In 2027, new more stringent power bank restrictions will be put into place for commercial aircraft across the globe, including the U.S., limiting their size, storage and use in the plane.
In 2014, the FAA (Federal Aviation Administration) reported nine Lithium-ion (Li-Ion) battery incidents aboard U.S. airlines. By 2021, there were 54 incidents involving Li-Ion battery thermal runaways on U.S. airlines. By 2024, the FAA reported 89 verified lithium-ion battery related incidents and last year there were 97 incidents. That’s almost two verified incidents of smoke or fire from Li-Ion battery thermal runaways per week on U.S. airlines, last year.
Air travelers bring many devices with Li-Ion batteries with them while traveling.
According to underwriter laboratories (UL), in 2024 the average air traveler brought four Li-Ion powered devices aboard their flights. They typically included smartphones, laptop computers, wireless headphones, and tablets. In my opinion, in 2026, based upon my personal observation, I believe that air travelers are carrying more Li-Ion powered devices than ever. My wife and I typically take smart phones, smart watches, tablets, hearing aids, laptop computers, mirrorless cameras, wireless headsets and portable power banks with us when we travel.
In 2024, vaping devices, according to UL, were carried by only 10 percent of air travelers on U.S. airlines, but were the leading cause of thermal runaway incidents, responsible for 28 percent of the total that year. Recently, however, power bank thermal runaway incidents on aircraft have been increasing.
What is thermal runaway?
In normal operation, Li-Ion batteries rapidly convert chemical energy into electricity. Thermal runaway occurs when when an internal cell of a lithium ion battery short-circuits or otherwise fails and starts to rapidly heat uncontrollably. Typically it’s caused by battery damage, improper charging, poor manufacturing or internal failure such as a short circuit.
Li-Ion battery fires are dangerous because they release toxic gases, have intensely hot flames and their fires are extremely difficult to put out. They’re difficult to put out is because they generate their own oxygen, so unlike most fires, starving them for air will not stop the fire. In the confined space of an airplane cabin, the toxic smoke and extreme heat can quickly endanger passengers.
Li-Ion batteries are particularly dangerous if packed in checked luggage because the airplane’s crew is unable to reach them, and the Halon gas firefighting system in the cargo hold isn’t effective in fighting Li-Ion battery fires.
The potential seriousness of thermal runaway fires is due to typical Li-Ion power bank’s substantial size, generally larger than even many if not most laptop computers. My Dell Latitude laptop has a 68Wh (watt-hours) capacity, but my Hyper-Juice 245W four position USB-C power bank has a 98.01Wh capacity, more than 44 percent larger than my Dell laptop battery.
Current IATA (International Air Transport Association) guidance for Li-Ion power banks state:
• Power banks are prohibited from checked luggage.
• Power banks should only be packed in carry-on luggage or personal items.
• Power banks’ capacity should be no more than 100Wh.
Currently, some U.S. airlines power bank rules are more strict than IATA and FAA guidelines.
American airlines limits each passenger to no more than two power banks of up to 100Wh. They may not be stowed in carry-on luggage that is stored in an overhead bin. If being used during a flight, a power bank on American planes must be visible or at least easily accessible. American doesn’t permit charging power banks on their planes.
Many international airlines have power bank rules that are more strict than in the U.S. Emirates, for example, permits passengers to carry no more than one power bank on to their flight. Like American Airlines, it can’t be larger than 100Wh. Unlike American Airlines, you’re not allowed to use it inflight.
Starting in January, 2027 more stringent IATA guidance for power banks has been added to existing guidance:
• Power banks may not be recharged while on board aircraft.
• Power banks may not be use to recharge other devices inflight.
• No passenger may bring a board more than two power banks.
Of course, as it is true today, airlines may have more stringent rules than the IATA’s guidelines, should they desire.
If passenger see a Li-Ion battery smoking or on fire, they need to notify the flight crew immediately.
If passengers see a Li-Ion battery smoking or on fire, they need to notify the flight crew immediately. Passengers should never try to put out a Li-Ion battery fire themselves. If an Li-Ion battery fire occurs, passengers should clear the area immediately for their safety and notify flight crew. Flight attendants have specialized tools to safely stop the thermal runaway.
In addition to following the airlines’ power bank rules, air travelers need to be alert for their personal safety to signs their power banks aren’t safe to use. Understanding when power banks must be properly disposed of at household hazardous waste collection sites, never in the trash or recycling, due to safety problems, is critical for anyone owning a power bank. An unsafe power bank can burn down a home as easily as it can cause severe problems in the air.
Several years ago, I had a laptop computer with a bulging case on its underside. I first noticed it in my home office when it wobbled on my desk. When I turned it over I immediately knew the battery was no longer safe to use. I turned off the computer and pulled out its plug. I let it sit to cool, then put it in a fireproof cabinet. I had an extended Dell business warranty and called support. By the next day they were at my office. They replaced my case and battery and took the old battery away for proper disposal.
Li-Ion Battery problems requiring proper disposal:
If you’re power bank has a bulging or swollen case, stop using it and don’t charge it. Dispose of it properly.
Power banks will get somewhat warm while in use or being charged. If it gets uncomfortably hot to your touch, it means that it’s headed for failure. While high quality power banks have thermal sensors that will shut the battery down, you can’t depend upon that. Immediately stop using and charging your power bank. Dispose of it properly.
If you’re power bank shows any physical damage or you detect a burning smell or chemical odor coming from it, immediately stop using or charging the power bank. A damaged power bank can have thermal runaway at any time. Immediately dispose of the power bank properly.
While lithium ion battery fires on airplanes are actually rare compared to the number of lithium-ion batteries in use on planes, you must be vigilant at all times to be sure your power bank is working properly with no damage whatsoever. When you fly, follow your airline’s rules for power banks at all times. They’re designed to keep you and the other passengers and the flight crew safe.
After many years working in corporate America as a chemical engineer, executive and eventually CFO of a multinational manufacturer, Ned founded a tech consulting company and later restarted NSL Photography, his photography business. Before entering the corporate world, Ned worked as a Public Health Engineer for the Philadelphia Department of Public Health. As a well known corporate, travel and wildlife photographer, Ned travels the world writing about travel and photography, as well as running photography workshops, seminars and photowalks. Visit Ned’s Photography Blog and Galleries.
