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The thermal stresses of various joints between contacts and wire conductors in Insulation Displacement Contact (IDC) connectors were calculated by the finite element method, and the life of each joint was predicted qualitatively. Next, several connectors evaluated well durable at the prediction were subjected to 1,000-hour combined environmental testing. Consequently, a highly reliable IDC connector for automotive applications was developed. Furthermore the predicted life trend of the connectors virtually agreed with the environmental test results.

Lately demand for more reliable automotive connectors has been highlighted, making it necessary to establish a quick and reliable accelerated life testing method. This has led to the adoption of a combined environmental test, which is to be performed under conditions resembling the field environment of automotive connectors. We have been achieving success by performing combined environmental tests to determine the reliability of connectors in the development stages while investigating the relation of this test with the field environment.