Interface‐Structure Synergistic Design Strategy for Copper Tailings/Resin Hollow Building Templates

ABSTRACT Currently, large stockpiles of copper tailings (CTs) are utilized mainly in low‐value applications such as cement admixtures and ceramic raw materials, with limited research exploring their high‐value application in polymer composites. In this study, CTs were modified with silane coupling agent (KH570) and titanate coupling agent (HY105) to prepare S‐CT and T‐CT, which were then incorporated into a polypropylene (PP)/ethylene‐vinyl acetate (EVA) matrix. Various characterization techniques such as X‐ray diffraction, Fourier‐transform infrared spectroscopy, mechanical tests (tensile, flexural, impact), dynamic mechanical analysis (DMA), thermogravimetric analysis and Differential Scanning Calorimetry were employed to investigate the modification effects and properties of the composites. ABAQUS finite element simulation was employed to optimize the structure of hollow building templates and conduct cost–benefit analysis. The results revealed that T‐CT exhibited a contact angle of 64.5°, with significantly improved hydrophobicity and the best interfacial compatibility with PP/EVA. The T‐CT/PP/EVA composite exhibited a 9.6% increase in crystallinity, enhanced thermal stability (with a maximum degradation temperature of 458°C), and significantly improved mechanical properties (tensile strength increased by 59.8%, flexural strength by 12.0%, flexural modulus by 37.3%, and impact strength by 25.5%). To optimize the structural design and cost efficiency of the hollow construction templates, finite element simulations of various template structures were conducted using ABAQUS/Explicit. The results indicated that the proposed cost–benefit analysis, represented by 2D contours, provided an effective approach for balancing performance and cost. This study provides both a theoretical foundation and practical guidance for the high‐value utilization of CTs in the construction industry.