
Electronic cigarettes, or e-cigarettes, have gained popularity as a healthier alternative to smoking tobacco or marijuana. However, there have been a growing number of reports of these devices exploding, causing severe injuries and even death. The explosions are often attributed to the lithium-ion batteries that power these devices, with faulty or improperly charged batteries being a common cause. Other factors include exposure to high voltage, low-quality manufacturing, and contact with metal objects. The lack of oversight in the sale and manufacture of e-cigarettes has led to dangerous safety mishaps, and the customizable nature of these devices presents additional challenges for safety regulators. As a result, the Food and Drug Administration (FDA) has issued new regulations to address the issue.
| Characteristics | Values |
|---|---|
| Cause of explosions | Overheated batteries, battery overcharging, low-quality manufacturing, exposure to high voltage, exposure to decomposed electrolyte solutions, contact with metal objects |
| Injuries | Burns, especially to the groin, hand, and face |
| Affected devices | Large devices shaped like a pen or a tape recorder |
| Consumer demographics | More than 10% of adult Americans, three million users in the UK |
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What You'll Learn

Overheating rechargeable lithium-ion batteries
E-cigarettes, or vapes, are handheld devices that have become increasingly popular. They are mostly powered by rechargeable lithium-ion batteries and require filling with liquids containing nicotine, alcohol, or aromatics. While these devices are widely used, there have been growing reports of e-cigarette explosions, leading to serious injuries. The primary cause of these explosions is believed to be the overheating of the lithium-ion batteries.
Lithium-ion batteries are known for their efficiency and power, but they can sometimes overheat, posing potential dangers. The heat generated by a lithium-ion battery is influenced by the current flowing through it (amps) and its internal resistance. High-power devices, such as electric vehicles or high-performance gadgets, can cause the battery to discharge high current, resulting in heat generation. Additionally, the ambient temperature plays a role, as high temperatures can cause the battery to overheat due to the combination of external and internal heat.
Intensive or continuous heavy usage without breaks can also lead to battery overheating. Devices like drones or electric bikes that demand substantial power for extended periods can contribute to this issue. Moreover, fast-charging methods, while convenient, rapidly push a large amount of current into the battery, generating significant heat. Chemical reactions during charging further contribute to heat production, and excessive heat indicates inefficient or rapid reactions.
In some cases, faulty or low-quality charging equipment may be the culprit. Using chargers that don't match the battery's specifications can overload it, resulting in overheating. Overheating has several adverse consequences for lithium-ion batteries. It can reduce the lifespan of the battery by accelerating the degradation of internal components. Heat can also cause capacity loss by damaging the internal cell structure, leading to a reduced ability to hold a charge. Additionally, excessive heat buildup can cause the battery to swell due to the buildup of internal gases.
To mitigate the risks associated with overheating rechargeable lithium-ion batteries in e-cigarettes, it is crucial to follow safety guidelines. These guidelines include using appropriate chargers, allowing batteries to cool down between intensive usage periods, and avoiding prolonged exposure to high ambient temperatures. By understanding and addressing the causes of overheating, users can enhance their safety and prolong the lifespan of their e-cigarette devices.
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Low-quality manufacturing
E-cigarettes are handheld devices that are mostly powered by rechargeable lithium-ion batteries. The exact causes of vape fires or explosions are not yet clear, but some evidence suggests that battery-related issues may be a cause. Overheating rechargeable lithium-ion batteries are supposed to be the responsible mechanism, especially in low-quality fabrications. Shoddily produced batteries will explode when in use, or when charged improperly with mismatching equipment.
The issue of low-quality manufacturing is particularly prevalent in China, which is the manufacturing hub for up to 90% of the world's e-cigarettes. The country's ultra-efficient and ultra-fragmented manufacturing ecosystem, coupled with a lack of enforceable oversight, has resulted in a flood of low-quality e-cigarettes and e-cigarette parts into the global market.
The customizability of e-cigarettes further exacerbates the problem. Consumers can tweak the device's coils, atomizers, and batteries to alter the nicotine intensity, flavor, or vapor. However, this customization can turn otherwise safe e-cigarettes into dangerous devices. For example, using a higher-wattage battery than intended or modifying the device to increase battery life can increase the risk of overheating and explosion.
To address the issue of low-quality manufacturing, stronger and more consistent safety standards are needed for e-cigarettes and their batteries. Western regulators need to keep up with the rapidly changing manufacturing landscape and enforce strict oversight to ensure that all e-cigarettes and their components meet high safety standards. Until then, consumers should be cautious and well-informed about their devices and how to properly handle and charge their batteries to minimize the risk of explosions.
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Battery overcharging
Although the exact causes of vape fires or explosions are not yet clear, battery-related issues are thought to be a cause. E-cigarettes, or vapes, are handheld devices that are mostly powered by rechargeable lithium-ion batteries. Overheating rechargeable lithium-ion batteries are supposed to be the responsible mechanism, especially in low-quality fabrications.
To avoid battery overcharging, it is important to follow the manufacturer's instructions for charging the device. It is also important to use the correct charger and to avoid overcharging the battery. If the battery is overcharged, it can cause the electrolyte solution to decompose, which can lead to a buildup of pressure and gas. This can eventually lead to the battery exploding.
It is also important to dispose of e-cigarettes properly. The FDA has resources on how to safely dispose of e-cigarettes and their batteries.
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Exposure to high voltage
In addition to the use of incorrect chargers, the lithium-ion batteries in e-cigarettes can also be prone to overcharging if charged for too long or at an incorrect voltage. This is especially true for low-quality batteries or those that have been physically damaged. Overcharging can lead to a build-up of pressure and heat within the battery, causing it to explode.
To prevent explosions caused by exposure to high voltage, it is important to use the correct charger specifically designed for the e-cigarette device. Users should avoid using chargers that have a higher voltage output than what is recommended for the device. It is also important to follow the manufacturer's instructions for charging times and voltages to avoid overcharging the battery.
Furthermore, it is advisable to use only high-quality batteries from reputable sources. Damaged batteries should be replaced immediately, and users should be cautious when carrying spare batteries to avoid contact with metal objects that can cause short-circuiting and subsequent explosions. By following these precautions, users can significantly reduce the risk of their e-cigarettes exploding due to exposure to high voltage.
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Battery contact with metal objects
E-cigarettes are driven by rechargeable lithium-ion batteries. While incidents of e-cigarette explosions are uncommon, they can be dangerous to the user and those around them. There have been several reports of battery ignition due to contact with metal objects, such as coins or keys, in trouser pockets. The resulting explosion usually produces small shrapnel-like particles that can penetrate soft tissue, and the surrounding clothes can also catch fire, leading to severe burn injuries.
To prevent battery contact with metal objects, it is important to keep batteries in a protective case when carrying spares. Do not store loose batteries with coins, keys, or other metal objects. Always transport batteries in a case, preferably plastic, and avoid keeping them in your pocket, where they can come into contact with metal objects.
Additionally, proper storage and charging practices can help prevent explosions. Charge your e-cigarette on a clean, flat surface, away from flammable materials and in a place where you can easily see it. Avoid charging in extreme temperatures, and do not leave your device in direct sunlight, in a hot car, or near heaters. Always inspect your device for damage, and if in doubt, dispose of it properly.
It is also crucial to follow the manufacturer's recommendations for use and care. Only use batteries recommended for your device, and do not mix different brands or charge levels. Stay informed about your device and how to properly handle and charge its batteries.
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Frequently asked questions
Electric cigarettes, or e-cigarettes, are handheld devices that are powered by rechargeable lithium-ion batteries. The batteries can explode when in use, or when charged improperly with mismatching equipment. Overheated batteries, exposure to cold temperatures, and batteries shorting out after touching other pieces of metal can also cause explosions.
Although incidents of electric cigarettes exploding appear to be uncommon, they are dangerous to the person using the device and others around them. In the US, there were an estimated 2035 e-cigarette explosion and burn injury cases presenting to hospital emergency departments from 2015 to 2017.
If you or a loved one has been injured by an exploding electric cigarette, you may be entitled to fair compensation. You can report any health or quality problems with a vape, including fires or explosions, to the FDA through their Safety Reporting Portal.


































