Global advancement, prospect and challenges of battery thermal management systems: A comprehensive review

Electric vehicles (EVs) offer a sustainable alternative to gasoline-powered cars by reducing pollution and fossil fuel dependency. Lithium-ion batteries (LIBs), which power EVs, are highly sensitive to temperature variations, impacting their performance, safety, and lifespan. This review paper provides a comprehensive assessment of Battery Thermal Management Systems (BTMS) with a focus on global advancements and current challenges. State-of-the-art BTMS technologies such as air-based, liquid-based, phase change materials (PCMs), and hybrid systems are examined. Notably, effective BTMS can maintain battery temperatures within the optimal range of 15–35 °C, limit the maximum cell-to-cell temperature variation to less than 5 °C, and reduce the risk of thermal runaway. Advanced systems have demonstrated up to 30 % improvement in charge/discharge efficiency and can extend battery lifespan by 20–40 %, depending on the configuration and thermal control strategy. Furthermore, innovative designs such as nano-enhanced PCMs and thermoelectric-assisted cooling have shown to reduce maximum battery temperatures by up to 40.5 %. This review also critically evaluates the emerging hybrid cooling solutions that integrate multiple technologies for high-performance EV applications. The review further highlights the emerging role of adaptive control systems and artificial intelligence in enhancing the efficiency and responsiveness of BTMS. These approaches offer promising pathways for real-time optimization and fault prediction in modern battery applications. The study concludes by recommending a mixed active-passive BTMS approach, tailored for fast-charging cycles and high-power operation scenarios. These insights contribute to the development of safer and more efficient battery systems for next-generation electric mobility.