Fan-out distribution box with isolating fiber chamber

A hardened fiber optic fan-out arrangement comprising:

• a hardened fan-out device having an in-line configuration, the hardened fan-out device including:
• an outer housing having a first end and an opposite second end;
• an inner housing configured to be located inside of the outer housing, the inner housing having a distal end and a proximal end that respectively align with the first and second ends of the outer housing;
• a space defined circumferentially between the outer housing and the inner housing, the space being adapted to form a flow passage for a filling material;
• and
• an inner cover adapted to be positioned on and fitted on the inner housing, the inner cover and inner housing together forming a chamber within the outer housing such that the filling material is prevented from flowing into the chamber;
• and
• an outer cover being adapted to be positioned on and fitted on the outer housing such that the space and the chamber are enclosed;
• a plurality of fiber optic pigtails that project outwardly from the second end of the hardened fan-out device;
• and
• a fiber optic feeder cable that projects outwardly from the first end of the hardened fan-out device, the fiber optic feeder cable being optically coupled to the plurality of fiber optic pigtails;
• wherein optical fibers are routed from the fiber optic feeder cable through the hardened fan-out device to the plurality of fiber optic pigtails;
• wherein the filling material encapsulates an end of the fiber optic feeder cable within the outer housing and encapsulates ends of the plurality of fiber optic pigtails within the outer housing;
• and
• wherein the filling material does not encapsulate the optical fibers within the inner housing such that the optical fibers are configured to move freely.

A method of fabricating a fan-out assembly for a fiber optic feeder cable which includes a plurality of fiber optic pigtails, the method comprising:

• providing a hardened fan-out device, the hardened fan-out device having an outer housing and an inner housing, a space being defined between the outer and inner housings;
• routing optical fibers from the fiber optic feeder cable through the hardened fan-out device to the plurality of fiber optic pigtails;
• terminating free ends of the plurality of fiber optic pigtails to a plurality of fiber optic connectors;
• routing excess slack of the optical fibers about a spool positioned within the inner housing of the hardened fan-out device;
• covering the inner housing of the hardened fan-out device with an inner cover;
• applying a filling material over the inner housing and into the space defined between the outer and inner housings, wherein the filling material does not enter the inner housing;
• and
• covering the outer housing of the hardened fan-out device with an outer cover to enclose the inner cover and inner housing of the hardened fan-out device.