Effect of “Spatially Confined” Sepiolite on the Processing and Properties of Natural Rubber/Silica Composites Prepared by Latex Compounding Method

To address the pronounced self-aggregation of highly loaded silica in the aqueous phase and the substantial filler loss occurring during the flocculation stage of latex compounding, this study introduces disaggregated and activated sepiolite possessing a spatial confinement effect as both a suspension stabilizer and a synergistic reinforcing component. On this basis, a multiscale natural rubber (NR)/silica/sepiolite composite system was constructed via a latex compounding route. Rheological characterization combined with static sedimentation observations revealed that the percolation threshold of the sepiolite is approximately 0.8 wt%. When the sepiolite content exceeds 1.0 wt%, its fibrous morphology enables the formation of a continuous three-dimensional network, which physically constrains silica particles and effectively suppresses their sedimentation and self-aggregation in the aqueous medium. Guided by this percolation behavior, a stable silica/sepiolite hybrid slurry was subsequently wet-mixed with natural rubber latex, and the influence of sepiolite loading on silica retention during flocculation, as well as on the resulting composite properties, was systematically examined. The results demonstrate that incorporation of sepiolite reduces filler loss during flocculation, with the loss rate decreasing from 4.7% to 1.1%. The Payne effect, SEM, dynamic and static mechanical analyses indicate that an appropriate sepiolite dosage promotes dispersion of silica within the rubber matrix while simultaneously strengthening filler–rubber interfacial interactions. Accordingly, tensile and tear strengths are increased from 32.1 to 35.5 MPa and from 92.3 to 133.4 N·mm−1, respectively, while wet skid resistance is preserved and both rolling resistance and wear resistance are further improved. The findings of this work establish a practical and efficient strategy for the wet preparation of high-performance NR/silica composites.