I have two PCCs, both about a year old and
both just started bulging. I didn't even realize it at first because the only thing I noticed was that the hinge was messed up on one of them and the lid wouldn't close all the way. I thought maybe I'd dropped it and forgotten or something and damaged the hinge.
I used it that way for about a week before the lid/hinge situation suddenly got worse. Then I knew something was up. On closer examination of the case, I could see the back was bulging. That's why the lid wouldn't close anymore - the case was warped from a bulging battery. Eek. I checked my other PCC and, though it has no lid problem, I can see a small gap along the hinge and slight bulge on the back of the case. The worst of my PCCs was retired immediately, but I'm still using the one with the slight bulge until the new ones I ordered arrive.
I wonder if one year is sort of the lifespan of these PCCs. Anyone else notice this happen at about that age or is it just a freak coincidence for me?
Pictures below are what the worst one looks like. It's hard to see that there's a bulge from the photos, but if you look at the curvature of the reflections on the back of the case, you can tell it's swollen.