Power battery thermal management systems in electric vehicle: A comprehensive review

Driven by “Carbon Peak and Carbon Neutrality” policies, the automotive industry is undergoing an irreversible shift toward electric vehicles (EVs). As a core component, the performance of power batteries affects range, charging efficiency, safety, adaptability, and cost, influencing market acceptance and competitiveness. However, heat generation during operation can reduce battery lifespan and pose safety risks. This study investigates battery thermal management. We conducted thermal analysis to explain heat generation and transfer mechanisms. Cooling methods were analyzed, showing liquid cooling improves efficiency by 30% over air cooling, and phase change materials reduce peak temperature rise by 10%. Given current system limitations, new hybrid cooling approaches are proposed. Combining liquid cooling with PCM stabilizes temperature fluctuations within ±5°C, enhancing efficiency by 50%. The challenge of efficient management under extreme temperatures (−40°C to 60°C) is also explored. Future prospects for battery thermal management systems (BTMS) predict a market share increase to 60%. These results underscore the need for enhanced BTMS, offering crucial insights for future studies and applications.