Tag: Batteries

Vapes Major Cause of Aviation Battery Incidents
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The rate of “battery thermal Runaway incidents”—instances of lithium-ion batteries overheating on passenger planes—hit a five-year peak last year, with e-cigarettes being the biggest culprit, according to a report from UL Standards & Engagement (ULSE), a nonprofit organization focused on safety standards.
The data comes from ULSE’s Thermal Runaway Incident Program (TRIP), a voluntary lithium-ion battery incident reporting system. TRIP comprises 35 passenger and cargo airline participants. The program was designed with the aviation industry to better understand the extent of thermal runaway incidents caused by lithium-ion batteries onboard aircraft and how to prepare for, or ideally prevent, future incidents.
“Passengers are often unaware that many devices they bring on board are powered by lithium-ion batteries, let alone the risks they carry, and it’s much harder to solve a problem that they do not know exists,” said David Wroth, director of technology and systems at ULSE and the leader of TRIP, in a statement. “Thermal runaway incidents on board aircraft are largely preventable but admittedly more difficult to contend with at 40,000 feet. TRIP provides a unique opportunity for the aviation industry to come together to find strategies to mitigate the risk of these incidents.”
As technology evolves and more products rely on rechargeable power, lithium-ion batteries are getting more powerful and in some cases larger, further complicating the thermal runaway threat. Damaged, substandard, or counterfeit batteries run the greatest risk of going into thermal runway, presenting serious consequences in flight.
Key takeaways from the report include:
Incidents are at the highest point in five years of data collection, rising 28 percent from 2019-2023. There are an average of two thermal runaway incidents reported in the TRIP database each week. While on the rise, with approximately 180,000 flights in U.S. airspace per week, it is still highly unlikely to experience a thermal runaway incident.
The average passenger brings four rechargeable devices on board. Most common items include smartphones (82 percent), laptops (41 percent), wireless headphones (39 percent), and tablets (36 percent). E-cigarettes were responsible for the most incidents in 2023, with 35 percent of reported incidents attributed to vaping devices on passenger flights, followed by power banks, representing another 16 percent of incidents.
Most incidents happen on the aircraft with devices that are stored near the passenger’s seat. Almost nine out of 10 (87 percent) incidents are reported on the aircraft, with the remaining 13 percent occurring when baggage and personal items are on the move. On the aircraft, thermal runaway incidents occur in or around the passenger’s seat nearly 60 percent of the time.
The vast majority of incidents are addressed before reaching the fire or explosion stage of thermal runaway. Most (85 percent) incidents in 2023 were addressed when batteries showed warning signs such as overheating and smoking prior to entering full thermal runaway. While only 15 percent of incidents resulted in fire or explosion, the speed in which thermal runaway can develop means that the events in the majority could have been more serious had the issue not been addressed quickly.
Rechargeable devices are being packed in checked luggage. The devices that were most cited in thermal runaway incidents in 2023 were also the two most frequently put in checked luggage, according to passengers surveyed. More than a quarter (27 percent) of travelers reported checking portable chargers, and another 27 percent said they checked e-cigarettes. Devices that enter thermal runaway in checked baggage cannot be accessed by crew while in flight, and fires may not be detected as quickly in the cargo hold as they would be in the cabin.
“Our research highlights several trouble spots that need to be addressed, from passengers missing warnings about lithium-ion batteries to packing rechargeable devices out of reach,” said Lesley Rohrbaugh, head of insights and policy analysis for ULSE. “But we also see clear opportunities to reduce the risk and that’s where we’re focused.”
Through additional passenger and cabin crew focus groups and interviews conducted by ULSE and data from TRIP, strategies to reduce these risks include passenger education, cabin crew training, and standards for aircraft baggage handling.
September 10, 2024
One-Use Vape Batteries Can ‘Recharge’ Many Times
Credit: Chepko Danil
While the lithium-ion batteries in disposable vapes are thrown away after a single use, researchers found that they can continue to perform at high capacity for hundreds of cycles.
The study, published in the journal Joule, was conducted by scientists from University College London (UCL) and the University of Oxford and supported by The Faraday Institution.
“The surprise for us were the results that pointed toward just how long these batteries could potentially cycle, Professor Paul Shearing, of the University of Oxford and UCL, said, according to media reports. “If you use a low charge and discharge rate, you can see that for over 700 cycles, you still have more than 90 percent capacity retention.
“That’s a pretty good battery. And these are just being discarded. They’re being chucked on the side of the road.”
December 14, 2023
Insurance Agent Sued for ‘Quietly’ Excluding Batteries

A federal lawsuit has been filed by four companies that sell vaping devices against Kinsale Insurance Co., claiming the insurer dropped coverage for batteries but failed to fully inform the policyholders before denying a claim.
If the case goes to trial and appeal, it could potentially help clarify insurers’ and insureds’ responsibilities when policy wording is changed or exclusions are added.
“Defendant owed a fiduciary duty to plaintiffs based on trust and good faith that required defendant to act in the best interest of plaintiffs, its customers,” reads the lawsuit complaint, filed last week in U.S. District Court in Nashville. “It is reasonable for the insured to assume the policies provided the requested coverage.”
Kinsale Insurance, based in Richmond, Virginia, offers casualty and specialty casualty insurance for cannabis, transportation and other industries. It has not yet filed an answer to the complaint, according to the Insurance Journal.
Industry experts, however, said that the practice of changing coverage without fully notifying customers is not uncommon, and is rarely challenged. And Tennessee law may be less than crystal-clear on how far an insurer must go in notifying policyholders of changes and how specific notifications should be.
Battery fires from nicotine and cannabis vape devices are relatively uncommon but have become a worldwide concern for consumers, fire departments and insurers. In October 2022, Michael and Elisha Schmidt suffered a fire, reportedly from a vape pen battery, and sued the four vape companies over the damage.
The companies, Isabella Industries, Maelynn Industries, Sancia Industries and Illumivaption Inc., all had umbrella and general liability policies with Kinsale for seven years. But when the vape sellers renewed their policies in October 2022, Kinsale excluded batteries and battery-fire claims from the policies, while raising premiums, the suit claims.
“Defendant led plaintiffs to believe that the batteries were covered after the renewal,” the complaint reads. “Defendant did not inform plaintiffs that it had removed batteries from the coverage and did not ask Plaintiffs prior to doing so.”
The plaintiffs also argue that the policy wording was ambiguous and illusory, and thus, unenforceable under Tennessee law. The companies had always paid their premiums on time and had been loyal customers to Kinsale, they noted.
When the Schmidts filed their lawsuit, the vape companies filed claims with Kinsale. But the insurer denied the claims, arguing that the policies did not cover batteries. Kinsale would not provide a legal defense for the insureds.
The vape sellers argue that Kinsale’s refusal amounted to bad faith and unfair trade practices, and has cost the companies damages and attorney fees. They are asking for compensatory damages, punitive damages, legal fees and a declaration that the insurer must provide coverage and a defense.
April 24, 2023
Texas Court to Hear Exploding Battery Case

Photo: unlimit3d
The Supreme Court of Texas has agreed to hear a lawsuit by a vaper burnt by an exploding battery to determine if Texas courts have jurisdiction over LG Chem America, a subsidiary of South Korea-based LG Chem, which made the battery, reports Law360.
In 2016, Texas resident Tommy Morgan bought an 18650 lithium-ion battery manufactured by LG Chem. He claims it unexpectedly exploded and caught on fire, leading to him suffering permanent and severe injuries, according to his lawsuit filed in 2019 in Brazoria County District Court.
The companies are facing other lawsuits by Texas residents with similar claims concerning batteries exploding. But intermediate appeals courts have come to different conclusions on whether LG Chem has enough contacts in the state to face claims.
LG Chem America and LG Chem have argued that Texas courts lack jurisdiction because the companies don’t sell individual batteries in Texas nor directly to Texas customers. LG has consistently stated in litigation throughout the country that this battery was never intended to be used in e-cigarettes or vaping devices.
Morgan told the Texas high court that the company deliberately shipped its products to Texas customers who were later injured, therefore Texas courts have jurisdiction.
February 27, 2023
Vape Battery Air ‘Incidents’ Have Tripled Since 2019

Credit: kamilpetran
The number of e-cigarette battery air incidents has tripled since 2019, reports The Wall Street Journal, citing a U.S. Federal Aviation Administration (FAA) database.
Vapes and e-cigarettes were the leading cause for lithium-battery incidents on aircraft in 2022, ahead of those caused by battery packs and laptops. Of the 55 incidents reported through September of last year, vapes and e-cigarettes accounted for 19, which was 35 percent of all incidents in 2022 and triple the incidents reported in all of 2019, the FAA says.
According to the agency, the batteries in these devices can catch fire if damaged or if the battery terminals are short-circuited.
Vapes aren’t allowed in checked luggage, and must be brought in carry-on luggage because of cargo-area fire risks.
The federal government banned smoking on most U.S. flights in 1990. In 2016, the U.S. finalized its ban on e-cigarettes on all domestic commercial flights, as well as on international flights to and from the country.
Passengers should refrain from charging e-cigarettes on a plane and store their device carefully to prevent them from accidentally turning on, according to the FAA. They should transport their vapes in a protective case or remove the battery and place each battery in its own case or plastic bag to prevent a short circuit, the agency says.
Passengers who violate federal vaping laws risk fines up to $1,771.
February 10, 2023
UK to Consider New Regulations for Vape Disposal

Disposing of used vaping devices, especially disposable devices, has become a major issue. So much so that the UK is set to consider changes to ensure the vaping sector “plays its part” in financing the collection and treatment of vaping products as part of the upcoming review of the waste electrical and electronic equipment (WEEE) regulations.
Fourteen million single-use vapes are bought each month and 1.3 million are thrown away every week, according to research from Material Focus, the not-for-profit organization funded by the WEEE compliance fee.
Last week, the Department for the Environment, Food and Rural Affairs (Defra) published its response to its consultation on commonly littered single-use plastic items, which ran from November 2021 to February 2022, according to Let’s Recycle. Within its response, Defra noted it had not explored the issues around waste generated from disposable vapes.
Defra says it is reviewing the current producer responsibility systems for WEEE and batteries and plans to publish the much-delayed consultations on both areas “this year”, and in doing so will look at vaping products.
The UK Vaping Industry Association (UKVIA), the trade body representing the UK’s vaping industry’s interests, says it is in discussions along with its member with several waste companies to create a recycling solution that is “fit for purpose for the vaping sector.”
January 18, 2023
CPSC Sends Warning on Repackaged 18650 Batteries
The U.S. Consumer Product Safety Commission (CPSC) has warned that consumers should not buy or use 18650 lithium-ion battery cells — used in some vaping products, flashlights and toys — due to a possible fire and even death risk.
Credit: Lithium Battery China
The Commission said it is working with e-commerce sites like ‘eBay’ to remove listings of loose or repackaged “18650 lithium-ion” batteries, according to a press release. A superior court in California recently denied a request by Samsung to dismiss a lawsuit about an exploding e-cigarette lithium-ion batteries.
The market does have single 18650 batteries that are intended for use in consumer products. The CPSC warning is about batteries separated from cells that use multiple 18650s such as battery packs for electric automobiles.
“These cells are manufactured as industrial component parts of battery packs and are not intended for individual sale to consumers. However, they are being separated, rewrapped and sold as new consumer batteries, typically on the Internet,” the CPSC said in a statement on Saturday. “Specifically these battery cells may have exposed metal positive and negative terminals that can short-circuit when they come into contact with metal objects such as keys or loose change in a pocket.”
Once shorted, loose cells could overheat and experience thermal runaway, igniting the cell’s internal materials and forcibly expelling burning contents, resulting in fires, explosions, serious injuries and even death.
“Unfortunately a growing number of small consumer products such as vaping devices, personal fans, headlamps and some toys are using loose 18650s as a power source,” the CPSC stated in the release.
January 11, 2021
Electric Shock
The U.S. FDA has released new guidance for batteries in vapor hardware and bottling improvements for e-liquids.
Battery safety in the vapor industry just got a whole lot better. On Nov. 26, the U.S. Food and Drug Administration (FDA) released an updated premarket tobacco product application (PMTA) guidance for the vapor industry. The new guidance will allow manufacturers of both hardware and e-liquids to provide safer, more effective products to consumers.
“We recognize there are certain modifications manufacturers can make to their tobacco products to address a voluntary industry battery standard and to comply with requirements related to safe packaging of liquid nicotine products, known as flow restrictors,” said Mitch Zeller, director of the FDA’s Center for Tobacco Products. “We encourage these limited safety-related modifications because they are intended to ensure the public is protected from risks such as battery explosions or accidental exposure to toxic levels of nicotine.”
The new guidance, “Compliance Policy for Limited Modifications to Certain Marketed Tobacco Products,” explains the FDA’s compliance policy for making limited safety modifications to vaporizers and e-cigarettes that were on the market as of Aug. 8, 2016, the date all e-cigarettes and other electronic nicotine-delivery system (ENDS) products became subject to the FDA’s tobacco authorities.
The guidance allows for “battery-operated tobacco products modified solely and only to the extent necessary to comply” with the voluntary industry UL 8139 standard for batteries. The FDA worked alongside the U.S. Consumer Product Safety Commission, external stakeholders and UL to develop a voluntary UL 8139 industry standard in order to help manufacturers alleviate potential battery-related risks associated with ENDS products.
A global safety consulting and certification company headquartered in Northbrook, Illinois, USA, UL maintains offices in 46 countries. The 100-year-old company collaborates with a diverse array of stakeholders to establish standards that create level playing fields working to develop new pathways for the latest innovations.
With the new guidance, the FDA is essentially telling vapor companies that the industry should submit batteries used in vapor products to UL for U.S. and Canadian certification, according to Josh Church, chief regulatory and compliance officer with Joyetech Group. Church was a member of the team of scientists and consultants that helped develop the vapor product battery standards and testing guidelines for UL.
The UL 8139 guidelines, titled an “Outline of Investigation for Electrical Systems of Electronic Cigarettes,” evaluates the safety of the electrical, heating, battery and charging systems while also addressing fire safety concerns raised by North American fire officials. The new UL standard has been published with the acceptance of the American National Standard Institute (ANSI) and Canada Standards (CAN). “The acceptance and publication of this standard was a huge landmark for the e-cigarette and vapor industry in general,” said Church.
UL 8139 requirements include determining if lithium cells are operating within safety windows, assessing the battery management system for both normal use and foreseeable misuse, and evaluating compatibility among interconnected systems. It also factors in wide environmental parameters and conditions, tests reasonably expected mechanical stress in use/misuse and requires mechanisms to direct venting away from the inhaler.
UL 8139 standards were written specifically for electronic vapor devices and are part of the larger UL 1642 standards (UL 1642 standards were approved in 2014 by the FDA for use in medical devices) that cover a wide array of lithium-ion products. It’s important to note that neither UL 1642 standards nor UL 8139 standards cover e-liquids or any consumable products used in vaporizer systems. Plus, to qualify for UL 8139 standards, the battery cells must be inside a battery pack, like what you see in a power drill.
This means that the stand-alone standard 18650 e-cigarette battery could never be packaged with “UL” if it’s changeable and not inside a battery pack. However, it can receive a UL “Recognized Component Mark,” or “RU.” This quality mark may be applied to components that are part of a UL listed product but that cannot bear the full UL logo themselves.
The guidance also provides insight into how the FDA wants e-liquids bottled. E-liquid products containing nicotine are now allowed to be modified “solely and only to the extent necessary to comply with the restricted-flow requirements for liquid nicotine containers set out in the Child Nicotine Poisoning Prevention Act of 2015 (CNPPA).” This guidance states that the FDA “does not intend to enforce violations” of the PMTA requirements for manufacturers making these limited modifications.
In order to help lessen the potential risks of accidental exposure to liquid nicotine by children, U.S. Congress passed the CNPPA, which requires liquid nicotine containers to have, among other things, special packaging that makes them difficult for children to open. “The FDA believes e-liquid containers that comply with the flow restrictor requirements will potentially mitigate the risk of children becoming accidentally exposed to toxic levels of nicotine from e-liquids,” a release from the FDA states.
“[This] guidance will provide clarity to manufacturers considering these limited safety-related modifications to their electronic nicotine-delivery system products by outlining our compliance policy for premarket review requirements for such modifications,” said Zeller.
December 23, 2019
Taking charge
Tackling the challenges associated with e-cigarette batteries
Contributed
Despite the rapid advances made in recent years, e-cigarette technology remains a work in progress. Perhaps the area least understood is that of power supply. This article takes a closer look at battery technology.
In e-cigarettes, batteries are used to power the heating elements. The current generation of products typically uses lithium polymer (LiPo) batteries. LiPo batteries are characterized by high energy density, which means they can store lots of energy in a small space. They are a suitable choice for devices that need to work for at least a few hours before requiring a recharge.
That said, a stated capacity of, say, 1,000 mAh doesn’t guarantee smooth operation. The battery must be able to withstand a current more than several times its nominal capacity. Only LiPo cells built for “high-drain” use can handle an e-cigarette’s high current consumption without suffering an excessive voltage drop.
When a normal LiPo is used, the battery’s internal temperature rises and causes dangerous internal structure damage—which can lead to an explosion. It’s not only the discharge current that can cause such problems. When the battery is charged too fast or at a too high-cut voltage, things can go wrong inside the e-cigarette as well.
Instances of exploding e-cigarette batteries have been widely reported, negatively affecting the vapor industry’s reputation. In some cases, the victims were badly burned.
Safe use
All of this raises the question of which batteries are safe to use. First, it’s important to note the steps of proper power management. Physics provides the basic formula: power = voltage x current. Contrary to what some believe, it is not a linear equation—a slightly higher/lower voltage does not equal slightly higher/lower power. Rather, the current relates directly to the voltage and the resistance of the coil. So the current flowing through the system is equal to the voltage divided by resistance of the coil.
The means that lowering the coil resistance to create a higher current and thus more power works only with a constant voltage. With battery power, the effective power increase—or, worse, power decrease—depends on the voltage drop caused by the increased current. In the worst case, the increased current creates dangerous structural damage without providing the expected power increase.
For e-cigarettes, we recommend LiPo batteries as long as they are built for high-drain use. The modern NiMH, LiFePO4 or LTO battery cells are suitable, as well. Regardless of what model is chosen, the device must cope with a voltage drop. This is not a problem as long as the battery can safely withstand the high current.
By choosing the appropriate battery technology and using it wisely according to the laws of physics, we can make the industry safer. This should benefit end users and e-cigarette manufacturers alike.
This article was contributed by tricas Industrial Design & Engineering
November 1, 2016