Bulk polymerization process for preparing high solids and uniform copolymers

Claim 1

A continuous bulk polymerization process for preparing enhanced yields of high solids, non-styrenic acrylic polymer product having a number average molecular weight of about 1000 to 2500 a polydispersity ratio of less than about 3; a dispersion index of up to about 5 and a low chromophore content comprising the steps of continuously: (a) charging into a continuous mixed reactor zone containing a molten resin mixture consisting esentially of; (i) at least one acrylic monomer; (ii) a polymerization initiator in amounts to provide a molar ratio of said initiator to said acrylic monomer from about 0.0005:1 to 0.06:1, (iii) from about 0 to 25 percent based on the weight of acrylic monomers of a reaction solvent, wherein said molten resin mixture comprises unreacted acrylic monomers and the acrylic polymer product; (b) maintaining a flow rate through said reaction zone sufficient to: (i) provide a residence time of said charged acrylic monomer in said reaction zone of from about 1-30 minutes; and (ii) maintain a predetermined level of reaction mixture in said reaction zone, and; (c) maintaining the molten resin mixture at an elevated temperature with the range of from about 180° C. to 270° C. sufficient to provide accelerated conversation to a readily processable, uniform, concentrated polymer product.