Compared
with single-component aerogels, hybrid aerogels with multiple
components possess enhanced properties, especially high thermal stabilities.
Thermal stability improvement depends on the mixing between the various
components. In the present research, a ZrO2/SiO2 hybrid aerogel was representatively chosen to study the mixing behaviors
and resultant thermal stabilities. A series of ZrO2/SiO2 hybrid aerogels were synthesized by using different sol–gel
parameters to study shrinkage, nanopore collapse, and crystallization
behavior upon heat treatment. The sol–gel hybridization of
weakly branched ZrO2 and SiO2 clusters was found
to provide maximum mixing of ZrO2/SiO2. The
highly mixed hybrid aerogel, with a ratio of 86/14 w/w ZrO2/SiO2, showed the best thermal stability. The thermally
stable ZrO2/SiO2 hybrid aerogel, after incorporation
into a mullite fiber blanket, showed very low thermal conductivities
of 0.026 ± 0.001, 0.037 ± 0.001, and 0.058 ± 0.002
W/(m K) at 600, 800, and 1000 °C, respectively. It was suggested
that weakly branched ZrO2 and SiO2 clusters
preferred to freely tangle with each other during the preparation
procedure, achieving the most highly mixed ZrO2/SiO2 hybrid with the maximum synergistic effect. This hybrid strategy
may provide pathways in designing other multiple-component hybrid
aerogels.