Volt Testing 40 Mile Range

GM says testing of the pre-production Chevy Volt is going well. The Volt batteries are averaging about 40 miles of all electric driving, but of course, your mileage will vary. After the initial all electric range, drivers can expect very high fuel efficiency from the small gas motor.

In the call this morning Andrew Farah, Volt Chief Engineer, had some interesting things to say.

Farah did explain that consumers will experience about a 20% variability in electric range depending on four variables in the following order of importance:

“Driving aggressiveness is number one, terrain is number two, weather and terrain is number three,” he said. Bly noted in cold weather a car consumes as much energy to keep its occupants warm as it does to travel down the road.

Farah also said that he uses 50 mpg as his 'bogey' when driving in charge sustaining mode (when the gas engine is recharging the battery pack). And that "So far I haven’t been disappointed.” But don't expect the EPA numbers to reflect that.

Also, GM is hoping battery costs will drop drastically as each successive generation enters production. Given the overall cost, it's the battery pack that is putting early estimates into the $40K range. So, if each successive generation can halve the cost, that's going to make the Volt into a contender against even the Prius.

But then, GM may just end up relying on smaller battery packs, with less electric range.  That would certainly cut costs, but it would also make the Volt less attractive to buyers, who may just opt for the Prius.

GM has recently completed a round of cold weather testing in Kapuskasing, Ontario, Canada, and will undergo additional hot weather testing in Yuma, AZ, in June and July.

The Volt is set to launch in November, with little chance the date will move either way at this point. As the date gets closer, GM says it is beginning to ramp up its production capabilities, with an additional $8 million to double the size of its automotive battery lab in Warren.

Read More

UCS Praises, Condemns New Hybrids

The Union of Concerned Scientists (UCS) have both praised and condemned two of the latest hybrid offerings. The UCS auto engineers feel the BMW ActiveHybrid X6, a 'muscle hybrid', squanders its hybrid drivetrain by boosting power.

At the same time, the Mercedes-Benz S400 is seen as partially successful. It lowers cost, but uses a 'relatively weak' hybrid drivetrain along with a downsized conventional gasoline engine, to increase fuel efficiency.

The UCS updated their Hybrid Scorecard to reflect their findings.

BMW ActiveHybrid X6

The ActiveHybrid X6
UCS points out BMW has added on to an already powerful eight cylinder engine to boost the X6 to the highest horsepower and torque of any hybrid on the market. And so the hybrid X6 has become the worst performer, from an environmental perspective, than the Lexus RX 450h. The RX450h has a 7.4 rating on the UCS Scorecard, while the X6 was given a 4.4.

The UCS also notes the X6 ActiveHybrid comes with $10,000 of 'forced features', including a deluxe sound system and other features not included in the base model. The UCS feels that unnecessary features drive up the cost of hybrid cars.

S400 Hybrid from Mercedes-Benz

The Mercedes-Benz S400 Hybrid
The first hybrid from Mercedes-Benz, on the other hand, took and eight cylinder engine and replaced it with a six-cylinder hybrid. That improved the costs and made for higher fuel economy. And for the first time for a hybrid, the S400 hybrid actually costs less than the base mode S550.

The S400 Hybrid is a mild hybrid, incapable of driving on electric power alone. But it does come with start-stop technology and regenerative braking. It's also the first production hybrid to use lithium-ion batteries. The S400 comes with no forced features.

The UCS engineers gave the S400 a score of 5.3 on their scorecard, but not the hybrid value is 'very high.'  In other words, the environmental 'bang for your buck' or cost effectiveness of the S400 Hybrid is very high in achieving its environmental performance.

Read More

Ford Will Build Batteries in Michigan

Ford is continuing to expand on their ability to build hybrid and electric cars. In January, Ford announced they would be building and assembling hybrid battery packs in the state of Michigan, but hadn't said where. Ford has just sent a letter to the Rawsonville plant (Source: freep.com | Detroit Free Press) letting them know they are in line for the assembly.

Ford has taken a cautious route to building up their hybrid and electric car line-up. Despite being the first to develop and sell a modern-day hybrid SUV (Ford Escape and Mercury Mariner Hybrid), Ford has only expanded their hybrid line-up by two cars since then.

But, with the initial investment in, and the costs coming down, it looks like Ford is beginning the process of truly expanding on their hybrid and electric car expertise.

Read More

Honda CR-Z May Add More Power

Honda CR-Z Hybrid

Maybe it's because the CR-Z has been so popular in Japan (it hasn't even launched yet), but rumors are out there Honda is working on a revamped, more powerful CR-Z Hybrid.

Motortrend is reporting the next generation hybrid sports coupe may come with a "2.5-liter, four-cylinder gas engine attached to Honda's well-known IMA hybrid system, which would lift this coupe's engine capacity by one full liter over the CR-Z."

Honda could add in a switch, making it possible for the driver to opt for a more fuel efficient configuration, or go sporty instead.

Honda is also looking at turning the CR-V into an E-REV like the Chevy Volt. Now that would be intriguing, although we'll have to wait and see how the Volt does. Will the extra cost of the battery outweigh people's desire to not use gasoline, while still having the security blanket the gasoline gives you? Or will people opt for the lower price of the Nissan Leaf, and go all electric.

Read More

Hybrid Car Brands

Just who is making hybrid cars these days and what brands are considering making hybrid cars in the future?

Major Hybrid Car Brands
Hybrid cars are currently being built and sold by General Motors, Ford, Honda, Toyota and Nissan. General Motors builds hybrid cars under several divisions including Saturn, Chevrolet, and GMC.  Ford has the Mercury and Ford divisions.  Toyota sells hybrids under the brand name of Lexus .  While Honda and Nissan just sell hybrids under their own name plates.

Toyota
Under the Toyota brand name, there are three models currently on sale. The iconic Prius is almost synonymous with hybrid and is the first car most people think of when they think of hybrids. Toyota also sells the Camry Hybrid and Highlander Hybrid under the moniker of Toyota.

Toyota also has their luxury division, the Lexus hybrids. Under the Lexus brand name, Toyota sells the HS, LS, RX, and GS Hybrids. They keep adding models under the Lexus nameplate, so expect and IS hybrid to arrive soon. The HS hybrid is a dedicated model like the Prius. The others are subtypes under the model. In other words, you can buy gas-only models, or you can opt for the hybrid engine.

Honda
Honda sells the Civic Hybrid under their brand name. They also currently sell the only other dedicated hybrid on the road, the Insight. They used to sell a Hybrid Accord, and the two-seater hybrid Insight, but have retired both models.

Expect to see Acura Hybrids in the future.

Nissan
Nissan has only one hybrid model for sale, the Nissan Altima Hybrid. It is built using hybrid technology from Toyota and is sold in only eight US states. Nissan has plans to bring an Infiniti M35 Hybrid to market in the coming year.

General Motors (Cadillac, Chevy, Saturn, GMC)
They build several models (currently) using the Chevrolet brand. There is the Chevy Malibu and Chevy Silverado. The Chevy Volt, the Extended Range Electric Vehicle (E-REV), will be out soon and while GM considers the Volt to be a subtype of electric vehicle, it still falls under the hybrid type.

GM also builds the GMC Yukon and Sierra. And the Cadillac Escalade Hybrid also falls under the GM brand.

The Saturn brand was at one point, the cornerstone for hybrids under the GM umbrella. But Saturn is no more. You can still see the hybrid Vue and Aura on the road today.

Ford
Ford sells four different models under two different brand names. The Mercury Division sells the Milan and Mariner Hybrid. While Ford retains the Fusion and Escape Hybrid. The Lincoln division will have its own hybrid soon, but it's not here yet. The Mercury hybrids are the upgraded version of the Ford Hybrids, so expect them to be very similar if you take a look at both of them.

Chrysler
Chrysler sold the Aspen and Durango Hybrids for a total of two months before pulling the plug on both models. The Dodge Durango is very similar to the Chrysler Aspen, and both were built using the dual hybrid technology developed in partnership with BMW and GM.

Chrysler at one point had plans to bring a Dodge Ram Hybrid to market, but that seems to be on hold.

Hyundai
Hyundai is jumping in with both feet in the next year, with the Sonata Hybrid. Distinguishing itself from the other hybrids listed above, it's going to be one of the first hybrids to use lithium polymer battery packs, giving it an advantage over some of the more established hybrid models and brands listed above.

Mazda
Mazda has sold the Tribute hybrid in very limited numbers.  The Tribute was built using Ford Hybrid technology, when Mazda and Ford were a lot tighter than they are today.  Now Mazda is looking to partner with Toyota for the technology used in the Prius for their future hybrid model in 2013.

Fisker and Tesla
Fisker and Tesla are both bringing hybrid cars to market (they probably don't appreciate being lumped together given the lawsuits over the past few years). These startups are working hard to go straight to electric or hybrid and are emphasizing performance, rather than fuel efficiency right from the get go.

Audi, Subaru, BMW, Mercedes-Benz, Daimler, Ferrari, Lotus, Kia, Maserati, Porsche, Suzuki, Volkswagen and Volvo
Each of the brands mentioned above are attempting their own hybrid models, and several have brought some noteworthy test models to auto shows. Several are on their way to bringing those cars to market right now, but are still a few years away from seeing them on the road in more than just 'test fleets'. Some are closer than others, while some probably have no intention of ever going hybrid unless they are forced to do so by the tighter restrictions being enforced in Europe, Asia and the US in the coming years.

Looking for more information on one of the brands above?
Either search for the brand name here on this site or use the categories below or on the sidebars.  Each of the major brands listed will have more information that I've accumulated over the years.

Read More

Prius is Top Seller in Japan for 11 Months Straight

The Japan Automobile Dealers Association noted the Prius was once again the top selling car in Japan. Helped by government incentives, the Prius has been and will continue to be the top selling car for months.

Toyota sold 35,546 units in March. That's 11 months in a row the Prius has held the top spot, which was briefly held by the Honda Insight before the third generation Prius came to market.

Sales have quadrupled in Japan this year. Toyota has sold over a quarter of a million units so far (277,485)

Read More

First Drive: 2010 Audi TTS Coupe

Finally, Speed Matches Style

By Nate Martinez

In the decade or so it's been on the market, the Audi TT has become world renowned for its avant garde style, but it's never ranked high as a true sports car. That perception changed recently thanks in large part to quattro GmbH -- the performance division responsible for the mighty R8. The result is the new TTS, a potent blend of speed, flair, and livability. Watch out, Porsche.

With the "S" onboard, Audi's small 2+2 has evolved into a mechanical ensemble that delivers as many smiles on its drivers' mugs as stares from passersby. Its 2.0-liter four-cylinder is fortified with a strengthened block, an aluminum-silicon alloy head, a bigger Garrett variable turbocharger, reinforced internals, and a remapped ECU. How does 265 horsepower sound?

Audi says a sprint to 60 mph in the TTS only takes 4.9 seconds. That's just a couple of ticks off the Porsche Cayman S PDK (4.4 seconds), putting the TTS squarely in the legitimate sports car neighborhood. Unfortunately, we weren't able to put the TTS through our usual barrage of instrumented testing, but there's no doubt this thing is fast. It's a point-and-shoot type of ride with boatloads of grip courtesy of an intelligent quattro all-wheel drive system and aluminum-bred suspension. And that's with the electronics set in "Normal."

Slide the S-tronic dual-clutch lever down into the more aggressive "S" mode, and the throttle's responsiveness noticeably steps up. Like in its R8 big brother, the TTS's magnetic variable-rate dampers can be stiffened at the press of a button for a considerably sturdier ride. We ran our Solar Orange tester on some rain-soaked serpentine byways of San Diego County, and it easily devoured pavement with a level of poise and eagerness not found on the standard model. Even with the hard mountain rain creating mini-skidpads ahead of us, the quattro all-wheel drive setup kept us out of the berms and pegged on the proper line.

The TTS is a capable all-arounder -- not just a straight line missile. In full-on sport mode (dampening and transmission in "S"), the dual-clutch 'box holds each of its six gears to high revs and shifts at the 6800-rpm max with a palatable "braap! braap!" from its quad pipes. Its 258 pound-feet. of torque is available between 2500 to 5000 rpm. Linger in this sweet spot, and heads will get sucked into their leather buckets with each seamless upshift.

Read More

2011 Porsche Cayenne S Hybrid MSRP

Porsche Cayenne

The price has been set on the 2011 Porsche Cayenne S Hybrid. At $67,700, the Cayenne Hybrid is not going to be the most expensive hybrid on the road, but it certainly puts it in the upper reaches.

It also puts it in the mid-range of the Porsche Cayenne line-up. The Cayenne base price is $46,700, the Cayenne S is $63,700, while the Turbo comes in at a paltry $104,800.

The all wheel drive Hybrid SUV comes with a 3-liter V-6 eight speed automatic transmission.  Together with the 47 hp electric motor the engine has a combined 380 hp capable of 150 mph.


Porsche says the EPA numbers are not available yet, but the Porsche Hybrid will be 23 percent more fuel efficient than the old Cayenne. You can also 'sail' at up to 97 mph (the gas engine will shut off if you're cruising along).

The Hybrid S will be on sale in the fall.

Read More

2011 Hyundai Sonata Hybrid

2011 Hyundai Sonata Hybrid

Hyundai introduced the 2011 Sonata Hybrid at the New York Auto Show and, as they've been very quick to point out, in a lot of ways, their hybrid is better than the Toyota Camry Hybrid, Nissan Altima Hybrid, Ford Fusion Hybrid, or the Lexus HS250h.

In a field that is starting to feel a little bit crowded, the Sonata Hybrid is going to need to stand out. With Toyota, especially, Hyundai has to overcome the decade of experience people are going to assume Toyota has over the newcomer.

Probably the biggest thing the Sonata Hybrid has over its rivals may be its battery pack.  By starting with Lithium Polymer, the Hyundai Hybrid is capable of getting 37/39 mpg (less than the Ford Fusion Hybrid, but better than the others), up to 62 mph of all electric driving,  and the most hp (compared to those others on the list).  All this while creating a car that's slightly bigger than its rivals.

How quickly that comparison will shift back depends on how soon the other car companies make the switch to the new batter packs.  But until they do, the Sonata Hybrid is certainly going to compare favorably.

Press Release follows:

2011 Hyundai Sonata Hybrid Interior

NEW YORK, March 31, 2010 /PRNewswire/ — As global automakers work out implementation timing for new fuel-efficient powertrain technologies such as gasoline direct-injection (GDI), twin-scroll turbochargers, and full-hybrid powertrains, Hyundai announced today that the all-new 2011 Hyundai Sonata is the first vehicle in the industry to offer all three technologies with the new Sonata 2.0T (turbo) and Sonata Hybrid joining the hot-selling GDI-equipped Sonata in Hyundai showrooms later this year.

At the New York Auto Show today, Hyundai unveiled its 2011 Sonata Hybrid, changing the game in hybrids with unique approaches in hybrid powertrain design, battery technology and vehicle appearance. The Sonata Hybrid is Hyundai’s first hybrid in the U.S. market.

“The Hyundai Sonata Hybrid is the new kid on the block, but it’s not a follower,” says John Krafcik, president and CEO, Hyundai Motor America. “Its full parallel hybrid configuration and breakthrough lithium polymer batteries offer a new take on traditional hybrid design, while its unique design sets it apart from the mid-size hybrid pack.”

The Hyundai-developed Hybrid Blue Drive architecture is a full parallel hybrid drive system, which can operate on an electric motor, gasoline internal combustion engine, and a combination of the two depending on driving conditions and driver demands. Hyundai’s proprietary full parallel architecture differs from the power split technology used by most competitors, allowing significant efficiency advantages at higher speeds. Hyundai Hybrid Blue Drive is the first and only system using lithium polymer battery technology – leapfrogging competitive in-market nickel-metal hydride and lithium-ion applications. Lithium polymer offers the benefits of lithium-ion, a technology used in laptops and cell phones, but adds robustness, power-density and package flexibility, making it ideal for automotive applications. Hyundai Hybrid Blue Drive also is unique in its use of the company’s own highly efficient, compact new 6-speed transmission, modified with hybrid starter-generator, electric motor, and low-friction oil pump, which together allow the elimination of the traditional torque converter.

Hyundai Hybrid Blue Drive is a new addition to a full suite of eco-focused products and technologies that Hyundai offers in its goal to be the auto industry’s global eco-leader. According to the EPA, Hyundai has led the U.S. industry in fuel economy for 2008 and 2009, and is currently the only automaker with average fleet fuel economy of more than 30 miles per gallon.

“Hyundai applies advanced technologies to vehicles to provide the best solutions for the everyday driver,” said Krafcik. “Unlike traditional hybrids that trade off highway fuel economy for higher city ratings, the Sonata Hybrid delivers best-in-class highway fuel economy, while still delivering about a 40 percent improvement in city fuel economy compared to a Sonata equipped with the Theta II GDI engine. We think this is a better balanced approach for the majority of car buyers.”

PERFORMANCE
Sonata Hybrid’s projected best-in-class highway fuel economy of 39 mpg offers significant benefit to hybrid owners with highway commutes, while also offering outstanding city fuel economy of 37 mpg. Government studies have shown that the typical U.S. driver operates in a highway mode 57 percent of the time. Hyundai’s approach to deliver class-leading fuel economy in highway mode provides a unique solution in the mid-size sedan hybrid market, and differentiates Sonata Hybrid from the likes of Toyota Camry Hybrid and Ford Fusion Hybrid. Sonata Hybrid delivers typical hybrid fuel economy gains in the city like its competitors, but also gives owners outstanding fuel economy on the highway, where these competitors fall short.

Sonata Hybrid delivers class-leading electric-vehicle operation at steady-state speeds of up to 62 miles per hour. Gasoline engine engagement depends on state of charge, acceleration and vehicle speed. Its two propulsion units develop a total output of 209 horsepower at 6,000 rpm, exceeding all mid-size competitors, and 195 lb-ft of torque. The weight-efficient architecture of the new Sonata platform, combined with the lightweight lithium polymer battery pack, make the Sonata Hybrid the lightest vehicle in the segment, at just 3,457 pounds, 263 pounds lighter than the Fusion Hybrid. Combined with Sonata’s best-in-class horsepower rating, Sonata Hybrid has a significant advantage in power-to-weight ratio, a key enabler of both performance and efficiency.

Hyundai’s proprietary parallel hybrid drive system is the heart of the Sonata Hybrid. The competition uses a power split system with a planetary-geared Continuously Variable Transmission (CVT). This is where the Sonata Hybrid gains a key advantage. Competing hybrid models use electric motors that have to power a planetary gear set. By utilizing a full parallel drive system, Sonata Hybrid uses the power from the electric motor more efficiently to directly control the vehicle, allowing it to be operated at much higher speeds than the competition in EV-only mode. This technology is also a key enabler of Sonata Hybrid’s best-in-class highway fuel economy.

SONATA HYBRID VERSUS ITS RIVALS

	2011 Sonata Hybrid	2011 Toyota Camry Hybrid	2010 Nissan Altima Hybrid	2010 Ford Fusion Hybrid	2010 Lexus HS250h
Engine	2.4-liter	2.4-liter	2.5-liter	2.5-liter	2.4-liter
Engine hp	169 hp	147 hp	158 hp	156 hp	147 hp
Engine torque	156 lb-ft	138 lb-ft	162 lb-ft	136 lb-ft	138 lb-ft
Electric Motor hp	40.2 hp	40 hp	40 hp	106 hp	40 hp
Electric Motor torque	151.2 lb-ft @ 0-1,400 rpm	199 lb-ft @ 0-1,500 rpm	199 lb-ft @ 0–1,500 rpm	166 lb-ft	138 lb-ft
Hybrid system net power output	209 hp	187 hp	198 hp	191 hp	187 hp
Hybrid system	Parallel	Power Split	Power Split	Power Split	Power Split
Trans.	6-speed	CVT	CVT	CVT	CVT
Battery type	Lithium Polymer	Nickel-Metal Hydride	Nickel-Metal Hydride	Nickel-Metal Hydride	Nickel-Metal Hydride
EV only operation limit	62 mph	42 mph	42 mph	47 mph	42 mph
Fuel economy city/ hwy	37/39 mpg(est.)	33/34 mpg	35/33 mpg	41/36 mpg	35/34 mpg
Curb wt.	3,457 lb	3,680 lb	3,469.8 lb	3,720 lb	3,682 lb
Power to wt. ratio (lbs./total system power)	16.54	19.68	17.52	19.48	19.69
Pass. Vol.	104 cu ft	101 cu ft	101 cu ft	101 cu ft	90 cu ft

HYUNDAI’S HYBRID BLUE DRIVE ARCHITECTURE
Hyundai’s Hybrid Blue Drive is a proprietary parallel hybrid drive system that runs on the already fuel-efficient 2.4-liter Theta II engine (169 horsepower at 6,000 rpm and 156 lb-ft of torque at 4,500 rpm) mated to a 6-speed automatic transmission and a 30kW (151 lb-ft) electric motor for maximum fuel economy. Hyundai’s Hybrid Blue Drive has an all-electric mode and a parallel drive mode. This means the wheels are turned by power coming directly from the gasoline engine, or the electric motor, or both together, as conditions demand. This parallel hybrid drive architecture will serve as the foundation for future hybrid drive vehicles to be developed by Hyundai.

In the Hyundai Hybrid Blue Drive system, the Theta II with multi-port fuel injection (MPI) operates on an Atkinson Cycle. Atkinson Cycle is a type of internal combustion engine strategy designed to dramatically increase fuel efficiency through changes in compression and power strokes in the four stroke engine. It is typically only used in hybrid systems where the high-torque electric motor boosts low-end power, which is traded off for internal combustion engine efficiency. By combining the electric motor and the Atkinson Cycle engine, the Hybrid Blue Drive system delivers best-in-class highway hybrid efficiency.

To further improve fuel economy, all of the Theta II major driveline and cooling system components have been optimized to reduce friction, while the crankcase has been filled with low friction oil. Hybrid Power Control (HPC) management software automatically shuts off the engine when the vehicle comes to a halt, cutting emissions to zero. When pressure is reapplied to the accelerator pedal, the Hybrid Starter Generator (HSG) automatically restarts the engine. This control strategy assures that maximum efficiency is achieved during gentle acceleration and greater power is immediately available during full acceleration. During deceleration, braking regeneration comes into play. Sonata Hybrid also features “smart brake” technology in which braking input over-rides accelerator pedal input.

The high-tech, all-aluminum, 16-valve engine also features Continuously Variable Valve Timing (CVVT) on both camshafts and newly developed engine components to reduce friction. This optimized Theta II engine achieves 10 percent better fuel consumption over a conventional Theta II engine.

Hyundai Hybrid Blue Drive uses the company’s proprietary 6-speed automatic transmission rather than a conventional hybrid’s CVT. Hyundai’s strategy involves an adaptation of the modular 6-speed transmission, replacing the torque converter with an electric motor and high-efficiency oil pump. This technique uses a traditional step-shift 6-speed transmission rather than a CVT to provide a more traditional shift feel that is preferred by customers and sometimes artificially replicated in CVT applications. This saves on cost, making the Hyundai Hybrid Blue Drive system a better value. It is a more robust and elegantly simple solution to a complicated engineering challenge.

Fuel efficiency improvements are evident throughout Sonata Hybrid. For example, the top three gear ratios in the transmission have been extended to ensure the engine runs at lower RPMs, the electric motor-assisted steering system reduces demands on the engine, and low resistance tires further optimize fuel economy.

Hybrid Blue Drive is made up of the following major components:

• An efficient 30kW electric motor delivering 151 lb-ft of torque
• A regenerative braking system
• An integrated starter generator that enables the engine to turn off at stops and restart automatically under acceleration
• A breakthrough lithium polymer battery package, with 5.3 Ah of capacity at 270 volts
• A fuel-efficient Theta II 2.4-liter engine
• 6-speed automatic transmission with an improved efficiency electric oil pump
• Weight-efficient architecture coupled with a low drag coefficient (.25 Cd target)
• Electric air conditioning compressor
• Hybrid power control unit

LITHIUM POLYMER BATTERY TECHNOLOGY
Sonata’s hybrid system stores its electrical charge in a 270V lithium polymer rechargeable battery (5.3Ah/270V) that surpasses existing nickel-metal hydride and pending lithium-ion applications. Lithium polymer batteries are more durable and space-efficient than other hybrid batteries. They are also more weight-efficient. The Sonata Hybrid’s battery pack weighs just 95.9 pounds versus the Camry Hybrid’s 123.9 pounds. The compact battery pack resides in the forward portion of the trunk to maximize cargo space.

Lithium Polymer Batteries vs. Nickel-Metal Hydride Batteries
Compared with nickel-metal hydride batteries, lithium polymer batteries deliver the same power with 20-30 percent less weight, 40 percent less volume and 10 percent greater efficiency over the nickel-metal hydride batteries found in today’s hybrids. Lithium polymer batteries offer 1.7 times more energy density than nickel-metal hydride batteries, allowing Hyundai engineers to devote less space and weight to the battery pack. Lithium polymer batteries hold their charge 1.25 times longer. Lithium polymer batteries also are more resistant to changes in temperature, which improves cycle life. Additionally, lithium polymer’s self-discharge rate is less than a third of a nickel-metal hydride battery.

Lithium Polymer Batteries vs. Lithium-ion Batteries
Lithium polymer has significant advantages over lithium-ion, including higher energy density and lower manufacturing costs. Lithium polymer is more resistant to physical damage and can handle more charge-discharge cycles before storage capacity begins to degrade. Lithium polymer technology also offers significant advantages in thermal robustness and safety.

A key difference between traditional lithium-ion batteries and Hyundai’s lithium polymer battery solution is the overall packaging of the cell – the anode, the cathode, the electrolyte, and the encasement material. Traditional lithium-ion batteries, like those found in laptops, use what’s known as the 18650 cell format. In this format, each mass-produced cell is 18 mm. in diameter and 65 mm. tall, which is a bit larger than a “AA” battery. Each of these small metal cylinders is filled with a liquid electrolyte that facilitates the movement of lithium ions across anode and cathode, creating the battery current.

Traditional lithium-ion batteries are easy to handle, withstand mild internal pressures, and have been around in various forms since 1991. That means a manufacturing infrastructure is in place, and economies of scale are reasonably high. However, they do have several disadvantages. For example, their cylindrical shape reduces packaging efficiency and they are surprisingly complicated to manufacture since they have so many small parts. These small parts make them robust to thermal fluctuations and add significant cost and weight to the overall battery system. Cell-to-cell consistency also is extremely critical in a vehicle battery package, since the pack is only as robust as its weakest cell. Traditional lithium-ion batteries have considerable cell-to-cell variation, while Hyundai’s lithium polymer batteries deliver outstanding cell-to-cell consistency.

Lithium polymer technology uses a completely different approach. Rather than using a liquid electrolyte, which requires a robust metal casing, lithium polymer batteries use a polymer gel as the electrolyte, which allows the use of a thinner and lighter aluminum-walled encasement, or pouch. Inside each lithium polymer cell, the cathode, separator, and anode are laminated together, enabling much simpler and more reliable manufacturing. This allows the battery pack to be about 20 percent smaller than a lithium-ion battery pack, making it much easier to change the cell footprint to fit the nooks and crannies of available vehicle space.

Hyundai and its battery supplier, LG Chem, have spent hundreds of hours testing the Hyundai Hybrid Blue Drive lithium polymer battery system. This testing has proven that Hyundai’s lithium polymer technology has greater thermal and mechanical stability than existing systems, meaning better safety and performance.

Another key engineering challenge for Hyundai Hybrid Blue Drive has been assuring maintenance-free battery operation over the vehicle’s life – at least 10 years, and 150,000 miles – in all weather conditions. Heat is the enemy of battery cycle life. Hyundai’s thermal imaging testing shows how much cooler a lithium polymer battery is compared to today’s nickel-metal hydride battery or a conventional lithium-ion battery. Consumers will notice these advantages in improved useful life and lower maintenance costs.

FLUIDIC SCULPTURE DESIGN ADDS A UNIQUE ECO FLAIR
Hyundai designers have taken Sonata’s fluidic sculpture design language a bit further with Sonata Hybrid, making it even more aerodynamic. The goal was a modern, eco-friendly design, with “at-a-glance” differentiation from the non-hybrid Sonata models.

• Unique exterior design elements
• Headlights and taillights
• Aerodynamic bumper fascias
• Aerodynamic rocker panels
• Bold hexagonal grille
• Eco-spoke wheels
• Air dam and aero side sills
• Hybrid Blue Drive badging
• Exclusive hybrid paint color
• Interior refinements
• Supervision cluster with eco-display options
• Unique interior color choice
• Unique seat patterns

The Sonata Hybrid also offers drivers a way to be more engaged in fuel-efficient driving thanks to Hyundai’s Hybrid Technology Display. The Hybrid Technology Display is featured on a 4.2-inch LCD screen located between the odometer and tachometer, or is visible on the optional seven-inch navigation screen. It features the following information:

• Driving mode
• Energy flow within the vehicle
• Engine and motor movement
• Fuel level
• Battery power levels and charge status
• Electric vehicle mode indicator
• Average and instant mpg

The Hybrid Technology Display’s most unique feature is an Eco Level scoring system. The high definition display acknowledges eco-focused driving with eight levels of sky color, ranging from gray to bright blue. It also accumulates points in Total Eco mode over time. An Eco Guide also provides instant fuel economy feedback.

Read More