Advanced Electronic Materials for Liquid Thermal Management of Lithium-Ion Batteries: Mechanisms, Materials and Future Development Directions

The rapid expansion of lithium-ion battery applications calls for efficient and reliable thermal management to ensure safety and performance. Liquid thermal management systems (LTMS) offer high cooling efficiency and uniform temperature control, effectively preventing thermal runaway. This review focuses on composite LTMS that integrate phase change materials and nanofluids and discusses how thermal modeling optimizes key material parameters. Despite notable progress, challenges remain in compatibility, stability, and sustainability. Emerging smart, self-healing, and AI-assisted materials are expected to drive the next generation of intelligent battery cooling systems. Compared with air-cooling systems (maximum temperature ≈ 55 °C, temperature difference ΔT ≈ 10 °C), liquid-based systems can reduce the peak temperature to below 42 °C and improve temperature uniformity (ΔT ≤ 5 °C). Particularly, nanofluid-enhanced LTMS achieve up to 15%~20% higher heat transfer efficiency and 3~5 °C lower surface temperature compared with conventional water-glycol cooling. Direct immersion cooling using dielectric fluids such as HFE-7000 further decreases the maximum temperature to ≈37 °C with ΔT ≈ 3.5 °C, achieving a cooling efficiency above 88%. Thermal modeling results show that accurate representation of material parameters (e.g., interfacial thermal resistance R(int) and thermal conductivity k) can reduce simulation error by more than 30%. This work uniquely bridges materials science with thermal system engineering through AI-driven innovation, providing a data-guided route for next-generation adaptive LTMS design.