Thermoplastic polymer particles and methods of production and uses thereof

1 . A method comprising:

providing a mixture within a reactor, the mixture comprising a thermoplastic polymer, a carrier fluid that is immiscible with the thermoplastic polymer, and an emulsion stabilizer comprising a plurality of nanoparticles;

shearing the mixture within the reactor at a temperature greater than a melting point or softening temperature of the thermoplastic polymer and at a shear rate sufficiently high to form the thermoplastic polymer into melted droplets in the reactor, the melted droplets being dispersed in the carrier fluid;

cooling the mixture to below the melting point or softening temperature of the thermoplastic polymer to form solidified particles comprising the thermoplastic polymer and the emulsion stabilizer associated with an outer surface of the solidified particles; and

separating the solidified particles from the carrier fluid.

2 . The method of claim 1 , wherein the plurality of nanoparticles comprises oxide nanoparticles, carbon black, polymer nanoparticles, or any combination thereof.

3 . The method of claim 1 , wherein the plurality of nanoparticles comprises oxide nanoparticles.

4 . The method of claim 3 , wherein the oxide nanoparticles comprise silica nanoparticles.

5 . The method of claim 1 , wherein at least a portion of the nanoparticles are embedded in the outer surface.

6 . The method of claim 1 , wherein the emulsion stabilizer comprises a surfactant and the plurality of nanoparticles.

7 . The method of claim 1 , wherein the emulsion stabilizer is present in the mixture at about 0.01 wt % to about 10 wt % by weight of the thermoplastic polymer.

8 . The method of claim 1 , wherein the thermoplastic polymer is present the mixture at about 5 wt % to about 60 wt % of the mixture.

9 . The method of claim 1 , wherein the carrier fluid has a viscosity at 25° C. of about 1,000 cSt to about 150,000 cSt.

10 . The method of claim 1 , wherein the carrier fluid is selected from the group consisting of silicone oil, fluorinated silicone oils, perfluorinated silicone oils, polyethylene glycols, alkyl-terminal polyethylene glycols, paraffins, liquid petroleum jelly, vison oils, turtle oils, soya bean oils, perhydrosqualene, sweet almond oils, calophyllum oils, palm oils, parleam oils, grapeseed oils, sesame oils, maize oils, rapeseed oils, sunflower oils, cottonseed oils, apricot oils, castor oils, avocado oils, jojoba oils, olive oils, cereal germ oils, esters of lanolic acid, esters of oleic acid, esters of lauric acid, esters of stearic acid, fatty esters, higher fatty acids, fatty alcohols, polysiloxanes modified with fatty acids, polysiloxanes modified with fatty alcohols, polysiloxanes modified with polyoxyalkylenes, and any combination thereof.

11 . The method of claim 1 , wherein the thermoplastic polymer is selected from the group consisting of polyamides, polyurethanes, polyethylenes, polypropylenes, polyacetals, polycarbonates, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polytrimethylene terephthalate (PTT), polyhexamethylene terephthalate, polystyrenes, polyvinyl chlorides, polytetrafluoroethenes, polyesters, polylactic acid, polyethers, polyether sulfones, polyetherether ketones, polyacrylates, polymethacrylates, polyimides, acrylonitrile butadiene styrene (ABS), polyphenylene sulfides, vinyl polymers, polyarylene ethers, polyarylene sulfides, polysulfones, polyether ketones, polyamide-imides, polyetherimides, polyetheresters, copolymers comprising a polyether block and a polyamide block, grafted or ungrafted thermoplastic polyolefins, functionalized or nonfunctionalized ethylene/vinyl monomer polymer, functionalized or nonfunctionalized ethylene/alkyl (meth) acrylates, functionalized or nonfunctionalized (meth)acrylic acid polymers, functionalized or nonfunctionalized ethylene/vinyl monomer/alkyl (meth)acrylate terpolymers, ethylene/vinyl monomer/carbonyl terpolymers, ethylene/alkyl (meth)acrylate/carbonyl terpolymers, methylmethacrylate-butadiene-styrene (MBS) core-shell polymers, polystyrene-block-polybutadiene-block-poly(methyl methacrylate) (SBM) block terpolymers, chlorinated or chlorosulphonated polyethylenes, polyvinylidene fluoride (PVDF), phenolic resins, poly(ethylene/vinyl acetate) s, polybutadienes, polyisoprenes, styrenic block copolymers, polyacrylonitriles, silicones, and any combination thereof.

12 . The method of claim 1 , wherein the solidified particles have a D10 of about 0.5 μm to about 125 μm, a D50 of about 1 μm to about 200 μm, and a D90 of about 70 μm to about 300 μm, wherein D10<D50<D90.

13 . The method of claim 1 , wherein the solidified particles have a Hausner ratio of about 1.0 to about 1.5.

14 . The method of claim 1 , wherein the solidified particles have a circularity of about 0.9 to about 1.0.

15 . The method of claim 11 , wherein the thermoplastic polymer contains an internal additive before forming the mixture.

16 . The method of claim 15 , wherein the internal additive is present in the thermoplastic polymer at about 0.1 wt % to about 60 wt % relative to the thermoplastic polymer.

17 . The method of claim 1 , wherein the plurality of nanoparticles has a D50 of about 10 nm to about 150 nm.

18 . The method of claim 1 , wherein shearing occurs in an extruder.

19 . The method of claim 11 , further comprising:

combining an external additive with the solidified particles after separation thereof.