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Reasons for battery swelling

1. Ventilation hole blockage

If the ventilation hole on the battery filling cover is blocked or not unobstructed, the gas that appears during long charging time or high charging voltage will gradually accumulate, leading to increasing pressure inside the battery case and ultimately causing the battery to bulge.

2. Charging time too long

As mentioned above, when the charging current of a battery is too high or the charging time is too long, a large amount of gas will appear. In addition, excessive current or prolonged charging time can also cause a rapid increase in electrolyte temperature, which can easily lead to battery swelling.

3. Sulfurization of battery plates

If the plates of the battery undergo vulcanization, during the charging process, the single cell voltage and electrolyte temperature will rapidly increase, and bubbles will appear earlier and react violently, which can easily cause the battery to bulge.

4. Continuously starting the motor for too long

When starting the starting motor, the battery needs to supply a large amount of current to the motor in a short period of time, and a large starting current will inevitably cause violent chemical reactions inside the battery, accompanied by the appearance of gas. When the starting motor is used for a long time, it will exacerbate the appearance of gas, which increases the possibility of battery cracking.

5. The welding between the inner plate, ear, and column of the battery and the busbar is not firm enough

When the ear and pillar of the inner plate of the battery are not firmly welded to the busbar, if a large current is discharged, the welding point will be ignited or burned due to too thin or poor contact, which will cause sparks and ignite the hydrogen and oxygen mixture in the battery, leading to battery explosion.

6. Electrolyte viscosity is too high

If the viscosity of the electrolyte is high, it is easy to cause slow infiltration into the pores of the electrode plate, which will also increase the internal resistance, resulting in an increase in the voltage drop consumed on the internal resistance during discharge. This will cause the electrolyte temperature to rapidly rise and a large amount of gas to appear, thereby increasing the gas pressure inside the battery and causing the battery to bulge.

7. Insufficient electrolyte volume

I believe everyone understands that after using a battery for a period of time, it will lead to a decrease in electrolyte, so it is necessary to add electrolyte or distilled water. After the electrolyte is reduced, overcharging can cause the battery to bulge and even cause an explosion.

8. Damaged charger

When the charger or generator on the engine is damaged, its current or voltage may fluctuate, which can easily cause violent reactions in the battery, resulting in a large amount of gas and causing the battery to swell.

How to prevent battery swelling

What causes the battery to bulge. So how should we prevent battery swelling in our daily work? Let's briefly explain it below.

1. Control the voltage and current well. As mentioned above, excessive voltage or current can easily cause the battery to swell, so it is necessary to control the voltage and current well.

2. Try to control the charging time as much as possible, avoid excessive charging time, and prevent overcharging.

3. Choose a better charger or regularly check the generator on the engine. Once a problem is found, repair or replace it in a timely manner to prevent battery swelling.

4. During the charging process, it is important to ensure that each connection point is secure, as loose connections can cause sparks, which can pose a risk of battery swelling.

5. Ensure timely and unobstructed ventilation holes. In regular maintenance, promptly clean the impurities around the battery.

6. Check in advance whether there are cracks on the battery casing and whether the electrolyte is leaking. Because once the electrolyte leaks, it may penetrate into the cable or circuit, causing an electrical connection and sparking.

7. Timely eliminate internal short circuits and electrode plate vulcanization in the battery. A short circuit inside a battery can cause sparks to ignite the hydrogen oxygen mixture, while vulcanization of the electrode plate can cause a large amount of gas to appear inside the battery. So, we should regularly check whether there is a short circuit or vulcanization phenomenon inside the battery.

8. It is prohibited to ignite the positive and negative poles of a battery with metal objects such as cables, as this can easily cause explosions of hydrogen and oxygen gas in the air, and in severe cases, even endanger personal safety.

9. When repairing electrical equipment, flammable gases inside the battery should be eliminated first, as sparks or high current in the battery may occur during maintenance, which is also a major safety hazard.

10. Timely check the amount and density of electrolyte. This will greatly protect the battery and prevent it from bulging.

11. When starting the engine, try to prevent prolonged continuous starting.

There are three reasons for explosions:

1. Excessive internal pressure of the battery can cause the battery casing to explode

Understanding the working principle of lead-acid batteries during the charging process, especially at the end of the charging period, due to overcharging, water decomposes into hydrogen and oxygen, short circuits, severe vulcanization, and a sharp increase in electrolyte temperature during charging, all of which can cause a large amount of water to evaporate. If the ventilation hole of the liquid filling hole cover is blocked, due to too much gas not being able to overflow in time, the pressure inside the battery will rise very high, causing deformation of the battery compartment first, When the internal pressure reaches a certain level, it will burst from the junction of the battery compartment cover or other weak points, which is a physical process. When the internal pressure of the battery exceeds 0.25MPa, the battery will burst, and the location of the burst is at the junction of the hot air on the slot cover or at the corner of the stress concentration.

2. Battery explosion caused by hydrogen gas encountering open flames

The explosion limit of a mixture of H2 and O2 is 4% -96% of the volume of the mixture, and the explosion limit of a mixture of H2 and air is 4% -74% of the volume of the mixture. If 80% of the overcharge is used for electrolysis of water, the H2 content inside the battery is greater than the explosion range. When the hydrogen content in the battery or air accumulates to the explosion limit, it will form an explosion when encountering an open flame, which is a chemical reaction.

Research has found that the explosion of batteries belongs to a branched chain explosion reaction. Too many of these types of explosions occur under overcharging conditions. If there are virtual solder joints inside the battery poles, through wall welding, etc., the probability of battery explosion is higher. A qualified battery will not undergo self heating explosion reaction under normal usage conditions. When the charging voltage of the battery is higher than 14.4V for gasoline vehicles and 28.8V for diesel vehicles, an explosion may occur under the condition of simultaneous presence of sparks. Through inspection of vehicles with battery explosions, it was found that most voltage regulators have defects and the battery is in a severe overcharged state.

3. Due to the blockage of the battery exhaust hole, the battery first bursts, causing the battery to vibrate and spark due to loose pole connections, resulting in an explosion.

Methods to prevent battery explosions:

1. Control the amount of charging, but charge to reduce gas release. Open flames are strictly prohibited in the charging room and ventilation should be maintained.

2. During charging, the wiring points should be secure and not spark due to looseness.

3. Low voltage constant voltage charging is used during use, resulting in less gas evolution.

4. Prevent cracks on the battery casing and electrolyte penetration.

5. When parking and disassembling batteries, the combustible mixture gas should be automatically discharged after parking before disassembly. When disassembling, the negative wire should be removed first, and then the positive wire. When installing batteries, the reverse order is used, otherwise there is a possibility of battery explosion.

6. Keep the battery cover dry and clean.

7. Regularly check the small side vent of the battery to ensure that the vent is unobstructed.

8. Control the liquid level of the battery well, ensure that the liquid level is within the specified range, and the electrolyte must not overflow.

9. The battery terminal connection wire should have a low contact resistance and a high contact pressure, and Vaseline should be applied at the connection to isolate it from the external environment, preventing sparks from entering the battery and igniting combustible gases.

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