Eaton’s expanded fuse portfolio for electrified vehicles includes low-voltage fuses for systems below 70 Vdc and high-voltage fuses rated at 500 Vdc (EVR), 900 Vdc (EVHD), and 1,000 Vdc (EVKR). The portfolio also features active and dual-trigger pyro fuses rated for 650 Vdc and 1,000 Vdc. Fuse sizes in the Bussmann series range from compact 10×38 mm up to larger sizes with rated currents from 5 A to 1000 A depending on the application. These fuses are designed to coordinate with vehicle electrical architectures featuring time constants around 2 ms.

Fuses operate with interrupting ratings up to 20 kA DC and are capable of withstanding high fault currents typical in EV battery systems. They provide protection for main battery circuits, power conversion equipment, contactors, and auxiliary systems, helping prevent damage in short circuit and overload conditions. The Bussmann series includes options optimized for fast clearing times and minimal let-through energy, reducing stress on downstream components and improving system safety.

Fuse manufacturing complies with automotive standards ISO 8820-8, JASO D622, and IATF 16949 quality management. Eaton applies simulation and testing, including thermal, vibration, and electrical performance, to ensure fuse reliability under harsh operating conditions. Each fuse is serialized and traceable for quality control. The compact design reduces space and weight requirements, supporting vehicle packaging and efficiency goals.

Typical fuse dimensions vary by current rating and voltage class but remain industry standard for bolt-on or blade mounting. Power loss and melting characteristics vary with rated current and fuse size, enabling system designers to select the appropriate fuse based on electrical and thermal system requirements.

This portfolio facilitates circuit protection across electrified vehicle types, including BEVs, PHEVs, hybrid vehicles, commercial, and off-highway platforms, providing tested components that meet evolving voltage and current demands in the electrification landscape. Eaton’s fuse range supports vehicle electrification with scalable, high-performance, and reliable short circuit and overload protection tailored for the automotive industry.

Eaton will showcase this expanded fuse portfolio at The Battery Show North America, October 6-9, 2025, in Detroit.

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