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Analysis of the causes of lithium battery bulging in electric vehicles

2026-04-06 05:15:00 · · #1

1. The charger is of poor quality.

Currently, the price war is fierce, and the quality of chargers is declining. They use inferior boards, refurbished or low-quality components, which cause overheating, inaccurate parameter drift, and uncontrolled charging voltage limiting. This leads to the compression of gas inside the lithium-ion battery pack, causing the battery shell to deform, bulge, crack, or even explode.

2. Charging time is too long

Some users have no concept of charging time, assuming that the battery will automatically stop charging once it's fully charged and then they don't care anymore. Some even charge for two days and two nights before realizing that charging for too long will threaten the lifespan of the electric vehicle's lithium-ion battery pack. Overcharging can cause a large amount of gas to flush the plates, leading to the shedding of active materials inside the battery, shortening the battery's lifespan, accelerating water loss, affecting electrolyte decomposition, and increasing battery temperature, causing the battery to swell!

3. Internal battery malfunction

The internal battery plate group has quality problems, micro-short circuit, lack of acid and leakage, lack of water, which causes thermal runaway. This increases the internal pressure of the lithium-ion battery, the safety valve cannot release the pressure, and the vent valve hole is blocked. This increases the internal gas pressure, causing the battery shell to deform, crack and swell.

4. Reasons for using a charger

Forgetting to bring a charger and borrowing one at random, or using several electric vehicle chargers of different sizes in the home, is a common phenomenon. Each electric vehicle battery brand has its own interface and current value. Different electric vehicles may have different charging voltages and charging currents, so the charging time and charging efficiency will naturally be different. Using the wrong charger will result in insufficient charging if the battery is too large for the charger, or overcharging, thermal runaway, and battery swelling if the battery is too small for the charger.


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