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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.

Mazda to use rotary engine as a range-extender with its first electric vehicle

There's more news from Mazda at the Tokyo Motor Show, where the brand made a big splash, including new developments in its never-ending rotary engine saga. First, Mazda execs confirmed that the Japanese automaker will bring back the rotary engine as a range-extender and battery juicer for its first electric vehicle in 2019. But secondly, the company won't have a rotary-powered successor to its RX-7 and RX-8 sportscars in time for the company's centennial anniversary in 2020. Autoblog previously confirmed that Mazda is planning to have an EV in 2019 that will be available in both pure electric and range-extending versions. Now, the Australian website Motoring reports that the global EV will feature a powertrain similar to the experimental Japan-only Mazda2 (Demio) EV, which used a single-rotor engine as a generator to power the battery pack and increase its driving range. The publication says Mazda plans to release a series of plug-in hybrids based on existing models around 2020, then a pure electric car co-developed with Toyota and Denso in 2021 as part of the EV Common Architecture Spirit Company joint venture. A Mazda spokesman tells Autoblog the company couldn't confirm any details about future products. Meanwhile, enthusiasts shouldn't wait for a rotary-based production version of Mazda's RX-Vision concept from 2015. Motoring cites two executives who explain that the company simply lacks the capital necessary to invest in developing the new model in time for its 2020 centennial. Mazda debuted its rotary engine 50 years ago in the Cosmo Sport in part as a way to stand out from its larger Japanese competitors. The engine, which uses a spinning three-tipped rotor in place of pistons, is smaller and lighter than conventional piston engines, with a greater power-to-weight ratio and quieter, smoother operation. But it delivers less fuel economy and higher emissions — two weaknesses that could be improved via a stop-start system Mazda has developed, based on a pair of U.S. patents. The company has also been hard at work developing its next-generation Skyactiv-X engine, which uses highly precise combustion ignition technology to deliver significant gains in fuel economy and power.Related Video:

Mazda2 nets Japan Car of the Year, Cherokee first US model to ever crack top 10

The 2015 Mazda2 is quite high up on our must-drive list. Yes, the teeny, tiny successor to the 100-horsepower five-door is worth getting excited over, largely because the previous generation was one of the absolute best smiles-per-dollar values on the market.
While we eagerly await for our opportunity to take to the 2's helm, our expectations of the new car have just been heightened thanks to its win in Japan's Car of the Year competition. Called "Demio" in the land of the rising sun, Japanese journalists handed out Mazda's second COTY award since the CX-5 took the title in 2012.
In more surprising news, the new Jeep Cherokee has made the list of 10 Best Cars in Japan. The Jeep's triumph marks the first time an American car has cracked the top ten, finishing eighth. It's not, however, the first Fiat Chrysler vehicle to snag the title, following in the footsteps of the Alfa Romeo Giulietta and Fiat Panda. Still, the fact that an American brand can make such impressive inroads into the traditionally tough-to-crack Japanese market is a seriously big deal.