Download Eaton’s 2024 eMobility technology guide – Charged EVs
Revolutionizing the journey to safe, reliable and efficient EVs
In the fast-paced evolution of electric vehicle (EV) technology, it is important to expand what is considered with automotive safety. Eaton combines its automotive and commercial vehicle expertise with electrical insights to offer proven safety-focused technologies that reliably protect both people and EV systems. With global research and development and manufacturing capabilities, Eaton’s innovations reflect a deep understanding of the challenges and opportunities inherent in the transition to electrified transportation.
Intelligently safe and reliable technology
At the forefront of Eaton’s advancements is Breaktor® circuit protection technology, an advanced circuit protection solution tailored for electrified vehicles. As the power levels in EVs soar, the coordination between fuses and contactors becomes increasingly complex. Breaktor addresses this issue by integrating the functions of fuses, pyro switches, and contactors into a single, coordinated device.
This innovation not only simplifies the architecture—replacing up to 15 components with one unit—but also enhances safety and reliability. With a rapid actuation time of less than 4 milliseconds for short-circuit faults up to 900 volts and 25,000 amps, Breaktor offers superior protection for high-power battery and inverter systems. Its resettable nature, akin to a circuit breaker, ensures cost efficiency for both original equipment manufacturers (OEMs) and consumers, enabling reactivation after a functionality check.
Breaktor’s benefits extend further with its self-triggering capability, current-limiting features, and independent operation from the current direction, which supports both charging and duty use under full electrical loads. Available in multiple configurations, Breaktor adapts to varying voltage levels and multi-pole designs, cementing its role as a versatile and indispensable component in the EV ecosystem. Learn more about Breaktor.
EV battery safety and efficiency
Complementing the Breaktor circuit protection technology is Eaton’s 3-in-1 battery pack vent valve, designed to enhance the safety and efficiency of EV batteries. This innovative valve serves three unique functions: it provides overpressure relief through passive and active venting, and it includes a pioneering battery case leak-check mechanism. This leak-check feature eliminates the traditional need to install the vent valve as the final step in battery assembly, streamlining the process and ensuring thorough testing of the sealing surface. Eaton’s tool for actuating the leak-check mechanism on assembly lines facilitates this process, ensuring robust and reliable battery packs.
The 3-in-1 battery vent valve is engineered, with precision, to meet specific opening pressures, optimizing venting and featuring proven resealing technology. Its spring-based actuation technology accommodates various pressure requirements, driving economies of scale. The valve’s low-flow breathing mode allows for pressure normalization during regular operation, and it can be assembled through a robust quick-connect feature or a screwed metal-to-metal connection, providing flexibility and reliability. Learn more about the EV battery vent valve.
Eaton Bussmann series EV fuses and pyro safety switch: optimal EV system protection
Eaton’s Bussmann® EV series fuses, with ratings of up to 1,000 volts of direct current (VDC) and up to 1400 amps, are designed to protect the charging systems of electric commercial, passenger and high-performance vehicles. These fuses isolate energy and interrupt circuits during severe short circuits, ensuring the safety and integrity of EV systems. Eaton’s proprietary simulation testing and innovative design distribute heat away from weak spots, enhancing the reliability and longevity of the fuses, which require less space and weight than traditional solutions.
The Bussmann EV series now includes pyro fuses with ratings of 1,000 VDC and 400A continuous current. The pyro fuse is offered in traditional single trigger as well as dual trigger variants which feature a self-triggering mechanism that can separate a short circuit event without an external trigger enhancing functional safety. Learn more about Bussmann® series EV fuses.
Hybrid fuel tank safety
In the hybrid vehicle space, Eaton’s next-generation fuel tank isolation valve (FTIV) is a significant advancement. Hybrids, which often operate in electric mode, accumulate pressure in their gas tanks that must be released to prevent evaporative emissions and ensure safe refueling.
Eaton’s new FTIV is 27% lighter, 39% smaller, and contains 24% fewer components than its predecessor, addressing these needs with enhanced efficiency. The FTIV’s reduced size and weight simplify mounting in various tank configurations, while its improved magnetic force and reduced copper content maintain reliability. Learn more about FTIVs.
Space-saving profile, superior performance
Eaton’s High Power Lock Box (HPLB) power connectors further exemplify the company’s commitment to innovation. Designed for use in current and future electrified and internal combustion vehicle solutions, these connectors offer a space-saving profile, superior performance, cost savings, and reduced manufacturing complexity. The HPLB connectors, sealed to prevent corrosion and withstand severe vibration, ensure a reliable power flow, meeting USCAR Safety Performance Requirements. Their unique connection system provides improved contact force and reduces heat, enhancing the overall performance and longevity of vehicle systems. Learn more about HPLBs.
Through these groundbreaking technologies, Eaton not only addresses the current challenges in the EV market but also anticipates future needs, paving the way for a safer, more efficient, and reliable electrified vehicle landscape.
Learn more about how Eaton is helping to revolutionize the journey toward safe, reliable and efficient electric vehicles. Eaton.com/eMobility
Download Eaton’s 2024 eMobility guide