<![CDATA[Effective thermal management is critical for ensuring the safety, performance, and longevity of EV batteries. This study presents a comprehensive assessment of advanced BTMSs using CFD simulations, experimental validation, and statistical modeling. Three advanced heat transfer mechanisms microchannel cooling, heat pipes, and jet impingement cooling— were evaluated alongside novel materials, including graphene-enhanced TIMs and hybrid PCMs incorporating carbon nanotubes (CNTs). Jet impingement cooling provided the lowest peak temperature (33.8 °C) and the greatest heat dissipation efficiency (94.5%) among the tested systems. Microchannel cooling maintained 34.5 °C with superior temperature uniformity while graphene CNT hybrid PCMs reached thermal conductivities of up to 15.8 W/m·K, reducing the maximum temperature to 32.4 °C under high-power loads. Regression analysis confirmed that thermal conductivity and flow rate were key predictors of cooling performance (R² > 0.85). Although these technologies are promising, integration remains constrained by high material costs and long-term reliability concerns, such as mechanical degradation and fatigue. This work offers a novel contribution by comparatively analyzing heat transfer mechanisms and material innovations across multiple validation platforms. This study provides data-driven insights to guide cost-effective and scalable thermal solutions for next-generation EV platforms.]]>
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