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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.

FIA introduces 'Hypercar Concept' for World Endurance Championship

One of the most common jabs at hypercars is the question, "Where can you drive them to their potential?" Imagine the answer being: to the checkered flag in the 24 Hours of Le Mans. We're not there yet, but the FIA World Motor Sport Council took a step closer to the possibility during its second annual meeting in Manila, the Philippines. One of three initiatives the WSMC announced for the 2020 World Endurance Championship was "Freedom of design for brands based on a 'Hypercar' concept." This "Hypercar concept" would replace LMP1 as the premier class in the WEC. The dream, of course, would be seeing racing versions of the AMG Project One, Aston Martin Valkyrie AMR Pro, Bugatti Chiron, Koenigsegg Regera, McLaren Senna GTR, Pagani Huara BC, and the rest of the gang trading paint and carbon fiber through Dunlop in a heinously expensive version of "Buy on Sunday, sell on Monday." The reality is that we don't have all the details yet on the set of regulations called "GTP," but the FIA wants race cars more closely tied to road cars, albeit with the performance level of today's LMP1 cars. Exterior design freedom would shelter internals designed to reduce costs, the FIA planning to mandate less complex hybrid systems and allow the purchase of spec systems. One of the FIA's primary goals is lowering LMP1 budgets to a quarter of their present levels. Audi and Porsche budgets exceeded $200 million, while Toyota - the only factory LMP1 entry this year and next - is assumed to have a budget hovering around $100 million. Reports indicated that Aston Martin, Ferrari, Ford, McLaren, and Toyota sat in on the development of the proposed class. If the FIA can get costs down to around $25 million, that would compare running a top IndyCar team and have to be hugely appealing to the assembled carmakers. The initiative represents another cycle of the roughly once-a-decade reboot of sports car racing to counter power or cost concerns. The FIA shut down Group 5 Special Production Sports Car class in 1982 to halt worrying power hikes, and introduced Group C. In 1993, Group C came to an ignoble end over costs; manufacturers were spending $15 million on a season, back when that was real money and not one-fifth of a Ferrari 250 GTO. Then came the BPR Global GT Series that morphed into the FIA GT Championship, which would see the last not-really-a-road car take overall Le Mans victory in 1998, the Porsche 911 GT1. That era would be most aligned with a future hypercar class.

Next-gen Toyota 86, Subaru BRZ could arrive by 2021

If these rumors are true, a small but dedicated core of fans could be in for a treat. According to Japan Times — and citing unspecified "sources" — Toyota and Subaru are developing a next-generation 86 and BRZ, with a possible launch around 2021. The new car(s) would reportedly have more power, improved handling and newer safety features. According to the report, the rear-drive sports coupes could do away with the current 2.0-liter engine in favor of one with a larger 2.4-liter displacement. The Japan Times sources say the next-gen 86 will also have a lower center of gravity, which will translate to an improvement on the car's already impressive cornering stability. Theoretically, the 2.4-liter in question could be the new FA24 mill used in the upcoming Subaru Ascent crossover that's turbocharged to produce 260 horsepower and 277 pound-feet. That output would be a mammoth jump from the current Toyobaru pair, and it seems doubtful that's what possible second-generation cars would get. Nevertheless, it's at least consistent with recent comments from Toyota engineer Tetsuya Tada that indicated a more powerful, turbocharged 86/BRZ would not be possible unless there was a new, next-generation model. In an interview with Australia's CarAdvice, Tada said, "I do like turbos, however if we come up with a turbo version of the 86 and boost up the power that would result in the necessity of changing the basic configuration completely, to come up with a car that I would be satisfied with." "One characteristic of the 86 is that in terms of the front balance it's slightly front loaded so it makes the handling more fast and agile," he continued. "So if we were to come up with a turbo version, we would have to go change the weight balance between the front and the rear. That means we have to come up with a completely new platform, so it's not about just changing or slight modification in the engine parts." Note that "we have to come up with a completely new platform" does not equal "we are coming up with a completely new platform." He could be talking strictly hypothetically, it could be a wink-wink nudge-nudge implication that his team is already hard at work, or things could've just been a bit fudged in translation. In any event, as hopeful as we are about the possibility of a new generation of Subaru BRZ and Toyota 86, we can't help but maintain a healthy dose of skepticism that the partnership will continue as the Japan Times report suggests.