Evolution of Battery Thermal Management Systems in Electric Vehicles: Advancements in Technologies, Models, and Future Perspectives

Batteries, especially lithium-ion, are rated best for the storage of energy for commercial electric vehicles (EVs) because of their higher energy density, life cycle, and quick charging features. These benefits are excellent candidates for satisfying the modern energy requirements for EVs. However, the longevity and performance are dependent on the temperature conditions at which operation occurs, making an effective battery thermal management system (BTMS) crucial. Lithium batteries work best in a specific temperature range temperature from 15°C to 35°C. Deviation from such limits results in serious damage, like capacity loss and increased internal resistance, thermal runaway, among others, and a decline in lifespan. The thermal performance of lithium-ion batteries (LIBs) and current developments in BTMS for EVs are addressed by reviewing articles from reputable journals published from 2018 to 2025 in this investigation. In addition, an analysis of different cooling strategies, in terms of performance benefits and shortcomings specific to the thermal management requirements of various EV configurations, is presented. This review also addresses some of the most significant challenges, knowledge gaps, and design requirements related to BTMS. Also, it emphasizes the necessity of further optimization to enhance battery safety, operation performance, and improve life span.