There is a lot the world couldn’t do without lithium or lithium-ion batteries.
Lithium batteries, especially lithium-ion ones, are the go-to choice for electronics because they're powerful, lightweight, and rechargeable. You can find them in smartphones, laptops, and tablets, as well as in power tools, pacemakers, drones and e-bikes.
The Dangers and Regulations Surrounding Lithium Battery Shipping
However common and useful these batteries are, the UN classifies them as dangerous goods because they are a potential source of heat, sparks, or even fire
In fact, lithium ion batteries are classified as Class 9 dangerous goods because of their fire hazard potential during transport. In 2022, the Federal Aviation Administration reported around 62 incidents involving lithium-ion batteries on airplanes and in airports.
It is crucial to select lithium ion battery storage and shipping containers and pack lithium batteries correctly for secure transport.
There is no universal answer to the question of what type of lithium-ion battery storage container is needed. To safely ship lithium batteries, one must consider the battery type, quantity, packaging quality, and the battery storage container’s ability to pass drop and stacking tests.
Also, the International Air Transport Association (IATA) and FAA have tightened regulations for shipping lithium batteries, making it more important than ever to understand safety classes, certifications and standards for lithium battery shipping boxes and storage cases.
Though the regulations are complex, the government expects compliance. Shippers who neglect international packing and shipping safety regulations may face fines and penalties.
How to Ship Lithium Batteries
Shipping criteria depends on factors such as battery size, location (whether it's separate or within equipment), and condition.
The FAA’s Interactive Guide to Shipping Lithium Batteries simplifies complex regulations for lithium battery shipments into a series of questions to ask before shipping them:
- What type of lithium battery or cell are you shipping? Are they lithium metal batteries or cells (non-rechargeable batteries) or lithium ion/polymer batteries or cells (rechargeable batteries)?
- How are you shipping them? Will the batteries or cells be packed with equipment (separately in the same package)? Will they be shipped within the equipment? Or will they be packaged alone?
- What is the capacity of the li-ion battery? What is the watt/hour rating of the lithium ion battery cell? All lithium batteries must be shipped at a state of charge not exceeding 30% of their rated design capacity.
- How much lithium does the battery/cell contain?
- How many lithium-ion cells does the package contain in total?
- How many packages are in the shipment?
The answers to these questions will dictate your lithium battery packaging and shipping requirements.
Take, for example, a package with multiple lithium batteries. Here, you must clearly label the case as containing lithium batteries and include instructions for handling if they are damaged. The storage case also must pass a 1.2-meter drop test without harming the batteries, prevent movement that could cause short circuits, and protect against leaks.
A lithium ion battery shipping box also must be strong and rigid unless the battery is well-protected by equipment. To prevent terminal caps from loosening or terminals from shifting, batteries should be packed securely and cushioned within a li-ion battery box.
To meet these specific demands, the most effective option is UN/IATA Certified Cases.
How to Select a UN/IATA Certified Case
If you only ship batteries now and then or travel with lithium batteries for an occasional vacation, you might not need a certified case. But if you frequently ship lithium batteries as a photographer, commercial drone operator or for other reasons, using a certified case for shipping is recommended.
UN/IATA cases provide a secure solution for storing and transporting lithium batteries, ensuring compliance with shipping regulations set by UN and IATA.
There are several considerations to help you select the right UN/IATA certified case for your needs.
First, understand the UN regulations that apply to your battery shipment. The UN has different certifications for different shipping circumstances. For example:
- UN 3090, best for lithium metal batteries (shipped by themselves)
- UN 3480, best for lithium ion batteries (shipped by themselves)
- UN 3091, best for lithium metal batteries in equipment or packed with equipment
- UN 3481, best for lithium ion batteries in equipment or packed with equipment
Next, consider a certified case constructed of aerospace-strength aluminum, rotationally molded polyethylene, injection-molded plastic, and custom-cut foam inserts to safely store lithium ion batteries during shipping.
Make sure the battery storage container is waterproof, dustproof, and tough enough to handle impact and shock. To meet these objectives, select a lithium ion shipping case that is designed and constructed under Chapter 7 of ATA Specification 300 and ATA Specification 300 Category I, and is compliant with DOT Title 49 CFR; Performance Oriented Packaging Standards, Section 178, as well as the UN/IATA Dangerous Goods Regulations.
ATA Specification 300 confirms the case has passed a demanding series of drop or impact tests and offers interior cushioning. Under this spec, lithium battery container cushioning must permanently attach to a battery storage container’s walls. It also must deflect or compress no more than 60% of its thickness when the case is dropped from a height of 1 meter.
Suitable lithium ion battery storage also meets MIL-STD-810, which ensures the cases can withstand specific conditions and environmental stresses, such as temperature, rain, wind, humidity, fungus, rust, sand and dust, explosive atmospheres, shock, and more.
What Lithium Storage & Shipping Cases are Available?
Cases2Go offers a range of UN/IATA approved and certified storage containers that meet the dangerous goods transit needs of lithium batteries.
Our UN/IATA Certified 4B Shipping Cases are durable, sturdy, stackable and palletizable. They feature stainless-steel hinges, two lid straps, and water-resistant seals. Cast aluminum stacking corners and beading at the periphery and corners further increase their stability and strength.
You can secure your equipment by sealing your lithium ion shipping case with a zip tie or lead seals during transit. Foam inserts and dunnage are also provided to secure the batteries in our lithium ion transport boxes.
Cases2Go's aluminum containers also comply with UN's 4B performance requirements, which include ATA Spec 300 Cat 1 and MIL-STD-810.
For added protection of lithium batteries and lithium ion batteries, Cases2Go also offers an unlimited selection of UN 4D Plywood boxes and 4H2 plastic cases that meet or exceed ATA Specification 300, Category 1. These cases work well as outer packaging for lithium ion batteries.
Lithium battery storage cases are available in custom sizes and for unique equipment needs, from drones to cameras to e-bikes and more.
Need a case for shipping your batteries? Contact Cases2Go for consultation and customization options.
With over 35 years of experience, we understand the requirements for lithium-ion battery shipping. Our ISO-certified team is here to help you find the right shipping containers to keep your products safe and compliant with federal air shipping rules. Call (800) 636-1690 to learn more.