The circuit board is made up of many many tiny little
transistors. These transistors are usually made up of p-well and
n-wells, they are side by side, and very near to each other, which
will facilitate the movement of the electron when an electricity
circuit passes through.
What I can think of is that the faulty batteries are easily heated
because their power is different. P=VI, more power=more
current=more heat generated. This may cause expansion in the wells,
causing the distance between them to be shortened, and when they
touch each other, the transistor gets fused and cause an
'explosion'.
My batteries are of same voltage, but the mmAh is different.
Something like those GP batteries, they have 600 800 100 1200 and
1400. Original Ipod batteries come with 400mmAh, which is the best
in the market at that point of time. If you choose to replace it at
ipod centre, they will just give u a refurbished set and transfer
your data over. I'm changing the battery for you, of a higher
capability. rating at 580mmAh. This will make your battery seem to
last longer by about an hour or so. However there are 600 and
750mmAh ones, which will make your ipod last 20-50% longer. But I'm
not going to try that because the rating is too high for me to try.
I have my reservations about overheating of ipod too.
Nevertheless, there are still no cases of ipod melting or
exploding. Do not worry about that. Trust their technology and
trust me. haha.