Low-density foams and aerogels based on upcycled and bio-based nanofibers and additives are promising alternatives to fossil-based thermal insulation materials. Super-insulating foams are prepared from upcycled acid-treated aramid nanofibers (upANF_A) obtained from Kevlar yarn and tempo-oxidized cellulose nanofibers (CNF) from wood. The ice-templated hybrid upANF_A/CNF-based foams with an upANF_A content of up to 40 wt% display high thermal stability and a very low thermal conductivity of 18–23 mW m⁻¹ K⁻¹ perpendicular to the aligned nanofibrils over a wide relative humidity (RH) range of 20% to 80%. The thermal conductivity of the hybrid upANF_A/CNF foams is found to decrease with increasing upANF_A content (5–20 wt%). The super-insulating properties of the CNF-upANF_A hybrid foams are related to the low density of the foams and the strong interfacial phonon scattering between the very thin and partially branched upANF_A and CNF in the hybrid foam walls. Defibrillated nanofibers from textiles are not limited to Kevlar, and this study can hopefully inspire efforts to upcycle textile waste into high-performance products.

Lightweight and mechanically robust hybrid foams based on cellulose nanocrystals (CNC) and multi-walled carbon nanotubes (MWCNT) with an anisotropic structure are prepared by directional ice-templating. The anisotropic hybrid CNC-MWCNT foams displayed a combination of highly anisotropic thermal conductivity and an orientation-dependent electromagnetic interference (EMI) shielding with a maximum EMI shielding efficiency (EMI-SE) of 41–48 dB between 8 and 12 GHz for the hybrid foam with 22 wt% MWCNT. The EMI-SE is dominated by absorption (SE_A) which is important for microwave absorber applications. Modelling of the low radial thermal conductivity highlighted the importance of phonon scattering at the heterogeneous CNC-MWCNT interfaces while the axial thermal conductivity is dominated by the solid conduction along the aligned rod-like particles. The lightweight CNC-MWCNT foams combination of an anisotropic thermal conductivity and EMI shielding efficiency is unusual and can be useful for directional heat transport and EMI shielding. 

By forming and directionally freezing an aqueous foam containing cellulose nanofibrils, methylcellulose, and tannic acid, we produced a stiff and tough anisotropic solid foam with low radial thermal conductivity. Along the ice-templating direction, the foam was as stiff as nanocellulose–clay composites, despite being primarily methylcellulose by mass. The foam was also stiff perpendicular to the direction of ice growth, while maintaining λ_r < 25 mW m^–1 K^–1 for a relative humidity (RH) up to 65% and <30 mW m^–1 K^–1 at 80% RH. This work introduces the tandem use of two practical techniques, foam formation and directional freezing, to generate a low-density anisotropic material, and this strategy could be applied to other aqueous systems where foam formation is possible.