Interlocking connector design for electrical connectors

A method of assembling an electrical connector, comprising the steps of:

• providing an inner housing defining a plurality of terminal cavities and a plurality of flexible terminal retaining arms configured to retain electrical terminals within the terminal cavities;
• providing a nose housing defining a plurality of apertures;
• providing an outer housing having a flexible latching arm extending from the outer housing;
• aligning the plurality of apertures with openings of the terminal cavities and attaching the nose housing to the inner housing;
• inserting an independent secondary lock defining a plurality of raised pads and a tab within the inner housing and placing it in a pre-staged position;
• attaching the outer housing to the inner housing by engaging the flexible latching arm with the inner housing, wherein the tab is offset from the flexible latching arm when the independent secondary lock is in the pre-staged position, thereby allowing the flexible latching arm to flex as it engages with the inner housing;
• inserting the electrical terminals within the terminal cavities, wherein the pads are offset from the terminal retaining arms when the independent secondary lock is in the pre-staged position, thereby allowing the terminal retaining arms to flex as the electrical terminals are inserted within the terminal cavities;
• and
• moving the independent secondary lock from the pre-staged position to a fully-staged position, wherein the pads are aligned with the terminal retaining arms, thereby inhibiting the terminal retaining arms from flexing and inhibiting removal of the electrical terminals from the terminal cavities and wherein the tab is aligned with the flexible latching arm, thereby inhibiting the flexible latching arm from flexing and disengaging from the inner housing.