Heat and acoustic insulation materials for construction based on polypropylene from recycled face masks reinforced with date palm leaves

Composite materials were developed by incorporating date palm leaves (DPL) into polypropylene (PP) from recycled face masks, with filler concentrations varying from 0 to 40 wt%, thereby recycling large amounts of face mask waste and date palm waste. A twin-melt extruder was used for mixing, followed by compression molding. Thus, this study provides a sustainable alternative to fossil-fuel-derived heat insulators used in construction by replacing a portion of the PP content with biodegradable wood fibers. Moreover, the research aims to provide a waste management for PP produced from face masks and agricultural waste from date palm trees. The composites were thoroughly characterized to assess their prospects for the desired applications. The outcomes of this study revealed that the addition of DPL filler reduced the thermal conductivity values, increased the acoustic absorption coefficient, and improved the mechanical strength. The composites demonstrated thermal conductivity values as low as 0.069 W/m·K, acoustic absorption coefficient of 0.4, light density of 0.81 g/cm³, compressive strength of approximately 45 MPa, and maximum water retention of 1.1 %. Furthermore, the composites exhibited specific heat of 1480–2030 J/kg·K, and thermal diffusivity between 0.0465 and 0.0573 mm²/s. Moreover, thermogravimetric analysis showed a high thermal stability for the composites, with degradation temperature exceeding 300 °C. Hence, the developed composites show strong potential for use as thermal insulation materials in the building and construction sector.