Comparative Study on the Foaming and Fireproof Properties of PDMS Foam Composites with Different Inorganic Fillers

In recent years, the increasing frequency of building fires has highlighted the limitations of traditional polymeric materials due to their inadequate fireproof performance. Ceramifiable polymer composites have emerged as a promising alternative by incorporating ceramic-forming fillers that create rigid ceramic-like structures through high-temperature eutectic reactions, offering exceptional thermal insulation and fireproof properties. These composites maintain structural integrity under fire exposure through sufficient mechanical strength retention. The effects of several ceramifiable inorganic fillers (CIFs) on the properties of polydimethylsiloxane (PDMS) foams were systematically investigated in this study. The research demonstrated that fillers with better matrix compatibility significantly enhance the foaming quality, mechanical performance, and fireproof capabilities. Notably, the CaCO3-filled PDMS foam composite (CPF-Ca) demonstrates exceptional foaming characteristics with 84% porosity and a remarkably low density of 0.36 g/cm3. The material achieves tensile and compressive strengths of 0.22 MPa and 0.84 MPa, representing 22% and 127% enhancements, respectively, compared to pure PDMS foam (PPF). Regarding the ceramic conversion capability, the sintered residue of CPF-Ca maintains a compressive strength of 4.39 MPa under high-temperature conditions. This composite material exhibited superior fireproof performance, successfully withstanding a butane torch for 300 s without penetration while maintaining a remarkably low backside temperature of merely 83.6 °C.