Selective Dispersion of Graphene Oxide via an Industry‐Compatible Process for High‐Performance Gas Barrier Rubber Nanocomposites

ABSTRACT Graphene oxide (GO) nanosheets offer significant potential to reduce the gas permeability of rubbers, facilitating the development of high gas barrier elastomers for diverse applications. While constructing segregated GO networks has proven effective in improving gas barrier properties, the limited scalability of current approaches remains a major barrier to practical implementation. In this study, we propose a simple, scalable strategy to achieve selective GO dispersion by blending a natural rubber (NR)/GO masterbatch with pre‐cured NR granules, NR gum, and curing additives, followed by hot pressing. The volume exclusion effect of the NR granules drives the selective distribution of GO nanosheets around them, resulting in a continuous segregated GO network. Meanwhile, the involvement of NR granules in vulcanization strengthens the interfacial adhesion within the composite. The heterogeneous composites exhibit desirable mechanical properties, showing a 340% improvement in modulus over the homogeneous counterpart with 2 phr GO. Notably, excellent gas barrier performance is achieved in heterogeneous composites, as indicated by a 44% decrease in nitrogen permeability relative to the homogeneous counterpart containing 0.5 phr GO. These NR/GO nanocomposites, developed through an industry‐compatible process, offer a combination of high gas barrier efficiency and excellent mechanical performance, making them well‐suited for high‐performance gas barrier applications.