— Powered by EverExceed Advanced Lithium Battery Technology

Lithium battery swelling is a common issue that can affect the safety, reliability, and service life of lithium-ion batteries. As a global manufacturer of high-performance lithium batteries, EverExceed explains the main causes of battery swelling and provides practical solutions to help users extend battery lifespan and ensure safe operation.

Main Causes of Lithium Battery Swelling

1. Overcharging and Over-Discharging

Overcharging is one of the primary causes of lithium battery swelling. When a lithium-ion battery is charged beyond its rated voltage, excessive lithium ions embed into the anode material, damaging its crystal structure and triggering gas generation inside the cell.

For example, if the charging control circuit malfunctions and the battery voltage exceeds the rated limit (typically around 3.75V per cell for common lithium-ion batteries), internal gas accumulation may occur, leading to battery swelling.

Over-discharging can also disrupt the internal chemical balance of the battery. When recharged after deep discharge, the battery is more likely to experience abnormal chemical reactions, increasing the risk of swelling.

2. High-Temperature Operating Environment

High temperatures accelerate chemical reactions inside lithium batteries. Prolonged operation or charging in high-temperature environments may cause electrolyte decomposition, generating gas that accumulates inside the battery enclosure.

For instance, lithium battery devices left under direct sunlight—such as inside a vehicle—may experience temperatures reaching 60–70°C, which can significantly increase the likelihood of battery swelling and performance degradation.

3. Battery Manufacturing Quality Issues

Battery swelling can also result from manufacturing defects, such as uneven electrode coating, internal contamination, or poor sealing.

Inadequate battery sealing may allow moisture or air to enter the cell, triggering unwanted chemical reactions that generate gas. This highlights the importance of choosing high-quality lithium battery manufacturers with strict quality control standards.

Effective Solutions to Prevent Lithium Battery Swelling

1. Proper Charging and Usage

Always use chargers equipped with overcharge and over-discharge protection. Disconnect the charger once the battery is fully charged, and avoid deep discharging during daily use. Intelligent Battery Management Systems (BMS) play a critical role in protecting lithium batteries from abnormal voltage conditions.

2. Avoid High-Temperature Conditions

Do not expose lithium battery systems to high temperatures or direct sunlight for extended periods. If a device becomes excessively hot during operation, stop using it temporarily and allow it to cool before resuming use.

3. Choose Reliable Lithium Battery Solutions

Selecting lithium batteries from reputable manufacturers is essential for long-term safety and performance. EverExceed designs and manufactures industrial lithium battery solutions using high-grade cells, advanced BMS protection, and rigorous testing to ensure reliability, safety, and extended service life.

EverExceed Lithium Battery Solutions

With decades of experience in energy storage and backup power applications, EverExceed provides lithium battery systems for UPS, data centers, telecom, renewable energy storage, and industrial applications. Our solutions are engineered to deliver high safety, long cycle life, and stable performance—even in demanding environments.

EverExceed lithium batteries are designed to minimize risks such as swelling while maximizing efficiency, reliability, and return on investment.