Polymer safety glazing for vehicles

1. A laminate comprising:

a polycarbonate substrate;

a film disposed on the polycarbonate substrate, the film including a first polyethylene terephthalate (PET) layer, a first adhesive interposed between the first PET layer and the polycarbonate substrate, and a first exterior hard coat disposed on the first PET layer opposite the polycarbonate substrate; and

an interior hard coat disposed on the polycarbonate substrate opposite the first PET layer, the interior hard coat being softer than the first exterior hard coat.

2. The laminate of claim 1 , wherein the polycarbonate substrate is 3-8 mm thick.

3. The laminate of claim 1 , wherein the first PET layer is 2-6 mil thick.

4. The laminate of claim 1 , wherein the first exterior hard coat is 2-10 microns thick.

5. The laminate of claim 1 , wherein the first adhesive is a pressure sensitive adhesive.

6. The laminate of claim 1 , wherein the film is a first of a plurality of films stacked on the polycarbonate substrate, the plurality of films including a second film disposed on the first film, the second film including a second PET layer, a second adhesive interposed between the second PET layer and the first film, and a second exterior hard coat disposed on the second PET layer opposite the first film.

7. The laminate of claim 6 , wherein the first adhesive is stronger than the second adhesive.

8. The laminate of claim 1 , wherein the laminate is thermoformed into the shape of a curved vehicle windshield.

9. A method comprising:

depositing a first hard coat on a first side of a polyethylene terephthalate (PET) carrier;

coating a second side of the PET carrier, opposite the first side, with an adhesive;

adhering the second side of the PET carrier to a first side of a polycarbonate substrate using the adhesive; and

disposing an interior hard coat on a second side of the polycarbonate substrate opposite the first side, the interior hard coat being softer than the first hard coat.

10. The method of claim 9 , wherein the PET carrier, the first hard coat, and the adhesive define a film, the method further comprising winding the film on a roll prior to the adhering.

11. The method of claim 10 , further comprising:

applying a removable liner to the second side of the PET carrier after the coating; and

removing the removable liner from the second side of the PET carrier prior to the adhering.

12. The method of claim 10 , wherein the PET carrier, the first hard coat, and the adhesive define a film, the method further comprising thermoforming the polycarbonate substrate with the adhered film to the shape of a curved vehicle windshield.

13. The method of claim 10 , wherein the PET carrier, the first hard coat, and the adhesive define a first film, the method further comprising:

depositing a second hard coat on a first side of a second PET carrier;

coating a second side of the second PET carrier, opposite the first side, with a second adhesive; and

adhering the second side of the second PET carrier to the first film using the second adhesive.

14. The method of claim 13 , wherein the adhesive of the first film is stronger than the second adhesive.

15. The method of claim 13 , wherein the second PET carrier, the second hard coat, and the second adhesive define a second film, the method further comprising thermoforming the polycarbonate substrate with the adhered first and second films to the shape of a vehicle windshield.

16. The method of claim 15 , further comprising peeling off the second film to reveal the first film.

17. The method of claim 16 , further comprising:

depositing a new second hard coat on a first side of a new second PET carrier;

coating a second side of the new second PET carrier, opposite the first side, with a new second adhesive; and

adhering the second side of the new second PET carrier to the first film using the new second adhesive.