The PC maker recalled 54,000 last May, and 70,000 in May 2009, as well.
The latest recall affects batteries in HP and Compaq laptops, including models from the Pavilion and Presario lines sold in 2007 and 2008.
"The recalled lithium-ion batteries can overheat and rupture, posing fire and burn hazards to consumers," the US Consumer Product Safety Commission said.
"Since the May 2010 recall expansion, HP has received 40 additional reports of batteries that overheated and ruptured, resulting in seven burn injuries, one smoke inhalation injury, and 36 instances of property damage," it added.
HP warned customers not to assume laptops given the all clear in previous years to assume their batteries are safe. "HP urges customers with notebooks listed in the 2009, 2010 and 2011 announcements to validate the battery even if they have validated it previously," it said.
Customers can check if their laptops are affected on the HP site.
This article originally appeared at pcpro.co.uk