Power banks require careful handling, regulation, and innovation to make their use safer
Airlines worldwide are tightening restrictions on power bank usage aboard flights.
The reason: there are rising concerns over lithium-ion battery safety.
At least 12 incidents of onboard fire (see list below) had been reported since 2004, with the latest incident being the Virgin Flight VA1528 on Monday, July 21, 2025.
The rules are evolving. The single aim: minimise the risk of battery fires disrupting flights.
Notably, starting October 1, 2025, Emirates has banned the use of power banks while in-flight.
Although passengers may still carry one power bank rated below 100 watt-hours, its use to charge devices or be recharged using the aircraft’s power supply is strictly prohibited.
Additionally, power banks cannot be stored in overhead compartments but must be kept within reach in seat pockets or bags under the seat.
Other major carriers have implemented similar measures to curb fire risks during flights.
This underscores the challenges airlines face balancing modern device connectivity with the inherent fire hazards of lithium-ion power banks.
It starts with passenger education.
Understanding the chemical and physical reasons lithium-ion batteries pose fire risks explains why power banks, a prevalent consumer product, require careful handling, regulation, and innovation to make their widespread use safer for all, especially in critical environments like aircraft.
The risk is primarily because they use lithium-ion batteries, which are inherently fire-prone due to their chemistry and energy density.
Lithium-ion batteries store a substantial amount of energy in a compact space, using flammable electrolyte liquids that facilitate ion flow between the battery’s cathode and anode.
When these batteries are damaged, defective, or subjected to extreme conditions, they can enter a dangerous state called “thermal runaway”, where internal heat buildup triggers a self-sustaining chemical reaction, often leading to fires or explosions.
Lithium-ion battery cells consist of a cathode (positive electrode), an anode (negative electrode), a separator, and a liquid organic electrolyte. The electrolyte is highly flammable.
During normal operation, lithium ions move between the cathode and anode to charge and discharge the battery.
However, if the battery experiences abuse — such as physical damage (crushing or puncturing), overheating, overcharging, or a manufacturing defect — it can cause an internal short circuit.
This short circuit generates heat beyond what the battery can dissipate. As the temperature rises, the separator can melt or collapse, causing more short circuits and releasing volatile and flammable gases.
This chain reaction is the thermal runaway process — a chemical escalation that produces intense heat (up to 1000°C), flames, toxic fumes, and sometimes explosions.
Thermal runaway can be triggered by:
Extreme temperatures (both heat and cold)
Overcharging or prolonged charging
Internal short circuits due to manufacturing defects or lithium plating
Mechanical damage (dropping, crushing, puncturing)
Exposure to moisture causing short circuits.
Because of the flammable materials inside, fires caused by lithium-ion batteries are difficult to extinguish. They produce oxygen and flammable gases internally, so removing external oxygen does not fully stop the fire. Thermal runaway events can continue for hours or days, with burned-out batteries potentially reigniting.
August 7, 2004 | FedEx | Lithium-ion battery shipment caught fire during loading in Memphis, TN.
2006 | UPS | Lithium-ion battery fire destroyed plane in Philadelphia, two crew fatalities.
September 3, 2010 | UPS | Cargo plane crashed in Dubai, lithium-ion battery fire, two fatalities.
April 26, 2014 | Unknown | Passenger’s bags in Melbourne caused fire in Boeing 737 cargo hold.
August 17, 2022 | American Airlines | Vape pen overheated in cabin during flight to Philadelphia.
August 29, 2022 | United Airlines | Power bank overheated, secured in thermal containment bag, no injuries.
March 1, 2023 | Spirit Airlines | Battery fire in overhead bin, diverted to Jacksonville, ten hospitalized.
February 2023 | United Airlines | Laptop battery fire on flight from San Diego, four injured.
July 2023 | American Airlines | Laptop battery ignited in carry-on, caused chaos, no injuries reported.
July 2023 | Virgin Australia | Power bank fire in overhead locker on Sydney-Hobart flight, extinguished.
January 28, 2025 | Air Busan | Power bank fire destroyed plane on South Korea tarmac, three injured.
(Sources: FAA, News Reports)
The International Air Transport Association (IATA) enforces strict rules for transporting lithium-ion batteries, including power banks, on commercial flights to mitigate fire risk:
Power banks must be carried only in carry-on baggage, not checked luggage, to allow quick response in case of fire.
Power banks must be individually protected to prevent short circuits (e.g., in original packaging or with terminals covered).
Batteries with a watt-hour rating over 100Wh require airline approval before carriage. Those above 160Wh are generally prohibited on passenger aircraft.
Quantity limits apply: usually up to two spare batteries above 100Wh per passenger, but airline policies may vary.
Usage of power banks during flight is typically restricted and must comply with crew instructions.
Given the surge in portable electronics, ensuring the safe use of lithium-ion batteries and power banks is critical. The path forward involves:
Improved battery design: Manufacturers are researching safer battery chemistries, solid-state electrolytes (non-flammable), better separators, and enhanced battery management systems (BMS) to detect faults early and prevent thermal runaway.
Stricter quality control: Ensuring batteries are manufactured without defects and conform to safety standards can reduce fire incidents.
Better user awareness: Educating consumers on safe charging practices, avoiding extreme conditions, and handling damaged batteries properly.
Regulatory tightening: Continued updates of transportation and handling rules by IATA, FAA, and other agencies reflect growing awareness and evolving battery technologies.
Firefighting innovation: Developing specialised firefighting techniques, materials, and protocols for lithium battery fires helps mitigate damage when incidents occur.
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