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Place all spare lithium-ion power cells in cabin baggage only. Installed cells inside consumer devices may be stowed in the aircraft hold in limited cases, but many carriers require devices with installed packs to travel in the cabin. Limit per-cell energy: ≤100 Wh allowed without carrier approval; 100–160 Wh allowed only with airline approval and typically limited to two spare units per passenger; >160 Wh is not permitted on passenger aircraft.
Packing requirements: protect terminals against short circuits by taping exposed contacts or using original packaging or individual plastic sleeves; place each spare cell in separate pockets to avoid contact with metal objects. Treat power banks and external chargers as spare cells–keep them in carry-on. Calculate energy using the formula Wh = (mAh ÷ 1000) × V; examples: a 3000 mAh, 3.7 V cell = 11.1 Wh; a 20 000 mAh, 3.7 V power bank ≈ 74 Wh.
At the airport: present any cells above 100 Wh to the carrier for approval and carry proof of the Wh rating (manufacturer label or spec sheet). Power devices down and avoid charging during boarding if crew requests device inspection. National regulators and individual airlines may impose stricter limits–confirm specific carrier rules and local authority guidance before departure to avoid refusal at the gate or confiscation.
Transporting lithium-ion and NiMH cells: immediate recommendation
Keep spare lithium-ion cells inside cabin baggage; cells installed in equipment are acceptable in the aircraft hold only when the device is completely powered off and terminals are insulated.
Energy-rating rules: consumer Li‑ion cells up to 100 Wh are permitted in the cabin without airline approval; spare units must remain there. Packs between 100 Wh and 160 Wh require airline approval and are typically limited to two spare packs per passenger. Packs above 160 Wh are not permitted on passenger aircraft except as properly declared cargo under dangerous‑goods procedures. Use the formula Wh = V × Ah to verify pack rating (example: 3.7 V × 2.6 Ah = 9.62 Wh).
NiMH (secondary) cells used in cameras and portable tools have lower thermal runaway risk; when fitted in devices they are usually allowed in the hold, but spare NiMH cells are best carried in the cabin or stored in protective cases to prevent short circuits.
Terminal protection and packing: retain original packaging or use individual plastic cases; cover exposed terminals with non‑conductive tape; avoid loose cells near metal objects; disable or remove batteries from devices when possible and immobilize power switches to prevent accidental activation.
Regulatory actions: follow IATA Dangerous Goods Regulations and the airline’s specific policy; U.S. Transportation Security Administration (TSA) prohibits spare lithium‑ion cells in the aircraft hold. For packs between 100–160 Wh obtain written airline approval before travel and notify the carrier at the airport counter about oversized packs destined for cargo handling.
Spare lithium‑ion cells: carriage in aircraft hold
Direct rule: Spare lithium‑ion cells and portable power banks are prohibited from the aircraft hold; transport them in the passenger cabin only. Cells installed inside equipment may be accepted in the hold by some carriers, but cabin carriage is strongly recommended and carrier policies must be confirmed before departure.
Regulatory thresholds: Nominal energy limits apply – up to 100 Wh: allowed in cabin without airline approval; >100 Wh and ≤160 Wh: allowed only with explicit airline approval and normally limited to two items per passenger; >160 Wh: forbidden for passenger transport in both cabin and hold.
How to determine Wh: Wh = (mAh ÷ 1000) × V. Examples: 3000 mAh at 3.7 V = 11.1 Wh; 20,000 mAh at 3.7 V = 74 Wh; 50,000 mAh at 3.7 V = 185 Wh (prohibited). If a power bank lists only mAh at 5 V, use the manufacturer’s Wh rating when provided.
Packing and protection: Insulate terminals (tape over exposed contacts), keep each cell or pack in original retail packaging or individual plastic pouches, prevent crushing/short circuits, and store items separately from metal objects. Power banks must be carried as spare equipment in cabin, not placed with hold-stowed items.
Defective or recalled items: Swollen, damaged, leaking, or recalled cells and packs are forbidden in both cabin and hold under international dangerous-goods rules.
Operational steps before travel: 1) Verify Wh rating on the label. 2) If Wh >100, obtain written approval from the carrier before flying. 3) Tape terminals and package each item separately. 4) Present items to cabin crew or gate agents if requested. 5) Keep all spare cells and power banks in carry-on for the entire journey.
How to pack devices with installed power cells for aircraft hold
Immediate action: Power the device off, secure all switches with tape or the manufactured lock, and place the unit in a hard-sided suitcase with at least 5–7 cm of soft padding on every side to prevent crushing and impact.
Placement: Position the device in the centre of the case, surrounded by clothing or foam inserts; keep it away from sharp objects, metal tools and liquids. Devices with external ports facing upward reduce risk of foreign-object shorting.
Terminal protection: Exposed conductive terminals must be insulated with non-conductive tape or dedicated terminal caps. For enclosed cells inside devices, confirm battery compartment doors are secured and cannot open under pressure.
State of charge: Maintain the cell charge at a moderate level when possible. For travel planning, aim for roughly 30–50% state of charge for long transit times to reduce thermal runaway risk.
Power-rating limits and documentation: Identify the cell rating on the product label. Use Wh calculation when only mAh and voltage are listed: Wh = (mAh ÷ 1000) × V. Cells over 100 Wh and up to 160 Wh require airline approval before transport; cells above 160 Wh are not permitted in passenger aircraft hold without special freight arrangements. Carry a copy of the manufacturer rating or user manual at the airline counter.
Damaged or recalled units: Do not place devices showing swelling, leakage, discoloration, overheating or strong odors in the hold. Arrange repair or professional disposal prior to travel.
Additional safeguards: Use original packaging or a padded protective sleeve, add a thermal- and flame-resistant barrier (e.g., thick clothing or a dedicated pouch), and avoid placing devices next to items that could puncture the case. Label the exterior of the suitcase with a brief note (e.g., “Contains sealed power cell device”) for airline staff handling.
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Watt‑hour (Wh) and cell limits for lithium cells in the aircraft hold
Do not place spare lithium‑ion cells or packs in the aircraft hold; carry spares in the cabin and follow the Wh thresholds below.
- Spare cells/packs: All spare lithium‑ion and lithium‑metal cells or packs are prohibited in the aircraft hold and must be transported in the cabin only.
- Installed packs in devices – Wh thresholds:
- ≤ 100 Wh: installed packs are generally permitted without airline approval; many carriers still prefer cabin carriage.
- > 100 Wh and ≤ 160 Wh: airline approval required; commonly limited to two spare packs per passenger (spares still forbidden in the hold); devices with such packs often must be carried in the cabin and declared.
- > 160 Wh: not permitted on passenger aircraft except as cargo under approved dangerous‑goods procedures.
- Lithium‑metal cells: Cells with lithium content ≤ 2 g are typically permitted only in the cabin when installed; cells with > 2 g lithium are not allowed on passenger aircraft.
- Cell count and multiple packs: Carriers may limit the number of devices with installed high‑Wh packs or the total installed capacity per passenger; declare devices containing multiple large packs when requested.
- Labeling and Wh calculation: Use the printed Wh value when present. If absent, calculate Wh = volts × ampere‑hours (Wh = V × Ah); convert mAh to Ah by dividing by 1000. Example: 3.7 V × 2500 mAh (2.5 Ah) = 9.25 Wh.
- Packing and handling for devices placed in the hold: Power switches must be locked off, terminals insulated or covered, devices cushioned to prevent damage; nevertheless, avoid placing devices with large packs in the hold when cabin carriage is allowed.
- Identify Wh rating on the pack or calculate and mark it.
- If pack exceeds 100 Wh, obtain airline approval in writing before travel and carry documentation onboard.
- Keep spare packs in carry‑on only; place each pack in individual protective pouches and insulate terminals.
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Power banks and external power packs: aircraft hold policy
Place all portable power banks and external power packs in cabin carry-on; transport in the aircraft hold is generally prohibited by aviation authorities and most carriers.
If discovered during screening or bag drop, items will be removed from checked compartments; possible outcomes include confiscation, travel delays, denied boarding and fines. Larger-capacity units require explicit airline approval prior to travel and may be refused for carriage in the hold.
Protect terminals by covering them with electrical tape or original caps and pack each unit in an individual protective pouch to prevent metal contact and short circuits. Keep units powered off and avoid stowing them in garment pockets or mixed with loose metal objects.
Report oversized, damaged, swollen or leaking units to the carrier before travel; such items are typically forbidden from air transport. Follow carrier instructions for documentation and prior approval when transporting units that exceed standard allowances.
Retain portable power sources in the cabin for security inspection when requested; failure to produce items on demand can result in their removal and refusal to carry them onboard.
How to verify airline and country rules on lithium power sources before travel
Confirm airline and national civil aviation authority rules at least 72 hours before departure through official policy pages and obtain written confirmation for non-standard items or higher-rated power cells.
Primary sources to consult: the carrier’s dangerous goods or special items web page, the origin and destination state aviation regulator (CAA) site, IATA Dangerous Goods Regulations (DGR) summaries, and ICAO Technical Instructions. Whenever carrier policy and national rules differ, follow the stricter requirement imposed by the carrier at time of boarding.
Required data to extract from each source: allowed carriage location (cabin versus checked hold), maximum watt-hour (Wh) per cell and per pack, permitted cell count per passenger, rule on spare/loose cells, packaging and terminal protection requirements, labeling or marking demands, and whether prior airline approval or a written declaration is mandatory.
Document set to carry at airport: printed carrier policy excerpt or written approval email, manufacturer datasheet showing Wh/cell and cell count, product label or invoice, and any special permit issued by the airline or regulator. Present these at check-in and security if asked.
| Source | What to extract | Action |
|---|---|---|
| Airline official policy page | Permitted locations, Wh limits, spare cell rules, approval contact | Save page PDF; get written approval for exceptions |
| Airline customer service (email/phone) | Confirm interpretation of policy for specific product models | Request confirmation in writing; note agent name and timestamp |
| State CAA / Transport authority | National restrictions, exports/transit rules, enforcement guidance | Download regulation excerpt relevant to passenger carriage |
| IATA / ICAO guidance | Baseline international limits, documentation formats, packaging standards | Use for technical reference when airline/regulator language is ambiguous |
| Manufacturer datasheet | Rated Wh, cell chemistry, cell count, labeling details | Carry printed spec sheet and product label photo |
Checklist of targeted questions to present to a carrier or authority: is the item allowed in cabin or hold; what exact Wh and cell-count limits apply; are spare/loose cells permitted; is prior written approval required; what packaging and terminal protection is required; are transit countries subject to additional restrictions. Phrase queries with model numbers and rated Wh values.
If a transit point or final destination has stricter rules than the origin, apply the most restrictive rule for the full itinerary. For requests requiring airline approval, allow 7–14 days for processing and secure written confirmation; airports and ground staff may deny acceptance without that documentation.
If refused at check-in, request a written denial stating the regulation or policy citation, retain all travel and product documents, and escalate to airline regulatory compliance or the national civil aviation authority for review before attempting rerouting or repackaging.
When ticketing or security staff question portable power sources
Immediate actions at the counter or checkpoint
Present the device and any spare power cells separately and accessible for inspection; power the device off, remove external cables, and place each spare cell in its original packaging or an individual plastic sleeve.
Cover exposed terminals with non-conductive tape or use terminal caps; place items inside a rigid protective case or padded pouch to prevent short circuits and mechanical damage during handling.
Produce the manufacturer’s label showing chemistry (for example Li‑ion), rated watt‑hours (Wh), voltage (V) and milliamp‑hours (mAh). Use Wh = (mAh × V) / 1000 to confirm values on the spot (example: 3000 mAh × 3.7 V = 11.1 Wh).
If transport is refused or additional proof is requested
Request a written reason or the specific airline/security policy reference and ask that a supervisor review the item; note staff names and take photos of the item, labels and packing for records.
Offer allowed alternatives: move the item to the cabin if permitted, replace with a smaller capacity cell under regulatory limits, or arrange movement via airline cargo or a licensed dangerous‑goods courier. Items above ~100 Wh per cell typically require carrier approval and formal hazardous‑goods paperwork; shipments via cargo require advance booking with the cargo/DG desk.
If instructed to surrender the item, retain documentation of the refusal and disposal; if the item is mission‑critical (medical device, business equipment), request written confirmation and contact the airline’s customer relations or cargo department immediately to explore exceptions or freight options.
FAQ:
Can I pack rechargeable lithium-ion batteries in checked luggage?
Spare lithium-ion batteries (including power banks) are not allowed in checked baggage and must be carried in the cabin. Batteries that are installed in devices are often permitted in checked bags if the device is switched off, but many airlines prefer devices with batteries to travel in carry-on so crew can respond to any thermal event. To reduce risk, protect battery terminals (tape them or use original packaging), place spares in a plastic bag or dedicated case, and follow any airline-specific limits on number and capacity.
How do I calculate a battery’s watt-hours (Wh) and what capacity limits apply for air travel?
Watt-hours equal voltage multiplied by ampere-hours (Wh = V × Ah). For example, a 3.7 V battery rated 3000 mAh is 3.7 × 3 Ah = 11.1 Wh. Typical limits: batteries up to 100 Wh are normally allowed in carry-on without prior approval; batteries between 100 Wh and 160 Wh usually require airline approval and are often limited in number (commonly two spares per passenger); batteries above 160 Wh are generally not permitted in passenger baggage and need special cargo handling if transport is possible. If the battery does not show Wh on its label, calculate and mark the value or carry the specification sheet when you travel.
Are power banks, e-cigarettes and electric bicycle batteries treated the same way?
Power banks are treated as spare batteries and must be in carry-on and within the capacity limits described by the airline. E-cigarettes and their spare batteries must also stay in the cabin and should remain switched off; using them on board is prohibited. Electric bicycle batteries tend to have much higher Wh ratings and are often banned from passenger baggage; some carriers permit shipment as cargo under strict rules, while others forbid them entirely. Always check the specific airline policy before travel and declare large batteries at check-in.
What happens if a rechargeable battery overheats in checked baggage and how can I lower the risk?
If a battery undergoes thermal runaway in checked baggage it can start a fire that is difficult to detect or control because crew cannot access checked hold compartments in flight. For that reason regulations restrict spare batteries to the cabin. At security, officers may remove or confiscate batteries found improperly packed, and an airline can refuse carriage of items that pose a hazard. To reduce the chance of overheating: keep spare batteries in carry-on only; insulate or tape exposed terminals and use protective cases; avoid placing loose batteries in luggage pockets where they might short or be crushed; do not send damaged or swollen batteries; if possible carry batteries at a partial charge (many manufacturers recommend storing around 30–50% for transport); and contact the airline before travel if you must transport high-capacity cells so you can follow any required procedures.
