Why Skived Films Excel in Hydrogen Gasketing

Hydrogen electrolysers and fuel cells can play a central role in the global transition towards a more sustainable energy supply. Countries such as Japan, Germany, and South Korea, for example, have placed significant emphasis and high hopes on hydrogen energy supply, with national roadmaps and funding initiatives accelerating its deployment across transportation, manufacturing, and energy storage.

With the increase in renewable energy production from wind and solar farms, the need to store surplus energy during periods of favourable wind and sun conditions also rises. Hydrogen can provide a solution by integrating electrolysers into power-to-gas systems to store renewable energy as hydrogen and inject it into natural gas grids when required.

In heavy industry, hydrogen is becoming increasingly important, for example in steel production, ammonia synthesis, and chemical refining, as a replacement for fossil-based feedstocks.

Fuel cells, meanwhile, are gaining traction in backup power systems for data centres, hospitals, and information technology infrastructure, where reliability and low-emission operations are critical.

The growing demand for hydrogen is driving rapidly expanding markets for sealing gaskets. The electrolyser sealing gasket market is projected to grow from USD 0.34B in 2024 to USD 0.69B by 2033. The fuel cell gasket market is expected to grow at a CAGR of 11.2% through 2030, with automotive applications currently dominating, but demand from the energy sector growing even faster.

However, storing hydrogen or using it in the demanding operating environments of electrolysers and fuel cells is not straightforward, and hydrogen gasketing can be particularly challenging due to its molecular nature. Let’s explore why.

Due to its unique molecular structure, producing, handling, and gasketing hydrogen is challenging. The small and light H₂ molecules are prone to leakage through even microscopic imperfections, and due to their high diffusivity, they can permeate through many materials. Additionally, extreme operating conditions with significant temperature fluctuations, combined with frequent pressure changes, can fatigue gasket materials and compromise sealing integrity. This can result in a gradual loss of containment and efficiency.

In general, hydrogen systems place extreme demands on gasket materials:

• Chemical resistance: Traditional elastomers may degrade in the acidic or alkaline environments of electrolysis. To minimise the inherent safety risks or failures, traditional gasketing materials need to be inspected and replaced regularly.
• Thermal stability: Operating temperatures can exceed 90°C, requiring materials that maintain integrity under heat and withstand temperature changes over time.
• Mechanical stress: Gaskets must endure high compression and maintain tight tolerances over long cycles. Traditional materials like EPDM tend to lose functionality over time, increasing the risk of failure, losses, and maintenance efforts.
• Weldability: For large frame gaskets (e.g., 1 × 2 m), materials must be weldable—something most conventional films cannot provide.

Challenges like these slow down the transition to hydrogen as the fuel of the future – but they are not insurmountable. Innovative skived films can help overcome these challenges. Let’s find out how.

Skived modified PTFE (polytetrafluoroethylene) films such as Saint-Gobain® Norgard 0200H are highly specialised materials that offer a unique combination of properties, making them exceptionally well-suited for hydrogen gasketing in electrolysers and fuel cells.

Skived PTFE films are produced by slicing thin layers from a solid PTFE billet. This results in films with uniform thickness, smooth surfaces, high dimensional precision and low compression set—ideal for sealing applications with tight tolerances, such as in hydrogen gasketing applications.

The non-reactive surface of PTFE, with its chemical inertness, does not react with moisture or most chemicals, including aggressive gases like hydrogen and oxygen. This allows reliable functionality, safety and efficiency over time, while minimising the need for costly maintenance or replacements.

Additionally, the excellent non-stick surface properties of skived PTFE films maximise resistance against wear and mechanical stresses, significantly reducing the risk of contamination or build-up. The following comparison can help identify the right material for your application:

Together with excellent thermal stability, Norgard Skived PTFE Films perform ideally in electrolyser and fuel cell applications, where reliability and durability are paramount. However, there are also functional advantages of skived PTFE films in hydrogen systems.

To improve precision, these films can be cut or formed into complex gasket geometries with tight tolerances, ensuring consistent and highly precise sealing performance. They are also weldable.

For maximised stack integrity and safety in electrolysers and fuel cells, skived PTFE films help maintain uniform compression across stack layers, reducing the risk of leaks or performance loss.

In supporting long-term durability, the material’s resistance to chemical and mechanical fatigue extends service life, reducing maintenance efforts and downtime.

The world’s energy supply of the future will be a mix of various technologies, from fossil fuels, renewable energy to nuclear power. We have seen that hydrogen can play an intriguing role in storing and transporting energy, but there are still challenges to address. In hydrogen gasketing for electrolyzers and fuel cells, skived PTFE films can help fulfil the promise of a cleaner, more resilient energy system.

However, a new generation of materials is already on the horizon. Saint-Gobain is developing non-PFAS solutions and refining its fluoropolymer strategy to deliver high-performing alternatives for an even more sustainable energy supply. Speak to your tape expert today and discover which solutions are best suited to help your hydrogen projects power the world.