Why Skived Films Outperform in Hydrogen Gasketing

Hydrogen electrolyzers and fuel cells can be central to the global transition towards more sustainable energy supply. Countries like Japan, Germany or South Korea for example set high hopes and priorities into hydrogen energy supply with national roadmaps and funding initiatives accelerating deployment across transportation, manufacturing, and energy storage.

With the increase of renewable energy production from wind and solar farms, the need to store energy surplus in times with good wind and sun conditions also increases. And hydrogen can be a solution by integrating electrolyzers into power-to-gas systems to store renewable energy as hydrogen and inject it into natural gas grids when needed.

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

Fuel cells, on the other hand, are gaining traction in backup power systems for data centers, hospitals, and information technology infrastructure, where reliability and reduced emission operations are critical.

The increasing demand for hydrogen leads to rapidly growing markets for sealing gaskets. The electrolyzer 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 11.2% CAGR through 2030, with automotive applications currently dominating but energy sector demand growing even faster.

But it is not easy to store hydrogen or use it in the demanding operating environments of electrolyzers and fuel cells and especially hydrogen gasketing can be challenging because of its molecular nature. Let’s find out why.

Due to its special molecular structure, producing, handing 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. In addition, extreme operating conditions with enormous temperature fluctuations in combination with frequent pressure changes can fatigue gasket materials and compromise sealing integrity. This can lead to gradual loss of containment and efficiency.

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

• Chemical resistance: Traditional elastomers may degrade in the acidic or alkaline environments of electrolysis. To reduce the inherent safety risk or failure, traditional gasketing materials need to be checked 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 withstand high compression and maintain tight tolerances over long cycles. Traditional materials like EPDM tend to lose functionality over time, which increases 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 offer.

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

Skived modified PTFE (polytetrafluoroethylene) films like Saint-Gobain® Norgard 0200H are highly specialized materials that offer a unique combination of properties, making them exceptionally well-suited for hydrogen gasketing in electrolyzers 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 like in hydrogen gasketing applications.

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

In addition, the excellent non-stick surface properties of skived PTFE films maximize resistance against wear and mechanical stresses and significantly reduce the risk of contamination or buildup. The following comparison can help identifying the right material for your application:

Together with excellent thermal stability, Norgard Skived PTFE Films perform ideally in electrolyzer and fuel cell applications, where reliability and durability are paramount. But 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. And they are weldable.

For maximized stack integrity and safety in electrolyzers 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 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 interesting role to store and transport energy but there are still challenges to overcome. In hydrogen gasketing for electrolyzers and fuel cells, skived PTFE films can help to seal the promise of a cleaner, more resilient energy system.

But a new generation of materials is already in the pipeline. Saint-Gobain is working on non-PFAS solutions and is adapting its fluoropolymer strategy to provide high-performing alternatives for even more sustainable energy supply. Talk to your tape expert today and see which solutions are ideal to help your hydrogen projects power the world.