Immediate action: before arriving at the airport, locate the battery label or product specification and confirm the Wh value. Batteries rated <100 Wh are normally permitted in carry‑on without advance approval; batteries between 100–160 Wh require airline approval; batteries over 160 Wh are not permitted on passenger aircraft. Spare battery packs must not be placed in checked baggage and should be carried in the cabin with terminals protected.
How to identify the pack: look for a sticker on the battery or inside the compartment showing voltage (V) and capacity (mAh) or a direct Wh number. Use the conversion Wh = (mAh × V) / 1000. Examples: 10,000 mAh at 3.7 V ≈ 37 Wh; 20,000 mAh at 3.7 V ≈ 74 Wh; 26,800 mAh at 3.7 V ≈ 99.16 Wh. If only mAh is listed and voltage is missing, consult the user manual, FCC/CE documentation, or the retailer’s tech sheet for the nominal cell voltage.
Practical recommendations at check‑in and security: if the pack is labeled under 100 Wh, keep it powered off and in the cabin; tape or cover exposed terminals; carry a copy of the spec or a screenshot showing the Wh rating. If the label shows 100–160 Wh, contact the airline before travel to request written approval and bring that approval to the airport. If the pack exceeds 160 Wh and the device is motorized or designed to assist movement, do not attempt to transport it on a passenger flight.
If no labeling or documentation is available, treat the unit as potentially regulated: contact the manufacturer or seller and ask for the battery chemistry and Wh rating (refer to the model number or FCC ID). Absent a reliable answer, remove the battery where possible and retain it for hand carriage or postpone the flight – carrying an unidentified high‑capacity pack in checked baggage risks confiscation or fines.
Integrated power packs – immediate recommendation
Recommendation: prefer models with removable Li‑ion packs rated at 100 Wh or less; transport those packs in the cabin, disable all electronics, and never stow spare batteries in checked baggage.
Regulatory limits: most airlines follow IATA/FAA guidance – cells up to 100 Wh are permitted in carry-on without airline approval; units between 100 Wh and 160 Wh require airline approval and are typically limited to two per passenger; cells exceeding 160 Wh are not allowed on passenger aircraft.
How to verify capacity: look for a marked Wh rating on the battery label or in the product spec sheet. If only mAh is listed, convert using Wh = (mAh/1000) × V. Example: a 20,000 mAh pack at a nominal 3.7 V equals 74 Wh; a 10,000 mAh pack at 3.7 V equals 37 Wh.
Practical checklist before flying: confirm removability (easy-release latch or access panel), note the exact Wh or mAh+V, tape or cover exposed terminals, carry packs in original sleeves or a protective pouch, and tell the airline agent if a pack exceeds 100 Wh and approval has been requested.
If built-in power modules cannot be removed, choose non-powered suitcase alternatives or convertible carry options to avoid potential gate denial – see best luggage sets that wont break the bank and best travel convertible tote backpack for options without integrated batteries.
Maintenance tip: for hard-shell exteriors use gentle cleaning; for stubborn dirt consider low-pressure washers reviewed at best pressure washer for monobloc, but avoid high-pressure settings near seals, zippers, and electronic compartments to prevent moisture ingress.
How to check your model number to verify battery inclusion
Find and copy the exact model/part code from the product label–include letters, hyphens and digits so you can match it to the manufacturer’s specifications.
Common label locations: inside the main compartment sewn tag, inside zippered organiser pockets, under the fabric liner, on an adhesive sticker on the case base, on the handle mounting, on the hang tag or on the original box and packing slip. Photographs help if the print is small.
If the label is missing or unreadable: check the retailer order page, invoice, or the barcode/UPC on the packing box; many online product pages list the exact model or SKU used by support teams.
How to verify inclusion using the model code: enter the copied code into the manufacturer’s support/specification pages or product manual PDF. Inspect the spec sheet for lines named “Battery type”, “Battery capacity”, “Removable battery”, “Internal battery”, “Battery compartment”, or for regulatory markings such as “UN3481” or “UN3090”.
What to look for in specifications: chemistry label (often shown as a short form like “Li‑ion”), rated voltage (V) and energy (Wh) or capacity (mAh). Example formats: “7.4 V / 20 Wh (2700 mAh)”, “Battery: removable, 10 Wh”. A plain “No battery” or absence of those entries usually means no installed power source.
When the online spec is ambiguous: contact manufacturer support with the exact model and serial numbers, attach clear photos of the label, interior pocket areas and any compartments. Request a written confirmation whether the specific model includes a rechargeable cell and whether it is removable.
Do not open sealed modules yourself; if a physical inspection is needed, ask an authorized service center or the seller to confirm presence and type of the cell to avoid warranty or safety issues.
Locating battery labels and specification sheets on brand connected suitcases
Check the exterior zipper pocket next to the charging port first: most models include a white adhesive label listing capacity (Wh or mAh), voltage (V), cell chemistry (often shown as “Li‑ion”), and regulatory marks (UN 38.3 or equivalent).
Where labels typically appear
Common physical locations to inspect: exterior pocket near USB/charging port, inside the main compartment under the lining, sewn-in fabric tag near the handle, underside of the telescoping handle housing, inner base plate behind the wheel bay, and inside a dedicated battery compartment accessed by a taped flap or small screw. If a battery pack is removable, a label is usually on the pack itself.
How to obtain the official specification sheet
Locate the model and serial numbers on the fabric hangtag or molded base plate, then use those identifiers on the manufacturer’s support/downloads page to pull the technical data sheet or user manual PDF. Search terms to use on the site: “specifications”, “battery”, “UN 38.3”, “Declaration of Conformity”, “SDS” or “safety data sheet”. If the online search returns nothing, request the battery spec sheet by email or phone from support and provide both model and serial.
Label field | Meaning | Recommended action |
---|---|---|
Capacity (Wh or mAh) | Amount of stored energy; Wh is the regulatory standard. mAh often paired with voltage. | If only mAh listed, convert to Wh: Wh = (mAh / 1000) × V. Keep a record of the calculated Wh. |
Voltage (V) | Nominal pack voltage needed for conversion and compliance checks. | Use to convert mAh → Wh; check against airline limits (see next row). |
Watt-hours (Wh) | Regulatory threshold for carriage: common cutoffs are 100 Wh and 160 Wh. | If Wh ≤ 100, normally permitted in carry-on. If 100 < Wh ≤ 160, airline approval required. If Wh > 160, carriage is typically prohibited. |
Cell chemistry | Specifies cell type (example: “Li‑ion” or “rechargeable cell”). | Record the chemistry; it determines applicable transport rules and required documentation. |
UN 38.3 / Test marks | Indicates the pack passed mandatory transport tests. | If absent, ask support for UN 38.3 test report or certificate before travel. |
Manufacturer / part number | Identifies the exact battery or pack model. | Use in support requests and when searching the manufacturer site for a spec sheet. |
Warnings / baggage guidance | May state carry-on vs checked-baggage instructions. | Follow the printed guidance and cross-check with airline rules; when in doubt, keep pack in carry-on and declare if required. |
Example conversion: a pack labeled 7000 mAh and 7.4 V → Wh = (7000 / 1000) × 7.4 = 51.8 Wh. Save label photos and the downloaded spec sheet; airlines and security may request both at check-in or screening.
Interpreting mAh and Wh values on batteries to determine airline compliance
Convert mAh to Wh using Wh = (mAh × V) / 1000; use the pack’s printed nominal voltage (if absent, use 3.7 V as a conservative default) and rely on the manufacturer’s stated Wh when present.
Regulatory thresholds: ≤100 Wh – allowed without airline approval for installed cells and for spare packs carried in the cabin; 100–160 Wh – airline approval required and limited to two spare packs per passenger; >160 Wh – forbidden on passenger aircraft.
When only mAh is shown, calculate with the pack voltage. Examples at 3.7 V: 5,000 mAh = 18.5 Wh; 10,000 mAh = 37 Wh; 20,000 mAh = 74 Wh; 30,000 mAh = 111 Wh (requires airline approval for spares). For multi‑cell packs, use pack voltage (e.g., 3 cells in series at 3.7 V → 11.1 V: 2,700 mAh × 11.1 / 1000 = 29.97 Wh).
Watch for marketing mAh figures quoted at output voltages (5 V USB) rather than cell voltage; that inflates apparent capacity. If both mAh and Wh are printed, accept the Wh figure. If only mAh is printed, document your Wh calculation and retain the specification sheet or label for inspection.
Handling and presentation: keep spare packs in carry‑on only, protect terminals with tape or original packaging, limit spare quantity per airline rules, and request written approval when planning to travel with packs in the 100–160 Wh range.
Airline and TSA rules: carry-on versus checked baggage for brand battery packs
Always carry spare high-energy battery packs inside the cabin; do not place spare cells in checked baggage.
- Regulatory thresholds
- Up to 100 Wh – widely accepted in cabin without airline approval for installed or spare units; carriers may set quantity limits.
- Greater than 100 Wh and up to 160 Wh – permitted only in the cabin and typically require prior airline approval; most carriers restrict spares to two units per passenger.
- Above 160 Wh – not allowed on passenger aircraft (both cabin and checked) except under specific, pre-approved cargo arrangements.
- TSA-specific points
- Spare battery packs are prohibited in checked bags; they must be carried in carry-on items.
- Devices with non-removable packs can be transported in checked baggage, but placing operational devices in the cabin is preferred by many carriers and inspectors.
- All battery terminals must be protected against short-circuit (original packaging, taped terminals, or terminal caps).
- Practical airport actions
- Verify the pack’s Wh rating from the label or spec sheet before travel; if label missing, obtain written manufacturer documentation.
- Contact the airline at least 48 hours prior to departure when any pack exceeds 100 Wh or when carrying multiple spare units; secure written approval when requested.
- At security screening, keep packs accessible in the carry-on for inspection; remove from bags if requested and power off devices.
- If gate or check-in staff insist a pack cannot be carried, do not attempt to check it; seek airline and TSA guidance – confiscation or return will be enforced if rules are broken.
- Handling and packing recommendations
- Place each pack in individual plastic bags or use original packaging to isolate terminals.
- Limit the number of spare packs in the cabin to the minimum necessary for personal use.
- Label carry-on with contact information if carrying high-capacity packs; have spec sheets ready for inspection.
- International travel notes
- Follow IATA/ICAO rules and the departure carrier’s policy; EU/UK/US authorities share similar thresholds but enforcement and allowable quantities can vary by airline and country.
- For connecting flights, comply with the most restrictive rule across all carriers involved.
Remove internal Li-ion pack from TC-branded connected suitcase: step-by-step checklist
Power the case off, remove any external power modules, and disconnect the internal Li-ion connector before loosening screws or prying panels.
Tools and protective gear
Phillips #000 and #00, Torx T6 and T5 drivers, plastic spudger/pry tool, needle-nose pliers, multimeter (DC volts), electrical tape, cut-resistant gloves, safety glasses, anti-static wrist strap, non-conductive work mat, zip bags or a fire-resistant metal container for temporary storage.
Step-by-step removal checklist
Step 1 – Prepare workspace: work on a flat non-metal surface in a ventilated area, empty the case, unzip/remove soft liners that block access panels, and document panel screw locations with a photo before removal.
Step 2 – Power down and secure electronics: shut the electronics off, remove any removable power bank from exterior pockets, and pull the external USB or charging cable; confirm indicator LEDs are dark.
Step 3 – Access panel removal: remove screws holding the access plate; keep screws in a labeled container and note which holes correspond to which screws.
Step 4 – Locate the battery pack: identify the rectangular pack usually held with Velcro or screws in a foam tray; photograph the connector and label for records (model/code, rated voltage, capacity).
Step 5 – Verify connection type: if pack uses a removable plug, depress the latch and pull straight on the connector; if wires are soldered or potting obscures the leads, stop and proceed to a certified repair or recycler–do not cut glued or soldered joints unless you have soldering experience and proper ventilation.
Step 6 – Disconnect and isolate terminals: after unplugging, wrap exposed terminals with electrical tape or place terminal ends into a non-conductive insulating bag; confirm open-circuit voltage with a multimeter and record the value on the battery label.
Step 7 – Secure the pack for transport: place the removed pack into a zip bag or fire-resistant metal box; add a removable label with removal date, estimated state of charge (approx %), and the pack serial/model.
Step 8 – Reassemble the case: reattach access panel and screws, leaving any mounting brackets empty or fitted with original foam; verify all locks and zippers operate and that no wiring is pinched.
Step 9 – Damaged or swollen pack procedure: if the pack is bulging, punctured, leaking, warm, or smoking, move the case outdoors to a non-combustible surface, place the pack in a metal container away from flammable materials, and contact local hazardous-waste services or the manufacturer’s emergency support line–avoid handling the cell directly.
Step 10 – Disposal and handoff: deliver the packed Li-ion unit to the manufacturer’s take-back program, an authorized electronics recycler, or a municipal hazardous-waste facility; provide the photo and recorded voltage on handoff paperwork.
After removal, keep the removed pack separated from other batteries, do not tape over vents or crush the pack, and do not attempt to reuse a pack that was soldered in place or shows physical damage.
Actions at check-in or gate if the bag’s battery is non-removable or exceeds allowed capacity
Request airline approval for cabin carriage immediately; if approval is refused, you must either ship the item via the airline’s cargo/hazardous‑goods service, remove the battery before travel, or leave the item behind.
Have these documents ready to show the agent: a clear photo of the battery label with watt‑hour (Wh) rating, the manufacturer’s specification sheet or user manual, and the suitcase model number. Presenting Wh value speeds decision‑making.
Apply capacity thresholds: devices rated ≤100 Wh are normally accepted in the cabin when installed; devices rated 100–160 Wh require explicit airline approval (limited quantity may apply); devices rated >160 Wh are not permitted on passenger aircraft and must be transported as cargo under hazardous‑materials rules.
If the battery is non‑removable and the Wh rating is ≤100 Wh, ask the agent to tag the item for cabin carriage and to note the approval on your boarding pass or manifest. Obtain a written note or email from the airline employee confirming the authorization.
If the battery is non‑removable and the rating falls between 100–160 Wh, request immediate escalation to the airline’s dangerous‑goods (DG) desk. Do not board until you receive explicit approval; if the DG desk approves, obtain written confirmation of quantity limits and any required packing or terminal‑insulation steps.
If the battery is non‑removable and the rating exceeds 160 Wh, advise the agent you need a cargo shipment. Ask for contact information for the airline cargo office and confirm whether same‑day cargo acceptance is possible; expect additional paperwork, DG labeling, and fees. Do not attempt to board with the item.
If removal is impossible at the airport and the airline refuses cabin carriage, request the options list in writing (refusal, cargo quote, or disposal). Photograph the item and all staff responses; if you must abandon the bag, secure a written refusal receipt from the airline to document the refusal to transport.
At the gate, declare the item to the gate agent before boarding. If approval paperwork is not already recorded, do not board. Gate staff can prevent carriage; insist on a DG desk call or supervisor review and record the outcome.
Packing requirements the airline may ask you to follow: device powered off, external switches blocked, terminals insulated (non‑conductive tape), and each item individually protected against short circuit. Follow any airline‑issued instructions exactly and keep a copy.
If cargo shipment is required, use only an airline cargo division or a carrier licensed for hazardous materials. Ask the agent for timelines; same‑day passenger departure rarely equals same‑day cargo acceptance, so plan for delayed delivery.
Useful short phrases to use with staff: “The suitcase contains a sealed rechargeable battery rated XX Wh – may I have dangerous‑goods approval for cabin carriage?”; “Please contact your DG desk; I need written confirmation of approval or refusal.”