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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.

The ugly economics of green vehicles

It's fair to say that most consumers would prefer a green vehicle, one that has a lower impact on the environment and goes easy on costly fuel (in all senses of the term). The problem is that most people can't – or won't – pay the price premium or put up with the compromises today's green cars demand. We're not all "cashed-up greenies." In 2013, the average selling price of a new vehicle was $32,086. The truth is that most Americans can't afford a new car, green or not. In 2013, the average selling price of a new vehicle was $32,086. According to a recent Federal Reserve study, the median income for American families was $46,700 in 2013, a five-percent decline from $49,000 in 2010. While $32,000 for a car may not sound like a lot to some, it's about $630 a month financing for 48 months, assuming the buyer can come up with a $6,400 down payment. And that doesn't include gas, insurance, taxes, maintenance and all the rest. It's no wonder that a recent study showed that the average family could afford a new car in only one of 25 major US cities. AutoTrader conducted a recent survey of 1,900 millennials (those born between 1980 and 2000) about their new and used car buying habits. Isabelle Helms, AutoTrader's vice president of research, said millennials are "big on small" vehicles, which tend to be more affordable. Millennials also yearn for alternative-powered vehicles, but "they generally can't afford them." When it comes to the actual behavior of consumers, the operative word is "affordable," not "green." In 2012, US new car sales rose to 14.5 million. But according to Manheim Research, at 40.5 million units, used car sales were almost three times as great. While the days of the smoke-belching beater are mostly gone, it's a safe bet that the used cars are far less green in terms of gas mileage, emissions, new technology, etc., than new ones. Who Pays the Freight? Green cars, particularly alternative-fuel green cars, cost more than their conventional gas-powered siblings. A previous article discussed how escalating costs and limited utility drove me away from leasing a hydrogen fuel cell-powered Hyundai Tucson, which at $50,000, was nearly twice the cost of the equivalent gas-powered version. In Hyundai's defense, it's fair to ask who should pay the costs of developing and implementing new technology vehicles and the infrastructure to support them.

Old Toyota Camry Hybrid batteries find new life in Yellowstone

Beginning this fall, used hybrid batteries that would otherwise be recycled will get a second life in Yellowstone National Park. 208 nickel-metal hydride batteries are being retired from the Toyota Camry Hybrids they once helped power and will become part of an off-the-grid energy system at Yellowstone's remote Lamar Buffalo Ranch field campus. The Lamar campus provides field seminars and other education and research in the northeastern corner of the park. The energy stored in the battery packs will come from solar panels and micro-hydro turbines. The total storage capacity of the batteries is 85 kWh, which is sufficient to provide plenty of emissions-free power to the five buildings at the field campus. Toyota says this program essentially doubles the life of the batteries that are no longer suitable for driving. It's great to see the batteries get another life cycle before recycling, especially in a place where wild animals easily outnumbers the cars. The battery project is part of a larger partnership between Toyota and Yellowstone. Toyota has previously donated a RAV4 and $50,000 to support sustainability projects at the park. In addition to the energy system being implemented at the Lamar Buffalo Ranch, Toyota has taken part in similar energy projects. Beginning last year, Toyota dealers in Japan have been using hybrid batteries for power storage. Also, Toyota Motor Manufacturing Alabama is testing a system to use hybrid batteries to power operations and for emergency backup power. Learn more in the press release from Toyota below. Buffalo and Bears and Batteries – Oh My! Toyota Brings Power to Yellowstone National Park June 04, 2014 Yellowstone...Where the Deer and the Antelope and the Prius Play Torrance, Calif. (June 4, 2014) – The nation's oldest National Park is ready for some new power. Toyota Camry hybrid batteries will soon power the Lamar Buffalo Ranch field campus in Yellowstone National Park. It's a new lease on life for the batteries and new, zero emission, energy option for the Park. Now that's a "bear-able" solution! The stationary distributed energy system will feature 208 used Camry Hybrid nickel-metal hydride battery packs and a total storage capacity of 85 kWh, more than enough pluck to power the five buildings on the Ranch field campus.