A strategy for portable high-power applications with a controlled thermal environment has been developed and has demonstrated the advantage of using the novel phase change material (PCM) thermal management systems over conventional active cooling systems. A passive thermal management system using PCM for Li-ion batteries is tested for extreme conditions, such as ambient temperature of 45°C and discharge rate of 2.08C-rate (10A). Contrary to Li-ion packs without thermal management system, high-energy packs with PCM are discharged safely at high currents and degrading rate of capacity of the Li-ion packs lowered by half. Moreover, the compactness of the packs not only decreases the volume occupied by the packs and its associated complex cooling system, but also decreases the total weight for large power application.