Abstract Thermal insulators were fabricated by freezing gelatin gels containing calcined kaolinite with alumina nanofibers, followed by sintering. The resultant porosity could be varied from 81.0% to 89.8% by solid loadings in the initial slurry. The relationship among porosity, microstructure, compressive strength, and thermal conductivity was examined. The compressive strength and thermal conductivities of the insulators prepared with initial solid loadings from 3 to 6 vol% ranged from 11.6 to 56.7 MPa and from .25 to .46 W/mK, respectively. Those properties were also estimated by simulation using modeling of overall pore morphology, resulting in good agreement.
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