I'm doing a miniaturized PMT replacement product that has to fit a pHEMT-bootstrapped front end, low noise PGA, variable ~50V MPPC bias supply, TEC controller, MCU, and serial communications into a 22x22x50 mm envelope. (Fun.)
It needs supply polarity and overvoltage protection, but I haven't got anything like enough space for a two-amp polyfuse, and couldn't stand the voltage drop if I had.
Soooo, I'm using back-to-back PFETs controlled by the MCU for the protection circuitry. Largish ceramic caps (4.7 uF 0603) look after ESD sensitivity on the supply lines. (Turns out that you can get reasonably decent ones, at least for low voltages--check out Kemet's C0603C475K9PACTU, which is down only 30% at 2.8V. Most are far worse.)
The MCU itself is powered via an LP2951, which is OK to 30V and has separate polarity protection from an SC70 PFET--no big worries there.
The current issue is the input filtering. Without the conveniently-sized resistance of the polyfuse, it's difficult to control the overshoot and ringing of the LC filter. It's not so bad at inrush, because I can use a PWM to control the two PFETs. (The big inductor is downstream of the PFETs, so it won't see the power-on inrush.) However, if the supply is momentarily interrupted, the turn-on transient could blow up quite a few things.
I'm planning to use a very small unidirectional 3.3V TVS in parallel with the largest inductor (4.7 uH). That way most of the inrush goes through the forward-biased diode, keeping the inductor current down, and the worst of the ringing will be damped by the zener action.
It's not as comfortable as the TVS/polyfuse approach, for sure. Any better ideas?
Cheers
Phil Hobbs