Method of forming a curved, shatterproof glass laminate

A method of forming a curved, shatterproof glass laminate for a vehicle side window, back window or sunroof, which comprises the steps of:

• providing a laminate layup comprising a curved outer layer of glass selected from the group consisting of heat tempered and heat strengthened glass, and a curved inner layer of a plastic material in a laminated relationship with a layer of adhesive material therebetween;
• positioning a mold member against the layup in pressure engagement against the curved plastic layer in conforming relationship therewith, to protect the plastic layer against deformation and to prevent the formation of air pockets in the adhesive during subsequent heating;
• subjecting the assembled laminate layup and mold member to a vacuum and then to heat under pressure to form the laminate;
• cooling the formed laminate and the mold member under said pressure;
• and
• removing the mold member from the laminate wherein the mold member material is selected from the group consisting of plastic and metal, the plastic having a Rockwell hardness reading in a range on the order of at least R18 to R35, a heat coefficient of thermal expansion in a range on the order of 3.0.times.10.sup.-5 in./in/.degree.F., and an initial softening point in a range on the order of not less than 80.degree. C. to 150.degree. C., the metal having a thickness in a range on the order of 0.5 to 2 mm, a heat coefficient of thermal expansion in a range on the order of 0.45.times.10.sup.-5 to 0.7.times.10.sup.-5 in./in/.degree.F., and a Rockwell hardness reading in a range on the order of R150 to R200.