Recycled silica as a renewable and sustainable alternative to carbon black in natural rubber foams

Sustainable natural rubber foams were prepared by replacing petroleum‐based carbon black (CB) with recycled silica (SiO 2 ) nanoparticles. The total nanofiller concentration was fixed at 40 phr, while the CB/silica ratio was changed from 40/0 to 0/40. The results showed that increasing the silica content increased the curing characteristics, such as delta torque (Δ M ) by 54%, scorch time ( t s ) by 50% and optimum curing time ( t 90 ) by 65%. But foams based on a hybrid system (20/20) produced a more homogeneous structure improving the cell nucleation step and leading to the smallest cell size (18 μm) and highest cell density (8.8 × 10 3 cells mm −3 ) due to reduced filler−filler interactions and better particle dispersion. This improved cellular morphology generated superior mechanical and thermal insulation performance, including the highest compression modulus (2.7 MPa), compressive strength (1.9 MPa) and recoverability (96.6%) combined with the lowest thermal conductivity (0.114 W m −1 K −1 ) at a density of 0.652 g cm −3 . Nevertheless, the foam with 40 phr silica showed higher compressive modulus (26%) and compression strength (15%) compared to the reference sample having 40 phr CB, mainly due to its higher crosslink density. As a final comparison, the recycled silica, being a suitable and sustainable alternative to petroleum‐based CB, showed superior mechanical and thermal insulation properties compared to a commercial grade of silica for natural rubber foams.