What is the biggest cause of lithium-ion batteries exploding?

Lithium-ion battery explosions are extremely rare, but when they do happen, they are very dangerous because lithium-ion fires release toxic gases and are difficult to extinguish.

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Over the years there have been product recalls for devices including hoverboards, smartphones, e-bikes and e-scooters. In recent months there has been a product recall for Vanon lithium-ion battery packs and for  1.2 million rechargeable lights following safety concerns and reports of fires.

Here we discuss how lithium-ion batteries work, why they are used, what can cause a lithium-ion battery explosion and what you can do to minimise the risk to lives and property.

How do lithium-ion batteries work?

Lithium-ion batteries make energy through the movement of lithium ions between two electrodes: a positive cathode and a negative anode. A gel-like electrolyte facilitates the movement of these ions, while a separator ensures the electrodes do not touch but allows ions to pass through.

During the charging process, an external power source applies a voltage across the battery, causing lithium ions to move from the cathode to the anode through the electrolyte, and electrons to flow from the cathode to the anode via the external circuit.

When discharging, the ions move back from the anode to the cathode, and electrons flow through the external circuit to power the device.

What are the advantages of lithium-ion batteries?

• Lightweight. As they have a high energy density, they can store a large amount of energy in a small, lightweight package.
• Versatile. They can be used in a wide range of applications, from small consumer electronics to large-scale energy storage systems.
• Environmental impact. When used in electric vehicles and renewable energy storage, li-ion batteries have lower greenhouse gas emissions than fossil fuel-based technologies.
• Long lifecycle. They can be recharged many times before their capacity significantly degrades.
• Efficient. Compared to other battery types, lithium-ion batteries have a low self-discharge rate. This means they retain their charge longer when not in use.
• Fast charging. They can be charged more quickly than many other types of batteries.
• No memory degradation. Lithium-ion batteries do not lose their maximum energy capacity if they are repeatedly recharged.

What are the dangers of lithium batteries?

Lithium-ion batteries have a high energy density, storing significant energy in a compact space, making fires intense and hard to control.

Overheating in one cell can trigger a chain reaction, leading to a rapid and uncontrollable temperature rise (called &#;thermal runaway&#;), potentially causing explosions or fires. The electrolyte, a flammable liquid, can ignite if the battery is damaged or short-circuited.

Burning lithium-ion batteries release toxic gases like hydrogen fluoride and carbon monoxide, complicating firefighting. Even after appearing extinguished, residual energy can cause the battery to reignite.

What is the biggest cause of a lithium-ion battery exploding?

These are the factors that may lead to a lithium-ion battery exploding:

1. Overcharging. Charging a lithium-ion battery beyond its capacity can cause excessive heat buildup, leading to thermal runaway. This can cause the battery to catch fire or explode.
2. Overheating. High temperatures can destabilise the chemical structure of the battery, potentially leading to a thermal runaway. This can be caused by environmental factors, such as leaving the battery in a hot car, or by internal factors, such as a malfunctioning device.
3. Short circuit. If the battery terminals come into direct contact, it can cause a short circuit, leading to rapid discharge and heat buildup, which may result in an explosion.
4. Physical damage. Puncturing, crushing, or otherwise damaging a lithium-ion battery can breach its internal structure, causing a short circuit or other failure modes that can lead to an explosion.
5. Manufacturing defects. Flaws in the manufacturing process, such as impurities in the materials, poor assembly, or defective components, can create conditions where the battery becomes unstable and prone to failure.
6. Improper charging. Using a charger that is not compatible with the battery or one that delivers the wrong voltage can cause overcharging and overheating which might lead to an explosion.
7. Aging and wear. Over time, lithium-ion batteries degrade, and their internal components can become less stable. This degradation can increase the risk of a failure that might lead to an explosion.
8. Electrolyte leakage. The electrolyte inside lithium-ion batteries is flammable. If it leaks due to damage or manufacturing defects, it can ignite, especially if it comes into contact with a spark or high heat source.
9. Poor ventilation. Lithium-ion batteries generate heat during charging and discharging. If they are enclosed in a space with poor ventilation, the accumulated heat can lead to thermal runaway.

How do you know if a lithium-ion battery is failing?

If you notice any signs that a lithium-ion battery is failing, it is advisable to replace the battery or consult a professional for a thorough check. Ignoring these symptoms can lead to fires.

Reduced capacity

The battery discharges quickly or does not hold a charge as long as it used to. If your device needs frequent recharging, it could indicate a failing battery.

Swelling or bulging

Physical changes such as swelling, bulging, or deformation of the battery are serious signs of failure. This can be dangerous and may require immediate attention.

Overheating

If the battery becomes excessively hot during charging or discharging, it may be failing. Normal operation should not cause significant heat.

Inconsistent performance

Unexpected shutdowns or reboots of your device, even when the battery shows a reasonable charge level, can be a symptom of battery issues.

Slow charging

If the battery takes much longer to charge than usual, it could be a sign of deterioration.

Visible damage

Any visible damage such as cracks, leaks, or corrosion is a clear sign that the battery is compromised and likely failing.

Battery warning messages

Many devices have built-in systems to alert you if the battery health is poor. Pay attention to any warning messages regarding battery health.

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Age of the battery

Lithium-ion batteries degrade over time. If your battery is several years old, it may naturally start to fail even without significant symptoms.

How can you prevent a lithium-ion battery explosion?

As well as checking for signs that a lithium-ion battery is failing (see above), you can also minimise safety risks by:

• Purchasing devices from reputable suppliers.
• Not overcharging batteries.
• Only using the manufacturer&#;s recommended charger for a device.
• Checking chargers and devices for signs of damage before use.
• Not leaving devices in direct sunlight.
• Disposing of batteries and devices properly and not in the general waste. Lithium-ion batteries must be taken to a local recycling centre.

For more about how to prevent lithium-ion battery explosions and fires and what to do in an emergency please read, How common are lithium-ion battery fires?

Lithium-ion battery safety training

Our lithium-ion battery safety training ensures participants are aware of the dangers of lithium-ion batteries and what simple steps they can take to prevent lithium-ion battery explosions and fires.

Although lithium-ion battery fires are rare, when they do occur, they pose a significant risk to life and property.

Find out more about lithium-ion battery safety training or contact our friendly team for further information.

Rob Sherman

Director of Fire Safety

Rob is the Director of Fire Safety at Praxis42. He joined in after serving with the London Fire Brigade for 32 years, so fire safety is basically in his DNA. Rob is passionate for saving lives and ensuring quality standards. At Praxis42, he is responsible for delivering customer fire safety support through a framework of training, information and third-party accreditation.

Lithium-ion (Li-ion) batteries are used in much of the technology we use today, including smartphones, laptops, electric vehicles and bicycles, drones, medical devices, vapes, and more. However, when Li-ion batteries are manufactured improperly, are overcharged, or overheat, they can explode and catch fire, putting consumers in serious danger.

In recent years, there have been several high-profile incidents involving lithium-ion battery fires. In , Samsung recalled millions of Galaxy Note 7 smartphones due to reports of battery fires. In , a Tesla Model S caught fire in California after a crash, and a year later, a Tesla Model 3 caught fire in a parking lot in Shanghai.

In this blog post, we&#;ll discuss the potential dangers of Li-ion batteries, what causes them to explode, and what to do in the case of a battery explosion. Additionally, if you have been injured by a Lithium-ion battery, you may have a right to compensation. Schedule a free consultation with our attorneys to discuss your potential case.

How do lithium-ion batteries work?

Lithium-ion batteries create energy through the movement of lithium ions between the battery&#;s electrodes. The lithium ions are transported through a liquid or gel-like substance called an electrolyte (this will be important later), which allows for the continuous flow of lithium ions, allowing these batteries to be rechargeable and providing a reliable and long-lasting source of energy.

Li-ion batteries typically have a higher voltage and capacity than other batteries, permitting them to deliver more power over a longer period. They also have a lower self-discharge, meaning they can retain their charge for longer periods when not in use, making them more convenient for devices that require intermittent or occasional use. For these and other reasons, Li-ion batteries have become a popular option for a variety of electronic devices. Unfortunately, these devices are not without their dangers.

Why do lithium-ion batteries explode?

Lithium-ion batteries can explode or catch fire due to a phenomenon called thermal runaway. Thermal runaway is a chain reaction that occurs when the battery experiences a rapid increase in temperature, leading to the release of energy and potentially causing a catastrophic failure. Li-ion batteries can overheat from being damaged or punctured, being overcharged, or being exposed to high temperatures or direct sunlight.

Additionally, the electrolyte liquid inside the battery is flammable. If the battery is damaged, the liquid can leak out and come into contact with oxygen in the air, potentially igniting and causing a fire or explosion.

However, the most egregious cause of the Li-ion battery explosions is manufacturer defects. Cheap materials and poor quality assurance can introduce impurities or foreign particles inside the battery, which can create short circuits and increase the likelihood of thermal runaway.

How can I tell if a lithium-ion battery is failing?

Unfortunately, there are not always visible warning signs before a lithium-ion battery fails.  However, some tell-tale signs that the battery may be failing include:

• Overheating: if the device containing the Li-ion battery becomes unusually hot to the touch, especially near the battery area, it could be a sign of a problem and you should not continue to charge or power the device/battery.
• Swelling or bulging: a failing Li-ion battery will often expand, causing the battery to swell or bulge. If you notice visible deformities to the shape of the device and/or battery, stop using the device immediately.
• Reduced battery life/inconsistent charging: if you notice that the battery life of your device has significantly decreased, or the charging process becomes erratic or unreliable, these can be signs of a failing battery.

What should I do in the case of a Lithium-ion battery explosion?

If a Li-ion battery explodes, there are a few immediate steps you should take to ensure your safety:

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1. Evacuate the area: Move away from the battery as quickly as possible to avoid exposure to any harmful fumes or flames.
2. Alert others: If you are in a public place, notify those around you of the explosion and instruct them to leave the area.
3. Call emergency services: Contact your local emergency services immediately and inform them of the explosion.
4. Handle the battery with caution: If you need to move the battery, use appropriate protective gear such as gloves and safety glasses. Do not touch the battery with your bare hands.
5. Ventilate the area: Open windows and doors to allow fresh air to circulate and clear any fumes that may have accumulated. Ruptured Li-ion batteries can release toxic gases that are harmful to human health.
6. Do not attempt to extinguish the fire: Lithium-ion batteries can be difficult to extinguish, and attempting to do so could put you at risk. Leave this to the professionals.
7. Dispose of the battery properly: Lithium-ion batteries should be disposed of at designated recycling centers to avoid environmental damage.