Newer iPhone Batteries Swell in Flight, Galaxy Note 7 Nightmare?

Recently, new and worrying reports have begun circulating among the communities of Apple device owners, suggesting that some of the most recent models, including the iPhone 16 Pro Max and the iPhone 15, may suffer from a battery assembly issue.

Although at present these are apparently isolated cases, the nature of the incident inevitably evokes the specter of batterygate that hit the Samsung Galaxy Note 7 years ago, raising questions about in-flight safety and the build quality of the new units.

iPhone Batteries: High-Altitude Swellings

Everything started from the direct testimony of a user who shared a frankly alarming experience regarding their iPhone 16 Pro Max.

According to reports, during a commercial flight, the device began swelling noticeably, to the point of exerting enough pressure to cause the rear panel to detach from the aluminum body of the smartphone.

The peculiarity of this incident, promptly documented with a photograph taken on board, lies in the device’s behaviour once landed: as soon as the plane touched down and the ambient pressure returned to ground levels, the phone deflated, returning to its normal size as if nothing had happened.

The situation became more complicated when, following this first report, another user intervened confirming they had lived an identical experience, but with an iPhone 15.

Also in this case, the device underwent a worrying deformation during two different flights, and then returned to its normal shape once back on land.

These coincidences suggest that this is not a single event tied to a single unlucky unit, but that there could be a batch of batteries in circulation more sensitive to environmental changes.

A Matter of Physics and Chemistry

The most credible hypothesis holds that some batteries may contain residual gas inside them, the result of imperfect assembly or an abnormal chemical reaction.

Under normal conditions, on the ground, atmospheric pressure is sufficient to contain this gas, keeping the battery in its standard shape. However, during a flight, especially if conducted on older aircraft where cabin pressurization may not be optimal or as stable as in latest-generation models, the external pressure decreases.

This reduction in external pressure allows the gas trapped inside the energy cell to expand, following the fundamental laws of physics, causing the swelling of the battery and the consequent opening of the phone’s chassis.

This would perfectly explain why the problem disappears once landed: the increase in atmospheric pressure at ground level compresses the gas again, hiding evidence of the defect. Furthermore, the fact that the second user no longer experienced the problem after replacing the battery supports the thesis that these are specific faulty components rather than a design flaw of the entire model.

What to do in these cases?

The safety implications of these events should not be underestimated. Being in flight with a swollen lithium battery represents a concrete risk, as the mechanical deformation can lead to internal short circuits and the dreaded “thermal runaway”, i.e. a chemical fire difficult to extinguish.

The recommendation in these cases is simple: if a passenger notices a swelling of their device, they must alert the cabin crew, trained to handle potential fires of electronic devices.

Ignoring the problem hoping it passes could endanger the safety of hundreds of people.

Always Document

Beyond the physical danger, there is a practical issue related to after-sales support. Since the phone returns to “normal” on the ground, proving the defect to Apple Store staff can become a frustrating undertaking.

The user with the iPhone 15 recounted that they were initially refused repair because technicians, not detecting visible anomalies in-store, argued that such an event was impossible.

Only by providing irrefutable photographic evidence of the flight occurrence was it possible to obtain the battery replacement.

It is important to note, finally, that even if the phone seems to be intact, the expansion has almost certainly compromised the seals that guarantee water and dust resistance, making the device vulnerable to future damage.

Although it seems to be a rare phenomenon, prudence is mandatory.