A Review of the Thermal Management System of Lithium-Ion Batteries in Electric Vehicles According to the Classification of Phase Change Materials

Thermal regulation of lithium-ion (Li-ion) battery modules is a critical constraint for electric vehicle (EV) safety and durability, particularly during high-C-rate operation. Phase change materials (PCMs) have emerged as promising passive solutions due to their latent heat storage capability; however, current literature is heavily biased toward organic paraffin-based systems and lacks structured benchmarking across PCM categories and integration architectures. This review provides a systematic comparative assessment of PCM-based battery thermal management systems (BTMSs) comprising organic, inorganic, and eutectic materials under EV-relevant discharge conditions. The review is structured according to the conventional classification of PCMs; however, the available literature is predominantly focused on organic materials, particularly paraffin-based PCMs, leading to greater depth of analysis for this category. Thermophysical properties are analyzed in conjunction with discharge rate, module configuration, and hybrid cooling strategies. The results indicate that peak temperature mitigation is weakly correlated with latent heat magnitude when thermal conductivity remains below critical values. Conductivity-enhanced composites incorporating expanded graphite or metal foams significantly improve heat diffusion, reducing hotspot intensity and inter-cell temperature gradients under medium-to-high C-rates. Pure passive PCM systems exhibit thermodynamic limitations during sustained high-power operation due to saturation effects, underscoring the need for hybrid architectures for continuous heat rejection. This work establishes a structured benchmarking framework and demonstrates that effective thermal conductivity, integration strategy, and discharge-dependent design dominate BTMS performance over latent heat alone. The findings also reveal that inorganic and eutectic PCM-based BTMSs remain comparatively less explored in the literature, particularly at the battery module level and under realistic electric vehicle operating conditions, highlighting opportunities for future research.