Progress in battery thermal management systems technologies for electric vehicles

Lithium-ion batteries have emerged as a key driver in the commercialization of electric vehicles due to their high energy density, outstanding performance integrated with powertrain systems. Nonetheless, battery performance is greatly influenced by operating temperature which requires precise a thermal management for optimal performance, safety, cost, and longevity especially in high-capacity Li-ion battery. Essentially, investigation of battery thermal management system calls for different aspects of design ranging from configuration and geometry design depending on battery cell and pack layouts to the material selection or development for expected performance and safety level of thermal system. This review formulates heat generation and thermal models in the batteries along with thermal management systems. It explores the effects of abuse conditions in batteries such as thermal runaway and aging. Furthermore, fast charging technologies is discussed in safety design of battery thermal management systems which is rarely studied in similar studies to date. The study also deliberates different types of thermal management system for electric vehicle having Li-ion batteries, such as passive, active, and hybrid models, based on thermal, hydraulic performance and safety. Various heat transfer mediums such as different phase change material types, refrigerant fluid, and combination of them are discussed and categorized based on material characteristic. This review not only collects and reviews the latest battery thermal management system designs, by exploring their future trends and solutions in the performance and safety aspect, but also aims to paves the way for a comprehensive framework in future battery thermal management system research and development.