Inner packaging helps prevent batteries from shifting and moving during transportation. Containers can be handled harshly as they move through the shipping process and from one carrier to another. Inner packaging secures the hazardous contents against damage along the way.
Regulations with carriers, like UPS, require packaging batteries in fully enclosed, non-conductive material, such as plastic bags or blister packs. Exposed terminals or conductors on batteries must be protected with tape, non-conductive caps, or similar protective means. This helps prevent static that can cause the batteries to activate.
Inner packaging can be placed in a container made from the following:
Some materials, like plastic bags, are more commonly used for their low cost and easy sourcing. They provide a strong, flexible barrier between batteries and other contents of the package.
It is recommended that lithium ion batteries are cushioned and packaged to prevent shifting during transport or loosening of protective coverings.
Dividers should be placed in between each separated battery for cushioning. Installing fixation points, applying attachments to the base and lid of the package, or including securing straps prevent movements of the contents. When multiple items are inside a single container, they must be cushioned to protect them from each other as well as external objects.