Rexolite
Rexolite is a rigid, transparent insulating material made by an irradiation cross-linking process. Rexolite is one of the best dielectric materials known with a dissipation factor 200 times better than nylon.
In contrast with other high temperature, ultrahigh frequency dielectrics, Rexolite has the rigidity and ability to resist deformation under load. These characteristics are extremely important where assembled insulators must withstand compression without yielding and loosening over long periods of time.
Rexolite materials are cast in liquid form and cured to make sheets, then ground to size, coated with a patented adhesive polymer and clad in a laminating press. Homogeneous and isotropic electrically as well as radiation resistant, they are available clad with electrodeposited or rolled copper on one or both sides.
Because it is cross linked polystyrene, rexolite has excellent machinability and shock resistance when compared to other unreinforced thermoset materials.
Rexolite 1422 has a combination of good physical and excellent electrical properties including low and stable dielectric constant. These properties make this material suitable for use in microwave lenses as well as for precision components.
Dielectric Properties of Rexolite® –
Outstanding! Rexolite® maintains a Dielectric Constant of 2.53 through 500Ghz with extremely low dissipation factors. Rexolite® is ideal for microwave lenses, microwave circuitry, antennae, coaxial cable connectors, sound transducers, TV satellite dishes & sonar lenses. Other applications for Rexolite® include nondestructive material testing devices, surveillance equipment, radar windows, radomes and missile guidance system housings. One interesting application for Rexolite® are radar lenses which are used in mapping the Earth’s surface from fast, high altitude aircraft.
High Voltage Insulators
Rexolite’s® ability to withstand high voltage is important for producing gap switch houses, capacitors and other components. Rexolite® is proven superior to Acrylics, Epoxies, Urethane and other plastics for dendriting resistance. (Failure caused by electron bombardment)
Radiation Resistance
Rexolite® is superior to most plastics. Little change in dielec-tric loss over a wide range of exposures up to 1000M rads. Rexolite® has superior resis-tance to mechanical deterioration by ionizing radiation.
Rigidity & Dimensional Stability
Rexolite® exhibits no permanent deformation or plastic flow under normal loads. All castings are produced stress-free and do not require stress relieving prior to, during or after machining.
Wide Temperature Range
Recommended operating temperature for Rexolite® 1422 is 100C; Glass transition temperature is 114C; maintains excellent dielectric properties from -270C to 176C (no load – short time).
Optical
Rexolite’s® Optical transmission is approximately equal to Acrylic – (87% visi-ble light, 1″ thick). Refractive index 1.59 @ 589 nanometers, 1.604 @ 486 nanometers and 1.585 @ 656 nanometers. Rexolite® is utilized in combination with Acrylic lenses for color correction.
Water Absorption
Less than .08%, Rexolite® type 1422, has been immersed in boiling water for 1000 hours without change in dielectric constant.
Machinability
Rexolite® handles well in all machining operations. Tool configura-tion is similar to those used on Acrylic. Due to high resistance to cold flow and freedom from stress, Rexolite® is easily machined by water jet, laser beam to very close tolerances. Accuracies of .0001 can be obtained by grinding. Crazing can be avoided by using sharp tools and avoiding excessive heat during polishing. Stress relieving of Rexolite® is not required before, during or after machining. Always maintain sharp tooling.
Sub-zero Properties
Rexolite® maintains a Dielectric Constant of 2.55; at -270C the dissipation factor is .00019.
Flammability
Rexolite® 1422 burn rate is less than 1 inch per minute.
Copper Cladding
For printed circuit boards. Available in Rexolite® 1422 or Rexolite® 2200, copper thickness range from one-half ounce to two ounce copper.
Environmentally Friendly
Rexolite® is nonhazardous, contains no ingredients harmful to the environment.
Properties, Applications and Availabilities for the Rexolite Sheet and Rod
| Properties | Applications | Availabilities |
|---|---|---|
| Resistant to load deformation | UHF, VHF and microwave insulators | Rod: .062″ to 8.000″ |
| Outstanding dielectric qualities | Communication, electronic equipment | Plate: .032″ to 6.000″ |
| High radiation resistance |
Rexolite® 1422 Properties Chart
| Electrical | Frequency | Test Method | Typical Value |
|---|---|---|---|
| Dielectric Constant | 1 Khz to 500 Ghz | ASTM-D-1531 | 2.53 ± 0.03 |
| Dissipation Factor | @ 1 Khz | ASTM-D-1531 | 0.0001 |
| @ 1 Mhz | ASTM-D-1531 | 0.0002 | |
| @ 30 MHz | ASTM-D-1531 | 0.0002 | |
| @ 10 Ghz | IPC-TM-650 | 0.0001 | |
| @ 120 Ghz | Army Electronics | 0.0008 | |
| @ 500 Ghz | Army Electronics | 0.0003 | |
| Dielectric Strength | (.010 Tk) | ASTM-D-149 | |
| Short time | (volts/mil) | ASTM-D-149 | 2100 |
| Step by step | (volts/mil) | ASTM-D-149 | 2000 |
| Volume Resistivity | (Megohm-cm) | PC-TM-650 | 1.1×1016 |
| Surface Resistivity | (Megohm) | PC-TM-650 | 4.5×1014 |
Physical Properties
| Physical | Test Method | Typical Value | |
|---|---|---|---|
| Temperature Range (Recommended) | -60 ºC to 100 ºC | ||
| Glass Transition Temp. | 114 ºC (237 ºF) | ||
| Specific Gravity | ASTM-D-792 | 1.05 | |
| Tensile Strength | ASTM-D-638 | 10,500 psi | |
| Tensile Modulus | ASTM-D-638 | 4.5 x 105 psi | |
| Compression Strength | ASTM-D-695 | 18,000 psi | |
| Flexural Strength | ASTM-D-790 | 18,000 psi | |
| Coefficient Thermal Expansion | ASTM-D-3386 | 7.0 x 10-5 °C | |
| Thermal Conductivity | ASTM-E-1530 | 1.23 Btuin/hr·ft2°F | |
| Water Absorption | ASTM-D-570 | 0.08% Max | |
| Poisson’s Ratio | 0.42 | ||
| Acoustic Impedance | 2.5 | ||
| Velocity of Sound | 93 x 10 3 Inches/Sec. | ||
| Rockwell Hardness | ASTM-D-785 | R130 | |
| Izod Impact Strength | ASTM-D-256-97 | 1.2 ftlbf/in2 | |
| Izod Impact Strength Un-Notched | 6.0 ftlbf/in2 | ||
| Out-Gassing @ 125 º | C | ASTM-E-595 | |
| TML | .04 % | ||
| CVCM | .01 % | ||
| WVR | .03 | ||
Chemical Properties
| Chemical | Effect |
|---|---|
| Alkalis (Sodium/Potassium Hydroxide) | No effect |
| Alcohols (Methanol/Isopropanol) | No effect |
| Aliphatic Hydrocarbons (Pentane, Cyclohexane, n-Heptane, n-Hexane) | No effect |
| Mineral Acids (Hydrochloric, Sulfuric, Nitric) | No effect |
| Aromatic Hydrocarbons (Benzene, Toluene, Xylene, Styrene) | Swells |
| Chlorinated Hydrocarbons (Carbon Tetrachloride, Chloroform) | Swells |
Optical Properties
| Optical | Typical Value |
|---|---|
| Total Transmission 1″ thick | 87% |
| Refractive Index 20°C (436 nm) | 1.614 |
| Refractive Index 20°C (467 nm) | 1.607 |
| Refractive Index 20°C (480 nm) | 1.604 |
| Refractive Index 20°C (508 nm) | 1.599 |
| Refractive Index 20°C (546 nm) | 1.594 |
| Refractive Index 20°C (589 nm) | 1.589 |
Rexolite's® Standard Shapes & Sizes
| Rexolite® 1422 rod from .030 to 9″ in diameter. |
| Rexolite® 1422 sheet from .010 to 6″ thick. |
| Rexolite® 2200 sheet from 1/32″ to 1/4″ thick. |
| Copper clad Rexolite® 1422 from .010 to 1/4″ substrate. |
| Copper clad Rexolite® 2200 from 1/32″ to 1/4″ substrate. |
| Rexolite® Adhesive #12517 in two half pint cans. |
| Rexolite® rings, tubes, larger rod and sheet available upon request. |