Michael Turner
Recommendation: Keep external power packs and any charging modules that contain lithium-ion cells in your carry-on (cabin baggage). Do not place spare cells or portable power sources in checked bags.
Regulatory limits: Standard rules from ICAO/IATA and US authorities allow up to 100 Wh per pack in cabin without approval. Packs between 100 Wh and 160 Wh require airline approval and are typically limited to two spares per passenger. Packs above 160 Wh are prohibited on passenger aircraft. Non-rechargeable lithium‑metal cells with more than 2 g lithium content are generally forbidden; under 2 g they may be accepted subject to carrier rules.
How to check capacity: Use the formula Wh = (mAh ÷ 1000) × V. Example: 10,000 mAh at 3.7 V → (10,000 ÷ 1000) × 3.7 = 37 Wh. If no Wh label is present, calculate from the device label or manufacturer specifications before travel.
Packing and handling: Prevent short circuits by keeping terminals covered (original packaging, terminal caps, or electrical tape), switch units off, and place each pack in a separate plastic bag or protective pouch. Present spare packs separately at security if requested and keep them accessible during the flight.
Adapter vs. powered unit: Standard wall adapters or USB power adapters without internal cells are permitted in checked or cabin baggage. Any charging device that contains an internal cell is treated as a portable power source and must be transported in cabin baggage.
Practical steps before travel: Verify the Wh rating on each item, count spare packs, confirm airline policy (some carriers ban specific high-capacity models or require prior approval), and contact the airline at least 48 hours before departure if approval is needed.
How to tell if your power adapter is classified as a lithium-cell device
Treat any power adapter that contains internal lithium cells or shows a capacity in mAh or Wh on the label as a lithium-cell item for air transport rules.
Step 1 – label and markings: look for “Li‑ion”, “LiPo”, “Lithium‑metal”, UN numbers (UN 3480, UN 3481, UN 3090, UN 3091), or explicit capacity values (mAh or Wh). Presence of USB output ports plus stored-capacity markings usually indicates integrated cells.
Step 2 – convert mAh to Wh when only mAh is given: Wh = (mAh × V) / 1000. Use nominal cell voltage 3.7 V for Li‑ion examples. Examples: 5,000 mAh × 3.7 V = 18.5 Wh; 20,000 mAh × 3.7 V = 74 Wh; 30,000 mAh × 3.7 V = 111 Wh.
Step 3 – manufacturer and model lookup: check the model number on the vendor site or the product manual for rated Wh. If the unit is marketed as “power bank”, “portable power pack” or “portable power station”, assume integrated lithium cells exist.
Step 4 – when label or specs are missing: treat ambiguous devices as containing lithium cells and present them to airline staff at check‑in or keep them in cabin baggage until clarified by the carrier or manufacturer support.
| Rated energy (Wh) | Classification / action |
|---|---|
| ≤ 100 Wh | Permitted in cabin baggage without airline approval in most jurisdictions; allowed as installed or spare with standard limits. |
| > 100 Wh and ≤ 160 Wh | Requires airline approval; quantity limits apply (often up to two spare packs per person); must be carried in cabin baggage. |
| > 160 Wh | Prohibited from passenger aircraft in both cabin and checked baggage unless approved for cargo transport under special provisions. |
If uncertainty remains after label inspection and online lookup, photograph the unit and its markings, refer to the manufacturer’s specifications at the gate, and present documentation to airline personnel. For a concise checklist method that helps structure what to verify before travel consult how can addressing the 5ws improve your business letter.
Wh and mAh limits for taking a power pack in carry-on
Recommendation: Keep portable power packs below 100 Wh (≈27,000 mAh at 3.7 V) for routine carriage in cabin; devices between 100 Wh and 160 Wh (≈27,000–43,000 mAh) require airline approval and are usually limited to two units per passenger; anything above 160 Wh is prohibited from passenger cabins.
- Regulatory thresholds:
- ≤100 Wh – allowed in cabin without prior approval.
- 100–160 Wh – permitted in cabin only with airline approval; common limit: 2 units per person.
- >160 Wh – not allowed on passenger aircraft (must use specialized cargo procedures if transportable at all).
- Conversion formula: Wh = (mAh × V) / 1000. If Wh is not printed, use the pack’s nominal cell voltage; when unspecified, use 3.7 V as the standard for lithium-based cells.
- Quick conversion examples (using 3.7 V):
- 10,000 mAh → 37 Wh
- 20,000 mAh → 74 Wh
- 27,000 mAh → ≈100 Wh
- 43,200 mAh → ≈160 Wh
- Labeling and proof: carry items with Wh markings when present; if only mAh is shown, calculate Wh and keep manufacturer specs or a screenshot for airline staff.
- Storage requirements: packs must travel in the cabin (not checked) and have terminals protected against short-circuit – use original packaging or insulating tape over exposed contacts.
- If uncertain, contact the airline and quote the Wh value; many carriers will refuse unmarked units or those exceeding 160 Wh.
Packing tip: place power packs in an easy-to-inspect pocket of your best ultra lightweight backpack so security can verify the Wh label quickly. For large external packs used with heavy tools or outdoor gear, secure them in a reinforced carrier such as the best backpack leaf blower for home use or similar rugged bag when moving between locations.
How to pack power adapters and spare cells to meet carry-on safety rules
Place spare cells in their original retail packaging or individual insulated sleeves; cover exposed terminals with non-conductive tape or terminal caps, then place each cell in a separate resealable plastic bag or a hard-sided protective case and keep them in your carry-on (cabin) bag where they are reachable for inspection.
Packing steps
1) Remove removable cells from devices when allowed and stow them separately; leave non-removable cells installed and switch devices fully off. 2) Coil and secure cables; stow adapters, power banks and cords in a padded pouch to avoid crushing and contact with metal items (coins, keys). 3) For power banks, disable any auto-on function and cover ports with tape or a small cap. 4) Place fragile or swollen cells aside and do not transport if casing is damaged, leaking, bulging or corroded.
Inspection and airline rules
Keep all packed items accessible in a single compartment for screening; if an inspector requests removal, present items in the same protective sleeves or cases. Verify airline and airport requirements ahead of departure for quantities and approval procedures when capacity exceeds airline thresholds; declare items if a form or staff request requires it.
How to verify airline and country‑specific restrictions before you travel
Recommendation: Verify the carrier’s and every country’s rules for departure, transit and arrival at least 7–14 days before travel and again within 24 hours; secure written approval from the carrier if your portable power item exceeds their published conditions.
1. Use authoritative sources: consult IATA Dangerous Goods Regulations and ICAO Technical Instructions for air transport baseline rules; check the airline’s official “dangerous goods” or “restricted items” page; consult national regulators relevant to your itinerary (examples: TSA/FAA for the United States, EASA for the EU, CAA for the UK, CASA for Australia, Transport Canada, CAAC for China).
2. Verify every stop: confirm requirements for origin, each transit point and destination. Some states impose stricter import, inspection or declaration rules for portable power packs and spare cells; a rule valid at origin may not apply in transit or at the destination.
3. Contact the carrier’s dangerous-goods office directly: use the airline’s dedicated DG email or phone (not generic social media). Provide flight number, date, item brand/model, rated capacity (Wh or mAh), serial number and intended stowage (cabin or checked). Request a written reply and record the reference number.
4. Prepare supporting documents: carry a printed copy of the device’s specification label (Wh or mAh), the manufacturer’s spec sheet, a screenshot or printout of the airline rule page and any emailed approvals. Keep digital backups accessible on your phone.
5. Use the airport and customs resources: check the departure airport’s security and customs pages for local restrictions; if uncertain, arrive earlier to allow time for inspection or documentation review by security or customs officers.
6. Sample message to request approval
Subject: Transport approval request – portable power device on [Airline] [Flight #] [Date]
Body: Flight: [number], Date: [dd/mm/yyyy], From: [airport], To: [airport]. Device: [brand/model], Rated capacity: [Wh or mAh], Serial: [xxx], Quantity: [n]. Requested stowage: cabin or checked. Please confirm whether transport is permitted and list any required steps or paperwork. Please reply in writing.
7. If the carrier refuses: request a written explanation quoting the specific regulation or clause; ask about alternatives (authorized freight/DG shipment, airport disposal, or returning the item to origin). Escalate to the airline’s DG manager if the response is unclear.
Documentation to retain: saved screenshots of policy pages, all email correspondence with the airline, the device spec sheet and any written approvals – keep both printed and digital copies to present during security or check-in.
What to do at security checkpoints if your power pack is questioned
Place the portable power pack on the screening tray separately and hand its visible specification label or product receipt to the security officer without delay.
If the label is worn or missing, open a browser on your phone and show the manufacturer specification page or a photo of the product label saved beforehand; printed manual or proof of purchase works as an alternative.
How to prove capacity on the spot: display the unit’s voltage (V) and milliampere‑hours (mAh) and use the formula Wh = (mAh ÷ 1000) × V. Example: 10,000 mAh at 3.7 V = 37 Wh. Thresholds to quote: ≤100 Wh generally allowed in cabin, 100–160 Wh require airline approval, >160 Wh generally prohibited.
If asked to power the device, switch it on to demonstrate normal operation; refuse to operate any device that shows swelling, leakage, excessive heat or physical damage and request a supervised alternative inspection.
When a screener requests additional inspection, offer to remove protective covers and show terminals; if terminals are taped, explain that as intended protection. Present spare units separately rather than stacked together.
If staff intends to confiscate or deny transport, request escalation to a supervisor or ground operations representative and ask for a written reason with reference to the applicable regulation (example references: IATA DGR, ICAO TI, or the local aviation authority rule cited).
If photography inside the checkpoint is restricted, note the officer badge number, time, checkpoint ID and take photos once permitted. Keep screenshots of product specs and purchase proof on your device for later claims or appeals.
If the item is refused for carriage, discuss alternatives: gate check with airline acceptance, documented refusal allowing shipment by road courier, or voluntary removal from the flight. Retain all paperwork issued by the airport or airline.
