The possibility of a vaping device exploding is a serious concern for users, and the root cause lies almost exclusively with the lithium-ion batteries that power the devices. An explosion is defined as a rapid, uncontrolled release of energy, which in this context is caused by a catastrophic battery failure leading to fire and the forceful ejection of components. While the potential for such an event exists, it is statistically rare when considering the millions of devices in daily use worldwide. The vast majority of incidents are preventable and linked to specific circumstances, not an inherent flaw in the act of vaping itself.
Frequency of Incidents
Vape explosions are uncommon, but when they occur, the injuries are often severe, leading to significant media attention. Between 2015 and 2017, an estimated 2,035 to 2,693 e-cigarette explosion and burn injuries were treated in US hospital emergency departments, according to data analysis of the US Consumer Product Safety Commission’s National Electronic Injury Surveillance System. This number represents a small fraction of the total user population, but highlights the real danger.
The U.S. Fire Administration also documented 195 separate fire and explosion incidents involving e-cigarettes between 2009 and 2016. These figures underscore that the risk, while low on a per-device basis, is measurable. The majority of these incidents involve the failure of a loose battery or occur during the charging process, rather than the device failing during active use.
Understanding Thermal Runaway
The scientific mechanism behind a vape explosion is thermal runaway, a process that affects all lithium-ion batteries. Thermal runaway is a self-sustaining cycle where the heat generated inside the battery exceeds the heat that can be dissipated, causing the temperature to rise uncontrollably. This process is often initiated by an internal short circuit, which rapidly generates heat within the cell.
As the temperature inside the battery increases, typically reaching over 194°F (90°C), exothermic chemical reactions begin. These reactions release more heat, accelerating the temperature rise in a feedback loop. The internal temperature can quickly reach over 1,112°F (600°C), causing the battery’s flammable electrolyte solution to boil and vent gas. This buildup of pressure and the ignition of the vented gas leads to the fire or forceful explosion.
User Actions That Increase Risk
The primary factor contributing to thermal runaway is not the device itself, but user-related errors or poor battery handling.
Improper Storage and Short Circuits
A significant number of incidents are caused by loose batteries coming into contact with metal objects like keys or coins while being carried in a pocket or bag. This contact creates a direct short circuit between the positive and negative terminals, instantly triggering rapid heat generation.
Charging Errors
Improper charging practices are a frequent cause of battery failure. Using a charger not specifically designed for the device or its battery chemistry can lead to overcharging, which destabilizes the battery cell. Leaving a device plugged in long after it has reached a full charge can also stress the battery and increase the risk of overheating.
Physical Damage and Component Mismatch
Physical damage to the battery is a severe risk factor that users often overlook. If the protective plastic wrap, known as the battery sleeve, is torn or damaged, the exposed metal surface can easily contact the device casing or other metal objects, causing a short. Furthermore, using mismatched components, such as a low-resistance coil that draws more current than the battery’s safety rating can handle, forces the battery to operate under dangerous stress.
Safeguards Against Device Failure
Modern, regulated vaping devices incorporate electronic safeguards designed to prevent the conditions that lead to thermal runaway. These integrated circuit protections monitor the battery’s performance and can interrupt the current flow if a problem is detected. Short-circuit protection, for example, is a standard feature that immediately cuts power if an accidental short occurs, preventing excessive current draw.
Many devices also feature overcharge protection, which stops charging once the battery reaches its maximum safe voltage, and low voltage protection, which prevents the battery from discharging too deeply. Users can further reduce risk by always transporting spare batteries in non-conductive, protective cases to eliminate contact with metal. Adhering strictly to the manufacturer’s instructions for charging and maintenance is an effective way to ensure the safety features function as intended.