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A circuit to soft-start, a.k.a. slew-limit, the charging of a 220 uF capacitor Cf at a maximum current in the neighbourhood of 300 mA. Cf is a filter cap preceding a further SMPS stage. My plan so far is to use an ESL227M035AG8AA, an aluminum electrolytic chosen for its ESR of 48 mohm @ 100 kHz. 220 uF was slightly arbitrary, only chosen because the SMPS asks for a minimum of 20 uF at the input with low ESR, and the 220 uF cap is the cheapest in that category.

Tony says that

If ESR * C <= 10 us ( for low ESR type e-caps) then Ic max = Vin/ESR = Vin * C /10us = 18V * 22 = ~ 400 Amps

In this case this would be basically true, because 48 mohm * 220 uF = 10.56 us; and 18 V * 220 uF / 10.56 us = 375 A.

Vin between 12 and 18 V. This is automotive line voltage but can go that high due to some non-standard modifications from hobbyists for this application.

Maximum continuous load is 1.1 A. The load is a simple SMPS powering a LED driver. The SMPS has its own soft-start circuit but of course can only protect its output, not capacitors at its input.

U1 would be replaced based on design parameters but a quick hack uses the default PMOS model for simulation.

schematic

simulate this circuit – Schematic created using CircuitLab

Simulation time-domain

Based on a related question, at these time scales U1 risks entering thermal runaway and there is barely any other resistance in the charging path so it could fry due to the Spirito effect. However, am I right in thinking that if I use something like the MCG35P04 which has only a weak thermal effect against Vgs:

Vgs against Id

then runaway may be mitigated?

It's possible to replace the PMOS with an NMOS and put it only in the charging path of the capacitor:

schematic

simulate this circuit

Speaking more broadly, it surprises me that manufacturers don't seem to offer integrated soft-start circuits for this purpose - only soft-start sections in other components like SMPS or load switches. Why is this?

Reinderien
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  • I'm not sure what the end application is, but you shouldn't need to really worry about having a soft start circuit for this small of a capacitive load. – bunker89320 Apr 21 '22 at 21:08
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    @bunker89320 heh ! If ESR * C <= 10 us ( for low ESR type e-caps) then Ic max = Vin/ESR = Vin * C /10us = 18V * 22 = ~ 400 Amps. But the correct approach is to use a PFM buck regulator with soft start – Tony Stewart EE75 Apr 23 '22 at 11:30
  • @TonyStewartEE75 That's very interesting to me and I would like to hear why; because it seems to set up a chicken-or-egg. SMPS ask for an input capacitor, but input capacitors ask for inrush protection. – Reinderien Apr 23 '22 at 14:28
  • That's why some DCDC conv. IC's have realtime current limiting to precharge output enable from DC OK signal. – Tony Stewart EE75 Apr 23 '22 at 15:47
  • Why do you need such a big cap? what is the source & load? – Tony Stewart EE75 Apr 23 '22 at 16:06
  • @TonyStewartEE75 Don't need such a big cap; the AP64200 SMPS specsheet calls for Cin > 20uF but this 220uF is the cheapest low-ESR one in this category. I could decrease it and pay a little more. Source is automotive line voltage (but from customizers who can often run higher than 12V). Load is a LED driver. – Reinderien Apr 23 '22 at 16:29
  • Why not just use 2x 10µF X7R ceramic caps? That will give you much lower ESR, cost less, and solve your problem... – bobflux Apr 24 '22 at 18:43
  • @bobflux Lower ESR makes the inrush situation worse, right? Are you suggesting that the inrush be mitigated by spreading it out over multiple components? 375A / 2 doesn't seem good enough. – Reinderien Apr 25 '22 at 02:34

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