Method of manufacture of electrical wire and cable having a reduced coefficient of friction and required pulling force

A process for making a finished wire and cable with an internal conductor, the finished wire and cable having a reduced coefficient of friction and reduced pulling force during installation, the process comprising:

• providing an extruder, wherein the extruder applies an insulating material and a jacket composition over the internal conductor, wherein the jacket composition comprises:
• a predetermined amount by weight of nylon;
• and
• at least 3% and less than 5% by weight of a predetermined amount of amorphous silica, wherein the nylon and silica are polymerized together without a pulling lubricant as an extrudable, pelletized compound;
• and
• wherein the extruded nylon and silica of the finished wire and cable reduces the coefficient of friction and reduces the pulling force during installation.

A process for making a finished wire and cable having a reduced coefficient of friction and reduced pulling force during installation, the process comprising:

• providing a payoff reel containing at least one internal conductor wire;
• supplying the at least one internal conductor wire from the reel to first extruder;
• providing the first extruder, wherein the least one extruder applies a first insulating material;
• providing a second extruder, wherein the second extruder applies jacket composition over the at least one internal conductor wire and insulating material, wherein the jacket composition consisting essentially of:
• a predetermined amount by weight of nylon;
• and
• at least 3% and less than 5% by weight of a predetermined amount of amorphous silica, wherein the nylon and silica are polymerized together as an extrudable, pelletized compound;
• providing a cooling device for lowering the temperature of the extruded insulating material and the polymerized jacket composition and cooling the insulating material and the polymerized jacket composition in the cooling device;
• and,
• reeling onto a storage reel the finished, cooled, wire and cable for storage and distribution;
• wherein the extruded nylon and silica of the finished wire and cable reduces the coefficient of friction and reduces the pulling force during installation.