An idea that I’ve toyed with is to take a 1/4″ EVA CCF pad of medium to high density, and take some 1/2″ lower density EVA foam and strategically bond strips and/or shaped pieces of that to the top of the full, 1/4″ pad. Combine with a sleeping bag.
Basically it borrows some from the Klymit concept of loft pockets, but you don’t have to worry about punctures etc compromising the system. The downside is that it will be bulky.
I’ve also been toying with this idea: take two sheets of 10 mil AeroZero sheets. Bond some high density 1/4″ EVA foam cylindrical pillar pieces to the top of one, and at the edges, bond the other AeroZero sheet to the one with the EVA foam, with the 1/4″ EVA foam inside and in between the two AeroZero sheets. For greater comfort, take some 1/2″ lower density EVA foam pieces and strategically bond them on the outer top for cushion.
This is where it gets tricky, create a valve where you can pull a partial vacuum at home using say a Foodsaver, manual vacuum pumps, etc Vacuum insulation is by far the most efficient thermal insulation and even partial vacuum is pretty good.
I’ve never handled the AeroZero material before. It might not be suited to even a partial vacuum; it might not have enough stiffness and might have too much flexibility and elasticity. Also, they say it’s porous, so it might need a coating to better seal it. Then creating a good valve system could be tough (at least it would for me).
Either way, even if the material did allow a partial vacuum to be pulled and to maintain it and with a good valve system, you would still probably need to occasionally re-pull a vacuum (might be a good ideal to have vacuum pump in your car that could be powered by same and do it right before you start your hike).
If it did work well enough, theoretically, you could get a pretty high R rating for relatively little weight with such a set up. Still would be bulky though. But if you put it in a lightweight fabric sleeve (when rolled up), and put it on the outside of your pack, should be fine.
And most likely quite expensive! (I imagine the AeroZero sheets are probably quite pricey). Does anyone know the prices of this material? I contacted the company once, and other than a brief initial reply, they never responded with prices.