Mechanical and Thermal Performance of In-Situ Synthesized PDMS-SiO2 Composite as Electrical Insulating Coatings

Polydimethylsiloxane (PDMS) has been extensively employed in electrical insulation applications owing to its excellent thermal stability, hydrophobicity, and dielectric properties. However, its inherent mechanical limitations require structural reinforcement to enhance its performance under more demanding operational conditions. In this study, the mechanical, thermal, and surface properties of PDMS-SiO₂ nanocomposites synthesized via in situ sol-gel process was systematically investigated. The influence of different SiO₂ nanoparticle concentrations (5, 10, and 15 wt%), sol-gel catalyst type (acidic and alkaline), and tetraethyl orthosilicate (TEOS) crosslinking agent ratios (15:1, 10:1, 5:1) was evaluated. Tensile mechanical testing, dynamic mechanical analysis (DMA), and thermogravimetric analysis (TGA) revealed that the incorporation of SiO₂ notably improved both the mechanical strength and thermal stability of the composites. The 5-15b and 10-15a composites exhibited the highest tensile stress and viscoelastic modulus among all samples. Furthermore, the composites retained key functional properties, including hydrophobicity, high volumetric electrical resistivity (~10¹¹ Ω·cm), and strong adhesion. These findings confirm the potential of in situ PDMS-SiO₂ nanocomposites for use as high-performance insulating coatings in advanced electrical applications.