Bimodal Interphase Architecture in Filled Elastomers: Molecular Dynamics Evidence and Experimental Signatures

The polymer–filler interphase in filled elastomers is often represented by a single thickness, obscuring internal heterogeneity. Coupling coarse-grained molecular dynamics with dynamic mechanical analysis of EPDM/carbon-black compounds, we resolve a bimodal bound-rubber layer with a dense inner zone set by surface adsorption and a looser outer zone sustained by chain connectivity. Heating contracts the outer zone about twice as strongly as the inner zone (outer: 26.5%, 95% confidence interval 17.4–34.8%; inner: 13.3%). Per-layer mean-squared displacement analysis shows a modest mobility gradient between the 1–2 nm outer zone and the bulk. Dynamic mechanical analysis at 120–140 ∘C shows a flatter reinforcement factor at higher temperature, consistent with interphase-linked thermal contraction. Lengthening the chain at fixed filler loading markedly enlarges the bridging fraction and the cumulative excess thickness, signaling a transition from adsorption-limited to connectivity-limited reinforcement. These results show that a single interphase boundary can miss a dynamically active outer zone relevant to reinforcement and thermal aging in filled elastomers.