Recent Advancements in Masterbatch Filler Technology and Filler Dispersion for Rubber and Polymer Composites: A Review

ABSTRACT Masterbatch technologies are continuously researched and developed to solve the filler aggregation in rubber or polymer composites. Filler masterbatches are becoming an effective strategy to enhance the dispersion of fillers and improve the overall performance of rubber and polymer composites. Nonetheless, a research gap remains in fields such as dispersion quantification, hybrid filler systems, the latex masterbatch process, and sustainability or eco‐friendly processing. Therefore, this review fulfills that research gap that presents the recent advances in masterbatch filler technologies, which improves the material properties. The type of filler and filler masterbatch preparations are presented in this review. The mechanism of filler incorporation and the effect of surface chemistry on disruption of the filler network are comprehensively analyzed. Various analytical technics are employed to evaluate the filler distribution, degree of agglomeration, interfacial interaction, and orientation within the matrix. Well‐dispersed masterbatches can significantly reduce filler incorporation and greatly improve mechanical reinforcement efficiency. Additionally, filler masterbatches prepared by latex masterbatch process have beneficial effects on material properties, resulting in high‐performance and sustainable composite materials. Finally, the review aims to provide a comprehensive understanding of current technologies and outline future directions for improving dispersion quality in advanced composite polymers.