Primary lock reinforcement for connector locking system with resilient and rigid locking surfaces

A method of assembling a connector, comprising:

• attaching a primary lock reinforcement (PLR) device to a connector body in a pre-staged position by inserting a free end of a cantilevered resilient secondary terminal locking arm into a first aperture defined by a cavity wall of a terminal cavity in the connector body, wherein the PLR device is inhibited from moving from the pre-staged position to a fully staged position prior due to a blocking condition caused by interference between the secondary terminal locking arm and the cavity wall;
• inserting a terminal within the terminal cavity, wherein the secondary terminal locking arm flexes outwardly due to contact with a terminal release ramp of the terminal as the terminal is inserted within the terminal cavity, thereby clearing the blocking condition;
• engaging a cantilevered resilient primary terminal locking arm defined by an outer wall of the terminal cavity with a locking ridge defined by the terminal, thereby securing the terminal within the terminal cavity;
• moving the PLR device from the pre-staged position to the fully staged position;
• inserting a free end of the secondary terminal locking arm into a second aperture defined by a cavity wall;
• and
• engaging the free end with a locking ridge of the terminal when the PLR device is in the fully staged position.

A connector assembly manufactured by a process, comprising:

• attaching a primary lock reinforcement (PLR) device to a connector body in a pre-staged position by inserting a free end of a cantilevered resilient secondary terminal locking arm into a first aperture defined by a cavity wall of a terminal cavity in the connector body, wherein the PLR device is inhibited from moving from the pre-staged position to a fully staged position prior due to a blocking condition caused by interference between the secondary terminal locking arm and the cavity wall;
• inserting a terminal within the terminal cavity, wherein the secondary terminal locking arm flexes outwardly due to contact with a terminal release ramp of the terminal as the terminal is inserted within the terminal cavity, thereby clearing the blocking condition;
• engaging a cantilevered resilient primary terminal locking arm defined by an outer wall of the terminal cavity with a locking ridge defined by the terminal, thereby securing the terminal within the terminal cavity;
• moving the PLR device from the pre-staged position to the fully staged position;
• inserting a free end of the secondary terminal locking arm into a second aperture defined by a cavity wall;
• and
• engaging the free end with a locking ridge of the terminal when the PLR device is in the fully staged position.