Due to the recent increase in electronic devices mounted on automobiles, a large number of connectors, especially low-cost tin plated connectors are being used. As a result, their contact reliability has become problematic. Furthermore, for the connectors which are subjected to fretting wear caused by heat cycle and vibrations, the contact resistance increases because of wear of tin and deposition of oxides, which generates problems of poor contact. This study is intended to analyze the change in contact resistance of tin plated connectors from the start of fretting wear to the end of their lifetime from the viewpoint of practical reliability, and to observe the trace and the characteristics of fretting wear microscopically. This study found that wear and oxidation of tin plated connectors start immediately with fretting wear, and thus accumulation of abrasion powder on fretting areas causes connectors to reach to the end of their useful lifetime quickly. Especially, it was demonstrated that amplitude of fretting has a considerable influence on a connector's lifetime. It is made clear that air-tightness, so-called "gas-tight" of tin in a fretting area influences fretting wear considerably.

Characteristics of conductive elastomer that is composed of silicone rubber and dispersed carbon black particles show conductive and elastic properties in one simple material. This material has been widely applied to make-break contacts of panel switches and connectors of liquid crystal panels. However, since surface state of the contact is very soft, it is difficult to remove contaminant films of contaminated opposite side contact surface and to obtain low contact resistance owing to break the film. This is an important problem to be solved not only for the application of make-break switching contact but also static connector contacts. This study has been conducted to examine some complex structures of the elastomer which indicate removal characteristics for contaminant films and low contact resistance. As specimens, six different types of elastomer contacts composed of different type of dispersed materials as carbon and metal fibers, metal mesh, and plated surfaces were used. The contacts of opposite side were Au and Sn plated contact surface on a printed circuit board (PCB) which is usually used in the static connector and make-break contacts. In order to contaminate contact surfaces of PCB, the surfaces were subjected to exposure in an SO2 gas environment. The elastomeric contacts contained hard materials showed lower contact resistance than only dispersed carbon particles in the elastomer matrix for both contaminated PCB contact surfaces.