The effects of the masticated state of isoprene rubber (IR) at the carbon black (CB) addition stage on subsequent mixing, microstructure, and physical properties in the case of a kneader with a characteristic large-diameter shaft are investigated by examining the mastication-time dependence. A sufficiently masticated IR shows a shorter black incorporation time, which results in an improved dispersion of CB and better physical properties. Observing the microstructure of a rubber compound using the atomic force microscope-based nanomechanical technique, poor CB dispersion is revealed for insufficient mastication. Specifically, large CB agglomerations surrounded by the interfacial rubber region with higher elastic modulus than that of a rubber matrix are formed. Such a large CB agglomeration, on the other hand, does not appear in rubber compounds with longer mastication times. The thickness of the interfacial region becomes shorter in these cases. These observations are further discussed by the concept of "rheological unit"introduced by Mooney et al. This study demonstrates that the microstructure of a rubber compound is highly heterogenous with rubber regions of different microscopic elastic moduli and that the microstructure has an influence on CB dispersion and the physical properties of rubber.
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