I've had good luck with Insul-Brite in between 2 layers of warm & natural cotton batting, then the outside fabric.

I have made many, many potholders sandwiching insulbrite between two layers of very thin batting. They are not bulky, they are flexible and they do the job! froggyintexas

I've made tons of potholders, and use a layer of Insulbrite with a layer of 100% cotton batting (it's less flammable than the cotton/poly blend), and have never had a problem getting burned. Even grabbing my turkey roasting pan that's been in the oven for hours, I've never had a problem with heat getting through. I don't quilt them very densely, allowing them to be a bit poofier : )

The product I bought at Hancock's may be insul-bright I have never used it before and ask the manager what to use and she got it and cut it for me.

I made these pot holders with the two layers of w & n, insul-bright and farmer's market fabric. I like to quilt them in rows across the pot holder for the feel and control it gives me while using them. Not that I have any right now, they are all gifted to others. Even the two I kept for myself. LOL...

On another note, there is a shiny ironing board fabric you can buy for casserole carriers and foldable portable ironing boards you take to class. I bought mine at nancy's notions. It is offered by the yard. I am thinking this might be the answer for many of you to use on the outside of the mitt that faces the hot surface. Remember the oven mitts of long ago that used that?

I forgot to mention, this is a pattern from the quilt store. I forgot the name of it. But, I just love this design. Your fingers go into the pockets and keep them protected.

I have used a layer of batting, with 1 layer insulbrite-be sure it faces the right way and then added a layer of jeans fabric, cut from an old pr of pants. thick to sew thru, but no hot fingers.

Insulbrite and a layer of wool work well together for me. Even better would be if you could get an old wool blanket for cutting up and then boil the pieces before you cut them to size.

I like your idea of using jeans fabric Cherrio.

Really wonderful pot holders everyone!

My mother always used several layers of old towels cut to proper size. Always worked well. Nobody ever got burned.

I found a good quilted cotton mattress pad at the thrift store. I bought it for $1.99 and cut it into squares and used it as the liners for potholders. It was perfect. It was about 1/4" thick so it was not too rigid and worked great as a pot holder and hot pad.