Electrical – thermal fuse as electrical fuse

PTC fuses can be wonderful in some ways, but they're not very good at providing overvoltage protection for Zener-clamp circuits. Suppose, for example, that one has a Zener that clamps absolutely rigidly at precisely 30.0 volts, the PTC has a tripped power dissipation of 7W (grabbed from the data sheet of a 32V 10A device), and the supply feeds out exactly 30.5 volts. Under that scenario, the resistance of the PTC would increase to 0.035 ohms and remain there indefinitely, passing 14 amps. In such a state, the PTC would continuously dissipate 7 watts perfectly happily, but the 30-amp Zener would need to dissipate 420 watts--not just briefly, but indefinitely. Note that if the supply voltage were to increase, the current through the Zener (and the power it would need to dissipate) would drop considerably, but in many scenarios a low-impedance supply is just as likely to be slightly over the required voltage as to be massively over.

If you want to use a PTC with a shunt, and are only interested in surviving over-voltage conditions rather than being able to operate through them, I would suggest using a circuit that selectively shorts to ground the voltage after the PTC. When such a circuit trips, it will cause a lot of power to be dissipated in the PTC, and relatively little in the protection circuit. Circuit operation will not be possible in such a circumstance, but downstream devices will be usable once everything is shut down and the PTC is allowed to reset.

The 10uF cap can be near the regulator where it does the most good. The inrush current with that size of capacitor should be no problem for a 3.5A fuse.

The fuse you have selected is a fast acting fuse but the thermal mass of the fuse will unlikely respond in the short time that it takes to charge a 10uF capacitor.

You will always have a certain amount of series resistance in the wiring, connectors, PCB traces that also will help to limit inrush current. Plus under normal circumstances I suspect that you would cycle the mains power switch of the 12V supply to power down your circuit instead of direct connecting the +12V. In this case the supply will have a fairly lengthy rise time at its output that limits the inrush current to same levels.

For grins I ran a simulation assuming a wiring resistance of 0.1 ohm and the 12V supply coming up to full voltage in 10us. Under these conditions the inrush current is ~12A for the 10usec rise time of the supply (linear rise used). My estimation that under such conditions the fuse material may over heat and blow only if the switching duty cycle was faster than the fuse can cool down from a 10usec pulse.

Do note that in the past I have had first hand experience of seeing fuses crystallize and fail after years of service being subjected to inrush currents. That was on the rectified DC lines of a Cromemco S100 chassis that had enormous capacitors. Your 10uF caps would look like specks in comparison. The Cromemco fuse in question was the 30A fuse on the 8V rail as shown (in the photo here). Inside the back of the unit the associated capacitor was the large soup can in the (closer part of this image). That capacitor was a 130,000uF / 15V unit.

Now if you had something like a 4700uF capacitor then there may be more concern. In that case you may want to select a time delay SloBlo type fuse.

In some electronics devices where there is indeed a very large inrush current possible the equipment is designed with a low ohms resistive device in series with the input. As the device comes up a special circuit either detects when the input caps are charged or just waits some nominal delay and then activates a relay that shorts out the low resistance device.