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How Toyota's 100-year textile history influenced FCV hydrogen fuel cell car

Turns out, Toyota had a surprising ace in the hole when it came to building the new fuel tanks for the FCV hydrogen fuel cell car, which is coming next year. Well before Toyota became the Toyota Motor Company, it was the Toyota Industries Corporation and it made textile looms. This is important because the main structure of the hydrogen tank is wound carbon fiber. When Toyota set out to increase the strength of the tanks to hold hydrogen stored at 10,000 psi (up from 5,000 in the previous tanks), it was able to draw on its 100-year-old history as it designed its car of the future. "A lot of that textile experience came back when we did the tank wrapping." – Justin Ward "We have a lot of experience with textiles," Justin Ward told AutoblogGreen at the 21st World Congress on Intelligent Transport Systems (ITS) in Detroit this week, "and a lot of that textile experience came back when we did the tank wrapping." On top of being able to hold the higher-pressure hydrogen, Toyota's first attempt to build its own hydrogen tank was six times faster than the industry standard, so it saved time and money as well as working better. The company will also be able to inspect its own tanks. Ward is the general manager of powertrain system control at the Toyota Technical Center and hydrogen vehicles are something he knows a lot about. The reason for the stronger, 10,000-psi tanks is because the 5,000-psi tanks only offered around 180-200 miles of range, even with four tanks in the early $129,000 FCHV Highlander hydrogen prototypes. The FCV only has two, but they will able to deliver the 300-mile range that customers told Toyota they wanted. Dropping the number of tanks not only obviously reduced the cost for the tanks themselves but also the number of valves and hoses and other components you need. Despite the benefits of higher compression, going much higher doesn't make sense. 10,000 psi is the "natural progression," Ward said, because "you start to bump up against compression inefficiencies." Think of an air compressor. When hydrogen is produced at a wastewater treatment plant or a reforming site, Ward said, is it at around ambient pressure (14 psi). That has to be raised, using compressors, all the way to 10,000 psi. "That takes energy," Ward said, "and every doubling of pressure adds another doubling of energy needed, so it starts to add up pretty fast if you go too high." Component specifications are also fine at 10,00 psi, but more difficult at higher levels.

Toyota reaffirms commitment to body-on-frame SUVs

Toyota sold 121,055 Highlander CUVs in 2012, according to Automotive News. By comparison, it sold 78,457 examples of four different body-on-frame, truck-based SUVs (4Runner, FJ Cruiser, Sequoia and Land Cruiser). One could argue then, that the traditional SUVs aren't pulling their weight from a sales perspective. Yet that isn't stopping Toyota from reaffirming its commitment to a segment that has seen its former champions - Ford, General Motors and Chrysler - abandon it with alarming speed. Ford and GM still offer body-on frame utilities, but only in the very largest offerings, catering to seven or even eight passengers. Everything outside of the Expedition or Tahoe rides now on a unibody.
Toyota's decision to stick with the technology is good news if you're in the market for smaller SUVs that are still capable of heading well off the beaten path. Outside of the Jeep Wrangler, Grand Cherokee (a unibody) and perhaps Nissan Xterra, there's not much in terms of capable SUVs between $20,000 and $50,000. As the Toyota brand's US head, Bill Fay, says, "Clearly, the trend has shifted, but there is still an owner base that is interested in these vehicles."
We don't doubt Fay on that, but it may also be somewhat telling that Toyota's SUV lineup is aging, and we haven't seen or heard much about replacement models in the pipeline. Admittedly, the 4Runner (pictured) has been facelifted for 2014, but it's mostly cosmetic in nature. Despite Toyota's posturing, we still expect its body-on-frame lineup to thin in the coming years as sales dwindle and escalating fuel-economy standards make business cases even tougher. Here's hoping that Toyota manages to keep at least one rough-and-tumble SUV in its lineup in the coming years.

Are Toyota and Lexus planning to use Mazda's straight-six and new platform?

Japan's Best Car magazine has what appears to be a whopper of a rumor. The mag said it scooped Mazda's development of a straight-six engine that Mazda only revealed in March, the carmaker having buried the information in a financial statement. By way of Lexus Enthusiast and according to Google translate, Best Car writes that as it was speaking to a Toyota source on an unrelated matter, the magazine found out that Mazda's work on the straight-six was predicated on the engine's use in Toyota Group vehicles, which includes Lexus. Here's the account of how the engine and Mazda's coming front-engined rear-drive platform, dubbed "Large Architecture," will make their way to Toyota City: The first appearance for the straight-six, predicted to come in at a hair under 3.0 liters, is the Mazda Atenza/Mazda6 successor coming around 2022. The powertrain will get a 48-volt hybrid system for increased fuel economy, and the automaker's said to be considering a plug-in hybrid version. Toyota's first shot at the platform and the straight-six will be whatever fills the slot of the Japanese-market Mark-X sedan. We once had a version of the Mark-X in the U.S. as the Toyota Cressida. In Japan, it's sold as a rear- and all-wheel drive option to the Camry. The Mark-X is slated to end production in December this year — a "sporty four-door coupe" on Mazda's platform and with Mazda's engine eventually taking its place. Lexus has a number of plans for the components from Hiroshima. The next Lexus IS is said to evolve from the current sedan, using a Lexus V6 but migrating to Toyota's TNGA platform. Best Car says the IS after that, perhaps sometime around 2026, will hop onto Mazda's new platform and use the inline-six engine. Before that, the replacement for the Lexus RC in 2022 will sit on the Mazda platform and get that inline-six. What's more, Lexus will introduce a new model to slot between the $64,750 RC and the $92,950 LC employing Mazda's architecture and engine. Best Car says the model will act as a "next car" for RC owners, but we can't tell if the magazine means a two-door or a four-door coupe; the article also says the Lexus model will compete with the Audi A7. Toyota and Mazda partnered up in 2016 on technology sharing. Best Car's take is that, as was done on the Supra, Toyota is picking up all the tech it can from suitable sources so that it can continue to sell models that don't make sense to develop alone.