Burns from Lithium-ion Batteries in the US - A Comprehensive National Analysis

Abstract Introduction Lithium-ion cells power most personal electronics and mobility devices, delivering high energy density with risk of thermal runaway in damaged cells or misuse. Consequent flames/explosions make these batteries an emerging hazard source from thermal injuries. Despite growing reports, the epidemiology remains poorly defined since injury surveillance rarely codes lithium-ion involvement explicitly and most reports are product- or jurisdiction-specific. To address this gap, we used two complementary national datasets to quantify the national burden and characterize hospitalized cases. Methods We performed a two-database analysis using the U.S. Consumer Product Safety Commission’s National Electronic Injury Surveillance System (NEISS), 2020-2024, and the American Burn Association’s Burn Care Quality Platform (ABA-BCQP), 2013-2022. From NEISS, burn cases were identified through the predefined injury mechanism field with the inclusion of a narrative field search. The mechanism was queried including all lithium battery operated devices with exclusions for non-lithium contexts. National weighting was specified with Stratum and Primary Sampling Unit variables. Subgroup for type of electronic was defined. The free text field for ABA-BCQP was queried for word combinations of lithium-ion batteries and devices. Inpatient demographics, injury severity, hospital course, and outcomes were described. Results Lithium-ion battery burns increased by 64.2% from 2222 in 2020 (6.7/1000,000) to 3648 in 2024 (10.7/1000,000). Fire service involvement was documented in 33.5% of events. The most frequent device categories included phone batteries (32.9%) and electronic cigarette/vape devices (12.8%). Mean age was 38.5 years and 86.4% were male. Median total body surface area (TBSA) injured was 4.0%, with a maximum injury size of 46% TBSA. 40.4% received surgical treatment; of those undergoing surgery, there was a median of 3 operations per patient. Overall mortality was 0.8%. Payer mix included 42.0% private insurance, 20.5% Medicaid, 12.3% uninsured, and 10.0% Medicare. Racial distribution was 75.2% White, 10.0% Black, 2.2% Asian; 10.1% were Hispanic. Conclusions Lithium-ion battery burns are increasing in the U.S., with mobile phones and electronic cigarettes/vaping as prominent drivers. While most inpatient injuries are relatively small, 40% require surgery and nearly 1% die—emphasizing the severity and the need for prevention. Applicability of Research to Practice Americans should only use certified devices per nationally recognized testing laboratories. Burn prevention programs should include targeted messaging on lithium-ion battery risks and early signs of thermal runaway (e.g., swelling, overheating, smoke/odor), safe charging/storage, and device/charger quality—paired with surveillance efforts that explicitly code battery involvement. Funding for the study N/A.