Utilizing discarded face masks to fabricate sustainable high-performance panels for enhanced building thermal and acoustic comfort

Abstract

This study aims to design, fabricate, and optimize fibrous panels made of discarded polypropylene face masks (FMs) for application in sound absorption and thermal insulation. The discarded FMs were shredded and transformed into a fibrous mass using a Garnet machine. The resulting fibers, after being mixed with a bio-based binder, were molded based on an experimental design using response surface methodology in conjunction with the central composite experiment design (RSM-CCD) with five different thicknesses, densities, and blending ratios of spunbond to meltblown fabrics. The average of the sound absorption coefficients for the twelve one‐third‐octave bands from 200 to 2500 Hz (SAA) and effective thermal conductivity (Keff) of the panels were measured as the dependent parameters. These values were calculated within the ranges of 0.28–0.53 and 0.031–0.056 W/(mK), respectively. Additionally, the interactive effects of input variables on SAA and Keff of the manufactured panels were discussed. The quadratic and two-factor interaction models were proposed for optimizing the values of SAA and Keff, respectively. The optimal conditions were determined to achieve the maximum SAA and minimum Keff in a thickness of 26.7 mm, density of 135 kg/m3, and blending percentage of 32.4 %. Under these conditions, the measured values of SAA and Keff were 0.534 and 0.0279 W/mK, respectively. Finally, three fibrous panels were manufactured under optimal conditions, and their acoustic and thermal properties were measured. It was observed that excellent agreement exists between the model results and the experimental data with a 95% confidence level. The bending properties of the optimally designed panels were also investigated and the panels exhibited an impressive flexural strength of 2.1 MPa. Additionally, the fire performance of the panels was examined and all panels showed self-extinguishing properties. These findings suggest that panels made of discarded FMs hold promise as an eco-friendly and sustainable construction material for manufacturing acoustic and thermal insulation panels. Moreover, the frequency-dependent absorption coefficients of the panels were predicted using the Johnson-Champoux-Allard model.