High Voltage Battery Fast Disconnect Gigafuse for Protection

Due to their high current and power densities, advanced battery systems require the use of high-performance safety components.

The GigaFuse from GIGAVAC, a Sensata Technologies trademark, is a fast-acting electromechanical device with low heat production that allows circuit trips at certain currents.

It is available in both passive and passive/active configurations, and its design makes it easy to connect with contactors while eliminating the thermal aging fatigue that is prevalent with DC fuses.

Highlights

• Extensive automotive understanding, including supply chain and quality
• Provide engineering, commercial support, and a global/local strategy
• Global production capacity ensures supply
• Leading provider of automobile components

Features

• Functional Safety: Passive technologies use electromechanical release mechanisms to ensure functional safety.
• Quick disconnect: Clears in less than 3 ms, regardless of current level
• Coordination of system protection: The adjustable trip current enables easy coupling with high-voltage contactors.
• Optional active control allows designers to choose between active and passive protection solutions.
• Interrupt capability of up to 10 MW
• 400 A continuous current carry (4/0 busbars); consult engineering for greater currents

Applications

Image Credit: Sensata Technologies, Inc.

The dimensions are in millimetres or inches. Unless otherwise specified, all dimensions have a tolerance of +/-1 mm.

The dimensions and tolerances indicated are from the product envelope drawing; when developing for specific applications, please contact Sensata to verify the values.

Image Credit: Sensata Technologies, Inc.

Mounting

• Use M5 or No. 10 screws
• Torque range: 1.7–4 Nm (15–35 in-lb).

Case Material

• Thermoplastic Polyamide Resin

Power Connection

• M8 x 1.25 Female
• Torque: 12–18 Nm [106–159 in-lb]

Pyro Connection

• See TE Instruction Sheet 411-78033 for additional connector information.
• Qualified for LV 16 and USCAR
• Initiator resistance: ≥ 1.7 Ω to ≤ 2.5 Ω
• Triggering pulse current ranges from 1.75 A/0.5 ms to 1.2 A/2.0 ms
• Diagnostic current: ≤ 100 mA
• No Trigger Current: ≤ 0.4 A or ≤ 5.0 A / 4 μs
• Color of connection retainer may change based on supplier availability

Specifications

Source: Sensata Technologies, Inc.

General Notes

1. For customers who can use a vented device, contact Sensata Technologies for further details.
2. The current rating (continuous and momentary) is determined by bus bar size and customer-specific circumstances. For specific details, contact Sensata Technologies.
3. Application performance may vary depending on client environment and system isolation needs. Validated for 650 V, 15.5 kA, and 12 μH system inductance. Up to 850 V, 12 kA, and 4 μH system inductance. Contact Sensata Engineering if a 1000 V application requires more than 3 kA.
4. Clear time below 5 kA can be up to 4 ms maximum. IR after 8 MW interrupt > 1 MΩ.
5. Insulation resistance (IR) depends on the power level of the maximum interrupt load and rises with lower power levels or system inductance. When the system inductance exceeds 4 uH, the IR after a solitary short circuit may be less than 0.5 M. When measured at the system level, performance will improve after an interrupt.
6. The device may function at higher ambient temperatures with reduced current carry while remaining below maximum terminal temperature.
7. Measured from the top of the bus bar at the fastened junction. The customer is responsible for ensuring that this requirement is satisfied; otherwise, equipment may be harmed.
8. Sensata Technologies suggests aligning the Z axis orthogonal to mechanical shock pulses for reliable performance under load. Sensitivity depends on the trip setting; for additional information, contact Sensata Technologies. The picture depicts the axis orientation.
9. Performance varies on vibration profile and trip level; consult Sensata Technologies for unique needs.
10. For automotive applications, please schedule a technical session with Sensata Technologies Application Engineering.

Momentary Current Curve

Rise in terminal temperature at 80 °C along a specified curve.

Image Credit: Sensata Technologies, Inc.

Image Credit: Sensata Technologies, Inc.