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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.

Green self-driving cars take center stage in Tokyo

Visions of cars that drive themselves without emitting a bit of pollution while entertaining passengers with online movies and social media are what's taking center stage at the Tokyo Motor Show. Japan, home to the world's top-selling automaker, has a younger generation disinterested in owning or driving cars. The show is about wooing them back. It's also about pushing an ambitious government-backed plan that paints Japan as a leader in automated driving technology. Reporters got a preview look at the exhibition Wednesday, ahead of its opening to the public Oct. 30. Nissan Motor Co. showed a concept vehicle loaded with laser scanners, a 360 degree camera setup, a radar and computer chips so the car can "think" to deliver autonomous driving. The Japanese automaker called it IDS, which stands for "intelligent driving system." Nissan, based in Yokohama, Japan, said it will offer some autonomous driving features by the end of next year in Japan. By 2018, it said vehicles with the technology will be able to conduct lane changes on highways. By 2020, such vehicles will be able to make their way through intersections on regular urban roads. Nissan officials said they were working hard to make the car smart enough to recognize the difference between a red traffic light and a tail light, learn how to turn on intersections where white lane indicators might be missing and anticipate from body language when a pedestrian might cross a street. Nissan's IDS vehicle is also electric, with a new battery that's more powerful than the one currently in the automaker's Leaf electric vehicle. Although production and sales plans were still undecided, it can travel a longer distance on a single charge and recharge more quickly. A major challenge for cars that drive themselves is winning social acceptance. They would have to share the roads with normal cars with drivers as well as with pedestrians, animals and unexpected objects. That's why some automakers at the show are packing the technology into what looks more like a golf cart or scooter than a car, such as Honda Motor Co.'s cubicle-like Wander Stand and Wander Walker scooter. Instead of trying to venture on freeways and other public roads, these are designed for controlled environments, restricted to shuttling people to pre-determined destinations. At a special section of the show, visitors can try out some of the so-called "smart mobility" devices such as Honda's seat on a single-wheel as well as small electric vehicles.

Akio Toyoda pledges return to WRC in 2017 with a Yaris

There have been rumors of Toyota returning to the World Rally Championship since the end of 2013, and a Yaris prepped by Toyota Motorsport in Germany has been caught on The Continent several times last year in testing. Akio Toyoda visited Rally Finland while we were there with Hyundai to watch a race up close, and he said that the passion people still had for Toyota's past exploits encouraged him. He finally answered the question about when they planned to enter the series, announcing in Tokyo that they'd line up for the season in 2017. The Japanese company, a legend in rallying, got into the sport in 1979 and left in 1999 after winning seven titles in ten years through the nineties with Carlos Sainz and Juha Kankkunen. The 2017 return is likely due to the regulation changes that year to allow more power than the roughly 300-horsepower in today's challengers and the switch to a fuel-flow formula to let manufacturers use different kinds of engines. Toyota has been sitting in on the WRC rules meetings, and the final slate of changes will be announced at the end of this year. The Yaris that's been testing is powered by a 1.6-liter, four-cylinder that meets current regulations, but we can expect it to change somewhat before it's race-ready. TMG will test the car for the next two years, then it will go up against fellow manufacturers Volkswagen, Hyundai, and Citroen, as well as Fords run by M-Sport. There's video of the Yaris running solo through the Belgian countryside above, and a gallery of the coming car below.