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The aim of this article is to upgrade the performance of polypropylene/ethylene propylene rubber (PP/EPR) blends by addition of hydrophobic nanosilica (SiR805) and using “high shear processing technology”. The morphological developments, mechanical and rheological properties of these composites were investigated as a function of processing conditions. High shear processing has proved to be an efficient process to decrease the size of the dispersed phase (EPR) up to 300 nm and to disperse finely nanosilica particles to less than 30 nm especially at 800 min −1 . Moreover, the morphology stability of the nanocomposite is ascribed to the formation of a core shell structure (EPR nodules = core; nano-silica = shell) and selective location of nanosilica at the interface. More importantly, this core-shell structure is favoured to enhance the impact strength of the (PP/EPR)/3 wt% SiR805 nanocomposite. In agreement to the obtained morphology, the improvement (about 60 %) of elongation at break attests a good adhesion between phases due to high shear effect as highlighted by viscoelastic properties. Therefore, high shear processing technology has proved to be a relevant method to prepare nanocomposites with high performances without adding any additive and offers new perspectives for recycling and lightening structures.

High Shear Processing of (PP/EPR)/Silica Nanocomposites: Improvement of Morphology and Properties