Fuel cells and water electrolysis devices are systems in which hydrogen, oxygen, coolant, and other substances continuously circulate. The part that prevents internal gases from leaking is the "gasket." If this part underperforms, efficiency drops and, in severe cases, it can lead to an explosion.
Lead researcher Oh Geun-hwan and the team at the Chemical Materials Research Division of the Korea Research Institute of Chemical Technology (KRICT) have developed a nanocomposite technology that boosts a gasket's strength, safety, and efficiency all at once. The findings were published in the international journal Advanced Composites and Hybrid Materials in Oct.
The team used an ultra-thin nanomaterial called two-dimensional boron nitride nanoflakes (BNNF). They added functionality by attaching a substance called pyrenemethyl methacrylate (1-PMA), then mixed it into silicone and ethylene propylene diene monomer (EPDM) gaskets.
As a result, they created a kind of dense "maze" inside the material that makes it difficult for hydrogen molecules to escape. Thanks to this structure, the performance of blocking gas leakage improved, and it was not easily damaged by high temperatures or chemicals.
Notably, performance clearly improved even when only 0.5% BNNF was added. In EPDM gaskets, stiffness (Young's modulus) rose by 32.1%, and the hydrogen leakage rate fell by 55.7%. In silicone gaskets, stiffness increased by 96.6%, and gas permeability decreased by 42.7%. In tests of 225 hours in acidic or alkaline environments, stability was outstanding, with almost no mass loss.
In single-cell tests applying this technology, current density was comparable to or better than that of commercial products. Internal pressure was more evenly distributed, improving contact between electrodes and boosting power efficiency. The team said this was thanks to the "maze effect" produced by uniformly dispersed BNNF and the robust bonding structure.
This technology goes beyond simply making a sturdy gasket; it simultaneously improves barrier properties, chemical resistance, and electrochemical performance, and it is significant for offering an alternative to conventional fluorinated and silicone gaskets that faced usage constraints due to environmental regulations. The team is currently proceeding with technology transfer and early demonstration tests and expects it can be applied across various settings, including hydrogen electric vehicles, fuel cells for power generation, and large-scale water electrolysis facilities.
The team noted that this study laid the groundwork for domestic production of silicone-based gaskets, which have a high import dependence. Korea Research Institute of Chemical Technology President Lee Young-guk said, "By securing non-fluorinated alternative materials that can meet environmental regulations, we will achieve both cost savings and enhanced safety."
References
Advanced Composites and Hybrid Materials (2025), DOI: https://doi.org/10.1007/s42114-025-01449-0