This paper presents the preparation of aerogel/polytetrafluoroethylene (PTFE) microporous materials via needleless electrospray technique, by using an aqueous dispersion of polytetrafluoroethylene as the basic spinning liquid. Different contents of aerogel powders were applied to the spinning liquid for electrospraying to investigate the effect on the structural characteristics and various properties of the materials. Cross-section, surface morphology, and particle size distribution of the electrosprayed materials were examined. Surface roughness, hydrophobicity, and thermal conductivity were evaluated and discussed. The results showed that the electrosprayed aerogel/PTFE layers were compact and disordered stacking structures composed of spherical particles with a rough surface. As the aerogel content increased, the electrosprayed materials demonstrated increased surface roughness and improved surface hydrophobicity with a contact angle up to 147.88°. In addition, the successful achievement of thermal conductivity as low as 0.024 (W m-1 K-1) indicated a superior ability of the prepared aerogel/PTFE composites to prevent heat transfer. This study contributes to the field of development of aerogel/PTFE composites via electrospray technique, providing enhanced final performance for potential use as thermal and moisture barriers in textiles or electronic devices.
Keywords: aerogel; electrospray; hydrophobicity; polytetrafluoroethylene; surface roughness; thermal conductivity.