How to make the busbars for smart film?
Tools：Dust-free cloth, Square resistance meter, Tape measure, Alcohol, Solder, Scissors, Film spliter, Copper foil, Tape, Brush, Silver paste, Marker pen, Squeegee, Electric soldering iron, Heat gun,Pins, Pliers
Step1: Film preparation.Lay the smart film on the glass table.
Step2: Mark busbars position.Measure and mark the position of the busbar according to the drawings on the side that busbar to be installed. The distance between the two busbars is 5-10cm and each busbar should be as long as possible.
Step3: Cut upper layer PET.Align the edge of the smart film with the glass, start from one end with the film splitter, and cut the upper layer of PET to the marked position.
Step4: Wipe off liquid crystal. Use a dust-free cloth dipped in alcohol to wipe off the liquid crystal exposed after cutting off the PET.
Note: Wipe gently, not only to remove all the liquid crystal , but also not to damage the conductive ITO.
Step5: Check ITO resistance. Use the square resistance meter to select at least 3 different points to measure the ITO after wiping, and the value should be less than 250 ohm, otherwise, the ITO may be damaged and thus the smart film may not work properly.
Step6: Apply tape. Stick the tape at a distance of 5-6mm from the edge of the film to cover the liquid crystal between the lower layer of ITO and the upper layer of PET, so as to prevent the silver paste from applying this gap and causing a short circuit.
Step7: Apply silver paste evenly to cleaned ITO.
Step8: Dry the silver paste with the heat gun. The heating temperature is about 70-100℃.
Step9: Tear off the tape pasted after heating.
Step10: Apply the copper foil carefully on the dried silver paste.
Step12: Cut off the excess part of the copper foil. In order to avoid the edges from lifting, the sharp corners of both the copper foil and the smart film are cut off.
Step13: Turn the smart film over and make another busbar according to the previous steps.
Step14: Pinning: use pliers to drive the pin into the connecting copper foil and smart film to make sure the copper foil stay with smart film.At least 2 pins for each busbars.
Step15: Solder the leads: Use a soldering iron to solder leads of the suitable length on the pin.
Step16: Power-on test: 1. Continuous power-on, power-off cycle 10 times; 2. Continuous power-on for 20 minutes. After test, check if there's any defect such as over heat and black spots.
Step17: Roll up the smart film for transport or storage.
If you want to get more informaion, please feel free to visit globalsmartglass.com.
https://globalsmartglass.com:Switch the smart glass,switch to a new world.
A liquid crystal is a hybrid between (i) a liquid which flows like a fluid and (ii) a crystal which is normally found as a solid, exhibiting short- or long-range symmetry.
No, the transmittance (level of transparency) of the PDLC can be varied from 0% in the OFF state up to any value you want until you reach the maximum transmittance (normally 70% or 80%). This is done by simply altering the voltage from 0 VAC up to 70VAC, which is typically the maximum recommended voltage. This can be done electrically with a variable isolating transformer, or electronically with a switched-mode smart glass dimmer.
A flexible polymer-based film (typically PDLC: Polymer Dispersed Liquid Crystal) with an adhesive layer on one side. It is applied directly to existing glass surfaces like a sticker. A laminated glass unit where PDLC film is permanently sandwiched between two layers of glass using EVA or PVB interlayers under high pressure/temperature. This creates a solid, structural glazing product. • Optical Clarity: • Energy Efficiency: • Durability: • Safety: • Film: Ideal for retrofitting offices, shower doors, storefronts, or rental properties. • Glass: Suited for high-end architectural projects (facades, security rooms, partitions), automotive sunroofs, and aviation. Choose self-adhesive smart film for cost-effective, non-invasive upgrades to existing glass. Opt for smart glass in new builds or high-traffic areas demanding durability and safety. Both deliver dynamic privacy/energy savings but cater to different project scales and budgets.1. What is self-adhesive smart film and smart glass
Self-Adhesive Smart Film:
Smart Glass:
2. Installation & Application
Feature
Self-Adhesive Smart Film
Smart Glass
Installation
Peel-and-stick onto existing glass; DIY-friendly.
Requires professional glazing; replaces entire glass unit.
Best For
Retrofitting existing windows/glass partitions.
New constructions or full renovations.
Complexity
Some skill is needed:
1. How to install the film;
2. How to deal with the edge sealant;
3. How to hide the wire.
Install the glass as the normal glass except for considering how to hide the wire.
How to make smart glass?
3. Functionality & Performance
Both switch between transparent (ON) and opaque (OFF) via electricity. Smart Glass often has higher clarity due to glass encapsulation.
Identical function: Blocks ~99% UV rays and reduces heat gain.
Power consumption is low (~5W/m²/hour).
Smart Glass is more robust (scratch resistant, impact-resistant, safety-glass properties, longer life time). Film is vulnerable to peeling/scratches comparing with smart glass.
Smart glass remains secure after breaking. Film lacks structural security but can prevent glass from shattering.
4. Applications
5. Pros vs. Cons Summary
Type
✅ Pros
❌ Cons
Self-Adhesive Film
Affordable, easy install, UV/heat blocking, retrofit-friendly
Less durable, no structural safety, prone to air bubbles, Lower clarity than smart glass.
Smart Glass
Premium finish, enhanced safety/durability, seamless integration, higher clarity and performance than film.
High cost, inflexible for existing spaces, complex replacement.
Conclusion
Smart glass is a laminated glass comprising 2pcs of glass sandwiched in between by an EVA/PVB interlayer.
The following information is from homeadvisor.com.
Smart Glass Cost
Smart glass costs $25 to $150 per square foot. Glass with film pre-installed is $50 to $150 per square foot, compared to $25 to $50 per square foot for the film alone. Price depends on the total square footage, with single units running up to $50 per square foot more than you’d pay to install several.
Smart glass makes it easy to change the look of your windows in an instant. You can make them completely opaque for privacy or add tinting to shade a home and cut your energy consumption. There are a few different types with unique benefits, so you’ll need to choose the one that’s right for you. Keep these cost factors in mind as you browse.
Average Smart Glass Price
| Average Cost | $100 Per Square Foot |
| High Cost | $150 Per Square Foot |
| Low Cost | $25 Per Square Foot |
Smart Glass Cost Per Square Foot
Smart glass costs $50 to $150 per square foot. Installers usually set rates by the project, offering a lower price per square foot if you replace several windows. One piece runs $125 to $150 per square foot, compared to $50 to $100 per square foot for 100 or more square feet. The cost to install a window with standard glass is $15 to $30 per square foot.
Smart Glass Pricing by Type
Smart glass prices are $50 to $150 per square foot, depending on the total square footage and type:
PDLC: Privacy, frosted, tinting
SPD: Tinting in an instant
Electrochromic: Gradual tinting to a set level
PDLC
PDLC glass tends to be the most expensive option. It offers privacy at the touch of a button, making it ideal for indoor and outdoor applications. This technology is the only type that turns completely opaque, which means you can use it for bathrooms, showers, private offices and more. You can also turn it into a television projector.
PDLC has crystals that are both liquid and solid, similar to what you’d get in an LCD television or monitor. It has a lot of names, including:
Electric privacy glass
LCD glass
Electric frosted glass
The crystals are inactive when turned off, which makes the glass appear frosted or dark. Once you turn it on, the window is completely clear or dimmable.
SPD
SPD glass is the middle-of-the road cost option, with pricing a little lower than PDLC. This type allows you to select the level of tinting from minimally shading to full darkness, although it can’t provide complete privacy. Its heat-blocking features make it a great choice for exterior windows. You can also use it for any interior room that needs additional darkness in daytime, like a home theater or child’s bedroom.
SPD suspends particles in a liquid. When you turn on the device, it brings those particles in line and allows you to the control the level of tinting. Like PDLC, these windows are dimmable.
Electrochromic
Electrochromic glass is the cheapest option. This type allows you to change the tinting over the course of a few minutes. It uses ions to force particles to the inside or outside of the window, making the material clear or tinted. Those particles stay in position until you use the control to move them again.
Electrochromic glass is similar to photochromic or thermochromic tinting, but it’s important to understand the difference. Photochromic and thermochromic products, like Transitions eyeglass lenses, tint based on light or heat. They don’t require energy to change, but you can’t control them. Electrochromic options use energy comparable to a single LED lightbulb, and make it easy to change whenever you want.
Switchable Glass Prices vs. Smart Window Film
Switchable glass, which may refer to PDLC, SPD or electrochromic products, costs $50 to $150 per square foot and includes all materials and installation. If you want to buy smart film that you can have a pro apply to your existing windows, you’ll pay $25 to $50 per square foot.
| Brand | Glass | Film |
|---|---|---|
| Smart Tint | N | Y |
| Invisishade | Y | Y |
| Sonte Film | N | Y |
| Smart Film | N | Y |
| View | Y | N |
| Gauzy | Y | N |
| GlobalSmartGlass.com | Y | Y |
How to make smart glass?
Step1. Wash and clean the glass.
Step2. Move the glass to the cleanroom for lamination.
Step3. Check the lower glass and clean possible stains.
Step4. Lay the pre-cut EVA interlayer on the lower glass.
Step5. Lay the PDLC film with busbars onto the EVA interlayer. During the process, the lower protective liner is removed. Then remove the upper protective liner. Note: Do not leave fingerprints or stains on the PDLC film.
Step6. Carefully adjust the position of the PDLC to align with the glass.
Step7. Lay out and align the upper layer of EVA interlayer.
Step8. Check and place the upper glass, carefully adjust the position of the glass to align with the lower glass.
Step9. Check the glass carefully to remove possible dirty spots and stains inside the glass.
Step10. Cut off the EVA interlayer to align with the glass.
Step11. Fix the busbars leads with high temperature tape, and wrap the glass edge with high temperature tape.
Step12. Move the glass to the next operating table.
Step13. Wrap the whole piece of glass in PET film.
Step14. Bond the PET film with silicone sealant strips to form a vacuum bag.
Step15. Set the vacuum port.
Step16. Pump the vacuum bag. Fold and firm the sides of the vacuum bag with high temperature tape.
Step17. During the pumping process, check whether the vacuum bag is leaking. After the pumping is complete, disconnect the pumping pipe.
Step18. Move the glass to the heating platform, connect the glass vacuum port to the vacuum system of the heating oven or autoclave, transfer the glass to the heating oven or autoclave, and heat the glass.
Step19. Heating. parameter settings.
Step20. After heating, remove the glass from the heating oven or autoclave. To pack and store.
If you want to get more informaion, please feel free to visit globalsmartglass.com.
https://globalsmartglass.com:Switch the smart glass,switch to a new world.
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