Why do USB cables always fray?

Once a USB cable starts to fray, it’s on its way out. Fraying occurs when the cable’s internal wires, braiding, or shielding begins to show because the jacket is broken. These cords typically fray where the cable and connector meet, which is a major weak point due to the amount of tension that typically occurs here.

After prolonged bending, twisting and pulling, it can easily begin to break, especially when there is nothing to relieve the tension at the connection point. USB cables fray for a variety of reasons. For example, when using a phone in bed while charging, we may rest the bottom of the phone on our chest or hold it at an angle, which puts pressure on the USB cable and leaves you improperly charging the phone in the process.

You can also pull it along the wire when disconnecting, creating tensile stress at the connector. Additionally, when we lay cables on the floor, they can get caught, bent and crushed by furniture. Regardless of how these cords begin to come undone, the problem should be addressed as soon as it occurs. There are ways to save a frayed USB cable if it’s not completely broken, but the fixes are temporary.

A frayed USB cable may still work, but there are a few good reasons why you should take it seriously. Depending on the severity, the cable may lose its ability to provide stable current to your device. Best case scenario, the voltage drops, meaning the device isn’t getting enough current and may take longer to charge. In the worst case, they can cause a short circuit, which could cause the device’s USB port to heat up and fry a component on the motherboard.

In some scenarios, your lithium-ion battery could catch fire due to overheating (although this is rare). So if you’re constantly trying to adjust the frayed cable by bending and twisting it to make it work, you may want to consider replacing it. Damage to the device is the least of your worries, as exposed wires and metal connectors can also shock you. There is also a risk of a fire starting, and although the chances of this happening are small, they are still non-zero and not worth the risk.

Once you know why USB cables fray, preventing it comes down to good habits. Avoid any scenario where the cable ends up excessively bent. These cables have a minimum bend radius, which is generally 10 times the diameter of the cord. When you exceed this value, the sheath, shielding, braiding and internal wires are put under stress. Also, instead of pulling on the cable, grab the connector and pull it out. This is the part that can withstand constant pulling.

Additionally, when storing your USB cables, wrap them lightly to prevent them from getting tangled with other items, such as when you keep the cable in a bag. If fraying occurs, you can wrap the affected area with electrical tape or remove the spring from a ballpoint pen and hook it around the cable near the connector to strengthen it. Another method is to wrap heat shrink tubing around the frayed section and heat it to create a waterproof cover. To prevent fraying in the longer term, consider getting a braided USB cable and if you’re in temporary repair mode, look to replace it with some of the best USB-C cables for your devices.