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A Swollen Battery Cracked the Back Cover. Here Is How Much Room a Battery Compartment Actually Needs.

When a swollen battery cracks the back cover, most of the time it is not a cell quality problem — the structure simply never gave the battery room to expand.

  • Swollen battery can crack back cover due to insufficient Z-axis clearance.
  • Radial or single crack in center indicates inadequate space for battery expansion.
  • Reserve 5% to 8% of cell's nominal thickness for expansion clearance.

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