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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.

Next Toyota Prius may get optional all-wheel drive

We've been hearing rumors about the next generation of the Toyota Prius for the last couple of years on a pretty regular basis. From the expectation of lithium-ion battery packs with more capacity for electric-only miles to wireless charging and more emotional styling, there's been no shortage of talking points for the car that's expected to see its first light of day at the very end of 2015 (we hope). But one thing we've yet to hear about, until now that is, is all-wheel drive. According to a report from Automotive News, Koei Saga, senior managing officer in charge of powertrain development of the Prius, said in an interview last week, "I think we will possibly do [all-wheel drive]" for the car's next generation. There isn't any further indication on how the AWD system would work, but we'd put our money on something similar, at least in principle, to the E-Four system that just debuted on the 2015 Lexus NX 300h, which uses an electric motor mounted at the rear to power the car's back wheels when the front wheels lose traction. The AN report also repeats a rumor we've heard before – that Toyota may offer two different battery pack options in its next Prius, one using lithium-ion chemistry and one using the nickel metal hydride technology that the Prius has featured from its very beginning. While the automaker has yet to talk efficiency, it's natural to expect more capacity for EV driving from newer lithium-based technology over that of nickel-based packs to go along with what we'd also expect would be a somewhat higher price. We're sure you're just as curious about the next Prius as much as we are, and so we'll leave you with these words, again from Saga: "The batteries will be renewed. Everything will be revised. And I think we will come up with a fuel economy that will surprise everyone."

West Coast labor dispute hampers Japanese automakers' US plants

The ongoing labor dispute between the International Longshore and Warehouse Union and port owners along the West Coast is starting to affect more Japanese automakers building vehicles in the US. The issue already forced Honda and Subaru to take the expensive option of airlifting some parts into the US weeks ago, and according to USA Today, Toyota and Nissan have begun doing so, as well. The choice hasn't been cheap, though, and Subaru's chief financial officer estimated that the decision cost around $60 million more per month than sending components by cargo ship. The effects continue to radiate, according to USA Today, and shortages of some models are possible. Honda is slowing production at its factories in Ohio, Indiana and Canada because the automaker doesn't have enough transmissions and electronics for some vehicles. Toyota already cut back on overtime at some factories. Nissan has only seen a small effect from the issue, though, because of its local suppliers. Dock workers and port owners have been negotiating on a new contract since last year, and the union has organized work slowdowns in response. According to USA Today, the automakers could move shipments to Canada or Mexico, but it would take longer for parts to arrive. News Source: USA TodayImage Credit: Mark Ralston / AFP / Getty Images Earnings/Financials Plants/Manufacturing UAW/Unions Honda Nissan Subaru Toyota shipping port labor dispute