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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.

Hurricane Sandy cost automakers 15,000 vehicles, may have ruined up to 200k

Hurricane Sandy was the largest Atlantic storm in US history, and its total economic impact is just now coming into view. According to Automotive News, Toyota, Chrysler, Nissan and Honda are set to scrap around 15,000 new vehicles ruined by the storm. Nissan alone accounts for about 40 percent of those, with 6,000 Nissan and Infiniti models deeded "un-saleable" due to damage. The company saw 56 dealerships shuttered due to the storm, but 51 of those have since reopened.
Toyota, meanwhile, had some 4,000 vehicles at its Newark port facility, and of those, 3,000 may be scrapped. An additional 825 were dealer inventory when they were ruined. Honda and Acura dealers are reportedly sending 3,440 vehicles to the salvage yard. By comparison, Chrysler weathered the storm fairly well with 825 units destroyed, while Hyundai suffered only 400 lost units and Kia scrapped around 200.
As you may recall, Fisker also suffered some losses, and Automotive News reports the manufacturer saw 320 Karma models damaged beyond repair. Ford and General Motors have yet to come up with estimates, and no automaker has commented on the full cost of replacing the vehicles.

Is 120 miles just about perfect for EV range?

When it comes to battery-electric vehicles, our friend Brad Berman over at Plug In Cars says 40 miles makes all the difference in the world. That's the approximate difference in single-charge range between the battery-electric version of the Toyota RAV4 and the Nissan Leaf. It's also the difference between the appearance or disappearance of range anxiety. The 50-percent battery increase has zapped any lingering range anxiety, Berman writes. The RAV4 EV possesses a 40-kilowatt-hour pack, compared to the 24-kWh pack in the Leaf. After factoring in differences in size, weight and other issues, that means the compact SUV gets about 120 miles on a single charge in realistic driving conditions, compared to about 80 miles in the Leaf. "The 50 percent increase in battery size from Leaf to RAV has zapped any lingering range anxiety," Berman writes. His observations further feed the notion that drivers need substantial backup juice in order to feel comfortable driving EVs. Late last year, the Union of Concerned Scientists (UCS), along with the Consumers Union estimated that about 42 percent of US households could drive plug-in vehicles with "little or no change" in their driving habits, and that almost 70 percent of US commuters drive fewer than 60 miles per weekday. That would imply that a substantial swath of the country should be comfortable using a car like the Leaf as their daily driver - with first-quarter Leaf sales jumping 46 percent from a year before, more Americans certainly are. Still, the implication here is that EV sales will continue to be on the margins until an automaker steps up battery capabilities to 120 or so miles while keeping the price in the $30,000 range. Think that's a reasonable goal to shoot for?