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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.

Lexus, Mazda win KBB 5-Year Cost To Own Awards

We focus a lot on what new cars are like to drive, but it's difficult on a one-week loan to really get a sense of what a car is like to live with. Sure, we try to recreate that sense with our long-term vehicles, but even after a year, it's impossible to know fully learn about a car, particularly in terms of reliability and cost of repairs. For 2014 model year vehicles, Kelley Blue Book has put together a list of the most affordable vehicles over a five-year period.
At the tippy top of the list are Mazda and Lexus, with the Zoom-Zoom automaker winning the award for best non-luxury brand. Lexus, meanwhile, was the most affordable luxury marque over a five-year period. It's interesting to note, though, that not a single Mazda won its segment in this year's awards.
General Motors did quite well, taking eight segments, including both the subcompact and plug-in segments, with the gas-powered Chevrolet Spark and Spark EV. The Chevy Camaro SS and ZL1 took the high-performance car award. Toyota was well represented, with five winners split between the main brand (Corolla, Prius C and Tacoma) and Lexus (LS and RX).

2014 Toyota Corolla and Tundra production underway

After months of leaked photos and speculative reports, Toyota finally unveiled its 2014 Corolla to the world in early July at a star-studded California party. The confetti has been swept up and the champagne flutes washed and stored, and now the real work can begin: production. Toyota has announced that its new C-segment player has begun rolling off the lines at its plants in Mississippi and Ontario, Canada this week ahead of the planned start of sales in September. What's more, the refreshed 2014 Tundra pickup has also segued into production in San Antonio, Texas.
Corolla production in Mississippi is still a relatively recent phenomenon, with the plant having begun assembly of the outgoing model in the fourth quarter of 2011, while Toyota's Cambridge, Ontario plant has been churning out the compact volume king since 1988. Conversely, the Tundra has been in production at the Texas facility since 2006, and Toyota projects that the plant will build its milestone one-millionth new vehicle in September, right around the time the reworked fullsize pickup goes on sale.