Mersen is delivering a comprehensive portfolio of electrical protection and power management solutions designed to support the evolving requirements of electric vehicles (EVs), spanning both on-board and off-board systems. The company’s approach combines advanced materials expertise with application-level engineering to address key challenges in safety, efficiency, and high-power operation across passenger cars, e-buses, and e-trucks.
Mersen’s EV technology offers two primary product lines: high-voltage fuses for protection and laminated bus bars for power distribution. Its EV fuses are specifically engineered to protect against overcurrent and short-circuit conditions, which are critical in high-energy battery systems and power electronics. These protection devices ensure rapid fault interruption and are essential for safeguarding both vehicle systems and passenger safety under demanding electrical conditions.
Complementing this, Mersen’s bus bar technologies are designed to enable efficient, compact, and reliable power distribution throughout the vehicle. These solutions are engineered for high conductivity, mechanical robustness, and optimized packaging, ensuring a stable and continuous flow of electrical power across subsystems such as inverters, onboard chargers, and auxiliary systems. Their compact design also supports space and weight optimization, key parameters in EV system design.
In battery systems, Mersen provides advanced Cell Contacting Systems (CCS) based on laminated conductor technology, where copper conductors are encapsulated within thin dielectric layers. This multilayer architecture enables reduced thickness and up to 30% weight savings in insulation materials, while maintaining high electrical performance. The CCS also integrates monitoring functions, including real-time temperature and voltage sensing, which interface directly with the Battery Management System (BMS) to enhance safety, diagnostics, and lifecycle performance.
For battery pack safety and control, Mersen supports Battery Disconnect Units (BDUs) by integrating fuses and laminated bus bars into compact assemblies. These systems manage the connection and isolation of high-voltage battery packs while ensuring compliance with stringent safety standards such as UN38.3 for lithium battery transport. The company’s EVpack fuse series provides reliable DC fault current interruption under harsh operating conditions, addressing the protection needs of high-voltage EV architectures.
Mersen also addresses thermal and electrical integration challenges through its laminated bus bar designs used within BDUs and power distribution units. These solutions enable thermal coupling between heat-generating components and cooling interfaces, reducing overheating while maintaining electrical insulation. Additionally, in inverter systems - particularly those based on SiC power modules - laminated bus bars help reduce parasitic inductance, weight, and volume, improving switching performance and overall system efficiency.
Beyond onboard systems, Mersen extends its expertise to charging infrastructure, providing fuses and surge protection devices that protect onboard chargers (OBCs) and external charging stations from overcurrent and overvoltage events. The company also offers cooling solutions, capacitors, and junction box optimization expertise, enabling efficient power distribution and thermal management across the EV ecosystem.
By integrating protection, interconnection, monitoring, and thermal management into a cohesive technology portfolio, Mersen supports the development of high-performance, reliable, and scalable EV architectures, aligned with the industry’s transition toward higher power densities and more efficient electrified powertrains.
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About Mersen
Mersen is a global leader in electrical power and advanced materials, providing high-performance solutions for energy, transportation, electronics, and industrial applications. The company specializes in the design and manufacture of components such as fuses, laminated bus bars, cooling systems, and advanced interconnection solutions, supporting the safe and efficient operation of power electronic systems.
