Half Million Power Tool Batteries Recalled Over USB-C Charging Fire Risk
Adding USB-C ports to high-capacity lithium batteries introduces new failure modes that require careful engineering.
The recall details
Greenworks Tools recalled approximately 554,780 Kobalt-branded power tool batteries after 34 reports of batteries smoking, sparking, or catching fire while charging through their USB-C ports. The affected batteries were designed for yard work equipment.
The US Consumer Product Safety Commission confirmed the fire hazard poses a serious injury risk. The failures occurred when batteries were inserted in tools and charged via the USB-C port, not during normal tool operation.
Design challenges with dual-purpose ports
Adding USB-C charging to high-capacity lithium battery packs creates complexity beyond typical consumer electronics. These batteries store significantly more energy than phones or laptops, and the charging circuitry must handle both the battery's own charging and potentially power delivery to connected devices.
The incident highlights the care required when integrating consumer-friendly features like USB-C into industrial battery systems. Engineers must account for fault conditions, thermal management, and charging state interactions that may not be immediately obvious during initial design.