Hydrogen storage is a key enabling technology for the extensive use of hydrogen as an energy carrier. However, none of the current technologies satisfies all of the hydrogen storage attributes sought by manufacturers, legislators and end-users. Therefore different European and French projects (StorHy, HyBou, Hype…) aims to develop robust, safe and efficient compressed hydrogen storage systems, suitable for use in hydrogen fuelled fuel cell or internal combustion engine vehicles.

This paper reviews materials and technologies investigated by CEA and applied to the development of type IV high pressure vessels in order to fulfil manufacturers’ specifications and international targets.

The presentation is dedicated respectively to polymeric and composite material development for respectively inner liner and outer composite shell manufacturing. CEA and its partners are using an innovative one step reactive rotomoulding process to access high performance liners. Thus, specific thermoplastic polymers have been developed with enhanced hydrogen tightness and outstanding cycling resistance. Several 700-bar prototypes have been capitalizing on these developments. Corresponding results and performances, at least coming within the highest european ranking, are presented. Based on this first material generation, CEA and its academic and industrial partners have investigated formulation and reactive moulding of thermosets to demonstrate feasibility and potential for the application. Recent promising results are presented particularly in terms of processing and properties. Overall composite design, calculation and manufacturing strategy is also presented and discussed.

To conclude a complete analysis is proposed to assess the potential of the corresponding high pressure cylinders compared to actual hydrogen storage technologies.