Michael Turner
Quick rule: installed energy cells inside devices may travel in either checked or carry-on but are best carried in the cabin; spare power packs and loose cells must remain in carry-on only. Airlines and regulators treat spare units as a fire risk when stowed in the hold.
Regulatory limits (IATA / FAA / TSA): individual rechargeable cells or packs up to 100 Wh are allowed in carry-on without prior approval; units between 100 Wh and 160 Wh require airline approval and are typically limited to two spare packs per passenger; units exceeding 160 Wh are forbidden on passenger aircraft except under special cargo arrangements. Terminals must be protected to prevent short circuits.
Practical steps: verify the Wh rating printed on the pack or calculate Wh = (V × mAh) / 1000; examples: a 3.7 V, 20 000 mAh power pack ≈ 74 Wh (allowed), a 3.7 V, 50 000 mAh pack ≈ 185 Wh (prohibited). Tape exposed terminals, keep packs in original packaging or separate plastic bags, switch devices off and prevent accidental activation.
At check-in declare any packs above 100 Wh, carry documentation or manufacturer labels, confirm the carrier’s written policy before boarding, and limit spare packs to the approved quantity. When in doubt, transfer units to carry-on and notify staff at the desk to avoid confiscation or delays.
Integrated power packs in travel cases
Choose a travel case with a removable power pack rated ≤100 Wh and transport it in the cabin.
Regulatory limits
- Spare rechargeable power packs: carry in cabin only; most carriers prohibit spares in checked baggage.
- Power source installed inside a device: allowed by many airlines in checked baggage but best kept in carry-on to reduce risk.
- Capacity thresholds:
- ≤100 Wh – airline approval typically not required.
- >100 Wh and ≤160 Wh – airline approval required; usually maximum two spare packs per passenger.
- >160 Wh – not permitted on passenger aircraft.
- Protect terminals: cover exposed contacts or place each pack in its own protective pouch to prevent short circuits.
Packing and labeling
- Convert mAh to Wh: Wh = (mAh × V) / 1000. Example: 20,000 mAh at 3.7 V ≈ 74 Wh.
- Keep original capacity label visible; if only mAh appears, calculate Wh and attach a tag with that value.
- Power down integrated output functions to avoid accidental activation during transit.
- Declare packs >100 Wh to the carrier at check-in and obtain written approval when required.
- Store all spare packs in carry-on with terminals insulated; do not pack spares inside checked travel cases.
Check the specific carrier policy before departure and consult IATA/ICAO guidance for international routes; non-compliant power packs can be confiscated or cause denied boarding.
How to identify built‑in Li‑ion power packs: labels, compartments, and model numbers
Check the shell and external tags for UN numbers and a watt‑hour (Wh) rating; if absent, open all external and internal pockets and inspect for a hard plastic module or USB port assembly.
Labels and markings to expect
Look for UN3480 (cells) or UN3481 (cells packed with equipment) and the small pictogram showing a cell with flames. Legitimate modules often show: rated capacity in Wh, mAh plus nominal voltage (V), a manufacture or model code, and safety approvals (UL, CE, PSE). Common label formats: “Rated capacity: 100Wh”, “5000mAh (3.7V) = 18.5Wh”, or “UN3481”. If the mAh is present but Wh is not, convert using Wh = (mAh × V) / 1000 (use 3.7V as cell nominal voltage unless a different V is printed).
Compartments, module locations and model‑number checks
Typical locations for integrated power packs: side pockets with a zippered flap, a molded panel in a telescopic‑handle cavity, a dedicated “USB” pocket with a fixed cable, and a removable foam insert under the main lining. The module itself will be a rectangular hard case with an adhesive label; connectors may be JST, Molex or a flat ribbon to a PCB. Photograph the module label and search the printed model number + “spec” or “Wh” to retrieve datasheets.
Practical checks: 1) If an external USB port is present, assume an internal power pack; 2) Measure mAh→Wh when only mAh is given (example: 20,000mAh at 3.7V = 74Wh); 3) If the module is sealed with rivets or glued and no label appears, treat the item as containing cells and consult the manufacturer or product manual for the model code; 4) For air travel, remember thresholds: under 100Wh generally permitted in carry‑on, 100–160Wh requires airline approval, above 160Wh is not allowed on passenger aircraft.
Airline rules: checked hold vs cabin for devices with built-in power cells
Quick answer: Keep spare power packs and loose rechargeable cells in cabin only; installed internal power packs may travel in checked hold on many carriers but placing devices in the cabin is safer and usually required for spare units.
Standard numerical limits (IATA/ICAO / FAA practice): up to 100 Wh – carriage in cabin without airline approval; 100–160 Wh – airline approval required and typically limited to two units per passenger; over 160 Wh – not permitted on passenger aircraft. Spare uninstalled cells must be in the cabin with terminals insulated (tape or original packaging).
What major carriers follow: U.S. airlines (American, Delta, United) align with FAA guidance: spare power packs banned from checked hold, installed power packs often allowed in checked but must be switched off and protected; EU and UK carriers follow EASA/IATA rules with similar limits and approval requirements for 100–160 Wh items. Individual carrier policies can add stricter controls – always check the specific airline page before travel.
Practical checks and actions: read the product label for Wh (or calculate Wh = (mAh/1000) × V), tape exposed terminals, declare any device over 100 Wh to the airline at booking/check‑in, obtain written approval if between 100–160 Wh, and never place spare power packs in checked hold. For a cabin bag that fits power banks safely and keeps terminals protected see best messenger bag for disney.
When uncertain, contact the carrier with model and Wh rating; keep documentation (manufacturer label/manual) handy at the airport.
How to safely disable or remove a fixed power pack from a suitcase before travel
Disconnect an internal power pack at its plug and insulate exposed terminals; if the pack is soldered or glued in place, stop work and contact the manufacturer or an electronics repair shop.
Required tools: Phillips #0/#1, Torx T6/T8, multimeter, insulated diagonal cutters, heat-shrink tubing, electrical tape, ESD-safe gloves and eye protection, plastic tray to contain screws. Work on a non-conductive surface with no metal jewelry.
Confirm voltage with a multimeter across the pack output: single-cell nominal ~3.6–3.7 V, 2S ~7.2–7.4 V, 3S ~10.8–11.1 V. If voltage reading is present, label the pack voltage and capacity before touching. If the enclosure lacks a service panel, consult the model number and the manufacturer’s service manual for access points.
If a detachable connector (JST, Molex, XT60, etc.) is present, unplug it and secure each exposed pin with non-conductive tape or heat-shrink. For inline fuses or circuit boards, note orientation and keep screws/small parts in a labeled bag so the unit can be restored later.
If the pack is permanently wired: do not puncture cells. Desolder the positive lead using a temperature-controlled iron and solder sucker, or cut the positive conductor with insulated cutters leaving 10–15 mm of slack; immediately cover both cut ends with heat-shrink and tape to prevent shorting. Never cut into cell casings or crush modules.
For permanent removal, lift the pack out with minimal flex on wiring, protect terminals with individual plastic caps or non-conductive tape, then store the module inside a rigid container or fire-resistant pouch. Target a storage state-of-charge of roughly 30–50% when possible; deep discharge below safe threshold can render packs unsafe and may void recycling acceptance.
Transport and disposal: do not place removed modules in checked compartments for air travel; keep them in carry-on in a protected, insulated case and declare if requested by carrier. Take removed modules to a certified recycling or hazardous-waste facility; do not puncture, incinerate, or place in household trash. If the pack shows swelling, heat damage, or corrosion, handle as damaged goods and notify the recycler in advance.
If unsure about access or internal wiring, hire a certified repair service or request an official removal kit from the manufacturer. For external protection of the opened shell or stored components during wet weather, consider a protective cover such as best waterproof and uv protection for umbrellas.
Rules for carrying external power banks and cases with built-in power cells: capacity limits and storage tips
Keep external power banks and spare power packs in carry-on only; spare packs must not be placed in checked baggage.
Capacity limits (Watt‑hours and mAh)
Allowed without airline approval: up to 100 Wh per unit. Units between 100 Wh and 160 Wh require airline approval and are limited to two per passenger. Units above 160 Wh are prohibited from both checked and carry-on compartments.
Quick conversions (nominal cell voltage 3.7 V): 100 Wh ≈ 27,000 mAh; 160 Wh ≈ 43,200 mAh. Convert using: mAh = (Wh ÷ 3.7) × 1000. If a pack lacks a Wh label, request manufacturer specification or refuse to carry it rather than guessing.
Practical packing and storage tips
Insulate terminals with electrical tape or protective caps; store each pack in a separate pouch to prevent contact and short circuits. Do not place loose cells or spare packs inside checked baggage.
Keep capacity markings visible (Wh or mAh and voltage); carry proof of specification (product label, invoice, or manufacturer PDF) for airline staff if questioned. Turn off any power‑management switches and disable pass‑through charging during transit.
Avoid locations with sustained temperatures above 60°C and protect from direct sunlight, heavy compression, or impact. Place packs in an accessible pocket of the carry-on so they can be removed quickly if requested during screening.
For replacements or higher‑capacity modules for tools and outdoor equipment, verify Wh rating before purchase; retailers list pack specifications – for an example product listing see best deal on cordless lawn mower.
If in doubt about a device with built-in cells, consult the manufacturer for the Wh rating and follow airline procedures for declaring units that require approval.
FAQ:
Do some pieces of luggage come with lithium batteries built in?
Yes. Several modern suitcases include built-in lithium-ion packs used as power banks for phones or to run motorized wheels. These batteries are often removable so they can be carried separately if required by an airline.
What airline rules apply to luggage that contains lithium batteries?
Air carriers and international rules treat lithium cells and packs as a safety risk on passenger flights. The usual practice is that batteries must travel in the cabin, not in checked baggage. Capacity limits are expressed in watt-hours (Wh): packs up to about 100 Wh are normally allowed in carry-on without prior approval; packs between about 100 Wh and 160 Wh typically need airline approval and are limited in number per passenger; packs above 160 Wh are generally not allowed on passenger aircraft. Spare batteries must be protected against short circuits and carried in hand luggage. Because carriers and countries may set stricter rules, check the airline’s page before you fly.
Can I check a suitcase that has a non-removable lithium battery inside?
Many airlines will refuse checked transport of luggage with non-removable lithium packs. If the battery cannot be removed, gate agents or security staff may require the item to be taken off the aircraft. To avoid problems, choose bags with removable batteries or remove the pack and carry it in the cabin. If you must travel with an item that has a fixed battery, contact the carrier well ahead of departure to get clear guidance and written approval if it is allowed.
How do I find the battery capacity and prepare the pack for flying?
Look for a label on the battery or inside a battery compartment that lists voltage (V) and capacity in ampere-hours (Ah) or milliampere-hours (mAh). Convert to watt-hours with this formula: Wh = V × Ah (to convert mAh to Ah divide by 1,000). For example, a 3.7 V, 5,000 mAh pack equals 3.7 × 5 = 18.5 Wh. Before travel, switch the battery off, cover exposed terminals (tape over contacts or use original caps), place the pack in a protective pouch, and carry it in your hand luggage. Keep documentation or the manufacturer label visible so staff can verify the rating if asked.
What hazards do lithium batteries in luggage pose and what should I do if one overheats or smokes?
Lithium batteries can fail and enter thermal runaway, producing heat, smoke, or flames. Warning signs include unusual warmth, a swollen case, or a chemical smell. If you spot these signs, move people away and alert staff or crew immediately. Do not try to breathe the fumes. On the ground, use the nearest fire alarm and call emergency services; trained responders will use appropriate extinguishing methods and containment. On board an aircraft, notify a flight attendant right away so crew can follow safety procedures; they carry fire suppression tools and trained protocols. Do not attempt to puncture or fully submerge a burning battery yourself; leave handling to professionals.
