Challenges, advances, and perspectives of battery thermal management cooling techniques in EVs

Effective thermal management cooling systems (TMCS) are essential for ensuring the safety, reliability, and performance of lithium-ion batteries (LIBs) in electric vehicles (EVs), particularly in preventing thermal runaway and related failures. However, existing studies often lack a systematic comparison of advanced cooling methods, hybrid approaches, and intelligent control strategies for real-time applications. Addressing this gap, the present study offers a comprehensive, focused review of TMCS for LIBs, analyzing over 334 publications. Unlike previous works, this study critically compares conventional and hybrid cooling techniques including PCM, heat pipes, thermoelectric modules, air, liquid, fins, and nanomaterials while highlighting the emerging role of AI, machine learning, and IoT in real-time temperature monitoring and adaptive control. The paper's novelty lies in its integrated, application-oriented perspective and its emphasis on future research needs for enhancing TMCS reliability in EVs. The main findings underscore the potential of hybrid systems and AI-based solutions to improve LIB safety and performance, offering practical guidance for advancing TMCS design.