Can new litium batteries be carried in luggage on plane

Key limits: cells and power packs with an energy rating up to 100 Wh are permitted in carry‑on without airline approval; devices with installed cells are generally allowed in checked and cabin baggage if protected; units between 100 Wh and 160 Wh require airline approval and are limited to two spare units per passenger; any unit above 160 Wh is not permitted on passenger aircraft and must move as regulated cargo with a dangerous‑goods declaration.

Treat portable power sources not installed in equipment as spares: they must be transported in the cabin where a crew can access them in case of thermal runaway. Protect terminals against short circuits by keeping items in original packaging, using terminal caps, taping exposed contacts, or placing each item in an insulated pouch or separate plastic bag.

To check rating when only mAh is shown, use the formula Wh = V × Ah (use nominal cell voltage 3.7 V for common Li‑ion chemistry). Example: a 10,000 mAh power bank → 3.7 V × 10 Ah = 37 Wh, well below the 100 Wh threshold.

Declare any units between 100–160 Wh to the carrier before travel and obtain written approval if required. Keep units switched off, carry them in the cabin, and store them in the aircraft cabin locker or under the seat as instructed by crew. For shipments exceeding passenger limits, arrange transport through a certified freight forwarder under dangerous‑goods procedures.

Confirm the carrier’s policy and the departure/arrival regulator’s rules before departure; rules and enforcement vary by airline and state, and noncompliance can result in delays, seizure, or fines.

Transport rules for Li‑ion power cells on flights

Recommendation: Keep spare Li‑ion cells and portable power packs in cabin (carry‑on) only; do not put spare cells in checked baggage; installed packs inside devices should be switched off and protected against accidental activation.

Watt‑hour limits and airline approvals

• Up to 100 Wh – normally allowed in cabin without airline approval. Typical examples: smartphone cells, most tablet cells, and small power banks (10,000 mAh at 3.7 V ≈ 37 Wh).
• 100–160 Wh – permitted only with explicit airline approval; carriers commonly limit spares to two units per passenger and require a clear Wh rating on the pack.
• Over 160 Wh – not accepted on passenger flights as carry‑on or checked items; transport only as cargo under dangerous‑goods procedures with carrier acceptance.

Packing, labeling and practical steps

• Calculate Wh when rating is not printed: Wh = (mAh × V) / 1000. Example: 20,000 mAh × 3.7 V = 74 Wh.
• Protect terminals: cover exposed contacts with tape or keep cells in original retail packaging or individual plastic pouches to prevent short circuits.
• Keep spares in the cabin and separate from conductive items (keys, coins). Place devices with installed packs in carry‑on and power them off.
• Labeling: packs between 100–160 Wh must display the Wh rating; if missing, carry manufacturer documentation or serial/tech info for inspection.
• Quantity: for cells ≤100 Wh, airlines usually permit a reasonable number for personal use but limits vary–check carrier policy before travel.
• Security screening: have spare packs accessible for inspection; remove from carry‑on if requested by security staff.
• Check carrier and national aviation authority rules for the departure and arrival airports; different countries and airlines may impose stricter limits or paperwork requirements.

Failure to comply can result in confiscation, denied boarding, or fines–confirm acceptance with your airline before flying.

Li-ion, LiPo, Li‑metal and Wh limits: cabin versus checked baggage

Keep all spare Li‑ion/LiPo and primary lithium (Li‑metal) cells and packs in the cabin; only cells installed in equipment may be placed in checked baggage, and spare units must never be placed in checked baggage.

Quick reference rules (follow airline/operator instructions and label markings):

Handling and packaging requirements: tape or use insulating caps on terminals, keep spare cells in original packaging or individual plastic pouches, limit quantity per device and per passenger as shown on pack markings, and power off devices to prevent accidental activation. Always declare large (>100 Wh) packs to the airline and obtain written approval before travel.

How to find and calculate the Wh rating on cells and packs

Multiply nominal voltage (V) by ampere-hours (Ah) to get watt-hours (Wh): Wh = V × Ah. If capacity is given in milliamp-hours (mAh), convert to Ah by dividing by 1000.

Locate the product markings: look for a direct Wh value first. If absent, find voltage (V) and capacity (mAh or Ah), or a cell-count notation such as 3S2P, 4 × 18650, etc. If only a cell model is listed (e.g., 18650), look up that cell’s nominal voltage and typical capacity in its datasheet.

Series and parallel rules: series count (S) multiplies nominal voltage; parallel count (P) multiplies capacity. Example calculation from a labelled configuration: a 3S2P pack made from 18650 cells (nominal 3.6 V, 2500 mAh) has pack voltage = 3 × 3.6 V = 10.8 V; pack capacity = 2 × 2500 mAh = 5000 mAh = 5 Ah; Wh = 10.8 × 5 = 54 Wh.

Single-cell example: a cell marked 3.7 V, 2600 mAh → Ah = 2.6 → Wh = 3.7 × 2.6 = 9.62 Wh.

Power banks: manufacturers sometimes quote capacity at internal nominal voltage (≈3.7 V) or at USB output (5 V). If a power bank reads 10,000 mAh at 3.7 V → Wh = 3.7 × 10 = 37 Wh. If the same 10,000 mAh is specified at 5 V → Wh = 5 × 10 = 50 Wh. Verify the voltage used in the label’s small print.

If markings are missing, measure open-circuit voltage with a multimeter to estimate series count (e.g., ~3.6–3.7 V per cell nominal; ~4.2 V when fully charged). Capacity must be obtained from the cell model or manufacturer; without capacity the Wh cannot be reliably calculated.

When packing multiple modules inside an enclosure, calculate each module’s Wh and sum them. If the pack lists only total cell count, derive S and P by matching total voltage and typical cell voltages, or consult the vendor for a definitive Wh label.

Practical rule: use the printed Wh value when available; otherwise compute Wh using nominal voltages (3.6–3.7 V per cell) and rated capacity, and keep a copy of your calculations or the manufacturer spec sheet for transport verification.

Quick calculation cheatsheet

Formula: Wh = V × (mAh / 1000). Examples: 3.7 V × 2600 mAh → 3.7 × 2.6 = 9.62 Wh. 4 × 18650 (3S1P) with each 3.6 V, 2500 mAh: pack V = 3×3.6 = 10.8 V, pack Ah = 2.5 Ah → Wh = 10.8 × 2.5 = 27 Wh.

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How to pack, insulate terminals, and store spare power cells in carry-on

Keep spare power cells inside your carry-on bag, individually insulated, immobilized in a hard-sided container, and readily accessible for inspection.

Terminal protection

Cover each terminal with non-conductive material: use Kapton or standard PVC electrical tape (wrap so no metal remains exposed), commercial plastic terminal caps, or heat-shrink tubing. Tape should extend beyond the terminal onto the cell casing by at least 5–10 mm to prevent slippage; apply two overlapping wraps for redundancy. Do not rely on folded paper alone.

Packing and storage method

Place insulated cells in individual compartments or padded sleeves; alternatives: original manufacturer blister, molded foam inserts, or clear resealable bags. Group cells in a rigid case (hard-sided small toolbox or purpose-made cell box) that prevents crushing, puncture, and metal contact. Separate spare cells from loose coins, tools, chargers, and other metal objects with at least one non-conductive layer (cardboard or foam).

For cylindrical cells (e.g., 18650) or prismatic cells, orient so terminals do not face each other and use dividers to prevent movement. For multi-cell packs, secure connectors and tape exposed leads; do not tape over safety vents. Place devices with installed packs in protective sleeves and switch devices off; if a device has an external on/off lock, engage it.

Do not transport swollen, cracked, leaking, or thermally damaged cells; isolate any suspect item in a non-flammable container and notify carrier staff before travel. Store cells away from heat sources and direct sunlight; avoid compressing into tight clothing pockets.

Label the hard case or resealable bag with contact information and keep the number of spare cells reasonable for personal use. If a pack exceeds airline-allowed watt-hour limits, obtain carrier approval before attempting to bring it in your carry-on.

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Obtain written airline approval before transporting power packs above 100 Wh on a passenger aircraft

Request explicit, written permission from the carrier’s Dangerous Goods/Operations office for any power pack or cell with a watt‑hour rating over 100 Wh; do not rely on verbal confirmation at check‑in.

Concrete thresholds and what carriers typically require

• Li‑ion units: ≤100 Wh – usually accepted in cabin without prior approval; 100–160 Wh – airline approval required and commonly limited to two spare units per passenger; >160 Wh – generally prohibited on passenger aircraft unless accepted as cargo under specific approvals.
• Primary lithium (metal) cells: check lithium content limit (often 2 g Li per cell for spare transport); cells exceeding national limits usually need special permits or are forbidden on passenger flights.
• Most carriers follow ICAO TI / IATA DGR; final decision rests with the operator and the destination/overflight states.

Step‑by‑step approval process

1. Identify the operator and the national Civil Aviation Authority (CAA) for origin, destination and any substantial overflight states (examples: FAA – USA, EASA – EU, Transport Canada, CAAC – China, CASA – Australia).
2. Gather technical documentation: manufacturer name, model, cell chemistry, Wh rating, serial numbers, quantity, whether installed in equipment or spare, method of terminal protection, UN number if known, and UN 38.3 test certification or equivalent.
3. Search the carrier website for “dangerous goods”, “DG”, or “special cargo”; if no clear guidance exists, email the airline DG office or submit a Dangerous Goods Acceptance request through their online portal.
4. In the request, include flight number(s), travel date, passenger name and contact, airport of origin and destination, and attach the technical documentation from step 2. Ask explicitly for a written approval (PDF or official email) that references the flight and item details.
5. Allow processing time: submit the request at least 72 hours before departure; for complex approvals or cargo processing permit requests, expect 5–7 business days or longer.
6. Keep the approval printed and in electronic form; present it at check‑in, at the gate and to security if asked. If approval is revoked or the carrier issues conditions (e.g., limits on quantity or required stowage), follow those conditions exactly.

Airline approvals commonly require photos of the item, the manufacturer’s specification/mass‑production label, and confirmation of UN 38.3 testing. If an approval letter cites specific handling or carriage instructions, carry that letter with the item at all times.

• If approval is denied for passenger transport, contact the airline cargo division or a certified dangerous‑goods shipper to arrange transport under the appropriate IATA/ICAO cargo packing instructions; cargo transport will require DG paperwork, UN packaging, and a trained shipper.
• For international travel, confirm that both origin and destination CAAs permit the proposed transport; some countries apply stricter limits than the carrier.
• Record the approval reference number and the name/title of the airline official who issued it; log any conditions imposed (quantity limits, terminal protection, where to present the item at the airport).

Sample concise request content (use in email or web form): airline, flight, date, passenger name, item description (make/model), cell chemistry, Wh rating, quantity, serial numbers, installed or spare, terminal protection method, attach UN 38.3 test certificate and manufacturer spec sheet, request written approval for carriage on specified flight.

What to expect at security checkpoints and penalties or seizure for non-compliant Li‑ion cells

Place spare Li‑ion cells, external power packs and large capacity packs in your carry‑on, power them off, insulate terminals and present any airline approval or datasheets at screening.

Screening staff will use X‑ray and visual inspection; expect requests to remove devices and packs for separate X‑ray or manual inspection. Officers may ask you to power on equipment to demonstrate it is not defective, to show the cell label or to open a pack for verification. If an item appears undeclared, oversized, damaged, leaking, or with exposed terminals, inspectors routinely remove it from the travel stream for hazardous goods assessment.

Common enforcement outcomes: (1) immediate confiscation and disposal of the item at security, (2) refusal to board or denial of acceptance by the airline, (3) requirement to transfer the item to approved cargo with a dangerous‑goods declaration, or (4) referral to local law enforcement or customs. Civil penalties and administrative fines can be imposed by aviation or transport regulators; amounts typically range from several hundred dollars for minor violations to multiple thousands for serious or repeated breaches. Criminal prosecution is rare but possible for deliberate misdeclaration or repeated endangering conduct.

If an item is seized, request a written seizure receipt or property tag number, photograph the item and its original packaging, and get contact details for the security/property office and the airline’s hazardous‑goods desk. Retention and disposal policies differ by airport and country: some airports permit retrieval after appeal, others destroy the item immediately. Follow up in writing and keep proof of purchase or specification sheets to support an appeal.

To reduce the chance of seizure: carry printed or digital manufacturer labels/spec sheets showing Wh rating and chemistry, obtain written airline approval for oversized packs before travel, and declare items at check‑in when required. In the event of cross‑border travel, expect customs involvement and additional penalties under local dangerous‑goods and import rules.

When stopped, cooperate, document the interaction and escalate to the airline’s hazardous‑goods office or national aviation authority if you believe seizure was improper.