Charged EVs | Sensata’s new FaultBreak combines EV fuse and contactor functions, clears 16 kA faults at 1 kV

Sensata Technologies has launched its FaultBreak high-voltage contactor for EV power systems, a passive, resettable fault-protection device that combines the functions of a fuse and a contactor in a single component, simplifying high-voltage fault management for more efficient, higher-voltage EV architectures.

Sensata says FaultBreak’s fault-clearing capability has been validated up to 16 kA at 1 kV, and that the device operates with low contact resistance to minimize power loss. Unlike single-use fuse technologies, the FaultBreak can be reset after temporary or nuisance faults are cleared, improving uptime and potentially reducing warranty claims.

By combining protection functions, Sensata says FaultBreak can:

reduce component count by more than 50% versus traditional fuse-and-contactor systems
eliminate pyrofuses, busbars and low-voltage harnessing
eliminate the need for complex electronics, supporting ISO-26262 compliance and system simplification
minimize downtime and warranty costs by enabling rapid system recovery after recoverable fault events

Join this webinar on March 11, where Sensata’s experts will share practical insights on managing high magnitude fault currents, improving system safety, and simplifying EV power architectures.

“Our FaultBreak contactor represents an important advancement in high voltage protection,” said EVP Markus Schwabe, EVP, Automotive, Sensata Technologies. “It helps our customers build electric vehicles that are safer, more dependable, and more economical to produce and maintain.”