Steel-Plastic Hybrid CCB
The core load-bearing component uses a carbon steel tube (e.g., DC01) as the main cross beam, responsible for critical strength requirements such as crash safety and steering column fixation. The peripheral bracket components are made of high glass-fiber reinforced nylon (e.g., PA6+GF50/60) and are directly overmolded onto the steel tube via insert molding, integrally forming the steering column bracket, airbag bracket, HVAC case bracket, ground bracket, and other components.
Steel-Plastic CCB vs. Pure Carbon Steel CCB
Lightweight: Replaces steel brackets with plastic, achieving a 25%–30% weight reduction to boost EV range.
Lower Tooling Cost: Requires only 1 injection mold instead of multiple stamping dies and welding fixtures, cutting tooling costs by 30%–50% for low-volume models.
High Precision: Insert molding eliminates welding thermal deformation, keeping key mounting tolerances within ±0.1 mm.
Better Performance: Offers superior corrosion resistance, crash energy absorption, and NVH (noise/vibration) insulation.
Platform Flexibility: The steel main beam can be fully reused across platforms; only the plastic brackets need adjustment for different models.
Steel-Plastic CCB vs. Aluminum Die-Casting Integrated CCB
Cost-Effective: Tooling costs are 1/3 to 1/2 of aluminum die-casting; material costs are significantly lower than aluminum ingots.
Ideal for Small Batches: Lower mold costs and flexible modifications make it perfect for small-to-medium batch projects, unlike expensive aluminum molds suited only for mass production.
Superior Quality Stability: Mature injection molding avoids common aluminum defects like porosity, cold shuts, and shrinkage.
Better Safety: The "rigid steel + flexible plastic" structure absorbs crash energy better than aluminum, which is prone to brittle fracture.
Design Freedom: Allows for complex rib structures and thin-wall designs without the flow limitations of metal casting.
Product Specifications
|
Parameter |
Details |
|
Product Name |
Electric Vehicle CCB |
|
Material |
SPCC / DC01 / ST12 (Low-carbon steel) / high glass-fiber reinforced nylon |
|
Dimension |
Customized, usually 1.2m - 1.5m |
|
Process |
Stamping, Spot Welding, Welding, E-coating |
|
Total Weight |
> 3KG (Design-specific) |
|
Corrosion Resistance |
12 - 480H (Design-specific) |
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