Sensata's 2026 launch · Passive fuse + contactor in one · 16 kA @ 1 kV market-leading fault clearing · Resettable · ISO-26262 compliant · −50% components
Sensata FaultBreak™, launched in March 2026, is a breakthrough next-generation EV protection contactor — the first industrial solution to combine fuse and contactor functions in a single device. Market-leading fault clearing is verified by repeated interruption tests at 16 kA @ 1 kV, protecting the vehicle and its occupants even under full battery short-circuit. The passive fuse function needs no external detection electronics and directly supports ISO-26262 functional-safety compliance.
Its principle is elegant: the magnetic field generated by the fault current is routed into the magnetic actuator, opening ultra-fast only under fault, while magnetic blowout + dielectric gas safely extinguish the arc. Unlike single-shot pyrofuses, the device is resettable after nuisance trips — boosting vehicle uptime and cutting warranty cost and service time. Versus a traditional fuse + contactor architecture it reduces component count by more than 50%, eliminating pyrofuses, extra busbars and LV harnesses to simplify the EV power architecture and lower weight and thermal losses. Hermetic sealing delivers low, stable contact resistance with no extra cooling; dual configuration provides system-level redundancy for higher reliability targets. Sensata showcased FaultBreak as the headline launch at ACT Expo, Las Vegas, 4-7 May 2026.