Can Electric Vehicle Battery Cables Handle the Heat? Tracking Degradation through Accelerated Thermal Aging

As electric vehicles evolve toward higher voltages, faster charging, and lighter designs, the performance demands placed on their wiring systems continue to rise. Yet, while these cables are expected to last decades in harsh environments, their long-term performance cannot be easily observed within reasonable development timelines. To bridge this gap, accelerated aging offers a path to predict how critical materials will behave over time without waiting years for results.

This study examines the chemical, thermal, and compositional evolution of a model high-voltage automotive battery cable subjected to controlled thermo-oxidative aging. Samples were extracted weekly to capture the progression of degradation in both the insulation and jacket layers. Multiple analytical techniques were used to assess oxidation, flame-retardant stability, and differences in material response between insulation layers. The results provide new insight into how electric vehicle battery cables may perform long-term and early indicators of end-of-life behavior to support safer, longer-lasting vehicle designs.