A reactive extrusion process for producing an ionomer is disclosed. The
process comprising adding a polymer containing a carboxyl functionality
to an extruder, then homogenously melting the polymer in a melting zone
of the extruder. A first melt seal zone of the extruder is formed to
separate the melting zone from an injection zone where an aqueous
solution of metallic ions are added to the molten polymer. The first melt
seal zone is formed by increasing the pressure in the melt seal zone to a
pressure which is higher than the vapor pressure of the water at any
point in the injection zone and the reaction zone. The aqueous solution
of metallic ions is then mixed with the polymer containing the carboxyl
functionality in a reaction zone of the extruder under conditions such
that the metallic ions are substantially reacted with the carboxyl
functionality. A pressure build-up zone is formed in the extruder,
wherein the pressure build-up zone is located no earlier than at the end
of the reaction zone wherein the pressure build-up zone is formed by
increasing the pressure to a level such that the aqueous solution of
metallic ions remains in the liquid phase for a time sufficient to allow
for the desired reaction between the metallic ions and the carboxyl
functionality of the polymer.