Sensata Launches FaultBreak to Advance EV Safety

As EV architectures move toward higher voltages, traditional protection methods—like pyrofuses and heavy busbars—have become increasingly bulky and expensive. FaultBreak eliminates the need for these components by providing a passive fuse function that triggers automatically during a fault, without relying on external sensors or electronics. Validated to clear faults up to 16 kA at 1 kV, it ensures that even a full battery short circuit can be managed safely.

One of the most significant advantages for fleet owners and manufacturers is that FaultBreak is resettable. Unlike traditional fuses that must be physically replaced after a "nuisance" or temporary fault, FaultBreak allows for rapid system recovery, maximizing vehicle uptime and drastically reducing warranty and service costs.

Beyond its protective capabilities, the device is a masterclass in system simplification. By combining switching and protection into a single hermetically sealed unit, Sensata has reduced the total component count by over 50%. This leads to a lighter, more compact power distribution unit (PDU) that doesn't require extra cooling or complex low-voltage harnesses. For OEMs aiming for ISO-26262 compliance and leaner manufacturing, FaultBreak offers a clear path toward more reliable and economical next-generation EV platforms.

www.sensata.com