A Comprehensive Review of Thermal Management Challenges and Safety Considerations in Lithium-Ion Batteries for Electric Vehicles

The transition to electric vehicles (EVs) is accelerating due to global efforts to reduce greenhouse gas emissions and reliance on fossil fuels. Lithium-ion batteries (LIBs) are the predominant energy storage solution in EVs, offering high energy density, efficiency, and long lifespan. However, their adoption is overly involved with critical safety concerns, including thermal runaway and overheating. This review systematically focuses on the critical role of battery thermal management systems (BTMSs), such as active, passive, and hybrid cooling systems, in maintaining LIBs within their optimal operating temperature range, ensuring temperature homogeneity, safety, and efficiency. Additionally, the study explores the impact of integrating artificial intelligence (AI) and machine learning (ML) into BTMS on thermal performance prediction and energy-efficient cooling, focusing on optimizing the operating parameters of cooling systems. This review provides insights into enhancing LIB safety and performance for widespread EV adoption by addressing these challenges.