Just spent 45 minutes on the phone with Apple Support in Australia regarding a battery in a MacBookPro that swelled, like others above, within an hour while on charge. After removing it and allowing it to either cool or cook itself in a safe location (concrete floor) I refitted it and saved the system profiler information. The battery had completed 298 cycles and had a full charge capacity of 2450mAh, the condition was listed as "Check Battery".
I checked the website as others have and phoned the local agent who said "bring it in". After taking the battery to the agent and supplying the requested information I was presented with a minimum service charge guarantee form to sign, "just incase the battery was not covered by the replacement program", which I thought was odd considering on the phone I was told it met the criteria as per the website information. Unfortunately I don't have signing authority so advised I was unable to sign the form. The next day I received a call asking if the laptop could be brought in, which it was, then I was given instruction to call Apple as the laptop was not on the list (?) and replacement would have to be authorised by customer support.
At this point customer support have advised the battery is not going to be replaced as it is outside the warranty and (as quoted from the response sheet?) "It is quite natural for a battery to either expand or fail to hold a charge when it fails".
With 25 Years experience as a technician, specialising for 15 years in battery maintenance, I'd like to challenge that statement.
A Lithium Ion cell should not expand, unless its internal chemical composition includes impurities that cause an unexpected/unintended reaction or it is incorrectly charged resulting in the cell becoming unable to vent during the change of state of internal chemicals. This will either occur as a result of a manufacturing defect or a charging error.
Given the high internal resistance of the cells being used this could result in cells exploding. The battery pack in our unit expanded with sufficient force to peel open the internal tin case and bow the lower Aluminium sheild.
Many Li-Ion battery manufacurers quote 1000 cycles as the lifespan of a cell, thats about 3 years if you plug the power in most days (a cycle is each time you connect the charger, not just each charge of the battery). So I was not concerned when the battery in my G4 PowerBook needed replacing after 3 years, many video camera batteries need replacing after 2 years, often due to the contitions under which they operate.
Apple seem to have missed the point they built the battery and charger so the manufacturing defect is wholly their responsability. Regional variations of interpretation of liablity aside they need to address the problem that they are producing cells that expand and were NOT CONSTRUCTED "Free of manufacturing defects".
What will happen if the new fully sealed laptops suffer battery expansion in 2 years? Will it just be tough when the keyboard bows or, like the current version, the trackpad stops reacting because the cells are squashing it from below. How much force will it take to crack the new unibody case?
I know many people buy and use Apple computers, happy to pay the price premium for a product that lasts longer and (ussually) has excellent customer support.
What is the cost to Apple for the loss of faith in the value of their laptops?