Sandwich Composite Panels with Thermal and Acoustic Insulation Properties for Sustainable Buildings

Urbanization and population growth have heightened the need for sustainable, efficient building materials that combine acoustic and thermal insulation with environmental and economic sustainability. Sandwich composite panels have gained attention as versatile solutions, offering lightweight structures, high strength, and adaptability in construction applications. This study evaluates manual, semi-automatic, and automatic production methods, selecting the automatic process for its efficiency, precision, and suitability for large-scale production. Extensive characterization techniques, including field emission scanning electron microscopy (FE-SEM), thermogravimetric analysis (TGA), Differential Thermogravimetry (DTG), Differential Scanning Calorimetry (DSC), and flammability tests, were employed to evaluate the morphological, thermal, acoustic, and fire-resistant properties of the panels. The P200 sample, produced automatically, demonstrated high acoustic absorption in the mid–high frequencies (2000–4000 Hz), strong interlayer adhesion, and low thermal conductivity (2.75 W/mK), making it effective for insulation applications. The flammability tests confirmed compliance with EPA 1030 standards, with a low flame propagation rate (1.55 mm/s). The TGA-DTG and DSC analyses revealed the thermal stability of the panel’s components, with distinct degradation stages being observed for the polyurethane core and non-woven textile layers. The FE-SEM analysis revealed a compact and homogeneous structure with strong adhesion between the core and textile layers. These results highlight the potential of sandwich composites as eco-friendly, high-performance materials for modern construction.