Patent ID: 8360803

Claim:
An electrical connection structure comprising: a conductive cable core; a terminal connected to said cable core; a molded hot melt seal bonded to said cable core and said terminal, said hot melt seal intimately surrounding and substantially filling any space around the entire interface of said cable core with said terminal and sealing said interface from ambient electrolytes, wherein said conductive cable core is made from aluminum or an aluminum alloy and said terminal comprises a copper alloy; an insulative outer cover surrounding said cable core; an exposed lead of said core disposed at one end of said core, said terminal comprising a pair of insulation crimp wings and a pair of core crimp wings, and said insulation crimp wings crimped onto said insulative outer cover and said core crimp wings crimped onto and making electrical contact with said exposed lead, said molded hot melt seal secured about said insulation crimp wings and said core crimp wings and intimately surrounding and substantially filling any space around said exposed lead; and a connector housing that defines a cavity having an opening, said exposed lead and said core crimp wings disposed in said cavity, said outer cover extending from an axial edge at said exposed lead through said opening, said molded hot melt seal entirely surrounding a length of said outer cover that extends from said axial edge to a location on said cover that is spaced a distance apart from said housing, whereby said hot melt seal suppresses flexing of said length of said outer cover.