A three-tier nanofibre assembly based on aluminum coated poly(vinyl alcohol) (PVA) nanofibres supported onto a spunbonded polypropylene (PP) web was fabricated via electrospinning and physical vapor deposition (PVD) for the first time. The scanning electron microscopy (SEM) and transmission electron microscopic (TEM) characterizations indicate that PVA nanofibers of approximately 430 nm in diameter and an aluminum coating of approximately 37 nm in thickness were successfully embedded on the supporting polypropylene web. Fourier transform infrared (FTIR) spectra and water vapor transmission rate (WVTR) were measured to determine the radiative heat and water vapor transfer through the materials with or without nanofibre or metal coating, respectively. Compared to the control uncoated PP web, the fabricated three-tier nanofibre assembly indicates a significant increase in thermal radiation extinction without noticeable weight increase or reduction in water vapor permeability. This represents a new and simple approach to produce light-weight hybrid layered assembly highly beneficial in reducing thermal radiation and heat loss in low density fibrous insulations without noticeable weight gain or reduction in water vapor impermeability for wide applications such as protective clothing, sleeping bags, building constructions and aircraft.

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