Solution polymerization of butyl
acrylate and divinylbenzene (DVB)
in toluene, initiated with 2,2′-azobisisobutyronitrile and
mediated with chain transfer agent dodecanethiol (DDT), was carried
out in a capillary microreactor with a 1 mm inner diameter. Through
the Strathclyde method, branched poly(butyl acrylate) with different
molecular weight distributions (MWDs) was prepared by adjusting the
feed formulation and the residence time. The dosages of DVB and DDT
were controlled to avoid gelation, and their effects on the branching
degree of the products were investigated. The multimodal MWDs were
deconvoluted to quantitatively study the branching process. The kinetics
in batch and continuous operation are compared. Aqueous miniemulsion
polymerization with a similar feed formulation was also conducted
in the microreactor, enabling faster reaction rate, lower solution
viscosity, and higher branching efficiency. This study demonstrated
the feasibility to use commercial monomers to prepare branched polymers
with high functionality and a dense architecture in continuous-flow
mode.