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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.

Toyota FT-1 hints at Supra, more aggressive hybrids

Toyota showed off the new FT-1 performance concept at the 2014 Detroit Auto Show today, and the obvious story angle is that this is the new Supra. That's enough weight for most concept cars to carry, but then we thought about it a bit more - FT-1 stands for "Future Toyota 1," after all - and re-read the hints Toyota is dropping about how the FT-1 fits into the company's future. Put all the pieces together, and we think there's a chance Toyota's hybrid models are about to get a whole lot cooler. Technically, the FT-1 is an EV, but that's just because all it has for a powetrain is a small battery and motor to move it around on stage. This concept doesn't even have a proposed powertrain, but a production Supra could have any number of powerplants under the hood (V6, V8, hybrid and inline-six are all mentioned by Automotive News). We also like the big red start button on the steering wheel, which owes at least a little to the blue start button in the Prius. What we're more interested here is what this sleek red beast could do for the look of Toyota's hybrids. The FT-1 could change how Toyota designs cars in the future. To make the FT-1, Akio Toyoda, the president and CEO of Toyota Motor Corporation, apparently challenged Toyota's Calty Design Research team to create a car with passion and "a palpable heart-pounding sense of excitement." Instead of making design decisions "by consensus among a large group of stakeholders," the company says "the [design] approval process has been streamlined. This new approach aims to produce cars that connect more deeply with customers." There was a sense in Detroit today that the FT-1 heralds a change in how the company designs cars in the future. The FT-1 is apparently not the result of Toyota's hybrid supercar partnership with BMW, but we know that Toyota isn't a total stranger to a high-performance hybrid category, having built the TS030 hybrid Le Mans race car. For an on-road gas-electric from the company, though, we're much more used to the egg-shaped Prius. While Toyota has backed off a 2003 pledge to make every model a hybrid, it has said that it wants gas-electrics powertrains to proliferate throughout the line-up. And, if the FT-1 previews a new Toyota look, then at least some of those hybrids will benefit from some of the good looks on display in Detroit.

Toyota recalls 1.37 million more vehicles for Takata airbags

Toyota is expanding its passenger-side Takata airbag inflator recall campaign by an additional 1.37 million vehicles in the United States. The models covered under this broadened recall are the 2003-2007 Corolla, Matrix, and Lexus SC430; the 2005-2006 Tundra; and the 2005-2007 Sequoia. In total, Toyota says that this expansion brings the number of its vehicles covered under the Takata inflator recall in the US to 2.915 million. For these latest models, owners will be notified by mail soon. The move is similar to a recent decision by Honda to broaden its recall list. As with millions of other vehicles covered under these recalls, it's possible for exposure to moisture to cause the inflator to ignite too quickly in an airbag deployment. This can cause shrapnel to be sprayed at occupants. At least seven deaths have been potentially linked to these ruptures worldwide. TOYOTA EXPANDS TAKATA AIRBAG SAFETY RECALL TORRANCE, Calif., June 16, 2015 – Toyota Motor Sales, USA, Inc. today announced that it is expanding its recalls involving Takata front passenger airbag inflators. Based on recent information from Takata and the National Highway Traffic Safety Administration (NHTSA), Toyota will recall approximately 1,365,000 additional 2003-2007 Corolla and Corolla Matrix; 2005-2006 Tundra; 2005-2007 Sequoia; 2003-2007 Lexus SC430 vehicles. This brings the total number of Toyota and Lexus vehicles covered by Takata recalls in the U.S. to approximately 2,915,000. In the involved vehicles, the front passenger airbag inflators could potentially be susceptible to rupture when deployed and seriously injure vehicle occupants. "Toyota's focus remains on the safety and security of our customers, and we will continue to respond promptly to new developments so we can resolve issues for them as quickly, conveniently and safely as possible," said Dino Triantafyllos, chief quality officer, Toyota Motor North America. Multiple investigations into the root cause of the potential for inflator rupture are taking place, including by Orbital ATK, an independent engineering firm commissioned by an industry-wide joint testing initiative comprised of the ten automotive manufacturers conducting Takata-related recalls. All known owners of the affected Toyota / Lexus vehicles will be notified by first class mail to return their vehicles to a Toyota / Lexus dealer. The dealer will replace the airbag inflator with a newly manufactured one.