Battery Thermal Management Systems for Electric Vehicles: Current Trends and Strategies for Sustainable Transportation

Abstract The advancement of electric transportation is critically dependent on high-performance battery systems for energy storage. Electric mobility applications require stringent demands on the power and energy density of the batteries. An effective battery thermal management system (BTMS) is therefore essential to maintain the optimal operating temperature range, typically between 20°C and 35°C, ensuring reliable performance and preventing thermal runaway. The BTMS technologies deal with comprehensive synthesis focused specifically on the latest experimental and numerical advancements across the full spectrum of cooling strategies. This paper addresses this gap by providing a systematic and in-depth review of current trends in active, passive, and hybrid BTMS configurations. A key contribution of this study is its comparative evaluation of the thermal performance, thermohydraulic attributes, and safety aspects of these diverse cooling systems. Furthermore, the review logically transitions from system-level classification to material-level analysis by categorizing key heat transfer media, including phase change materials, air, liquids, and refrigerants, based on their thermophysical properties and suitability for different applications. A thorough summary of recently developed BTMS is presented, outlining their respective advantages, disadvantages, and potential applications to guide system selection. By consolidating recent designs, future trends, and potential solutions, this work serves as a crucial and updated resource for guiding ongoing research and development toward more efficient and sustainable transportation.