Extruding ready-to-use soft PVC film or profile from uncompounded PVC
A method for producing flexible PVC films or profiles by adding plasticizer and other additives directly to raw (uncompounded) PVC in an extruder so the final extrudate already meets mechanical specs. The process controls energy input (specific energy input, SEI) to 0.03, 0.20 kWh/kg and achieves gelation of 60, 100%, elongation at break ≥200% and tensile strength ≥10 N/mm2, intended for makers of soft PVC sheeting, hoses, flooring and profiles.
(57) What the patent covered
The independent claim covers a process that starts from uncompounded PVC, introduces additives (not necessarily precompounded) during extrusion, and controls the extrusion so that the polymer composition has 60, 100% gelation, at least 200% elongation at break, tensile strength ≥10 N/mm2, and the specific energy input during processing is 0.03, 0.20 kWh/kg.
The distinctive part: Controlling and limiting the specific energy input during single-step extrusion of uncompounded PVC while adding plasticizer in portions to reach finished soft PVC properties without a prior compounding step.
Novelty 4/5. Prior practice was to precompound PVC into pellets with stabilizers and plasticizers before shaping; this patent claimed a new approach by doing the additive incorporation and gelation control in a single extrusion step using restricted SEI.
Making it
High-shear extrusion where plasticizer (and stabilizers/additives) are metered in multiple portions into the extruder, mixed into the PVC melt while controlling screw design, temperature profile and throughput to keep SEI at 0.03, 0.20 kWh/kg; cooling and forming to film or profile.
Materials: Polyvinyl chloride (raw/uncompounded PVC), Phthalate or alternative organic plasticizer (likely DOTP, DINP, etc.), Thermal stabilizers (metal soaps, organic stabilizers), Fillers or pigments (calcium carbonate, titanium dioxide)
Manufacturability 4/5. Requires a single-extruder production line with accurate metering of liquid plasticizer and tight control of screw geometry, temperature and motor power (to meet SEI); tooling itself is conventional for extrusion but requires process control and handling for liquid additions.
Is anyone buying?
This design, or something very close to it, is on sale now. US-based suppliers advertise flexible PVC film and related bulk rolls; price points are shown for at least one listing (TXP flagging) and catalogs indicate multiple film grades and widths.
- Presco Roll Flagging (PVC film extruded by Presco) TXP · Duncan-Parnell (Presco manufacturing info included in listing)$2.63
- Presco Extruded PVC Film (flexible PVC film for various applications) · Presco Products Company
- PVC Bulk Rolls (flexible PVC film/sheet material, US seller with... · Brussard Associates (PVC Bulk Rolls catalog/listing)various, see catalog page (example prices shown in listing)
This demand check was run with a web search in the week of Oct 5, 2026. Listings change often, so treat it as a starting point for your own research.
Who buys it: manufacturers of flexible PVC flooring, hoses, cable sheathing and extrusion shops
Before you make it
We didn't find any related continuation or divisional patents still in force, although that doesn't rule out design patents, trademarks or unrelated patents covering the same product.
Watch processing limits, tight control of energy input, temperature and additive dosing is necessary and stabilizer choice affects thermal stability; patent has lapsed but regulatory and formulation constraints for plasticizers and stabilizers remain.
Owners occasionally revive lapsed patents (about 1.5% are), and this page is a research lead rather than legal advice, so get a freedom-to-operate opinion before you manufacture anything.