Lithium-ion battery shipping regulations require standalone cells and battery packs to be shipped at a specific state of charge (SOC). While the 30% SOC requirement applies to batteries shipped separately, it does not apply to batteries installed in equipment.
Understanding battery chemistry, storage conditions, and product logistics is important when determining the appropriate charge level for shipped products.
Understanding Lithium Battery Shipping Classifications
Proper charging for shipping begins with understanding how batteries are classified during transportation.
Lithium batteries are commonly shipped in several forms:
- Standalone batteries that are not contained within a device
- Individual battery cells shipped from a battery manufacturer to a distributor or assembler
- Completed battery packs
- Batteries packed with equipment
- Batteries contained in equipment
Example of battery pack shipping labels for lithium-ion batteries.
The applicable shipping requirements can vary depending on how the battery is packaged and transported.
State of Charge Requirements for Shipping Lithium-Ion Batteries
A common question is whether lithium-ion batteries can be shipped fully charged. For standalone lithium-based cells and battery packs, the answer is no.
Current shipping regulations require lithium-ion cells and battery packs to be shipped at a state of charge of 30% when transported as standalone products. Battery manufacturers have implemented this practice at the cell level, and battery pack assemblers follow the same approach for completed packs.
Shipping State of Charge Requirements
- Shipping SOC for standalone lithium-ion cells and battery packs = 30%
- Recommended storage SOC range for extended idle periods = 30-50%
The 30% state of charge requirement is intended for cells and battery packs being shipped as batteries rather than as part of a finished product.
When the 30% SOC Requirement Does Not Apply
The 30% state of charge requirement does not apply to battery packs that are packed with equipment or contained within equipment.
When a battery is installed in a finished product, the battery is electrically disconnected within the device and receives additional protection from the product packaging. As a result, the state of charge is no longer the primary shipping consideration in the same way it is for standalone cells and battery packs.
This distinction is an important part of understanding lithium battery shipping requirements and helps explain why charge levels may differ between replacement batteries and batteries shipped inside finished products.
Choosing the Appropriate State of Charge for Finished Products
Once a battery is installed in a product, determining the appropriate charge level becomes a product and logistics decision rather than a standalone shipping requirement.
Several factors should be evaluated:
- Battery chemistry
- Expected self-discharge rate
- Device application
- Expected warehouse storage duration before first use
The appropriate charge level can vary depending on how the end product will be stored, distributed, and ultimately used by the customer.
Storage Considerations for Lithium-Ion Batteries
For products that may remain idle for extended periods, maintaining a lower state of charge can provide important benefits.
A storage charge level between 30% and 50% is generally preferable when batteries are expected to sit unused for longer periods. Lower charge levels help reduce self-discharge effects and can minimize the non-recoverable capacity loss that may occur when fully charged batteries remain in storage while gradually self-discharging.
Careful management of storage charge levels can help support battery performance throughout the product distribution and warehousing process.
Battery Chemistry and Product Logistics Matter
There is no single charging strategy that applies to every lithium-ion battery application.
Determining the most appropriate state of charge requires consideration of:
- The battery chemistry selected for the application
- Product distribution and logistics requirements
- Expected storage duration
- End-user experience requirements
Many rechargeable battery-powered products include instructions directing users to fully charge the battery before first use. As a result, manufacturers must balance shipping, storage, and customer-use considerations when determining the charge level of batteries delivered within finished products.
Compliance with Lithium Battery Shipping Regulations
Shipping regulations for lithium batteries continue to evolve. Manufacturers, assemblers, distributors, and product suppliers should remain aware of current requirements and regulatory updates.
Key compliance considerations include:
- Following applicable SOC requirements for standalone lithium-ion cells and packs
- Understanding the differences between standalone batteries and batteries contained in equipment
- Managing charge levels appropriately for storage and warehousing conditions
- Monitoring and complying with changing battery transportation regulations
Proper compliance helps support safe transportation and effective battery management throughout the supply chain.
Summary
Most products that use rechargeable batteries will include an “Instructions for Use” with the device stating that the battery needs to be fully charged before first use. The answer for charging lithium-ion batteries is not a generic one and involves understanding of the battery chemistry you choose for your application, with the logistics of your product to the consumer.
It is important, however, to be aware of and comply with all applicable regulations and regulatory changes when shipping lithium-ion batteries.
Key Takeaways
- Lithium-ion batteries must be shipped at a state of charge (SOC) of 30% or less when shipped as standalone cells or packs, per regulatory requirements.
- The 30% SOC rule does not apply to batteries installed in equipment, as these are electrically disconnected and better protected during transit.
- Proper SOC levels help minimize self-discharge and capacity loss, especially for products that may remain in storage for extended periods.
- Factors like battery chemistry, application, and warehouse time should guide the decision on how much charge to maintain in shipped products.
- Compliance with shipping regulations is critical, and manufacturers, assemblers, and distributors must stay updated on evolving lithium battery shipping rules.
