Synthesis of functionalized polyolefins in a new continuous bench‐scale reactor apparatus

In‐reactor functionalized polyolefins (FPOs), produced by molecular catalysts, are a new class of polymer materials with applications ranging from high performance adhesives to bitumen compatibilization. In this work, we disclose a procedure for the synthesis of FPOs in a new Continuous Bench‐scale Reactor Apparatus (COBRA). The COBRA is a miniature unit equipped with many of the features of a commercial pilot plant. We have found that large amounts of MAO, a common catalyst activator, result in dark‐colored polymers. The color was attributed to the decomposition of residual MAO in polymer degassing operations. The color can be eliminated by reducing the amount of MAO, but only at the expense of catalyst productivity. The addition of TTB as a co‐catalyst increases catalyst productivity while still producing clear resins. The final MAO‐TTB catalyst system is more suitable for large scale production of the functionalized resins.