Mobile High Pressure Hydrogen Storage System for Subfloor Installation

The widespread adoption of hydrogen fuel cell electric vehicles (FCEVs) is currently hindered by the significant cost and lack of geometric flexibility of conventional Type IV pressure vessels made from carbon fiber reinforced plastic (CFRP). These tanks are difficult to integrate into future vehicle platforms optimized for modular batteries. This study, therefore, presents a novel compressed hydrogen storage system (CHSS) based on a modular assembly of seamless steel cylinders. The objective of this approach is to create a design-flexible and cost-effective alternative that adapts to the limited installation space of modern electric vehicle architectures while offering a sustainability advantage through the high recyclability of steel. The system was specifically designed to meet the stringent requirements of the UNECE R134 regulation and subsequently subjected to rigorous experimental validation. The evaluation included all four test sequences required for component certification: Baseline Tests, Performance Durability Test, On-Road Performance Test and Fire Test. The successful validation demonstrates that the developed modular steel-based CHSS meets all relevant safety and performance requirements. It, therefore, represents a technically and economically promising technology that can make a decisive contribution to accelerating hydrogen mobility through its superior design flexibility and sustainability.