In order to meet the demands of the insulation layer in the swiftly advancing aerospace thermal protection system and enhance the ablation resistance of ethylene propylene diene rubber (EPDM) insulation layer, a novel EPDM ablation resistance composite was designed by integrating benzoxazine fine-tuned with octal (propyl glycidyl ether) polyhedral oligomeric silsesquioxane (BA-POSS) into the network structure of EPDM. The resulting composite exhibited a more densely cross-linked EPDM/BA-POSS network, consequently augmenting both the mechanical and ablation properties of the EPDM ablation resistance composite. The cross-linking density and tensile strength of EPDM/BA-POSS composite with 18 phr (parts per hundred rubber) BA-POSS increased by 78.4% and 30.7%, respectively, and the linear ablation rate significantly reduced by 47.7%, compared with EPDM composite without BA-POSS. Additionally, the ablation mechanism of EPDM/BA-POSS composites was elucidated through an investigation of the thermo-chemical transformation and analysis of the ablated carbon layer. This study contributes novel insights and methodologies for the future design of low-density rocket motor insulation compounds that offer cost efficiency, enhanced functionality, and wider applicability.
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