Buzz
In 2015, a man sustained life-threatening injuries when his e-cigarette suddenly burst in his face. Another individual experienced severe burns on his hands, a pierced tongue, and lost teeth. This article explores the reasons behind such incidents and offers practical advice to reduce the risks associated with vaping.
While it may sound exaggerated to claim that e-cigarettes “explode,” this footage demonstrates that something is undeniably igniting. This safety concern led the U.S. Fire Administration (USFA) to investigate, resulting in a 2014 report titled Electronic Cigarette Fires and Explosions (PDF). It’s important to note that their findings are based on 25 reported incidents of e-cigarette accidents from 2009 to August 2014.
The Primary Culprit: The Battery Inside Your E-Cigarette
The majority of e-cigarettes rely on lithium-ion batteries, which are the primary source of fire risks. These batteries are ubiquitous, powering devices like cell phones, cameras, and hybrid vehicles. When you inhale from an e-cig, the battery activates a heating element that transforms the liquid solution into vapor. Some models require manually pressing a button to take a puff, but in both cases, a lithium-ion battery is at the core of the operation.
Lithium-ion batteries can become a fire hazard under specific conditions, such as in pressurized environments like airplane cargo holds. In early 2015, the Federal Aviation Association banned e-cigarettes and spare lithium-ion batteries from being stored in checked luggage. Under normal circumstances, the likelihood of a lithium-ion battery malfunctioning is extremely low (approximately one in a million). When such rare failures occur, the USFA report details:
During a typical lithium-ion battery failure, the electrolyte heats up to its boiling point, causing internal pressure to rise until the battery's seal ruptures. This sudden release of pressure occurs through the sealed end of the battery casing.
The cylindrical shape of e-cigarettes, combined with their structurally vulnerable ends, increases the risk of fire.
When the battery seal ruptures, pressure inside the e-cigarette cylinder builds rapidly, often causing an explosive rupture at the end. This can propel the battery or the device itself across the room like a projectile. Unlike e-cigarettes, lithium-ion batteries in laptops and power tools are housed in sturdy plastic casings that typically prevent such dangerous ejections. While battery failures can cause fires, they usually remain confined to the device housing the battery.
Lithium-ion batteries typically encounter issues when exposed to external heat sources such as direct sunlight, short circuits, or overcharging. In 20 out of the 25 cases mentioned in the USFA report, the battery failed while the e-cigarette was connected to a USB port for recharging.
Batteries usually come equipped with safety mechanisms to prevent short circuits and overcharging. However, e-cigarettes often feature USB ports that seem compatible with any USB cable or charger. Many users mistakenly believe that any charger, whether manufacturer-approved or third-party, will work as long as it fits and powers the device, but this is not true.
The USFA and the Consumer Product Safety Commission (CPSC) warn that using non-approved power adapters to charge e-cigarettes “may expose the battery to unsafe voltage levels,” raising the risk of overheating, known as thermal runaway. During thermal runaway, the battery can melt, generating intense heat, and the electrolytes may boil, leading to potentially dangerous outcomes.
Steps to Reduce the Risk of an E-Cigarette Malfunction
The Food and Drug Administration (FDA) recently announced plans to regulate vaping products. While the focus is on ingredients and packaging, the FDA’s expanded authority also covers “components and parts,” including specific types of batteries.
The Federal Register notes that the FDA has expressed concerns over reports of e-cigarette explosions and has issued draft guidelines outlining safety requirements for manufacturers. For instance, the FDA recommends that product labels include warnings or graphics advising users to recharge only with approved chargers to reduce the risk of battery failure. However, these guidelines are not yet finalized.
In the meantime, educating yourself can help ensure safety. It’s crucial to handle e-cigarette batteries—or any lithium-ion batteries—with care. Here are some essential tips:
Use the manufacturer’s charger: Always rely on the charger provided with the device and follow the manufacturer’s instructions. This ensures compatibility and reduces risks. Avoid leaving the device plugged in overnight.
Be cautious with USB ports: Don’t plug your e-cigarette into just any USB port. Refer to the user manual for the correct voltage specifications.
Purchase from trusted sources: Avoid homemade or DIY modifications, as they often lack the safety features needed to prevent overheating and other hazards.
Verify battery safety: Ensure the battery matches the device’s specifications and avoid low-quality or counterfeit products. Online forums like Planet of the Vapes often provide updates on recalls and safety alerts.
Maintain your battery: Clean the battery and terminals regularly with tissue or alcohol wipes. Turn off the battery when not in use, and avoid over-tightening when attaching it to the clearomizer. If you notice any damage, replace the battery or have it inspected by a professional.
If a battery overheats, Battery University advises moving the device away from flammable materials (if safe to handle) and placing it on a non-combustible surface. If possible, remove the battery and let it cool outdoors. In case of fire, use a fire extinguisher (for lithium-metal batteries) or water or non-alcoholic liquids (like soda) to contain the flames.
While not every battery failure can be avoided, the chances of an e-cigarette battery malfunctioning are statistically minimal. However, given the rising popularity of vaping (with over 2.5 million Americans reported by the USFA), the risk remains a genuine concern. If you vape, always prioritize safety.
Illustration by: Sam Woolley. Images by Ozont.
