Safety Handling Guide for Swollen or Leaking Lithium Batteries

If bulging, or leakage occurs in a lithium battery, it indicates internal damage or degradation. Here’s what should be done — both immediately and for long-term prevention:

1. Immediate Actions

• Stop using the battery immediately.
• Disconnect it from any device or charger.
• Continuing to use a damaged battery can cause thermal runaway, fire, or explosion.
• Do not puncture, press, or attempt to repair the battery.
• Swollen (bulging) cells contain gas and can be very dangerous if breached.
• Move the battery to a safe, well-ventilated area.
• Keep it away from flammable materials and heat sources.

2. If leaking:

• Avoid direct skin or eye contact with the electrolyte.
• Use gloves and wipe spills with a dry cloth, then dispose of the cloth safely.
• If contact occurs, rinse immediately with plenty of water and seek medical attention if irritation persists.
• Dispose of it properly, take the damaged battery to a certified recycling or hazardous waste facility.
• Do not throw it in regular trash or general recycling bins.

3. Investigate the Cause

• Overcharging or deep discharging → Check your charger or BMS settings.
• High temperature or poor ventilation → Ensure proper cooling during operation.
• Poor-quality cells or long-term aging → Replace with high-quality or fresh batteries.
• Mechanical damage → Review installation and handling procedures.

4. Prevention Tips

• Use a BMS (Battery Management System) for protection against overcharge, overdischarge, and overcurrent.
• Store batteries in a cool, dry place (ideally 15–25 °C).
• Avoid charging or discharging at extreme temperatures.
• Use only compatible chargers and follow manufacturer charging parameters.
• Conduct regular inspection and maintenance on packs in operation.