Introduction

Power banks have become a daily necessity in our increasingly mobile lives. Whether you’re commuting, traveling, or working remotely, a power bank provides the essential backup your smartphone, tablet, or wearable device needs. However, with great convenience comes great responsibility — and concern. Recent reports involving well-known brands like ROMOSS have reignited debates about power bank safety, manufacturing standards, and what consumers and distributors should be looking out for.

In 2024, a serious in-flight incident caused by a ROMOSS power bank prompted a massive recall and industry-wide reflection. This article takes an in-depth look at the incident, explains why power banks explode, and what both consumers and businesses can do to prevent such risks.

Who Is ROMOSS?

ROMOSS is a Chinese electronics brand founded in 2012 under Shenzhen ROMOSS Technology Co., Ltd. The company quickly established itself in China’s domestic electronics market before expanding internationally through platforms such as Amazon, AliExpress, and B2B trade shows. ROMOSS offers a variety of charging solutions, including:

– High-capacity mobile power banks
– Solar and outdoor power solutions
– Fast-charging data cables and adapters

The brand is known for its affordability and wide range of products, but the recent safety concerns have sparked serious discussions about quality control.

What Happened: The Explosion Incident and Recall

In mid-2024, a ROMOSS 20,000mAh power bank overheated and caught fire aboard a Hong Kong Airlines flight. The flight made an emergency landing. Thankfully, no passengers were seriously injured, but the incident triggered an immediate investigation. ROMOSS later announced a voluntary recall of nearly 500,000 power banks manufactured between June 5, 2023, and July 31, 2024.

It wasn’t just ROMOSS affected. Anker, another major player in the power bank industry, also issued a recall involving the same batch of battery cells from a common supplier.

Root Cause: Faulty Battery Cell Manufacturing

Investigations traced the issue to Amperex Technology Limited (ATL), one of the largest lithium battery suppliers globally. ATL outsourced the production of two batches of cells to a smaller subcontractor factory in Jiangxi, China. This subcontractor replaced the original separator material in the battery — a vital safety layer that prevents the anode and cathode from touching. This unauthorized change introduced serious risks of short circuits and thermal failure.

Since these battery cells were used by both ROMOSS and Anker, both brands took immediate action to remove affected products from the market.

Why Power Banks Explode: A Technical Breakdown

A power bank is composed of three main components:

1. Battery Cells – Store the energy
2. PCB Circuit Board – Controls power flow and adds safety protections
3. Housing – Physical casing that protects internal components

Most explosions result from poor-quality battery cells, malfunctioning PCBs, or physical damage to the unit. Low-cost manufacturers may use defective or recycled cells without rigorous testing, greatly increasing the risk.

Battery Types and Their Safety Differences

There are two common battery cell types used:

– 18650 lithium-ion cells: cylindrical, inexpensive, but more prone to overheating.
– Lithium polymer cells: flat and compact, more stable, used in high-end models.

Polymer cells are generally safer because they don’t contain free-flowing liquid electrolyte. If they fail, they tend to burn slowly rather than explode violently. That’s why top-tier power bank manufacturers now prefer lithium-polymer cells for safety and performance.

How the PCB Affects Safety

The PCB (Printed Circuit Board) inside a power bank ensures the battery is charged and discharged within safe limits. A good PCB includes:

– Overcharge protection
– Over-discharge protection
– Overcurrent and voltage limits
– Thermal protection
– Short circuit cutoff

PCBs without these features are risky. They may allow overcharging or over-discharging, causing batteries to swell, heat up, or ignite.

How User Behavior Can Increase Risk

Even if a power bank is manufactured to high safety standards, improper use can still lead to accidents. Common user mistakes include:

– Leaving the power bank in hot environments, like a closed car in summer
– Charging in confined spaces, such as under pillows or inside drawers
– Continuing to use a power bank that shows signs of damage or swelling
– Charging devices overnight without supervision

These habits trap heat or increase internal pressure, potentially leading to overheating or even combustion. Educating users on these risks is essential.

Emergency Response: What To Do If a Power Bank Catches Fire

If you notice your power bank overheating, swelling, or emitting smoke, here’s what to do:

1. Disconnect the power bank immediately using non-metallic tools.
2. Do not touch it directly; move it to a fire-safe area.
3. If it catches fire, use a dry powder or CO₂ fire extinguisher.
4. Avoid inhaling fumes; battery fires release toxic chemicals.
5. Call emergency services if the fire is large or uncontrollable.
6. Preserve the damaged product for investigation or recall reporting.

What We Do Differently as a Power Bank Manufacturer

As a professional power bank manufacturer with over 10 years of OEM/ODM experience, our products have never encountered explosion or fire issues. Here’s why:

Only Use A-Grade Battery Cells

We source lithium polymer cells exclusively from verified premium suppliers, avoiding cheap or unverified cell batches.

Strict Incoming Material Inspection

Every batch of incoming battery cells, PCBs, and components is subjected to quality control before production begins.

Advanced PCBs with Temperature Monitoring

Our custom-designed PCBs include temperature sensors and multi-layer protection circuits to shut down power when overheating occurs.

7-Stage Quality Control System

Our QC steps include:

Incoming inspection

Soldering and assembly testing

Voltage test

Current Test

Appearance inspection

Aging tests (minimum 8–12 hours)

Final packaging inspection

Compliance with Global Certifications

All our products come with certifications such as CE, RoHS, MSDS, UN38.3, and air/sea shipment reports, ensuring global safety standards are met.

Tips for OEM and Wholesale Buyers

When sourcing power banks for  your brand or retail business, avoid the mistakes many make by following these tips:

Don’t Chase the Lowest Price

Cheap products often mean compromises in battery quality, PCBs, and testing.

Check Factory Capabilities

Reliable factories have:

Clean workshops

Multiple production lines

Proper testing equipment

Certifications

Ask About Testing Protocols

Confirm whether the factory runs:

Aging tests

QC team

incoming materials testing

Understand the Basics of Power Bank Design

Learn the difference between 18650 vs. polymer cells, or good vs. bad PCB boards, so you can ask informed questions.

Choose Factories Offering OEM/ODM Services

Factories like ours offer:

Custom logo printing

Custom packaging

Warranty and after-sales services

Conclusion

The ROMOSS battery explosion is a case study in what can go wrong when supply chains aren’t tightly controlled. It also shows how critical battery safety is in modern electronics.

For manufacturers, it’s a reminder that shortcuts in sourcing or testing can have severe consequences. For buyers and consumers, it highlights the importance of choosing power banks not just for price or capacity, but for quality and safety as well.

At D-WIRELESS, our mission is to produce power banks that are as reliable as they are powerful — built to meet the demands of modern users without compromising safety. Whether you’re buying in bulk or building your brand, we’re here to help you power safely.

Frequently Asked Questions

Q1: Is it safe to leave a power bank plugged in?
A: While most power banks have overcharge protection, it’s best to unplug them after charging to preserve battery life and prevent overheating.

Q2: What happens when a power bank swells up?
A: Swelling is a sign of internal failure. Stop using it immediately and dispose of it at a battery recycling center.

Q3: Is it okay to leave a power bank charging overnight?
A: Not recommended. Charging overnight increases the chance of overheating, especially with low-quality units.

Q4: Why is my power bank hot when charging?
A: A slight warmth is normal, but excessive heat could mean the PCB or cell is faulty. Stop charging and let it cool down.