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Stop using a power bank immediately if it is swollen or misshapen, dangerously hot, leaking or venting, or showing unusual discoloration or noises. Unplug it from every device, do not recharge it, and move people away if it smokes or burns. Ordinary warmth during charging is not, by itself, proof of failure; safety guidance describes excessive or unusual heat but sets no universal temperature cutoff.
The four groups below combine the warning symptoms identified by the Australian Competition and Consumer Commission (ACCC) and the National Fire Protection Association (NFPA). They are a practical screening guide, not an official test that requires you to find every symptom. One serious sign is enough to retire the unit.
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Quick decision guide
| What you notice | What it can indicate | Action now |
|---|---|---|
| Bulging case, lifted seam, changed shape or visible damage | Internal cell damage or swelling | Stop charging and using it; isolate it from combustible items if this can be done without touching a hot or leaking unit. |
| Much hotter than usual, rapidly heating or overheating | Abnormal electrical or chemical reaction | Disconnect it if safe, stop use and watch for smoke, odor or further heating. |
| Liquid, residue, hissing, venting gas or chemical smell | A leaking or venting lithium-ion cell | Do not touch the material; keep away and arrange hazardous-waste advice. |
| New discoloration, odd sounds or another unexplained physical change | Battery fault or thermal event developing | Stop using and charging it, even if it still powers a phone. |
NFPA’s 2025 lithium-ion battery safety tip sheet states: “Stop using the battery if you notice these problems: odor, change in color, too much heat, change in shape, leaking, or odd noises.” A power bank contains lithium-ion cells, so that stop-use advice applies to these portable chargers.
1. Swelling, shape change or visible damage
A safe power bank should keep its original shape. A case that bulges, a seam that starts to separate, a button or port that appears pushed outward, or a unit that rocks because its base has deformed are warning signs. Dents, cracks, crushed corners and damage around the USB ports also matter, particularly after a drop, being sat on or exposure to water.
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Swelling means gas is building inside a cell. Continuing to charge a swollen pack adds energy to a component that may already be internally damaged. Do not squeeze the case flat, pierce it, open it, glue it or attempt a cell replacement. Those actions can release flammable material or create a short circuit.
The ACCC says never to use a power bank that is damaged or swelling. A 2025 U.S. Consumer Product Safety Commission (CPSC) warning about the Yiisonger KT-D007 documented reports of swelling alongside ignition and explosion. Those reports concern that named model; they are not a general failure rate for all power banks. Nevertheless, the visible symptom warrants the same immediate stop-use decision.
What to do with a swollen unit
- Unplug all cables and stop charging it.
- If it is cool and stable, place it where people, pets and combustible materials cannot contact it while you obtain disposal instructions. Do not put it in a drawer, car or sealed container.
- If it is hot, hissing, smoking or giving off an odor, do not handle or move it. Leave the area and call emergency services if there is an active fire.
2. Excessive or unusual heat
Power banks can feel warm while converting power, especially when they are charging themselves and a phone at the same time, operating in direct sun or covered by bedding. Warmth alone does not establish a failure. The safety boundary is qualitative: stop when the unit is too hot to handle comfortably, heats much faster than it normally does, remains intensely hot after a load is removed, or overheats while idle.
Neither the ACCC nor NFPA sets a universal temperature threshold for every power bank. Designs, ambient temperatures, charging rates and measurement methods differ, so a single number would create false reassurance. Do not rely on an oven thermometer or an internet temperature claim as permission to continue using a suspicious pack.
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Responding to overheating
- Disconnect the phone or other device if you can do so without touching a dangerously hot surface.
- Stop charging the power bank. Do not place it in a refrigerator or freezer; condensation and handling can create additional hazards.
- Move people away and monitor from a safe distance for smoke, flames, popping, odor or swelling.
- If it ignites or produces heavy smoke, evacuate. The ACCC’s Australian guidance says to close doors behind you if that is safe and call Triple Zero (000). Triple Zero is Australia-specific; elsewhere, call your local emergency number.
Do not resume use merely because the case cools. A thermal event can leave internal damage that is not visible.
3. Leakage, venting or an unusual odor
Liquid, sticky residue, crystals, a sharp chemical smell or a hissing sound can indicate that a cell is leaking or venting gas. A lithium-ion battery does not need to be visibly wet to be hazardous. Odor around the vents, ports or seams is enough to stop using the unit.
Do not touch leaked material with bare hands, wipe it onto clothing or bring the pack indoors for inspection. Keep your face away from it and prevent children and animals from approaching. If material contacts skin or eyes, follow local medical or poison-control advice. Do not wash a leaking battery down a sink or place it in water.
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4. Discoloration, odd noises and other abnormal changes
Brown, black, white or heat-darkened areas; a melted port; a case that changes color; crackling, popping, clicking or hissing; and intermittent behavior that was not present before are all abnormal. NFPA specifically lists a change in color and odd noises as reasons to stop using a lithium-ion battery.
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A power bank that repeatedly starts and stops, refuses to charge, becomes unusually hot at one port or emits a sound while no device is connected may have an internal fault. Performance problems alone do not identify the exact cause, but they remove the safety margin needed to keep charging a high-energy lithium-ion pack. Do not test it with another cable, open it to diagnose the board or leave it connected overnight.
What to do after you identify a warning sign
Stop both use and charging
Turn off connected devices, unplug cables and do not recharge the suspect unit. Do not lend it to someone else or leave it at a workplace charging station. A power bank that still shows four LEDs or can charge a phone is not necessarily safe.
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Read the label for the manufacturer, model number, batch or date code and input/output ratings. Search the current recall database for that exact combination, not just the brand name. CPSC warnings are product-specific. Its May 15, 2025 warning for the Yiisonger KT-D007 reported 79 incidents involving explosion, ignition or swelling, including one serious fire with reported property damage of $15 million. Those figures apply to that named model and warning.
On September 17, 2026, CPSC reported 16 fire reports involving the Hererod PW40/EW40 and seven reports of property damage. Again, these are reports concerning those products, not a population-wide rate. A separate CPSC recall dated November 13, 2025 covered Belkin BPB002 and PB0003 power banks and wireless-charging stands. A brand having no notice in a database search does not prove that an individual damaged unit is safe.
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Arrange disposal through the right channel
Do not put a defective or recalled lithium-ion power bank in household trash or ordinary recycling. CPSC advises contacting your local household hazardous-waste facility in advance to ask whether it accepts defective or recalled lithium-ion batteries. If it does not, ask your municipality for its designated procedure. Acceptance rules, packaging requirements and drop-off locations vary by jurisdiction.
Tell the facility that the item is damaged, swollen, leaking or recalled. Follow its instructions about transport; do not improvise by mailing a damaged battery or placing it in a collection bin intended only for intact consumer batteries.
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When a power bank is smoking or burning
Fire takes priority over saving the device. Warn everyone nearby, leave the area and close doors as you exit if doing so is safe. Call your local emergency service; in Australia, ACCC guidance directs people to Triple Zero (000). Do not re-enter for the power bank, do not carry a burning pack outside through occupied areas and do not attempt to suppress a spreading lithium-ion fire unless trained responders direct you.
After an incident, do not handle the cooled-looking remains. Damaged cells can reignite. Firefighters or the hazardous-waste authority can explain how to secure and remove the remains.
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Choosing a replacement safely
Replace a retired unit rather than repairing it unless a qualified service specifically certifies the repair. When selecting a new power bank, verify four things for the exact model:
- Safety listing: NFPA recommends devices listed by a nationally recognized testing laboratory. Confirm that the listing applies to the precise model, not merely to a similar product or a seller’s generic claim.
- Device compatibility: Match the output voltage, USB-C or other connector, charging protocol and wattage to your phone, tablet or laptop. A higher capacity does not make an incompatible output safe.
- Manufacturer instructions: Follow the specified charger, cable, storage conditions and replacement interval. Do not mix instructions from another model.
- Supplier reputation: ACCC recommends reputable suppliers. Keep the receipt, model information and recall contact details so you can identify the unit if a safety notice appears.
A replacement should never be used to justify keeping a suspect power bank in service, charging it “one last time” or transferring its cells into another case. If you are considering a product described as a UL-listed USB-C power bank, verify the current listing for that exact product and its applicable region before purchase; a label or marketplace description alone is not independent confirmation.
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Preventing avoidable power-bank failures
- Use the charger and cable specified by the manufacturer, and stop if either becomes damaged.
- Charge on a hard, nonflammable surface with ventilation. Do not cover the pack with clothing, bedding or luggage.
- Keep it away from high heat, direct sun, water and severe cold. Never leave it charging in a hot vehicle.
- Inspect the case, ports and cable periodically for swelling, cracks, discoloration or residue.
- Do not charge or store a pack where a fall, crush or sharp object could damage the cells.
- Store it according to the manufacturer’s instructions, with enough charge for storage but not connected indefinitely.
These habits reduce stress on the cells, but they cannot make a damaged battery safe. The stop-use signs remain the deciding factor.
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