Thermal-Insulation Fillers’ Influences on the Heating Resistance of PDMS-Based Aerogel Layer

PDMS-based aerogel layers were synthesized as insulation layers by adopting mullite fiber (MF), hollow glass microspheres (HGM) and silica aerogel (SA) as the main fillers, and their loading amounts and content ratios were checked to investigate their effects on the thermal insulation properties in PDMS composites by thermal conductivity, thermal stability, and thermal insulation. The loading amount of nanofillers can significantly influence the insulation-layer performance, and the best performance with the lowest thermal conductivity of 0.0568 W/(m·K) was obtained by 10 wt% loading in PDMS with MF:SA:HGM = 2:2:1, which can achieve a temperature difference (∆T) of 67 °C on a 200 °C hotplate. Moreover, the variation of the filler content ratios can also affect the thermal insulation behavior when the loading amount is fixed at 10 wt%, and the best thermal barrier performance can be found for the sample with more SA as the filler (MF:SA:HGM = 1:3:1). The formed sample had the best thermal stability and thermal insulation property, which can stand a 9 min flame test without burning by butane spray gun, and the backside of the sample showed ∆T > 500 °C for the whole test.