flashlights with LEDs or 3V lithiums are banned from airline carry-on & checked baggage.
avoid flashlights Surefire G2 & M6 & 9P, Pelican M6. The M6 tailcap nearly went through a solid oak cabinet door.
some say in a 2-cell system, if one cell is slightly discharged, the imbalance can lead to an explosion. The partial cell depletion (30%), coupled with cooler evening ambient temperature (65F-70F), appears at the moment to cause an explosion (during testing). Also, do not mix brands. when you buy them and need them as a set, buy them as a matched set, not separately.
At the moment, Kevin of Battery Station, seems to be expending extra effort to actually test his cells, the best way he knows how, to assure that the cells are matched in as full up battery (not depleted at all) as well as he can. This step, after finding 3 out of 3 venting incidents in the partial depletion scenarios, in hind sight, was a *very* prudent move on his part.
avoid "Surefire" batteries, maybe avoid Eveready, Panasonic, Streamlight, Browning, and others due to PTC crimping. Avoid batteries made in China such as Sanyo.
recall Fuji Power, A&T Fuji Power CR123A 3-volt lithium batteries originally provided with the Dorcy Spyder Tactical Xenon Light (Product 41-4200), also sold in packages of two flashlights under the name Dorcy Xenon Tactical Light.
Recall of Fuji Power, A&T Fuji Power Batteries Sold with Galls® H.A.L.O. Tactical Flashlights
recall Browning brand CR123A Lithium (3-Volt) Batteries. The batteries were sold in two-packs and packed with the Black ICE 6V Xenon 6 LED Flashlights. Batteries are labeled "Mad in China." Batteries can short out, resulting in a rupture of the flashlight canister and injury to the user.
Did you realize that in 2004, 63% of Lithium battery recalls were due to cells manufactured in China, and they only produced 34.5% of the batteries? That means Chinese batteries are twice as likely to be the subject of a recall:
I am afraid that even though our battery had a $6000 upgrade almost two years ago and is UL rated, the shear numbers are working against us. We are going through almost 100,000 of them in a busy month now and it has become a numbers game more than a quality game. I can assure everyone that we have gone way overboard regarding safety. This is another reason we do not sell unprotected cells. Trouble waiting to happen.
I have spoken to people at several factories including domestic big names and they all have incidents similar to this. This is being caused by mixing batteries that are not exactly matched. I am not saying this is anyones fault or putting blame on any customer. You should not have to worry about things like this. This is a factory issue. You do of course not want to mix a discharged battery with a good one. Most people know this.
I would like to replace the light, batteries, and anything else necessary to make this right. I hope people understand this is a random freak thing that we have only limited ability to prevent. We are going to begin a program of testing every CR123A battery that goes in CPF orders and maybe every order. It is that one out of 10K or one out of 100K cells that may cause a potential problem. Please be advised that this is possible with any brand of battery. Please be careful.
I sincerely apologize for this and will take even further steps to hopefully prevent it from ever happening again. Our goal is to offer a quality product. We have never been a company to take shortcuts. There are cheaper batteries everywhere but we won't carry them.
Please give me a call with any questions or comments or ideas. We really want you to have the best.
CR123A $1, Surefire Lights, HDS EDC Lights, Pelican M6LED and MOREhttp://www.batterystation.com/cpf.htm
Kevin
The most likely cause is that one battery was drained more than the other one. As things warm up, the fuller charged cell tries to reverse charge the under charged cell and things heat up fast. Hydrogen gas is vented and when ignited, blows up. Once one cell is burning, it doesn't take much to ignite the other cell.
I should point out that the fumes are not good for you, nor is the slimy residue. Take care and make sure you wash your hands after playing around with the burned up batteries and light. Gloves may be an even better consideration. If you plan on storing the burned up parts, I would suggest that you move them outside.
I have had a discussion with Kevin at BatteryStation. He will be posting his thoughts shortly.
I know that the ZTS tester has not given us exact information, but it is beginning to look like a reasonable investment at this time...
Tom
gas in a sealed flashlight will cqause the flashlight to explode, for one thing.
I hope your husband is alright. I've heard that some people drill tiny holes in their waterproof flashlights in order to let the gas escape rather than take the chance of an explosion. That's okay as long as you don't need your light to be waterproof.
Combining different battery manufacterers will cause explosions.
Regarding the cost of primary 123s they are available from reputable retailers on the web (Amondotech, Battery Station) for around $1 apiece. Not a bad deal. I've always treated any battery powered tool with respect. I learned when I was a kid the danger of coupling new and old cells together in a high-powered (Pelican M6) flashlight. Amondotech sells matched cells in 2, 3, and 4x123 sticks (my preference). In high-output lights there are issues with matching low capacity rechargeable cells- too much draw.
got mine at walmart for $34
http://www.molalla.net/~leeper/minorv~1.wmv
This event left nearly no debris. I have had other incidents, where I had a substantial fireball, and the innards of the cell, were ejected (about 98%) of it, all on fire, which continued to burn, until I sealed the container. There was an amazing amount of smoke. Remember, this is a test, where a cell is partially discharged by 30%, like one might find in a new pack of batteries. This problem with 123 cells has been discussed many times on cpf, where the usual result is the flashlight doesn't light up (fully depleted new cell), or it only runs for a short period of time (partial depletion).
I have had multiple failures in a Pelican M6, and failures of flashlights which use two or more cells are found to happen to Streamlight, SureFire, Cyclops, and other miscellaneous flashlight brands. The failures have occured with cells from multiple manufacturers. The interesting common factor is that it has always happened in flashlights that utilize 2 or more cells. There was one incident overseas, where there was some sketchy information on a single cell Lithium light that failed, but that is all I have seen.
My testing shows that a failure can occur, even when the cells are not forcefully squeezed, I was able to replicate a failure with contacts made from soft copper, which bends very easily. This shows that the failure can occur outside the forceful squeeze that was in the old style PM6 flashlight.
Trying to fully contain a battery failure can be futile at times, as in some of these incidents, the force was obviously rather great. The failures I have seen, where the forcefully cells eject their flaming guts, with fireballs and all, leave no doubt in my mind, the difficulty of containing the failure mode. One can light a small pile of gunpowder and you get a small woof and smoke. Contain that very same event in a sealed pipe, and you end up with a bomb. I have pondered the idea of a safety vent on flashlight bodies, but that is really up to someone that has more resources to investigate further.
The wisdom at the moment seems to be:
- never ever mix cell brands
- never mix a new cell with a used cell
- cells that measure similar remaining new capacity, I've conducted many, many tests, and seen no failures- BatteryStation is now utilizing a device called a ZTS tester, in order to sift out new cells that have partially depleted themselves
- Always lock out your flashlight so it cannot be accidentally turned on, some folks are actually removing cells to assure the light doesn't accidentally turn on
- do not store your lithium flashlight around other items which may be hazardous
- do not short a 123 cell, it can generate gasses within the cell
- if your light drops all of a sudden in brightness, or goes out, lock it out (off). If it continues to get hot, vibrate, make funny sounds, or other wierd behavior, you should consider leaving the immediate area. Personally, I'd toss it in a safe direction/area that doesn't pose a hazard to others, but thats my personal preference.
- never, ever use a cell that has leaked a bit, or is dented/deformed.
- if the cell/flashlight gets hot, like around flame or in the sun, it may explode or internally vent.
- if possible, at a minimum, consider measuring the cell voltage with a volt meter. If the cell is low, do not use it.
- this list is by no means complete, and is only meant to be a starting guide.
There are a great many other tidbits of wisdom, which will likely be added upon.
Burning lithium ion batteries can produce toxic fumes including HF Acid, oxides of carbon, aluminum, lithium, copper, and cobalt. Volatile phosphorus pentafluoride may form at a temperature above 230° F.
The most of the MSDS for the Lithium Primaries also warn of Hydrofloric Acid, Lithium Hydroxide, hazardous fumes of manganese and lithium, oxides of carbon and sulfur and other toxic by-products for burning/thermal degradation of the cells.
We have already had one member who was hospitalized due to exposure from a combusted Lithium cell.
Notes to Physician
1) Potential leakage of dimethoxyethane, propylene carbonate and lithium trifluoromethane sulfonate.
http://www.duracell.com/oem/safety/pdf/2003_9.pdf
(Hydrofluoric Acid is definitely not something one should even think about messing around with.)
(Alot of these byproducts are just as nasty as what comes out of a Li-Ion rechargable cell.)
Please keep in mind that when these batteries vent (and/or burn), there are nasty chemicals involved. Take extreme precautions when handling the remains and don't keep them around. After disposing, make sure you scrub your hands throughly. If you look at a MSDS for the chemicals used in these batteries, you will realize that exposure to the chemicals inside them, or breathing the fumes from them burning can have serious health effects.
The general rule of thumb for using multi cell lights is that you should change out the batteries as soon as the light begins to dim. Don't try to run the batteries all the way down to the extreme end.
Energizer's take on things:
Under normal conditions of use, the battery is hermetically sealed.
Ingestion: Swallowing a battery can be harmful.
Contents of an open battery can cause serious chemical burns of mouth, esophagus, and gastrointestinal tract.
If battery or open battery is ingested, do not induce vomiting or give food or drink. Seek medical attention immediately.
CALL NATIONAL BATTERY INGESTION HOTLINE for advice and follow-up (202-625-3333) collect, day or night.
Inhalation: Contents of an open battery can cause respiratory irritation. Provide fresh air and seek medical attention.
Skin Absorption: Dimethoxyethane, dioxolane, and lithium trifluoromethanesulfonate may be absorbed through the skin, causing
localized inflammation.
Skin Contact: Contents of an open battery can cause skin irritation and/or chemical burns. Remove contaminated clothing and
wash skin with soap and water. If a chemical burn occurs or if irritation persists, seek medical attention.
Eye Contact: Contents of an open battery can cause severe irritation and chemical burns. Immediately flush eyes thoroughly with
water for at least 15 minutes, lifting upper and lower lids, until no evidence of the chemical remains. Seek medical attention.
Note: Carbon black is listed as a possible carcinogen by International Agency for Research on Cancer (IARC).
http://data.energizer.com/PDFs/lith...ioxide_psds.pdf
Please don't pretend to be an expert when you are not, and pass supposedly "informed" opinions.
Navy Lithium battery testing results
I'm also curious to know why batteries like the SureFire 123 Lithium Primary cell have a tendency to leak. Remember, the cell is very well sealed. You can store them in a nice moderately cool area, subject them to nothing, and they just start leaking. This has been well documented here on CPF many times. Could it be that something happened inside the cell, which caused the vent to pop?Another very well documented problem is SureFire 123 Lithium Cells also have a strong tendency to have various states of charge. Some of them will have nearly no charge left in them, and others will only operate for a few minutes, before the light goes out. So the batteries have a tendency to self mis-match on their own. Plop these in a thousand lights, with another cell that hasn't degraded on it's own, turn them on and let them rip, it is definitely a betting man's game as to whether you get a boom.
Even if a cell was tested at the factory by a ZTS tester (or something that checks the cells in one way or another), it still does not prevent the cell from depleting itself later on, over time, but it might lower the risk.
Sanyo even mentions a strong physical force on the cell, nor handle roughly, both can cause issues- Doing so may cause heat generation, leaking, or bursting.
They go on to mention, do not leave batteries in the sun, and not to leave in high temperature areas. Doing so may cause heat generation, leakage, or bursting.
When the cell is made, there is tremendous power stored within the cell, just waiting for some form of release. A Lithium Primary is the closest battery to a stick of dynamite that I know of.
Sanyo warns if there is any strange smells or leakage, keep away from fire to prevent ignition. You know how Surefire 123 Lithium cells are well known for leakage, what happens if it starts to leak in a light that is sitting (seals now compromised)? Could this leakage material cause a conductive path that causes further issues for the cell?
If one looks carefully at the Sanyo guide I linked in my previous post, one will find that the maximum operating temperature for a crimped Lithium Primary cell is 60C (140F), and they make a special cell that is laser sealed, which can operate up to 85C (185F).
There are many scenarios which are very real, that cause issues. The hard part, is to find the one that is the one that most commonly causes explosions, fires, venting with flame, spews hot gasses (including the very nasty HydroFluoric Acid), etc...
Often this actually ends up damaging the PTC itself, and can even result in a short within the PTC, which causes a failure that is just like having no PTC in the cell.
As such, is a highly discouraged method of getting more performance out of the battery.
See, the PTC, starts to kick off slowly, it's resistance rising with temperature (and temperature caused by current). Often this temperature lies in the neighborhood of 60C, and really starts to kick in by 90C. The rise in resistance limits the current draw out of the battery, which then lowers the battery temperature, thus protecting it.
On recent cells made by Energizer/Surefire which say made in USA (Energizer also makes cells for other companies, which include SureFire, Panasonic, Streamlight, Browning, and others), I've noted what appears to be a routine over crimp of the PTC cell, on Energizer cells as well as the ones they make for SureFire, and the other above mentioned companies. Is it over crimped to the point of destroying the PTC protection mechanism? I have no idea, as I did not test for that. Could it just affect some cells? IMHO, very possible.
I see *zero* denting of the PTC on quite a number of Duracell batteries I have disassembled.
Example of the dent in the PTC, labeled as crimp line:
There are a number of good pictures and examples in one of my threads:
http://candlepowerforums.com/vb/sho...44&page=1&pp=40
Did you know that burning Lithium metal can actually reach temperatures in the range of 3,000 degrees F?
Other failures of LiIon cells: http://wcco.com/consumer/local_story_148150249.html
CBS news story on the event: http://wcco.com/video/?id=17281@wcco.dayport.com
Apple Powerbook fire: http://www.powerbook-fr.com/forum/viewtopic.php?t=1154
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Apple Ipod catches fire after user abuse: http://www.mantissa.net/blog/2006/0...n-ipod-shuffle/
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Christmas Day... Our new iPod Speakers Nearly Burned Down Our Home http://www.1esc.com/Applefusion.html
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In one of the threads here on cpf, someone mentioned that Lithium Polymer rechargeable cells would be safer. This is another technology, like the LiIon rechargable cells, where you can find plenty of examples of failures on the internet, usually due to abuse, but it demonstrates what can happen with them. An example (you may need to refresh the page a couple of times to get all the photos to load, for some reason):
http://klaudius.free.fr/lipo.htm
This guy had a fire in his house: http://www.rcgroups.com/forums/show...114#post747114-
Videos of abused LiPoly:
http://chemistry.about.com/gi/dynam...s/Lipofires.wmv
http://www.utahflyers.org/movies/Lipo2.wmv
http://video.google.com/videoplay?d...260570423705609
http://rchomepage.com/~dna/LipoFire.wmv
http://www.helihobby.com/videos/LithiumBattery.wmv
Battery bunker testing: http://www.utahflyers.org/movies/lipo3.wmv
As far as that emergency landing by UPS, it was in fact Lithium cells on board: http://www.courier-journal.com/apps...S/60620045/1003
Find a photograph of the fire that continued for several hours: http://www.courier-journal.com/apps...INESS/606210499
Fed-Ex (Federal Express, also has a lithium battery package catch fire):
"According to NTSB records, a company's improper packaging of lithium batteries was the "probable cause" of an Aug. 7, 2004, fire in a freight bin at FedEx's air hub in Memphis, Tenn. The bin had been raised on loading equipment and pushed halfway onto an airplane when loading personnel smelled smoke. "
More details on the AC Propulsion (San Dimas, California) Lithium Ion batteries (rechargeables) which caused the fire: http://www.ntsb.gov/publictn/2005/HZB0501.htm
"On June 30, 2005, a package containing lithium-ion batteries was discovered at the United Parcel Service (UPS) airfreight terminal in Ontario, California. One of four battery packs within a package had caught fire and been completely destroyed during transportation. The fire was out and the package cold when it was discovered. The package containing the battery packs had flown on UPS aircraft from Shanghai, China, to Anchorage, Alaska, and on to Ontario. "
Lithium Primary shipping banned on passenger flights: http://www.dot.gov/affairs/faa001.htm
Please respect your batteries and treat them properly, you can lower your risk in doing so.
1. user and/or mfg places two or more primary lithium cells into incan and/or LED flashlight.
2. one or more of cells is in substantial lessor state of charge than other cell(s) in series. 100% for first cell and say 60% for second cell.
3. operator accidentally leaves light on for extended run.
4. 100% cell starts to reverse charge 60% cell. large current drain from 100% heats up source cell and 60% cell also heats up from being reversed charged.
5. if PTC is defective on host cell(s) and heavy internal reverse charge is occuring. This leads to venting with flames by one and/or both cells.
6. if this venting with flames is contained within an air tight container like a flashlight. explosion will result.
number of reported primary lithium failures has only recently spiked. past cpf threads will show timeline of failure reports. IMHO spikes in failures is directly related to primary lithium cells mfg in China. there is a need to identify who actual manufactors of failed primary cells are.
please correct me if I wrong. So far no documented venting with flames has occured with single primary lithium cell lights. No documented venting with flames has occured with li-ion cells in single cell lights. (bare and protected li-ion cells)
It is possible to get them to vent on occassion when the ambient temperature is 100F- like in this video. This time the cell vented about 5 minutes after the bulb went out. Which once again emphasizes the importance of shutting off the light when the bulb dims or goes out, and locking it out to assure the flashlight is actually off and the circuit is not completed.