Lithium-ion batteries (LIBs) are increasingly being adopted for applications requiring high energy density, such as energy storage power stations and electric vehicles. However, their thermal safety remains a significant concern, particularly due to the risks of thermal runaway (TR) and battery fires. Efficient battery thermal management systems (BTMS), particularly those based on phase change materials (PCMs), have emerged as a promising solution to address these issues. PCM-based BTMS offer advantages such as effective heat dissipation, temperature uniformity, and low energy consumption. However, the inherent flammability of PCMs poses additional risks, highlighting the need for advancements in their flame-retardant properties and overall thermal stability. Research into PCM-based BTMS has focused on enhancing the thermophysical properties of modified PCMs, including their thermal response rate, latent heat, and flame retardancy. The use of carbon-based, metallic-based, nanomaterial-based and polymer-based additives has been shown to improve the thermal response rate property of PCMs, making them more suitable for demanding applications. Additionally, the development of structure-enhanced PCM-based BTMS, which incorporates design elements aimed at mitigating thermal hazards, has been explored to further improve safety and performance. Despite these advancements, challenges remain in optimizing heat dissipation and improving TR propagation suppression in PCM-based BTMS. Future research directions should prioritize the development of flame-retardant PCMs that can effectively manage both regular operation and extreme conditions, such as TR events. This comprehensive approach is essential for building resilient, self-safety BTMS that ensure the reliability and longevity of LIBs in high-energy applications. By addressing these challenges, future designs can better safeguard against thermal hazards, contributing to the broader adoption of LIBs in various industries.
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