Primary directive: Spare lithium‑ion cells and portable battery packs are prohibited from the aircraft hold and must be carried in cabin baggage. International regulations (IATA/ICAO) classify spare batteries as dangerous goods when transported outside a device.
Watt‑hour thresholds: up to 100 Wh – allowed in cabin without airline approval; 100–160 Wh – airline approval normally required and usually limited to two spare units; above 160 Wh – not permitted on passenger aircraft.
Items that lack a lithium cell – AC adapters, USB cables, wall plugs and passive USB power bricks – are acceptable to pack in the hold. Any product with a built‑in or removable lithium battery should remain in the cabin where security staff can inspect it and where fire mitigation is faster.
Protect battery terminals against short circuits: keep cells in original packaging, use terminal covers or insulating tape, and label capacity where possible. For packs between 100–160 Wh, carry manufacturer documentation of the watt‑hour rating and obtain carrier approval before travel.
Practical packing tip: Put bulky adapters and spare cables in hold baggage to free cabin space, but always transport external battery packs and loose lithium cells in the cabin, with terminals insulated and capacity markings visible; if in doubt, declare items at check‑in and follow the airline’s instructions.
Are wall adapters and USB cables permitted in the aircraft hold under TSA and IATA rules?
Recommendation: pack wall adapters and USB cables in carry-on when practical; plain adapters and cords are allowed both in cabin and in the aircraft hold, but any spare lithium batteries or power banks must travel in the passenger cabin only.
TSA specifics: adapters and USB cords that contain no batteries are permitted in both cabin and hold. Spare lithium‑ion batteries (including power banks) are prohibited from the aircraft hold and must be in carry‑on. Batteries installed inside equipment may be transported in the hold if the device is powered off and protected from damage, but TSA frequently advises keeping such devices in the cabin.
IATA/Dangerous Goods rules: lithium‑ion batteries follow watt‑hour limits – ≤100 Wh: carriage allowed in cabin without airline approval; >100 Wh and ≤160 Wh: airline approval required and usually limited to two spare units per passenger; >160 Wh: forbidden on passenger aircraft. Spare lithium batteries must be in the cabin; batteries installed in equipment are subject to protection against short circuits and accidental activation. Lithium‑metal batteries have separate lithium‑content limits and may also require airline approval.
Packing recommendations: insulate battery terminals (tape exposed contacts), switch devices completely off, place adapters and cables in a protective pouch to avoid connector damage, keep paperwork or approvals for any >100 Wh batteries accessible, and check carrier-specific rules before travel.
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When must power banks travel in carry-on – how to read Wh ratings and apply airline limits
Always carry power banks in cabin baggage; do not stow them in the aircraft hold.
How to read Wh and convert mAh
Look for an energy rating in watt-hours (Wh). If only milliamp-hours (mAh) are printed, convert using Wh = (mAh ÷ 1000) × V. Use the internal cell voltage (typically 3.7 V) for the conversion unless the label explicitly states the voltage used for the mAh rating. 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 ≈ 99.2 Wh. If the manufacturer lists Wh directly, use that value without conversion.
Applying airline and regulatory limits
– Batteries under 100 Wh: permitted in the cabin without airline approval; treat as spare/portable batteries and keep with carry-on items.
– Batteries 100–160 Wh: permitted only with airline approval; most carriers allow up to two such batteries per passenger and they must remain in the cabin. Obtain written approval from the carrier ahead of travel when possible.
– Batteries over 160 Wh: not permitted as passenger carriage (cabin or aircraft hold) and must be transported only as cargo under dangerous-goods rules; many airlines will refuse to accept them for passengers.
Practical steps: verify the Wh printed on the unit or calculate from mAh and voltage, round up to the next whole number for safety, check the airline’s policy and request approval if between 100–160 Wh, protect terminals against short-circuiting (cover contacts or keep in original box), keep units accessible for inspection, and limit the number of high-capacity units you bring.
Packing steps to prevent damage, short circuits and accidental activation in stowed bags
Switch off all devices, remove removable cells where possible, and insulate any exposed contacts with non-conductive tape or terminal caps before placing items into a stowed bag.
Required materials
- Electrical or Kapton tape (non-conductive)
- Plastic terminal caps or heat-shrink tubing
- Zip-top plastic bags (individual for each battery or small device)
- Padded pouch or small hard-shell case
- Bubble wrap, foam pads or clothes for padding (minimum 5 cm / 2 in cushion)
- Velcro straps / twist ties to secure cables
- Silica gel packets (optional, for humidity control)
- Power state: Power down devices completely; disable wake-on notifications, scheduled alarms and any auto‑on timers. For devices with internal lithium-ion cells that must be transported in stowed baggage, set state of charge to ~30–50% if storage will exceed 24 hours.
- Remove and isolate cells: Take removable batteries from devices. Place each cell in its own zip-top bag and cover terminals with tape or terminal caps. Do not allow loose cells to contact metal objects (coins, keys, zips).
- Insulate exposed connectors: Tape over USB connectors, barrel plugs and pogo pins using non-conductive tape. For multi‑pin ports use small pieces of Kapton or electrical tape to prevent bridging.
- Prevent accidental switches: Secure sliding or push buttons with a strip of tape; use a zip tie or rubber band on removable toggles when practical. Place taped devices into a padded pouch so pressure on buttons is unlikely.
- Separate power sources from metal items: Pack adapters, cables and batteries away from loose metal. Use dedicated compartments or individual bags to avoid contact with zippers, jewelry or tools.
- Protect against puncture and crush: Put adapters and battery‑containing items inside a hard-shell case or surrounded by at least 5 cm (2 in) of soft padding on all sides; place centrally in the suitcase away from the outer walls and heavy objects.
- Secure cables and small parts: Coil cords neatly and fasten with Velcro or twist ties; store chargers and cables in a zipped pocket so plugs cannot snag other items.
- Label and document: If transporting multiple batteries or devices, label the case contents (e.g., “batteries inside”) for handlers and, if requested, airline staff.
- Final check before sealing: Verify all terminals taped, all toggles immobilized, and nothing metallic can contact contacts. If any item becomes warm during a pre-trip check, isolate it in a non-flammable container and seek professional advice rather than packing it.
Placement and handling tips
- Position protected electronics at the suitcase center with softer items (clothes) as buffer layers above and below.
- Keep heavy, rigid objects separate from padded electronics to avoid concentrated pressure points.
- Avoid storing devices next to aerosols or flammable liquids.
- Consider carrying high-value or critical battery-powered devices in cabin baggage to reduce rough handling risk.
Confirm an airline’s battery and power-adapter policy and handle check-in questions
Before travel – document and verify
Request written confirmation from the carrier that lists permitted battery capacities (Wh), maximum quantity per passenger, and whether spare cells must remain in the cabin; save the exact web page URL, a screenshot with timestamp, or an agent email reply that includes their name or reference number.
Search the airline site for pages titled “Dangerous Goods”, “Batteries”, “Lithium batteries”, “Conditions of Carriage” or “Contract of Carriage”; use the site search box with the flight number to find flight-specific notices and operational exceptions. If policy wording is ambiguous, call reservations and open a ticket asking for policy wording copied into the reply.
Prepare the following facts for any inquiry: flight number, travel date, device model, battery label showing Wh (or mAh + voltage), and quantity. Photograph the device label and the accessory serial number and attach those images to any email or chat so the carrier can verify against their rules.
Keep printed copies of the carrier’s policy page and the device label in your carry item and store a PDF on your phone; for travel gear recommendations see best luggage brands online store.
At the check-in desk – phrasing, escalation and outcome tracking
Start interactions with a concise script: “My reservation is [PNR]; my device is model [X] with [Y] Wh batteries. Your published policy at [URL] permits cabin transport. Please confirm and note this on my booking.” Present printed or screenshot evidence immediately.
If the agent disputes the policy, ask for a supervisor and request a written explanation stating the specific regulation the agent is applying (keep a photo of any written note). Obtain the supervisor’s name, employee ID and a reference or incident number; if they refuse escalation, ask for the airline operations desk contact and record the time of the refusal.
If the final check-in decision differs from the carrier’s published policy, ask for that decision in writing (email or printed form) so you have a record to dispute fees, delays or lost property later. Save all correspondence and receipts for claims or complaints.
Arrive at the airport earlier than usual to allow time for verification and possible escalation. For unexpected spills or messes in transit use instructions such as how to clean cat puke off carpet when needed.