January 9, 2026 – An incident report details multiple instances of the NeoCharge Smart Splitter 240V overheating and melting during normal operation, raising significant concerns about potential fire hazards. Consumers report a burning smell and visible signs of extreme heat, including melting of the device’s outer casing and plug area.
Product Details
Incident Overview
The incident report describes a consumer’s experience with the NeoCharge Smart Splitter 240V, used for charging an electric vehicle (EV). The unit was reportedly installed precisely according to the manufacturer’s safety guidelines and direct instructions. The EV’s power draw, approximately 22 amps, was well within the stated load limits of 24 amps, indicating that the device was not being overloaded. This particular incident involved the second replacement unit the consumer received, after the first unit had simply ceased functioning.
After a period of routine use, the user noticed a distinct burning smell emanating from the Smart Splitter. Upon inspection, the outer shell casing of the device was found to be exceptionally hot, registering 145°F and continuing to climb. Further examination revealed clear signs of overheating and melting around the plug area. The burning smell persisted whenever the EV was charging.
The consumer confirmed that the EV charger, the electrical outlet, and the surrounding wiring setup were all functioning normally and showed no signs of issues. The Smart Splitter itself was identified as the sole source of the heat and burning odor. A subsequent online search by the consumer revealed numerous similar reports from other users, describing identical overheating and melting incidents with the same product, amplifying concerns about a recurring manufacturing defect or design flaw. No injuries were reported, but the evident burning smell and melting components presented a serious and immediate fire risk, prompting the consumer to immediately disconnect the unit.
Safety Concerns
The reported incidents of the NeoCharge Smart Splitter 240V overheating and melting present a range of severe safety concerns for consumers and their property:
- Immediate Dangers: The primary and most critical danger is a significant fire hazard. Extreme overheating and melting of electrical components can ignite nearby flammable materials, leading to house fires, vehicle fires, and potentially catastrophic property damage. There is also a risk of electrical shock if the device’s insulation breaks down due to melting, exposing live wires.
- Long-Term Risks: Repeated incidents of failure, even if not immediately leading to fire, erode confidence in product safety and indicate a systemic problem. If left unaddressed, these incidents could escalate, leading to more widespread fires or injuries. The device’s function is to manage high-voltage electricity, and any failure in its integrity poses a continuous, underlying risk.
- Who Might Be Affected: Owners of the NeoCharge Smart Splitter 240V, particularly those using it for EV charging, are directly at risk. Anyone present in a home or garage where such a device is operating is potentially exposed to the dangers of fire or electrical hazard.
- Property Damage Potential: A fire originating from an overheating Smart Splitter could cause extensive damage to the electric vehicle, the garage, and the entire residential property. The financial and emotional toll of such damage can be devastating.
What Consumers Should Do
Given the serious nature of the reported incidents, consumers who own a NeoCharge Smart Splitter 240V should take immediate action:
- Immediate Steps to Take: If you notice any burning smell, unusual heat, discoloration, or melting of your NeoCharge Smart Splitter, immediately unplug the device from the wall outlet. Do not attempt to continue using it or repair it yourself. Ensure the area around the device is clear of flammable materials.
- How to Check if You Own the Affected Product: Verify if you own the NeoCharge Smart Splitter 240V. Check the product’s labeling, packaging, or your purchase records for the model name and manufacturer.
- Prevention Measures: Until the issue is fully resolved by the manufacturer, consider discontinuing use of the product. If you must use it, frequently inspect the unit and surrounding electrical connections for any signs of overheating (e.g., discoloration, plastic deformation, unusual odors, or excessive heat to the touch). Ensure proper ventilation around the device. Always use dedicated circuits as recommended for EV charging.
- Reporting Procedures: Report any incidents of overheating, melting, or malfunction immediately to the U.S. Consumer Product Safety Commission (CPSC) at SaferProducts.gov. You should also contact NeoCharge Inc. directly to report the issue and seek guidance. Collecting photographic evidence of the damage can be highly beneficial for reporting.
Manufacturer’s Response
The manufacturer, NeoCharge Inc., has confirmed receiving the incident report regarding the Smart Splitter 240V. However, specific details concerning their investigation, proposed solutions, or actions taken in response to this particular incident and the broader pattern of reported overheating are not provided within the incident report. Consumers experiencing issues are encouraged to contact NeoCharge Inc. directly.
Legal Help Available
If you or a loved one has been injured by a defective product or suffered property damage due to a product malfunction, you may be entitled to compensation. The experienced product liability attorneys at Farzan Law understand the complexities of defective product cases and can help you navigate the legal process.
Contact us today for a free consultation: 424-325-3112
Our legal team has successfully represented clients in product liability cases involving defective appliances, automotive defects, medical devices, and consumer products. We work on a contingency fee basis, which means you don’t pay unless we win your case.
Note: This information is based on incident reports provided by the U.S. Consumer Product Safety Commission. If you find information that is incorrect, please contact us immediately so we can correct the post to reflect accurate information.
Disclaimer: The information provided in this post is not intended to be legal or medical advice. This article is based on publicly available incident reports. The incidents mentioned have not necessarily been independently verified or adjudicated.