Rexolite

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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  

Rexolite® 1422 MSDS Standard

Rexolite® Adhesive 12517 MSDS

 
 
 
 
 
 
 
 
 
 
 
 

e® Adhesive #12517 MSDS

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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