Battery Safety for Vaping: Questions and Answers for Safety

The vaping market is growing rapidly. There are millions of devices in the US, and thousands more are sold every day. It is estimated that a new vape device is purchased worldwide every two seconds. But while popularity is on the rise, batteries often remain an underestimated safety risk. Defective batteries or their improper use have led to several accidents in recent years, including overheating and explosions. More than 200 such incidents have been reported in the US alone.

What types of battery are there?

Lithium-ion and lithium-polymer vape batteries are among the most common types used in vaping devices. A long lifespan and consistent power characterize lithium-ion batteries, making them ideal for regular vapers who rely on a dependable power source. Improper handling, however, can lead to overheating. More flexible in design, lithium-polymer batteries can be molded into different shapes, allowing for more compact device designs. Their performance, however, often degrades faster over time compared to lithium-ion alternatives.

Battery types for special applications

Some vapes use built-in batteries that cannot be replaced. These offer the advantage of easy handling and safety, but are difficult to replace if defective. In contrast, replaceable batteries allow users to customize and have flexibility. However, they carry the risk of improper replacement procedures causing safety hazards.

Recognizing defects

Between January 2009 and December 2016, 195 incidents of e-cigarette-related explosions and fires were reported in the United States. One of the most common signs that something is wrong is if the battery generates an unusually high amount of heat. If a battery gets hot during normal use without being subjected to intense stress, this may indicate internal damage. An unusually slow recharge also signals potential problems. This often occurs in batteries that have been in use for some time and are beginning to lose performance. In addition, rapidly declining performance often indicates advanced wear.

Charging Cycles and Lifespan of Lithium-Ion Batteries

The lifespan of a lithium-ion battery, which is used for many vaping devices, averages 300 to 500 charging cycles. Under optimal conditions, it can last up to two years before there is a noticeable drop in performance. With each charging cycle, the battery loses a small amount of capacity.

Self-replacement – What to consider

Care should be taken with devices that have replaceable batteries, as improper replacement can pose safety risks. Before replacing, it is important to ensure that the replacement battery is compatible with the device to prevent short circuits or overheating. Original batteries or high-quality alternatives from reputable manufacturers are usually safer than cheap imitations. In addition, when replacing the battery, always handle it with clean hands and in a dry, non-conductive place to minimize the risk of short circuits. The charger also plays a role; only recommended chargers should be used to maintain the integrity of the battery and to avoid overcharging.

One common mistake is using mismatched batteries with different capacities or brands, especially in dual-battery devices. This imbalance can cause the batteries to drain unevenly, leading to potential overheating or reduced performance. Another frequent error is inserting the battery in the wrong orientation, as even a simple mistake in polarity can result in dangerous malfunctions or short circuits. Lastly, charging vape batteries with an incompatible charger—especially a low-quality one—can lead to overcharging, overheating, and long-term damage to both the battery and the device.

Legal basis for battery safety in vaping in the USA

In the US market, battery safety for vaping is subject to strict legal requirements. To minimize the risk of accidents, federal agencies such as the Consumer Product Safety Commission (CPSC) and the Food and Drug Administration (FDA) have established specific guidelines and standards. The CPSC enforces product safety standards and can order recalls of products with potential safety risks, including e-cigarettes and batteries. Since 2016, the FDA has regulated vaping more comprehensively, requiring manufacturers to submit safety reports to show that their products do not pose undue risks to public health.

Battery safety and product liability regulations

Manufacturers and importers of vape products and batteries are subject to product liability, which means that they can be held liable for damages caused by defective batteries. If a battery defect causes an explosion or fire, affected consumers can take legal action against the manufacturer. In addition, the Battery Safety Act requires lithium-ion batteries to undergo comprehensive safety testing before they are placed on the market. Consumers in the United States are also protected by the Magnuson-Moss Warranty Act, which strengthens rights under product warranties and makes it easier to replace defective batteries.

Safety regulations and legal requirements

To increase safety, there are nationwide requirements for labeling and handling lithium-ion batteries, which, for example, are intended to warn against the risk of improper use. Manufacturers and retailers face heavy fines and product recalls if they fail to comply with safety regulations.

Where to put the old battery?

Proper handling of old or damaged vape batteries is essential for vapers, as improper disposal can lead to serious hazards, including fires and explosions. Many vaping devices use removable lithium-ion batteries, which can be easily replaced if they become damaged. However, other models contain built-in batteries that are not designed for easy replacement, requiring careful consideration when they start showing signs of wear or malfunction.

Safe Disposal and Recycling of Used Batteries

In the United States, strict regulations govern the disposal of lithium-ion batteries, prohibiting their disposal in household trash in many states. Throwing them away improperly not only poses environmental risks but can also create safety hazards for sanitation workers. To comply with regulations, vapers must take used or damaged batteries to specialized recycling facilities that can handle the specific requirements of these power sources. Nationwide, organizations like Call2Recycle and Battery Solutions offer drop-off points for consumers to recycle batteries safely and in an environmentally responsible manner. These facilities have the expertise to process lithium-ion batteries correctly, ensuring that valuable materials can be reused while minimizing the risk of harmful chemicals leaching into the environment.