RSM Optimization of Lithium-Ion Batteries for Enhanced Battery Safety in Electric Vehicles

Abstract

Lithium-ion batteries (LIBs) are the dominant energy storage technology for electric vehicles (EVs) due to their high energy density, long cycle life, and efficiency. However, their performance and safety are highly temperature-dependent, with deviations from the optimal range (20–40 °C) leading to accelerated degradation, capacity loss, and thermal runaway risks. To address these challenges, battery thermal management systems (BTMS) have emerged as critical enablers of reliable EV operation. This paper provides a comprehensive review of current and emerging thermal management strategies, including air cooling, liquid cooling, phase-change material (PCM)-based systems, heat pipes, thermoelectric cooling, and hybrid solutions. Each method is critically evaluated in terms of thermal performance, cost, scalability, integration complexity, and suitability for various EV applications. The analysis highlights that while liquid cooling dominates commercial adoption, hybrid systems integrating PCM, advanced fluids, and predictive control are promising for next-generation EVs. Key challenges, including thermal runaway mitigation, lightweight material development, and system integration with vehicle thermal loops, are discussed alongside future research directions. The findings suggest that intelligent, sustainable, and adaptive BTMS designs will be central to enhancing battery safety, extending lifespan, and supporting the continued growth of electric mobility.