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<p>The rapid expansion of electric vehicles (EVs) has increased the demand for effective battery storage systems, with lithium–ion batteries (LIB) playing a vital role due to their high-energy density, efficiency, and endurance. However, LIB safety and effectiveness are extremely sensitive to temperature changes, making thermal management a significant hurdle for EV technology. This study looks into the limitations of current research and the issues connected with different battery thermal management systems (BTMS). It examines cooling strategies employed by leading EV manufacturers, including Tesla, Volkswagen, BYD, BMW, Hyundai and Nissan and evaluates techniques. Liquid cooling emerges as the dominant strategy, achieving temperature uniformity (Δ<i>T</i> &lt; 5&#xa0;°C) even at high discharge rates (5C), with Tesla’s glycol–water microchannel systems. Hybrid systems, such as Volkswagen’s liquid–air cooling and BYD’s phase change material (PCM)-enhanced approaches, reduce peak temperatures by up to 17.7&#xa0;°C, offering a balance between efficiency and cost. In contrast, air cooling (Nissan Leaf) remains limited to low-cost, short-range EVs due to its susceptibility to thermal gradients (Δ<i>T</i> ~ 8&#xa0;°C) in extreme climates. Recent advancements highlight transformative innovations: immersion cooling with dielectric fluids reduces peak temperatures by 28%, nano-enhanced PCMs improve thermal conductivity by 42%. However, challenges persist, including the 30–50% cost premium for hybrid/PCM systems and the energy-intensive nature of thermoelectric cooling (TEC). This work contributes to the ongoing development of next-generation BTMS, addressing critical challenges in the EVs industry.</p>

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Recent update progress for the battery thermal management of electric vehicles: challenges and solutions

  • 期刊论文

  • 发表日期：

    2025年7月22日

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  • Fatima Abbas Khalaf,
  • Ali Lateef Tarish

摘要

The rapid expansion of electric vehicles (EVs) has increased the demand for effective battery storage systems, with lithium–ion batteries (LIB) playing a vital role due to their high-energy density, efficiency, and endurance. However, LIB safety and effectiveness are extremely sensitive to temperature changes, making thermal management a significant hurdle for EV technology. This study looks into the limitations of current research and the issues connected with different battery thermal management systems (BTMS). It examines cooling strategies employed by leading EV manufacturers, including Tesla, Volkswagen, BYD, BMW, Hyundai and Nissan and evaluates techniques. Liquid cooling emerges as the dominant strategy, achieving temperature uniformity (ΔT < 5 °C) even at high discharge rates (5C), with Tesla’s glycol–water microchannel systems. Hybrid systems, such as Volkswagen’s liquid–air cooling and BYD’s phase change material (PCM)-enhanced approaches, reduce peak temperatures by up to 17.7 °C, offering a balance between efficiency and cost. In contrast, air cooling (Nissan Leaf) remains limited to low-cost, short-range EVs due to its susceptibility to thermal gradients (ΔT ~ 8 °C) in extreme climates. Recent advancements highlight transformative innovations: immersion cooling with dielectric fluids reduces peak temperatures by 28%, nano-enhanced PCMs improve thermal conductivity by 42%. However, challenges persist, including the 30–50% cost premium for hybrid/PCM systems and the energy-intensive nature of thermoelectric cooling (TEC). This work contributes to the ongoing development of next-generation BTMS, addressing critical challenges in the EVs industry.