FIELD OF THE INVENTION
The invention relates to formation of a joint between two or more materials and in particular, relates to a process of forming joints between two materials by induction soldering.
BACKGROUND
As is generally known, soldering is one of the oldest known joining techniques. Soldering is a technique of joining two materials, for example, metals by using a solder alloy. The solder alloy may be an alloy made by introducing varying proportions of Lead and Tin. Conventionally, a joint is formed between two metals by melting a wire formed of soldering alloy, and pouring molten soldering alloy at an interface between two metals to form the joint.
In particular, for forming the joint by soldering, a soldering wire may automatically be fed to a soldering gun. At a tip of the soldering gun, a temperature within a range of 300°C to 400°C is maintained. The particular temperature may be selected based on the soldering wire. For example, the temperature may be selected to be close to a melting point of the alloy of the soldering wire. When the soldering wire comes in contact with the tip, the soldering wire starts melting and the molten solder is poured at an interface between both materials to be joined. Once the molten solder is solidified, it forms a firm joint between the two materials.
However, owing to manual intervention involved in the process, such as holding the soldering gun and pouring the molten solder, possibility of error is high. Further, consistency in the quality of soldering poses a concern. It is not practically possible for a human to maintain same level of quality in all the soldering tasks. Consequently, an overall strength of the joint so formed may be compromised as well. In order to address such concerns, currently, a high-skilled operator is required, which in itself is a cumbersome task. Moreover, even with the high-skilled operator, such concerns may still exist.

SUMMARY
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
In an embodiment of the present disclosure, a method of forming a joint between two materials is disclosed. The method includes dispensing a soldering material to be collected into a joining site of a component made of a first material. The method includes attaching at least one cable made of a second material at the joining site. The at least one cable is passing through the soldering material to be attached with the component at the joining site. The method includes placing the component having the joining site with the soldering material and the at least one cable on a heating plate. The method then includes heating the component with the soldering material and the at least one cable to form the joint by the soldering material.
In another embodiment of the present disclosure, a method of forming a joint between at least one cable and a body of a gear indicator switch is disclosed. The method includes dispensing a soldering material to be collected into a metal terminal of the body. The method includes attaching at least one cable to the metal terminal. The at least one cable is passing through the soldering material to be attached with the metal terminal. The method includes placing the gear indicator switch having the metal terminal with the soldering material and the at least one cable on a heating plate. The method then includes heating the metal terminal with the soldering material and the at least one cable to form the joint by the soldering material.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Figure 1 illustrates an exploded view of a gear indicator switch assembly for performing an induction soldering process, according to an embodiment of the present disclosure;
Figure 2 illustrates steps of forming a joint between at least one cable and a metal terminal of the gear indicator switch assembly, according to an embodiment of the present disclosure;
Figure 3 illustrates a flow chart depicting a method of forming a joint between two materials, according to an embodiment of the present disclosure; and
Figure 4 illustrates a flow chart depicting a method of forming a joining between at least one cable and a metal terminal of the gear indictor switch, according to an embodiment of the present disclosure.
Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.
DETAILED DESCRIPTION OF FIGURES
For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated

system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.
Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.
A method of forming a joint between two materials is disclosed. The materials are joined by an induction soldering process as proposed in the present disclosure. The induction soldering process of the present disclosure involves minimum manual intervention and that too, for handling of the equipment and not for performing the induction soldering process. In the present disclosure, the induction soldering process is explained for joining a cable with a body of a gear indicator switch. It should be appreciated by a person skilled in the art that the induction soldering process of the present disclosure is not just limited to the gear indicator switch and can be used for joining any two materials, without departing from the scope of the present disclosure.
Figure 1 illustrates an exploded view of a component 100 for performing an induction soldering process, according to an embodiment of the present disclosure. In the present embodiment, the component is a gear indicator switch assembly 100, also referred to as the gear indicator switch 100. The gear indicator switch assembly 100 may include, but is not limited to, a body 102, a plurality of metal inserts 104, a plurality of metal terminals 106, chunks of a soldering material 108, and a plurality of cables 110. In an embodiment, the metals inserts 104 may individually be referred to as a metal insert 104 or a metal insert 104-1 and a metal insert 104-2. The metal terminals 106 may interchangeably be referred to as the joining sites 106. Further, the metal terminals 106 may individually be referred to as a metal terminal 106 or a metal terminal 106-1, a metal terminal 106-2, and a metal terminal 106-3. Similarly, the cables 110 may individually be referred to as a cable 110 or a cable 110-1, a cable 110-2,... and a cable 110-6.

In an embodiment, the metal inserts 104 and the metal terminals 106 are to be insert-molded into the body 102. In an embodiment, the metal terminals 106 may be formed of Brass. The metal terminals 106 may be insert-molded with the body 102 during a molding process. In an embodiment, a metal terminal 106 may be drilled to have a cavity, for example, of 4 milli¬meters (mm), before performing the insert-molded process.
Further, each chunk of the soldering material 108 is indicative of the soldering material to be dispensed for being collected into one of the metal terminals 106. Each chunk may solder one of the cables 110 into one of the metal terminals 106. A cable 110 and a chunk of the soldering material 108 may be positioned in the cavity of the metal terminal 106. In particular, a chunk of the soldering material 108 is first dispensed into a cavity of a metal terminal 106. In an embodiment, the soldering material 108 may be dispensed to be collected into the metal terminal 106 by a dispensing unit (not shown). Further, a cable 110 is inserted into the cavity. In an embodiment, the cable 110 may pass through the soldering material 108 while being inserted into the cavity to be attached with the metal terminal 106.
After the insertion of the cable 110, the cavity may be closed and crimped by a pneumatic crimping gun (not shown). Therefore, the soldering material 108 and the cable 110 are crimped with the metal terminal 106. Once all the metal terminals 106 are crimped by the pneumatic crimping gun, the gear indicator switch assembly 100 may be placed on a heating plate (not shown). The heating plate may be heated to heat the crimped metal terminal 106 with the soldering material 108 and the cable 110 to form the join by solidification of the soldering material 108. In particular, in an embodiment, the heating plate may be heated to a temperature within a range of 200°C to 270°C. The heat is transferred to the metal terminals 106. The heat may melt the soldering material 108 to melt and therefore, forming the joint between the cable 110 and the metal terminal 106. In an embodiment, the entire process may take about 2 minutes for completion.
Figure 2 illustrates steps of forming the joint between the cable 110 and the metal terminal 106 of the gear indicator switch assembly 100, according to an embodiment of the present disclosure. Figure 2A illustrates an exploded view of the gear indicator switch assembly 100, according to an embodiment of the present disclosure. In the illustrated embodiment, the gear indicator switch assembly 100 may include the body 102 to be insert-molded with seven metal

terminals 106 and two metal inserts 104. In an embodiment, the body 102 may be formed of SMC-60 material.
Figure 2B illustrates a top perspective view of the gear indicator switch assembly 100 in an assembled state, according to an embodiment of the present disclosure. Figure 2C illustrates a bottom perspective view of the gear indicator switch assembly 100 in the assembled state, according to an embodiment of the present disclosure. Figure 2D illustrates a cross-sectional view of the gear indicator switch assembly 100, according to an embodiment of the present disclosure. The cross-sectional view depicts the metal terminals 106 having corresponding cavities 202 for receiving the soldering material 108.
Figure 2E illustrates a cross-sectional view of the gear indicator switch assembly 100 when the soldering material 108 is inserted into the cavities 202, according to an embodiment of the present disclosure. Figure 2F illustrates dispensing of the soldering material 108 into the cavity 202 of the metal terminal 106, according to an embodiment of the present disclosure. In the present embodiment, the soldering material is being dispensed by the dispensing gun 204.
Figure 2G illustrates insertion of the cables 110 into the cavities 202 of the metal terminals 106, according to an embodiment of the present disclosure. Each cable is dipped in the soldering material 108 filled into the cavities 202 of the metal terminals 106. Figure 2H illustrates crimping of the soldering material 108 and the cables 110 with the metal terminals 106. In an embodiment, the pneumatic crimping gun 206 is crimping the metal terminals 106. Figure 21 illustrates the gear indicator switch assembly 100 in the crimped state, according to an embodiment of the present disclosure.
Figure 2J illustrates heating of the gear indicator switch assembly 100 having the crimped metal terminals 106, according to an embodiment of the present disclosure. In an embodiment, after the crimping, the gear indicator switch assembly 100 may be placed on a fixture plate 208. In an embodiment, 20 such assemblies may be simultaneously placed on the fixture plate 208. Once the gear indicator switch assembly 100 is mounted on the fixture plate 208, a steel ball 210 may be placed on the gear indicator switch assembly 100. The steel ball 210 is placed to avoid any unwanted movement of the cables 110. It also ensures that the metal terminals 106 are flat during the induction soldering process.

Further, the fixture plate 208 may be placed on the heating plate 212. In an embodiment, the heating plate 212 may be the induction plate 212. Once positioned on the induction plate 212, the induction plate 212 is operated to heat the gear indicator switch assembly 100 to a temperature of 230°C-250°C. In the proposed technique, the heat is transferred to the metal terminals 106 from bottom to top. Due to the heat, the soldering material 108 melts and forms the joint between the cables 110 and the metal terminals 106.
In an embodiment, after the induction soldering process, the gear indicator switch assembly 100 may be tested in an epoxy-filling infrared set-up for quality assurance. Further, a final continuity testing may also be performed.
Figure 3 illustrates a flow chart depicting a method 300 of forming a joint between two materials, according to an embodiment of the present disclosure. For the sake of brevity, features of the present disclosure that are already explained in the description of Figure 1 and Figure 2 are not explained in detail in the description of Figure 3.
At block 302, the method 300 includes dispensing the soldering material 108 to be collected into the joining site 106 of a component 100 made of a first material. In an embodiment, the soldering material 108 may be in the form of at least one of a paste, a tablet, foam, a liquid, and a semi-solid.
At block 304, the method 300 includes attaching the cable 110 made of a second material at the joining site 106. The cable 110 may pass through the soldering material 108 to be attached with the component 100 at the joining site 106. In an embodiment, the first material and the second material may be same.
At block 306, the method 300 includes placing the component 100 having the joining site 106 with the soldering material 108 and the cable 110 on the heating plate 212. In an embodiment, the heating plate 212 may be an induction plate.

At block 308, the method 300 includes heating the component 100 with the soldering material 108 and the cable 110 to form the joint by the soldering material 108.
In an embodiment, the method 300 may include crimping the soldering material 108 and the cable 110 with the joining site 106. In an embodiment, the soldering material 108 and the cable 110 may be crimped with the joining site 106 by the pneumatic crimping gun 206.
In an embodiment, the method 300 may include placing the component 100 having the joining site 106 with the soldering material 108 and the cable 110 on the fixture plate 208. Further, the fixture plate 208 may be heated to heat the joining site 106 with the soldering material 108 and the cable 110 to form the joint by the soldering material 108. In an embodiment, the method 300 may include placing the steel ball 210 on the component 100 before heating the fixture plate 208.
Figure 4 illustrates a flow chart depicting a method 400 of forming a joint between the cable 110 and the body 102 of the gear indicator switch 100, according to an embodiment of the present disclosure. For the sake of brevity, features of the present disclosure that are already explained in the description of Figure 1, Figure 2, and Figure 3 are not explained in detail in the description of Figure 4.
At block 402, the method 400 includes dispensing the soldering material 108 to be collected into the metal terminal 106 of the body 102. The soldering material 108 may be in the form of at least one of a paste, a tablet, foam, a liquid, and a semi-solid. At block 404, the method 400 includes attaching the cable 110 to the metal terminal 106. The cable 110 may pass through the soldering material 108 to be attached with the metal terminal 106.
At block 406, the method 400 includes placing the gear indicator switch assembly 100 having the metal terminal 106 with the soldering material 108 and the cable 110 on the heating plate 212. At block 408, the method 400 includes heating the metal terminal 106 with the soldering material 108 and the cable 110 to form the joint by the soldering material 108.
In an embodiment, the method 400 may include placing the gear indicator switch assembly 100 having the metal terminal 106 with the soldering material 108 and the cable 110 on the

fixture plate 208. The fixture plate 208 may be heated to heat the metal terminal 106 with the soldering material 108 and the cable 110 to form the joint by the soldering material 108. In an embodiment, the heating plate 212 may be heated to a temperature within a range of 200 Degree Celsius to 270 Degree Celsius.
In an embodiment, the method 400 may include crimping the soldering material 108 and the cable 110 with the metal terminal 106 before placing it on the fixture plate 208.
The present disclosure offers a method of forming a joint between two materials by induction soldering technique. The present disclosure offers a controlled environment for the induction soldering process. As a result, an overall quality of the process is significantly high. The possibility of formation of weak joints, i.e., the instance of dry soldering, is eliminated ensuring formation of strong joints.
Further, the proposed technique facilitates simultaneous soldering of at least 140 joints. Moreover, the time taken to solder 140 joints is less than 2 minutes. Furthermore, the number of joints that can be simultaneously soldered can be increased by making minor modifications in the constructional aspects of the proposed technique. Moreover, this is being achieved without the need of a skilled person to perform the process. Therefore, manual intervention is minimum ensuring consistency and quality in the formation of joints. Further, since the soldering is performed by heating the metals terminals 106 from bottom, an overall efficiency of the induction soldering process is increased. Therefore, the proposed technique is flexible, cost-effective, time-effective, efficient, convenient, and has a wide range of application.
While specific language has been used to describe the present subject matter, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.

WE CLAIM:
1. A method (300) of forming a joint between two materials, the method (300) comprising:
dispensing a soldering material (108) to be collected into a joining site (106) of a component (100) made of a first material;
attaching at least one cable (110) made of a second material at the joining site (106), wherein the at least one cable (110) is passing through the soldering material (108) to be attached with the component (100) at the joining site (106);
placing the component (100) having the joining site (106) with the soldering material (108) and the at least one cable (110) on a heating plate (212); and
heating the component (100) with the soldering material (108) and the at least one cable (110) to form the joint by the soldering material (108).
2. The method (300) as claimed in claim 1, further comprising:
placing the component (100) having the joining site (106) with the soldering material (108) and the at least one cable (110) on a fixture plate (208); and
heating the fixture plate (208) to heat the joining site (106) with the soldering material (108) and the at least one cable (110) to form the joint by solidification of the soldering material (108).
3. The method (300) as claimed in claim 2, further comprising placing a steel ball (210) on the component (100) before heating the fixture plate (208).
4. The method (300) as claimed in claim 1, wherein the heating plate (212) is an induction plate.
5. The method (300) as claimed in claim 1, wherein the soldering material (108) is in form of at least one of a paste, a foam, a liquid, a tablet, and a semi-solid.
6. A method (400) of forming a joint between at least one cable (110) and a body (102) of a gear indicator switch (100), the method (400) comprising:
dispensing a soldering material (108) to be collected into a metal terminal (106) of the body (102);

attaching at least one cable (110) to the metal terminal (106), wherein the at least one cable (110) is passing through the soldering material (108) to be attached with the metal terminal (106);
placing the gear indicator switch (100) having the metal terminal (106) with the soldering material (108) and the at least one cable (110) on a heating plate (212); and
heating the metal terminal (106) with the soldering material (108) and the at least one cable (110) to form the joint by the soldering material (108).
7. The method (400) as claimed in claim 1, further comprising:
placing the gear indicator switch (100) having the metal terminal (106) with the soldering material (108) and the at least one cable (110) on a fixture plate (208); and
heating the fixture plate (208) to heat the metal terminal (106) with the soldering material (108) and the at least one cable (110) to form the joint by solidification of the soldering material (108).
8. The method (400) as claimed in claim 1, wherein the heating plate (212) is heated to a
temperature within a range of 200 Degree Celsius to 270 Degree Celsius.