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Tougher than steel: Wood pulp could make lighter auto parts

KYOTO, Japan — The global push among carmakers to make ever lighter vehicles is leading some auto suppliers in Japan to turn to what seems like an unlikely steel substitute — wood pulp. Japanese researchers and auto component makers say a material made from wood pulp weighs just one-fifth of steel and can be five times stronger. The material - cellulose nanofibers — could become a viable alternative to steel in the decades ahead, they say, although it faces competition from carbon-based materials, and remains a long way from being commercially viable.> Related: Jay Leno drives the Renew cannabis car — hemp you can't dent Reducing the weight of a vehicle will be critical as manufacturers move to bring electric cars into the mainstream. Batteries are an expensive but vital component, so a reduction in car weight will mean fewer batteries will be needed to power the vehicle, saving on costs. "Lightweighting is a constant issue for us," said Masanori Matsushiro, a project manager overseeing body design at Toyota. "But we also have to resolve the issue of high manufacturing costs before we see an increased use of new, lighter-weight materials in mass-volume cars."A NEW PROCESS Researchers at Kyoto University and major parts suppliers such as Denso Corp, Toyota's biggest supplier, and DaikyoNishikawa Corp, are working with plastics incorporated with cellulose nanofibers — made by breaking down wood pulp fibers into several hundredths of a micron (one thousandth of a millimeter). Cellulose nanofibers have been used in a variety of products ranging from ink to transparent displays, but their potential use in cars has been enabled by the "Kyoto Process," under which chemically treated wood fibers are kneaded into plastics while simultaneously being broken down into nanofibers, slashing the cost of production to roughly one-fifth that of other processes. "This is the lowest-cost, highest-performance application for cellulose nanofibers, and that's why we're focusing on its use in auto and aircraft parts," Kyoto University Professor Hiroaki Yano, who is leading the research, told Reuters in an interview. The university, along with auto parts suppliers, are currently developing a prototype car using cellulose nanofiber-based parts to be completed in 2020.

Mazda rotary engine returning, in an autonomous Toyota delivery vehicle

With the return of the Toyota Supra, the Lotus Esprit and Mazda RX-7 probably share the trophy for hardcore sports cars we'd most like sequels for. The Esprit's too hopeless to consider. Mazda continues to speak in riddles about a new RX-7, but the company has confirmed that the RX-7's heart will return: The company's building a rotary-engined range-extender engine for an autonomous Toyota. At this year's Consumer Electronics Show, Toyota announced its e-Palette autonomous electric delivery vehicle. The e-Palette will come in bus, shuttle, and car versions to service the delivery needs of companies like Amazon, Pizza Hut, and Uber. They'll also be built in custom configurations such as mobile hotel rooms and emergency command centers. Toyota owns 5.25 percent of Mazda, the two automakers recently signed a deal to open a factory in Alabama, and Mazda's known for ace work with small engines. It's not surprising that Toyota chose Mazda for help with the e-Palette, but the rotary aspect is novel. Mazda U.S. president Masahiro Moro said, "This is a very suitable engine to run a generator because it's compact and lightweight, with no noise or vibration, and it has very good fuel economy." There have been rumors of this development previously, as far back as 2016, then again last October in reference to an electric architecture Mazda intended for release in 2019, but Toyota was never mentioned. As to pining for that RX-7 redux, Mazda's head of powertrain said the company's overcome the technical issues of a sports-car-sized rotary engine — the challenge is making a business case for such a sports car. We think the RX-VISION made the case three years ago, and it's already fitted with the Skyactiv-R rotary. Separately, a Toyota spokesman added that the two companies are looking into whether the rotary can be useful beyond the electric car. That's not much to go on when it comes to pining for another RX-7, but hope lives on a scanty diet. Related Video:

Toyota, Honda, Nissan and more collaborating to increase fuel efficiency

Toyota, Honda, Mazda, Nissan, Subaru, Mitsubishi, Suzuki and Daihatsu have announced an alliance that will see a push to improve fuel economy from both gas-powered and diesel-powered engines by as much as 30 percent before the end of the decade.
The newly assembled Research Association of Automotive Internal Combustion Engines put the roughly $20-million project together, with the Japanese government committing to half the cost while the eight manufacturers will chip in the rest.
According to Automotive News, the automakers will team up and share basic research on internal-combustion engines in a bid to cut costs. Eventually, the results of the research will find its way into a production vehicle, although it's unclear just when we'll see the fruits of this partnership on the road.