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Toyota finds 10% MPG improvement in hybrid PCU

Keeping up its from-all-angles approach to efficiency, Toyota has found yet another way to eke out up to ten percent more precious MPGs in its hybrid vehicles, this time electronically. The automaker has announced the development of new silicon carbide (SiC) power semiconductors for use in power control units, which it will begin testing on Japanese roads within the next year. The PCU using the silicon carbide compound offers less electrical resistance, which improves efficiency when passing current between the battery and electric motor. It also loses less power after shutting off, and can operate at a higher frequency. The net power loss of the new PCU is just one-tenth of the current silicone-only version (the latter accounting for 20 percent of total electrical power loss in today's hybrids). The result, so far, is a claimed five-percent improvement in fuel economy in test vehicles, with the potential of ten percent by the time the new SiC power semiconductor comes to market. Additionally, the carbide wafers allow for smaller a power module, coil and capacitor, thus allowing the entire PCU to be 80 percent smaller (see the side-by-side comparison in the accompanying photo, which you can click to enlarge). We've got a while to wait before we start to see the carbide technology to start making a real-world impact. Toyota aims to begin using the SiC units in 2020. By then, with improvements in the company's other key efficiency factors - engine technology and aerodynamics - cars like the Prius will likely see significant gains in fuel economy. Read more in the press release below. Toyota Develops 'Diamond-like' Computer Chips to Boost Hybrid Mileage May 20, 2014 Toyota City, Japan – Toyota is using one of the hardest materials in nature after diamonds to develop a semiconductor chip it hopes will improve the fuel efficiency of its hybrids, such as the Prius, by as much at 10 percent. The company and its partners announced today that they have developed a silicon carbide (SiC) power semiconductor for use in automotive power control units. Toyota plans to begin test-driving vehicles with the technology on public roads in Japan within a year. The chips, made from carbide - one of the hardest materials in nature, theoretically have superior characteristics such as one-tenth the electrical power loss and 10 times the drive frequency. Toyota said the chips would also allow it to reduce the size of current automotive power control units by 80 percent.

2014 Toyota Highlander recalled over seatbelt anchors

Toyota has announced a small recall of its redesigned, 2014 Highlander over issues with one of its seat belts. The affected vehicles, which were built from November 20, 2013 to January 18, 2014, could have a seatbelt assembly in the middle seat of the third row that wasn't properly secured to a floor anchorage at the factory.
In total, 7,067 of the new Highlanders are included in the recall, which was discovered not after a crash, but during a post-build inspection at the factory. It's unclear if there have been any injuries as a result of the faulty seat belts.
Toyota is set to inform owners of the affected vehicles as well as dealers with the recalled Highlander models in their inventory. Naturally, repairs will be performed free of charge. For the full bulletin form the National Highway Traffic Safety Administration, scroll down.

Next Toyota Prius coming in 60-mpg 'Eco Grade' version?

There's some mystery surrounding the fuel economy level of the next-generation Toyota Prius. The closest we've had to an official number is 55 miles per gallon, which was hinted at by Toyota Motor Corporation's managing officer, Satoshi Ogiso, last year. That number wasn't an official target, but the company even provided a graphic (above) showing how each next generation Prius beat the previous one by four or five mpg. Since the current, third-gen model gets 50, well, we have been left to guess that 55 is the next logical target. But, according to a new report in Automotive News, the new, fourth-generation Prius that's due next year will come in two versions, with one having a bigger ego – sorry, eco – than the other. AN says that the model will arrive with a standard nickel-metal hydride battery pack in a version that gets "about 55 mpg" and then a new "eco grade" version with a li-ion battery that "will be rated at more than 60 mpg." AN says this information came from company executives who were speaking at an August meeting with Toyota dealers. Our sources within Toyota say that they haven't heard anything about two high-efficiency models, so we'll take this with the requisite grain of salt. The current version of the Prius Plug-In Hybrid does use lithium-ion batteries, but this is the non-plug model the dealers are talking about. We think. The dual-battery strategy is certainly a rumor we've heard before. We had thought that the li-ion pack would be for an extended EV range (the current Prius has a barely noticeable EV-only range), but such a pack would be lighter and could boost efficiency, too. In other words, we look forward to hearing more during the upcoming auto show season.