A New Process to Make a Porous PTFE Structure from Aqueous PTFE Dispersion with the Help of Hydrogel

A novel method to make a porous material having relatively large cell diameter (200–300 μm), which consisted of mainly poly(tetrafluoroethylene) (PTFE), was developed from aqueous PTFE dispersion by using the characteristics of hydrogel with the addition of carbon nanofiber (CNF). The porous material was produced as follows: firstly, an aqueous agar gel containing PTFE and CNF was prepared; secondly, the gel was freeze-dried; thirdly, the dried gel was heat-treated at 400°C where the agar was almost decomposed and PTFE became molten. The porous material showed electric conductivity (about 50 Ω), high porosity (about 96 vol%), and relatively uniform cell structures without shrinkage during freeze drying and heat treatment. While the method without CNF resulted in large shrinkage during heat treatment, meaning that CNF prevented the shrinkage. It was explained by the idea that the existence of rigid CNF, which was dispersed in the cell wall, prohibited the shrinkage of PTFE during heat treatment. It was unexpectedly found by SEM analysis that the porous materials had another macro-porous structure inside the cell wall, suggesting that the developed materials had a double porous structure.