Sensata Technologies has introduced the STPS500P Series Active + Passive PyroFuse, a high-voltage protection device designed to improve safety and simplify electrical system architecture in electric vehicles.
The new PyroFuse combines system-triggered and current-driven circuit interruption within a single unit, enabling rapid fault isolation while reducing the need for multiple protection components.
Dual Protection Improves Fault Response
Conventional high-voltage protection systems typically rely on either active devices that require signals from vehicle electronics or passive solutions that respond to thermal or current conditions.
Sensata’s Active + Passive PyroFuse integrates both approaches into one device. Its passive mechanism is activated directly by excessive current rather than heat, allowing the fuse to interrupt electrical faults within milliseconds regardless of current level.
The integrated pyrotechnic trigger also provides active protection when commanded by the vehicle’s safety systems, maintaining circuit interruption capability even if upstream sensors or electronic controls become unavailable.
Designed to Simplify EV Architectures
According to Sensata, the faster interruption capability helps reduce peak energy exposure during electrical faults while lowering the short-circuit demands placed on contactors and other high-voltage components.
This allows electric vehicle manufacturers to optimize component sizing, reduce system complexity and streamline high-voltage architectures without compromising safety.
The company said the new device also protects critical components such as busbars, contactors and downstream electrical systems before damage can occur.
Expanding High-Voltage Safety Portfolio
The Active + Passive PyroFuse complements Sensata’s existing portfolio of high-voltage contactors, sensors and electrical protection technologies, enabling automakers to source multiple safety components from a single supplier.
Markus Schwabe, Executive Vice President of Automotive at Sensata Technologies, said the new product eliminates the compromises associated with conventional protection systems.
“EV manufacturers have long been forced to work around the limitations of active-only or passive-only protection. Our Active + Passive PyroFuse removes that tradeoff and helps our customers design safer, more resilient systems with less complexity.”