DEVELOPMENT OF CERAMIC-POLYMER COMPOSITE FOR KITCHEN SINK FABRICATION

Abstract

Inadequate skilful manpower is a major reason for the collapse of the ceramic industries in Nigeria. Other factors include poor management, poor infrastructural facilities, energy crises, high cost of importation of raw materials and spare parts. The expertise that is not available can be address through this research to improve the provision of sinks locally, using locally sourced materials through a system that requires simple production route and minimized energy consumption without compromising the property and functionality of the product. The corrosion tendencies of metallic sink makes fabricated composite sink a superior alternative to all forms of metal sinks due to its non-corrosion properties. The thrust of this research was anchored on the need to develop a kitchen sink product from ceramic fillers using polymer matrix as binder with good functionality, better physical and mechanical properties of the product when compared with similar product made from metallic forms. The intention to reduce the high energy consumption that is peculiar to conventional method of sink production was addressed through a simple processing route and energy saving technique. In this research, ceramic filled polymer composites was developed using clay, limestone and hybrid particulates as ceramic filler and polyester resin as the matrix to produce a composite material for the fabrication of kitchen sink. The mechanical properties of the composites showed that bending strength, flexural modulus, wear and hardness were influenced by both filler morphology and filler loading. The control samples improved in its mechanical properties as the reinforcement increased from 0% – 40% for both clay and limestone filler volume fraction; The fabricated sink showed high wear resistance to abrasion and this behaviour can be attributed to the high strength of interfacial adhesion between the polyester matrix and the limestone-clay fillers used which is due to increased surface area and surface energy of the fillers. The sink showed good resistance to water absorption at 90oC after 24 hours and good bending strength property. The fabricated sink has a hardness value that is similar to steel in terms specific strength and stiffness. The composite sink cannot corrode on like metallic sink that corrode after long exposure to air and water. However, in the design concept of the fabricated composite sink, there exist possibilities of angular grooves which bothers on hygiene and functionality of the sink. It is advised that whoever is going into mass production of this product should fill-up the grooves to give a geometry that allows for free flow into the drains.