New safety rules for power banks on aircrafts

Smartphones, tablets, and headphones are indispensable for business travelers, but without a power bank, staying connected is often difficult. However, passengers carrying portable battery packs on board should be aware of stricter regulations introduced by international aviation authorities and airlines.
Several incidents involving lithium-ion batteries have once again highlighted the risks associated with these energy storage devices. The German TÜV Association (TÜV-Verband e.V.) has reviewed the new safety requirements for power banks on aircraft.
Risks of Lithium-Ion Batteries
According to Dr. Hermann Dinkler, a fire and explosion protection expert at TÜV-Verband, power banks are generally safe products when they are well manufactured and used properly. However, lithium-ion batteries store large amounts of energy in a very small space. If battery cells are severely damaged, an internal short circuit can occur, generating extremely high temperatures within a short time. The affected cell may overheat uncontrollably and trigger a thermal runaway reaction, causing neighboring cells to heat up as well, potentially resulting in smoke and flames.
Carry-On Luggage Only
Power banks may only be transported in carry-on baggage. This allows cabin crew to respond quickly in an emergency, whereas a battery fire in checked luggage would be much more difficult to detect and contain. The key issue is not cruising altitude or cabin pressure, but ensuring that any defect can be identified and managed immediately during the flight.
Proper Storage and Handling
Power banks should be protected from mechanical stress and stored so that their terminals cannot come into contact with metal objects. Even dropping a power bank on a hard surface or exposing it to heavy pressure from luggage can damage the battery cells. Loose power banks carried in bags or backpacks alongside keys, coins, or other metal objects may cause a short circuit. Protective caps, cases, or the original packaging can significantly reduce this risk.
Damaged, swollen, or unusually warm power banks should no longer be used and should never be taken on a flight. Depending on the airline, using a power bank to charge other devices during the flight may be prohibited, and some airlines also ban charging the power bank itself. Certain carriers additionally require passengers to keep power banks easily accessible throughout the flight.
Purchase Criteria and Capacity Limits
When purchasing a power bank, consumers should pay attention to certified safety standards. Extra caution is advised when considering low-cost products or devices from unknown manufacturers. If information about the manufacturer, capacity, or technical specifications is missing, consumers should be skeptical.
Power banks with a capacity of up to 100 Wh (approximately 27,000 mAh) can generally be carried in hand luggage without special approval. For devices between 100 Wh and 160 Wh, airline approval is often required. High-quality power banks include protection against overcharging, deep discharge, overheating, and short circuits. The CE marking and additional certifications such as the GS mark provide useful guidance when assessing product safety.

Source: TÜV-Verband e.V.