Toyota’s hydrogen fuel cell development

Building on its extensive experience, Toyota is developing its next-generation of hydrogen fuel cell, which is expected to deliver industry leading performance through longer lifecycles and reduced costs.

Toyota has continued to refine the technology since 1992, and in 2015 the Mirai became the world’s first mass-produced hydrogen fuel cell sedan, using Toyota’s first-generation fuel cells. Five years later, a new Mirai introduced the second generation of fuel cells, which extended the driving range by 30% to around 650 km.

To expand the potential of hydrogen beyond cars, Toyota has repackaged its fuel cells into a compact modular form. The main components – the fuel cell stack and components that handle air supply, hydrogen supply, cooling, and power control – are integrated in a compact shape which can be easily adapted into a variety of products and applications. The modules are available in a box or a flat, rectangular format to allow greater flexibility and easier adaptation into new applications.

These fuel cell modules are assembled locally in Europe, at TME’s R&D centre in Belgium, which houses an assembly line combining advanced technologies with high-quality assembly. The Hydrogen Factory Europe operation will produce an increasing number of fuel cell systems and is closely connected with Toyota’s other hydrogen operations to achieve global reach and service.

A key element of Toyota’s plan for an expansion in hydrogen usage is the new, third-generation fuel cell technology currently under development, with sales scheduled for 2026-27. These units will deliver a higher power density and an expected 20% increase in driving range. Technical advances and increased production volumes can help to reduce costs by more than a third.

Further research is also looking at the potential of scalable fuel cell stacks with different power outputs and design of fuel tanks with complex shapes, compatible with different size vehicles.

About the consortium members

Toyota Motor Manufacturing UK (TMUK) produces Corolla Hatchback, Touring Sports and Commercial models at its production centre in Burnaston, Derbyshire, and hybrid engines at its facility in Deeside North Wales. TMUK began production in 1992 as Toyota’s first fully owned manufacturing business in Europe and went on to become the company’s first location for hybrid electric vehicle manufacturing outside Japan. To date, Toyota has invested more than £2.75 billion in its UK manufacturing operations; TMUK currently employs more than 3,000 people and supports many further jobs in its extensive UK supplier network.

Ricardo is a global strategic engineering and environmental consultancy specialising in the transport, energy and scarce resources sectors. Ricardo has supported the technical integration of the fuel cell components into the Hilux chassis.

ETL (European Thermodynamics) is committed to delivering high-integrity thermal solutions through excellence in design and innovation. ETL has studied reversible and multi fan arrangements.

D2H Advanced Technologies provides high-technology engineering services in simulation, modelling, aerodynamics, thermodynamics and design for motorsport and other high-performance industries. D2H has completed CFD analysis to highlight where improvements could be made.

Thatcham Research, the automotive risk intelligence company dedicated to understanding the opportunities and risks of new vehicle technology, supported the project through the provision of sustainable repair consultancy and the preparation of hydrogen training for the repair market.

Vehicle specifications (tentative)

FUEL CELL STACK
TYPE	POLYMER ELECTROLYTE
NUMBER OF CELLS	330
FC POWER OUTPUT (kW/DIN hp)	128 / 174
MOTOR GENERATOR
MOTOR TYPE	PERMANENT MAGNET, SYNCHRONOUS
MOTOR POWER OUTPUT (kW/DIN hp)	134 / 182
MAX TORQUE (NM)	300
BATTERY
BATTERY TYPE	LITHIUM-ION / 84 CELLS
BATTERY CAPACITY (Ah)	4.0
TANK
FUEL TANK CAPACITY	7.8 kg (3 x 2.6 kg)
DRIVE TRAIN
LAYOUT	REAR WHEEL DRIVE
PERFORMANCE
MAX. SPEED (KM/H)	N/A
ACC. 0-100 KM/H (SEC)	N/A
FUEL CONSUMPTION (L/100KM)
WLTP COMBINED CYCLE	N/A
TOTAL RANGE	Up to 600 km
FUEL TANK CAPACITY	7.8 kg (3 x 2.6 kg)
CHASSIS
FRONT SUSPENSION	DOUBLE WISHBONE
REAR SUSPENSION	DE DION
STEERING	ELECTRONIC POWER STEERING
EXTERIOR DIMENSIONS (MM)
OVERALL LENGTH	5,325
OVERALL WIDTH (excluding mirrors)	1,855
OVERALL HEIGHT	1,810
TREAD FRONT	1,570
TREAD REAR	1,570
WHEELBASE	3,085

Hydrogen Fuel Cells in Retail Material Handling