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High Voltage, High Performance
Rexolite®, a distinctive cross-linked polystyrene microwave plastic, is produced by C-Lec Plastics Inc. It stands out for its stable electrical properties, which remain consistent up to the Giga-hertz frequency range.
These characteristics make Rexolite® a popular choice for applications in high-frequency circuit substrates, microwave components, and lenses utilized in acoustic, optical, and radio-frequency domains.
Rexolite® is also known for its optical clarity, exhibiting a mild yellow hue and is similar to acrylic when machined and polished. Additionally, it maintains dimensional stability and is known for its excellent sound transmission qualities.
Revolutionize High-Frequency Applications
Superior Material Qualities
Unmatched Precision and Stability
High Voltage and High Performance
Preferred Choice in Various Industries
Unique Properties Suitable for Diverse Applications
Benefits
The benefits of Rexolite, a unique type of cross-linked polystyrene, are closely tied to its distinctive properties. These benefits make it a valuable material in various industries, particularly in electronics, telecommunications, and aerospace. Here’s an overview of its key benefits:
Excellent Electrical Insulation
Rexolite’s high dielectric strength makes it an excellent insulator, particularly in high-frequency electronic applications. This property is crucial for components in communication devices, radars, and other electronic equipment.
Minimal Energy Loss at High Frequencies
Due to its low loss tangent, Rexolite is highly efficient in applications involving high-frequency transmissions. This means it can transmit signals with minimal energy loss, a crucial factor in radar systems and advanced telecommunications.
Transparency to Microwaves and Other Radiation
Rexolite’s ability to allow the passage of microwaves and other forms of radiation makes it suitable for use in lenses and components in radar systems, as well as in certain medical and scientific equipment.
Dimensional Stability and Precision
Rexolite maintains its shape and dimensions under various environmental conditions, including temperature fluctuations. This stability is essential for manufacturing precision parts where exact dimensions are critical.
Ease of Machining
Being easily machinable to precise specifications allows for creating complex and intricate parts without the material losing its integrity or properties.
Chemical Resistance
Rexolite’s resistance to many chemicals, acids, and alkalis enhances its durability and longevity, especially in environments where exposure to such substances is common.
Lightweight
Its relatively low density compared to other materials like glass or metals makes it advantageous in applications where weight is a concern, such as in aerospace or portable electronic devices.
Optical Clarity
In some grades, Rexolite offers excellent optical clarity, which is beneficial in optical systems and components.
These benefits make Rexolite a highly sought-after material in industries that require materials with high precision, stability, and efficiency in electrical and radiation applications. Its unique combination of properties is not commonly found in other plastics, which sets it apart in its range of applications.
PROPERTIES
Rexolite® is a unique type of plastic known for its exceptional properties. It’s a cross-linked polystyrene, which gives it several notable benefits:
Outstanding Dielectric Properties
Dielectric constant of 2.53 (through 500GHz) with extremely low dissipation factors.
Valuable for microwave lenses, microwave circuitry, antennae, coaxial cable connectors, sound transducers, TV satellite dishes, and sonar lenses.
Other uses include non-destructive material testing devices, surveillance equipment, radar windows, radomes, and missile guidance system housings. One interesting application is for radar lenses, which are used for mapping the earth’s surface from fast, high-flying aircraft.
High Voltage Insulators
The ability to withstand high voltage is important for producing gap switch houses, capacitors, and other components. Rexolite® is proven superior over Acrylics, Epoxies, Urethanes and other plastics for dendriting resistance (failure caused by electron bombardment).
Radiation Resistance
Superior to most plastics. Little change in dielectric loss over a wide range of exposures up to 1000M rads. It has superior resistance to mechanical deterioration by ionizing radiation.
Rigidity and Dimensional Stability
Rexolite® exhibits no permanent deformation or plastic flow under loads of 10 psi to 2000 psi at temperatures of 20°C to 200°C. In addition, all castings are stress-free, not requiring any stress relieving prior to, during or after machining.
Temperature Range
Recommended operating temperature is 100°C; Glass transition at 114°C; maintains excellent dielectric properties from -270°C to 176°C (no load-short time).
Optical
Optical transmission approximately equals Acrylic – (87% visible light @ 1″ thick). Refraction index 1.59 @ 589 nanometers, 1.604 @ 486 nanometers and 1.585 @ 656 nanometers. Used in combination with acrylic lenses for color correction.
Sound Transmitting
Excellent acoustic impedance close to water. Velocity 93×10³ inches per second. Ideal for sonar lenses.
Out Gassing
Negligible at elevated temperatures.
ASTM-E-595 Total Mass Loss (TML) .04% Collected Volatile Condensable Materials (CVCM) .01%
Water Absorption
Less than .08% Rexolite 1422 has been immersed in boiling water for 1000 hours without change in dielectric constant.
Machinability
Handles well in all machining operations. Tool configuration is similar to those used on Acrylic. Because of it’s high resistance to cold flow and freedom from stress, it is easily machined by water jet or laser beam. Accuracy of .0001 can be obtained in grinding. Crazing can be avoided by using sharp tools and avoid excessive heat when polishing. Stress relieving of Rexolite is not required before, during or after machining. Always maintain sharp tooling.
Chemical Resistance
Alkalies, Alcohols, Aliphatic Hydrocarbons and mineral acids have no effect. Contact with Aromatic hydrocarbons cause swelling and should be avoided.
Light Weight
Specific gravity of 1.05. Approximately 15% lighter than Acrylic and less than half of TFE (Teflon).
Sub-zero Properties
Maintains a Dielectric Constant of 2.55. At -270°C the dissipation factor is .00019.
Flammability
Burn rate is less than 1 inch per minute.
Adhesive
Rexolite® Adhesive #12517 has been developed especially for bonding Rexolite® to itself.
Environmentally Friendly
Non-hazardous, contains no ingredients harmful to the environment.
Military Specification
Rexolite® 1422 conforms to military specification LP-516A, type E2, formerly known as MIL-P-77C-E2.
Standard Shapes and Sizes
- Rexolite® 1422 rod from 1/16″diameter to 9″diameter.
- Rexolite® 1422 sheet from .010″ to 6″ thick.
- Rexolite® Adhesive #12517 supplied in 2 – 1/2 pint containers.
- Rexolite®-1422-Standard-Sheet-Sizes Rexolite®-1422-Standard-Rod-Sizes
Background of Cross Linked Polystyrene
Cross linked polystyrene was originally developed for the U.S. Military during World War II for use in coaxial cable connectors. There were two manufacturers sharing the market, Dow Chemical and General Electric. After the war, Dow Chemical passed their manufacturing rights of Q200.5 to the Polymer Corporation and General Electric sold their Texolite 1422 production facility to the Rex Corporation. The Rex Corporation changed the name Texolite to Rexolite® and registered the trade name. It then passed in succession to Brand Rex, Dodge Industries, Oak Materials, and Norplex Oak. With all these manufacturers, the production of Rexolite® was limited to sheets up to two inches thick and rods up to four inches in diameter. During the early 1960’s, C-Lec Plastics developed a process to produce stress free sheets up to 6 inches thick and rods up to 8 inches in diameter, creating a new market for cross linked polystyrene. C-Lec marketed this material as Dielco 100. In the mid 1970’s, Norplex Oak terminated production of Rexolite® and passed the Trade Name rights to C-Lec Plastics . Additionally,in the mid 1990’s the Polymer Corporation ceased the production of their Q200.5. C-Lec has continued to improve production techniques through research and development and with computer control. Stress free castings more than 10 inches thick and 6 feet in diameter have been produced.
SPECIFICATIONS
Rexolite® 1422
- Rexolite® 1422 is chemically resistant, light weight, resists water absorption, and has negligible outgassing.
- Military Specifications of Rexolite®
- Rexolite® 1422 conforms to military specification LP-516A, type E2, formerly known as MIL-P-77C-E2.
Current: Mil Spec LP-516A, type E2
Former: Mil Spec MIL-P-77C-E2
Rexolite Product Sheets
RexoliteR 1422 Standard Sheet Sizes
RexoliteR 1422 Standard Rod Sizes
Rexolite® Adhesive #12517
It is for bonding Rexolite® 1422 to itself.
Rexolite® Adhesive 12517 Instructions
Rexolite MSDS Sheets
Typical Properties of Rexolite
| ASTM OR UL TEST | Property | Rexolite 1422 |
| – | Acoustic Impedance | 2.5 |
| D696 | Coefficient of Linear Thermal Expansion (x 10-5 in./in./°F) |
3.8 |
| D792 | Density (lb/in³) (g/cm³) |
0.038 1.05 |
| D150 | Dielectric Constant (1 MHz to 500 GHz) | 2.53 |
| D149 | Dielectric Strength (V/mil) short time, 1/8″ thick | 500 |
| D150 | Dissipation Factor at 1 MHz at 10 MHz at 10 GHz |
0.00012 0.00025 0.00066 |
| D638 | Flexural Strength (psi) | 11,500 |
| D256 | IZOD Notched Impact (ft-lb/in) | 0.3 |
| Optical Transmittance, Visible Light | 87% | |
| D648 | Recommended Operating Temperature Range (°F) (°C) |
-76 to +212 -60 to +100 |
| – | Refractive Index @ 589 nM @ 486 nM @ 656 nM |
1.59 1.604 1.585 |
| D257 | Surface Resistivity (ohm-cm)at 50% RH | >1014 |
| D638 | Tensile Strength (psi) | 9,000 |
| C177 | Thermal Conductivity (BTU-in/ft²-hr-°F) (x 10-4 cal/cm-sec-°C) |
1.01 3.5 |
| – | Velocity of Sound (in/sec) | 93,000 |
| D257 | Volume Resistivity (ohm-cm)at 50% RH | >1016 |
| D570 | Water Absorption, 24 hrs (%) | 0.08 |
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