Advanced Battery Thermal Management: A Review of Materials, Cooling Systems, and Intelligent Control for Safety and Performance

ABSTRACT Thermal management systems have become increasingly important in addressing the critical challenges associated with lithium‐ion battery operation. Proper temperature regulation is essential for maintaining safety, optimizing electrochemical performance, and extending cycle life. This review provides a comprehensive and structured analysis of the latest developments in battery thermal management systems (BTMS), encompassing foundational commercial systems and advanced active, passive, and hybrid cooling strategies. The discussion integrates insights from materials science, thermodynamics, systems engineering, and artificial intelligence‐based control strategies. Among the most significant advancements are phase change materials (PCMs) with enhanced thermal conductivity, such as graphene‐reinforced paraffin composites, which improve heat absorption and dissipation. Another key innovation is the use of microchannel liquid cooling systems, particularly those optimized through advanced topological design techniques, enabling more efficient heat transfer. Additionally, intelligent control mechanisms, including digital twin‐assisted thermal management systems, allow for real‐time monitoring and adaptive cooling strategies. The review critically examines the trade‐offs between cooling performance, energy efficiency, and cost considerations, evaluating technologies based on key performance indicators. It also highlights several transformative developments, including self‐healing thermal interface materials, 3D‐printed microchannel cold plates, radiative cooling surfaces, and smart, self‐regulating materials. Looking ahead, emerging frontiers such as digital twin‐assisted thermal control, blockchain for lifecycle management, and quantum‐optimized design are identified as promising next‐generation solutions with potential to enhance scalability and sustainability. These innovations have the potential to significantly improve thermal management in both electric vehicles and grid‐scale energy storage applications, ensuring safer and more reliable battery operation.