Abstract

The role of intelligent thermal composites is highlighted in regulating heat flow in comact, energy demanding systems. This review examines the integration of phase-change materials (PCMs) within composite architectures, emphasizing their capacity to store and release latent heat for passive and adaptive control. The current study reviewed research from 2020 to 2024 that focused on encapsulation strategies (micro/macro/shape-stabilized), thermal conductivity enhancement (graphitic carbons, metal foams, ceramic fillers), and structural designs that mitigate limitations of conventional PCMs, including low conductivity, leakage, and cycling degradation. The study has surveyed applications across automotive battery packs, aerospace electronics, building envelopes, wearable devices, and emerging 3D-printed thermal lattices, with attention to geometry, interface resistances, and manufacturability. Key performance metrics, latent heat, effective conductivity, supercooling, and cycle stability, are analyzed in addition to in mass & volume, viscosity, and flammability. The study ends with outlining research priorities in nano-enhanced and bio-derived PCMs, anti-leakage/self-healing shells, and standardized test protocols to bridge laboratory gains to field performance and enable sustainable, scalable thermal-energy solutions.

Key words: Phase-change materials; Thermal-conductivity enhancement; Metal-foam scaffolds; Supercooling mitigation; Cycling durability.