The Complete Guide To Vape Battery Safety

We have deliberately made this page as comprehensive as we can, which means it contains a lot of information.

However, the routine inspections on this checklist are a summary of the most important safety advice.

If you only skim the rest of the page, please pay particular attention to advice on charging, storing and transporting batteries.

Daily practices:

〈  〉 Use battery cases for all spare batteries

〈  〉 Inspect battery wraps before use

〈  〉 Turn devices off when not in use

〈  〉 Charge batteries supervised only

Weekly maintenance:

〈  〉 Check battery performance and capacity

〈  〉 Clean battery contacts

〈  〉 Rotate battery usage

〈  〉 Inspect charging equipment

Monthly reviews:

〈  〉 Assess overall battery condition

〈  〉 Check for recalls or safety notices

〈  〉 Review and update safety knowledge

〈  〉 Properly dispose of degraded batteries

External Removable Batteries

Most advanced vape kits use cylindrical lithium-ion batteries:

• 18650 (18mm x 65mm) – Most common, 2000-3500mAh capacity
• 20700 (20mm x 70mm) – Higher capacity, 3000-4000mAh
• 21700 (21mm x 70mm) – Latest standard, up to 5000mAh capacity

Internal Built-in Batteries

Pod systems and starter kits often feature non-removable batteries:

• Safer for beginners (no handling required)
• Fixed capacity typically 400-1500mAh
• Entire device disposal when battery degrades

Understanding Battery Specifications

mAh (Milliampere-Hour)

• Indicates battery capacity (runtime per charge)
• Higher mAh = longer vaping sessions
• Typical range: 2000-5000mAh for external batteries

CDR (Continuous Discharge Rating)

• Maximum amps the battery can safely provide continuously
• Critical for sub-ohm vaping (low-resistance coils)
• Never exceed this rating – it can cause overheating

Voltage

• Fresh lithium-ion batteries: 4.2V (fully charged)
• Nominal voltage: 3.7V
• Cut-off voltage: 3.2V (needs recharging)

Most battery explosions occur during charging, making proper charging practices absolutely critical.

Rule 1: Use Only Dedicated Battery Chargers

Never use:

• Phone chargers or USB adapters
• Car chargers not designed for vape batteries
• Cheap, unbranded charging equipment

Always use:

• Dedicated lithium-ion battery chargers (Nitecore, Efest, XTAR)
• Chargers with individual bay monitoring
• Quality chargers we stock and recommend

Rule 2: Supervised Charging Only

Essential practices:

• Never charge batteries overnight or while sleeping
• Don’t leave charging batteries unattended for extended periods
• Remove batteries immediately when fully charged
• Stop charging if batteries become warm to touch

Rule 3: Optimal Charging Environment

Safe charging setup:

• Charge on non-flammable surfaces (concrete, tile, metal)
• Keep away from flammable materials (papers, fabrics, curtains)
• Ensure good ventilation around charger
• Consider fireproof charging bags for additional safety

Rule 4: Monitor Battery Condition

Before every charge:

• Inspect battery wraps for damage
• Check for dents, dings, or deformation
• Ensure positive terminal is clean and undamaged
• Verify charger contacts are clean

Warning Signs to Stop Charging Immediately

• Battery becomes hot (not just warm)
• Unusual smells (sweet, chemical, or burning odors)
• Battery swelling or deformation
• Charger making unusual noises
• Error messages on charger display

The #1 Safety Rule: Always Use Battery Cases

Why battery cases are essential:

• Prevent short circuits from metal contact (keys, coins)
• Protect battery wraps from damage
• Organize batteries by charge level
• Required for airline travel

Types of battery cases:

• Hard plastic cases (most protective)
• Silicone cases (flexible, impact-resistant)
• Individual sleeves (minimal protection, budget option)

Daily Handling Best Practices

Inserting Batteries:

• Match positive/negative orientation exactly
• Never force batteries into devices
• Ensure battery wraps aren’t pinched
• Check that battery door closes properly

Removing Batteries:

• Turn device off first
• Use battery ribbon tabs when available
• Don’t pull batteries out by the wrap
• Store immediately in cases

Transportation Safety

For daily carry:

• Always use battery cases – no exceptions
• Separate spare batteries from metal objects
• Keep devices in pockets without keys/coins
• Turn devices off when not in use

For travel:

• Always carry vape devices in hand luggage
• Remove batteries from devices if possible
• Pack chargers in carry-on bags
• Check destination country regulations

Extending Battery Life

Optimal charging habits:

• Charge when batteries reach 20-30% capacity
• Don’t fully drain batteries to 0%
• Avoid charging to 100% every time (80-90% is ideal for longevity)
• Use lower charging currents when possible (0.5A vs 2A)

Storage recommendations:

• Store at 40-60% charge for long-term storage
• Cool, dry environment (avoid temperature extremes)
• Check stored batteries monthly
• Rotate battery usage to prevent degradation

When to Replace Batteries

Replace immediately if you notice:

• Significantly reduced runtime
• Battery getting hot during normal use
• Visible damage to wrap or casing
• Battery no longer holding charge
• Age over 2-3 years with regular use

Battery Wrap Maintenance

Why wraps matter:

• Provide electrical insulation
• Prevent short circuits
• Essential safety barrier
• Easy and inexpensive to replace

DIY rewrapping:

1. Purchase correct size pre-cut wraps
2. Remove old wrap completely
3. Clean battery surface
4. Apply new wrap ensuring complete coverage
5. Use heat gun or hair dryer to shrink
6. Ensure insulator ring is properly positioned

Warning Signs of Battery Failure

Visual indicators:

• Bulging or swelling
• Dents, dings, or deformation
• Discoloration or rust
• Leaking electrolyte
• Damaged positive terminal

Performance indicators:

• Rapid capacity loss
• Excessive heat generation
• Failure to hold charge
• Device not recognizing battery
• Unusual odors during use or charging

Emergency Response Procedures

If a battery becomes hot:

1. Stop using immediately
2. Remove from device if safe to do so
3. Place in safe, ventilated area
4. Monitor for 30 minutes
5. Do not charge or use again

If you smell unusual odors:

1. Evacuate area immediately
2. Ensure good ventilation
3. Do not touch or move the battery
4. Call emergency services if concerned
5. Never use water on lithium battery fires

Battery venting signs:

• Hissing sounds
• Sweet or chemical smell
• Visible vapor or smoke
• Battery becomes very hot

Understanding Battery Chemistry

Lithium-ion advantages:

• High energy density
• No memory effect
• Low self-discharge
• Thousands of charge cycles

Potential hazards:

• Thermal runaway if damaged
• Toxic electrolyte
• Fire risk if punctured
• Explosion risk if severely abused

Sub-Ohm Safety Considerations

For low-resistance coils (under 1.0Ω):

• Use only high-drain batteries (20A+ CDR)
• Understand Ohm’s law calculations
• Monitor battery temperature closely
• Consider dual-battery mods for safety margin

Battery calculations:

• Amps = Voltage ÷ Resistance
• Always account for voltage sag under load
• Add safety margin (never use 100% of CDR)
• Consider device inefficiencies

Mechanical Mod Safety

Additional precautions for unregulated devices:

• Essential to understand Ohm’s law
• No built-in safety protections
• Battery shorts can cause explosions
• Only for experienced vapers
• Always use battery cases and wraps

Legal Requirements in the UK

Under WEEE Regulations, vape retailers must offer take-back services for battery recycling. This includes batteries from both disposable and refillable devices.

Where to Dispose of Vape Batteries

Retail take-back:

• Return to any vape shop (including Vapable)
• Most electronics retailers accept batteries
• Many supermarkets have battery disposal points

Local recycling centres:

• Council household waste recycling centres
• Specialized battery recycling facilities
• Some libraries and community centres

What NOT to do:

• Never put in household bins
• Don’t mix with general recycling
• Avoid throwing in skip bins
• Don’t incinerate or attempt to dismantle

Preparing Batteries for Disposal

1. Discharge batteries to safe level (not completely dead)
2. Cover terminals with tape to prevent short circuits
3. Place in clear plastic bags
4. Label as “lithium-ion batteries”
5. Transport safely to disposal point