What a PTC In‑rush Current Limiter Is
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PTC (Positive Temperature Coefficient) thermistor is a semiconductor device whose resistance rises sharply when its temperature exceeds a certain threshold. When it’s used as an
in‑rush current limiter, the component behaves like this:
| Phase | What Happens | Why It Works |
| Initial power‑on | The PTC is cold, so its resistance is very low (typically a few Ω or less). This allows the supply voltage to reach the downstream circuit quickly, but the low resistance also limits the instantaneous surge because the device still presents a finite impedance. | The material’s intrinsic resistance at room temperature is modest, so the initial surge is reduced compared with a plain short. |
| Current flow | As current passes, the device self‑heats (Joule heating). Once the temperature reaches the trip point (the “switch‑over” temperature), the resistance jumps dramatically—often by two orders of magnitude or more. | The positive‑temperature‑coefficient characteristic means resistance ∝ temperature. The rapid rise in temperature pushes the device into its high‑resistance region. |
| Steady‑state | After tripping, the PTC presents a high resistance (hundreds of Ω to kΩ), effectively limiting the current to a safe, low level. The downstream circuit now sees a normal operating voltage because the voltage drop across the PTC is small relative to the supply. | In the high‑resistance region the device behaves like a resistor that limits current according to Ohm’s law (I = V/R). |
When the load is turned off and the PTC cools, it returns to its low‑resistance state, ready for the next power‑on event.
Typical Characteristics (Qualitative)
| Parameter | Typical Range / Description |
| Cold‑state resistance (R₍c₎) | < 10 Ω (often 0.1–5 Ω) |
| Trip temperature (Tₜ) | 60 °C – 120 °C, selectable by material formulation |
| Hold current (Iₕ) | Maximum current the device can carry indefinitely in the high‑resistance state (often 0.1 × rated current) |
| Maximum (rated) current (Iₘₐₓ) | Specified by the part; typical values 0.5 A – 10 A for surface‑mount devices, higher for larger through‑hole parts |
| Resistance after trip (R₍t₎) | 100 Ω – kΩ, depending on size and material |
| Voltage rating | Up to several hundred volts for larger devices; lower for SMD versions |
| Response time | Tens of milliseconds to a few seconds to reach the high‑resistance state, depending on current and thermal mass |
These ranges are generic; exact numbers come from each manufacturer’s datasheet.
Common Applications
| Application | Why a PTC In‑rush Limiter Is Chosen |
| Power supplies & adapters | Prevents large charging currents when bulk capacitors charge, protecting diodes, fuses, and upstream transformers. |
| Motor drives & actuators | Limits the surge that occurs when a motor winding is energized, reducing stress on contacts and drivers. |
| LED lighting | Controls the initial surge that can damage LED drivers or cause flicker. |
| Battery chargers | Reduces the in‑rush to the charger’s input stage, helping meet IEC/UL safety requirements. |
| Automotive electronics | Handles the high‑current spikes when a vehicle’s ignition or infotainment system powers up. |
| Telecommunications equipment | Protects sensitive front‑end circuitry during line power restoration. |
Advantages Over Alternatives
| Feature | PTC Limiter | Series Resistor | NTC Thermistor (soft‑start) | Active MOSFET Soft‑Start |
| Self‑resetting | Yes (cools → low R) | No (needs replacement) | Yes (but resistance falls with temperature) | Requires control circuitry |
| Simple wiring | Two‑terminal passive | Two‑terminal passive | Two‑terminal passive | Needs driver IC |
| Robust against overload | Trips to high R, limiting current | Fixed R → may overheat | R decreases with temperature → can exacerbate overload | Depends on controller design |
| Cost | Low to moderate (depends on rating) | Very low | Low | Higher (controller + MOSFET) |
| Size | Small SMD or through‑hole options | Same as resistor | Similar to resistor | Larger due to active components |
Selecting a Suitable PTC
1. Determine the maximum steady‑state current your downstream circuit will draw. Choose a PTC whose rated current (Iₘₐₓ) is at least that value, preferably with a safety margin (~20%).
2. Identify the expected in‑rush current (often the capacitor charging current). The PTC’s hold current (Iₕ) should be higher than this peak, otherwise the device will trip prematurely.
3. Pick a trip temperature that matches the thermal environment. For ambient temperatures near 40 °C, a device with Tₜ ≈ 80 °C gives enough headroom.
4. Check voltage rating to ensure it exceeds the highest line voltage the part will see (including transients).
5. Consider physical constraints – board space, mounting style (SMD vs. through‑hole), and thermal dissipation.
Manufacturers such as
Bourns, Littelfuse, Murata, and TE Connectivity publish families of PTC in‑rush limiters with detailed tables that map these parameters. Their datasheets also include derating curves for temperature and voltage, which are useful for robust design.
Practical Design Tips
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Parallel Capacitors: If you have a large bulk‑cap bank, split it into smaller groups and place a PTC in series with each group. This spreads the heating load and improves reliability.
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Thermal Coupling: Keep the PTC away from heat‑generating components (e.g., power MOSFETs) to avoid premature tripping.
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Fuse Coordination: Pair the PTC with a fast‑acting fuse sized for the maximum allowable fault current. The fuse protects against catastrophic failures while the PTC handles normal surges.
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Testing: Verify the in‑rush behavior on a bench power supply with a current probe. Observe the voltage across the PTC during turn‑on to confirm the expected resistance transition.
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EMI Considerations: The rapid change in resistance can generate a brief voltage spike. Adding a small snubber (RC network) across the PTC can tame ringing in high‑frequency circuits.
Summary
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PTC in‑rush current limiter is a passive, self‑resetting device that reduces the damaging surge that occurs when power is first applied to a circuit. By exploiting the positive temperature coefficient of its semiconductor material, it starts with low resistance, heats up under current, and then jumps to a high resistance, thereby limiting the steady‑state current. It’s widely used in power supplies, motor drives, LED drivers, and many other applications where protecting upstream components from a brief but large current spike is essential.
If you need a specific part recommendation or want to compare datasheets for a particular current/voltage rating, let me know the exact requirements (max steady‑state current, expected in‑rush, voltage, package type), and I can fetch the latest details using the Proton information service.