An efficient method to prepare high grafting montmorillonite with silane coupling agent and its improvements for styrene butadiene rubber composites.

The quantity of silane chemically bonded to the organoclay's surface significantly influences its dispersion within the polymer matrix, as well as the interfacial interaction. This research presents a groundbreaking method for enhancing the surface properties of montmorillonite (Mt) through the use of γ‐(methacryloxy) propyl trimethoxy silane (KH570) coupled with acid treatment, leading to increased grafting efficiency. Confirmed by FT‐IR, TGA, and XRD, the process effectively bonds organo‐silanes to Mt and achieves a high grafting level of 1.59 mequiv/g. Utilizing a latex compounding method, Mt/rubber nanocomposites are synthesized with thoroughly modified clay for peak performance. Dispersion and interfacial properties are evaluated through XRD, TEM, AFM, and DMTA. The findings reveal that the well‐modified Mt is an exceptional filler, ensuring a high level of dispersion and robust interaction with the rubber matrix. This synergy translates to a marked improvement in the mechanical properties of the composite, with notable enhancements observed in both tensile strength and elongation at break of 9.7 MPa and 1141%, respectively. This innovative approach to the graft modification of clays presents a potent method, offering the potential for the industrial‐scale manufacture of high‐performance clay‐based composites. Highlights: A processing method for preparing high grafting clay with a silane coupling agent.Functionalized clay presents better nano‐dispersion in the polymeric matrix.Strong covalent interfacial interaction is constructed between clay and rubber.Tensile Strength and elongation at break of the composites are obliviously improved. [ABSTRACT FROM AUTHOR]