Overheated battery-powered devices reported more often on planes: Report

Devices with lithium-ion batteries are overheating more often in air travel, according to a report released Monday.

A report from UL Standards found overheating incidents increased 28 percent from 2019 to 2023 in an analysis of data from 35 passenger and cargo airlines.

An average of two overheating — or thermal runway — incidents were recorded each week on a plane the past five years, though the report noted these events are still “highly unlikely” given the estimated 180,000 flights that take place in the United States per week.

Nearly 9 out of 10 — or 87 percent — of thermal runway incidents were reported on the aircraft, while 13 percent occurred when baggage and personal items were moving, the report said. More than half (60 percent) of these incidents took place in or around the passenger’s seat.

The Federal Aviation Administration reported 37 thermal runway incidents have taken place this year, through Aug. 15.

E-cigarettes overheated the most on planes last year, with 35 percent of thermal runway incidents linked to vaping devices on passenger flights, followed by power banks, which accounted for 16 percent of the incidents.

E-cigarettes are also one of the most frequent items to be packed in checked luggage, along with portable chargers. The Transportation Security Administration (TSA) does not allow e-cigarettes, chargers and power banks with lithium-ion batters in checked bags, though more than a quarter of passengers surveyed reported doing it, the report stated.

Checked luggage usually goes in the cargo hold, meaning fires may not be discovered as quickly as they would be in the cabin, the report noted.

Passengers typically bring four rechargeable devices on board including smartphones, laptops, wireless headphones and tablets, the report said.

UL Standards , a division of safety-science company UL Solutions Inc., said its surveys showed “an alarming lack of awareness and concerning behavior” and recommended clearer and repeated education on the issue to decrease the risk of these incidents.

The report also reinforced the importance of flight crew training to prepare all cabin crew to handle thermal runway incidents and suggested the training be “regularly evaluated and revised” to ensure the most effective training.

The UL Standards and Engagement further laid out a set of safety standards that were created upon the request of aviation industry representatives.

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