# 19 CEA patents for on-board type IV 70 MPa H2 COPV

Stéphane Villalonga

► To cite this version:

Stéphane Villalonga. 19 CEA patents for on-board type IV 70 MPa H2 COPV. COPV Wolrd 2025, Sharp Composites, Sep 2025, Dusseldorf, Germany. hal-05469887

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https://hal.science/hal-05469887v1

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# 19 CEA PATENTS FOR ON-BOARD TYPE IV 70 MPA H2 COPV

Stéphane VILLALONGA

COPV WORLD 2025, Düsseldorf, 30th of september

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# 70 MPa Type IV H₂ Composite Pressure Vessel (CPV)

* Metallic boss (AL)

* Plastic liner (PE, PA)

* Composite shell (CF+TS or CF+TP)

AL: Aluminium

PE: Polyethylene

PA: Polyamide

CF: Carbon Fibre

TS: ThermoSet polymer

TP: ThermoPlastic polymer

<figure><img src="image_8.png" /></figure>

Carbon fibre mass = 70% Composite mass

* tow of 24k filaments
  7µm filament diameter

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thermoplastic powder (PE, PA)

<figure><img src="image_10.png" /></figure>

Epoxy resin (TS)
or
PA (TP)
# Agenda

1. CEA

2. Patents on Materials

3. Protected program for Design

4. Patents on Manufacturing

5. Patents on Testing, PHM & SHM, Standard&Regulation

6. Other innovations

7. Conclusion
# 1. CEA
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* CEA, the world's leading research institution, ranked among the Clarivate 2025 Top 100 innovators

* The CEA is active in four main areas:

* low-carbon energies

* defense and security

* information technologies

* health technologies

* 9 research centres

* 20 000 technicians, engineers, researchers and staff

* 1 400 PhD & Post Doc

* 750 priority patents filed / year

* 200 start-ups since 1972 in the innovative technologies sector

<figure><img src="image_18.png" /></figure>

<table><thead><tr><th>Rank</th><th>Top 100 Global Innovator, 2025</th></tr></thead><tbody><tr><td>1</td><td>Samsung Electronics</td></tr><tr><td>2</td><td>Tencent</td></tr><tr><td>3</td><td>Honda</td></tr><tr><td>4</td><td>Canon</td></tr><tr><td>5</td><td>Toyota</td></tr><tr><td>6</td><td>Epson</td></tr><tr><td>7</td><td>LG Chem</td></tr><tr><td>8</td><td>FUJIFILM</td></tr><tr><td>9</td><td>Huawei</td></tr><tr><td>10</td><td>RTX</td></tr><tr><td>11</td><td>LG Electronics</td></tr><tr><td>12</td><td>BOE Technology</td></tr><tr><td>13</td><td>Mitsubishi Electric</td></tr><tr><td>14</td><td>Panasonic</td></tr><tr><td>15</td><td>Siemens</td></tr><tr><td>16</td><td>Hyundai Motor</td></tr><tr><td>17</td><td>Sony</td></tr><tr><td>18</td><td>TSMC</td></tr><tr><td>19</td><td>SK hynix</td></tr><tr><td>20</td><td>Kia</td></tr><tr><td>21</td><td>Murata Manufacturing</td></tr><tr><td>22</td><td>Qualcomm</td></tr><tr><td>23</td><td>Toshiba</td></tr></tbody></table>

<table><thead><tr><th>Rank</th><th>Top 100 Global Innovator, 2025</th></tr></thead><tbody><tr><td>24</td><td>Fanuc</td></tr><tr><td>25</td><td>Tokyo Electron</td></tr><tr><td>26</td><td>Sumitomo Electric</td></tr><tr><td>27</td><td>General Motors</td></tr><tr><td>28</td><td>Foxconn</td></tr><tr><td>29</td><td>Samsung Electro-Mechanics</td></tr><tr><td>30</td><td>CEA</td></tr><tr><td>31</td><td>Hitachi</td></tr><tr><td>32</td><td>Airbus</td></tr><tr><td>33</td><td>Ericsson</td></tr><tr><td>34</td><td>GE Aerospace</td></tr><tr><td>35</td><td>AUO</td></tr><tr><td>36</td><td>Dow</td></tr><tr><td>37</td><td>MediaTek</td></tr><tr><td>38</td><td>Philips</td></tr><tr><td>39</td><td>DENSO</td></tr><tr><td>40</td><td>Bosch</td></tr><tr><td>41</td><td>Realtek Semiconductor</td></tr><tr><td>42</td><td>Safran</td></tr><tr><td>43</td><td>Applied Materials</td></tr><tr><td>44</td><td>STMicroelectronics</td></tr><tr><td>45</td><td>Wistron</td></tr><tr><td>46</td><td>NTT</td></tr><tr><td>47</td><td>ITRI</td></tr><tr><td>48</td><td>Kyocera</td></tr></tbody></table>

<table><thead><tr><th>Rank</th><th>Top 100 Global Innovator, 2025</th></tr></thead><tbody><tr><td>49</td><td>Volkswagen</td></tr><tr><td>50</td><td>Siemens Energy</td></tr><tr><td>51</td><td>Kioxia</td></tr><tr><td>52</td><td>Fujitsu</td></tr><tr><td>53</td><td>Brother Industries</td></tr><tr><td>54</td><td>Daikin Industries</td></tr><tr><td>55</td><td>Omron</td></tr><tr><td>56</td><td>Philip Morris International</td></tr><tr><td>57</td><td>TDK</td></tr><tr><td>58</td><td>Nidec</td></tr><tr><td>59</td><td>Ricoh</td></tr><tr><td>60</td><td>MHI</td></tr><tr><td>61</td><td>Nitto Denko</td></tr><tr><td>62</td><td>Infineon Technologies</td></tr><tr><td>63</td><td>Yazaki</td></tr><tr><td>64</td><td>Boeing</td></tr><tr><td>65</td><td>Shin-Etsu Chemical</td></tr><tr><td>66</td><td>Swatch Group</td></tr><tr><td>67</td><td>Alphabet</td></tr><tr><td>68</td><td>BASF</td></tr><tr><td>69</td><td>Johnson &amp; Johnson</td></tr><tr><td>70</td><td>Deere &amp; Co</td></tr><tr><td>71</td><td>Screen</td></tr><tr><td>72</td><td>Micron Technology</td></tr><tr><td>73</td><td>Sumitomo Chemical</td></tr><tr><td>74</td><td>Samsung SDI</td></tr></tbody></table>

<table><thead><tr><th>Rank</th><th>Top 100 Global Innovator, 2025</th></tr></thead><tbody><tr><td>75</td><td>Otis</td></tr><tr><td>76</td><td>ABB</td></tr><tr><td>77</td><td>Ant Group</td></tr><tr><td>78</td><td>Coretronic</td></tr><tr><td>79</td><td>ZEISS</td></tr><tr><td>80</td><td>Nanya Technology</td></tr><tr><td>81</td><td>Evonik</td></tr><tr><td>82</td><td>Halliburton</td></tr><tr><td>83</td><td>Nokia</td></tr><tr><td>84</td><td>Honeywell</td></tr><tr><td>85</td><td>Quanta Computer</td></tr><tr><td>86</td><td>Delta Electronics</td></tr><tr><td>87</td><td>Komatsu</td></tr><tr><td>88</td><td>NEC</td></tr><tr><td>89</td><td>Thales</td></tr><tr><td>90</td><td>AAC Technologies</td></tr><tr><td>91</td><td>CATL</td></tr><tr><td>92</td><td>TE Connectivity</td></tr><tr><td>93</td><td>Caterpillar</td></tr><tr><td>94</td><td>CNRS</td></tr><tr><td>95</td><td>ASML</td></tr><tr><td>96</td><td>Asus</td></tr><tr><td>97</td><td>Winbond</td></tr><tr><td>98</td><td>Michelin</td></tr><tr><td>99</td><td>FORVIA</td></tr><tr><td>100</td><td>Emerson</td></tr></tbody></table>
## 70 MPa Type IV H₂ CPV R&D Lab at CEA

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Dedicated R&D H2 CPV plateform at CEA
from 2001 to 2027

* **Materials**

* Polymer synthesis (PA6)

* Polymer & Composite : characterisation, ageing

* **Design & FE Calculation**

* **Industrial Processes and Manufacturing** (industrial transfer)

* **CPV Testing & SHM**

* ISO Standards, EC79,&R134 Regulations, additional severe condition tests

* **Standard & Regulation contribution**

* (AFNOR, ISO-TC197, EC-SFEM, UNECE-GTR13)

* **Teaching in universities, Support for industry**

## CPV prototyping and testing
# Onboard 70 MPa Type IV H₂ CPV R&D at CEA

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R&D
since 2001

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57
National &
International
projects

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19
patents

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Maintenance & Composite

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MFTECH

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CARBON AXIS

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ARKEMA

NIVITECH COMPOSITES

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62
Industrial
Partners

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20
Academic
Partners

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Wroclaw University
of Science and Technology

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INSA

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Isae

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ENSMA

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Arts et Métiers

EP4443000_A1.pdf

FR2927566_B1.pdf

FR3147367_A1.pdf

IDNN.FR.001.04015.000.S.P.2019.000.20600.pdf

IDNN.FR.001.53003.000.S.P2013.000.30000.pdf

US20240328439_A1.pdf

WO200218117_A1.pdf

WO200218135_A1.pdf

WO200760199_A1.pdf

WO202388977_A1.pdf

WO2005123359_A2.pdf

WO2005123359_A3.pdf

WO2007144426_A1.pdf

WO2009101183_A1.pdf

WO2013127902_A1 (1).pdf

WO2013127902_A1.pdf

WO2016166326_A1.pdf

WO2022136811_A1.pdf

WO2022136812_A1.pdf

WO2022229554_A1.pdf

WO2023217934_A1.pdf
# Current collaborative research R&D projects

## HYPERSTOCK

ANR-22-PEHY-0004

### Materials and Methodologies repository

* Enhancing the security and confidence of hyperbaric solutions

* Providing solutions for the advent of H2 heavy-duty mobility

* Reducing the carbon footprint of reservoirs, including lifecycle analysis

* Increasing the social acceptability of hyperbaric solutions

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CEA H₂ 36L CPV : Conformable

## ULHYS

ANR-21-CE05-0019-01

### Rotomolding process optimization with Ultrasonic method and simulation

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US signal studies and Process simulation during liner rotomolding
Commercialized by Raigi

# Rotomolding & Filament Winding at CEA

<figure><img src="image_40.png" /><figcaption>## Rotomolding</figcaption></figure>

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<figure><img src="image_42.png" /><figcaption>Inputs</figcaption></figure>

<figure><img src="image_43.png" /><figcaption>## Robotic Filament Winding</figcaption></figure>

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<figure><img src="image_46.png" /><figcaption>CEA H₂ 36L CPV : Conformable</figcaption></figure>

<figure><img src="image_47.png" /><figcaption>CEA H₂ 62L CPV : Thermoset matrix</figcaption></figure>

<figure><img src="image_48.png" /><figcaption>CEA H₂ 37L CPV : Full thermoplastic</figcaption></figure>

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CPV testing at CEA: R134 EC79 + severe tests

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(c) Hypactor Project [JTI GA 621194]
CEA Impact with pneumatic canon (5kJ)

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2. CEA Patents on
Materials
Patents on liner materials

PA6 by reactive rotomolding

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(10) Numéro de publication internationale
WO 2007/060199 A1

<figure><img src="image_65.png" /><figcaption>FIG. 4</figcaption></figure>

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Epoxy by reactive rotomolding

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(10) Numéro de publication internationale
WO 2007/144426 A1

<figure><img src="image_69.png" /><figcaption>FIG. 1</figcaption></figure>
# Patents on Adhesion Material between Boss and Liner polymer

## Boss Liner adhesion

<figure><img src="image_70.png" /></figure>

(10) Numéro de publication internationale
WO 2016/166326 A1

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# Patents on Materials : Fastcuring Epoxy fot Wet Winding

<figure><img src="image_75.png" /></figure>

INSA

INSTITUT NATIONAL
DES SCIENCES
APPLIQUEES
LYON

<figure><img src="image_76.png" /></figure>

VITECH COMPOSITES

## Fastcuring Epoxy fot Wet Winding

<figure><img src="image_77.png" /></figure>

WO 2023/217934 A1

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<figure><img src="image_79.png" /></figure>

Heating : 6h45

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<figure><img src="image_83.png" /></figure>
# Patents on Materials : Fastcuring Epoxy Towpreg

<figure><img src="image_84.png" /></figure>

INSA

INSTITUT NATIONAL
DES SCIENCES
APPLIQUEES
LYON

<figure><img src="image_85.png" /></figure>

VITECH COMPOSITES

Fastcuring Epoxy Towpreg

<figure><img src="image_86.png" /></figure>

(10) Numéro de publication internationale
WO 2023/088977 A1

<figure><img src="image_87.png" /></figure>

<figure><img src="image_88.png" /></figure>

<figure><img src="image_89.png" /></figure>

Heating : 6h00

<figure><img src="image_90.png" /></figure>

<figure><img src="image_91.png" /></figure>

<figure><img src="image_92.png" /></figure>
# Patents on Fire protection coating

## Fire protection coating

<figure><img src="image_93.png" /></figure>

(10) Numéro de publication internationale
WO 2013/127902 A1

<figure><img src="image_94.png" /></figure>

<figure><img src="image_95.png" /><figcaption>Time before burst or leak for H₂ TS&TP CPV with or without CEA coating, without TPRD during an engulfed fire function of initial pressure (bar)</figcaption></figure>

<figure><img src="image_96.png" /></figure>

Fire resistance > 30 min
3. CEA protected program
■ for Designing
# Designing: FIWIQUS CEA protected program

Filament winding in Abaqus

Each composite layers are modelled with program stability

<figure><img src="image_97.png" /></figure>

<figure><img src="image_98.png" /></figure>
# Vi: Adimensionless number for Laminate efficiency assessment

$$Vi = \frac{\overline{P}_{burst} \times V_{fluid}}{\sigma_{UD ply}^{l} \times V_{laminate}}$$

$$Vi_{Type IV CPV}^{70MPa} < 20\%$$

<figure><img src="image_99.png" /></figure>

Highest load (break) in dome region for internal helical layer

Highest load (break) in cylinder region for internal circonferential layer

<figure><img src="image_100.png" /></figure>

<figure><img src="image_101.png" /></figure>

<figure><img src="image_102.png" /></figure>

<figure><img src="image_103.png" /></figure>
4. Process & Manufacturing
Patents on Rotomolding process

EVOH layer bewteen 2 TP layers

<figure><img src="image_104.png" /></figure>

(10) Numéro de publication internationale
WO 02/18117 A1

<figure><img src="image_105.png" /><figcaption>FIG. 3</figcaption></figure>

<figure><img src="image_106.png" /></figure>

<figure><img src="image_107.png" /></figure>

TP Multilayers

<figure><img src="image_108.png" /></figure>

(10) Numéro de publication internationale
WO 02/18135 A1

<figure><img src="image_109.png" /><figcaption>FIG. 3</figcaption></figure>
Patents on Rotomolding process

Liner by reactive rotomolding

<figure><img src="image_110.png" /></figure>

(10) Numéro de publication internationale
WO 2005/123359 A3

<figure><img src="image_111.png" /></figure>

<figure><img src="image_112.png" /></figure>

<figure><img src="image_113.png" /></figure>

Liner Rotomolding process

<figure><img src="image_114.png" /></figure>

(10) Numéro de publication internationale
WO 2009/101183 A1

<figure><img src="image_115.png" /></figure>
## 2005 Robotic Rotomolding Innovation

<figure><img src="image_116.png" /><figcaption>Figure n°2 : rotomouleuse robotisée mono-moule</figcaption></figure>

### One robot for 3 processes

- rotomolding

- filament winding

- fibre placement
# 2010 CEA Robotic Filament Winding machine

Commercialised by MFTECH : MF3

Concept used on a large scale by
CPV manufacturers

<figure><img src="image_117.png" /></figure>

<figure><img src="image_118.png" /></figure>

Maintenance & Composite

<figure><img src="image_119.png" /></figure>

MFTECH

<figure><img src="image_120.png" /></figure>
Patents on Manufacturing: FW Robot evolution

Controlled bobbin holder

<figure><img src="image_121.png" /></figure>

(10) Numéro de publication internationale
WO 2022/136811 A1

<figure><img src="image_122.png" /><figcaption>Fig. 8</figcaption></figure>

<figure><img src="image_123.png" /></figure>

Rotating delivery unit

<figure><img src="image_124.png" /></figure>

(10) Numéro de publication internationale
WO 2022/229554 A1

with

<figure><img src="image_125.png" /></figure>

MFTECH

<figure><img src="image_126.png" /><figcaption>Fig. 2</figcaption></figure>

Depositing head

<figure><img src="image_127.png" /></figure>

(10) Numéro de publication internationale
WO 2022/136812 A1

<figure><img src="image_128.png" /><figcaption>Fig. 2</figcaption></figure>
5. Process & Testing
# Patents on Testing: Cycling process

## Extreme Temperatures Cycling Unit

<figure><img src="image_129.png" /></figure>

FR3147367 A1

<figure><img src="image_130.png" /></figure>

<figure><img src="image_131.png" /></figure>

<figure><img src="image_132.png" /></figure>

## Cycling process unit

<figure><img src="image_133.png" /></figure>

EP 4 443 000 A1

<figure><img src="image_134.png" /></figure>

## Multiplicator cylinders

<figure><img src="image_135.png" /></figure>

US 20240328439A1

<figure><img src="image_136.png" /></figure>

FIG. 3

<figure><img src="image_137.png" /></figure>
# WUT-CEA PHM during FW & Curing

2014

**ponctually** sensitive OF

## Development of SHM strategy and technology with WUT (Copernic Project)

* Following CPV behaviour during manufacturing (FW, Curing)

* Following CPV behaviour during cycling

* Proposition of an update SAE J2601 standard with SHM strategy

<figure><img src="image_138.png" /></figure>

<figure><img src="image_139.png" /></figure>
# WUT-CEA SAE J2601 protocol improvement

Proposition of an update SAE J2601 standard with SHM strategy

<figure><img src="image_140.png" /></figure>

## Requirements:

- **no communication** between vehicle and HRS

- COPV continuously monitored by integrated sensors

- data collected and analyzed by on-board Reading Unit

- SHM parameter controls the filling valve

SAE J2601 establishes the protocol and process limits for hydrogen fueling
6. Other innovations
Other CEA innovations

* Parametric Technico-economical tool (Copernic=>600 €/kg)
  2014

<figure><img src="image_141.png" /><figcaption>Inputs</figcaption></figure>

<figure><img src="image_142.png" /><figcaption>Outputs</figcaption></figure>

* IR TP Filament winding robotic head (Hype, good composite closure near the boss)
  2008

<figure><img src="image_143.png" /></figure>

<figure><img src="image_144.png" /></figure>

<figure><img src="image_145.png" /></figure>

<figure><img src="image_146.png" /></figure>

<figure><img src="image_147.png" /></figure>

* FW & ATL composite layers for H2 CPV
  2023

<figure><img src="image_148.png" /></figure>

CARBON AXIS

* Conformable 70 MPa vessels
  2024-2027

<figure><img src="image_149.png" /></figure>
6. Conclusion
Conclusion

* CEA developed the on-board 70MPa Type IV composite pressure vessel technology from 2001 to 2027

* 23L (Calhypso 2018) & 62L (Hiphone 2017) 70MPa CPV are ready for industrialisation

* Several innovations have made it possible to better understand and improve materials, design methods, processes and manufacturing, processes and testing and process and structural health monitoring

* Many technologies have been passed on to industrialists (rotational molding, filament winding, sensors) who were able to develop their activities

* This was possible thanks to National and European collaborative research projects between industrialists and academics

* There is still a lot of work to be done to optimize the tanks through the improvement of materials, calculations, processes, and monitoring.

* It is essential to better use the entire composite structure.

* Today, the burst coefficient of the tanks will be reduced from 2.25 to 2, which means a reduction in the safety coefficient of 1.8 to 1.6.
# Thanks & Acknowledgement

* The audience

* The COPW World 2025 organisation

* Sharp Composites

* CEA partners since 2001

* The French National Research Agency (ANR: Agence Nationale de la Recherche) and European Commission (EC)

<figure><img src="image_150.png" /></figure>

<figure><img src="image_151.png" /></figure>

<figure><img src="image_152.png" /></figure>

<figure><img src="image_153.png" /></figure>

<figure><img src="image_154.png" /></figure>

Maintenance & Composite

<figure><img src="image_155.png" /></figure>

MFTECH

<figure><img src="image_156.png" /></figure>

INSA

INSTITUT NATIONAL
DES SCIENCES
APPLIQUÉES
LYON

<figure><img src="image_157.png" /></figure>

Arts
Sciences et
Technologies
et Métiers

ARKEMA

<figure><img src="image_158.png" /></figure>

VITECH COMPOSITES

<figure><img src="image_159.png" /></figure>

<figure><img src="image_160.png" /></figure>

Wrocław University
of Science and Technology

CARBON AXIS

Isae
Institut Supérieur de l'Aéronautique et de l'Espace

<figure><img src="image_161.png" /></figure>

ENSMA