Smart hybrid thermal management: Bridging innovation for sustainable electric and hybrid vehicles

The growing need for electric and hybrid vehicles (EHV) requires new technologies that can enhance battery performance, longevity, and safety. Efficient thermal management is an important factor that influences these parameters. Through the incorporation of phase change materials (PCMs), liquid and air cooling mechanisms, heat pipes (HP), and thermoelectric coolers (TECs), these systems attain exceptional thermal regulation, thereby minimizing temperature gradients and improving system adaptability in response to fluctuating thermal loads. This research describes a new Smart Hybrid Thermal Management System (S-HTMS) that optimizes the thermal management of battery packs in future EHVs. The suggested hybrid strategy combines liquid cooling and air-based or phase change material (PCM) systems to take benefit of both passive and active cooling strategies. The present article combines recent advances in HBTMS, including nanomaterial-enhanced PCMs, adaptive control techniques, and high-efficiency heat exchangers, all of which serve to maximize energy transfer and enable real-time thermal response. This review additionally outlines critical trade-offs in efficiency, cost, and design which govern the advancement of next-generation BTMS, which are vital for high-performance EV and HEV applications. The insights presented herein intend to establish a foundational framework for the design of battery systems that are not only safe and efficient but also sustainable, thereby contributing to the EV and HEV technology towards enhanced efficiency and reliability.