Eaton’s new dual-trigger pyro fuse enhances EV circuit protection and safety

SOUTHFIELD, Mich. – Intelligent power management company Eaton today announced the expansion of its circuit protection portfolio with the introduction of advanced pyro fuses, including a dual-trigger version that provides a significant safety and reliability advantage for electrified vehicles (EVs).

Unlike traditional fuses that melt to interrupt a circuit during a fault, a pyro fuse operates similarly to an airbag, using an igniter and propellant to rapidly separate the main busbar and disconnect power. Eaton’s dual-trigger pyro fuse goes a step further, incorporating a stand-alone backup trigger that enables it to separate short circuits without requiring an external command. This unique capability mimics the passive safety function of a traditional thermal fuse, ensuring an added layer of protection.

Eaton’s expanded circuit protection portfolio now includes these advanced pyro fuses alongside its Bussmann^® series EV fuses and Breaktor^® circuit protection technology, offering a complete suite of solutions for OEMs.

• Breaktor circuit protection technology provides ultra-fast actuation--less than 4 milliseconds--for short-circuit faults up to 900 volts and 25,000 amps. Unlike traditional fuses, Breaktor is resettable like a circuit breaker, reducing costs and downtime for manufacturers and consumers.
• Bussmann series EV fuses, designed for up to 1,400 amps and 1,000 volts, can be customized to meet specific OEM needs. Eaton’s expertise in thermal management and circuit protection enables flexible design modifications and scalable solutions.

Eaton has long been at the forefront of power management, leveraging its expertise in both electrical and vehicle systems to create solutions that help OEMs navigate the challenges of EV cost and performance optimization. Eaton’s eMobility portfolio is specifically designed to reduce system complexity, improve efficiencies, and enhance safety without compromising performance. By integrating innovative technology into EV architectures, Eaton is helping global OEMs deliver vehicles that meet consumer expectations while also streamlining production and keeping costs in check.

Beyond cost savings, reducing complexity plays a critical role in improving manufacturing efficiency. By simplifying electrical architectures and minimizing the number of components required, Eaton helps OEMs accelerate production timelines, reduce assembly costs, and lower the risk of supply chain disruptions. These efficiencies are key to making EVs more affordable and competitive in a market where consumers have more choices than ever before.

Learn more about Eaton’s pyro fuses and its comprehensive circuit protection portfolio for electrified vehicles.

Eaton is an intelligent power management company dedicated to protecting the environment and improving the quality of life for people everywhere. We make products for the data center, utility, industrial, commercial, machine building, residential, aerospace and mobility markets. We are guided by our commitment to do business right, to operate sustainably and to help our customers manage power ─ today and well into the future. By capitalizing on the global growth trends of electrification and digitalization, we’re helping to solve the world’s most urgent power management challenges and building a more sustainable society for people today and generations to come.  

Founded in 1911, Eaton has continuously evolved to meet the changing and expanding needs of our stakeholders. With revenues of nearly $25 billion in 2024, the company serves customers in more than 160 countries. For more information, visit www.eaton.com. Follow us on LinkedIn.