Sealed electric terminal assembly

1. A wire terminal assembly, comprising:

a conductive cable core comprising a first metal;

a conductive terminal connected to the conductive cable core along a conductive connection interface, the conductive terminal comprising a second metal; and

a coating over the conductive connection interface derived from the free radical addition polymerization of a liquid coating composition applied over the conductive connection interface, said liquid coating composition comprising:

(1) an oligomer comprising at least two active unsaturated bonds, and

(2) a monomer comprising an unsaturated bond.

2. The assembly of claim 1 , wherein the oligomer is the polymerizate of a reaction mixture comprising a polyisocyanate, a polyol, and a hydroxy-functional acrylate.

3. The assembly of claim 2 , wherein the oligomer includes aliphatic groups derived from aliphatic polyols or aliphatic polyisocyanates.

4. The assembly of claim 2 , wherein the polyol includes a hydroxy-terminated polyester.

5. The assembly of claim 1 , wherein the monomer comprises a (meth)acrylate group.

6. The assembly of claim 1 , wherein the first metal and the second metal have different electrode potentials.

7. The assembly of claim 6 , wherein the terminal comprises tin-plated copper, and the cable core comprises aluminum.

8. The assembly of claim 1 , wherein the cable further comprises an electrically insulating outer cover, from which a lead portion of the cable core extends, and wherein the conductive connection interface comprises a crimp connection of a structure of the terminal onto the lead portion of the cable core and a crimp connection onto the electrically insulating outer cover.

9. The assembly of claim 8 , wherein the coating covers the conductive connection interface and the lead.

10. The assembly of claim 9 , wherein the coating further covers a portion of the cable outer cover adjacent to the lead portion of the cable core.

11. The assembly of claim 1 , wherein the coating has a cured thickness of 50 μm to 5 mm.

12. The assembly of claim 1 , wherein the coated assembly is treated with a corrosion-inhibiting oil.

13. The assembly of claim 1 , wherein the coated assembly exhibits a change in resistance of less than 7.5 micro ohms between the terminal and the conductive cable core after exposure to three test cycles, each test cycle comprising 100 thermal cycles comprising 15 minutes at −40° C. followed by 15 minutes at 130° C., 4 salt exposure cycles comprising 2 hours of salt mist/spray at 35° C. followed by 22 hours at 93% relative humidity at 40° C., and 1 conditioning period comprising 72 hours at 45-55% relative humidity at 23° C.

14. The assembly of claim 1 , wherein the coating composition further comprises a UV-activated free radical initiator.

15. A method of making a wire terminal assembly, comprising

connecting a conductive terminal to a conductive cable core along a conductive connection interface; and

depositing a liquid coating composition over the conductive connection interface, said liquid coating composition comprising:

(1) an oligomer comprising at least two active unsaturated bonds, and

(2) an acrylic monomer; and

curing the deposited liquid coating composition.

16. The method of claim 15 , wherein the curing is carried out by exposing the coated substrate to ultraviolet light.

17. The method of claim 16 , comprising depositing the coating with a jet coating apparatus.

18. The method of claim 17 , wherein the coating composition has a viscosity of 300-1000 centipoise at 40° C.

19. The method of claim 17 , wherein the jet coating apparatus deposits the coating composition in drop sizes of 0.25 ml-2 ml.

20. The method of claim 15 , further comprising treating the coated substrate with a corrosion-inhibiting oil.