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Due to strict regulations and the requirement to reduce greenhouse gas emissions, electric vehicles (BEVs) are a promising mode of transportation. The lithium battery is the most important power source for an electric vehicle, but its performance and life are greatly restricted by temperature. To ensure the safety of automobile operation and alleviate mileage anxiety, it is urgent to understand the current situation and predict the development and challenge of battery thermal management system. This work reviews the existing thermal management research in five areas, including cooling and heating methods, modeling optimization, control methods, and thermal management system integration for lithium batteries. Battery thermal management types include air-based, liquid-based, PCM-based, heatpipe-based, and direct cooling. Designing a better battery thermal management system not only needs to be optimized using algorithms on the model but also it uses intelligent algorithms for precise control to achieve safety and reduce energy consumption. This work also reviews the differences in thermal management systems between square and cylindrical batteries and summarizes the development trend of modularity in battery thermal management systems.

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Waste heat recovery can not only reduce the heating energy consumption during heating, but also assist the PTC to improve the heating efficiency. In this work, a motor waste heat recovery system composed of two four‐way valves is proposed. Through simulation and test, the thermal management system model is established based on the parameters of each component. Experiments and simulations were also conducted at 0 °C, 20 °C and 40 °C. Under the New European Driving Cycle (NEDC), it was verified that the motor waste heat recovery system can meet the heating demand of the cabin. At the same time the temperature rise of the battery increased by 2.9% from 0 °C to 15 °C compared to no heat recovery system. From 0 °C to 18 °C, the cabin temperature increased by 8.1%. The cooling rate of the battery increased by 5.8% from 40 °C to 30 °C and the cooling rate of the cabin increased by 9.7% from 40 °C to 23 °C.This article is protected by copyright. All rights reserved.