The present invention is directed to a novel high temperature
polymerization process operating at high pressures for producing a
polymer. The process includes conveying hybrid reactor mixtures, which
include one or more hybrid reactor monomers and one or more hybrid
reactor initiators to one or more hybrid reactors. The hybrid reactors
are maintained at effective hybrid polymerization temperatures and
sub-reflux polymerization gage pressures to cause polymerization of a
portion of the hybrid reactor monomers into the polymer. The process
further includes conveying hybrid reactor contents from the hybrid
reactors to one or more batch reactors maintained at effective batch
polymerization temperatures and reflux polymerization pressures to cause
polymerization of a remaining portion of the hybrid reactor monomers into
the polymer. The hybrid reactors are smaller in volume than the batch
reactors. By utilizing the hybrid/batch reactor combination, the process
of the present invention can be operated under safe working conditions.
The process of the present invention also allows control of the
polydispersity and molecular weight of the resulting polymers. As a
result, the polymers made therefrom can be used as binders in
compositions, such as coating compositions used in the automotive
refinish and OEM applications having desired coating properties. The
present invention is also directed to a polymerization system used in the
process of the present invention.