Laptop catches fire, burns passenger on US flight: Why it happens and what you should do

A laptop caught fire on an American Airlines flight last week, prompting a mid-air emergency and leaving a passenger with burns. The incident serves as a reminder that lithium-ion batteries in everyday electronic devices can pose serious risks during flights. The fire occurred on American Airlines Flight 2398 as the aircraft approached Dallas Fort Worth International Airport with 133 passengers on board.

The pilot informed air traffic controllers of a "cabin fire in the back of the airplane" and the crew swiftly contained the blaze using a thermal containment bag. The FAA is currently investigating the incident.

While power bank fires have gained recent attention, laptops have also experienced battery malfunctions, leading to similar emergencies. In July 2024, another American Airlines flight at San Francisco International Airport had to make an emergency landing after a laptop battery caught fire, injuring three passengers. These incidents highlight the vulnerability of lithium-ion batteries in laptops, smartphones, tablets, and power banks, which share the same susceptibility to thermal runaway.

Thermal runaway occurs when a battery produces heat faster than it can dissipate it, triggering a chain reaction of chemical reactions that can rapidly escalate. This can cause the battery to swell, smoke, ignite, or even rupture. The FAA warns that thermal runaway can happen unexpectedly if a battery is damaged, overheated, exposed to water, overcharged, or improperly packed. Manufacturing defects can also contribute to these issues.

Passengers must remain vigilant and alert cabin crew if they notice any signs of a lithium battery malfunction, such as overheating, swelling, or burning. Flight crews are trained to handle such incidents, but quick detection and response are crucial. Power banks and spare lithium batteries must be carried in cabin baggage, not checked luggage, to ensure they can be quickly spotted and managed.

Proper protection against short circuits is also recommended, such as keeping batteries in their original packaging or protective cases.

Checked baggage rules allow portable electronic devices with lithium batteries to be carried, but the FAA advises keeping them in the cabin whenever possible. If checked, devices must be completely switched off and protected. Battery size is limited to 100 watt-hours for most devices, with larger batteries requiring airline approval.

Damaged or swollen batteries should not be taken aboard, as they present an immediate threat to flight safety. If a laptop or other device starts smoking in flight, passengers must immediately inform the cabin crew, avoiding attempts to deal with the situation themselves.