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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, Morgan Spurlock say hydrogen can be bullsh*t

Toyota wants the world to know that it's not full of crap about hydrogen as the future of fuel. Months before the Mirai arrives at dealers on the West Coast, the automaker is trying to get the word out through documentary series called Fueled by Everything. In the first episode, director Morgan Spurlock (best known for Super Size Me) shows how to make the futuristic fuel cell sedan run on a load of dung. After some processing, anyway. The whole point of the series is to show viewers the myriad sources available to generate hydrogen, and Toyota starts at an attention-grabbing extreme. A pickup truck takes a bed full of cow manure and demonstrates the steps needed to make it into hydrogen for the Mirai. Of course, the new model gets lots of screen time, too. For those in the audience curious to learn more, Toyota also digs a little deeper into the generation process on the series' website. Fueled by Bullsh*t Toyota Taps Morgan Spurlock to Direct First Video in "Fueled by Everything" Series TORRANCE, Calif. (April 22, 2015) – Sometimes reality stinks. Toyota has tapped award-winning documentary filmmaker Morgan Spurlock to show how calling hydrogen fuel cell vehicles "bullsh*t" isn't far from the truth. "Fueled by Bullsh*t" is the first online video in a multi-part "Fueled by Everything" series aimed to educate a broad audience about the innovative ways hydrogen fuel can be made from renewable sources. Spurlock directed the 3-minute piece which features a dairy farmer and mechanical engineer as they follow cow manure from a mooing supply source to its ultimate use in powering the hydrogen fuel cell electric Toyota Mirai. "This project gave us the opportunity to dive into a world that most people don't understand but has the potential to change our world," said Spurlock. "Witnessing manure, something most of us view as being pretty disposable, being transformed into hydrogen fuel to power a car was pretty remarkable. I think this short film is pretty compelling evidence of what could be possible in the years ahead." Beyond high quality dung, hydrogen can be manufactured from other renewable energy sources like solar, wind and biogas from landfills. These production methods can result in a domestic and locally sourced fuel that powers the Mirai while emitting only water vapor from the tailpipe. The multi-series video campaign is launching through the Toyota Mirai website (www.toyota.com/mirai) and additional digital properties with paid online media support.

Toyota RAV4 "Adventure" brings the butch

Just last week, your humble author had a 2013 Toyota RAV4 in his garage, and he couldn't help noting that even in mid-level XLE trim, its aesthetics lacked oomph, due in large part to its cheap-looking black bumpers and airy-looking wheel wells. Judging by the RAV4 "Adventure" on display at the Geneva Motor Show, someone at Toyota must've been thinking the same thing.
With Japan's biggest automaker understandably focused on bigger reveals, information on this butched-up softroader has proven to be hard to come by, with no press materials whatsoever. We don't even know if this is a pure concept or if it's actually being considered for production. Either way, we approve. The 20-inch dark-finish alloys probably don't do much for ride quality, but they certainly look nicely aggressive, as does the new lower fascia with its prominent lower lip. Other changes include beefier wheel arches, side rails, headlamps with integrated LEDs, twin-element fog lamps and mesh grille inserts. All of the changes are quite well integrated - enough so that the Adventure largely avoids looking like a SEMA refugee in person.