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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 asking NHTSA for fuel cell car safety exemption regarding electric shocks

Toyota is requesting an exemption from federal safety regulations that govern electric cars as it prepares to launch a small-scale hydrogen fuel-cell vehicle fleet.
The Japanese automaker is targeting Federal Motor Vehicle Safety Standard 305, which covers the packaging of high-voltage parts in electric cars. According to Uncle Sam, these systems need to be isolated so that passengers and first responders aren't electrocuted in the event of a crash. That seems pretty smart, but it's become a problem for Toyota's upcoming production fuel cell vehicle, as the mechanism that prevents electric shocks in low-speed crashes will apparently simply keep Toyota's car from even functioning.
Instead of the federally approved system, Bloomberg reports that Toyota plans to insulate the high-voltage wires and cables in the car, along with shielding electrical components like the fuel cells, electric motor and batteries with (presumably non-conductive) metal barriers.

Audi S4 drivers are the most accident-prone, insurance report says

Culling data from more than 4.6 million automobile insurance applications, researchers at the Insurify insurance comparison marketplace picked a winner — or more to the point, a loser — in its determination of the car model with the most accidents so far in 2023: the Audi S4. Why does the sporty, luxury-class German sedan rank so high (or so low)? The organization found that S4 drivers, piloting a car with almost 350 horsepower, are among those who collect the most speeding tickets, and that they get into accidents at a rate 54 percent higher than the national average. If the S4 isnÂ’t a surprise with an at-fault accident rate of 11.7 percent, consider the “family friendly” brand that appears three times on the Insurity list: Subaru. It is represented by three models, including the turbocharged WRX and XV Crosstrek, and at the better-performing bottom of the list, the Subaru Impreza, with an accident rate of 10.3 percent.  In 2023, 7.6 percent of U.S. drivers were involved in at least one at-fault accident in the prior seven years. For drivers of cars on this list, the average at-fault accident rate was 10.5 percent, meaning these drivers are 1.4 times as likely to have an at-fault accident on record. According to its statement, the Insurity data science team explored key safety features, driver behavior, and Insurance Institute for Highway Safety (IIHS) evaluations to pinpoint possible reasons behind these carsÂ’ high accident rates. Following is the list, counting down to the models with most reported accidents: 10. Subaru Impreza (percentage of drivers with a prior at-fault accident on record: 10.3 percent; MSRP base model): $19,795) 9. Kia Niro (percentage of drivers with a prior at-fault accident on record: 10.4 percent; MSRP base model): $26,590) 8. Chevrolet Silverado LD (percentage of drivers with a prior at-fault accident on record: 10.4%, MSRP base model): $34,500) 7. Subaru XV Crosstrek (percentage of drivers with a prior at-fault accident on record: 10.5 percent, MSRP 6. Subaru WRX.(percentage of drivers with a prior at-fault accident on record: 10.7% MSRP base model): $29,605) 5. Toyota GR86 (percentage of drivers with a prior at-fault accident on record: 10.8 percent MSRP base model): $29,900) 4. Hyundai Veloster N (percentage of drivers with a prior at-fault accident on record: 10.9 percent; MSRP base model): $32,500) 3.