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Installation Guide of Smart Film Busbar

1. Cut the film

1.1 Regulate the corner before cutting the film, for correct right-angle and size.
1.2 Use the high precision measurement to measure the size and mark with "
". The mark is for cutting more accurate film.
1.3 Measure the diagonals of the film to recheck the cutting size. The length difference
of two diagonals should be less than 3mm.

Note:
We recommend cutting machine to cut smart film. It's high efficiency, labour-saving,
and more accurate. There are two types of cutting machine: full-automatic cutting
machine and semi-automatic cutting machine.

1.4 Stick the sticker after cutting. Sticker information: self-adhesive film or non-
adhesive film, size, etc. For self-adhesive film, the sticker is on the self-adhesive side.

2. Cut electrode/busbar position

2.1 Cutting self-adhesive film is more difficult than cutting non-adhesive film, because
the self-adhesive side is harder.
2.2 Recheck the quality of the film. Make sure the busbar position is on width side,
length side or both sides.
2.3 Keep straight line when cutting the electrode position. The knife (Fig. 1) should be
very sharp. Take care not to cut the ITO film on the opposite side (seeFig 2).

Fig.1 Knife to cut busbar position

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Fig.2 Smart film structure

2.4 An busbar position(positive pole) is on the front side, and the other busbar
position (negative pole) is on the back side of the film (see Fig 2). If the TWO
electrodes are cut on the same front side, it can cause short circuit.
For film width = 1000mm, positive position 400mm + gap 200mm+
negative position 400mm.
For film width = 1800mm, positive position 800mm + gap 400mm+
negative position 800mm.
Note:
4:2:4 is recommended when cutting the busbar position.
The width of the busbar position is 6mm.

Fig.3 Positive position + gap + negative position

2.5 Radian finish the busbar, as shown in Fig.4.
2.6 For smart film longer than 2.5m, you need to cut busbar position on both width side.
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Fig .4

3. Rub away PDLC mixture

After cutting the busbar position, rub away the white PDLC mixture with rubber block
wrapped with a dust-free cloth(Non-woven cloth), which is wetted with alcohol. Wipe
lightly (from white to clear). Don't wipe too clean. If ITO conductive layer is wiped away,
unenergized occurs.

Fig.5 Rubber block

4. Brush sliver paste

After the alcohol has completely evaporated, brush the silver paste (sliver has good
conductivity). The silver paste must be 1-1.5 mm away from inside of the electrode (see
Fig.6). If there's no gap between the silver paste and the electrode, short-circuit occurs
when power is on.
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Fig.6

Note:
Recommend screen printing plate(Fig.7) to apply the silver paste. It can
save the silver paste, increase the efficiency, and ensure that the silver
paste is evenly attached to the busbar position.

Fig.7 screen printing plate

5. Dry silver paste

Use dryer (eg.hair dryer) to dry the silver paste. Hold the hair dryer in an inclined
direction. Dry for 3—5 minutes. Don't put hair dryer onto the film, or it will burn the film.

6. Stick the copper foil

6.1 After drying the silver paste, stick the copper foil. If the silver paste is not dry when
sticking copper foil, the smart film will not turn clear after some time.
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Note: The width of copper foil is 5 mm.

6.2 The copper foil must be completely attached onto the silver paste, aligned along the
edge of the busbar. Copper foil is not allowed to exceed the silver paste (See Fig.6).
6.3 If it is self-adhesive film, two extra small copper foils (width: 10mm, see Fig.8) are
applied on the busbar position of the adhesive side for soldering. (5mm on the adhesive
side, 5mm folded onto the other side. See Fig.9) Usually, we stick small copper foils first.

Fig.8 Small copper foil

Fig.9 Small copper foil

6.4 Use a scraper (yellow color) to smoothen the copper foil.

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7. Solder the busbar wire

7.1 Distinguish between black and red wires when welding wires. Make sure the
smoothness and evenness of the solder joint, or the hump will hurt the film when you roll
the film.

Note:
The lentth of wire is 15cm. Usually we attach 2 red and 2 black wires. One black/red are
spare wires. When installing smart film onto the glass, connecting 2 red/black wires to the
transformer is recommended.

7.2 For self-adhesive smart film, tin soldering onto two small copper foils (width: 10mm),
so that there is no soldering joint on the adhesive side (See Fig.9).
7.3 Apply High Temperature Resistant Tape onto the copper foil of non adhesive side,
protecting copper foil from water or moisture. Also, it can help securethe copper foil in
place. The tape should cover copper foil as well as the gap between copper foil and the
white film.

Note: No need to apply this tape onto the adhesive side.

7.4 The soldering iron must not stay on the copper foil for a long time, or touch the film.
Take care not to drop tin onto the film. These might burn the film.

8. Testing
8.1 Test the film at 60V ac for 5 minutes, switching on/off at least 10 times. On
transparent state, examine the film carefully to see whether there are defects.
8.2 When energized, touch one busbar with one hand. One hand only. If the copper foil
feels hot, it means short-circuit occurs somewhere in the film. Turn off the power and
examine the film immediately.

9. Roll up the film

9.1 For smart film with busbars on both sides, before rolling, allign the busbar wires of one
side in parellel with the edge of the film, secured with masking tape. (Masking tape must
be smooth so as not to hurt the film.)
9.2 Wrap the smart film around the paper roll (Diameter: 16cm or more) carefully. Align
the busbar wires in parellel with the edge of the film, secured with masking tape.
9.3 Wrap cling film to protect the smart film, and then covered with 3-5 mm thick
EPE-foam. Try your best to protect the smart film.
9.4 Roll the film from the largest width, and then roll the film a bit narrower. A film shorter
than 1.4m can be rolled up to 20 sheets; 1.4 to 2.5m can be rolled up to 10-15 sheets.
You can roll up 6 sheets together, cover the busbars using EPE-foam, and then roll
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another 6 sheets. See Fig. 10.

Note:
Place the self-adhesive side onto the desktop(adhesive side is in contact with the
desktop), then wrap around the paper roll. Can't wrap self-adhesive film in the opposite
way.

Note:
Self adhesive smart film should keep this wrapping direction during the whole process.
Otherwise, wrong wrapping direction will do harm to smart film.
The smart film is rolled up for 15 days at most. If longer than 15 days, unrolled the smart
film and lay it flat on a clean surface.

Fig.10
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10. Packing

Fig.11 Roll up the smart film