Wireless power innovates toy safety

By Eric Biel, Director of Strategic Partnerships, Powercast

Over a decade after the problem first gained widespread attention, thousands of children continue to suffer injuries from ingesting or mishandling these tiny batteries each year. In the most tragic cases, the result is fatal.

The challenge is not just legislative—it’s engineering. That’s why the shift toward radio-frequency (RF)-powered or RF-recharged devices represents a significant innovation in consumer electronics. While eliminating batteries entirely is possible in select applications, the broader opportunity lies in reducing reliance on traditional batteries by enabling safe, wireless recharging. This approach addresses battery-related hazards while maintaining the convenience and functionality consumers expect.

Button batteries: a persistent engineering risk

The risks are well documented. According to the U.S. Consumer Product Safety Commission (CPSC), between 2011 and 2021, over 54,000 emergency room visits and at least 25 child deaths were linked to button battery exposure.

In addition, a 2022 study by Safe Kids Worldwide and Nationwide Children’s Hospital revealed a troubling trend: paediatric battery-related emergency department visits have more than doubled over the past decade, with incidents occurring every 75 minutes. Button batteries were involved in 85% of these cases, and 84% of affected children were aged five or younger. The study also found that 12% of battery exposures resulted in hospitalization, up from 7% in the previous decade.

However, enforcement and compliance remain inconsistent. A Consumer Reports investigation in 2023 found that nearly one-third of children’s products tested still posed button battery hazards, due to poor labeling or insufficient battery compartment protection.

Even industry experts like Dr. Toby Litovitz of the National Capital Poison Center have said this issue won’t truly be resolved until we stop relying on button batteries altogether.

RF wireless power: a long-awaited solution

This is where RF-based wireless power offers a transformative alternative. Using the same type of radio waves that enable Wi-Fi and Bluetooth, RF power technology can wirelessly deliver small amounts of energy to electronic devices. For applications like toys, remote controls, wearables, and other low-power consumer devices, this energy is sufficient to recharge batteries or in some cases eliminate the need for traditional replaceable batteries altogether.

Unlike inductive charging, which requires close contact and precise alignment (think of placing a phone on a charging pad), RF wireless power can transmit energy over distances—up to several metres — without physical connectors or exposed terminals. It also works in conjunction with other wireless technologies like magnetic resonance and inductive power for hybrid solutions where sealed rechargeable systems are preferred.

This opens the door to fully enclosed toy designs with no accessible battery compartment—dramatically improving safety while also enabling more durable, water-resistant, and creatively engineered products.

Design possibilities: from safe to seamless

RF wireless power isn't just a safety upgrade—it allows designers to rethink how toys function, interact, and recharge.

• A toy storage bin could double as a wireless charging station, automatically recharging any toy placed inside
• A board game could light up and interact with smart pieces placed on the surface, no cords or slots required
• A playroom shelf or TV stand could wirelessly recharge game controllers and devices using inductive charging up close and RF energy for longer-range, creating a seamless charge-as-you-store experience without cables

Key considerations for designers

For engineers and product developers looking to integrate RF wireless power into toys or other battery-free devices, several factors need to be considered:

• Power requirements: RF is best suited for low-power applications (typically under 100mW). For higher loads, hybrid models using rechargeable capacitors or batteries are more suitable
• Antenna design and placement: devices must include an RF energy-harvesting circuit and antenna optimised for the frequency used (typically in the 915MHz or 2.4GHz ISM bands)
• Regulatory compliance: while RF power transmission is FCC-approved, devices must meet emissions limits and other standards to ensure interference-free operation
• Coverage and range: power zones must be designed to ensure consistent energy availability where play or use is expected

When done well, RF-powered designs can operate indefinitely within a designated coverage area—removing the need for manual battery changes or charging cycles.

Safety by elimination, not mitigation

What makes RF power especially compelling from a safety standpoint is that it allows for elimination, not just mitigation, of the risk.

Rather than designing safety features around batteries —adding locks, latches, or labels—RF solutions enable products to be completely sealed, with no user-accessible power source at all. This inherently removes the choking hazard, the possibility of toxic leakage, and the need for parents or caregivers to maintain or monitor battery life.

This level of safety is not only achievable—it’s now technically and commercially viable.

The path ahead

As pressure mounts for manufacturers to build safer, more sustainable products, RF wireless power provides a roadmap for doing both. It reduces reliance on disposable batteries, cuts down on e-waste, and gives product designers greater freedom in form and function—all while significantly improving user safety.

Like all technology shifts, adoption will take time. But the case is growing stronger each year, especially as the limitations of conventional battery-powered designs become more apparent.

We cannot regulate our way out of every safety challenge— but we can design our way past them.