What Makes a Battery Explode?

From smartphones to e-bikes and automobiles, batteries power much of our daily lives.

But what happens when a tool meant to energize your world suddenly turns dangerous? 

Exploding batteries, such as lithium-ion batteries, are more common than many people realize. These incidents can lead to devastating injuries, property damage, and, in some cases, even fatalities.

Battery explosions are not just fluke accidents, however; they’re often the result of preventable design flaws, careless manufacturing, or a lack of regulation. In other words, many battery explosions aren’t as random as they seem and often happen due to someone else’s negligence.

If you or a loved one has been injured by a battery explosion, contact Morgan & Morgan for a free case evaluation. We can hear the details of your story and advise you on your legal options—and whether you might be owed compensation.

What Types of Batteries Can Explode?

While any battery has the potential to malfunction, lithium-ion batteries are the most common culprits in explosive incidents. These high-energy batteries are found in:

• Smartphones
• Laptops
• Electric vehicles (EVs)
• E-bikes and e-scooters
• Vapes and e-cigarettes
• Power tools
• Tablets and smartwatches

Because lithium-ion batteries store a large amount of energy in a compact space, they are both efficient and inherently risky when not designed, manufactured, or handled properly.

What Causes a Battery to Explode?

Battery explosions are often sudden and violent, but the conditions that cause them usually develop over time or due to a defect. Some of the most common causes include:

Thermal Runaway

Thermal runaway is the most well-known cause of battery explosions. It’s a chain reaction inside the battery where:

• The internal temperature rises uncontrollably
• The battery cells rupture or catch fire
• Pressure builds until the battery explodes

Thermal runaway can be triggered by external heat, overcharging, physical damage, or internal short circuits.

Overcharging

Most modern batteries have built-in safeguards to prevent overcharging, but if these systems fail or if a faulty charger is used, overcharging can cause:

• Excessive heat
• Swelling of the battery
• Combustion or explosion
   

Overcharging is particularly risky with e-bikes, scooters, and off-brand chargers.

Manufacturing Defects

Errors during the manufacturing process can make batteries inherently unstable. Examples include:

• Poorly assembled battery cells
• Contaminants or debris inside the battery
• Inadequate separators between the anode and cathode
   

When these components fail, they may cause a short circuit or fire.

Physical Damage

Puncturing, crushing, or dropping a battery can disrupt its internal structure and cause a short circuit. Even if the damage isn’t immediately obvious, the battery may explode minutes, hours, or even days later.

Exposure to Extreme Temperatures

Leaving a device with a lithium-ion battery in a hot car or near a heat source can be extremely dangerous. Heat accelerates chemical reactions inside the battery and may lead to an explosion.

What Injuries Can Result from an Exploding Battery?

Battery explosions are violent and can cause catastrophic injuries, including:

• First-, second-, or third-degree burns from fire or caustic battery chemicals
• Lacerations and shrapnel injuries from flying battery fragments
• Inhalation injuries due to toxic fumes from burning lithium compounds
• Eye damage or blindness
• Hearing loss from the sound of the explosion
• Amputations or permanent scarring
• Traumatic Brain Injury

In addition to physical injuries, victims often suffer psychological trauma, medical debt, and lost wages from time off work.

Can I Sue if a Battery Explodes?

Yes. If you were injured by a battery explosion, you may be entitled to compensation under product liability law. That means you may be able to sue:

• The battery manufacturer
• The device manufacturer (if the battery was integrated)
• A third-party charger manufacturer
• A retailer or distributor
   

There are three main types of liability claims if someone else is responsible for a battery explosion injury:

• Design Defect: The battery was inherently dangerous due to poor design.
• Manufacturing Defect: The battery was damaged or contaminated during production.
• Failure to Warn: The manufacturer didn’t provide adequate safety instructions or warnings.

Even if the battery was made overseas, you can often sue the importer or the U.S.-based brand that sold the product.

What Compensation Can I Recover?

If you file a battery explosion lawsuit, you may be entitled to both economic and non-economic damages, such as:

• Medical expenses (emergency care, surgery, rehab)
• Lost income or reduced earning capacity
• Pain and suffering
• Disfigurement and emotional trauma
• Property damage
• Punitive damages (in cases of extreme negligence)

At Morgan & Morgan, we fight to ensure you receive the full value of your claim, not just what the insurance company thinks you deserve.

How Long Do I Have to File a Lawsuit?

The statute of limitations varies by state, but generally you have two to four years from the date of injury to file a product liability claim. Some states also have a "discovery rule" that gives you extra time if you didn’t know the battery caused your injury right away.

Because these cases can take time to investigate, it’s smart to contact a lawyer as soon as possible after the incident.

What Should I Do After a Battery Explosion?

If a battery explodes and you’re injured, take these steps immediately:

• Seek Medical Attention: Even minor burns or breathing issues can worsen over time.
• Preserve the Evidence: Keep the device (or what's left of it), charger, battery packaging, and any receipts.
• Take Photos: Document your injuries, the scene of the incident, and damaged property.
• Avoid Talking to Insurance Companies Alone: They may try to downplay your injuries or blame user error.
• Contact a Product Liability Attorney at Morgan & Morgan: A lawyer can help determine whether the manufacturer is liable and build a strong case.
  
   

Morgan & Morgan Can Help

Battery explosions are often the result of preventable design flaws, careless manufacturing, or a lack of regulation. However, these cases can be highly technical and difficult to prove. You need a legal team with the resources, experience, and dedication to take on major manufacturers and win.

As the largest personal injury law firm in the nation, Morgan & Morgan is uniquely qualified to face massive corporations that won’t take responsibility for shoddy designs and faulty products.  Our attorneys are ready to help you file a claim, fight for justice, and secure the compensation you need to recover.

For over 35 years, we have fought For the People and have recovered over $25 billion in compensation in the process.

Whether your injury came from a vape pen, e-bike, smartphone, or power tool, we’re here to fight for your right to compensation. Hiring one of our lawyers is easy, and you can get started in minutes with a free case evaluation.