ABSTRACT

A traditional fuse is a one time over current protection device employing fusible link that
melts after the current exceeds a certain level for a certain length of time. Typically, a wire or
chemical compound breaks the circuit when the current exceeds the rated value. Like traditional
fuses, poly fuse limit the flow of dangerously high current during fault conditions. Unlike
traditional fuses, it reset after the fault is cleared and the power to the circuit is removed. It is the
main advantage of poly fuse over other circuit protection devices. Poly fuse is a new standard for
circuit protection. They provide both over current protection and automatic restoration. A PPTC
device does not usually have to be replaced after it trips and because it is small enough to be
mounted directly into a motor or on a circuit board, it can be located inside electronic modules.

KEY WORDS: poly fuse

 CONTENTS

1. INTRODUCTION 1

2. BASICS OF POLY FUSE 2

3. PRINCIPLE OF OPERATION 3

3.1 Resistance VS Temperature 5

4. CONSTRUCTION AND WORKING 6

5. OPERATING PRAMETERS FOR POLY FUSES 8

6. DESIGN CONSIDERATION FOR PPTC DEVICES 9

6.1 Hold And Trip Current 9

6.2 Effect Of Ambient Conditions On Device Performance 10

6.3 Time To Trip 11

7. DESIGN CRITERIA 12

8. DIFFERENT TYPES OF POLY FUSES 14

8.1 Surface Mount Resettable Fuses 14

8.2 Radial Leaded Resettable Fuses 14

8.3 Battery Strap Resettable Fuses 15

9. EDGES OVER CONVENTIONAL FUSES 16

10. ADVANTAGES OF POLY FUSE 17

10.1 Utilities Over Conventional Fuses 17

10.2 Typical Resistance Recovery 18

11. APPLICATIONS 19

11.1For Protecting Speakers 19

11.2 For Protecting Transformers 20

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11.3 For Protecting Batteries 20

11.4 In Industrial Process Controls 21

11.5 In Computers 21

11.6 Hard Disk Driver 22

11.7 In Rechargeable Battery Packs 23

11.8 In Automobile Sectors 24

11.9 Automotive Electronics 25

11.10 Examples Of Poly Fuses 26

11.11 Applications For Resettable Circuit Protection 28

12. CONCLUSION 32

13. REFERENCE 33
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LIST OF FIGURES
FIGURE 3.1 OPERAING CHARACTERISTICS 3

FIGURE 3.2 RESISTANCE VS TEMPERATURE 5

FIGURE 4.1 CONDUCTIVE PATHS AND POLYMER CARBON 6

FIGURE 4.2 POLYMER MOLECULES IN AMORPHOUS STATE 7

FIGURE 4.3 TRANSITION OF MOLECULES 7

FIGURE 6.1 HOLD CURRENT VS TRIP CURRENT 9

FIGURE 10.1 TYPICAL RESISTANCE RECOVERY 18

FIGURE 11.1 SPEAKER PROTECTION 19

FIGURE 11.2 TRANSFORMER PROTETION 20

FIGURE 11.3 APPLICATIONS OF POLY FUSES IN INDUSTRY 21

FIGURE 11.5 USE OF PPTC DEVICES IN KEYBOARD/MOUSE 22

FIGURE 11.6 APPLICATION OF POLY FUSES IN HARD DISK DRIVER 23

FIGURE 11.7 POLY FUSE IN RECHARGEABLE BATTERY PACKS 24

FIGURE 11.8 POLY FUSE IN AUTOMOTIVE CIRCUITS 25

FIGURE 11.9 USE OF POLY FUSE IN AUTOMOTIVE ELECTRONICS 25

FIGURE 11.10.1 AUTOMOTIVE POLY FUSE DEVICES 26

FIGURE 11.10.2 RADIAL-LEADED POLY FUSE DEVICES 26

FIGURE 11.10.3 SURFACE-MOUNT POLY FUSE DEVICES 27

FIGURE 11.10.4 STRAP BATTERY POLY FUSE DEVICES 27

FIGURE 11.11 ELECTRONIC CONTROL MODULE PROTECTION 29

FIGURE 11.12 PPTC DEVICE AND SWITCH 31

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CHAPTER-1

1. INTRODUCTION

A fuse is a one-time over-current protection device employing a fusible link that melts or
blows after the current exceeds a certain rated value. Typically, a wire or chemical compound
breaks the circuit when the current exceeds the rated value. A fuse interrupts excessive current so
that further damage by overheating or fire is prevented. Wiring regulations often define a
maximum fuse current rating for particular circuits. Over current protection devices are essential
in electrical systems to limit threats to human life and property damage. Fuses are selected to allow
passage of normal current and of excessive current only for short period

Poly fuse is a new standard for circuit protection .It is re-settable by itself. Many
manufactures also call it as Poly switch or Multi fuse. Poly fuses are not fuses but Polymeric
Positive temperature Coefficient Thermistors (PPTC). We can use several circuit protection
schemes in power supplies to provide protection against fault condition and the resultant over
current and over temperature damage. Current can be accomplished by using resistors, fuses,
switches, circuit breakers or positive temperature coefficient devices.

Resistors are rarely an acceptable solution because the high power resistors required
are expensive .One shot fuses can be used but they might fatigue and they must be replaced after
a fault event. Another good solution available is the resettable Ceramic Positive Temperature
Coefficient (CPTC) device. This technology is not widely used because of its high resistance and
power dissipation characteristics. These devices are also relatively large and vulnerable to cracking
as result of shock and vibration. The preferred solution is the PPTC device, which has a very low
resistance in normal operation and high resistance when exposed to fault. Electrical shorts and
electrically overloaded circuits can cause over current and over temperature damage.

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CHAPTER-2

BASICS OF POLY FUSE

Technically Poly fuses are not fuses but Polymeric Positive Temperature Coefficient
Thermistors. For thermistors characterized as positive temperature coefficient, the device resistance
increases with temperature. The PPTC circuit protection devices are formed from thin sheets of
conductive semi-crystalline plastic polymers with electrodes attached to either side. The conductive
plastic is basically a non-conductive crystalline polymer loaded with a highly conductive carbon to
make it conductive. The electrodes ensure the distribution of power through the circuit.

Poly fuses are usually packaged in radial, axial, surface mount, chip or washer form. These
are available in voltage ratings of 30 to 250 volts and current ratings of 20 mA to 100A.

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CHAPTER-3

PRINCIPLE OF OPERATION

PPTC circuit protection devices are formed from a composite of semi-crystalline polymer and
conductive carbon particles. At normal temperature the carbon chains form low resistance conductive
network through the polymer. In case an excessive current flows through the device, the temperature
of the conductive plastic material rises. When the temperature exceeds the device’s switching
temperature, the crystallites in the polymer suddenly melts and become amorphous. The increase in
volume during melting of the crystalline phase cause separation of the conductive particles and results
in a large non-linear increase in the resistance of the device .The resistance typically increases by 3 or
orders of magnitude.

FIGURE 3.1 Operating Characteristics

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The principle of operation and increase in resistance is shown in the Fig.1.1. The increase
in resistance protects the equipment in the circuit by reducing the amount of current that can flow
under the fault condition to a low steady state level. The device will remain in its latched (high
resistance state) until the fault is cleared, providing continuous protection to the circuit. At this
time the conductive polymer particles cool and recrystallise restoring the PPTC to a low resistance
state within few seconds. The circuit and the affected equipment return to the normal operating
condition.

Thus a poly fuse acts like a self-resetting solid-state circuit breaker, which makes it suitable for
providing low cost over current protection. The resistance of poly fuse at room temperature is in
the order of few ohms and increases rapidly above 110°C.

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3.1 RESISTANCE VS TEMPERATURE

The resistance/temperature characteristics of the two types are shown in Fig.1. The
resistance the NTC falls following an exponential characteristic over a wide temperature range.
The NTC Thermistor shows a large increase of resistance over a small temperature range of power
dissipation within the component. When thermistors, especially the small bead type, are used for
temperature measurement, the power dissipation must be kept to a low level to avoid inaccuracies
due to self-heating. Fig1.3 shows the voltage-current characteristic of an NTC thermistor. Initially
the relationship is linear, since, at low power levels, the dissipation is insufficient to raise the
temperature above ambient.

FIGURE 3.2 Resistance VS Temperature characteristics of PPTC

At higher power level resistance falls and a value of voltage E max is reached when further
increases of current cause a fall in potential across the thermistor. Dissipation factor and thermal
time-constant are two further properties frequently quoted. The first of these is the power expressed
in mill watts required to raise the temperature of the thermistor by 1°C. The time constant is the
time for the resistance of the thermistor to change by 63 % of the total change when subjected to
a step function change in temperature.

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CHAPTER- 4
CONSTRUCTION & WORKING

PPTC fuses are constructed with a non-conductive polymer plastic film that exhibits two
phases. The first phase is a crystalline or semi-crystalline state where the molecules form long
chains and arrange in a regular structure. As the temperature increases the polymer maintains this
structure but eventually transitions to an amorphous phase where the molecules are aligned
randomly, and there is an increase in volume. The polymer is combined with highly conductive
carbon. In the crystalline phase the carbon particles are packed into the crystalline boundaries and
form many conductor combination has a low resistance.

FIGURE 4.1 Conductive Paths and Polymer Carbon

A current flowing through the device generates heat (I2R losses). As long as the
temperature increase does not cause a phase change, nothing happens. However, if the current
increases enough so that corresponding temperature rise causes a phase change, the polymer’s
crystalline structure disappears, the volume expands, and the conducting carbon chains are broken.
The result is a dramatic increase in resistance.

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FIGURE 4.2 Polymer Molecules in Amorphous State

FIGURE 4.3 Transition of Molecules from Semi crystalline to Amorphous State

At normal working conditions, the molecules of the device are in low resistance state, which
is known as crystalline structure of the Poly fuse. When current starts to flow through the device,
the temperature of the molecules tends to increase and when the current exceeds from a certain
level the temperature increases and the resistance increases. So the molecules of the material go
into high resistance state so the current reduces accordingly in the device. Due to leakage current
and I2R losses the circuit is still open, until the power is fully removed from the circuit then the
molecules of the device cooled down and reforms in its original structure so the Poly fuse resets .

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CHAPTER-5.
OPERATING PARAMETERS FOR POLYFUSES

1. Initial Resistance: The resistance of the device as received from the factory

2. Operating Voltage: The maximum voltage a device can withstand without damage at rated
current

3. Holding Current: Safe current through the device.

4. Trip Current: The current at which the interrupts the current

5. Time To Trip: The time it takes for the device to trip at a given temperature and current

6. Tripped State: Transition from low resistance state to high resistance state due to an overload

7. Leakage Current: A small value of stray current flowing through the device after it has switched
to high resistance mode.

8. Trip Cycle: The number of trip cycles the device sustains without failure.

9. Trip Endurance: The duration of time the device sustains its maximum rated voltage in the
tripped state without failure.

10. Power Dissipation: Power dissipated by the device in the tripped state.

11. Thermal Duration: Influence of ambient temperature.

12. Hysterisis: The period between the actual beginning of the signaling of the device to trip and
the actual tripping of the device.

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CHAPTER-6
DESIGN CONSIDERATION FOR PPTC DEVICES

Some of the critical parameters to consider when designing PPTC devices into a circuit
include device hold current and trip current, the effect of ambient conditions on device
performance; device reset time, leakage current in the tripped state and the automatic or manual
reset conditions.

6.1 HOLD AND TRIP CURRENT: The Fig.2 below illustrates the hold and trip current
behavior of the PPTC devices as a function of temperature.

FIGURE 6.1 HOLD CURRENT AND TRIP CURRENT VARIATION WITH TEMPERATURE

Region A shows the combination of current and temperature at which the PPTC device
will trip and protect the circuit. Region B shows the combination of current and temperature at
which the device will allow normal operation of the circuit.

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In Region C it is possible for the device to either trip or o remain in low resistance state depending
on the individual device resistance and its environment.

Because PPTC devices can be thermally activated, any change in the temperature around
the device could affect the performance of the device. As temperature around a PPTC device
increases, less energy is required to trip the device and thus its hold current (I hold) decreases. The
heat transfer environment can accurately define hold current. It can be affected by the design
choices such as:

1. Placing the device in proximity to a heat generating source such as a power field effect transistor
(FET), a resistor or a transformer resulting in reduced hold current, power dissipation and time to
trip.

2. Increasing the size of the traces or leads that are in electrical contact with the device resulting
in increased heat transfer and greater hold current, slower time to trip and greater power dissipation

3. Attaching the device to a long pair of wires before connecting to the circuit board, increasing
the lead length of the device which results in reduced heat transfer and lowered hold current, power
dissipation and time to trip.

6.2 EFFECT OF AMBIENT CONDITIONS ON DEVICE PERFORMANCE:

The heat transfer environment of the device can significantly affect the device performance. In
general, by increasing the heat transfer of the device, there is a corresponding increase in power
dissipation, time to trip and hold current. The opposite occurs if the heat transfer from the device
is decreased. Furthermore, changing the thermal mass around the device changes the time to trip
of the device.
If the heat generated is greater than the heat lost to the environment, the device will increase in
temperature resulting in a trip event. The rate of temperature rise and the total energy required to
make a device trip depends on the fault current and heat transfer environment. Under normal

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operating conditions the heat generated by the device and the heat lost to the environment are in
balance.
Increases in current or ambient temperature or increase in both cause the device to reach a
temperature at which the resistance rapidly increases. This large change in resistance causes a
corresponding decrease in the current flowing through the circuit, protecting the circuit from
damage.

6.3 TIME TO TRIP:

The time to trip of a PPTC device is defined as the time needed from the onset of a fault
current to trip the device. Time to trip depends upon the size of the fault current and the ambient
temperature.

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CHAPTER-7
DESIGN CRITERIA

To select the best device for a specific application, circuit designers should consider
the following design criteria:

1. Choose the appropriate form factor. Select from radial- leaded, surface-mount, or
chip parts. For mounting on circuit boards, a radial-leaded or surface- mount
configuration is preferred. Radial-leaded parts are typically wave soldered to the
board. Chip parts are designed to be held in clips, usually in an electric motor.

2. Choose a voltage rating. The voltage rating of a PPTC device should equal or exceed
the source voltage in a particular circuit. Also the expected fault voltage should not
be later than the PPTC voltage device. When a PPTC device trips, the majority of
circuit voltage appears across the device because it is the highest resistance element
present in the circuit.

3. Choose a hold current rating (At the proper ambient operating temperature). Hold
current is defined as the greatest steady state current the PPTC device can carry
without tripping into a high resistance state. Designers must choose a PPTC device
with a hold current at maximum ambient temperature equal to or greater than the
steady state operating current.

4. Check trip time. Designers should determine what fault currents may occur and
how quickly the most sensitive system components could be damaged at these
currents. A PPTC device should be selected that trip before these sensitive
components would be damaged. Many applications experience a start-up surge
current from a capacitance or motor. Normally, this in-rush current does not contain

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enough energy to trip the PPTC device, but the designers should confirm performance
in their application over the range of expected ambient conditions.

5. Check maximum interrupt current. A PPTC device normally has a maximum

interrupt current rating, i.e., the maximum fault current that the device consistently
interrupts while remaining functional.

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CHAPTER-8

DIFFERENT TYPES OF POLYFUSES

8.1 SURFACE MOUNT RESETTABLE FUSES

This surface mount poly fuse family of polymer of polymer based resettable
fuses provides reliable over current protection for a wide range of products such as
computer motherboards, USB hubs and ports, CD/DVD drives , digital cameras and
battery packs. Each of these poly fuse series features low voltage drops and fast trip
times while offering full reset ability. This makes each an ideal choice for protection
in data component and battery powered applications where momentary surges may
occur during interchange of batteries or plug and play operations.
The SMD0805 with the industry’s smallest footprint, measuring only 2.2mm
by 1.5mm, features four hold current ratings from 100mA to 500mA with a current
interruption capability of 40A at rated voltage. Both the SMD1206 and SMD1210
series are optimized for protection of computer peripherals, PC cards and various port
types.

8.2 RADIAL-LEADED RESETTABLE FUSES

Due to the automatic resetting of the poly fuse, these components are ideal
for applications, where temporary fault conditions (for example during hot plugging)
can occur. The radial-leaded RLD-USB-series 709 is specifically designed for
universal serial bus (USB) applications with lower resistance, faster trip times and
lower voltage drops.

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8.3 BATTERY STRAP RESETTABLE FUSES

This type profile strap type poly fuse family of resettable fuses provides
thermal and over charge protection for rechargeable battery packs commonly used in
portable electronics such as mobile phones, notebook computers and camcorders.
Both Li-Ion and NiMH pack designs are enhanced with 0.8mm high form factor on
the VTD-719 series. The LTD-717 series is optimized for prismatic packs and exhibits
faster trip times- down to 2.9 sec at five times the fuse’s hold current rating.

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CHAPTER-9
EDGES OVER CONVENTIONAL FUSES

1. Overcurrent protection

2. Low base resistance

3. Latching operation

4. Automatic reset ability

5. Short time to trip

6. No arching during faulty situations

7. Small dimensions and compact designs

8. Internationally standardized and approved

9. No accidental hot plugging

10. Withstand mechanical shocks and vibrations

11. Life time up to 10 times longer

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CHAPTER-10
ADVANTAGES OF POLYFUSE

10.1 UTILITIES OVER CONVENTIONAL FUSES

Conventional thermal fuses are not resettable and are therefore limited in their ability to match
the low temperature protection of PPTC devices. The selection of a low fusing temperature in
conventional thermal fuses is limited by the need to avoid nuisance tripping in temporary high
ambient temperature environments, such as car dashboards on a hot day or high storage
temperatures. Even thermal fuses with 94°C or higher fusing temperatures often nuisance trip
during normal operation or pack assembly. As we know that conventional fuses use some
protecting cover, this increases the size of the conventional fuses while the Poly fuse are installed
in a thin chip form so the size of the Poly fuse is much less in comparison to traditional fuses. Poly
fuses are considered as more safe than traditional fuses as these are connected internally in series
with the devices and reduces the arcing probability in the circuit and there are much less power
losses in Poly fuses as these requires less amount of energy for its operation.

Hence, the major benefits of Poly fuse are as,

Low base resistance

Non-cycling operation

Automatic reset ability

Short time to trip

No arcing during faulty situations

Small dimensions and compact design

Inter nationally standardized and approved

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10.2 TYPICAL RESISTANCE RECOVERY BY POLY FUSE AFTER A

TRIP EVENT

Figure shows typical behavior of a Poly fuse device that is tripped and then allowed to cool
over an extended period of time, device resistance will continue to fall and will eventually
approach initial resistance. However, since this time can be days, months, or years, it is not
practical to expect that the device resistance will reach the original value for operation purposes.
Therefore, when Poly fuse devices are chosen R1MAX should be taken into consideration when
determining hold current. R1MAX is the resistance of the device one hour after the thermal event.

Figure 10.1 Typical Resistance Recovery after a Trip Event

CHAPTER-11

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APPLICATIONS

Poly fuses are used in automobiles, batteries, computers and peripherals, industrial
controls, electronic modules, medical electronics, loud speakers, transformers etc.

11.1 FOR PROTECTING SPEAKERS:

Nowadays, speakers are designed and sold independently of amplifiers. Therefore, there
are possibilities of damage due to mismatches; for example high power amplifiers coupled with
low power speakers or a speaker coil driven with a high volume. The protection choices for loud
speakers are limited. Fuses protect the speaker but a blown fuse is always a source of frustration.
Using a poly fuse in series with the speaker will protect it from over current and overheating
damage. Choosing a correct trip current rated poly fuse is important to match the power level of
the speaker.

. FIGURE 11.1 SPEAKER PROTECTION

11.2 FOR PROTECTING TRANSFORMERS:

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The equipment powered by a transformer got over heated due to excessive current or short
circuit. A poly fuse on the secondary side of the transformer will protect the equipment against
overload.

FIGURE 11.2 TRANSFORMER PROTECTION

11.3 FOR PROTECTING BATTERIES:

Batteries are constantly charged and discharged over their life cycle. Overcharge results
in an increase in the temperature of the electrolyte. This could cause either a fire or an explosion.
Poly fuse can play a vital role in the charging and discharging cycles of batteries.

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11.4 IN INDUSTRIAL PROCESS CONTROLS

As we know that different type of controllers are needed to control the different process of
any industry and these controllers require some overcurrent protecting devices to be protected from
overheating.so poly fuses are best suitable devices for these controllers as these are resettable
devices and doesn’t need to be replaced again and again.

Figure 11.3 Application of Poly fuse in Industrial Controllers

11.5 IN COMPUTERS
11.5.1 KEYBOARD/ MOUSE:

The operating current of keyboard mouse is usually from 200 to 500 mA, but in a short
circuit the current will increase many times. Using Poly fuse in series between the connector and
host power supply will limit the current cut the keyboard mouse port to the specified maximum.

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Figure 11.5 Use of PPTC Device in Keyboard/Mouse

11.6 HARD DISK DRIVER:

Hard disk driver is an important tool for computers. So we require an efficient over current
protection device to protect the circuit .In hard disk driver the Poly fuse (PPTC device) is
connected in series with platon motor and head actuator when the over current flows through the
circuit, the operation of Poly fuse takes place and Poly fuse provide protection from overheating
of the elements.

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FIGURE 11.6 Application of Poly fuses in Hard Disk Driver

11.7 IN RECHARGEABLE BATTERY PACKS

PPTC in series within battery pack will avoid the followed faults occurring:

a.Shorting of the positive and negative terminals.

b. A runaway charging condition in which the charger during charging, fails to stop supplying
current to the package when it is fully charged.

c. Using the wrong charger or the pack is reverse changed.

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Figure 11.7 Poly fuses in rechargeable Battery Packs

11.8 IN AUTOMOTIVE SECTORS

11.8.1 AUTOMOTIVE HARNESS:

The conventional solution in wire harnesses is that groups similar circuits together and
protects them with a single fuse. In order to limit risk of fire, the wire high current carrying
capability, and the oversized wire is commonly used. If anyone circuit under the same fuse short,
the other circuits will all stop. PPTC devices can be installed to each circuit, which allows the
optimum wire to be selected. And the other hand, the circuits don't have to be through the central
fuse box, thus reducing the length of wire required.

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FIGURE 11.8 Poly fuses in Automotive Circuits for the Solution of Wire Harness

11.9 AUTOMOTIVE ELECTRONICS:

Automotive electronics is the electronics used in automobiles. Automotive electronics or

automotive embedded systems are the distributed systems. So there are some types of poly fuses
used for automotive electronics equipment for current protection. The following figure shows that
a Poly fuse is connected in automotive electronics equipment to protect the circuit.

FIGURE 11.9 Use of Poly fuse in Automotive Electronics

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11.10 EXAMPLES OF THE POLYFUSES CLASSIFIED ON THE BASIS OF

THE APPLICATIONS

11.10.1 AUTOMOTIVE DEVICES:

Poly fuse automotive devices are qualified and sold under PS400 specification which is
derived from AECQ200, the standard for electronic components used in the automotive industry.
These devices have successfully passed to meet the demanding environmental conditions that can
be found in automotive applications. In the following figure the poly fuses used in the automotive
devices are shown. These devices have ratings according to the devices.

FIGURE 11.10.1 Automotive Poly fuse devices

11.10.2 RADIAL-LEADED DEVICES:

For design or volume application the poly fuse radial-leaded devices represent the most
comprehensive and complete set of PPTC available in the industry today.

Figure 11.10.2 Radial-Leaded Poly fuse Devices

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11.10.3 SURFACE MOUNT DEVICES:

These devices are preferred circuit protection method for computer, consumer multimedia,
portable and automotive electronics application. Surface mount devices are shown in figure.

Figure 11.10.3 Surface–mount Poly fuse Devices

11.10.4 STRAP BATTERY DEVICES :

Many materials platforms and device forms factors allowing the engineer greater design
flexible also. Poly fuse devices for battery protection include SRP, LTP, LR4 and MXP series,
disc and special application strap devices.

Figure 11.10.4 Strap Battery Poly fuse Devices

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11.11 APPLICATIONS FOR RESETTABLE CIRCUIT

PROTECTION IN AUTOMOTIVE ELECTRONICS

The conventional solution groups similar circuits together and protects them all with a
single fuse. The fuse must be sized to carry the sum of the currents drawn by each of the protected
loads; and, to limit risk of damage and fire, the wires feeding from the fuse to each load must be
chosen according to the fuse size selected. This design practice often results in oversized wires
with high current-carrying capability feeding loads that require relatively low currents. Using
heavy-gauge wire also requires use of larger terminals and connectors, which further increases
cost, size, and weight. It also increases harness weight, and the weight of the automobile, which
has an effect on fuel efficiency.

Because PPTC devices reset when a fault condition clears and power is removed from the
circuit, they do not generally require routine replacement or service. Therefore, such devices can
be placed inside doors, in switch assemblies, behind instrument panels, in electronic modules, and
in other inaccessible areas within the vehicle. As shown in Figure 3, the option of locating circuit-
protection devices strategically throughout the vehicle also allows power to be routed via the most
direct and efficient route (rather than through a central fuse box), which reduces the number of
wires in the harness and allows reduction in their length and weight.

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Figure 11.11 Electronic Control Module Protection

Electronic Control Module Protection As more and more circuitry is packed into
smaller and smaller packages, the width of the copper traces on printed circuit boards (PCBs) is
reduced. Because motorized accessories are generally powered from high-amperage circuits, these
narrow circuit board traces are susceptible to damage from excessive currents. Printed circuit
traces function as wires carrying signals from one point to another. Depending on the cross-
sectional area, the traces can carry only a certain amount of current before the heat generated by
I2R losses causes them to either melt or become hot enough to delaminate, resulting in damage to
the PCB and mounted components.

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Electronic module outputs typically require protection from over current situations
caused by a short circuit or by the high stall current of motors. Module outputs can also be damaged
by failure of some other portion of the system, such as a diode short or loss of a power ground.
Because they are one-use devices and must be replaced in the event of a transient fault, fuses are
not considered an acceptable solution to these potential problems. Multicomponent circuits used
to sense and switch, called smart FETs, are frequently used to address these situations, but such
devices require careful design and consume valuable board space. They can also be quite costly.

PPTC circuit-protection devices are gaining acceptance as a practical, cost-effective

solution to over current and over temperature protection of electronic modules. Because they
rapidly and effectively limit current to safe levels and are small enough to be mounted directly on
the circuit board, each power circuit within the control module can be individually protected with
a single device.

Most automotive actuators are used in applications that require them to move something
until it reaches the end of its motion range to move a seat or close a window, for example. However,
because these activities can be manually controlled, the actuator may remain energized after the
mechanism reaches its limit of travel. When this condition occurs, the actuator stalls, and it’s back
electromotive force (EMF) falls to zero. Without the back EMF opposing the supply voltage, the
actuator's current may rise rapidly to levels typically between two and four times its normal
operating value

Because the actuator's winding is made with very-small-gauge wire, the high stall current
causes a rapid rise in temperature. Often within seconds, the temperature may rise sufficiently to
permanently damage the enamel varnish used to insulate the wire in the actuator's winding. With
the loss of insulating properties, turn-to-turn short circuits may develop throughout the winding,
rendering the actuator inoperable and creating a potential for a thermal event (see Figure 4).

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FIGURE 11.12 PPTC Device and Switch

When the current or temperature of a winding rise above a certain value the
PPTC device latches into a high-resistance state, limiting current to a low level and preventing
damage to the actuator. After the fault and power are removed and the PPTC device cools, the
device resets for normal current flow.

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CHAPTER-12
CONCLUSION

Polymeric Positive Temperature Coefficient device provide net cost savings through
reduced component count and reduction in wire size. They can help provide protection against
short circuits in wire traces and electronic components. The low resistance, relatively fast time to
trip and low profile of these devices improve reliability. In addition, these devices provide
manufacturing compatibility with high volume electronic assembly techniques and later design
flexibility through a wide range of product options.

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CHAPTER-13
REFERENCES

 www.google.com

 www.wikipedia.org

 www.studymafia.org

 J. Fellner, P. Boesmueller, and H. Reiter, “Lifetime study for a poly fuse in a 0.35 μm
polycide CMOS process,” IRPS, 2005.

 M. Alavi et al., “A PROM element based on salicide agglomeration of polyfuses in a

CMOS logic process,” in 1997.

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