This study proposes that the foaming pre‐dispersion technology is combined with the gas‐phase‐assisted spray technology, and a foaming agent potassium oleate is introduced. The volume expansion power generated by the bubbles promotes the dispersion of the filler. The uniformity of foaming promotes the chemical bridging of potassium oleate between rubber and silica. Then, with a large velocity difference between the compressed air and the emulsion, the gas‐phase‐assisted spray gun refines the emulsion and breaks the filler aggregates. Next, the atomized droplets splash on the surface of the high‐temperature roller, and then deposit on it to achieve instant drying, which reduces the loss of non‐rubber components, thereby improving the preparation efficiency and comprehensive properties of masterbatch. The Payne effect of the composite prepared by the FGS technology is weaker. The tensile strength, elongation at break, and tensile product of the vulcanizate prepared by the FGS technology with 7 phr PO have increased by 9%, 5%, and 15%, respectively, and the aging coefficient is 23% higher than that of the dry mixing.

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This paper prepared potassium oleate/silica/natural rubber composites by atomization spray drying technology. This study compared the effects of the environmental protection accelerator potassium oleate and amine accelerator 1,3-diphenylguanidine on the Payne effect, silane reaction index, vulcanization performance, mechanical properties, static and dynamic mechanical properties, and aging properties of silica/natural rubber. The results show that potassium oleate can promote the silane reaction and increase the silane reaction's efficiency. When potassium oleate formed the silica coating, the carboxyl group of potassium oleate and the hydroxyl group of silica were bonded to form a covalent bond, which reduced the polarity of silica and promoted the dispersion effect of silica in the rubber matrix and enhanced the compatibility with rubber. Compared with the original formulation, after adding 3 phr of potassium oleate, the fracture elongation of vulcanized rubber was increased by 17.2%, tensile product increased by 57.3% and rolling resistance decreased by 54.6%. After adding 3 phr of 1,3-diphenylguanidine, the fracture elongation of vulcanized rubber was increased by 1.1%, tensile product increased by 51.1% and rolling resistance decreased by 48.6%. In contrast, the anti-aging performance of the rubber composites with potassium oleate was better than that of 1,3-diphenylguanidine. This study opens up a new way to apply a new green rubber accelerator and prepare high-performance rubber composites.

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