If you are reading this article, you may have encountered a similar situation: the battery health shows above 90%, and everything seems "normal," but one day the bottom of the computer case suddenly bulges, and the touchpad lifts, and you realize that the battery is bulging.
In the past two years, there has been a significant increase in cases of bulging laptops – not only on older machines, but also on many newer laptops that are 2-3 years old.
As long-time employees of the laptop battery industry, we've also noticed this trend.
In this article, we will primarily explain why this situation is becoming increasingly common, what steps you can take to avoid it, and what steps you can take to make it safer.
1. Why a Battery Can Swell Even When Health Looks “Normal”
Most users rely on Windows, macOS, BIOS, or third-party tools to check battery health.
But here’s the truth: Battery health numbers are NOT designed to detect swelling risk.
Health percentages only reflect: capacity loss (how much energy it can hold)
Not:
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internal pressure
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degradation rate
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gas generation
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thermal stress history
This means a battery can still show 85–95% health while internal chemical reactions have already started producing gas, causing the pack to expand.
2. The New Culprit: Temperature Spikes
Swelling isn't caused only by battery age.
A major 2025 trend is the occurrence of short, frequent temperature peaks that stress the internal chemistry.
Why temperature spikes matter
Lithium-ion batteries contain electrolytes and additives that start breaking down when exposed to high, sudden heat, causing:
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gas generation
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expansion of the pouch cell
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increased internal pressure
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irreversible swelling
Even a few minutes at high temperature can initiate damage that continues silently for weeks.
3. Modern Laptops Run Hotter Than Ever
AI workloads (Copilot+, background indexing, NPU tasks)
2024–2025 laptops constantly run:
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AI photo indexing
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local Copilot processing
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real-time subtitles
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face recognition
These tasks increase CPU/NPU power consumption by up to 2–4 times the normal usage.
Extremely thin laptop designs
Modern machines prioritize thinness over cooling.
Less space = less airflow = pockets of high heat around the battery.
Higher-density battery packs
To achieve longer battery life, manufacturers use higher-density cells that:
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run warmer
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tolerate heat poorly
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swell faster when stressed
USB-C fast charging and higher wattage chargers
Charging at 65W–100W generates heat inside the battery pack, especially during:
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gaming
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video editing
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AI tasks
Users who “use and charge at the same time” face an even higher risk.
4. Why the System Still Shows “Battery Normal” While Swelling Happens
You might assume Windows or macOS would warn you before anything goes wrong, but the reality is different.
Battery health indicators do not track swelling at all—they only measure cycle count and capacity, so they miss the early chemical changes that cause the pouch to expand.
Many 2025 laptop models also use softer reporting thresholds, meaning manufacturers intentionally avoid issuing aggressive warnings because it would dramatically increase warranty claims.
As a result, the system may continue to display perfectly normal numbers even when the battery is already under stress.
What makes this even more confusing is that swelling often occurs before any noticeable drop in capacity.
The chemical breakdown begins inside the battery pouch and does not immediately affect how much charge the battery can hold.
This leads to situations where the health shows around 92%, the cycle count is only 150, and the system status still says “Normal,” even though the battery has already started to bulge.
6. Swollen Battery Risks
A swollen battery is dangerous, not just inconvenient, and the risks associated with it are far more serious than most users realize. A swollen cell can damage internal components, cause the trackpad to fail, bend the frame, warp the chassis, or even crack the screen.
7. What You Should Do If Your Battery Starts Swelling
If your battery shows any signs of swelling, the first step is to power off the laptop immediately, as both charging and discharging can further stress an already compromised cell.
You should never puncture a swollen battery under any circumstances, because doing so may trigger combustion. For laptops with removable batteries, taking the battery out carefully is the safest option, while built-in batteries should be replaced as soon as possible and not left to worsen.
After removal, the swollen battery should be stored safely in a fireproof container and taken to an appropriate e-waste recycling center.
When choosing a replacement battery, make sure it uses brand-new production cells, certified protection circuits, the correct voltage and capacity, and comes from a pack that has passed essential safety tests such as UN38.3 and MSDS.
8. How to Prevent Temperature-Related Swelling (Practical Tips)
To reduce temperature-related swelling, it is helpful to avoid heavy workloads while charging, as this has become the number-one trigger in 2025.
Keeping your laptop elevated improves airflow beneath the chassis and helps heat escape more efficiently.
Disabling unnecessary AI features, especially those related to background indexing or automatic photo processing, can also prevent sudden thermal spikes.
You should avoid leaving your laptop inside a car, as only ten minutes in a hot vehicle can push internal temperatures above 60°C.
Using the correct wattage charger prevents unnecessary heat generation, and cleaning the vents regularly ensures dust does not block airflow.
When possible, maintaining the battery between 20% and 80% can further reduce heat buildup during charging and prolong overall battery health.
If you see early signs of swelling, act immediately and replace the battery with a high-quality, certified pack. Protecting your device from heat is now one of the most important steps in maintaining long-term battery health.
If your laptop battery is showing early signs of swelling, you can find high-quality replacement laptop batteries at BatteryMall.com
Looking for more guides on battery care, charging habits, or troubleshooting tips?
Visit: BatteryMall.com/blogs/support for expert advice and practical maintenance tutorials.
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