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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.

Anti-EV messaging alive and well at Toyota, sort of

The folks at Toyota in Japan can be pretty blunt about electric-vehicle technology prospects as a viable transportation alternative to the internal combustion engine. Here in the states? Slightly more sanguine. Toyota global head of research and development Mitsuhisa Kato, according to Automotive News, discounts the potential of substantial EV sales in the near future because the appropriate technology that provides comparable driving distances and fill-up times relative to conventional vehicles doesn't yet exist. While Toyota has been conducting testing programs with shorter-commute-distance EVs in countries such as Japan and France, its only production EV in the US is the RAV4 EV, and Toyota sold just 546 of those in the States during the first half of the year. Toyota is much more excited about the debut of its first hydrogen fuel-cell production vehicle, in both Japan and the US, next year. Toyota Motor North America spokeswoman Jana Hartline was a little more charitable when discussing the EV's prospects in an interview with AutoblogGreen. "For shorter range, EVs serve a really great purpose, but as far as having equal mile range to an internal combustion engine, there's going to need to be some serious breakthroughs," Hartline said. "And that where the fuel cell comes in." Last month, Toyota said its fuel-cell sedan that will debut in Japan next April will be priced at about $69,000, though the company emphasized that it shouldn't be assumed it will be priced similarly in the US and Europe. Toyota hasn't released many performance details, though the sedan is expected to have a full (hydrogen) tank range of about 435 miles, or about five times that of a Nissan Leaf. Read here for Autoblog's First Drive of Toyota's fuel-cell sedan.

Subaru to stop building Camry for Toyota in the US

It was back in 2007 that Subaru of Indiana Automotive, under contract from Subaru minority shareholder Toyota, built the first Toyota Camry at its plant in Lafayette, Indiana. Rumblings of the end of that contract work have been around for a while, as Subaru talked of expanding capacity to build more units and add a line for the Impreza, and Toyota talked of moving Camry production to its Georgetown, KY plant. The news was official internally last November when SIA Executive Vice President Tom Easterday told the Louisville Courier-Journal that Camry production would end. Now, Automotive News reports that both automakers have admitted publicly that the end will come in 2016.
SIA currently has a 170,000-unit capacity devoted to the home-brand Legacy and Outback models, while a $400-million expansion increases that to 300,000 units to prepare the facility for Impreza production in two years. Freeing up the 100,000 units of production devoted to the Camry means a 400,000-unit capability, which is far more than Subaru needs at the moment, but the Toyota exit will allow it to expand any way it sees fit. Subaru has said it will absorb the workers on the Camry line and no jobs will be lost, the mayor of Lafayette saying the development could change the timetable for the expansion.