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The manufacturing process for the film coverlay is very complicated compared to the solder masks of the rigid boards, so the final cost of the circuits cannot be low. Flexible, screen-printable inks are a low-cost solution; however, most of the ink materials made of epoxy resins do not have good mechanical properties and cannot be applied for dynamic flexing usage. A combination of polyimide-based screen-printable coverlay on adhesiveless copper-clad laminate provides the smallest total thickness with very long flexing endurance life. A comparison of cross sections is shown in Fig. 62.5.

Since the gauge is displaying a single value, just like the output text field it replaced, you can use the same binding. Set the Value property of the gauge to #{row.TotalInStock}. NOTe At the time of writing, the current implementation is that if the gauge tries to display an attribute value that is null, then a default value of 63 is displayed. To work around this problem, you can make a slight change to the EL to check for a null value. If you set Value to #{empty row.TotalInStock 0 : row.TotalInStock } this will check whether the value of TotalInStock is empty. If it is, then the value 0 will be used. This is standard EL and demonstrates the flexibility of EL. You might want to fine-tune the look and feel of the gauge, such as setting ImageHeight and ImageWidth so that the gauge fits comfortably in the table row. Setting the Position property on the Metric Label component allows you to define where the data value appears. You may also choose to add a Number Format component and a Gauge Font component as child tags to the Metric Label component. The Number Format component allows you to set features like the scale and format of the number, while the Gauge Font component allows you to define font properties such as Name, Bold, and Italic.

FIGURE 62.5 Cross section of a single-sided flexible circuit showing (a) adhesives-based laminate and film overlay; (b) adhesiveless laminate with liquid coverlay.

TABLE 62.3 Varieties of Coverlay Thickness (mm) 30 100 30 100 10 20 25 50 10 20 Dimensional accuracy (minimum opening) 0.3 mm (800 mm) 50 mm (50 mm) 0.3 mm (600 mm) 50 mm (80 mm) 50 mm (80 mm) Reliability (flexing endurance) High (long) High (long) Acceptable (short) Acceptable (short) Acceptable (short)

Material selection Traditional film coverlay Film coverlay + laser drilling Screen print liquid ink Photoimageable (dry film type) Photoimageable (liquid ink type) PI, PET PI, PET Epoxy, PI Epoxy, PI, acrylic Epoxy, PI

High-density flexible circuits that have been developed since 1990 need a small pitch opening with high accuracy on the coverlay Because traditional coverlay technologies have no capabilities to meet these requirements, new technologies were required Many new technologies and new materials have been developed to satisfy the new requirements of high-density flexible circuits The capabilities of the major technologies are shown in Table 623 For example, laser drilling is capable of generating openings smaller than 100 microns on the traditional film coverlay; therefore it satisfies the requirements of physical performance and high density SMT assembling However, the processing costs of the laser abrasion are much higher than other coverlay processes, and it is difficult to apply for the high volume production of consumer applications.

'This is running in the new cog 'set up the LCD u 'Print to LCD routine 'Position LCD cursor 'Pulse 'print value 'write over old data 'print data 'write over old data 'Position LCD cursor 'Cycle time 'print value 'write over old data 'Position LCD cursor 'Frequency 'print value 'write over old data

A screen-printing process provides a slightly higher resolution than traditional pre-punching process of the film coverlay, but the process can not satisfy the recent requirement for high density SMT assembly A practical solution is the combination of film coverlay for the flexing areas and solder mask for the SMT areas It needs supplemental processing to complete the construction, accordingly the total process yield will be lower and the final cost of the circuits could be higher The idea of the photo-imageable coverlay could be the final solution to solve the all requirements, including the processing cost The photo-imageable solder mask materials developed for rigid boards are too brittle, however, and a lot of cracks can be created easily by small radius bending requiring flexible materials Several types of flexible photo-imageable coverlay materials have been developed with different base resin systems.

Most of the photo-imageable coverlay materials provide finer resolutions than 200 micron pitches, but the physical performances very depend on the base resin systems Suitable material should be chosen for the applications Appropriate surface treatments for the bare conductors after the coverlay construction should be chosen according to termination technologies Several examples are listed in Table 624 Details are explained in Chap 64..