Unlock the Hydrogen Economy with Skived PTFE Films

Many countries like Japan and industries have high hopes in hydrogen as energy supply solution of the future. Especially green hydrogen, which is hydrogen that has been produced with renewable energy, has great potential to decarbonize energy supply as no CO₂ is being emitted in use. Hydrogen itself is not a primary source of energy, but it can be used to store and transport energy to when and where it is needed. Especially in times when solar/wind power generation is low, hydrogen can act as temporary storage to reach net zero carbon emissions. As part of the hydrogen supply chain, hydrogen electrolyzers and fuel cells are central to the global transition toward sustainable energy. The market for frame gaskets in these systems is growing rapidly:

• The electrolyzer sealing gasket market is projected to grow from USD 0.34B in 2024 to USD 0.69B by 2033, with a CAGR of 8.3%  
• 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

Still, there are key barriers to widespread adoption with:

• Storage and transportation
• Safety and leakage concerns
• Cost and scalability issues

These remain among the most pressing issues today.

What makes hydrogen so demanding are mostly the small molecular size with a high permeation risk and therefore tough material and gasketing challenges and extreme conditions like high pressure, harsh chemicals and temperatures during production and storage that can cause permanent stress on materials.

Hydrogen systems impose extreme demands and specific challenges on gasket materials where traditional materials often fall short:

• Chemical resistance: Traditional elastomers degrade in the acidic or alkaline environments of electrolysis
• Thermal stability: Operating temperatures can exceed 90°C (194° F), requiring materials that maintain integrity under heat
• Mechanical stress: Gaskets must withstand high compression and maintain tight tolerances over long cycles
• Weldability: For large frame gaskets (e.g., 1 × 2 m), materials must be weldable—something most conventional films cannot offer  
• Electrical insulation: Short circuits must be prevented at all costs, as they not only reduce efficiency and damage components, but also pose safety hazards
• Tolerances: Low thickness tolerances are a must, enabling sealability and preventing leakage

These challenges often render traditional materials like EPDM or silicone inadequate, especially in high-performance or long-lifetime applications. This is why high-performance polymers with strong chemical resistance and durability have become increasingly important in hydrogen production to maintain system integrity under stress. Let us have a closer look at skived modified PTFE films, their unique properties and how they could help solve the main challenges hydrogen energy supply is facing today. 

Skived modified PTFE films are ultra-thin sheets of polytetrafluoroethylene (PTFE) that are created by skiving thin layers off large, sintered cylindrical PTFE billets of resin with a sharp blade. As PTFE cannot be melt-processed due to its high melting point and viscosity, this skiving process allows to create thin films with customizable thicknesses from the rotating billet.

These skived modified PTFE high-performance fluoropolymer films provide excellent chemical inertness, low friction and non-stick properties, high thermal stability even under extreme conditions and excellent dielectric and insulation properties which make them ideal for demanding hydrogen applications like in electrolyzers and other hydrogen gasketing needs. The modification grade of PTFE makes it weldable, an absolute must to create large format frame gaskets.

Especially their low permeability and excellent sealing performance are highly advantageous in hydrogen applications due to the small size of the molecule. Skived modified PTFE films also provide various benefits for the hydrogen infrastructure, like:

• Safety and Reliability: Preventing leaks and contamination
• Efficiency and Longevity: Reducing maintenance costs and downtime
• Scalability: Supporting large-scale hydrogen deployment

Saint-Gobain® Norgard Films — especially grades like 0200H — are engineered to overcome these limitations:

• Material composition: Skived, highly modified PTFE offers exceptional chemical resistance, thermal stability, and mechanical strength
• Weldability: 0200H is weldable, enabling the production of large, seamless frame gaskets  
• Precision: Tight thickness tolerances and low compression set ensure consistent sealing performance  
• Environmental protection: Norgard Films resist degradation from moisture, oxygen, and aggressive media, protecting sensitive MEA components  

These attributes make Norgard Films ideal for both electrolyzer and fuel cell applications, where reliability and durability are paramount.

There is no sign that the need for energy is about to decrease. In contradiction, there are many signs that energy consumption will further increase to new highs. Hydrogen may be the fuel of the future and become an important part of energy supply, but it’s the materials behind the scenes like skived modified PTFE films that make that future possible. 

Talk to your tape experts today and find out how skived films with unmatched performance in the harshest environments are helping to seal the promise of a cleaner, more resilient energy system.