Facile Preparation of Styrene‐Butadiene‐Rubber Composites Combining Surfactant‐Assisted Carbon Black Slurry Formation and Latex Phase Mixing

ABSTRACT A high‐performance masterbatch composite of styrene‐butadiene‐rubber (SBR) and carbon black (CB) was developed via a latex stage mixing technique using surfactant‐assisted CB dispersions. To enhance dispersion and interfacial interaction, CB slurries were prepared with non‐ionic, anionic, and cationic surfactants and evaluated for colloidal stability via zeta potential. The resultant composites were extensively characterized by TGA, DSC, FTIR, and RPA strain/frequency/temperature sweep techniques. Surfactant‐assisted systems significantly reduced mixing energy and enhanced polymer–filler interaction, as confirmed by bound rubber content, the Payne effect, and SEM/TEM imaging. Among all formulations, the cationic surfactant CTAB yielded superior composite performance, characterized by higher bound rubber, improved filler dispersion, elevated crosslinking density, and enhanced mechanical properties, including tensile modulus and tear strength. These effects are attributed to strong filler–rubber interactions and improved dynamic properties such as reduced heat build‐up and rolling resistance. This study demonstrates the efficacy of CTAB in producing energy‐efficient, dust‐free SBR‐CB composites with significantly enhanced performance characteristics over traditional dry mixing methods.