A comprehensive review on lithium-ion battery thermal management (BTM) using phase change materials: advances, challenges, and future perspectives

Abstract

The necessity of robust battery thermal management (BTM) systems is paramount for ensuring the safety, performance, and longevity of lithium-ion batteries (LIBs), especially in high-demand sectors like electric vehicles (EVs). Effective thermal regulation is crucial to prevent thermal runaway, a potentially catastrophic event that can lead to fires. As the global transition toward renewable energy and electric mobility accelerates, the demand for sophisticated BTM systems capable of maintaining optimal battery temperatures across various operational conditions has become increasingly clear. This review focuses on the role of phase change materials (PCMs) in BTM systems, highlighting their ability to absorb excess heat through phase transitions and maintain battery stability. PCMs are particularly effective in passive and hybrid BTM systems, where energy efficiency is critical. However, the low thermal conductivity of PCMs presents a challenge, often leading to uneven cooling. Research into enhancing PCM performance through the integration of materials like metal foams, expanded graphite, and nanoparticles, as well as optimizing system designs, is ongoing. Significant advancements in hybrid BTM systems that combine PCM with air or liquid cooling have demonstrated superior thermal regulation. These hybrid systems, especially those incorporating heat pipes, effectively manage battery temperatures and improve temperature uniformity, even in high-power applications. The present review explores and discuses all these aspects of BTM. Despite challenges such as increased system mass and cost, PCM-based BTM systems offer long-term benefits, including extended battery life and reduced operational expenses. Future research is expected to focus on developing advanced materials, such as nano-enhanced PCMs, and integrating artificial intelligence (AI) for real-time optimization of BTM systems. These innovations are likely to enhance efficiency and safety further, making PCM-based BTMs a key component in the future of battery technology, particularly in renewable energy and EV sectors.