A battery thermal management system integrating phase change material and mini-channels, with a focus on safety and economic considerations, is proposed to enhance thermal performance across various working conditions, safety scenarios, and realistic driving cycles while minimizing energy consumption. A battery thermal model and PCM simulation model were developed and validated using experimental data. Numerical analyses were conducted to compare the combination of PCM and liquid cooling (hybrid cooling) with fully liquid cooling under different charge/discharge rates and realistic driving cycles, evaluating their safety characteristics, power consumption, and thermal efficiency. The results demonstrated that the hybrid cooling approach can effectively maintain both the maximum temperature and the temperature difference within a desirable range, even when the inlet velocity is reduced from 0.12 to 0.05 m/s compared to liquid cooling. Additionally, the hybrid BTMS provides better working conditions for the battery pack, requiring only 4 × 10−5 W of pumping power compared to 16 × 10−5 W in the liquid cooling system. This underscores the capability of the designed BTMS to cool high-capacity battery packs with significantly lower fluid flow rates. Furthermore, the performance of the proposed cooling system was examined in the event of liquid channel failure, with results showing that the hybrid BTMS can successfully maintain the battery's maximum temperature within an allowable range during fast charge/discharge processes. Lastly, evaluations under realistic driving conditions revealed the superiority of hybrid cooling in reducing peak temperatures and minimizing battery temperature variation.