I'm tired of continuously fixing wire on headphones.
Can you recommend good wire that resistant to the frequent bending and thus will be last ultimate replacement as headphone wire ?
The simplest solution to wire breakage by repeated flexing has traditionally been seen in the (ancient) wired telephone handset:
The specific cable listed above is just one example, it is a 5-conductor shielded audio cable. There are lighter coiled audio cables available, which may be better suited to headphone use, if the weight is a concern.
There are two primary ways of making ultra-flexible wire.
The first is to use many, many strands of really fine wire, rather than fewer strands of relatively coarse wire. Compare the stranded wire used for house wiring to the same guage wire found in flexible power cords used on appliances. You might try searching for "test prod wire".
The other way is to use a core of nonmetallic fiber and then wrap either fine wires or a very thin, flat copper ribbon around that core in a spiral. This is the wire most often found in headset and microphone cable. This kind of wire can be difficult to make connections to, because the fiber core can get in the way of proper soldering, and you need to be careful about strain relief near the joint.
In either case, the outer insulation of the wire needs to be suitably flexible, too. Silicone rubber provides a good balance between flexibility and wear resistance.
I've just replaced some headphone wire with RG-178 mini-coax (2-off: glued together as a pair). It's not pretty, but it works so far... I'll report back in a few months (as that seems to be the usual length of time it takes for the kids to break them... :)
protected by W5VO♦ Apr 8 '13 at 14:02
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