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Researchers halfway to cutting carbon fiber costs by 90%

Carbon fiber has been utilized for decades to build racecars, as a means to cut weight while maintaining strength. But until recently, the space-age material has been largely absent from the street on anything but supercars because of the expense to use it. Recently, BMW signaled a major shift in that trend when it starting using carbon fiber reinforced plastic panels on the i3 and i8. This relatively small scale start might be just the beginning; the German company believes that a breakthrough to inexpensively manufacture the lightweight stuff is just on the horizon.
MAI Carbon Cluster Management GmbH counts BMW, Audi, Airbus, the German government and many other organizations as supporters, and it's researching how to make carbon fiber cheaper to produce, according to Automotive News Europe. The company thinks it can reduce costs by 90 percent in the near future. "We've certainly reached a halfway point on our cost-cutting target for suitable carbon-fiber parts," said project head Klaus Drechsler to Automotive News Europe.
Unfortunately, it isn't entirely clear just what MAI Carbon is doing to make such a huge leap possible. However, a recent post on the company's website talks about a new form a carbon fiber using a thermoplastic matrix that could be cured in less than three minutes. That's compared to about 90 minutes in the traditional process with an autoclave.

Recharge Wrap-up: BMW plans for retired batteries; automakers support dual-standard chargers

Toyota will test hybrids with silicon-carbide (SiC) power semiconductors. In Japan, Toyota has put the SiC power semiconductors into the power control units of a Camry Hybrid prototype and a fuel cell bus for a year-long test. Research suggests the SiC units will decrease electrical losses while managing power supply, thus improving overall powertrain efficiency. Current power semiconductors account for about 20 percent of electrical losses, and success with these tests could mean more efficient hybrids on the roads in the future. Read more at Hybrid Cars. Automakers from CCS and CHAdeMO camps are supporting dual-standard charging station networks. https://www.autoblog.com/bmw/, Volkswagen (CCS camp) and ChargePoint announced plans to build "express charging corridors" by installing about 100 DC fast chargers, many of which will support both types of charging. Kansas City Power & Light is partnering with Nissan (CHAdeMO camp) and ChargePoint to install DC chargers that "will charge any model of electric vehicle on the market." This leads the folks at Green Car Reports to look into whether this ends the looming standard war between automakers in the US. Read more at Green Car Reports. BMW, Bosch and utility company Vattenfall are making plans for a second life for retired BMW i3 batteries. The Second Life Batteries Alliance project will recycle the old lithium ion battery packs - which can still hold a charge - in off-grid storage and grid-stabilization applications, beginning with a grid storage system in Hamburg, Germany. Bosch has created a battery management algorithm to extend the life of the batteries and make sure they don't cause harm to Vattenfall's facilities. Read more at Transport Evolved.

BMW will electrify all brands and model lines, including Mini

BMW has announced that it plans to produce a fully electric version of the three-door hatchback Mini. The car will go into production in 2019, and the battery electric drivetrain will be produced at BMW's Bavarian facilities, then transported to Plant Oxford where it will join the cars. BMW says there will remain a diesel variant in addition to the petrol, plug-in hybrid, and EV versions of the Mini. No prototype shots have been released of the upcoming cars; the current one was unveiled in late 2013. The UK production location isn't the only place where BMW builds Minis, as the former Volvo/Mitsubishi/Smart NedCar plant in the Netherlands has been tooled to build some of the 360,000 Minis built yearly. According to the BBC, UK Business Secretary Greg Clark considers the choice to build EV Minis in Britain a "vote of confidence" despite Brexit, and that it would see battery technology development boosted in the UK. By the time the EV version starts production, UK will likely have already left the European Union. The electrification of the Mini is part of BMW Group's continuing addition of full-electric or plug-in versions to all its brands and model series. Of all the vehicles it will sell in 2025, 15-25 percent will be electrified in one way or the other. Similarly to Volvo, BMW sees flexible production to be in a key position in the future: The facilities would have to be able to build all versions at the same time, as markets fluctuate depending on incentives and infrastructure. If EVs sell strongly, the production process can quickly respond to the demand. An electric Mini underwent trials back in 2008, so the full-scale production vehicle would have over a decade's worth of engineering behind it. Green BMW MINI mini ev bmw group