Sensata Technologies Launches FaultBreak™ Contactor to Advance EV Safety and Reliability

Sensata Technologies announced the launch of its FaultBreak™ contactor, a next generation high voltage switching and protection solution engineered to improve fault clearing performance, enhance safety, and simplify electric vehicle power systems.

Sensata Technologies has launched the FaultBreak™ contactor, a next-generation high-voltage switching and protection solution for electric vehicles. Combining contactor functionality with a passive, resettable fuse function, FaultBreak provides fast and reliable protection against high-magnitude fault currents while reducing system cost, weight, and complexity.

FaultBreak has been validated through repeated fault interruption tests up to 16 kA at 1 kV and features low contact resistance to minimize power losses. The solution protects EV systems against severe faults, including full battery short-circuit conditions.

Its passive fuse functionality allows faults to be interrupted without relying on external detection electronics, simplifying system architecture and supporting safety requirements. For applications requiring additional protection, FaultBreak can also be used in a dual configuration to provide system-level redundancy.

By combining a fuse and contactor in a single device, FaultBreak can reduce component count by more than 50%. It eliminates the need for pyrofuses, busbars, and low-voltage harnesses, resulting in a simpler, lighter and more cost-effective system with reduced thermal losses.

Unlike conventional single-use fuses, FaultBreak can be reset after temporary or nuisance faults, helping maximize vehicle uptime and reduce warranty and maintenance costs.

With hermetic sealing, a compact footprint and stable, low contact resistance, FaultBreak is designed for current and next-generation EV platforms where safety, reliability and system simplification are key priorities.

“Our FaultBreak contactor represents an important advancement in high voltage protection,” said 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.”

If you have any questions or would like additional information, please contact Nijkerk Electronics!