A novel method for the preparation of low-cost and easily dispersible graphene-rubber masterbatch and its application in tyre tread compound

A cost-effective and scalable method for producing a graphene-rubber masterbatch (GRMB) was developed using pristine graphite (PG) as the precursor and natural rubber (NR) as the polymer matrix. The process involves shear-induced thermomechanical exfoliation of graphite within a co-rotating twin-screw extruder, enabling intercalation of NR chains between graphite layers. Design of experiments (DOE) was employed to optimize processing conditions and composition. The optimized GRMB was incorporated into truck and bus radial (TBR) tyre tread formulations at varying dosages. The incorporation of 3.33 phr of GRMB containing 15% graphene (equivalent to 0.5 phr graphene) yielded the best balance of properties, including improvements in modulus (26.3%), tensile strength (10.1%), hardness (7.4%), and tear strength (13.4%). This approach provides an industrially viable route to introducing graphene into rubber products without requiring costly precursors or complex dispersion techniques.