SWINDON, UK, Mar 13, 2026 – Sensata Technologies has introduced the FaultBreak contactor, a high voltage switching and protection device for electric vehicle (EV) power systems. The unit combines switching and fault protection in a single component. Its passive, resettable fuse protects against high magnitude fault currents. The design reduces system cost, weight, and complexity while supporting vehicle safety and serviceability.
As electric vehicles move to higher voltage architectures, managing high magnitude fault currents requires additional protection. Automakers need devices that respond quickly during high magnitude electrical faults. FaultBreak provides fault clearing validated up to 16 kA at 1 kV and operates with low contact resistance to limit power loss. The device is designed to protect EV power systems from faults such as full battery short circuits.
FaultBreak also includes passive fuse functionality that interrupts faults without external detection electronics. Engineers can deploy two contactors together to create system level redundancy. FaultBreak combines fuse and contactor functions in one device, reducing component count, weight, and thermal losses.
Removing pyrofuses, busbars, and low voltage harnesses reduces electrical architecture and lowers total system cost. The contactor can reset after temporary faults, which supports vehicle availability and reduce warranty claims.
FaultBreak uses hermetic sealing to maintain low and stable contact resistance in a compact design. The device protects against high magnitude short circuits. These features support current and future EV platforms that require safety, lower system complexity, and reliability.
Key benefits of Sensata’s FaultBreak Contactor include:
- Market-Leading Fault Clearing: Validated by testing of repeated breaks of 16kA @ 1kV.
- Passive Fuse Functionality: Eliminates the need for complex electronics, supporting ISO-26262 compliance.
- Resettable Fault Protection: Minimizes downtime and warranty costs after temporary fault events, which may reduce downtime.
- Compact & Lightweight: Reduces component count by over 50%; no extra cooling or equipment required.
“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.”
Source: Sensata Technologies
About Sensata Technologies
Sensata Technologies is an industrial technology company that designs and manufactures sensors, electrical protection components, and sensor-rich solutions. Established in 1916, the company has over a century of experience serving sectors like automotive, aerospace, industrial, heavy vehicle, off-road, and HVAC systems. Its products are used to improve safety, efficiency, and sustainability in both consumer and industrial applications. Sensata’s offerings include pressure sensors, temperature sensors, position sensors, and circuit breakers, along with emerging smart and connected solutions that support electrification and autonomy trends. Headquartered in Attleboro, MA, Sensata operates in more than 13 countries with manufacturing and R&D facilities worldwide. In 2024, the company reported annual revenue of approximately $4 billion, reflecting its presence in the market. Sensata employs over 20,000 people globally, highlighting its reach and focus on sensor innovation.