Sensata Technologies Launches High-Efficiency Contactor for EV Architectures

Published: 18 Jul 2025

Author: Precedence Research

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Sensata Technologies announced an industry-leading edge in electric vehicle (EV) power systems with the introduction of its High Efficiency Contactor (HEC). A compact yet powerful product designed to streamline and optimize the industry's need to transition to 800V EV structures. The current HEC is designed to facilitate easy interoperability between older 400V charging infrastructure and newer 800V systems, a necessary step toward enabling faster charging, greater energy efficiency, and increased operational flexibility in EVs. Sensata utilizes this solution to address one of the critical engineering issues of new EV platforms, namely the ability to adapt to voltage, while ensuring system safety and reliability in real-world conditions.

Its HEC happens to be a complete reconfiguration and switching system, which not only allows 400V/800V transitions but also benefits from extended battery management capabilities. This technology autonomously decides when to gain access to either of two 400V battery packs is a form of uniqueness and thus new functionality, such as the introduction of a limp-home mode and battery balancing, an essential issue in battery life. This ability to keep a vehicle operational if a single battery pack loses performance or fails is now made possible. Such is especially important due to the increasing rate of EV adoption and the ways manufacturers find to increase the lifespan of their vehicles.

Sensata is strengthening its position as an important facilitator of the electric mobility revolution with the HEC. The capability to close the gap between two generations of EV architecture, with the ability to add value to it through such features as the limp-home algorithm, battery balancing, and diagnostic readiness. This allows the company to enable automakers to design smarter, safer, and more flexible EV systems. Furthermore, the HEC can make a significant increase in overall resilience and performance of the electric vehicle, which is in line with industry targets in efficiency, sustainability, and user-centric innovations.

Executive’s Statement

Brian Wilkie, Executive Vice President, Vehicle Business, Sensata Technologies

“The launch of the HEC reflects Sensata’s commitment to solving real-world electrification challenges with innovative, efficient solutions. Our HECs power safer, more efficient vehicles with seamless charging, making EVs more practical and accelerating the adoption of next-generation platforms.”