethylene (LLDPE)), of commerce are normally solid, somewhat flexible, thermoplastic polymers formed by the polymerization of the particular monomer(s) by various methods well known in the art. For example, such polymers can be prepared by free-radical polymerization at high pressures, or by low pressure processes, such as fluidized-bed, gas phase technology', with molybdenum-based catalysts, with chromium-based catalysts, with vanadium-based catalysts, with Ziegler-Natta catalysts systems, or with metallocene catalyst systems. The high pressure processes produce polymers with long chain branching and the low pressure processes produce essentially linear polymers with controlled levels of short chain branching. In Ziegler-Natta catalyst systems, the catalyst is formed by an inorganic compound of a metal of Groups I-III of the Periodic Table, (for example, an aluminum alkyl), and a compound of a transition metal of Groups IV-VIII of the Periodic Table, (for example, a titanium halide). A typical crystallinity' is about 21 to about 75 wt. % by the method of Wunderlick & Guar, J. Phys. Chem. Ref. Data, Vol 10, No. 1 (1981). Also, the typical melt indexof said ethylene homopolymers or copolymers is from 0.2 and 50 g / 10 minutes (measured according to ASTM 1238, Condition E).

[0069] Suitable polyethylenes for a polyolefin recyclate include ethylene homopolymers and copolymers of units derived from ethylene and units derived from one or more of C3-C20 alphaolefins or mixtures thereof. In some embodiments, the units derived from the one or more Cs-Cs alpha-olefin comonomers are present in amounts up to 15 wt. %. based upon the total weight of the copolymer of ethylene. The ethylene homopolymers and copolymers can be produced using either Ziegler Natta catalyst, chromium-based catalyst, vanadium-based catalyst or single-site catalyst, e.g., metallocene catalyst. The ethylene homopolymers and copolymers can be produced using a gas phase process, high pressure process, slurry process, or solution process. Ethylene homopolymers and ethylene-CT-Cs alpha-olefin copolymers include very low density polyethylene (VLDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE) and high density polyethylene (HDPE). VLDPE is defined as having a density of 0.860 to 0.910 g / cm3, as measured by ASTM D-1505 “Column Method.” LDPE and LLDPE are defined as having densities in the range of from 0.910 to 0.930 g / cm3. MDPE is defined as having a density of 0.930 to 0.945 g / cm3. HDPE is defined as having a density of at least 0.945 g / cm3, preferably from 0.945 to 0.969 g / cm1. The ethylene homopolymers and copolymers preferably have melt indexes (Mis), as measured by ASTM D 1238, condition 19O°C / 2.16 kg. from 0.01 to 400 dg / min., preferably, from 0.1 to 200 dg / min., more preferably from I to 100 dg / min.

[0070] In some embodiments, LDPE homopolymers can be produced in a high pressure, free- radical polymerization process, such as in one or more tubular reactors, one or more autoclave reactors, or a combination thereof. Operating conditions for the high-pressure process can include, but are not limited to, a pressure in the range of from 70 MPa to 700 MPa and a temperature in the range of from !50°C to 500°C. Such homopolymers have a high degree of long-chain branching and a density in the range of from 0.910 g / cm3to 0.940 g / cm3.

[0071] In some embodiments, LDPE copolymers of ethylene and C3-C12 alpha-olefins can be produced in a high pressure, free-radical polymerization process, such as in one or more tubular reactors, one or more autoclave reactors, or a combination thereof. Such C3-C12 alpha-olefins include, but are not limited to, substituted or unsubstituted C3 to C12 alpha olefins such as propylene, butene, pentene, hexene, heptene, octene, nonene, decene, undecene, dodecane, and isomers thereof. When present, comonomers can be present in amounts up to 15 wt. %, 10 wt. %, or 5 wt. %. Operating conditions for the high-pressure process can include, but are not limited to, a pressure in the range of from 70 MPa to 700 MPa and a temperature in the range of from 150°Cto 500°C. Such homopolymers have a high degree of long-chain branching and a density in the range of from 0.910 g / cm3to 0.940 g / cm3.

[0072] LDPE as described above, can be characterized by having: i) a density in the range of from 0.910 g / cm3to 0.940 g / cm3or from 0.915 g / cm3to 0.935 g / cm3; ii) a melt index (2.16 kg, 190°C) less than or equal to 70 g / 10 min., less than or equal to 2.0 g / 10 min., less than or equal to 0.5 g / 10 min., less than or equal to 0.2 g / 10 min., or less than or equal to 0.1 g / 10 min.; iii) a molecular weight distribution (Mw / Mn) greater than 4.0, greater than 8.0, or greater than 15, and / or less than 35, less than 30, or less than 25; iv) a weight average molecular weight (Mw) greater than or equal to 100,000 daltons, greater than or equal to 150,000 daltons, greater than or equal to 200,000 daltons, or greater than or equal to 250,000 daltons, and / or less than or equal to 600,000 daltons, less than or equal to 500,000 daltons, less than or equal to 400,000 daltons, or less than or equal to 300,000 daltons; and v) a melt elasticity (“ER”) greater than or equal to 1.0, greater than or equal to 1.4, or greater than or equal to 2.0.

[0073] It should be noted that the polyolefins described above, both polyethylene and polypropylene, are the virgin polymers that entered the stream of commerce. The polyolefin recy elates herein are what is recovered after use and disposal by the consumer or post-industrial use. Consumer waste plastic is collected, sorted, and processed to produce various grades of polyolefin recyclates. The original properties are lost by reprocessing of a mixture of multiple polymers and typically have higher molecular weight than is desirable for reuse in manyapplications. The polyolefin recyclates also contain contaminants such as volatile organic compounds, which make the polyolefin recyclates unsuitable for reuse in many applications.Nonwoven absorbent layer

[0074] In some embodiments, the nonwoven absorbent layer comprises a nonwoven polyester felt, a nonwoven fiberglass mat, a nonwoven aramid felt, a nonwoven carbon fiber felt, nonwoven polyethylene terephthalate felt, or a combination thereof.

[0075] In some embodiments, nonwoven polyester felt is used as a resin absorbent layer in CIPP liners. Nonw oven polyester felt is composed of polyester fibers bonded together without weaving or knitting, resulting in a fabric that is both flexible and strong. The nonwoven structure allows for uniform distribution and impregnation of the thermosetting resin, ensuring that the entire felt layer is thoroughly saturated.

[0076] In some embodiments, a polyester mat comprises polyethylene terephthalate (“PET”). Polyester reinforcement layers typically range from about 120 to 250 grams per square meter (g / m2) in w eight, which translates to a thickness of about 0.3 to 0.8 mm, depending on the density and manufacturing specifications. In addition to excellent tensile strength, durability, andresistance to punctures and tears, polyester mats can absorb a bit of the bitumen, creating a strong bond with the moisture boundary layer.

[0077] In some embodiments, a nonwoven fiberglass mat is used as a resin absorbent layer where the damaged pipe to be rehabilitated is in a high temperature service having exposure to high or low pH, organic solvents, or hydrocarbon products. Nonwoven fiberglass mats are made from fine glass fibers that are bonded together in a nonwoven format having an open structure that allows the curable resin to penetrate deeply. Fiberglass mats have high tensile strength and are highly resistant to heat and chemicals, making them suitable for applications where the rehabilitated pipe will be exposed to harsh conditions.

[0078] In some embodiments, a fiberglass reinforcement layer is typically around 50 to 120 g / m2, which translates to a thickness of approximately 0.2 to 0.5 millimeters. Fiberglass layers are generally thinner and lighter than comparable polyester layers. Fiberglass mats provide high tensile strength and do not stretch or shrink significantly, which helps the membrane maintain its shape and size under temperature changes and other environmental conditions. Fiberglass is also highly resistant to rot and decay.

[0079] In some embodiments, a nonwoven aramid felt provides high strength and thermal stability where the damaged pipe to be rehabilitated is in a high pressure, high temperature application. Certain aramid fibers, such as but not limited to Kevlar™ (available from DuPont de Nemours. Inc.), have high tensile strength as well as resistance to heat and abrasion. Nonwoven aramid felt can absorb curable resin effectively, ensuring a strong and uniform bond upon curing.

[0080] In some embodiments, a nonwoven carbon fiber felt is selected for its exceptional strength-to-weight ratio and high stiffness as well as excellent thermal and chemical resistance. This material is particularly suitable for high-performance applications where minimal weight and maximum strength are required.Thermosetting hot curing-resin

[0081] In some embodiments, the thermosetting resin comprises a polyester, a vinyl ester, an epoxy resins, or a combination thereof. Selection of a thermosetting resin composition is based on the available curing conditions and / or the long-term operating conditions of the damaged pipe to be rehabilitated. Each of these resins offers unique properties that make them suitable for certain applications and conditions.

[0082] In embodiments relevant to municipal sewer lines, stormwater drains, and residential and commercial plumbing systems, polyester resin can be selected for its cost effectiveness, ease of handling, and / or quick curing times. It is formed by the reaction of dibasic organic acids withdiols and may contain styrene as a reactive diluent to facilitate the curing process. Polyester resins are suitable for general purpose application requiring only good mechanical properties, limited exposure to high temperatures, and moderate chemical resistance. In some embodiments, a polyester resin comprises one or more orthophthalic polyester resins, one or more isophthalic polyester resins, one or more dicyclopentadiene (DCPD) polyester resins, or a combination thereof.

[0083] In embodiments subject to exposure to chemicals, such as but not limited to acids, alkalis, and solvents, vinyl ester resins can be selected and further, have better mechanical properties and higher thermal stability7than polyester resins. Vinyl ester resins are hybrids of polyester resins and epoxy resins. Vinyl ester resins are created by reacting an epoxy resin with an unsaturated monocarboxylic acid, such as methacry lic acid. The curing process for vinyl ester resins involves catalysts, such as but not limited to organic peroxides, and requires precise handling for optimal performance. In some embodiments, a vinyl ester resin comprises one or more bisphenol-A epoxy vinyl ester resins, one or more novolac epoxy vinyl ester resins, one or more brominated vinyl ester resins, or a combination thereof.

[0084] In embodiments subject to exposure to a wide range of chemicals, including but not limited to solvents, acids, and bases, epoxy resins provide exceptional strength, adhesion, and chemical resistance, making it suitable for the most demanding CIPP applications. Epoxy resins are derived from the reaction of epichlorohydrin with bisphenol-A or similar compounds and require a curing agent, such as an amine or anhydride, to initiate the cross-linking process. This results in a highly durable and rigid structure that can withstand significant mechanical stress and high temperatures. In some embodiments, an epoxy resin comprises one or more bisphenol-A epoxy resins, one or more bisphenol-F epoxy resins, one or more novolac epoxy resins, one or more cycloaliphatic epoxy resins, one or more glycidyl amine epoxy resins, or a combination thereof.

[0085] In some embodiments, the thermosetting hot curing-resin suitable for the present invention is a polyester resin formulated for hot curing around 80-85°C.Certain Embodiments

[0086] Disclosed is a multilayer pipe liner installed by eversion of the liner into a damaged pipe in need of rehabilitation. In a first set of embodiments, the pipe liner comprises a moisture barrier layer, a nonwoven absorbent layer, and a thermosetting hot curing-resin impregnating the absorbent layer. The moisture barrier layer comprises a thermoplastic polyolefin component in an amount in the range of from 1 wt. % to 99 wt. % and a polyolefin recyclate component in an amount in the range of from 1 wt. % to 99 wt. %, wherein wt. % is based on the total weight of thethermoplastic polyolefin component and the polyolefin recyclate component. In some embodiments, the moisture barrier layer has as flexural elastic modulus (MEF) ISO 178 less than or equal to 350 MPa. equal to 350 MPa, less than or equal to 300 MPa, less than or equal to 250 MPa, less than or equal to 200 MPa, or less than or equal to 180 MPa. In some embodiments, the blend composition has a flexural elastic modulus greater than or equal to 40 MPa, greater than or equal to 60 MPa, greater than or equal to 80 MPa, greater than or equal to 100 MPa, or greater than or equal to 120 MPa.

[0087] In a second set of embodiments, in addition to the limitations of each embodiment in the first set of embodiments, the thermoplastic polyolefin component comprises: a first heterophasic copolymer, wherein a propylene homopolymer or a random copolymer (RACO) with ethylene is mixed with a bipolymer; a second heterophasic copolymer containing three components: A) a semi-crystalline propylene homopolymer, or random copolymer with ethylene or other alpha-olefins; B) a polyethylene homopolymer, or a polyethylene copolymer with 1 -butene or other alpha-olefins; and C) an elastomeric component consisting of a copolymer of propylene, ethylene, and optionally 1 -butene; or a combination thereof.

[0088] In a third set of embodiments, in addition to the limitations of each embodiment in the second set of embodiments, the first heterophasic copolymer comprises:(A) from about 8 to about 25% by weight of a crystalline polymer fraction selected from the group consisting of (i) a propylene homopolymer having solubility in xylene at room temperature lower than 10% by weight; and (ii) a copolymer of propylene and at least one alpha-olefin of formula H2C=CHR, where R is H or a C2-C6 linear or branched alkyl, containing at least 85% by weight of propylene, having solubility in xylene at room temperature lower than 15% by weight; and(B) from about 75 to about 92% by weight of an elastomeric fraction comprising(i) a first elastomeric copolymer of propylene with at least one alpha-olefin of formula H2C=CHR, where R is H or a C2-C6 linear or branched alkyl, optionally containing 0.5 to 5% by weight of a diene, the first elastomeric copolymer containing from about 15 to 32% by weight alpha-olefin, and having solubility in xylene at room temperature greater than 50% by weight, the intrinsic viscosity of the xylene soluble fraction ranging from about 3.0 to 5.0 dl / g; and(li) a second elastomeric copolymer of propylene with at least one alpha-olefin of formula H2C=CHR, where R is H or a C2-C6 linear or branched alkyl, optionally containing 0.5 to 5% by weight of a diene, the second elastomeric copolymer containing more than 32% up to 45% by weight alpha-olefin, and having solubility in xylene at room temperature greater than 80% by weight, the intrinsic viscosity of the xylene soluble fraction ranging from about 4.0 to 6.5 dl / g; wherein the (b.i) / (b.ii) weight ratio ranges from about 1 :5 to 5: 1 , and wherein the total weight of (A) + (B) is 100 wt. %.

[0089] In a fourth set of embodiments, in addition to the limitations of each embodiment in the second set of embodiments, the first heterophasic copolymer comprises:(A) from about 10 to 70% by weight of a copolymer of propylene and one or more comonomers) selected from ethylene and CH2=CHR alpha-olefins where R is a 2-8 carbon alkyl, wherein the copolymer contains from about 0 to 8% of co-monomer(s); and(B) from about 30 to 90% by weight of a copolymer of ethylene and (i) propylene or (ii) CH2=CHR alpha-olefins, where R is a 2-8 carbon alk l radical, or (iii) a combination thereof, optionally with minor amounts of a diene, with this copolymer containing from about 50% to 80% of ethylene, wherein the total weight of (A) + (B) is 100 wt. %.

[0090] In a fifth set of embodiments, in addition to the limitations of each embodiment in the second set of embodiments, the second heterophasic copolymer comprises:(A) from about 5 to 35% by weight of a propylene-based polymer containing 90% by weight or more of propylene units and 10% by weight or less of a fraction soluble in xylene at 25 °C;(B) from about 25 to 50% by weight of an ethylene homopolymer containing 5% by weight or less of a fraction soluble in xylene at 25°C; and(C) from about 30 to 60% by weight of a copolymer of ethylene and propylene containing from about 25% to 75% by weight of ethylene units and containing from about 55% to 95% by weight of a fraction soluble in xylene at 25°C, wherein the total weight of (A) + (B) + (C) is 100 wt. %.

[0091] In a sixth set of embodiments, in addition to the limitations of each embodiment in the second set of embodiments, the second heterophasic copolymer comprises:(A) from about 5 to 35% by weight of a propylene-based polymer containing 90% by weight or more of propylene units and 10% by weight or less of a fraction soluble in xylene at 25 °C;(B) from about 25 to 50% by weight of a copolymer of ethylene and a Ca-Cs alpha-olefin containing from about 0.1% to 20% by weight of alpha-olefin units and 75% by weight or less of a fraction soluble in xylene at 25°C; and(C) from about 30 to 60% by weight of a copolymer of ethylene and propylene containing from about 25% to 75% by weight of ethylene units and containing from about 55% to 95% by weight, of a fraction soluble in xylene at 25°C, wherein the total weight of(A) + (B) + (C) is 100 wt. %.

[0092] In a seventh set of embodiments, in addition to the limitations of each embodiment in the second set of embodiments, the first heterophasic copolymer comprises:(A) from 30% to less than 70% of a semi-cry stalline polypropylene component selected from the group consisting of a propylene homopolymer, a random copolymer of propylene containing up to 8% of ethylene, a random copolymer of propylene containing up to 8% of at least one C4-C10 a-olefin, or any combination thereof, wherein the semi-crystalline polypropylene component has a monomodal molecular weight distribution; and(B) greater than 30% to about 70% of a bipolymer component of propylene and at least one co-monomer selected from ethylene and / or C4-C10 a-olefms, wherein the bipolymer itself has from about 50% to about 75% of propylene, wherein the bipolymer is partially soluble in xylene at room temperature and has an intrinsic viscosity of from about 4 to 7.5 dl / g (in decalin), wherein the total weight of (A) +(B) is 100 wt. %.

[0093] In an eighth set of embodiments, in addition to the limitations of each embodiment in the second set of embodiments, the second heterophasic copolymer comprises:(A) from about 10 to 60% by weight of a homopolymer of propylene with isotactic index greater than 80, or a copolymer having over 85% by weight of propylene with (i) ethylene or (ii) CH2=CHR alpha-olefins, where R is a 2-8 carbon alkyl radical, or combinations of (i) and (ii);(B) from about 5 to 20% parts by weight of a copolymer fraction containing ethylene that is insoluble in xylene at ambient temperature; and(C) from about 37 to 80% by weight of a copolymer fraction of ethylene and (i) propylene or (ii) another CH2=CHR a-olefin, or combinations of (i) and (ii), and, optionally, minor portions of a diene, wherein component (C) is less than 40% byweight of ethylene, being soluble in xylene at ambient temperature, and having an intrinsic viscosity from about 1.5 to 5 dl / g; wherein the total weight of (A) + (B) + (C) is 100 wt. %; and the percent by w eight of the sum of the (B) and (C) components with respect to the total polyolefin composition is from about 40% to 90% and the (B) / (C) weight ratio is lower than 0.4.

[0094] In a ninth set of embodiments, in addition to the limitations of each embodiment in the second set of embodiments, the second heterophasic copolymer comprises:(A) from about 5 to 35% by weight of a propylene and ethylene copolymer having 15% by weight or less of a fraction soluble in xylene at 25°C (XSA) referred to the w eight of A, and having from about 0.5 wt. % to 7.0 wt. % of ethylene derived units;(B) from about 20 to 50% by weight of an ethylene homopolymer having 5% by weight or less of a fraction soluble in xylene at 25°C (XSB) referred to the weight of (B); and(C) from about 30 to 60% by w eight of a terpolymer, wherein the terpolymer contains propylene, about 45% to 65% by weight of ethylene derived components, and from about 15% to 38% by weight of 1-butene derived components, wherein the terpolymer has from about 30% to 85% by w eight of a fraction soluble in xylene at 25°C (XSc), the amount of ethylene units; 1-butene units and the fraction XSc being referred to the weight of (C), wherein the total weight of (A) + (B) + (C) is 100 wt. %.

[0095] In a tenth set of embodiments, in addition to the limitations of each embodiment in the second set of embodiments, the second heterophasic copolymer comprises:(A) from about 5 to 35% by weight of a propylene homopolymer containing 10% by weight or less of a fraction soluble in xylene at 25°C (XSA), the amount of the fraction XSA being referred to the weight of (A);(B) from about 20 to 50% by weight of an ethylene homopolymer having 5% by weight or less of a fraction soluble in xylene at 25°C (XSB) referred to the weight of (B); and(C) from about 30 to 60% by weight of a terpolymer, wherein the terpolymer contains propylene, about 45% to 65% by weight of ethylene derived components, and from about 15% to 38% by weight of 1-butene derived components, wherein the terpolymer has from about 30% to 85% by weight of a fraction soluble in xylene at 25°C (XSc), the amount of ethylene units; 1-butene units and the fraction XSc being referred to the weight of (C); wherein the total weight of (A) + (B) + (C) is 100 wt. %.

[0096] In an eleventh set of embodiments, in addition to the limitations of each embodiment in the second set of embodiments, the first heterophasic copolymer comprises:(A) from about 60 to 85% by weight of a broad molecular weight distribution propylene polymer having a poly dispersity index from about 5 to 15 and melt flow rate of from about 40 to 75 g / 10 min.; and(B) from about 15 to 40% by weight of a partially xylene-soluble olefin polymer rubber consisting of a poly(ethylene-co-propylene) containing at least 65% by weight of ethylene, wherein the xylene-insoluble content of (B) is 25- 40% by weight, measured by dissolving the polymer in xylene at 135°C, cooling the solution to 25°C, allowing to settle for 30 minutes, followed by filtering, wherein the total weight of (A) + (B) is 100 wt. %.

[0097] In a twelfth set of embodiments, in addition to the limitations of each embodiment in the second set of embodiments, the first heterophasic copolymer comprises:(A) from about 25 to 50% by weight of a crystalline propylene homopolymer with a solubility in xylene at room temperature of less than or equal to 4%, or a crystalline copolymer of propylene with ethylene or a C4-C8 alpha-olefin having an ethylene or alpha-olefin content 0.5 to 3%, and a solubility in xylene at room temperature of from less than or equal to 4%; and(B) from about 50 to 75% by weight of a partially amorphous copolymer of ethylene with a C4-C8 alpha-olefin, wherein the alpha-olefin content is from about 10 to 20%. and the copolymer is from about 10 to 40% soluble in xylene at room temperature, wherein the total weight of (A) + (B) is 100 wt. %.

[0098] In a thirteenth set of embodiments, in addition to the limitations of each embodiment in the first through the twelfth sets of embodiments, the polyolefin recyclate comprises a polyethylene, a polypropylene, or a combination thereof.

[0099] In a fourteenth set of embodiments, in addition to the limitations of each embodiment in the thirteenth set of embodiments, the polyethylene comprises a high-density polyethylene (HDPE), a medium density’ polyethylene (MDPE), a low-density polyethylene (LDPE). a linear low-density polyethylene (LLDPE), or a combination thereof.

[0100] In a fifteenth set of embodiments, in addition to the limitations of each embodiment in the thirteenth and fourteenth sets of embodiments, the polypropylene comprises: a) a propylene homopolymer; b) a random copolymer of propylene and ethylene and / or one or more C4-C20 alphaolefins, wherein the maximum content of ethylene and / or alpha-olefins is 10% by weight, and the random copolymer has an isotactic index of at least 80; c) a heterophasic propylene polymer materials consisting essentially of by weight,(1) 99-55% of a polymeric material selected from the group consisting of a propylene homopolymer having an isotactic index greater than 90, and a crystalline copolymer of propylene and an alpha-olefin of the formula CH2=CHR, where R is H or a 2-6 carbon linear or branched alkyl group, having an isotactic index of at least 80, the alpha-olefin being less than 10% of the copolymer, and(ii) 1-45% of an elastomeric olefin polymer of propylene and an olefinic material selected from the group consisting of alpha-olefins of the formula CH2=CHR, where R is H or a 2-6 carbon linear or branched alky l group, the alpha-olefin being 50-70% of the elastomeric polymer; or d) a combination thereof.

[0101] In a sixteenth set of embodiments, in addition to the limitations of each embodiment in the first through the fifteenth sets of embodiments, the nonwoven absorbent layer comprises a fiberglass, a thermoset polymer, or a combination thereof.

[0102] In a seventeenth set of embodiments, in addition to the limitations of each embodiment in the first through the sixteenth sets of embodiments, thermosetting hot curing-resin impregnating the absorbent layer comprises a polyester resin, a vinyl ester resin, an epoxy resin, or a combination thereof.EXAMPLES

[0103] The following examples are included to demonstrate preferred embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples which follow represent techniques discovered by the inventor to function well in the practice of the invention, and thus can be considered to constitute preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention.Test Methods

[0104] Melt Flow Rate (MFR) ISO1133, at 230° C.. 2. 16 kg where not differently specified.

[0105] Shore A Hardness (Sh.A) and ShoreD (Sh.D): measured on a compression moulded plaques (thickness of 4 mm) following the ISO 868.

[0106] DSC — thermal properties: The peak melting temperature Tm was measured followingISO 11357-3, via DSC performed at 10° C. / min where not differently specified.

[0107] Flexural Elastic Modulus (MEF) ISO 178 on 1 mm thick compression moulded plaque.

[0108] Comonomer content (% wt) IR. Spectroscopy

[0109] Xylene soluble and insoluble fractions (% wt): determined as follows: 2.5 g of polymer composition and 250 cm3 of O-xylene are introduced in a glass flask equipped with a refrigerator and a magnetical stirrer. The temperature is raised in 30 minutes up to the boiling point of the solvent. The so obtained clear solution is then kept under reflux and stirring for a further 30 minutes. The closed flask is then cooled to 100° C. in air for 10 to 15 minute under stirring and then kept for 30 minutes in thermostatic water bath at 25° C. for 30 minutes as well. The formed solid is filtered on quick filtering paper. 100 cm3 of the filtered liquid is poured in a previously weighed aluminum container which is heated on a heating plate under nitrogen flow, to remove the solvent by evaporation. The container is then kept in an oven at 80° C. under a vacuum until constant weight is obtained. The weight percentage of polymer soluble in xylene (XS) at room temperature (25°C) is then calculated.Products that could be used to prepare examples

[0110] HPO1 : Heterophasic polyolefin composition having MFR 0.8 g / 10 min, Flexural modulus 100 MPa, Shore D Hardness (Sh.D) 28, Tm=160° C.; Tvicat=57° C. and comprising:• 24% wt. of a crystalline propylene homopolymer (component a), having MFR 25 g / 10 min, soluble fraction in xylene at 25° C. of 3% wt, and• 76% wt. of an elastomeric fraction (component b) of propylene with ethylene having 28% by weight of units derived from ethylene, 89% wt of fraction soluble in xylene at 25° C.

[0111] Polypropylene recyclate copolymer, RPP103 GY5, available from Braskem America Inc., Philadelphia, PA 19103-7534, USA

[0112] Felt support: commercial felt produced by SIOEN Industrial Application sold under the tradename Siopipe C — selected to couple to the membrane obtained from the thermoplastic compositions.Thermosetting resins that could be used to impregnate the felt:

[0113] Polyester resin 1 (hot curing resin): an isophthalic neopentylglycol unsaturated polyester resin marketed by Resintex Technology' S.r.l. under the tradename CRYSTIC 4044T V01, with 0.8% Perkadox 16+1% Trigonox C, having reactivity at 80° C. with a time to peak of 7-8 min and a peak temperature of 250° C.

[0114] Polyester resin 2 (mild curing resin): orthophthalic polyester resin solved in styrene marketed by Leda Industrie srl under the tradename R.601 / T formulated with 2% Methyl ethyl ketone peroxide (MEKP) 50% (catalyst) for curing at 25° C., having an exotherm curve defined by a gel time 10 min, peak temperature 160° C. and time to peak temperature 23 min.Preparation of the Coated Membranes:

[0115] Membrane samples having nominal thickness of 0.4 mm could be manufactured, starting by the polymer granules, on a Brabender 30 mm equipped with a flat die (150 mm) and a calendaring stack, under the following conditions:• throughput 6-8 Kg / h,• rotation speed 150 rpm,• melt temperature 245° C. for polypropylene based materials,• head pressure 40 bar for polypropylene based materials,• melt temperature 205° C. for polyethylene based material, and• head pressure 38 bar for polyethylene based materials.

[0116] A layer of felt could be laminated on the bottom layer during the calendaring of the membranes.Preparation of the Liner:

[0117] The external edges of two membranes samples could be welded with a Leister Comet hot wedge welding machine, at a welding temperature of 300° C. and a welding speed of 2.5 m / min, in order to realize a pipe 400 mm long and 95 mm of diameter. Pipes have been reversed in order to have the felt as an external layer.

[0118] The felt on the external layer could be impregnated with the resin and the liner put inside a steel made pipe 100 mm of internal diameter and 0.5 mm of pipe wall thickness.

[0119] A series of holes of 5, 10, 15 mm diameter, could be made in order to replicate the failure in the real application. The holes could be made on the steel pipe along its middle circumference (situated at half pipe length at about 200 mm from the pipe sides).

[0120] The steel pipe could be equipped with two removal caps on the sides. One cap could be equipped with a connection for the addition of water, the other cap has been equipped with a connection for the extraction of water.

[0121] Once the removal caps have been closed, a flow of water could be given inside the device to start the curing in place process.Water parameters of the curing in place:• Temperature: ramp of 4° C. / min from 60° C. to 100° C. and 100° C. for 20 minutes• Pressure: 1 bar• At the end of the cycle the water could be extracted by a flow of nitrogen.• The device has been opened after 6 hours of the cycle completion in order to ensure the termination of the self-curing of the resin.• Visual inspection could be done in order to assess the status of the membrane and the quality of the reparation.

[0122] Membrane sample hners were prepared as above described and used for pipe lining according to the following list of coupled materials:• Example 1: 50 wt. % HPO1 / 50 wt. % PP recyclate blend moisture barrier layer + Polyester resin 1 impregnating felt; and• Comparative example 2: HPO1 moisture barrier layer + Polyester resin 1 impregnating felt.

[0123] Ideally, Example 1 would perform competitively with comparative Example 2.

[0124] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, in addition to recited ranges, any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, within a range includes every point or individual value between its end points even though not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[0125] All documents and references cited herein, including testing procedures, publications, patents, journal articles, etc., are herein fully incorporated by reference for all jurisdictions in which such incorporation is permitted and to the extent such disclosure is consistent with the description of the present invention.

[0126] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the processes, machines, film structures, composition of layers, means, methods, and / or steps described in the specification. As one of the ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, film structures, composition of layers, means, methods, and / or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein, may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, film structures, composition of layers, means, methods, and / or steps.

Claims

CLAIMSWhat is claimed is:

1. A pipe liner comprising: a moisture barrier layer; a nonwoven absorbent layer; and a thermosetting hot curing-resin impregnating the absorbent layer; wherein the moisture barrier layer comprises: a thermoplastic polyolefin component in an amount in the range of from 1 wt. % to 99 wt. %; and a polyolefin recyclate component in an amount in the range of from 1 wt. % to99 wt. %; wherein wt. % is based on the total weight of the thermoplastic polyolefin component and the polyolefin recyclate component.

2. The pipe liner of claim 1. wherein the moisture barrier layer has as flexural elastic modulus (MEF) ISO 178 less than or equal to 350 MPa.

3. The pipe liner of claim 1. wherein the thermoplastic polyolefin component comprises: a first heterophasic copolymer, wherein a propylene homopolymer or a random copolymer (RACO) with ethylene is mixed with a bipolymer; a second heterophasic copolymer containing three components: A) a semi-crystalline propylene homopolymer, or random copolymer with ethylene or other alpha-olefins; B) a polyethylene homopolymer, or a polyethylene copolymer with 1 -butene or other alpha-olefins; and C) an elastomeric component consisting of a copolymer of propylene, ethylene, and optionally 1 -butene; or a combination thereof.

4. The pipe liner of claim 3, wherein the first heterophasic copolymer comprises:(A) from about 8 to about 25% by weight of a crystalline polymer fraction selected from the group consisting of (i) a propylene homopolymer having solubility in xylene at room temperature lower than 10% by weight; and (ii) a copolymer of propylene and at least one alpha-olefin of formula H2C=CHR, where R is H or a C2-C6 linear or branched alkyl, containing at least 85% by w eight of propylene, having solubility in xylene at room temperature low er than 15% by w eight; and(B) from about 75 to about 92% by weight of an elastomeric fraction comprising(i) a first elastomeric copolymer of propylene with at least one alpha-olefin of formula H2C=CHR, where R is H or a C2-C6 linear or branched alky l, optionally containing 0.5 to 5% by weight of a diene, the first elastomeric copolymer containing from about 15 to 32% by weight alpha-olefin, and having solubility in xylene at room temperature greater than 50% by weight, the intrinsic viscosity of the xylene soluble fraction ranging from about 3.0 to 5.0 dl / g; and(ii) a second elastomeric copolymer of propylene with at least one alpha-olefin of formula H2C=CHR, where R is H or a C2-C6 linear or branched alky l, optionally containing 0.5 to 5% by weight of a diene, the second elastomeric copolymer containing more than 32% up to 45% by weight alpha-olefin, and having solubility in xylene at room temperature greater than 80% by weight, the intrinsic viscosity of the xylene soluble fraction ranging from about 4.0 to6.5 dl / g; wherein the (b.i)Z(b.ii) weight ratio ranges from about 1:5 to 5: 1; wherein the total weight of (A) + (B) is 100 wt. %.

5. The pipe liner of claim 3, wherein the first heterophasic copolymer comprises:(A) from about 10 to 70% by weight of a copolymer of propylene and one or more comonomers) selected from ethylene and CH2=CHR alpha-olefins where R is a 2-8 carbon alkyl, wherein the copolymer contains from about 0 to 8% of co-monomer(s); and(B) from about 30 to 90% by weight of a copolymer of ethylene and (i) propylene or (ii) CH2=CHR alpha-olefins, where R is a 2-8 carbon alkyl radical, or (iii) a combination thereof, optionally with minor amounts of a diene, with this copolymer containing from about 50% to 80% of ethylene. wherein the total weight of (A) + (B) is 100 wt. %.

6. The pipe liner of claim 3. wherein the second heterophasic copolymer comprises:(A) from about 5 to 35% by weight of a propylene-based polymer containing 90% by weight or more of propylene units and 10% by weight or less of a fraction soluble in xylene at 25 °C;(B) from about 25 to 50% by weight of an ethylene homopolymer containing 5% by weight or less of a fraction soluble in xylene at 25°C; and(C) from about 30 to 60% by weight of a copolymer of ethylene and propylene containing from about 25% to 75% by weight of ethylene units and containing from about 55% to 95% by weight of a fraction soluble in xylene at 25°C. wherein the total weight of (A) + (B) + (C) is 100 wt. %.

7. The pipe liner of claim 3, wherein the second heterophasic copolymer comprises:(A) from about 5 to 35% by weight of a propylene-based polymer containing 90% by weight or more of propylene units and 10% by weight or less of a fraction soluble in xylene at 25 °C;(B) from about 25 to 50% by weight of a copolymer of ethylene and a Cs-Cs alpha-olefin containing from about 0.1% to 20% by weight of alpha-olefin units and 75% by weight or less of a fraction soluble in xylene at 25°C; and(C) from about 30 to 60% by weight of a copolymer of ethylene and propylene containing from about 25% to 75% by weight of ethylene units and containing from about 55% to 95% by weight, of a fraction soluble in xylene at 25°C. wherein the total weight of (A) + (B) + (C) is 100 wt. %.

8. The pipe liner of claim 3, wherein the first heterophasic copolymer comprises:(A) from 30% to less than 70% of a semi -crystalline polypropylene component selected from the group consisting of a propylene homopolymer, a random copolymer of propylene containing up to 8% of ethylene, a random copolymer of propylene containing up to 8% of at least one C4-C10 a-olefin, or any combination thereof, wherein the semi-crystalline polypropylene component has a monomodal molecular weight distribution; and(B) greater than 30% to about 70% of a bipolymer component of propylene and at least one co-monomer selected from ethylene and / or C4-C10 a-olefins, wherein the bipolymer itself has from about 50% to about 75% of propylene, wherein the bipolymer is partially soluble in xylene at room temperature and has an intrinsic viscosity of from about 4 to 7.5 dl / g (in decalin). wherein the total weight of (A) + (B) is 100 wt. %.

9. The pipe liner of claim 3. wherein the second heterophasic copolymer comprises:(A) from about 10 to 60% by weight of a homopolymer of propylene with isotactic index greater than 80, or a copolymer having over 85% by weight of propylene with (i) ethylene or (ii) CH2=CHR alpha-olefins, where R is a 2-8 carbon alkyl radical, or combinations of (i) and (ii);(B) from about 5 to 20% parts by weight of a copolymer fraction containing ethylene that is insoluble in xylene at ambient temperature; and(C) from about 37 to 80% by weight of a copolymer fraction of ethylene and (i) propylene or (ii) another CH2=CHR a-olefin, or combinations of (i) and (ii), and, optionally, minor portions of a diene, wherein component (C) is less than 40% by weight of ethylene, being soluble in xylene at ambient temperature, and having an intrinsic viscosity from about 1.5 to 5 dl / g; wherein the total weight of (A) + (B) + (C) is 100 wt. %; and the percent by weight of the sum of the (B) and (C) components with respect to the total polyolefin composition is from about 40% to 90% and the (B) / (C) weight ratio is lower than 0.4.

10. The pipe liner of claim 3, wherein the second heterophasic copolymer comprises:(A) from about 5 to 35% by weight of a propylene and ethylene copolymer having 15% by weight or less of a fraction soluble in xylene at 25°C (XSA) referred to the weight of A, and having from about 0.5 wt. % to 7.0 wt. % of ethylene derived units;(B) from about 20 to 50% by weight of an ethylene homopolymer having 5% by weight or less of a fraction soluble in xylene at 25°C (XSB) referred to the weight of (B); and(C) from about 30 to 60% by weight of a terpolymer, wherein the terpolymer contains propylene, about 45% to 65% by weight of ethylene derived components, and from about 15% to 38% by weight of 1-butene derived components, wherein the terpolymer has from about 30% to 85% by weight of a fraction soluble in xylene at 25°C (XSc), the amount of ethylene units; 1-butene units and the fraction XSc being referred to the weight of (C), wherein the total weight of (A) + (B) + (C) is 100 wt. %.

11. The pipe liner of claim 3. wherein the second heterophasic copolymer comprises:(A) from about 5 to 35% by weight of a propylene homopolymer containing 10% by weight or less of a fraction soluble in xylene at 25°C (XSA), the amount of the fraction XSA being referred to the weight of (A);(B) from about 20 to 50% by weight of an ethylene homopolymer having 5% by weight or less of a fraction soluble in xylene at 25°C (XSB) referred to the weight of (B); and(C) from about 30 to 60% by weight of a terpolymer, wherein the terpolymer contains propylene, about 45% to 65% by weight of ethylene derived components, and from about 15% to 38% by weight of 1-butene derived components, wherein the terpolymer has from about 30% to 85% by weight of a fraction soluble in xylene at 25°C (XSc), the amount of ethylene units; 1-butene units and the fraction XSc being referred to the weight of (C); wherein the total weight of (A) + (B) + (C) is 100 wt. %.

12. The pipe liner of claim 3, wherein the first heterophasic copolymer comprises:(A) from about 60 to 85% by weight of a broad molecular weight distribution propylene polymer having a poly dispersity index from about 5 to 15 and melt flow rate of from about 40 to 75 g / 10 min.; and(B) from about 15 to 40% by weight of a partially xylene-soluble olefin polymer rubber consisting of a poly(ethylene-co-propylene) containing at least 65% by weight of ethylene, wherein the xylene-insoluble content of (B) is 25- 40% by weight, measured by dissolving the polymer in xylene at 135°C, cooling the solution to 25°C, allowing to settle for 30 minutes, followed by filtering; wherein the total weight of (A) + (B) is 100 wt. %.

13. The pipe liner of claim 3, wherein the first heterophasic copolymer comprises:(A) from about 25 to 50% by weight of a crystalline propylene homopolymer with a solubility in xylene at room temperature of less than or equal to 4%, or a crystalline copolymer of propylene with ethylene or a C-i-Cx alpha-olefin having an ethylene or alpha-olefin content 0.5 to 3%, and a solubility in xylene at room temperature of from less than or equal to 4%; and(B) from about 50 to 75% by weight of a partially amorphous copolymer of ethylene with a C4-C8 alpha-olefin, wherein the alpha-olefin content is from about 10 to 20%. and the copolymer is from about 10 to 40% soluble in xylene at room temperature;wherein the total weight of (A) + (B) is 100 wt. %.

14. The pipe liner of claim 1. wherein the polyolefin recy elate comprises a polyethylene, a polypropylene, or a combination thereof.

15. The pipe liner of claim 14, wherein the polyethylene comprises a high-density polyethy lene (HDPE), a medium density polyethylene (MDPE), a low-density polyethylene (LDPE), a linear low-density polyethylene (LLDPE), or a combination thereof.

16. The pipe liner of claim 14, wherein the polypropylene comprises: a propylene homopolymer; a random copolymer of propylene and ethylene and / or one or more C4-C20 alpha-olefins, wherein the maximum content of ethylene and / or alpha-olefins is 10% by weight, and the random copolymer has an isotactic index of at least 80; a heterophasic propylene polymer materials consisting essentially of by weight,(i) 99-55% of a polymeric material selected from the group consisting of a propylene homopolymer having an isotactic index greater than 90, and a crystalline copolymer of propylene and an alpha-olefin of the formula CH2=CHR. where R is H or a 2-6 carbon linear or branched alkyl group, having an isotactic index of at least 80, the alpha-olefin being less than 10% of the copolymer, and(ii) 1-45% of an elastomeric olefin polymer of propylene and an olefinic material selected from the group consisting of alpha-olefins of the formula CH2=CHR, where R is H or a 2-6 carbon linear or branched alkyl group, the alpha-olefin being 50-70% of the elastomeric polymer; or a combination thereof.

17. The pipe liner of claim 1. wherein the nonwoven absorbent layer comprises a fiberglass, a thermoset polymer, or a combination thereof.

18. The pipe liner of claim 1. wherein the thermosetting hot curing-resin impregnating the absorbent layer comprises a polyester resin, a vinyl ester resin, an epoxy resin, or a combination thereof.