Shipping classes of lithium-ion rechargeable batteries / lithium batteries

Due to the various sources of danger that can arise from both intact and even more so from damaged Li-ion batteries, a distinction is made between different shipping classes when transporting/shipping these products. In combination with the respective transport medium (road transport or rail on the one hand or air freight on the other), the packaging instructions and special regulations are derived from the shipping classes, which must be observed during transport and which must be complied with, for example, by the different battery transport containers.

Terminology - cell and battery, Li-ion or lithium metal

When categorizing the shipping classes, a distinction is made between cells and batteries, as well as lithium-ion batteries and lithium-metal cells. These terms are therefore briefly explained below.

A battery is an interconnection of individual cells

In battery technology, a distinction is generally made between individual cells, which each represent a separate unit, and a combination of these individual cells, which is then referred to as a battery. The term battery also includes rechargeable batteries, i.e. rechargeable battery units. The individual cells fulfill the actual function of providing electricity by maintaining a voltage difference between the two poles when charged.

Lithium-ion and lithium-metal batteries

In addition to the size of the compound (the individual compound is the cell, the overall compound is the battery), a distinction is also made according to the chemical elements contained. Lithium-metal batteries are generally non-rechargeable and, as the name suggests, contain lithium in metallic form. In contrast, lithium-ion batteries are rechargeable and are therefore also referred to as Li-ion batteries. Lithium-polymer batteries (often referred to as LiPo batteries) also fall into this product area.

Differentiation based on the rechargeable batteries / batteries to be transported

The type or condition of the batteries is used to select a suitable transport container for shipping lithium batteries. Depending on the condition and quantity, the requirements that must be observed when transporting batteries differ.

Regular shipping of intact lithium-ion batteries

The regular shipment of intact lithium batteries will be the most common case in practice. In addition to the condition of the batteries (they must be intact), the performance or nominal energy of all lithium-ion batteries to be transported is decisive when differentiating between regular and facilitated shipping. If the lithium-ion batteries have a capacity of more than 100 Wh or the lithium-ion batteries have a total capacity of more than 20 Wh, they fall within the scope of regular shipping. If lithium metal batteries are transported, the lithium content is decisive: for cells the limit is 1g lithium content, for batteries this value is 2g lithium. The requirements for regular shipping must then also be complied with.

Facilitated shipping of intact Li-ion batteries

If the total power of the lithium batteries is less than 100 Wh or less than 20 Wh (for cells), they can be transported under the conditions of simplified shipping. The same applies if the total lithium content of Li-metal batteries is less than 2g, or less than 1g for individual cells.

Shipping in the context of recycling / disposal

If lithium-ion batteries, LiPo batteries or Li-metal batteries are to be recycled, special requirements apply. It is important to note that the packages must not be defective or damaged, but must be intact. Damaged Li-ion batteries are subject to much stricter transportation requirements.

Shipping battery prototypes

If rechargeable batteries or batteries with lithium content are still in pre-production or prototype status, they are not subject to the requirements for regular shipping or simplified shipping, but must be transported with special care due to the lack of UN certifications. This applies, for example, to pre-production types intended for testing, but also to production series with very small runs. The guideline value here is an annual production of less than 100 Li-ion batteries / rechargeable battery cells. Accordingly, the lithium-ion batteries transported here have not yet undergone battery testing.

Shipping defective / damaged lithium batteries

By far the highest requirements for shipping Li-ion batteries apply to defective and damaged cells / batteries. This includes all batteries that have obvious damage that is visible on the outside (e.g. deformation, mechanical damage), but also cells that have degassed and leaked. Li-ion batteries also count as damaged if a test has shown the defect. If the condition of a lithium-ion battery is unclear, i.e. it cannot be said with certainty that there is no defect/damage, this battery must also be treated as if it were defective and is therefore also subject to the strict regulations for shipping damaged lithium batteries.