A. Field of Invention
This invention pertains to the art of methods and apparatuses related to vehicle construction and more specifically to methods and apparatuses related to the connection of vehicle roof panels to side panels.
B. Description of the Related Art
It is well known in the automotive industry to attach roof panels to side panels. Typically, the roof panel is formed of steel and the side panel (sometimes referred to as a side panel outer, or SPO) is also formed of steel. In this case, it is relatively easy to connect the roof panel to the side panel in a welding operation.
It is also known, however, to form roof panels out of various thermoplastics, such as fiber reinforced (composite) plastics. This usually means the roof panel is formed of a carbon fiber reinforced thermoplastic, or the like. In some specific cases, the thermoplastic roof panel may be transparent. A problem with thermoplastic roof panels is that they are more difficult to connect to the steel (or other metal) side panels because the different materials make the panels incompatible for welding operations.
Various methods for connecting thermoplastic roof panels to steel side panels are known. They include the use of adhesives, bolts, and rivets. While these methods and apparatuses generally work well for their intended purposes, they have disadvantages. Disadvantages to the use of adhesives include relatively high cost and relatively limited connection strength. Disadvantages to the use of bolts include increased weight and increased manpower for assembly. Disadvantages to the use of rivets include limitations in types of rivets that can be used, relatively high cost, relatively limited connection strength, and increased manpower for assembly. A common disadvantage to all types of fasteners (whether bolts, rivets, or other fasteners) is that their visibility is often considered undesirable to customers.
Therefore, what is needed is a method for connecting thermoplastic roof panels to side panels in a manner to reduce or eliminate the disadvantages known in the art.