Exploding flashlight batteries

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Hmm, this might be why BatteryStation is switching suppliers. I have gone through about 25-30 of their "old style" (like the ones pictured above) without any problems but when I ordered a new batch they were all Rayovac brand. Might be that BatteryStation is leery of the old manufacturer.
 
Where are the Rayovacs manufactured?
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Ray-O-Vac branded batteries sold in the U.S. are manufactured in Portage, WI. But Ray-O-Vac does have manufacturing facilities all over the world. Unknown if re-branded Ray-O-Vac batteries are of U.S. manufacture.


-T.
 
The flashlight went to Surefire today. At this point, I just want a replacement, and a fanny pack back for the wife, but I don't think that will happen. Have had my integrity challenged many times over this.
 
Last night UPS delivered a package from LAPG, a new Surefire Nitrolon flashlight, in original packaging, with Surefire batteries inside, and 6 Rayovac brand CR123A batteries included. Also included a 10% off coupon for internet orders. At this point, I am satisfied with LAPG response, and replacement, even if thier customer service verbal/e-mail responses were less than staisfactory. Would have been nice to getthe fanny pack replaced, but I guess it will be the $50 lesson to never buy Chinese made products if possible. I wonder how much stuff in my house was made in China? I shudder to think...
 
LAPG and Battery Station have made good on all losses, and have stood up. I appreciate that, and say publicly thank you for that action.
 
Odd as it may sound, and as weird as it is, a package arrived tonight by UPS, from Surefire, a brand new Nitrolon G2 flashlight. I stand formally corrected. Surefire did stand behind thier product...just a little later.
 
"Lithium batteries are like little bombs."

This is a quote from a technical presentation from Texas Instruments that I attended several years ago. The problem with lithium batteries is that current charge and discharge must be regulated strictly. They will explode with force if charged improperly or discharged too quickly. Back 2-3 years ago you can buy lithium batteries at any retail stores, now they are NiMH or Alkalines since many electronic devices have IMPROPERLY/NON-EXISTING charge protection circuits. Now manufacturers that build products that use Li- Li-ion batteries will tell you specifically what brand battery with what serial number to use.

Judging from what you said, if the flashlight was off and the battery still exploded. You probably had 2 mismatched cells and there was no internal breaker to disconnect it. That shows poor manufacturing standards AND poor product design by the flashlight manufacturer. It is a simple process to regulate the current and have a shut off in case there is overcharge instead of assuming that the batteries are always functioning.This is common practice in most electronic devices for safety concerns (cell phones, laptops, battery chargers..), but that flashlight manufacturer obviously didn't do it.

Personally, I would not buy from the battery manufacturer or the flashlight manufacturer again. I would also be careful to always use the SAME BATTERY PAIR TOGETHER. Li batteries do degrade over time and if you mix and match the different state of degrade will give you mismatched cells again with no surge protection.


Thanks for the link. I'm curious about this because although I understand (now) the basic mechanics of how a lithium battery can explode, I'm still greatly puzzled how one can explode in a flashlight that isn't being used.
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This manufacturer must have some type of current regulator, but did not implement surge protection (or poor surge protection). So the batteries still have a close circuit path through the regulator, but there was nothing to shut it off.
 
The actual batteries are not being sold in the United States by the original supplier. They are Chinese, maked Madein P.R.C.. The Battery Station switched to Rayovac as thier supplier right before this incident.
As for cell mismatch, maybe that's they way thier were made, but they sure looked exactly alike!
I have two other Li-Ion flashlights that work perfectly...so far...
 
A cell mismatch can occur from two identical batteries if they have been cycled differently or if there were low tolerances by the manufacturer. Again I have to stress that there should be a regulator to prevent this type of closed circuit surging. Especially since you're dealing with potential "explosives".
 
In that case, I'd have to say I certainly hope the Surefire brand and Rayovac brand are well made cells. I will definately never use Chinese made cells again!
As for a regulator for that, I would have to ask Surefire if they have such a device built in thier flashlights.
 
It is a simple process to regulate the current and have a shut off in case there is overcharge instead of assuming that the batteries are always functioning.This is common practice in most electronic devices for safety concerns (cell phones, laptops, battery chargers..), but that flashlight manufacturer obviously didn't do it.
Click to expand...

How do you propose to do that in a flashlight where the batteries are in physical serial connection, just like in virtually all flashlights?
 
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