Michael Turner
Recommendation: Carry spare lithium-ion power cells only in your cabin carry-on; each cell must be ≤ 100 Wh. Units between 100 Wh and 160 Wh require written approval from the airline and are limited to two per passenger. Cells above 160 Wh are prohibited from passenger aircraft.
Follow IATA Dangerous Goods Regulations: check the marked capacity in Wh or calculate Wh = voltage × ampere-hours (V × Ah). If only mAh is shown, convert by dividing mAh by 1,000 then multiply by the nominal voltage (typically 3.7 V for lithium-ion). Example: a 10,000 mAh power pack → (10,000/1,000) × 3.7 = 37 Wh.
Packing rules: spare power cells must be carried in the cabin, not placed in hold baggage. Terminals should be insulated (original packaging, taped terminals, or individual plastic pouches) and each cell protected against short circuits. Devices with installed cells may travel in cabin or hold but should be switched off and protected against accidental activation; if a device contains a non-removable high-capacity cell, contact the carrier before departure.
Before travel: verify the unit label for Wh or V/mAh; if capacity falls in the 100–160 Wh band, obtain airline approval and carry documentation. Keep spare power packs in accessible carry-on for inspection and consult the carrier’s customer service plus IATA/DGR guidance when uncertain.
Cabin rules for portable power cells on the carrier
Keep spare lithium cells in your cabin bag only; do not pack loose spares in the hold and do not board with damaged or swollen units.
- Lithium‑ion (rechargeable): up to 100 Wh per pack allowed in the cabin without prior approval. Packs rated between 100 Wh and 160 Wh require explicit airline approval and are typically limited to two spares per passenger. Packs above 160 Wh are prohibited on passenger aircraft.
- Lithium‑metal (non‑rechargeable): restricted by lithium content; high‑content cells may be forbidden or require permission from the operator. If unsure, check the cell label or manufacturer data sheet before travel.
- Power banks and external chargers count as spare cells and must follow the same Wh limits and cabin‑only rule.
- Alkaline, NiMH and other non‑lithium chemistries are generally permitted in both cabin and hold, but protect terminals to prevent short circuits.
- Terminal protection: cover exposed contacts with tape, use original packaging or individual plastic pouches, and prevent contact with metal objects.
- Label reading and calculation: find Wh on the label; if only mAh and voltage are shown, calculate Wh = (mAh × V) ÷ 1000. Example 20000 mAh at 3.7 V = (20000×3.7)/1000 = 74 Wh.
- Security screening: be ready to remove devices and spare packs from your cabin carrier for X‑ray inspection; carry manufacturer specs or packaging for items near the 100 Wh threshold.
- Refusals and penalties: damaged, modified, or unlabelled high‑energy cells are likely to be denied boarding and may be confiscated; declare irregular items at check‑in.
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Permitted cell chemistries and sizes for cabin carriage
Allowed without prior approval: lithium‑ion cells/packs up to 100 Wh and lithium‑metal cells with ≤ 2 g lithium content per cell.
Cells between 100 Wh and 160 Wh: airline approval required; passengers are normally limited to two spare packs in addition to those installed in equipment. Cells/packs above 160 Wh are prohibited for passenger transport.
Non‑lithium chemistries: alkaline, NiMH, NiCd and lead‑acid (small sealed types) used in everyday items such as AA, AAA, C, D and 9V are allowed in both cabin and checked baggage; spare uninstalled cells should be packed with terminals protected.
Spare cells and power banks: all spare lithium‑ion and lithium‑metal cells/packs (including power banks and external chargers) must be carried in the cabin only; protect terminals (tape/individual plastic sleeves/original packaging) and avoid loose contacts. Power banks must show Wh rating; if only mAh is marked use the formula below to confirm compliance.
Wh calculation: Wh = V × Ah = V × (mAh ÷ 1000). Example: a 3.7 V, 2600 mAh pack = 3.7 × 2.6 = 9.62 Wh.
Examples: phone and laptop packs are typically ≤100 Wh; camera packs often fall under the same cap; coin cells (lithium‑metal) usually contain <2 g lithium and are acceptable. For mobility aids, large sealed lead‑acid or high‑Wh packs require prior operator approval and special handling.
Practical packing tips: keep spares in carry‑on, label or calculate Wh where markings are missing, and isolate terminals. For other travel gear like protective cases or colourful suit options see best umbrella rental miami and best luggage in pink.
How to calculate watt-hour (Wh) rating for lithium-ion cells and airline limits
Quick calculation
Use Wh = V × Ah. If capacity is given in mAh, convert: Ah = mAh ÷ 1000. Use the nominal voltage printed on the cell or pack; if only cell type is listed, use 3.6–3.7 V for typical lithium‑ion chemistry.
Examples: 3.7 V × 3000 mAh (3.0 Ah) = 11.1 Wh; 11.1 V × 2200 mAh (2.2 Ah) = 24.42 Wh; 7.4 V × 10000 mAh (10 Ah) = 74 Wh; 3.85 V × 3000 mAh = 11.55 Wh.
Limits, handling and practical rules
The carrier applies standard IATA/ICAO thresholds: up to 100 Wh per cell/pack is normally permitted in the cabin without prior approval; 100–160 Wh requires airline approval and is usually limited to two spare packs per passenger; over 160 Wh is not allowed on passenger aircraft. Treat the pack voltage as the voltage for Wh calculations when cells are configured in series; parallel arrangements increase Ah, not voltage.
Protect terminals from short circuits by taping exposed contacts or keeping packs in original packaging or individual plastic sleeves. Store spare packs in cabin baggage only; do not place spare packs in checked baggage. When capacity or voltage are not visible, obtain manufacturer specifications or request written confirmation from the carrier before travel. Round calculated Wh to one decimal place and compare with the thresholds above when seeking approval.
Packing and protecting spare lithium cells for cabin carriage
Insulate each spare lithium cell’s terminals with non-conductive electrical tape or manufacturer terminal caps; cover both positive and negative ends and extend tape at least 5 mm onto the casing to eliminate exposed metal.
Keep each protected cell in its original retail packaging or in individual rigid plastic cases or molded foam inserts; single-compartment holders prevent contact and reduce abrasion risk better than loose soft pouches.
Do not bundle multiple cells together or allow contact with metal objects (coins, keys, cables). Use individual sleeves or separated pockets so no two terminals can touch under pressure or movement.
Use closed-cell foam, molded trays or purpose-made cylindrical holders for mechanical protection; for pouch-type cells, avoid pressure on seams and place them flat with padding on both faces to prevent puncture.
Contain spares inside a certified flame-resistant pouch or a small metal tin designed for lithium transport when possible; these items localize heat and ash if a thermal event occurs, unlike general toiletry or clothing compartments.
Inspect every cell before packing: discard or leave at home any with dents, swelling, torn wrappers, corrosion, leakage or missing insulation. Do not include compromised units in travel containers.
Label each spare with visible capacity and voltage or keep a photograph/specification sheet on your phone for quick verification by security staff; keep all spares together in an easily accessible compartment to speed inspection.
For rechargeable power packs with removable cells, secure the pack inside a protective case and isolate removed cells as above; avoid taping packs to devices or placing extra cells in device cavities where terminals remain exposed.
Rules for installed power cells versus spares and checked-bag restrictions
Always store devices with installed power cells in the cabin when possible; spare power cells are not permitted in checked baggage and must remain in the cabin compartment.
Rechargeable lithium-ion packs: cells or packs up to 100 Wh may be carried as spares in the cabin without prior approval. Packs greater than 100 Wh but not exceeding 160 Wh require airline approval before travel and are typically limited to a maximum of two spare packs per passenger. Packs above 160 Wh are prohibited from both cabin and checked carriage.
Non-rechargeable lithium metal cells: spare cells with lithium content ≤2.0 g per cell are allowed in the cabin only; cells with lithium content over 2.0 g are not permitted on passenger aircraft. Installed lithium metal cells inside equipment follow stricter handling–expect screening and possible carriage restrictions.
Checked-bag rules for installed packs: equipment with internal packs may be transported in checked baggage if the pack is fixed inside the device, the device is switched off, power triggers are blocked, and terminals cannot short. Despite this allowance, carriers commonly advise taking devices containing lithium cells into the cabin whenever practicable.
Large fixed packs (medical devices, mobility aids) that exceed 160 Wh require written approval from the carrier and advance coordination. Prepare product documentation showing Wh or lithium-content, secure the device against movement, and arrive at the airport early for possible special-handling procedures.
Terminal protection and labeling: for spares kept in the cabin, insulate terminals (tape or original covers), place each pack or cell in separate protective pouches or original retail packaging, and prevent contact with metal objects. For installed packs destined for the hold, ensure the device cannot power on accidentally and that terminals remain protected.
Before travel, notify the carrier when carrying any spare pack above 100 Wh, any device with packs over 160 Wh, or multiple spares; provide Wh/lithium-content data and manufacturer/model information to obtain necessary approvals and carriage instructions.
