A reproducible pressure-driven impact test method for laminated automotive windshield glass

Windshield glass is a critical safety component in vehicles. However, existing impact tests do not adequately represent localized loading under actual driving conditions. In this study, a pressure-driven impact method was developed using a sharp-tipped impactor propelled by compressed air to reproduce localized loading. The developed system was validated against the conventional free-fall drop test, with a 3.8 % difference in the 99 % reliability energy threshold. The method was further applied to both component-level specimens and fully installed vehicle windshields, to examine laminate thickness, environmental temperature, and installation conditions. The results revealed that thinner inner plies (1.6 mm) exhibited higher impact resistance due to enhanced elastic energy absorption, while both low (−20 °C) and high (40 °C) temperatures reduced fracture resistance. In addition, vehicle-mounted tests demonstrated that sealant bonding significantly increases impact strength through boundary damping and load redistribution effects. Overall, the proposed testing procedure provides a reproducible impact test for laminated windshield glass that can be applied from laboratory specimens to vehicle-mounted conditions. The method can be used for validation and quality control of lightweight automotive glazing systems.