Safely Pack Batteries for Airplane Transport in 2025

陈玛丽

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Safely Pack Batteries: Key Rules

Carry-On vs. Checked Bags

When you get ready to fly, you need to know where to pack your batteries and devices. Airlines and the TSA have strict rules for 2025. Most batteries, especially lithium-ion batteries, must go in your carry-on luggage. You cannot put spare lithium batteries or power banks in checked bags. This rule helps prevent fires in the cargo hold, where crew cannot reach them quickly.

Here’s a quick guide to help you:

Battery Type / Item	Carry-On Rules	Checked Baggage Rules
Spare Lithium-ion & Lithium-metal Batteries (including power banks)	Allowed only in carry-on; must not exceed 2 larger spare batteries (101–160 Wh) with airline approval; max 15 lithium batteries total onboard	Strictly prohibited in checked baggage
Devices with Installed Batteries (e.g., laptops, cameras)	Allowed in carry-on; recommended to keep in carry-on to prevent damage	Allowed only if batteries are installed; spare batteries not allowed
Power Banks and Extra Phone Batteries	Must be carried in carry-on only	Not allowed

You should always keep your portable devices, like laptops and cameras, in your carry-on luggage. If you pack them in checked bags, make sure the batteries stay inside the device. Never pack spare lithium batteries in checked baggage. This is one of the most important safety rules for air travel.

小贴士 Double-check your airline’s website for any extra regulations before you pack. Some airlines have their own rules for the transport of batteries.

Spare Battery Restrictions

You might want to bring extra batteries for your portable devices, but you need to follow some important precautions. Spare lithium-ion batteries must always go in your carry-on luggage. You cannot put them in checked bags or any area you cannot reach during the flight. The FAA and TSA do not set a strict limit on the number of spare batteries, but you must pack them safely and follow watt-hour limits.

Here are the main restrictions you need to remember:

Spare lithium and lithium-ion batteries must be protected from damage and short circuits. Use the original packaging, tape the terminals, or place each battery in a separate pouch.
You cannot carry loose batteries that are not protected from short circuits anywhere on the plane.
Lithium metal batteries shipped alone are not allowed on passenger flights.
Devices with batteries installed can go in checked bags, but spare batteries cannot.
Damaged or recalled batteries are not allowed unless made safe.

Many travelers make mistakes with these rules. Here are some common errors:

Packing spare lithium batteries in checked luggage.
Ignoring watt-hour limits for lithium-ion batteries.
Carrying too many batteries or not protecting the terminals.
Not turning off devices completely before packing.
Forgetting to check airline-specific regulations.

请注意： Always keep spare batteries in your carry-on and make sure they are easy to inspect at security.

Preventing Short Circuits

Short circuits can cause fires, so you need to take extra care when you safely pack batteries. Lithium-ion batteries are sensitive and can spark if their terminals touch metal or other batteries. You can prevent this by following a few simple steps:

Cover battery terminals with electrical tape or use the original packaging.
Wrap each battery in bubble wrap or place it in a protective case.
Use inner packaging, like small boxes, to keep batteries separate.
Store batteries upright and away from heat sources.
Use strong outer packaging, such as a hard case or fiberboard box, to protect against bumps.
Seal packages well to stop leaks or spills.
Handle batteries with care and use non-conductive tools if needed.

Safety Reminder: Never pack damaged or swollen batteries. Dispose of them before your trip.

You can also follow these practical tips to stay safe and follow all regulations:

Do not crush batteries by putting heavy items on top of your devices.
Keep at least one battery installed in each device.
Avoid exposing batteries to heat before or during your trip.
Report any damaged or hot batteries to airline staff right away.
Label large batteries and carry any needed paperwork.
Check for updates on airline and international rules before you travel.

If you follow these steps, you can safely pack batteries and avoid problems at the airport. You will also help protect yourself and others from fire risks linked to lithium batteries.

Battery Safety and Risks

Fire Hazards

You might not realize how much risk batteries can bring on a plane. The main danger comes from fire. Lithium-ion and lithium metal batteries can overheat and catch fire if you do not follow the right precautions. Here are some reasons why fires start:

Internal defects or damage inside batteries
Short circuits from metal objects touching battery terminals
Overcharging or exposing batteries to extreme heat
Mishandling or crushing batteries in your bag

When a battery catches fire, it can release hot gel and even shrapnel. The smoke and vapors are not just flammable—they can also irritate your eyes and nose. Fires from lithium metal batteries are even harder to put out. Standard airplane fire extinguishers do not work well on these fires. That is why airlines set strict rules and limit how many batteries you can bring. You should always pack batteries in your carry-on and keep them in sight for safety.

小贴士 If you notice a device overheating, cool it with water or a non-alcoholic drink and alert the crew right away.

Thermal Runaway Incidents

Thermal runaway incidents sound scary, and they are. This happens when a battery gets so hot that it starts a chain reaction, causing more heat and sometimes an explosion or fire. On U.S. flights, about two thermal runaway incidents happen every week, even though there are around 180,000 flights each week. Most of these incidents involve e-cigarettes or power banks. They usually happen near passenger seats, which helps the crew spot and handle them fast.

Here is a quick look at the numbers:

Metric	Value
Weekly incidents (2023)	~2
Weekly flights (2023)	~180,000
Incident increase (2019-2023)	28%
Most common sources	E-cigarettes, power banks

Thermal runaway incidents are rare, but they can cause serious problems. Fires in checked luggage are more dangerous because the crew cannot reach them quickly. That is why you should always keep devices with batteries in the cabin and follow all safety precautions.

Inspecting for Damage

Before you pack, you need to check your batteries for any signs of trouble. Damaged batteries are much more likely to cause a fire or thermal runaway incidents. Here is a simple checklist to help you:

Look for cracks, leaks, or swelling on the battery.
Check the terminals for rust or corrosion and clean them if needed.
Make sure batteries are attached securely to your devices.
Tape the terminals or use protective cases for spare batteries.
Never pack recalled or damaged batteries.

You should avoid crushing or bending batteries. Always use the original packaging or a plastic bag to keep batteries safe. These precautions help you lower the risk of fire and keep everyone on your flight safe.

Lithium-Ion Batteries: Airline Rules

Watt-Hour Limits

When you pack lithium-ion batteries for your flight, you need to know the watt-hour (Wh) limits. Airlines set these limits to keep everyone safe. Most major airlines in 2025 let you bring lithium-ion batteries up to 100 Wh in your carry-on bag without any special approval. If your lithium-ion batteries are between 100 Wh and 160 Wh, you must get airline approval before your trip. You can only bring two spare batteries in this range, and they must stay in your carry-on.

Here’s a quick list to help you remember:

Lithium-ion batteries up to 100 Wh: Allowed in carry-on, no approval needed.
Lithium-ion batteries between 100 Wh and 160 Wh: Need airline approval, max two spares.
Lithium-ion batteries over 160 Wh: Not allowed on passenger flights, except for some medical or mobility devices with special arrangements.
Spare lithium-ion batteries: Never allowed in checked baggage.

Different airlines have their own rules. For example, American Airlines lets you bring up to four spare batteries under 100 Wh, while United Airlines allows up to three power banks under 100 Wh. Always check your airline’s website before you pack.

小贴士 Always pack your lithium-ion batteries so the terminals do not touch. Use tape or the original packaging to prevent short circuits.

Airline Approval

If you need to bring large lithium-ion batteries (over 100 Wh), you must get airline approval. This process helps airlines track and control high-capacity lithium-ion batteries. You will need to show that your lithium-ion batteries meet UN 38.3 certification. Airlines follow IATA Dangerous Goods Regulations, which cover how you pack, label, and document your batteries.

Here’s what you should do:

Contact your airline at least 72 hours before your flight.
Provide details about your lithium-ion batteries, including watt-hour rating and certification.
Make sure your batteries are in strong packaging that protects against drops and short circuits.
Only trained staff can handle and approve these batteries.

If your lithium-ion batteries are damaged or defective, you cannot bring them on the plane.

Hazardous Materials Regulations

Lithium-ion batteries fall under hazardous materials regulations for air travel. In 2025, new rules include updated UN numbers for lithium and sodium ion batteries. Airlines and shippers must follow the 2025 IATA Dangerous Goods Regulations and US DOT rules. These regulations cover how you classify, pack, and label lithium-ion batteries. They also set limits on the state of charge—most lithium-ion batteries should be at 30% charge or less when shipped.

You will see new UN numbers like UN 3556 for lithium-ion battery powered vehicles. Packing instructions now include extra steps for safety and confidentiality. Airlines must report any incidents and follow strict packaging rules. You should always check for the latest regulations before you fly, as rules can change each year.

请注意： If you travel with lithium-ion batteries, always follow the latest airline and government regulations to avoid delays or confiscation.

Transporting Lithium Batteries and Other Types

Alkaline and NiMH Batteries

When you travel, you probably pack more than just lithium batteries. You might have AA or AAA alkaline batteries for your camera, or NiMH batteries for your wireless mouse. The good news? Transporting lithium batteries comes with strict rules, but alkaline and NiMH batteries are much easier to handle.

Check out this table to see how the rules compare:

电池类型	Watt-hour Limits & Quantity	Luggage Rules	Safety Tips
Lithium-ion	Up to 100 Wh (no approval); 100-160 Wh (max 2, airline approval)	Spare batteries in carry-on only	Protect terminals, use original packaging
Alkaline	No strict limits	Allowed in both carry-on and checked luggage	General protection recommended
NiMH	No strict limits	Allowed in both carry-on and checked luggage	General protection recommended

You can pack alkaline and NiMH batteries in either your carry-on or checked bags. You do not need to worry about watt-hour limits for these types. Just keep them protected from damage. If you carry extra batteries for your laptops, tablets, or cameras, store them in a pouch or their original packaging. This helps prevent leaks or short circuits. Devices like smartphones, tablets, and laptops almost always use lithium batteries, so remember those have stricter rules.

小贴士 Always turn off your devices before packing them. This helps prevent accidental activation during your flight.

Prohibited Batteries

Some batteries are not allowed on planes at all. You need to know these rules before transporting lithium batteries or any other type. Here are the main types you cannot bring:

Loose lithium-ion batteries over 160 Wh
Uninstalled lithium metal batteries in checked baggage
E-cigarettes and vape devices with batteries (must go in carry-on only, never checked bags)

If you try to pack these in your checked luggage, airport security will take them out. Lithium metal batteries have a higher fire risk, so airlines watch them closely. Always keep spare lithium batteries in your carry-on and protect the terminals. If you carry too many spare batteries, security may ask you to remove some.

🚫 Never pack damaged or recalled batteries. If you see swelling, leaks, or cracks, leave them at home.

Transporting lithium batteries safely means following the rules for each battery type. You protect yourself and everyone on board when you pack the right way.

Packing Guide

Preparation Steps

Getting ready to safely pack and ship batteries for air travel takes a little planning. You want to make sure your devices and batteries meet all packaging requirements before you head to the airport. Here’s a step-by-step process you can follow:

Identify the type of battery you have. Check the chemistry, size, and condition. This helps you know which packaging requirements apply.
Keep batteries inside your devices whenever possible. If you have spare batteries, separate them from each other with nonconductive dividers.
Use a sturdy outer box. Place batteries side by side, not stacked, and fill any empty spaces so nothing moves around.
Protect terminals with tape or caps to prevent short circuits.
Seal your package using the H taping method. Cover all seams and flaps with strong tape.
Never pack damaged, swollen, or leaking batteries. Leave recalled batteries at home.
If you have nonspillable wet batteries, mark them clearly as “NONSPILLABLE.”
Place all required labels and markings on the largest side of your package.

Following these steps will help you meet packaging requirements and avoid problems when shipping lithium batteries.

Packaging Materials

Choosing the right packaging materials is a big part of the lithium battery guide. You want to keep your batteries and devices safe during travel. Here are some materials that work best for proper packaging:

Strong, durable outer boxes that protect against drops and bumps.
Non-conductive dividers or sleeves to keep batteries from touching each other or metal surfaces.
Bubble wrap or foam padding to fill empty spaces and stop movement.
Pressure-sensitive tape for sealing all seams and flaps.
Insulating caps or tape for battery terminals.
Labels that show the type of batteries inside and meet all packaging requirements.

These materials help you safely pack and ship batteries, prevent short circuits, and keep your devices secure. Always check that your packaging meets the latest shipping lithium batteries rules.

Labeling

Labeling is a key part of shipping lithium batteries and meeting packaging requirements. In 2025, you need to use the new Battery Mark, which covers both lithium-ion and sodium-ion batteries. Make sure your package shows the correct UN number for the batteries you are sending. Place the Battery Mark and UN numbers on the largest side of your package. This helps airport staff and customs know what’s inside and keeps your shipment moving smoothly. If you follow the lithium battery guide and use proper packaging, you will avoid delays and make sure your devices arrive safely.

Damaged or Recalled Batteries

Identifying Unsafe Batteries

You might think all batteries look the same, but some can be dangerous. Damaged, defective, or recalled lithium batteries can overheat, catch fire, or even explode on a plane. These batteries can start a fire by themselves, especially if they have cracks, swelling, or leaks. Sometimes, a battery can get too hot because of a short circuit or a problem inside the battery. This is called 热失控. It can happen fast and cause a fire that spreads quickly.

Airlines and safety groups warn you not to bring damaged or recalled batteries on your flight. If you see a battery with dents, bulges, or leaking fluid, do not pack it. You should also check if your battery has been recalled by the manufacturer. Carrying these batteries in your bag puts everyone at risk. Rules from the FAA and DOT say you must keep spare lithium batteries in your carry-on, but you should never bring damaged ones at all.

🚨 Safety Alert: If you find a battery that looks damaged or has been recalled, leave it out of your luggage. Tell airline staff if you discover a problem at the airport.

Safe Disposal

You cannot just throw damaged or recalled batteries in the trash. These batteries need special care to keep people and the environment safe. Here are some ways you can get rid of them safely:

Disposal Method	说明
Avoid Carrying Damaged Batteries	Never pack damaged, defective, or recalled lithium batteries in your carry-on or checked bags.
Local Recycling Centers	Take batteries to a community recycling center that handles lithium batteries safely.
Manufacturer Take-Back Programs	Return batteries to the company that made them if they offer a recycling or take-back program.
Call2Recycle	Use groups like Call2Recycle, which have drop-off spots for safe battery disposal.

You should always check with your local recycling center or city website for the best way to dispose of batteries. This helps protect the planet and keeps everyone safe when you travel.

Traveler Checklist

Pre-Trip Review

Before you zip up your suitcase, take a few minutes to double-check your battery items. This quick review can save you from headaches at the airport and help keep everyone safe.

Look through all your bags for devices powered by lithium batteries.
Move every battery-operated item into your carry-on. Checked bags should only have devices with batteries installed, never loose spares.
Use battery-safe travel cases or the original packaging for loose batteries. Cover exposed terminals with tape.
Label high-risk devices, like large power banks or medical equipment, so security can spot them fast.
Never pack damaged, swollen, or recalled batteries. Replace or recycle them before your trip.
If you travel with many devices, bring a TSA-approved fire-resistant battery pouch.
Check your airline’s website for any special rules about battery types or quantities.

小贴士 Avoid last-minute packing. Give yourself time to organize your batteries and devices for maximum safety during travel.

Airport Reminders

Once you arrive at the airport, you still need to follow a few important steps to stay compliant and avoid delays.

Keep all spare lithium batteries in your carry-on, never in checked luggage.
Power off devices with batteries if you must check them. Tape over on/off switches or remove batteries to prevent accidental activation.
Don’t crush your devices—avoid stacking heavy items on top of them.
Carry spare batteries in an easy-to-reach spot for TSA inspection.
Watch out for extreme temperatures. Don’t leave your bag in hot cars or direct sunlight.
If you notice a battery is damaged, leaking, or overheating, tell airline staff right away.
Electronic cigarettes and vape devices must stay in your carry-on. Never put them in checked bags.
Remove batteries from smart luggage before checking it.
Never bring hoverboards or electric scooters with large lithium batteries—they are banned from flights.
Avoid gate-checking bags that contain restricted battery items.

If you don’t follow these reminders, TSA may confiscate your items, delay your flight, or even fine you. Stay alert and make safety your top priority.

Staying Updated

Latest Regulations

Battery rules for air travel change often. In 2025, you will see some big updates. Airlines and governments want to keep everyone safe, so they update regulations as battery technology changes. Here are some of the most important changes you should know:

New UN numbers now cover sodium-ion batteries, not just lithium-ion. You must follow the same packing instructions for both types.
Three new UN numbers were added for electric vehicle batteries. These include lithium-ion, lithium metal, and sodium-ion powered vehicles.
The Battery Mark and Class 9 Miscellaneous Battery Label now mention sodium-ion batteries.
Airlines set new state-of-charge limits. Loose lithium-ion and sodium-ion batteries cannot be charged above 30%. Batteries inside equipment must stay at 30% or 25%, depending on the device. These rules become mandatory on January 1, 2026.
Manufacturers must do more safety testing and provide test summaries to prove their batteries are safe.

In 2025, you cannot put lithium-ion batteries in checked bags on passenger planes. This rule became even stricter after a fire on Air Busan Flight 391. Always check the latest regulations before you fly. You can find updates on the TSA website or in the latest battery guidance document from your airline.

🛫 Tip: Rules can change fast. Check for updates every time you travel, even if you fly often.

Contacting Airlines

Every airline has its own way of handling batteries. Some airlines allow more spare batteries, while others have stricter limits. Before you pack, reach out to your airline for the most current information. You can:

Visit the airline’s official website and search for their battery policy.
Call customer service and ask about battery limits and packaging rules.
Use online chat or email if you need written proof of what is allowed.

If you travel with special batteries, like those for medical devices or large power banks, always get approval in advance. Save any emails or documents you receive. This helps you avoid problems at the airport.

Airline Contact Method	What You Get
Website	Latest battery policy details
Phone	Direct answers to questions
Email/Chat	Written confirmation

If you are not sure about a rule, ask before you fly. It is better to be safe than sorry.

Packing batteries for air travel doesn’t have to be stressful. Just follow these steps:

Keep batteries in original packaging or use Ziploc bags and tape terminals.
Carry spare lithium batteries in your carry-on, not checked bags.
Inspect batteries for damage or leaks before you pack.
Know your airline’s rules and watt-hour limits.

Always check the FAA or your airline’s website for the latest battery rules. Staying updated keeps you, your devices, and everyone on board safe.

常见问题

Can I bring my phone charger or power bank on the plane?

Yes, you can bring your phone charger and power bank in your carry-on bag. Power banks must stay out of checked luggage. Make sure your power bank is under the airline’s watt-hour limit.

What should I do if my battery looks swollen or damaged before my flight?

Do not pack it. Swollen or damaged batteries can catch fire. Take them to a recycling center or use a battery take-back program. Tell airline staff if you find a problem at the airport.

How many spare batteries can I carry in my bag?

Most airlines let you bring up to 15 spare lithium batteries in your carry-on. You can only bring two larger batteries (101–160 Wh) with airline approval. Always check your airline’s rules before you travel.

Do I need to tape the ends of my spare batteries?

Yes, you should cover the battery terminals with tape or use the original packaging. This helps prevent short circuits and keeps everyone safe during your flight.

Can I pack AA or AAA batteries in my checked luggage?

You can pack AA or AAA alkaline and NiMH batteries in both checked and carry-on bags. Keep them in their original packaging or a battery case to avoid leaks or short circuits.

Statistic / Incident Detail	说明
Total lithium battery incidents in 2024	89 incidents involving smoke, fire, or extreme heat aboard aircraft
Passenger disruption rate	18% caused diverted landing, evacuation, or return to gate