Gasket composition

Abstract

Embodiments presented provide for a gasket composition. Embodiments provide a composition that provides superior material features that allows for limitation of elasticity reduction damage for installations over time. Embodiments presented provide a gasket composition comprising at least one layer of one or more polymer compounds with a specified tensile strength, hardness, and a minimum thermal expansion coefficient.

Description

ATTORNEY DOCKET IS24.1870GASKET COMPOSITIONCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to United States Provisional Application 63 / 734238 dated December 16, 2024, the entirety of which is incorporated by reference.FIELD OF THE DISCLOSURE

[0002] Aspects of the disclosure relate to gaskets used in mechanical operations. More specifically, aspects of the disclosure relate to gasket materials that may be used, for example, in hydrocarbon recovery projects.BACKGROUND

[0003] Gasket materials have played a pivotal role in the advancement of both society and industry, serving as essential components in a wide range of mechanical and electrical applications. From the early days of industrialization, gaskets have been employed to create reliable seals, prevent leakage, and ensure the safe and efficient operation of machinery and systems. Their importance extends beyond mechanical operations, as gaskets are also critical in achieving electrical isolation, which safeguards sensitive electronics from external contaminants and electrical interference. Over time, the evolution of gasket technology has paralleled advancements in engineering, enabling greater reliability, safety, and performance across industries such as automotive, energy, telecommunications, and consumer electronics.

[0004] In electrical connections, gasket materials fulfill specialized functions that go beyond mechanical sealing. The primary purpose of these gaskets is to provide both mechanical and electrical isolation between conductive components, thereby preventing short circuits, corrosion, and the ingress of moisture or dust. Common types of gasket materials used in electrical applications include elastomers such as silicone and EPDM, fluoropolymers like PTFE, and various composite materials that combine flexibility withATTORNEY DOCKET IS24.1870 high dielectric strength. These materials are selected for their unique properties, including resistance to temperature extremes, chemical inertness, low electrical conductivity, and the ability to maintain a tight seal under dynamic conditions. By effectively separating electrical pathways and environmental hazards, gaskets contribute to the longevity and reliability of electrical systems.

[0005] The development of high-quality gasket materials for electrical connections presents significant challenges, particularly in industries where environmental conditions are harsh and operational demands are stringent. Factors such as exposure to high temperatures, aggressive chemicals, ultraviolet radiation, and mechanical stress can compromise the integrity of gasket materials, leading to potential system failures. Achieving the ideal balance of mechanical strength, flexibility, and electrical insulation requires extensive research and testing. Material scientists must consider not only the physical and chemical compatibility with adjoining surfaces but also long-term aging characteristics and the risk of degradation under cyclic loading or environmental attack. These challenges are especially pronounced in sectors such as aerospace, oil and gas, and renewable energy, where the reliability of electrical connections directly impacts safety and operational continuity.

[0006] Development costs associated with high-performance electrical gasket materials are a major consideration for manufacturers and end-users alike. The research, formulation, and validation of new materials require substantial investment in laboratory testing, prototyping, and field trials. In applications where demanding environments make material suitability difficult, such as offshore platforms or high-voltage substations, the economic stakes are even higher. Here, the cost of failure can far exceed the price of the gasket itself, driving the need for robust solutions that justify their premium through reduced maintenance and extended service life. However, in many industries, economic constraints necessitate the pursuit of low-cost alternatives that still meet minimum performance requirements. This tension between performance and affordability shapesATTORNEY DOCKET IS24.1870 material selection strategies, encouraging innovation in both new material development and the creative use of established compounds.

[0007] Economic considerations extend beyond initial development and procurement costs. The total cost of ownership for gasket materials includes installation labor, downtime for maintenance or replacement, and the potential consequences of premature failure. Industries operating in cost-sensitive environments, such as consumer electronics manufacturing or mass-produced electrical assemblies, often prioritize materials that offer an acceptable balance of performance and price. In these contexts, standardized gasket solutions and economies of scale can help mitigate costs but may also limit the adoption of cutting-edge materials with superior properties. As a result, decision-makers must carefully evaluate trade-offs between upfront investment and long-term reliability, especially when deploying electrical connections in challenging or mission-critical applications.

[0008] Gasket materials for electrical connections are integral to the safe and reliable operation of modern technology. Their roles in mechanical and electrical isolation have evolved alongside industrial progress, addressing increasingly complex requirements for performance and durability. The development of high-quality gasket materials is shaped by technical challenges and economic realities, demanding careful consideration of environmental suitability and cost-effectiveness. Ultimately, selecting the optimal gasket material involves balancing these factors to ensure both operational excellence and economic sustainability, supporting the continued advancement of electrical systems across diverse industries.

[0009] While PTFE (polytetrafluoroethylene) is widely valued for its chemical inertness and high temperature resistance in gasket applications, it exhibits notable limitations in environments where ongoing flexibility is required. Over prolonged periods, PTFE tends to lose its elasticity when subjected to mechanical stress, elevated temperatures, andATTORNEY DOCKET IS24.1870 continuous pressure cycles. This gradual loss of flexibility can result in reduced sealing effectiveness, especially in dynamic settings where gaskets need to accommodate movement or thermal expansion.

[0010] The inability of PTFE to maintain its original pliability is a consequence of its molecular structure, which becomes increasingly rigid with age and exposure to harsh conditions. As PTFE hardens over time, the material may crack or fail to conform to mating surfaces, leading to potential leakage or compromised isolation. For applications demanding reliable long-term flexibility, alternative gasket materials with better sustained elasticity may offer superior performance and durability compared to PTFE.

[0011] There is a need to provide gasket materials that are superior to conventional materials for use in a variety of environments.

[0012] There is a further need to provide apparatus that does not have the drawbacks discussed above, such as loss of elasticity over time, due to environmental exposure.

[0013] There is a still further need to reduce economic costs associated with operations and apparatus described above with gasket materials.SUMMARY

[0014] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized below, may be had by reference to embodiments, some of which are illustrated in the drawings. It is to be noted that the drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments without specific recitation. Accordingly, the following summary provides just a few aspects of theATTORNEY DOCKET IS24.1870 description and should not be used to limit the described embodiments to a single concept.

[0015] In one embodiment, an electrolyzer gasket is disclosed. The gasket may comprise at least one layer of one or more polymer compounds having a tensile strength of at least in the range of 1000 to 3500 psi, hardness of 80 Shore A to 75 Shore D at an ambient temperature, and a minimum of thermal expansion coefficient, 100 (pm / nr degrees Celsius).

[0016] In another example embodiment, an electrolyzer gasket is disclosed. The gasket may comprise at least one layer of a polymer compound having a tensile strength in the range of 1000 to 3500 psi at an ambient temperature, and at least one or more filler / s, wherein a filler comprises at least one of an oxide, a carbide, a nitride, a boride, or a transition-metal or non-metal ceramic-forming element, and wherein the fillers content is in the range of 15 to 40 weight percent.

[0017] In another example embodiment, an electrolyzer gasket is disclosed. The gasket may comprise at least one layer of a polymer compound having a tensile strength of at least in the range of 1000 to 3500 psi, at an ambient temperature, and at least one or more filler / s, wherein the filler comprises at least one of an oxide, a carbide, a nitride, a boride, or a transition-metal or non-metal ceramic-forming element, and wherein the fillers comprise sizing agents.

[0018] In another example embodiment, an electrolyzer gasket is disclosed. The gasket may comprise at least one layer of a polymer compound having a tensile strength of at least in a range of 1000 to 3500 psi, at an ambient temperature, and at least one or more filler / s, wherein the filler comprises at least one of an oxide, a carbide, a nitride, a boride, or a transition-metal or non-metal ceramic-forming element, wherein the fillers comprise sizing agents, and wherein the gasket comprises various geometries designed to optimizeATTORNEY DOCKET IS24.1870 sealing performances by providing enhanced adaptability to mating surfaces, improved pressure distribution, and superior resistance to gas and fluid leakage.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the drawings. It is to be noted; however, that the appended drawings illustrate only typical embodiments of this disclosure and are; therefore, not be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.

[0020] FIG. 1 is an example of an alkaline electrolyzer structure, according to one or more examples of the disclosure.

[0021] FIG. 2 is a graph illustrating a compression stress relaxation result, according to one or more examples of the disclosure.

[0022] FIG. 3 is a is a series of diagrams illustrating a multi-layer design concept of the present gasket according to one or more examples of the disclosure.

[0023] FIG. 4 is a series of diagrams illustrating various design patterns for the surface of the present gasket, according to one or more examples of the disclosure.

[0024] FIG. 5 is a series of diagrams illustrating various types of labyrinth seal structures, according to one or more examples of the disclosure.

[0025] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures (“FIGS”). It is contemplated that elements disclosed in one embodiment may be beneficially utilized on other embodiments without specific recitation.ATTORNEY DOCKET IS24.1870DETAILED DESCRIPTION

[0026] In the following, reference is made to embodiments of the disclosure. It should be understood; however, that the disclosure is not limited to specific described embodiments. Instead, any combination of the following features and elements, whether related to different embodiments or not, is contemplated to implement and practice the disclosure. Furthermore, although embodiments of the disclosure may achieve advantages over other possible solutions and / or over the prior art, whether or not a particular advantage is achieved by a given embodiment is not limiting of the disclosure. Thus, the following aspects, features, embodiments, and advantages are merely illustrative and are not considered elements or limitations of the claims except where explicitly recited in a claim. Likewise, reference to “the disclosure” shall not be construed as a generalization of inventive subject matter disclosed herein and should not be considered to be an element or limitation of the claims except where explicitly recited in a claim.

[0027] Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, components, region, layer or section from another region, layer, or section. Terms such as “first”, “second”, and other numerical terms, when used herein, do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed herein could be termed a second element, component, region, layer, or section without departing from the teachings of the example embodiments.

[0028] When an element or layer is referred to as being “on”, “engaged to”, “connected to”, or “coupled to” another element or layer, it may be directly on, engaged, connected,ATTORNEY DOCKET IS24.1870 coupled to the other element or layer, or interleaving elements or layers may be present. In contrast, when an element is referred to as being “directly on”, “directly engaged to”, “directly connected to”, or “directly coupled to” another element or layer, there may be no interleaving elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion. As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed terms.

[0029] Some embodiments will now be described with reference to the figures. Like elements in the various figures will be referenced with like numbers for consistency. In the following description, numerous details are set forth to provide an understanding of various embodiments and / or features. It will be understood; however, by those skilled in the art, that some embodiments may be practiced without many of these details, and that numerous variations or modifications from the described embodiments are possible. As used herein, the terms “above” and “below”, “up” and “down”, “upper” and “lower”, “upwardly” and “downwardly”, and other like terms indicating relative positions above or below a given point are used in this description to more clearly describe certain embodiments.

[0030] Aspects of the present disclosure relate to a gasket composed of non-conductive materials designed to provide critical electrical isolation between the anode and cathode in electrolyzers. In these embodiments, by preventing electrical short circuits, the example gaskets described ensure that the electrolysis process operates efficiently, which is vital for the performance of electrochemical systems. The use of non-conductive gaskets significantly mitigates the risk of electrical hazards, particularly in applications involving high voltages or currents, thereby enhancing safety in chemical processing environments.

[0031] Gaskets are commonly used in an electrolyzer environment or configuration and FIG.1 illustrates an alkaline electrolyzer structure. In this FIG.1 , the alkaline, water electrolysis, hydrogen, production system includes the main body of the alkalineATTORNEY DOCKET IS24.1870 electrolyzer and the BOP (Balance of Plant) auxiliary system. The main body of the alkaline electrolyzer is assembled from components such as end pressure plates, sealing gaskets, plates, alkaline electrolyzer electrodes, and diaphragms. A bipolar plate, frame, and gasket support electrodes, and separators are used to conduct electricity. A diaphragm is used to prevent gas mixing. The use of alkaline electrolyzer electrodes promote electrochemical reaction, thereby determining the efficiency of hydrogen production.

[0032] In the embodiments illustrated and described, the gasket’s innovative design integrates advanced elastomeric materials, featuring engineered elastic cores that are complemented by less permeable outer layers. This combination not only improves the gasket’s durability but also its resistance to chemical degradation, making it suitable for demanding industrial applications.

[0033] In one non-limiting embodiment, the core polymer of the new gasket material is formulated from high-performance materials, including hydrogenated nitrile butadiene rubber (HNBR), silicone, ethylene propylene diene monomer (EPDM), fluorocarbon elastomers (FKM), and thermoplastic vulcanizates (TPV). These materials are enhanced with nano-sized fillers that provide exceptional resistance to hydrogen permeation, ensuring the integrity of the gasket under operational conditions.

[0034] In one embodiment, non-conductive fillers utilized in the gasket include silica (SiO?), boron nitride (BN), tungsten nitride (WN), aluminum oxide (AI2O3), zirconium dioxide (ZrC ), magnesium oxide (MgO), and alumina-silicate. These fillers are available in various shapes and sizes, including sphere, irregular, rod, tubular, and sheet forms, allowing for tailored applications based on specific operational requirements. Furthermore, the filler content is in the range of 15 to 40 weight percent.ATTORNEY DOCKET IS24.1870

[0035] In one embodiment, the gasket material comprises a tensile strength of at least in the range of 1000 to 3500 psi, hardness of 80 Shore A to 75 Shore D at an ambient temperature, and minimum of thermal expansion coefficient, 100 (pm / m- degrees Celsius).

[0036] In one embodiment, the gasket material is designed to have high fluid compatibility in extreme pH levels (high alkalinity and acidity) at temperatures above 10, 20, 30, 40, 50, 60, 70, 80 degrees Celsius with life span of over 10 years.

[0037] In another embodiment of the present disclosure, the gasket is manufactured via a curing process, which employs peroxide with co-agents, such as triallyl isocyanurate (TAIC), to enhance the mechanical properties and thermal stability of the gasket. This method ensures a robust and reliable product that meets the rigorous demands of modern industrial environments.Testing and Results

[0038] In embodiments, testing was done on the gasket material via a sintering process, wherein the gasket material tested was a hybrid of materials (PTFE power plus Elastomer powers plus AI2O3 (ZrO2, MgO)) and further exposed to the sintering process.

[0039] FIG. 2 shows the result of the testing, described above, wherein the compression stress relaxation of the gasket material (elastomer) showed a much higher retention of compression stress over time of around 83 percent, while Modified PTFE and PTFE 73 percent range.Design ConceptMulti LayersATTORNEY DOCKET IS24.1870

[0040] In one embodiment, the gasket may comprise a multi-layer structure as shown in FIG. 3, wherein the multi-layer structure further comprises two or more materials, which include elastomers or plastic compounds.Surface Patterns

[0041] The surface of the gasket can feather either a smooth or patterned design. The pattern may be in the form of a labyrinth, also known as a non-contact seal, Leidenfrost seals, or mini maze seal, which works by creating a series of pressure drops that prevent fluids or gases from passing through. Such embodiments may be used for implementation used by the Parsons steam turbine concept.

[0042] FIG. 4 illustrates a series of different patterned designs that may be used on the surface of the gasket, while FIG. 5 further shows different types of labyrinth seal structures.

[0043] The examples described above provide gasket materials and designs that are superior to conventional materials for use in a variety of environments.

[0044] The examples described provide apparatus that does not have the drawbacks discussed above, such as loss of elasticity over time due to environmental exposure.

[0045] The examples described above provide reduce economic costs associated with operations and apparatus described above with gasket materials.

[0046] Example embodiments of the claims are recited next. The embodiments disclosed should not be considered limiting of the disclosure. In one embodiment, an electrolyzer gasket is disclosed. The gasket may comprise at least one layer of one or more polymer compounds having a tensile strength of at least in the range of 1000 toATTORNEY DOCKET IS24.18703500 psi, hardness of 80 Shore A to 75 Shore D at an ambient temperature, and a minimum of thermal expansion coefficient, 100 (pm / m- degrees Celsius).

[0047] In another example embodiment, the gasket may further comprise incorporation of non-conductive materials providing an electrical isolation of an anode from a cathode.

[0048] In another example embodiment, the gasket may be configured wherein the one or more polymer compounds are formulated from hydrogenated nitrile butadiene rubber (HNBR), silicone, ethylene propylene diene monomer (EPDM), fluorocarbon elastomers (FKM), and thermoplastic vulcanizates (TPV).

[0049] In another example embodiment, the gasket may be configured wherein the one or more polymer compounds in a compression stress relaxation show a high retention of more than 83 percent over time.

[0050] In another example embodiment, the gasket may be configured wherein the at least one layer comprises one of a single, double, and multi-layer structure.

[0051] In another example embodiment, the gasket may be configured wherein the multi-layer structure comprises two or more compounds, and wherein the multi-layer structure comprises elastomers or plastic compounds.

[0052] In another example embodiment, an electrolyzer gasket is disclosed. The gasket may comprise at least one layer of a polymer compound having a tensile strength in the range of 1000 to 3500 psi at an ambient temperature; and at least one or more filler / s, wherein a filler comprises at least one of an oxide, a carbide, a nitride, a boride, or a transition-metal or non-metal ceramic-forming element, and wherein filler content is in the range of 15 to 40 weight percent.ATTORNEY DOCKET IS24.1870

[0053] In another example embodiment, the gasket may be configured wherein the fillers encompass silica (SiC>2), boron nitride (BN), tungsten nitride (WN), aluminum oxide (AI2O3), zirconium dioxide (ZrC ), magnesium oxide (MgO), lumina-silicate.

[0054] In another example embodiment, the gasket may be configured wherein the fillers comprising various 2D and 3D morphologies selected from the group consisting of rods, filaments, spherical, rod-like, plate-like, fibrous, needle-like, cubic, pyramidal, irregular, angular, rounded, elongated, branched, helical, or tubular.

[0055] In another example embodiment, the gasket may be configured wherein the fillers comprise various surface features such as porous, smooth, or faceted surfaces.

[0056] In another example embodiment, the gasket may be configured wherein the filler comprises a size in the range of nanometers to microns.

[0057] In another example embodiment, an electrolyzer gasket is disclosed. The gasket may comprise at least one layer of a polymer compound having a tensile strength of at in a range of 1000 to 3500 psi at an ambient temperature; and at least one or more filler / s, wherein the filler comprises at least one of an oxide, a carbide, a nitride, a boride, or a transition-metal or non-metal ceramic-forming element, and wherein the filler comprises sizing agents to protect the fillers from damage and to improve compatibility with a matrix.

[0058] In another example embodiment, the gasket may be configured wherein a filler surface is treated with a sizing agent prior to the compounding of the gasket matrix based on an epoxy resin size of varying molecular weight or silanes at different coating thickness.

[0059] In another example embodiment, an electrolyzer gasket is disclosed. The gasket may comprise at least one layer of a polymer compound having a tensile strength of atATTORNEY DOCKET IS24.1870 least in the range of 1000 to 3500 psi, at an ambient temperature; and at least one or more filler / s, wherein the filler comprises at least one of an oxide, a carbide, a nitride, a boride, or a transition-metal or non-metal ceramic-forming element, and wherein the fillers comprise sizing agents.

[0060] In another example embodiment, the gasket may be configured wherein the gasket has a surface pattern, wherein the surface pattern has at least one of interlock grooves and chambers, and comprises various geometries including O-ring, custom shape profiles in labyrinth patterns, maze, honeycomb, with rectangular, sharp and round tips, and valise.

[0061] In another example embodiment, an electrolyzer gasket is disclosed. The gasket may comprise at least layer of a polymer compound having a tensile strength of at least in a range of 1000 to 3500 psi, at an ambient temperature; and at least one or more filler / s, wherein the filler comprises at least one of an oxide, a carbide, a nitride, a boride, or a transition-metal or non-metal ceramic-forming element, wherein the fillers comprises sizing agents, and wherein the gasket comprises various geometries designed to optimize sealing performances by providing enhanced adaptability to mating surfaces, improved pressure distribution, and superior resistance to gas and fluid leakage.

[0062] In another example embodiment, the gasket may be configured wherein the gasket has a surface pattern, wherein the surface pattern has at least one of interlock grooves and chambers, and comprises various geometries including O-ring, custom shape profiles in labyrinth patterns, maze, honeycomb, with rectangular, sharp and round tips, and valise.

[0063] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited toATTORNEY DOCKET IS24.1870 that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

[0064] While embodiments have been described herein, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments are envisioned that do not depart from the inventive scope. Accordingly, the scope of the present claims or any subsequent claims shall not be unduly limited by the description of the embodiments described herein.

Claims

ATTORNEY DOCKET IS24.1870CLAIMSWhat is claimed is:1 . An electrolyzer gasket comprising: at least one layer of one or more polymer compounds having a tensile strength of at least in the range of 1000 to 3500 psi, hardness of 80 Shore A to 75 Shore D at an ambient temperature, and a minimum of thermal expansion coefficient, 100 (pm / m- degrees Celsius).

2. The gasket according to claim 1 , further comprising incorporation of non- conductive materials providing an electrical isolation of an anode from a cathode.

3. The gasket according to claim 1 , wherein the one or more polymer compounds are formulated from hydrogenated nitrile butadiene rubber (HNBR), silicone, ethylene propylene diene monomer (EPDM), fluorocarbon elastomers (FKM), and thermoplastic vulcanizates (TPV).

4. The gasket according to claim 1 , wherein the one or more polymer compounds in a compression stress relaxation show a high retention of more than 83 percent over time.

5. The gasket according to claim 1 , wherein the at least one layer comprises one of a single, double, and multi-layer structure.

6. The gasket according to claim 5, wherein the multi-layer structure comprises two or more compounds, and wherein the multi-layer structure comprises elastomers or plastic compounds.

7. An electrolyzer gasket comprising: at least one layer of a polymer compound having a tensile strength in the range of 1000 to 3500 psi at an ambient temperature, and at least one or more filler / s, wherein a filler comprises at least one of an oxide, a carbide, a nitride, aATTORNEY DOCKET IS24.1870 boride, or a transition-metal or non-metal ceramic-forming element, and wherein the fillers content is in the range of 15 to 40 weight percent.

8. The gasket according to claim 7, wherein the fillers encompass silica (SiCh), boron nitride (BN), tungsten nitride (WN), aluminum oxide (AI2O3), zirconium dioxide (ZrCh), magnesium oxide (MgO), lumina-silicate.

9. The gasket according to claim 7, wherein the fillers comprising various 2D and 3D morphologies selected from the group consisting of rods, filaments, spherical, rod-like, plate-like, fibrous, needle-like, cubic, pyramidal, irregular, angular, rounded, elongated, branched, helical, or tubular.

10. The gasket according to claim 7, wherein the fillers comprise various surface features such as porous, smooth, or faceted surfaces.

11. The gasket according to claim 7, wherein the filler comprises a size in the range of nanometers to microns.

12. An electrolyzer gasket comprising: at least one layer of a polymer compound having a tensile strength of at least in a range of 1000 to 3500 psi at an ambient temperature, and at least one or more filler / s, wherein the filler comprises at least one of an oxide, a carbide, a nitride, a boride, or a transition-metal or non-metal ceramic-forming element, and wherein the filler comprises sizing agents to protect the fillers from damage and to improve compatibility with a matrix.

13. The gasket of claim 12, wherein a filler surface is treated with a sizing agent prior to the compounding of the gasket matrix based on an epoxy resin size of varying molecular weight or silanes at different coating thickness.

14. An electrolyzer gasket comprising:ATTORNEY DOCKET IS24.1870 at least one layer of a polymer compound having a tensile strength of at least in the range of 1000 to 3500 psi, at an ambient temperature, and at least one or more filler / s, wherein the filler comprises at least one of an oxide, a carbide, a nitride, a boride, or a transition-metal or non-metal ceramic-forming element, and wherein the fillers comprise sizing agents.

15. The gasket according to claim 14, wherein the gasket has a surface pattern, wherein the surface pattern has at least one of interlock grooves and chambers, and comprises various geometries including O-ring, custom shape profiles in labyrinth patterns, maze, honeycomb, with rectangular, sharp and round tips, and valise.

16. An electrolyzer gasket comprising at least layer of a polymer compound having a tensile strength of at least in a range of 1000 to 3500 psi, at an ambient temperature, and at least one or more filler / s, wherein the filler comprises at least one of an oxide, a carbide, a nitride, a boride, or a transition-metal or non-metal ceramic-forming element, wherein the fillers comprises sizing agents, and wherein the gasket comprises various geometries designed to optimize sealing performances by providing enhanced adaptability to mating surfaces, improved pressure distribution, and superior resistance to gas and fluid leakage.

17. The gasket according to claim 16, wherein the gasket has a surface pattern, wherein the surface pattern has at least one of interlock grooves and chambers, and comprises various geometries including O-ring, custom shape profiles in labyrinth patterns, maze, honeycomb, with rectangular, sharp and round tips, and valise.ABSTRACT

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