IEC 62368-1 - Battery Design

IEC 62368-1 is an international product safety standard published by the International Electrotechnical Commission (IEC) that establishes safety requirements for audio/video (AV), information technology (IT), and communication equipment with a rated voltage not exceeding 600 V. It is the primary electrical safety standard for consumer electronics and IT equipment globally, replacing both IEC 60950-1 (ICT equipment) and IEC 60065 (audio/video equipment) under a unified Hazard-Based Safety Engineering (HBSE) framework.

Published by: IEC (International Electrotechnical Commission)
Current edition: IEC 62368-1:2023 (Edition 4, published 2023)
Replaces: IEC 62368-1:2020 (Ed.3); prior editions superseded IEC 60950-1 and IEC 60065

Scope

IEC 62368-1 applies to electrical and electronic equipment with a rated voltage not exceeding 600 V that is used for audio/video, IT, or communication functions. Products within scope include, but are not limited to:

Computers, laptops, tablets, and smartphones
Televisions, projectors, monitors, and displays
Audio equipment: amplifiers, speakers, headphones
Gaming consoles and set-top boxes
Routers, modems, and network equipment
AC/DC power adapters and power supplies
Networked printers, copiers, and digital signs

The standard does not cover medical equipment, industrial machinery, or equipment specifically designed for use in explosive atmospheres. Medical devices are covered by the IEC 60601 series.

Hazard-Based Safety Engineering (HBSE) Approach

IEC 62368-1 adopts a Hazard-Based Safety Engineering (HBSE) methodology, classifying energy sources by their potential to cause harm and specifying safeguards accordingly. Energy sources are categorised into three classes:

PS1: energy levels not likely to cause pain or injury (no safeguard required)
PS2: energy levels that may cause pain or injury (one safeguard required)
PS3: energy levels that can cause irreversible injury (two independent safeguards required)

This approach allows engineers flexibility in how safety is achieved, rather than mandating prescriptive design rules.

Key Requirements

Electric shock protection: insulation, clearances, creepage distances, and touch-current limits based on hazard class
Thermal burn prevention: surface temperature limits for accessible parts based on material and contact duration
Fire prevention: requirements for enclosures, flammability ratings, component power dissipation, and fire-resistant materials
Mechanical safety: strength, stability, and sharp edge requirements
Battery safety (Annex M): requirements for lithium battery cells and packs, protection circuit requirements, over-charge and over-discharge protection, short circuit protection, thermal runaway mitigation, and button cell accessibility restrictions (significantly expanded in Edition 4)
Edition 4 key change: removal of Clause 4.1.1 legacy acceptance — components previously certified only to IEC 60950-1 or IEC 60065 must be re-evaluated to IEC 62368-1

Certification and Regional Recognition

IEC 62368-1 is adopted across major global markets:

USA: adopted as UL 62368-1; required for NRTL certification by OSHA-recognised labs
EU: harmonised as EN IEC 62368-1 under the Low Voltage Directive (LVD) and Radio Equipment Directive (RED); EU has harmonised the 3rd edition
Canada: adopted as CSA C22.2 No. 62368-1
Japan: formally adopted 3rd edition; mandatory from 2026
Global: tested and certified via the IECEE CB scheme, which provides mutual recognition across 50+ member countries

Edition 4 (2023) is at various stages of national adoption; mandatory compliance is expected in most markets by 2026–2027.

Related Standards

IEC 62133-2 — Safety requirements for portable sealed secondary lithium cells and batteries (referenced for cell-level compliance within 62368-1 Annex M)
UL 1642 — UL standard for lithium cells and batteries (North American cell-level safety, often used alongside 62368-1)
UN 38.3 — UN transport testing requirements for lithium batteries (prerequisite for shipping battery-powered products)
EU Battery Regulation — EU regulation covering battery sustainability, labelling, and end-of-life (applies to batteries within products covered by IEC 62368-1)
IEC 60950-1 — Superseded: Safety of information technology equipment (predecessor standard)
IEC 60065 — Superseded: Safety of audio, video and similar electronic apparatus (predecessor standard)

Disclaimer: this is not a definitive guide, just an indication and it is important that you always go back to the source for legislation.