Why Can’t You Send Your Mobile Phone Casually? Revealing the Transport Safety Hazards of Lithium Batteries

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When you plan to send an unused mobile phone to relatives or friends via courier, the courier may ask for purchase certificates, require professional packaging, or even directly inform you that “it cannot be shipped.” This is not the courier company deliberately making things difficult, but because the built-in lithium battery of the mobile phone hides fatal safety hazards. As the world’s largest producer and consumer of lithium batteries (accounting for over 70% of the global market in 2024), China experiences hundreds of fires and explosions every year due to improper transportation of lithium batteries, with mobile phones and other consumer electronic products accounting for over 30%. Why have lithium batteries become “high-risk goods” in the transportation industry? How can ordinary users avoid risks when sending mobile phones? This article will comprehensively reveal the transport safety hazards of mobile phone lithium batteries from four aspects: scientific principles, accident cases, global regulations, and compliance guidelines.

I. The “Fatal Genes” of Lithium Batteries: The Scientific Nature of Transport Hazards

The reason why mobile phone lithium batteries have become a “disaster zone” for transportation safety lies in the inherent risks of their chemical properties and structural design. Lithium-ion batteries achieve energy storage and release through the migration of lithium ions between the positive and negative electrodes, and this process has extremely strict requirements for environmental conditions and physical states. Any minor abnormality may trigger a chain reaction.

(I) Thermal Runaway: The “Self-Destruction” Mechanism of Lithium Batteries

Thermal runaway is the core safety hazard of lithium batteries and the main cause of fires and explosions during transportation. When a mobile phone lithium battery is exposed to abnormal environments such as extrusion, collision, or high temperature, the internal temperature of the battery rises sharply, triggering a series of exothermic reactions that ultimately lead to fire and explosion.

1. The Chain Reaction of Thermal Runaway: The safe temperature of the electrolyte in mobile phone lithium batteries is usually below 80℃. When the battery casing is deformed due to extrusion during transportation, the positive and negative electrode materials come into direct contact, causing a short circuit. The heat generated instantly causes the electrolyte temperature to exceed the critical value. At this time, the electrolyte decomposes to produce a large amount of flammable gas, and the internal pressure of the battery surges. When the pressure exceeds the bearing limit of the casing, the battery undergoes “thermal runaway”—the temperature soars to over 600℃ in a few seconds, the electrolyte burns violently, releasing toxic gases containing fluorine and phosphorus, accompanied by explosion risks. Data shows that about 65% of lithium battery transportation accidents are directly caused by thermal runaway, and once it occurs, the fire spreads 3-5 times faster than ordinary cargo fires.
2. Risk Amplifiers in Transportation Scenarios: Collisions and extrusions are inevitable during the sorting and loading/unloading of express deliveries. The stacking pressure of ordinary packages can reach 50kg/m², far exceeding the compression limit of mobile phone lithium battery casings (usually 30kg/m²). In addition, the temperature inside express delivery vehicles can reach up to 55℃ in summer, close to the safe critical value of the electrolyte, further lowering the threshold for triggering thermal runaway. Nearly 70% of global lithium battery transportation accidents in 2024 occurred in ports and express sorting centers, confirming the risk amplification effect of transportation scenarios.

(II) Three Acquired Risks: Human Factors Exacerbating Hazards

In addition to inherent chemical properties, improper human operations have further amplified the transportation risks of mobile phone lithium batteries, becoming an important driver of frequent accidents.

1. Illegal Modification and Quality Defects: To improve mobile phone battery life, some users illegally modify lithium batteries through “small workshops,” using shoddy or recycled battery cells. These irregular products have extremely poor thermal stability, with a safe temperature as low as 60℃. More seriously, modified batteries often lack a complete Battery Management System (BMS) and cannot real-time monitor temperature and voltage. Once overcharged or short-circuited, thermal runaway is almost inevitable. Among the illegal lithium battery shipping cases investigated and handled in China in 2024, 35% involved modified mobile phone batteries.
2. Improper Packaging and Mixed Transportation: When sending mobile phones, ordinary users often mix mobile phones with hard objects such as keys and chargers. Shaking during transportation can cause hard objects to hit the battery part; some even send bare phones without buffer material protection. This packaging method increases the probability of physical damage to the battery by 80%. To reduce costs, some courier companies mix mobile phones with ordinary goods. Once the battery catches fire, the fire will quickly spread to other packages, expanding the accident hazard.
3. Misdeclaration and Illegal Transportation: Individual users disguise mobile phones as ordinary items to avoid inspections by courier companies; some small courier companies illegally use transportation exemption clauses to ship mobile phones with lithium batteries as ordinary goods to compete for business, evading necessary safety inspections. This “knowing violation” deprives lithium batteries of special protective measures, greatly increasing the risk of short circuits caused by collisions and extrusions. Nearly 40% of lithium battery transportation accidents in China, the United States, Britain, and France in 2024 involved misdeclaration or illegal transportation.

II. Shocking Real Cases: The Painful Price of Transport Hazards

Globally, lithium battery transportation accidents involving mobile phones have caused numerous casualties and huge property losses, serving as a wake-up call for safety.

(I) Domestic Case: An “Unprovoked Disaster” in an Express Truck

In August 2024, a truck belonging to a courier company traveling from Shenzhen to Wuhan caught fire suddenly on the highway, burning more than 1,200 packages in the carriage, including over 30 mobile phones to be sent. Fire department investigations confirmed that the accident was caused by a modified second-hand mobile phone battery that triggered thermal runaway and caught fire after being squeezed during transportation. The flames engulfed the entire carriage within 5 minutes. Due to the toxic gases generated by the lithium battery fire, two firefighters at the scene suffered mild poisoning symptoms. The direct economic loss caused by this accident exceeded 2 million yuan, and the involved courier company was fined 500,000 yuan for illegally accepting lithium batteries without compliant packaging.

Similar cases are not uncommon. In 2023, a fire broke out at an express sorting center in Shanghai, caused by a mobile phone battery that was deformed by a conveyor belt during sorting, triggering thermal runaway. The fire forced the sorting center to suspend operations for 8 hours, burning more than 500 packages with a direct loss of 800,000 yuan. These cases fully illustrate that the transportation risk of mobile phone lithium batteries is not a theoretical hazard but a “mobile bomb” that can explode at any time.

(II) International Case: Fatal Risks in Air Transport

Air transport has stricter safety requirements for lithium batteries, but accidents still occur from time to time. In March 2024, a cargo flight from Hong Kong to Los Angeles detected smoke in the cargo hold during the flight and made an emergency landing at Tokyo Narita Airport. Investigations revealed that the source of the smoke was a batch of undeclared second-hand mobile phones. The battery of one mobile phone short-circuited due to pressure changes and transportation vibrations, triggering thermal runaway. Due to the closed space of the air cargo hold, toxic gases were difficult to diffuse. If not detected in time, it could have led to the crash of the entire aircraft. This incident caused a 12-hour flight delay, the involved goods were completely destroyed, and the shipper was blacklisted by the airline.

Data from the International Air Transport Association (IATA) shows that there were 18 aviation transport safety incidents involving lithium batteries in consumer electronic products worldwide between 2023 and 2024, 12 of which were directly related to mobile phone lithium batteries. These incidents have prompted the global aviation industry to strengthen the control of lithium battery transportation and further tighten shipping standards.

III. Global Regulatory Escalation: The “Safety Red Line” for Mobile Phone Lithium Battery Transport

Faced with the increasingly severe safety situation, countries around the world have introduced strict regulatory policies, clarifying the “safety red line” for mobile phone lithium battery transportation and preventing risks at the institutional level.

(I) China: A Multi-Level Regulatory System and Shipping Norms

China has established a three-level regulatory system of “laws + departmental regulations + industry standards” to implement full-process control over the transportation of mobile phone lithium batteries.

1. Core Regulatory Policies: The “Work Safety Law of the People’s Republic of China” and the “Regulations on the Safety Administration of Hazardous Chemicals” classify electronic products containing lithium batteries as “dangerous goods in limited quantities,” clearly requiring safety testing and compliant packaging before transportation; the “Measures for the Safety Administration of Road Transport of Dangerous Goods” revised by the Ministry of Transport in 2024 stipulates that courier companies must inspect product qualification certificates and confirm that packaging meets standards when accepting items such as mobile phones containing lithium batteries, otherwise they shall not accept or ship them.
2. Specific Shipping Requirements: According to the regulations of the State Post Bureau, individuals sending mobile phones must meet three core conditions: first, the mobile phone must be completely turned off, and shipping in an on or standby state is prohibited; second, independent packaging must be used, wrapped with buffer materials (such as foam, bubble film) to ensure that the mobile phone does not shake in the package, and the battery part requires additional protection; third, the item name must be truthfully declared, and it shall not be falsely reported as ordinary goods such as “daily necessities.” For second-hand mobile phones, some courier companies also require the presentation of purchase certificates or battery test reports to prevent illegally modified batteries from entering the transportation link.
3. Increased Penalties: Regulatory authorities have continuously increased penalties for illegal shipping behaviors. The revised version of the “Regulations on Express Delivery” implemented in 2024 stipulates that courier companies that illegally accept and ship lithium battery products without compliant packaging may be fined up to 500,000 yuan; individuals who misdeclare or falsely report shipped items leading to safety accidents shall bear civil liability for compensation, and criminal liability shall be pursued if the circumstances are serious.

(II) International: Combination of Unified Standards and Regionalized Control

Globally, regulatory standards for lithium battery transportation are gradually becoming unified, while countries have formulated supplementary requirements according to their own conditions.

1. International Unified Standards: The United Nations “Recommendations on the Transport of Dangerous Goods – Manual of Tests and Criteria” (TDG) classifies mobile phone lithium batteries as “UN3480” dangerous goods, requiring the use of UN-certified packaging during transportation, which must have fire and leakage prevention functions; the International Air Transport Association (IATA) stipulates that when individuals send mobile phones by air, each person is limited to 1 unit per trip, which must be carried with the person and is prohibited from being placed in checked luggage.
2. Special Requirements of Major Countries: The U.S. Federal Aviation Administration (FAA) requires that all electronic products containing lithium batteries must undergo a “1.2-meter drop test” and a “temperature cycle test” before transportation to ensure that the packaging can withstand impacts and environmental changes during transportation; the European Union has stipulated through the “Battery Regulation” that starting from 2024, all mobile phone lithium batteries entering the EU market must be equipped with a “Digital Product Passport,” recording the full-process information of battery production, testing, and transportation, and non-compliant products are prohibited from transportation; Japan Post stipulates that when individuals send mobile phones, professional packaging must be carried out by courier companies using designated fireproof buffer materials, otherwise shipment will not be accepted.

IV. Safe Shipping Guide: How Ordinary Users Can Send Mobile Phones Compliantly

For ordinary users, understanding regulatory requirements and mastering correct shipping methods are the keys to avoiding transportation risks of mobile phone lithium batteries. The following is a practical and compliant shipping guide that balances safety and convenience.

(I) Three Preparations Before Shipping

1. Confirm the Mobile Phone Status: Before shipping, be sure to turn off the mobile phone completely and remove the SIM card and memory card to avoid battery discharge caused by accidental startup during transportation. For old mobile phones, it is recommended to conduct a battery test first. If the battery has abnormalities such as bulging, leakage, or overheating, shipping is strictly prohibited, and it should be sent to a professional institution for recycling. Data shows that the transportation accident rate of bulging batteries is more than 10 times that of normal batteries.
2. Prepare Compliant Packaging Materials: Priority should be given to using special packaging provided by courier companies, which are usually UN-certified with built-in fireproof buffer layers. If packaging by yourself, three requirements must be met: first, use a rigid packaging box with a thickness of not less than 3mm; second, fill sufficient buffer materials (such as bubble film, EPE foam) around the mobile phone to ensure no gaps between the mobile phone and the packaging box, and the battery part can be additionally wrapped with a layer of flame-retardant cloth; third, package the mobile phone separately from chargers, data cables, etc., to avoid hard objects colliding with the battery.
3. Prepare Relevant Certification Materials: When sending a new mobile phone, keep the purchase certificate (invoice or electronic order), which some courier companies may require to present; when sending a second-hand mobile phone, it is recommended to conduct a battery test at a formal institution in advance to obtain a test report, reducing the probability of rejection. Truthfully fill in the express waybill, clearly mark words such as “contains lithium battery,” “fragile,” and “handle with care,” and do not conceal the nature of the item.

(II) Key Notes During Shipping

1. Choose a Regular Courier Company: Select courier companies with dangerous goods transportation qualifications such as SF Express and JD Logistics. Employees of these companies have received professional training, can identify whether the packaging of lithium batteries is compliant, and have corresponding emergency handling capabilities. Avoid choosing small courier companies or “scalpers” as agents, as these channels often operate illegally to save costs with extremely high risks.
2. Cooperate with Courier Inspections: Couriers have the right to open and inspect shipped items, and you must actively cooperate and not refuse. If the courier finds that the packaging is non-compliant, re-package as required and do not take chances. Some courier companies provide free special packaging services for lithium batteries, which can be actively consulted and used.
3. Choose the Appropriate Transportation Method: Select the transportation method according to the shipping distance. For short-distance transportation (intra-city or intra-provincial), land transportation can be chosen; for long-distance transportation requiring air transport, confirm whether the courier company has the qualification for air transportation of lithium batteries. It should be noted that most courier companies have quantity limits for air shipping of mobile phones, and individuals are usually limited to 1 unit. For quantities exceeding this limit, commercial transportation procedures need to be completed.

(III) Shipping Solutions for Special Scenarios

1. Cross-Border Shipping: Cross-border shipping of mobile phones must comply with the regulatory requirements of the destination country. For example, mobile phones sent to the EU must ensure that the battery has a “Digital Product Passport,” and those sent to the Middle East must comply with relevant Halal certification regulations. It is recommended to choose international courier companies such as DHL and FedEx, which provide compliance guidance and assist in completing declaration procedures. For cross-border shipping, an additional layer of waterproof film should be used for packaging to prevent moisture from affecting battery safety during transportation.
2. Bulk Shipping: Enterprises or individuals shipping mobile phones in bulk (more than 5 units) need to report to the courier company in advance, complete the “dangerous goods in limited quantities transportation filing,” and use standard collective packaging. Mobile phones shipped in bulk must be turned off and individually packaged one by one, and shall not be stacked.

V. Future Trends: Technological Innovation and Regulatory Upgrades Build a Solid Safety Defense Line

With the continuous development of lithium battery technology and the improvement of the regulatory system, the transportation safety of mobile phone lithium batteries will be further guaranteed, but this requires the joint efforts of enterprises, regulatory authorities, and consumers.

(I) Technological Level: Improving the Intrinsic Safety of Lithium Batteries

Enterprises are reducing the inherent risks of lithium batteries through technological innovation. On the one hand, optimizing battery materials, developing high-safety electrolytes and positive/negative electrode materials, increasing the safe temperature of electrolytes to above 120℃, and enhancing thermal stability; on the other hand, upgrading the Battery Management System (BMS), improving the monitoring accuracy of temperature and voltage, and realizing early warning of thermal runaway. Once an abnormality is detected, the power can be automatically cut off to prevent accidents. At present, semi-solid-state batteries have entered the commercial trial stage, with significantly higher safety than traditional lithium batteries, and are expected to be widely used in mobile phones and other consumer electronic products in the future.

(II) Regulatory Level: Digitalization and Full-Life Cycle Control

Regulatory authorities are promoting the digital supervision of lithium battery transportation, establishing a full-life cycle traceability system through blockchain technology. Every mobile phone lithium battery will be recorded from production, testing, transportation to recycling, realizing “traceable source, traceable destination, and accountable responsibility.” At the same time