Patent ID: 7954235

Claim:
A method of forming a seal about a copper-based terminal and a cable having an insulative outer cover and an aluminum-based core, the method comprising the steps of: providing a lead of said core extending beyond an axial edge of the insulative outer cover; applying a conformal coating wet onto said lead, said lead being disposed into a counterbore of a nozzle and said wet conformal coating is dispensed into said nozzle and applied to said lead disposed within the counterbore; crimping said copper-based terminal onto said lead while said applied conformal coating is still wet to displace the applied conformal coating from between said lead and said abutting contact surfaces of said copper-based terminal to provide electrical contact between said lead and said terminal and to cover and seal remaining portions of said lead not in direct contact with said terminal; and curing said applied conformal coating over said remaining portions of said lead.