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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 Prius sales could come up short in 2013

A Toyota executive has said that the automaker's hybrid Prius model may not reach its 2013 goal of selling 250,000 units in the US marketplace. Bill Fay, group vice president for Toyota's US sales, told Reuters, "The 240,000 to 250,000 range is kind of where we're settling our sights for the Prius family."
The first-generation Prius, a five-passenger model, was introduced to the States in 2001 (its arrival made it the second mass-produced hybrid, after the two-seat Honda Insight). The second-generation model arrived in 2004, followed by the current third-generation design that arrived for the 2010 model year. The automaker has subsequently added the Prius V, a hatchback wagon (shown above) and the Prius C, a subcompact hatchback. As of March, 2013, cumulative worldwide sales of the Prius had reached 3.67 million units.
Last year, Toyota sold 236,659 Prius models in the US. However, sales of the model have fallen 5.1 percent in the first six months of 2013. In response, the automaker has boosted its marketing for the model, and the promotions are expected to continue through at least July.

Submit your questions for Autoblog Podcast #336 LIVE!

We're set to record Autoblog Podcast #336 tonight, and you can drop us your questions and comments via our Q&A module below. Subscribe to the Autoblog Podcast in iTunes if you haven't already done so, and if you want to take it all in live, tune in to our UStream (audio only) channel at 10:00 PM Eastern tonight.
Discussion Topics for Autoblog Podcast Episode #336
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