Cable could be shorting with something internally on its way out of the controller? Does it do the same thing if you unplug it at the USB end on the computer first instead of unplugging from the controller first?
I think the USB voltage on that 3.5mm jack end is catching something on the way out. There is 5 volts present in that 3.5mm jack end, but we don't use it - not connected inside the controller, the batteries do all the work.
