Swollen LiPo Battery? When to Stop Using It and How to Replace and Dispose Safely (2025)

If your LiPo (lithium‑ion polymer) battery looks puffy or is pushing your device apart, treat it as a safety emergency. The short answer: stop using it and replace it. Below is a step‑by‑step, safety‑first guide to recognize swelling, decide what to do next, and handle transport and disposal correctly in the U.S.

Note on stance: Authoritative sources agree that any observable swelling indicates damage and increased fire risk. The U.S. EPA’s 2025 consumer guidance states that swelling is a potential fire hazard and recommends isolating the battery/device (for example, in sand or kitty litter) and never placing it in household trash; call 911 if fire risk seems imminent, as summarized in the EPA’s Frequent Questions on Lithium‑Ion Batteries (2025) U.S. EPA — lithium‑ion battery FAQs. iFixit likewise explains that swollen batteries result from internal gas generation and must be handled carefully and replaced rather than punctured or compressed, per its 2025 explainer iFixit — why phone batteries swell.

TL;DR: What to do right now

• Power down the device immediately and unplug it.
• Do not charge, use, puncture, bend, or compress the battery or device.
• Move it to a nonflammable surface (metal tray, concrete) in a well‑ventilated area, away from anything that can burn.
• If you must handle it, wear gloves and eye protection.
• Isolate the device or battery in a fire‑resistant, nonconductive container (e.g., metal tin with sand/kitty litter, or a LiPo‑safe bag) until you can take it to a proper drop‑off.
• Do not mail swollen/damaged batteries; U.S. Postal Service rules (2025) prohibit mailing them USPS Publication 52 — hazardous mail.
• Arrange safe disposal at a Household Hazardous Waste (HHW) site or certified recycler (see “Where to dispose” below).

Time estimate: 10 minutes to isolate; 1–2 hours to transport to a recycler/HHW facility.

How to recognize a swollen LiPo

Common signs:

• Your phone or tablet case is separating, the screen is lifting, or the back panel feels soft/spongy.
• A laptop trackpad won’t click or the chassis bulges at the palm rest.
• On RC packs (soft pouches), the pack looks visibly puffed or no longer lies flat.
• You notice unusual heat, a sweet/solvent chemical odor, hissing, or crackling.

Verification checkpoints:

• If you see heat, smoke, hissing, or smell strong odors, evacuate the area and call 911. The EPA’s 2025 guidance explicitly calls out the fire hazard and recommends immediate isolation and contacting emergency services when risk is imminent U.S. EPA — lithium‑ion battery FAQs.
• Do not press on the case to “confirm” swelling; compression can cause internal shorting, as iFixit warns in its 2025 guidance on swollen batteries iFixit — why phone batteries swell.

Decision: Continue to use vs. replace

Short answer: Replace immediately. Any routine continued use is unsafe.

When is limited continued use even considered? Only for an emergency, last‑resort data backup — and only if ALL of the following are true:

• The device powers on without plugging in a charger.
• There is no heat, odor, smoke, or hissing.
• You can avoid pressing on the battery (no elastic bands, cases, or clamps).
• You supervise the device the entire time and keep it on a nonflammable surface with a clear exit path.

If any of the above conditions fail, do not proceed. Seek professional help. Even in this narrow exception, the safer choice is to have a professional perform data recovery. This cautious framing aligns with repair‑safety guidance from 2025 sources like iFixit, which stress replacement and careful handling rather than continued use iFixit — swollen battery safety basics.

Immediate actions (step‑by‑step)

1. Power down and unplug.
2. Move to a nonflammable surface in a ventilated area; keep away from paper, fabric, solvents, and flammables.
3. Put on PPE if available (nitrile gloves, safety glasses).
4. Prepare a containment setup: a metal container (cookie tin or small steel bin) partially filled with sand or unscented kitty litter, or a LiPo‑safe bag.
5. Gently place the device or battery inside; do not stack other items on top.
6. Observe briefly for heat, odor, or hissing. If these occur, evacuate and call 911.
7. Plan disposal promptly at a HHW or certified recycler. The EPA’s 2025 consumer page specifies not to trash or curbside‑recycle lithium batteries and suggests sand/kitty litter for safe interim storage U.S. EPA — lithium‑ion battery FAQs.

Safe handling and removal basics (consumer devices)

If you’re comfortable with basic electronics repair and your model is serviceable, you can remove and replace the battery. If not, seek professional service.

Before you start:

• Difficulty: Moderate to challenging depending on the device (30–120 minutes). Some phones use strong adhesives; laptops often require partial disassembly.
• Safety setup: Work on a clean, nonconductive, nonflammable surface. Keep a metal container with sand/kitty litter nearby. Have a Class ABC extinguisher available. Do not use water on a battery fire. UL and NFPA materials emphasize lithium‑ion fire hazards and the need for isolation and appropriate extinguishing methods (2024–2025) NFPA — lithium‑ion battery safety 和 UL Solutions — battery safety resources.

Tools and technique:

• Use plastic cards/picks and isopropyl alcohol (>90%) to soften adhesive; avoid metal prying near the cell.
• Do not bend or crease the pouch. Lift evenly and slowly.
• Disconnect power and data cables before lifting the battery where possible.
• If the pack is taped, slide a plastic card under adhesive edges rather than under the center.

Model‑specific references with up‑to‑date techniques:

• Google Pixel 7a battery replacement (adhesive softening, no prying near cell center): see the 2025 repair steps in iFixit — Pixel 7a Battery Replacement.
• iPhone 15 Pro battery replacement (adhesive pulls or solvent method): see iFixit — iPhone 15 Pro Battery Replacement.
• Samsung Galaxy S22/S23 battery replacement (adhesive remover technique): see iFixit — Galaxy S22 Battery Replacement 和 iFixit — Galaxy S23 Battery Replacement.

After removal:

• Insulate terminals with electrical tape, or place the battery in an individual plastic bag to prevent short circuits — a preparation step emphasized in EPA consumer guidance (2025) U.S. EPA — battery preparation for recycling.
• Place the battery in your isolation container (metal + sand/kitty litter, or LiPo‑safe bag) until drop‑off.

Storage and transport until disposal

• Where to keep it: Cool, dry, ventilated place on concrete/tile (e.g., garage), away from living/sleeping areas, pets, and children.
• Container options: Metal tin or latching steel box with a few inches of sand or unscented kitty litter; or a LiPo‑safe bag placed inside a nonconductive box. This aligns with EPA’s 2025 advice for interim storage using sand/kitty litter to mitigate fire risk U.S. EPA — lithium‑ion battery FAQs.
• Label: “Damaged lithium‑ion battery — do not charge.”
• Transport: Secure the container in your vehicle so it won’t tip. Do not place on seats or near heaters.
• Supervision: Don’t leave it unattended for long periods; check periodically for heat or odor.

Important mailing restriction:

• Do not mail damaged or swollen batteries or devices containing them. USPS’s 2025 Publication 52 classifies damaged/defective lithium batteries as nonmailable, and federal hazmat rules tightly restrict transportation of damaged cells USPS Publication 52 (2025) 和 U.S. DOT “Check the Box” hazmat guidance.

Where and how to dispose/recycle in the U.S.

• Never put lithium‑ion batteries in household trash or curbside recycling. The EPA reiterates this in its 2025 guidance and advises insulating terminals or bagging each battery to prevent shorts U.S. EPA — lithium‑ion battery FAQs.
• Best options:
  • Local Household Hazardous Waste (HHW) facility or event — check your city/county website for lithium‑ion acceptance and instructions.
  • Call2Recycle participating drop‑off sites for rechargeable batteries — use the nationwide locator to find a nearby retailer or collection center Call2Recycle — locator.
  • Certified electronics recyclers: R2 or e‑Stewards facilities accept electronics and often batteries; confirm acceptance before you go SERI (R2) — program info 和 e‑Stewards — certified recycler locator.
• What to say at drop‑off: “This is a swollen/damaged lithium‑ion battery.” Hand it over in your isolation container or follow staff instructions.

Regulatory note for businesses/technicians:

• Damaged/defective/recalled lithium cells are restricted in transport under 49 CFR §173.185; specialized packaging and labeling apply for disposal/recycling shipments through approved channels. For consumer purposes, hand‑carrying to an HHW or certified program is appropriate; do not ship without hazmat compliance. See USPS 2025 Pub 52 and DOT/PHMSA consumer materials USPS Publication 52 (2025) 和 DOT — Check the Box.

RC hobby packs (drones, FPV, RC cars): what’s different

• Retire immediately when a pack is puffed. Do not fly or drive “one more run.” RC expert guides emphasize that swelling signals cell damage and heightened risk; retire and dispose properly. See the 2025 updates in Oscar Liang — LiPo Battery Guide and the companion on when to retire a LiPo pack.
• Charging practices: Only charge in a LiPo‑safe bag or fire‑resistant container, on a nonflammable surface, and never unattended. Follow recommended charge rates (typically 1C unless the pack specifies otherwise) — a standard best practice in RC circles reiterated by 2025 hobby guides like Oscar Liang’s LiPo Battery Guide.
• Storage: Keep healthy packs at ~3.8 V per cell for storage in a cool, dry place, inside a fire‑resistant container.
• Handling swollen packs: Do not attempt to “vent,” puncture, compress, or re‑shrink; these myths are dangerous and can lead to fire. Retire, isolate, and dispose via HHW/certified recyclers.

Causes and how to prevent future swelling

• Heat: High temperatures accelerate electrolyte breakdown. Don’t charge under pillows, on couches, or inside hot cars.
• Overcharge/over‑discharge: Use manufacturer‑approved chargers/cables. Hobbyists: observe recommended charge rates and low‑voltage cutoffs.
• Physical damage: Drops, bending, or pinching the cell can cause internal shorting and gas generation.
• Age/cycle wear: Batteries degrade over time; moderate your depth of discharge and avoid leaving devices at 100% or 0% for long storage.

Authoritative context: iFixit’s 2025 explainer ties swelling to internal gas generation during failure, underscoring why puncturing or compressing is dangerous iFixit — swollen battery causes. NFPA/UL safety pages (2024–2025) highlight lithium‑ion fire hazards and the importance of safe charging/storage environments NFPA — lithium‑ion battery safety 和 UL Solutions — battery safety resources.

If you must retrieve data (strictly limited)

Only proceed if all safety criteria are met and you accept residual risk:

• The device powers on without a charger; battery is cool; no odor/hissing.
• The device sits flat on a nonflammable surface with nothing pressing on it.
• You can complete a quick offline backup in a few minutes (e.g., copy photos to a USB drive or local computer with battery power only).
• You supervise continuously, with a clear exit path and isolation container nearby.

Otherwise: Do not attempt; seek professional service. Many OEMs advise backing up before service generally, but do not endorse using a swollen device — reinforcing that replacement and professional handling are the correct next steps (2025 support norms; see Apple trade‑in/service policies that decline shipment of devices with swollen/damaged batteries) Apple — trade‑in restrictions.

What to do if things go wrong

• If the device starts to heat rapidly, smoke, hiss, or flame:
  • Do not pick it up with bare hands. Evacuate people and pets.
  • If safe, place the device/container outside on concrete away from combustibles.
  • Call 911. Fire services are trained for lithium‑ion incidents. EPA’s 2025 consumer guidance explicitly notes calling 911 for imminent risk U.S. EPA — lithium‑ion battery FAQs.
  • Expect possible reignition; do not assume the incident is over after one flare‑up.

FAQs and myths

• Can I poke a hole to “deflate” the pack? No. Puncturing can ignite flammable gases and cause fire. Replace and recycle instead, as emphasized by iFixit’s 2025 safety write‑up iFixit — why batteries swell.
• Can I put a swollen battery in the freezer to shrink it? No. Temperature extremes and condensation increase risk; no reputable safety authority recommends this.
• Is it okay to keep using a slightly swollen battery? No. Swelling means damage; discontinue use and replace. EPA’s 2025 guidance treats swelling as a fire hazard requiring isolation and proper disposal U.S. EPA — lithium‑ion battery FAQs.
• Can I mail my damaged battery to a recycler? No. USPS’s 2025 Publication 52 deems damaged/defective lithium batteries nonmailable; use in‑person drop‑off programs USPS Publication 52 (2025). For general consumer hazmat awareness, see DOT’s materials U.S. DOT — Check the Box.
• Where can I take it today? Try your local HHW site or the nationwide Call2Recycle — locator. For electronics with embedded packs, certified recyclers such as e‑Stewards or R2 facilities via SERI’s directory can help confirm acceptance SERI (R2) — program info.

Final printable checklists

Immediate actions checklist

• Power down and unplug.
• Move to nonflammable surface; ventilated area.
• PPE on (gloves, eye protection) if available.
• Do not charge, puncture, compress, or bend.
• Isolate in metal tin with sand/kitty litter, or LiPo‑safe bag.
• Monitor for heat/odor/hissing; call 911 if risk escalates.
• Plan disposal at HHW/certified recycler; do not mail.

Transport & disposal checklist

• Tape over terminals or place in individual plastic bag.
• Label container: “Damaged lithium‑ion — do not charge.”
• Secure container in vehicle; keep cool and upright.
• Drop at HHW, Call2Recycle location, or certified recycler (R2/e‑Stewards).
• Tell staff the battery is swollen/damaged and follow instructions.

Replacement & prevention checklist

• Use manufacturer‑approved chargers and cables only.
• Keep devices/packs cool; avoid charging under pillows/soft furnishings.
• Don’t leave charging unattended.
• For RC packs: charge at recommended rates (often 1C), store at ~3.8 V/cell.
• Inspect periodically for early signs of swelling or damage; retire promptly.

Key sources (for your reference)

• The 2025 EPA consumer page on lithium‑ion batteries covers swelling hazards, interim isolation with sand/kitty litter, and proper disposal routes: U.S. EPA — lithium‑ion battery FAQs.
• iFixit’s 2025 explainer details why batteries swell and how to handle them safely: iFixit — why phone batteries swell.
• USPS’s 2025 Publication 52 clarifies that damaged/defective lithium batteries are nonmailable: USPS Publication 52 (2025).
• DOT’s “Check the Box” program provides consumer‑friendly hazmat guidance for shipments: U.S. DOT — Check the Box.
• RC hobby safety and retirement criteria: Oscar Liang — LiPo Battery Guide (2025) 和 When to Retire a LiPo Battery.
• Finding drop‑off locations: Call2Recycle — locator, e‑Stewards — certified recyclers, and SERI’s R2 resources SERI (R2) — program info.