An ultralight all‐fiber‐structure sponge with thermal and electromagnetic integrated insulation property

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AbstractThe integration of thermal and electromagnetic interference (EMI) insulation is of great significance for fields such as aerospace that face extreme environments. The challenge lies in ensuring that the protective layer is lightweight while simultaneously possessing the ability to suppress heat conduction, heat convection, thermal radiation, and electromagnetic radiation. To address these challenges, we propose a novel ultralight all‐fiber‐structure composite sponge, yttria‐stabilized zirconia/polyvinyl butyral‐supported silver (YAP) nanofiber sponge, with ultralight mass (∼65 mg/cm3), exceptionally low thermal conductivity (21 mW/m K at 25°C, and 329 mW/m K at 500°C), and remarkable EMI shielding effectiveness (∼62.6 dB). Moreover, benefiting from its all‐fiber‐structure, the YAP nanofiber sponge can endure 100 cycles of compression up to 50% of its original volume while retaining its mechanical properties with minimal degradation. These characteristics render YAP nanofiber sponge an ideal material for integrated thermal and EMI insulation, offering a promising solution to the rigorous demands of extreme environment protection such as space exploration.