Methods and apparatus for terminating wire wound electronic devices

An insert structure assembly for use with a connector assembly, the insert structure assembly comprising:

• an insert structure comprising:
• a body element comprised of a polymer material and having an electronic component receiving cavity configured to have one or more electronic components disposed therein;
• a plurality of conductive terminals;
• and
• a plurality of termination grooves disposed within at least a portion of the body element, the termination grooves configured to have a plurality of conductive ends of the one or more electronic components disposed substantially therein;
• and
• a substrate positioned adjacent the insert structure, the respective conductive ends of the one or more electronic components being terminated to the substrate.

A method of manufacturing a connector assembly comprising an insert body element, the insert body element having at least one termination groove formed therein, the method comprising:

• disposing one or more wire-containing electronic components within the insert body element;
• routing a conductive wire from the one or more wire-containing electronic components within the at least one termination groove;
• disposing a substrate adjacent the at least one termination groove of the one or more insert body elements;
• terminating the conductive wire from the one or more wire-containing electronic components to the substrate, thereby forming an insert body assembly;
• and
• inserting the insert body assembly into a connector housing, thereby forming the connector assembly.