Headset audio cable differences? - Page 1
Forum section: electronics / repair

author: Yion
author_rank: Newbie
timestamp: March 23, 2022, 03:09:10 pm
content: Hi,for repairing my broken headset, I bought an audio cable from Ali.But their not the same size. It's a lot bigger than the tiny one from the headset.Comparision picture:Will that cable still work too or what type is that tiny one?Thanks!

author: madires
author_rank: Super Contributor
timestamp: March 23, 2022, 03:32:40 pm
content: It should work fine, but is not as flexible as the thin one. If you're looking for a thinner one search for Mikrofonleitung/kabel (microphone cable) with a wire cross section of 0,08 or 0.1 mm².

author: Yion
author_rank: Newbie
timestamp: March 28, 2022, 01:35:33 pm
content: Great! Thanks.I just noted some odd copper wire wrapped/drilled around the others:Is that for the current or what does this cable do?Thanks.

author: madires
author_rank: Super Contributor
timestamp: March 28, 2022, 02:24:28 pm
content: Looks like a shielding braid. In most applications it's used for the ground connection.

author: tooki
author_rank: Super Contributor
timestamp: March 28, 2022, 06:17:38 pm
content: Quote from: Yion on March 28, 2022, 01:35:33 pm(FYI, Yion, “drilled” means “gebohrt” in English, no connection to “verdrillt”, which would be “twisted”.)

author: shianne
author_rank: Contributor
timestamp: March 29, 2022, 04:17:00 pm
content: I think the main problem is to know, how this special cable is called.Earphones are equipped with this special type of cable we can see on the right hand side of the photo from Yion.These cables are high flexible because the thin enameled copper strands are wound around a plastic fiber bundle for each core.This is the difference to "normal" wires/cables.Telephone handset cables have a similar construction sometimes (but the copper/aluminium strands are not enameled, every core has "normal" insulation).Here are some more photos:https://electronics.stackexchange.com/questions/60031/what-material-are-the-thin-colored-wires-in-my-headphone-cableThe thinnest (affordable) wire I know and bought in Germany is called "Tonarmleitung" in German (could be tonearm wire in English - I am not sure).This type of cable is thin and flexible, but not suitable for frequent (bending-)mechanical stress.For me it worked two years but I handled the earbuds with care.If you want to buy something from Ali:https://de.aliexpress.com/item/4000262397782.htmlI'm not sure about the quality.For headphones (= small loudspeaker next to the ear) nearly everything will work.If you have a microphone, the signal wire should be shielded.The shielding should not be shared with one of the loudspeakers wires.

author: commongrounder
author_rank: Frequent Contributor
timestamp: March 29, 2022, 09:23:05 pm
content: The type of wire used in highly flexible/durable cables is called “Litz wire”. It has many small individually insulated wires twisted together. Often on headphone cables these color coded stranded conductors are directly adjacent to each other, and would appear to be shorting, but the clear insulation separates them. It takes high heat to break through and tin these wires. Immersing the end of the wire in a pool of solder on the tip of your iron usually does the trick.

author: tooki
author_rank: Super Contributor
timestamp: March 30, 2022, 02:15:17 am
content: Litz wire is the stuff for high frequency (RF) use. Earphone wire is different, though related. Litz is lots of strands of thin enameled wire bundled together with a fiber wrap; earphone wire is the opposite, a fiber core wrapped with either enameled wire or enameled ribbon.Why? Because the fiber core takes up all the force from tugging, completely relieving the wire itself, and makes it more flexible. Litz wire isn’t necessarily all that flexible, depending on how it’s been wrapped.

author: Yion
author_rank: Newbie
timestamp: March 31, 2022, 07:57:41 am
content: Thank you for your answers.Searching the web I found more specific details about the headset and images from another one who tried to repair it.https://www.ifixit.com/Device/Logitech_G533more pictureshttps://imgur.com/gallery/qnF8eTbHopefully the replacement cable doesn't need some kind of specific ohm?So, as far as I understood, my already bought cable will work as a replacement too, but that copper one wrapped around the bundle which pulls to ground, is necessary, right?Greetings

author: madires
author_rank: Super Contributor
timestamp: March 31, 2022, 09:41:53 am
content: It's recommended to shield wires carrying low and unbalanced signals from things like mains hum.

author: commongrounder
author_rank: Frequent Contributor
timestamp: April 01, 2022, 02:34:55 pm
content: Quote from: Yion on March 31, 2022, 07:57:41 amThe replacement cable you have will work just fine, as long as you can make it fit physically. Headphone cables don’t require shielding, but its presence shouldn’t cause issues either. You can tie the shield to the common return wire, or leave it disconnected.

author: TimFox
author_rank: Super Contributor
timestamp: April 01, 2022, 07:12:50 pm
content: The US term for this ultra-flexible but low-current wire is "tinsel wire".https://en.wikipedia.org/wiki/Tinsel_wireIt is a big pain to solder, given that it is very fine copper wire around a plastic or fiber-thread core.

author: shianne
author_rank: Contributor
timestamp: April 03, 2022, 07:54:37 am
content: Thank you for the term "tinsel wire".This seems to be a term for which there is no German equivalent. The translators point in the direction of Christmas decorationsI need to do some more research on wire types...

author: kleiner Rainer
author_rank: Regular Contributor
timestamp: April 03, 2022, 09:11:46 am
content: The german equivalent to "tinsel wire" is "Lahnlitze":https://de.wikipedia.org/wiki/LahnlitzeGreetings,Rainer

author: madires
author_rank: Super Contributor
timestamp: April 03, 2022, 11:12:22 am
content: Though, the fine print says that tinsel wire is meant to be crimped/IDCed.

author: Gyro
author_rank: Super Contributor
timestamp: April 03, 2022, 11:36:30 am
content: Yes, it's a real pain to solder and, without the fibre core, the joint has no mechanical strength.P.S. You could maybe use tiny ferule crimps to attach it to a more suitable wire though.

author: TimFox
author_rank: Super Contributor
timestamp: April 03, 2022, 02:04:39 pm
content: When used in 2000 ohms communications headphones, there were special crimp terminals for tinsel wire that then went into screw terminals.In Christmas decorations, "tinsel" was originally lead foil that was draped over the tree branches to simulate ice--later replaced by aluminum which doesn't hang right.Also, Oscar Levant said "Strip away the phony tinsel of Hollywood and you find the real tinsel underneath" in another context.