Showroom & The Screen Gallery | Intelligent Glass

HOW IS SMART GLASS MADE?

We are often asked ‘How is Smart Glass Made?’ by customers wanting to understand the wider technology. Due to the sheer diversity of the Switchable Smart Privacy Glass range, the answer to this question is not a simple one, with various products demanding different manufacturing processes to create them.

Smart Glass technology comes in two main forms: Switchable Smart Glass and Switchable Smart Film, both bringing different advantages and benefits to its users. On this page, we will be taking a look into the various types of Switchable Smart Glass products, their composition and the special conditions necessary to enable production. In doing this, we will shed light on how the products are made, how they work and how we get them to you.

WHAT IS SWITCHABLE FILM?

Switchable Film, (also known as Switchable Smart Privacy Film or PDLC Film) is a technology that is capable of adjusting light transmission by applying an AC power source. The active component in Switchable Film – Polymer Dispersed Liquid Crystal (PDLC) – consists of liquid crystal micro-droplets which are suspended in polymer. In the film’s natural state the PDLC molecules are arranged randomly which causes light waves to be bent (refracted) and reflected in random directions, resulting in a frosted appearance. When an electrical current is passed through the PDLC layer, the liquid crystal molecules align with each other (polarise), allowing light to pass straight through, like regular glass.

SWITCHABLE FILM

As Figure 1 shows, standard PDLC technology is composed of multiple layers to create this incredible product.

The outer layers are an optically-clear protective coating – a polyethylene terephthalate (PET) film. This encloses / protects the film and its PDLC core whilst still allowing for optical transparency.

The 350 micron ITO film – a conductive Indium Tin Oxide layer – enables an electrical current to pass through the PDLC core safely, again, whilst allowing for striking optical clarity so as not to distort the technology’s effect.

The PDLC core comprises of liquid crystal droplets that are suspended in polymer and then enclosed between the ITO film layers to allow for the electrical current to pass through it.

Achieving consistency in the manufacture of switchable PDLC film is both a science and an art. Many suppliers have come and gone during our time, and we are justifiably proud of our track record.

Figure 1

Figure 2

HOW IT WORKS

Figure 2 demonstrates how the technology works. We can see that with an absence of electrical current, the natural state of the film is frosted – The liquid crystals in the PDLC core are naturally arranged randomly in a way that blocks out a lot of the light that would pass through it otherwise. However, one of the benefits of this technology is that it is not a complete black-out technology, so ambient light still passes through whilst providing users their privacy.

Figure 2 also displays the technology when it is switched on, where we can see that almost all of the light is able to pass through the film and the product appears clear/transparent. Due to the nature of the technology, switchable glass is not as optically-clear as standard glass and may still present with a slight haze. Whilst clarity is a very important property that we work towards, a subtle haze is a normal manifestation of the product, especially when viewed from an oblique angle.

SWITCHABLE GLASS

Switchable Film is designed for application to glass or plexiglas, and recent years have given rise to the development of numerous switchable products that make the most out of the substrate being used.

The most common uses of PDLC film are for the Switchable Glass products featured below.

Figure 3

SWITCHABLE LAMINATE GLASS

Laminated safety glass ideal for high traffic areas, bathrooms and hospitals. The Switchable element is fully encapsulated between the two pieces of glass using our patented process.

TOUGHENED SWITCHABLE GLASS

The switchable element is factory-coated using UV light to any thickness of glass. Ideally suited for projection applications, Self-Adhesive Switchable Film can also be coated to the glass for a more cost effective solution.

Figure 4

Figure 5

SWITCHABLE DOUBLE GLAZING

Energy-efficient double glazed units with an integral Switchable layer – Ideal for both external and internal windows for commercial building and homes. This technology is also available as triple glazed units, for increased energy efficiency, security, and noise reduction.

SELF-ADHESIVE SWITCHABLE FILM

Previous versions of switchable film were manufactured for professional application by lamination to glass, restricting both usage and price.

However, in recent years, we have seen numerous developments of switchable technology such as higher clarity, faster switching, improved reliability, greater consistency, and purer crystal dispersion.

Intelligent Glass is dedicated to developing specialist technology to bring the market the next generation in switchable technology – Retrofit Self-Adhesive Switchable Film.

Figure 6

Figure 7

NEXT GENERATION PDLC TECHNOLOGY

Designed specifically to retrofit to existing transparent surfaces like glass or plexiglas, Self-Adhesive Switchable Film by Intelligent Glass provides a simple and cost effective alternative to previous switchable film technologies.

Compared to older switchable products, its main feature is its self-adhesive cling layer on one side (Figure 6), manufactured to allow a peel and stick application. This simple improvement enables customers to apply switchable technology to both new and existing surfaces without specialist installation equipment required (Figure 7).

The film works in the same way as standard switchable products – a simple ON – OFF mode switches the film from being clear to frosted in an instant.

Intelligent Glass has refined a manufacturing process that allows us to offer Self-Adhesive Switchable Film in custom shapes and sizes up to 1800mm in width. In addition, multiple pieces can be joined together to add switchable functionality to large transparent surfaces.

INDUSTRY LEADING MANUFACTURING FACILITIES

The manufacturing process of previous switchable technology forced early innovators to invest in the highest quality manufacturing facilities. Even the slightest imperfection in the raw materials or manufacturing process could result in a substandard switchable product, making quality and control a highly important consideration for manufacturers of switchable technology.

Intelligent Glass are proud to have industry-leading manufacturing facilities that has enabled us to produce the highest quality switchable products for over a decade, building an illustrious reputation and working with some of the world’s leading brands.

The manufacturing sensitivities of switchable technology not only require expert handling but also manufacturing facilities that meet exacting requirements.

Intelligent Glass offers the promise that all Switchable Glass products are manufactured in a ‘clean room’ environment, minimising the risk of manufacturing imperfections ensuring the customer receives the very best product possible.

Our Switchable Technology is manufactured on-site using the latest in manufacturing equipment which enables us to offer the range of products we produce. From our DGU (Double Glazed Units) production bay to our product testing environments, Intelligent Glass production facilities boast the highest quality output and specification available on the market.

CARE FROM START TO FINISH

Intelligent Glass offers a full crating and shipping service for UK and worldwide export. The fragility of Switchable products requires that they are exported in protective wood crates, keeping them safe and secure in transit.

The bespoke nature of many Switchable products means that shipping crates are usually custom-made to accommodate the size of each unique order.

Robust, and designed with protection in mind, our crates are equipped to safeguard glass, film and accessories during its journey across the world.

Manufacturing Process