Connector assembly with terminal position assurance and blocking feature

A method of assembling a connector, comprising:

• inserting a terminal position assurance (TPA) device within a terminal cavity of a connector body and holding the TPA device in a pre-staged position via contact between a stop ridge projecting from an inner wall of the connector body into the terminal cavity and a free end of a cantilevered flexible arm extending from the TPA device and disposed between the terminal locking arm and the inner wall of the connector body, the cantilevered flexible arm being oriented such that it flexes toward the inner wall during terminal insertion and returns to engage the terminal after insertion, thereby providing staged retention distinct from the terminal locking arm and further providing a first blocking condition for the TPA device;
• partially inserting a terminal within the terminal cavity which contacts the cantilevered flexible arm, thereby moving the free end out of contact with the stop ridge and clearing the first blocking condition for the TPA device, the terminal further coming in contact with a terminal locking arm and pushes the terminal locking arm into contact with a tab defined by the TPA device, thereby holding the TPA device in the pre-staged position by creating a second blocking condition for the TPA device;
• fully inserting the terminal within the terminal cavity, the terminal locking arm engaging the terminal and returning to an unflexed condition, thereby moving the terminal locking arm out of contact with the tab, clearing the second blocking condition, and creating a non-blocking condition for the TPA device that allows the TPA device to be moved from the pre-staged position to a fully staged position;
• and
• moving the TPA device from the pre-staged position to the fully staged position.

A connector assembly manufactured by a process, comprising:

• inserting a terminal position assurance (TPA) device within a terminal cavity of a connector body and holding the TPA device in a pre-staged position via contact between a stop ridge projecting from an inner wall of the connector body into the terminal cavity and a free end of a cantilevered flexible arm extending from the TPA device and disposed between the terminal locking arm and the inner wall of the connector body, the cantilevered flexible arm being oriented such that it flexes toward the inner wall during terminal insertion and returns to engage the terminal after insertion, thereby providing staged retention distinct from the terminal locking arm and further providing a first blocking condition for the TPA device;
• partially inserting a terminal within the terminal cavity which contacts the cantilevered flexible arm, thereby moving the free end of the cantilevered flexible arm out of contact with the stop ridge and clearing the first blocking condition for the TPA device, the terminal further coming in contact with a terminal locking arm and pushing the terminal locking arm into contact with a tab defined by the TPA device, thereby holding the TPA device in the pre-staged position by creating a second blocking condition for the TPA device;
• fully inserting the terminal within the terminal cavity, the terminal locking arm engaging the terminal and returning to an unflexed condition, thereby moving the terminal locking arm out of contact with the tab, clearing the second blocking condition, and creating a non-blocking condition for the TPA device that allows the TPA device to be moved from the pre-staged position to a fully staged position;
• and
• moving the TPA device from the pre-staged position to the fully staged position.