Polyolefin nanocomposites with polyelectrolyte coated redispersible nanoparticles produced continuously and massively via reactive flash nanoprecipitation

Redispersibility of nanoparticles to a polymer matrix was crucial for composite performances. In order to massively produce redispersible nanoparticles for industrial applications, this study for the first time realized a continuous process of the reactive flash nanoprecipitation (RFNP) with a confined impinging jets (CIJ) micromixer and the developed desktop device even with low power-output pumps. A nanosuspension of magnesium hydroxide (MH) was successfully produced and simultaneously coated with a polyelectrolyte of sodium alginate (NaAlg) via RFNP. The produced NaAlg/MH nanoparticles had a good compatibility with polypropylene (PP) as well as a good redispersibility during their melt blending. The produced PP/NaAlg/MH nanocomposite showed a significant deduction of the initial decomposition temperature even with a low MH feed for flame retardancy. This study created a genetic way to massively and rapidly produce narrow sized and redispersible nanoparticles for nanocomposites and would also push forward the FNP and analogous methods to a real industrial implementation. [Display omitted] •A continuous process of the reactive flash nanoprecipitation is realized firstly.•A massive and rapid production of Mg(OH)2 nanosuspensions is achieved.•NaAlg is in-situ coated on Mg(OH)2 nanoparticles during particle formation.•NaAlg/Mg(OH)2 particles are well compatible with and dispersible in PP substrate.•NaAlg/Mg(OH)2/PP composite shows a superior flame retardancy.