Multi-fiber splice protector, fiber optic cable assembly incorporating same, and fabrication method

A fiber optic cable assembly comprising:

• a first fiber optic cable section comprising a first plurality of optical fibers, and a second fiber optic cable section comprising a second plurality of optical fibers, wherein each optical fiber of the first and second pluralities of optical fibers includes a pre-coated section and a stripped section;
• a plurality of fusion splices including a plurality of splice joints joining ends of the stripped sections of the first plurality of optical fibers with ends of the stripped sections of the second plurality of optical fibers to form a plurality of fusion spliced optical fibers;
• and
• a multi-fiber splice protector comprising a strength member including at least one wall arranged in a tubular shape having a central axis extending in a longitudinal direction, wherein the strength member is bend-resistant, the at least one wall bounds an inner cavity extending in the longitudinal direction, and a longitudinal opening extends through an entire thickness of the at least one wall to permit passage of a pre-coated section of a fusion spliced optical fiber of the plurality of fusion spliced optical fibers into the inner cavity;
• wherein fusion spliced optical fibers of the plurality of fusion spliced optical fibers are not exclusively arranged in a one-dimensional array within the inner cavity;
• and
• wherein a thermoplastic hotmelt material is present in the inner cavity of the strength member to encapsulate the plurality of fusion spliced optical fibers, including the plurality of splice joints as well as at least the stripped sections of the first and second pluralities of optical fibers.

A method for fabricating a fiber optic cable assembly, the method comprising:

• heating a strength member comprising at least one wall arranged in a tubular shape having a central axis extending in a longitudinal direction, wherein the at least one wall bounds an inner cavity extending in the longitudinal direction, a longitudinal opening extends through an entire thickness of the at least one wall, a solid thermoplastic hotmelt material is arranged within the inner cavity prior to the heating, the longitudinal opening comprises a first width extending in a direction transverse to the longitudinal direction;
• and the heating is sufficient to melt the solid thermoplastic hotmelt material;
• sequentially inserting individual fusion spliced optical fibers of a plurality of fusion spliced optical fibers through the longitudinal opening into the inner cavity and the melted thermoplastic hotmelt material, while manipulating the plurality of fusion spliced optical fibers to cause fusion spliced optical fibers of the plurality of fusion spliced optical fibers inserted into the inner cavity to not be exclusively arranged in a one-dimensional array within the inner cavity;
• and
• permitting the strength member and the melted thermoplastic hotmelt material to cool sufficiently to cause the thermoplastic hotmelt material to solidify around and encapsulate splice joints and stripped sections of fusion spliced optical fibers of the plurality of fusion spliced optical fibers.