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A method of manufacturing wire from a conductor and a supply of thermoplastic insulating material. The method involves heating the insulating material, adding pressurized gas to the material, and extruding a sheath of the insulating material about the conductor to generate bubbles of the gas in the

A method of manufacturing wire from a conductor and a supply of thermoplastic insulating material. The method involves heating the insulating material, adding pressurized gas to the material, and extruding a sheath of the insulating material about the conductor to generate bubbles of the gas in the sheath. The method may operate by limiting the temperature of the material prior to extrusion, to increase viscosity to limit bubble expansion, and may provide a significant pressure drop on extrusion by limiting the gap between a wire-supplying guide and the extrusion die.

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1. A method of manufacturing wire comprising: providing a conductor; providing a supply of thermoplastic insulating material; heating the insulating material; adding pressurized gas to the material; extruding a sheath of the insulating material about the conductor; extruding a sheath includi

1. A method of manufacturing wire comprising: providing a conductor; providing a supply of thermoplastic insulating material; heating the insulating material; adding pressurized gas to the material; extruding a sheath of the insulating material about the conductor; extruding a sheath including passing the conductor through a central bore defined by a guide having a nose, positioning the nose a limited distance from a die defining a passage through which the conductor passes, such that the die and the nose define a first gap; extruding a sheath further including passing the conductor through an outlet bore defining a second gap with respect to the conductor; and while passing the insulating material through the first gap, generating bubbles of the gas in the sheath. 2. The method of claim 1 wherein heating the insulating material includes limiting the temperature to less than a preselected threshold prior to extruding the sheath. 3. The method of claim 2 wherein the insulating material has a melting point, and the preselected threshold is at least 140° F. below the material melting point. 4. The method of claim 2 wherein the insulating material has a glass transition temperature, and wherein the threshold is limited to less than 316° F. above the glass transition temperature. 5. The method of claim 1 including mixing the material after adding pressurized gas in an extrusion screw facility having a length at least 36 times its diameter. 6. The method of claim 1 wherein the insulating material is a polyolefin material. 7. The method of claim 1 wherein the insulating material is poly methyl pentene. 8. The method of claim 1 wherein the gas is carbon dioxide. 9. The method of claim 1 wherein the gas in nitrogen. 10. The method of claim 1 wherein the bubbles have diameters less than 0.002 inch. 11. The method of claim 1 wherein the sheath has a thickness of less than 0.008 inch. 12. The method of claim 1 wherein the bubbles have diameters between 0.5 and 0.10 times the thickness of the sheath. 13. The method of claim 1 wherein the first gap has a width of less than 2.5 times the diameter of the conductor. 14. The method of claim 1 including reducing the pressure of the material as passes through the first gap. 15. The method of claim 14 wherein the pressure reduction across the first gap is greater than 90%. 16. The method of claim 1 wherein the outlet bore has a length at least 2 times the diameter of the bore. 17. The method of claim 1 including increasing the viscosity of the material after the gas has been added. 18. The method of claim 17 wherein increasing the viscosity includes decreasing the temperature. 19. The method of claim 14 wherein the pressure drop within the material across the first gap is substantially greater than the pressure drop across the second gap. 20. The method of claim 1 wherein the first gap is an annular gap. 21. The method of claim 1 wherein the first gap has a width of less than 0.020 inch. 22. The method of claim 21 wherein the first gap has a width of less than 2.5 times the diameter of the conductor.