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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.

Most reliable cars and trucks of 2022

Related: Least reliable cars and trucks of 2022   For years now, Consumer Reports has been one of the most prolific sources of vehicle reliability data around. The organization tests a number of vehicles each year and surveys its members on various automotive topics, including reliability. The results of its 2022 annual auto survey are in, and the list of most reliable vehicles has been revealed. Unsurprisingly, Toyota and Lexus dominated the list of most reliable vehicles, but BMW and Mini snuck into the top 10 as well. The list includes: Toyota Corolla Hybrid: 93 Lexus GX: 91 Mini Cooper: 89 Toyota Prius: 89 Mazda MX-5 Miata: 85 Lincoln Corsair: 82 Toyota Corolla: 81 Subaru Crosstrek: 80 BMW 3 Series: 80 Toyota Prius Prime: 77 In terms of the most reliable vehicle type, Consumer Reports says that sedans remain the best choice. Their average score is 58, which is notably better than SUVs’ average score of 51. Minivans and pickup trucks are lower, at 44 and 39, respectively. As Consumer Reports notes, many sedans are older models that have allowed their manufacturers to iron out the wrinkles, making them more reliable. Domestic automakers' SUVs and trucks performed better in the survey than their imported counterparts, with scores of 45 and 41, respectively. The study also showed that hybrids and plug-in hybrids are becoming more reliable, and have climbed the score ladder to the tops of their segments in many cases.  Consumer Reports says its study includes 17 trouble areas, including small stuff like creaks and rattles and much larger problems like drivetrain failures. The organization states that it weights each issue based on its severity to create its predicted reliability scores, with 100 being the best. A car must be in production for at least two model years to be considered for the list. Related video: Green BMW Lexus Lincoln Mazda MINI Subaru Toyota Car Buying Maintenance Ownership Convertible Coupe Crossover Hatchback SUV Hybrid Sedan Consumer Reports reliability

Toyota's Bob Carter says far fewer stations needed in shift from gas to hydrogen

Toyota's Bob Carter has been talking about green cars for years, but it's only been recently that his comments have really caught widespread attention thanks to his disparaging remarks about electric vehicle supporters like Elon Musk and Carlos Ghosn and optimism about hydrogen. Speaking at the opening of the Chicago Auto Show this morning, Carter said that Toyota has claimed the "pole position on CAFE," thanks to its deep hybrid bench. The company's green car cred will continue to grow because of its upcoming hydrogen fuel cell car, due out next year. Carter is relentlessly optimistic: "I truly believe fuel cells will fundamentally change how we feel about transportation," he said. The reason, Carter said, is that a hydrogen infrastructure will be easier to install than people think. He referenced a study conducted by the University of California (which we've heard about before) that found that California would only need 68 hydrogen stations to refuel the roughly 10,000 H2 vehicles that Toyota hopes to sell in by 2016 or so. That's a lot more than the nine that exist today, but the state has already approved funding for 20 new stations by 2015 and then up to 100 by 2024. Then he said this: "If every vehicle in California ran on hydrogen, we could meet refueling logistics with only 15 percent of the nearly 10,000 gasoline stations currently operating in the state." "We could meet refueling logistics with only 15 percent of gasoline stations currently operating in CA" - Bob Carter This made us wonder: if the refueling time and range are roughly equivalent between hydrogen and gasoline – Toyota's hydrogen car is supposed to be able to go 300 miles on a five-minute fill-up - then why has the market decided that there should be 10,000 gas stations in California and why would 1,500 be sufficient for hydrogen? "If the locations are optimized," he said, "we don't need 10,000 stations." For example, at major intersections, instead of three gas stations, you'd really just need a single hydrogen one. "There are a lot of questions about the infrastructure, but it's coming. ... It's a hurdle that we've got to climb but it's not as steep as some may imagine." Toyota's Mike Michaels, the national manager, media and public affairs at Toyota Motor Sales, then stepped in to point out that there are gas stations closing and admitted that there might be too many gas stations in California.