<p>Battery thermal management system (BTMS) is a vital component that is required to determine the safety, optimal performance and long-term stability of lithium-ion batteries (LIBs), particularly in the adverse operational conditions of electric vehicles (EVs). The high sensitivity of LIBs to changes in temperature can severely impair the capacity, power output, and cause catastrophic thermal runaway. This is a critical review of the existing BTMS technologies that reveal the natural limitations of standalone conventional systems like air cooling, liquid cold plates and pure phase change materials (PCMs). In order to eliminate these thermal bottlenecks, this paper points out the transformative potential of hybrid architectures that synergistically integrate passive and active cooling methods. In particular, we highlight the integration of nanocomposite PCMs including those that are reinforced with high-conductivity fillers such as graphene, carbon nanotubes, and metal oxides, which drastically improve thermal conductivity and heat absorption. In addition to this, this review examines the importance of the use of advanced control strategies, discussing how artificial intelligence (AI) machine learning (ML) and model predictive control (MPC) may be dynamically optimized to control cooling operations, minimize parasitic energy consumption, and provide strict inter-cell temperature uniformity. However, in spite of these drastic technological advances, practical implementation is still hampered by the issues of scalability of manufacturing, system mass, pressure drops and long-term material stability. To close the disconnect between laboratory research and commercial viability, we suggest a strategic roadmap that advocates the development of modular, adaptable hybrid systems with multi-modal sensing and predictive digital twins, ultimately, ensuring cost-effective and highly reliable thermal management of next-generation EVs.</p>