Toward high-performance Li-ion batteries for EVs: A review of fast charging barriers and emerging BTMS solutions

The widespread adoption of electric vehicles (EVs) hinges on the ability of lithium-ion batteries (LiBs) to support fast charging without compromising safety, performance, or longevity. This review provides a comprehensive and systematic analysis of the critical challenges associated with high-rate charge/discharge in EV batteries, including degradation mechanisms such as lithium plating, mechanical cracking, and excessive heat accumulation. Key developments in anode and cathode materials, as well as electrolyte engineering are critically examined in terms of their influence on charge acceptance, heat generation, and electrochemical stability under high C-rate conditions. In parallel, particular emphasis is placed on the evolution of battery thermal management systems (BTMS), with an in-depth evaluation of nanofluid-based, composite phase change material (CPCM)-based, hybrid systems, and advanced configurations such as liquid, heat pipe, and immersion cooling. These approaches are comparatively evaluated with respect to cooling performance, thermal uniformity, and suitability for fast-charging applications. Furthermore, emerging intelligent thermal management frameworks enabled by artificial intelligence (AI) and machine learning (ML) are discussed, highlighting their capability for accurate thermal prediction, real-time control, and early detection of thermal runaway risks. The review identifies the fundamental trade-offs between fast charging capability, thermal safety, and energy density, and discusses key challenges such as material degradation, system complexity, and scalability. Finally, future research directions are outlined, emphasizing the need for integrated material-thermal-intelligent design strategies to achieve safe, efficient, and reliable fast-charging LiBs.