Optical connectivity solution for fiber to home network

Abstract

The present disclosure provides a fiber enclosure (100) for an optical fiber network comprising one or more breakout assemblies (1021, 1022, … 102n), each breakout assembly (102) configured to divide an IBR bundle (204) into a plurality of IBR bundle segments (2061, 2062, …206n) while preserving intermittent bonding within each IBR (208) forming part of the IBR bundle segment (206); and one or more protective cassette modules (1041, 1042, … 104n), each protective cassette module (104) comprising: at least one input port (3021, 3022, … 302n) to receive one or more of the IBR bundle segments (2061, 2062, … 206n); and a plurality of output adapters (3041, 3042, … 304n), the plurality of output adapters being aligned for mating with downstream optical connections; and each protective cassette module is a self-contained unit configured to be mounted and demounted within the fiber enclosure using a frame (504)

Description

TITLE OPTICAL CONNECTIVITY SOLUTION FOR FIBER TO HOME NETWORK The following specification particularly describes the invention and the manner in which it is to be performed: FIELD OF INVENTION

[0001] The present disclosure relates to optical fiber cable management, and more particularly, relates to a fiber enclosure for an optical fiber network. This application claims priority from an Indian application with application number 202411069311 filed on 13 September 2024, the complete reference of which is incorporated herein. BACKGROUND

[0002] Optical fiber cables are a critical component in a fiber-to-home network. Hence, various methods and systems are used for distributing and managing the optical fiber cables in the fiber-to-home network.

[0003] Referring to US20240427101A1, there is disclosed an aerial distribution terminal for optical fiber communication that includes at least one feeder port and multiple distribution ports. It receives a fiber via the feeder port and distributes multiple fibers through the distribution ports. The terminal contains fiber management modules or cassettes with splice trays for handling both loose tube and ribbon fiber splices. The prior art does not disclose a fiber distribution assembly for managing input cables with one or more IBR bundles.

[0004] Referring to US20230085572A1, there is disclosed an optical fiber management tray for guiding and organizing rollable ribbon and individual optical fibers. The disclosed optical fiber management tray is configured to route and secure rollable ribbon fibers (IBR) and loose fibers using improved tray geometries and pivotable designs. The prior art does not disclose an aerial distribution assembly specifically for managing input cables composed of one or more IBR / rollable ribbon bundles, nor does it disclose a portable bulkhead unit with multiple protective cassette modules that are installable without tools.

[0005] While prior technologies provide various solutions for optical connectivity in the fiber-to-home network, there remains a room for improvement in reducing traditional fiber installation tasks such as on-field splicing, fiber management, buffer tube storage, and cable fixation, while also ensuring low cost and high performance. Moreover, existing solutions suffer from high production assembly costs, low throughput, cable assembly complexity, and fragile construction, especially with 250µm and / or 900µm (for example) fiber exposure. These solutionsare often tailored to specific applications, which increases production costs and limits portability across different use cases. There is a need for a fiber enclosure which aims to address these issues and provide an improved solution. OBJECT OF THE INVENTION

[0006] A principal object of the present invention is to provide a fiber enclosure for an optical fiber network that addresses one or more of the aforesaid disadvantages.

[0007] Another object of the present invention is to divide IBR bundle into multiple IBR bundle segments.

[0008] Yet another object of the present invention is to provide a bulkhead unit having multitude of protective cassette modules and configured to be portable and mountable within different enclosure formats, including an aerial enclosure, a pedestal, or a cabinet housing.

[0009] Yet another object of the present invention is to provide a self-contained protective cassette module that can be mounted within a frame to form a bulkhead unit without using tools.

[0010] Yet another object of the present invention is to provide a fiber enclosure for high- density fiber management for high-density networks. SUMMARY

[0011] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key or essential features.

[0012] Accordingly, the present invention provides a fiber enclosure for distribution of optical fibers forming part of one or more input cables, each input cable comprising at least one intermittently bonded ribbon (IBR) bundle, each IBR bundle comprising at least one of IBR bundle segment, each of the IBR bundle segment comprises at least one IBRs such that each IBR bundle comprises plurality of IBRs, wherein each IBR comprising plurality of optical fibers where the adjacent optical fibers are bonded intermittently with a matrix material in a staggered bonding pattern such that pitch at a bonded region is in the range of 150 to 250 micrometers.

[0013] In an embodiment of the invention, the fiber enclosure comprises one or more breakout assemblies, with each breakout assembly being configured to divide an IBR bundle into a plurality of IBR bundle segments while preserving intermittent bonding within each IBR forming part of the IBR bundle segment. The fiber enclosure further comprises one or more protective cassette modules with each protective cassette module comprising at least one input port receiving one or more of the IBR bundle segments; and a plurality of output adapters, with each of the plurality of output adapters being aligned for mating with downstream optical connections.

[0014] In another embodiment of the invention, each protective cassette module is a self- contained unit configured to be mounted and demounted within the fiber enclosure using a frame. Each protective cassette module and the frame being portable and adaptable within different enclosure formats, including an aerial enclosure, a pedestal, or a cabinet housing.

[0015] In another embodiment of the invention, each breakout assembly comprises a housing having a first opening sized to receive an IBR bundle having fiber count between 24 and 10800 fibers. Each of the through holes is sized to output an IBR bundle segment having one of 12 optical fibers, 16 optical fibers, or 24 optical fibers.

[0016] In another embodiment of the invention, each breakout assembly comprises the housing having one or more openings sized to receive an IBR bundle having fiber count between 24 and 288 fibers.

[0017] In another embodiment of the invention, each breakout assembly further comprises a guided separation channel configured to receive and internally route the IBR bundle; and a transition fixture configured to divide the IBR bundle into the plurality of IBR bundle segments without disrupting the pitch at the bonded region of the IBR forming part of the IBR bundle segment.

[0018] In another embodiment of the invention, a plurality of protective cassette modules are vertically stacked and held between a frame and a removable locking piece to form a portable bulkhead unit and the fiber enclosure comprises at least one portable bulkhead unit.

[0019] In another embodiment of the invention, each protective cassette module further comprises at least one splice sleeve, each splice sleeve receiving at least one IBR bundle segment from the at least one input port, wherein the at least one splice sleeve stores mass fusion splicing of the at least one IBR bundle segment to a plurality of pig tails, wherein the plurality of pig tails are connected to a corresponding port of the plurality of output adapters.

[0020] In another embodiment of the invention, each input port of the protective cassette module is sized to receive one or more IBR bundle segments, with each IBR bundle segment having one of 12 optical fibers, 16 optical fibers, or 24 optical fibers.

[0021] In another embodiment of the invention, each splice sleeve stores mass fusion splicing of 4N fibers, where N is an integer between 1 and 10.

[0022] In another embodiment of the invention, each protective cassette module further comprises a base unit, a removable cover unit, and at least one of a snap fit latching mechanism or a hinge mechanism for joining the base unit and the removable cover unit. Thus, the cover unit can be removed with respect to the base unit without any tool.

[0023] In another embodiment of the invention, the frame comprises a plurality of slots and a plurality of openings; the removable locking piece comprises a plurality of apertures; each of the protective cassette module comprises a first sidewall and a second side wall, the second side wall being opposite to the first side wall, the first side wall comprising a first protruded region, a second protruded region and a first lever portion; the second side wall comprising at least a third protruded region; each of the plurality of slots being adapted to receive the first protruded region provided on adjacently stacked protective cassette modules; each of the plurality of openings being adapted to receive the second protruded region and the first lever portion provided on the adjacently stacked protective cassette modules; and each of the plurality of apertures being adapted to receive the third protruded region provided on the adjacently stacked protective cassette modules.

[0024] In another embodiment of the invention, the plurality of output adapters are formed as a single piece integrated output adapter.

[0025] In another embodiment of the invention, the single piece integrated output adapter comprises 12 to 24 output adapters.

[0026] In another embodiment of the invention, the fiber enclosure further comprises at least one splitter cassette configured to receive an input from the single piece integrated adapter, wherein each splitter cassette is configured to divide a single fiber input into multiple outputs.

[0027] In another aspect of the invention there is provided a method for terminating one or more input cables at a fiber enclosure, each input cable comprising at least one intermittently bonded ribbon (IBR) bundle, each IBR bundle comprising at least one of IBR bundle segment, each of the IBR bundle segment comprises at least one IBR such that each IBR bundle comprises plurality of IBRs, wherein each IBR comprising plurality of optical fibers where the adjacent optical fibers are bonded intermittently with a matrix material in a staggered bonding pattern such that pitch at a bonded region is in the range of 150 to 250 micrometers. In an embodiment of the invention, the method comprises providing, as an input to the fiber enclosure, the one or more input cables. The method further comprises receiving one or more IBR bundles at one or more breakout assemblies, with each breakout assembly being configured to divide an IBR bundle into a plurality of IBR bundle segments while preserving intermittent bonding within each IBR forming part of the IBR bundle segment. The method further comprises providing at least one of the plurality of IBR bundle segments to an input port forming part of a protective cassette module. The method further comprises performing a mass fusion splicing to connect each individual optical fiber of the plurality of IBR bundle segments to a corresponding pigtail of the protective cassette module.

[0028] In yet another aspect of the invention, there is provided a protective cassette module, comprising a base unit, a removable cover unit, and a first sidewall and a second side wall projecting perpendicularly from the base unit, where the second sidewall is opposite to the fist sidewall. The protective cassette module further comprises at least one input port to receive one or more of the IBR bundle segments; and a plurality of output adapters, the plurality of output adapters being aligned for mating with downstream optical connections. In an embodiment of the invention, the first side wall comprises a first protruded region, a second protruded region and a first lever portion. In an embodiment of the invention, the second side wall comprises at least a third protruded region. In embodiment of the invention, the first protruded region, the second protruded region, and the first lever portion are adapted to be joined to a frame without using a tool. In an embodiment of the invention, the removable locking piece is mounted to the frame after the protective cassette modules are stacked and inserted in the frame. The removable locking piece receives the third protruded region from the side walls of the adjacently stacked protective cassette modules, which forms a portable bulkhead unit. These units can be mounted and demounted in various enclosures, such as an aerial closure, a pedestal, or a cabinet housing.

[0029] In an embodiment of the invention, the lever portion is configured to be pressed inward during coupling to the frame and to return to an original position upon full engagement with the frame.

[0030] In still another aspect of the invention, there is provided a portable bulkhead unit comprising a plurality of protective cassette modules vertically stacked and held between a frame and a removable locking piece.

[0031] In an embodiment of the invention, the frame comprises a plurality of slots and a plurality of openings; the removable locking piece comprises a plurality of apertures; each of the protective cassette module comprises a first sidewall and a second side wall, the second side wall being opposite to the first side wall, the first side wall comprising a first protruded region, a second protruded region and a first lever portion; the second side wall comprising at least a third protruded region; each of the plurality of slots being adapted to receive the first protruded region provided on adjacently stacked protective cassette modules; each of the plurality of openings being adapted to receive the second protruded region and the first lever portion provided on adjacently stacked protective cassette modules; and each of the plurality of apertures being adapted to receive the third protruded region provided on adjacently stacked protective cassette modules.

[0032] In a further aspect of the invention, there is provided a method of forming the portable bulkhead unit, said method comprising providing a plurality of protective cassette modules, wherein each of the protective cassette modules comprises a base unit, a removablecover unit, a first sidewall and a second side wall projecting perpendicularly from the base unit; at least one input port to receive one or more of the IBR bundle segments; a plurality of output adapters aligned for mating with downstream optical connections; with the first side wall comprising a first protruded region, a second protruded region and a first lever portion and the second side wall comprising at least a third protruded region. The method further comprises providing a frame and a removable locking piece. The method further comprises attaching plurality of protective cassette modules between a frame and the removable locking piece such that the plurality of protective cassette modules are vertically stacked thereby forming the portable bulkhead unit.

[0033] In an embodiment of the invention, the frame comprises a plurality of slots and a plurality of openings; the removable locking piece comprises a plurality of apertures; and each of the protective cassette module comprises a first sidewall and a second side wall, the second side wall being opposite to the first side wall, the first side wall comprising a first protruded region, a second protruded region and a first lever portion; the second side wall comprising at least a third protruded region; each of the plurality of slots being adapted to receive the first protruded region provided on adjacently stacked protective cassette modules; each of the plurality of openings being adapted to receive the second protruded region and the first lever portion provided on adjacently stacked protective cassette modules; and each of the plurality of apertures being adapted to receive the third protruded region provided on adjacently stacked protective cassette modules.

[0034] An advantage of the invention is that the fiber enclosure enables organized, scalable distribution of high-count fiber cables through structured breakout and cassette modules.

[0035] The invention is specifically designed for Intermittently Bonded Ribbon (IBR) fibers, allowing high-density fiber management while preserving bonding integrity.

[0036] The invention minimizes traditional splicing and cable handling challenges, especially in ribbonized fiber structures, by allowing segment-level breakout.

[0037] The invention supports fiber bundles from 24 to 10800 fibers, preferably between 24 and 288 fibers, with segment outputs of 12, 16, or 24 fibers, suitable for current and future network needs.

[0038] The protective cassette modules are self-contained and stackable, enabling flexible installation and removal without disturbing the system.

[0039] The snap-fit latching and lever-based design simplify module access and maintenance, reducing downtime and the need for special tools.

[0040] The invention reduces production and installation costs by offering mass-fusion splicing compatibility, reusable modules, and a simplified enclosure design.

[0041] The protective cassette modules shield fibers during splicing and routing, minimizing breakage and micro-bending, especially for 250µm / 900µm fibers.

[0042] The integrated output adapters and controlled routing reduces unnecessary connectors or splices, leading to lower optical signal loss.

[0043] The stackable modular cassettes allow easy scaling from small deployments to large centralized networks by simply adding the protective cassette modules.

[0044] The use of pre-defined protruded regions, lever portions, apertures, openings, and slots enables quick and secure assembling of plurality of protective cassette modules without additional fasteners or adhesives.

[0045] The protective cassette modules can be standardized which streamlines production and assembly, increasing throughput at manufacturing and installation levels.

[0046] The invention can be adapted for use with various downstream optical systems due to standardized output adapter interfaces.

[0047] The IBR bundles and modular breakouts reduce the need for excessive cable clamping and fixation, simplifying internal cable routing.

[0048] The guided separation channels and internal routing ensure clean paths and bend- radius control, aiding long-term reliability.

[0049] The splitter cassettes allow signal distribution within the same enclosure, reducing the need for external splitter boxes.

[0050] The protective cassette modules and the frame form a portable, pre-assembled bulkhead unit, ideal for rapid deployment in FTTH networks or data centers.

[0051] The invention supports mass fusion splicing (e.g., 4N where N = 1–10), significantly reducing the time and skill required for fiber termination.

[0052] The invention is suitable for indoor, outdoor, aerial, or wall-mounted installations, increasing its utility across various FTTH topologies.

[0053] The pre-configured modules and simplified routing accelerate field installation, reducing labor costs and increasing deployment speed.

[0054] These and other aspects herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the invention herein without departing from thereof.BRIEF DESCRIPTION OF FIGURES

[0055] In order that the invention may be readily understood and put into practical effect, reference will now be made to exemplary embodiments as illustrated with reference to the accompanying drawings, where like reference numerals refer to identical or functionally similar elements throughout the separate views. The figures together with a detailed description below, are incorporated in and form part of the specification, and serve to further illustrate the embodiments and explain various principles and advantages, in accordance with the present invention where:

[0056] Figure 1 illustrates a fiber enclosure constructed in accordance with an embodiment of the invention

[0057] Figure 2 illustrates a schematic view of an input cable in accordance with an aspect of the invention;

[0058] Figure 3 illustrates a sectional view of an intermittently bonded ribbon having 12 optical fibers in accordance with an aspect of the invention;

[0059] Figure 4 illustrates a sectional view of a breakout assembly constructed in accordance with an embodiment of the invention;

[0060] Figure 5 illustrates an exploded view of a protective cassette module constructed in accordance with an embodiment of the invention;

[0061] Figure 6 illustrates a top view of the protective cassette module constructed in accordance with an embodiment of the invention after removing the cover unit and showing routing of an IBR bundle segment therein;

[0062] Figure 7 illustrates a first perspective view of a portable bulkhead unit constructed in accordance with an embodiment of the invention;

[0063] Figure 8 illustrates a second perspective view of the portable bulkhead unit constructed in accordance with an embodiment of the invention;

[0064] Figure 9 illustrates a first exploded view of the portable bulkhead unit constructed in accordance with an embodiment of the invention;

[0065] Figure 10 illustrates a second exploded view of the portable bulkhead unit constructed in accordance with an embodiment of the invention; and

[0066] Figure 11 illustrates a first perspective of a portable bulkhead unit constructed in accordance with an embodiment of the invention and having a lesser number of protective cassette modules as compared to the portable bulkhead unit shown in Figures 7 to 10.

[0067] It may be noted that to the extent possible, like reference numerals have been used to represent like elements in the drawings. Further, skilled artisans will appreciate that elementsin the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. For example, the dimensions of some of the elements in the drawings may be exaggerated relative to other elements to help improve understanding of aspects of the present invention. Furthermore, one or more elements may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. DETAILED DESCRIPTION

[0068] For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

[0069] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the invention and are not intended to be restrictive thereof.

[0070] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0071] Reference throughout this specification to “an aspect”, “another aspect” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrase “in an embodiment”, “in another embodiment”, and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0072] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that one or more devices or sub-systems or elements or structures or components proceeded by "comprises... a" does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.

[0073] As used herein, and unless the context dictates otherwise, the terms "coupled to", “connected to”, “operably connected to”, and “operatively connected to” are intended to includeboth direct connection / coupling (in which two elements that are coupled / connected to each other contact each other) and indirect coupling / connection (in which at least one additional element is located between the two elements). Therefore, the terms "coupled to" and "coupled with" are used synonymously. Similarly, the terms “connected to” and “connected with” are used synonymously.

[0074] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one ordinary skilled in the art to which this invention belongs. The device, methods, and examples provided herein are illustrative only and not intended to be limiting. Without prejudice to the above, some of the terms more regularly used in the specification are being defined herein-below.

[0075] Fiber Enclosure - A fiber enclosure is a protective box which is used to organize, manage, and protect optical fiber connections and splices. It is used for providing a secure environment for fiber terminations, ensuring minimal signal loss, and physical damage.

[0076] Input Cable – An input cable typically contains a large number of fibers to support multiple downstream connections in FTTH, FTTx, and broadband networks. The input cable in optical fiber networks connects the central office (or headend) to distribution points. It carries aggregated data signals over long distances before being split and routed through distribution cables to individual end-users. The input cable is one of a feeder cable or a distribution cable.

[0077] Intermittently Bonded Ribbon - Intermittently Bonded Ribbon (IBR) consists of multiple optical fibers, typically groups of 12, bonded intermittently (at intervals) along their length with a matrix material in a staggered bonding pattern such that pitch at the bonded region is in the range of 150 to 250 micrometers. Due to their intermittent bonding and flexible design, IBRs offer much greater fiber-packing density in the same physical diameter compared to traditional flat ribbon or loose-tube cables. This makes them ideal for high-density installations where duct or tray space is limited.

[0078] IBR bundle refers to a grouping of intermittently bonded ribbons (IBR).

[0079] IBR bundle segment: IBR bundle segment comprises at least one IBR.

[0080] Pitch at bonded region: The pitch is a distance between the center of one fiber and the center of the adjacent fiber at the bonded region. In the IBR cable the pitch at the bonded region is in the range of 150 to 250 micrometers. This range of pitch in IBR cable ensures precise fiber alignment, which is essential for low-loss mass fusion splicing. The pitch in the range of 150–250^micrometers ensures proper fiber alignment, low splice loss, and compatibility with fusion splicing tools. Below 150^µm, fibers forming part of the IBR cable risk microbending and damage; above 250^µm, alignment and handling issues arise due to excessive spacing.

[0081] Staggered Bonding Pattern - In staggered bonding pattern, instead of being continuously bonded together, the optical fibers are joined at specific, offset points along their length. This creates an IBR cable that is less rigid than a traditional, continuously bonded ribbon cable. The intermittent, staggered points act as hinges and allow IBR cable to bend and flex more easily. The staggered bonding improves the flexibility of an optical forming part of the IBR cable while allowing for mass splicing, where multiple fibers are spliced at once. This dual advantage allows for efficient cable routing and management in tight spaces without damaging the fibers or causing signal loss.

[0082] Breakout assembly: A breakout assembly is used for splitting an IBR bundle, the breakout assembly splits the bundle into multiple IBR bundle segments while maintaining the intermittent bonding. For example, an IBR bundle of 144 fibers at an input of the breakout assembly is divided into 12 IBR bundle segments of 12 fibers. The breakout assembly includes a guided separation channel configured to receive and internally route the IBR bundle; and a transition fixture configured to segment the IBR bundles (having >=24 fibers and <=10800 fibers) into a plurality of IBR bundle segments without disrupting the bonded pitch structure.

[0083] Protective cassette modules: The protective cassette module includes an input port where it receives the IBR bundle segment. It has internal channels and space for routing excess fiber, as well as one or more dedicated splice sleeves. The module also contains multiple output adapters, pigtails, and splice holder(s).

[0084] Splicing: Splicing (e.g., mass fusion splicing) is performed to connect the incoming fibers of the IBR bundle segment with the bare ends of the pigtails. Once spliced, the connectors on the pigtails are secured to the adapters of the cassette, which then provides the optical output.

[0085] Splice Sleeve - A splice sleeve is a protective sleeve used to encase and safeguard a fiber optic splice.

[0086] Splice holder - Splice holder is used for holding and aligning optical fibers in the correct position before and during the splicing process. The splice holder is present in a splice region of the protective cassette module allowing for a more efficient and accurate splicing process. Splice holder securely holds the fibers in a precise, fanned-out configuration. This prevents the fibers from shifting, which significantly reduces the chance of alignment errors and ensures a high-quality, reliable connection.

[0087] Bend Radius - Bend radius is the minimum radius a fiber can be bent without risking damage or transmission loss (macro-bend loss). Exceeding this limit can cause signal attenuation, fiber breakage, or long-term reliability issues.

[0088] Strain relief mechanism – Strain relief mechanism is used to protect the optical fiber from mechanical stress, such as pulling, bending, twisting, or vibration, which could otherwise damage the fiber or degrade its performance.

[0089] Furcation tube: Furcation tube is a protective sleeve or tubing used to encase and protect individual optical fibers, especially after the outer cable jacket and buffer tube have been stripped away.

[0090] Curved Path / Guide – The protective cassette module has curved paths / guides defined between the sidewalls along with retention fingers to route the optical fibers of the IBR bundle segments within the cassette. For better control on losses, the bend radius of the optical fibers is maintained above 30 millimeters while routing the optical fiber within the protective cassette module. This ensures handling of the flexible IBR bundle segments carefully to prevent twisting, kinking, or excessive bending stress during installation and operation.

[0091] Retention fingers are flexible or rigid protrusions inside the fiber enclosure cassette that hold and secure optical fibers or IBR bundle segments in place.

[0092] Routing channel within the protective cassette module is a groove or passage located between the sidewalls and the retention fingers within the fiber enclosure cassette.

[0093] The present invention is intended for distribution of optical fibers forming part of one or more input cables. Thus, before going into elaborating the construction of the fiber enclosure (100) as disclosed in Figure 1 (explained below), construction of the input cable (202) as disclosed in Figure 2. Now referring to Figure 2, there is demonstrated an input cable (202) of the one or more input cables (202). Each input cable (202) comprises at least one intermittently bonded ribbon (IBR) bundle (2041, 2042,…204i, …204n) housed in a protective jacket (212). It can be furthermore seen that each IBR bundle (204) comprises one or more IBR bundle segments (2061, 2062, …206i, …206n). Each IBR bundle segment (206) comprises at least one IBR (208). It may however be noted that each IBR bundle (204) comprises the plurality of IBRs (208). Now referring to Figure 3, the IBR (208) comprises 12 optical fibers (2101, 2102, … 210i, … 210n) where the adjacent optical fibers are bonded intermittently with a matrix material in a staggered bonding pattern such that pitch at a bonded region (214a) is in the range of 150 to 250 micrometers. The plurality of optical fibers (2101, 2102, … 210i, … 210n) may comprise an unbonded region (214b). It may however be noted that the IBR (208) can comprise more than 12 optical fibers. In yet another option, the IBR (208) comprises 4 optical fibers where the adjacent optical fibers are bonded intermittently with a matrix material in a staggered bonding pattern such that pitch at a bonded region (214a) is in the range of 150 to 250 micrometers. In another option, the IBR (208) comprises 8 optical fibers where the adjacent optical fibers are bondedintermittently with a matrix material in a staggered bonding pattern such that pitch at a bonded region (214a) is in the range of 150 to 250 micrometers. Hence, an IBR (208) comprises plurality of optical fibers (2101, 2102, … 210i, … 210n), where the adjacent optical fibers are bonded intermittently with a matrix material in a staggered bonding pattern such that pitch at a bonded region (214a) is in the range of 150 to 250 micrometers. In an embodiment of the present invention, an IBR (208i) may comprise plurality of optical fibers (2101, 2102, … 210i, … 210n), where the adjacent optical fibers are arranged in parallel and bonded intermittently with a matrix material in a staggered bonding pattern such that pitch at a bonded region (214a) is in the range of 150 to 250 micrometers.

[0094] FIGURE.3 illustrates an intermittently bonded ribbon (208) including a plurality optical fibres (210) secured or embedded substantially parallel to one another by matrix material. In addition, a plurality of IBRs (208)are enclosed inside the input cable (200) that require high fibre counts within less installation space. The IBR (208) is mechanically robust. In addition, the IBR (208) is capable of handling and manufacturing operations due to the strong mechanical strength. In addition, the IBR (208) is flexible. The flexibility of the IBR (208) allows the IBR (208) to roll easily.

[0095] Now referring to Figure 1, there is illustrated a view of a fiber enclosure (100) for distribution of optical fibers forming part of a least one input cable (202) as shown in Figures 1 and 2. The fiber enclosure (100) comprises one or more breakout assemblies (1021, 1022, … 102i, … 102n). Each breakout assembly (102) is configured to divide an IBR bundle (204) into a plurality of IBR bundle segments (2061, 2062, …206i, …206n) while preserving intermittent bonding within each IBR (208) forming part of the IBR bundle segment (206). The fiber enclosure (100) further comprises one or more protective cassette modules (1041, 1042, … 104i, … 104n). Each protective cassette module (1041, 1042, … 104i, … 104n) is a self-contained unit configured to be mounted and demounted within the fiber enclosure (100) using a frame (504). The fiber enclosure (100) further comprises at least one splitter cassette (1061, 1062, … 106i, … 106n) configured to receive an input from the protective cassette module (104) and is configured to divide a single fiber input into multiple outputs.

[0096] Now referring to Figure 4, there is shown a detailed sectional view of a breakout assembly (102). The breakout assembly (102) comprises a housing (402) having a first opening (404) sized to receive an IBR bundle (204) having fiber count between 24 and 10800 fibers, preferably between 24 and 288 fibers, a guided separation channel (408), and transition fixture (410) with a plurality of through holes (406i) configured to divide the IBR bundle (204) into a plurality of IBR bundle segments (2061, 2062, …206i, …206n) without disrupting the pitch atthe bonded region of the IBRs,. Each of the through holes (406) being sized to output an IBR bundle segment (206) having one of 12 optical fibers, 16 optical fibers, or 24 optical fibers. In an embodiment of the present invention, the guided separation channel (408) is positioned between the first opening (404) and the transition fixture (410).

[0097] In an embodiment of the invention, the guided separation channel (408) of the breakout assembly (102) is configured to receive and internally route the IBR bundle (204); and the transition fixture (410) configured to divide the IBR bundle (204) into the plurality of IBR bundle segments (2061, 2062, …206i, …206n) without disrupting the pitch at the bonded region of the IBR (208i) forming part of the IBR bundle segment (206). In an embodiment of the invention, the housing (402) of the breakout assembly (102) may further comprise an integral strain relief mechanism configured to secure the IBR bundle (204) and furcation tubes for protecting the IBR bundle segments (2061, 2062, …206i, …206n).

[0098] In an embodiment of the invention, to provide strain relief mechanism, a heat shrink tube (HST) (not shown) may be used at the first opening (404) of the breakout assembly (102) where the IBR bundle (204) enters. It provides strain relief by absorbing mechanical stress and preventing the IBR bundle (204) from transferring the mechanical stress directly to the delicate fiber cores, which could otherwise cause bending, micro-bending losses, or breakage. The strain relief mechanism also offers securement by tightly holding the IBR bundle (204) in place as it enters the breakout assembly (102), preventing movement or slippage over time. Upon heating, the heat shrink tube shrinks around the IBR bundle (204), an internal adhesive (of the heat shrink tube) bonds to the surface of the IBR bundle (204) that ensures a firm and sealed fit.

[0099] The furcation tubes (not shown) are used at the plurality of through holes (406) of the breakout assembly (102) to protect the IBR bundle segments. The number of furcation tubes is equal to the number of through holes (406) of the breakout assembly (102) such that each furcation tube houses an IBR bundle segment (206). So, if there are 12 through holes in the breakout assembly to output 12 IBR bundle segments then there will be 12 furcation tubes for enclosing each IBR bundle segment.

[0100] In different embodiments, the one or more breakout assemblies (102i) may afford the advantage of portability to different closures / applications due to the fiber breakout ruggedness. In some aspects, the housing may be cylindrical housing or a rectangular housing or conical housing or the like.

[0101] Now referring to Figure 5 and Figure 6, there is illustrated an exploded view of the protective cassette module (104) and a top view of the protective cassette module (104) constructed in accordance with an embodiment of the invention. The protective cassette module(104) comprises at least one input port (3021, 3022, … 302i, … 302n) to receive one or more of the IBR bundle segments (2061, 2062, …206i, …206n); and a plurality of output adapters (3041, 3042, …304i, …304n), the plurality of output adapters (3041, 3042, …304i, …304n) being aligned for mating with downstream optical connections. The protective cassette module (104) further comprises at least one splice sleeve (306). While in Figure 5 and in Figure 6 the protective cassette module (104) is shown to comprise one splice sleeve (306), it may be noted that the protective cassette module (104) may comprise a plurality of splice sleeves (306). Each splice sleeve (306) receives at least one IBR bundle segment (2061, 2062, …206i, …206n) from at least one input port (3021, 3022, … 302i, … 302n). The splice sleeve (306) stores mass fusion splicings of the at least one IBR bundle segment (2061, 2062, …206i, …206n) to a plurality of pig tails (3201, 3202, … 320i, … 320n). The plurality of pig tails (3201, 3202, … 320i, … 320n) are connected to a corresponding port (332) of the plurality of output adapters (3041, 3042, …304i, …304n). In an embodiment of the present invention, the splice sleeve is configured to store or protect mass fusion splicing of 4N fibers, where N is an integer between 1 and 10

[0102] In an embodiment of the present invention, each input port (302) of the protective cassette module (104) is sized to receive one or more IBR bundle segments (2061, 2062, …206i, …206n) each IBR bundle segment (206) having one of 12 optical fibers, 16 optical fibers, or 24 optical fibers. By way of another non-limiting example, each splice sleeve (306) mass fusion splices 4N fibers, where N is an integer between 1 and 10. By way of another non-limiting example, the OD of the input entry port can be in the range of 3 mm to 5 mm. OD stands for Outer Diameter. It refers to the external diameter of the IBR bundle segment that the port is designed to accommodate.

[0103] The protective cassette module (104) furthermore comprises a base unit (308) and a removable cover unit (310). The removable cover unit (310) may be attached to the base unit (308) via a locking mechanism (312) chosen from at least one of a snap fit mechanism or a hinged mechanism. In an embodiment of the invention, the protective cassette module (104) comprises at least one splice holder (324) projecting perpendicularly from the base unit (308) towards the removable cover unit (310). The at least one splice holder (324) is adapted to securely hold the splice sleeve (306). It may be noted that a number of splice holders (324) provided in the protective cassette module (104) may correspond to a number of splice sleeves (306). The splice holder (324) allows for a more efficient and accurate splicing process. The splice holder (324) securely holds the fibers in a precise, fanned-out configuration. This prevents the fibers from shifting, which significantly reduces the chance of alignment errors and ensures a high-quality, reliable connection.

[0104] In an embodiment of the invention, the base unit (308) may be adapted to store excess length of the IBR bundle segments (206) and / or optical fibers. Thus, in one embodiment of the invention, the base unit (308) may comprise one or more retention fingers (3261, 3262) to hold and secure optical fibers or IBR bundle segments in place. In an embodiment of the invention, the excess length of the IBR bundle segments (206) and / or optical fibers follows a curved routing channel / path (328) defined between the sidewalls along with the one or more retention fingers (3261, 3262). This allows for better control of the bend radius of the optical fibers and hence, on losses. By way of a non-limiting example, the bend radius of the optical fibers is maintained above 30 millimeters while routing the optical fiber within the protective cassette module. This ensures handling of the flexible IBR bundle segments carefully to prevent twisting, kinking, or excessive bending stress during installation and operation.

[0105] In an embodiment of the invention, the plurality of output adapters (3041, 3042, …304i, …304n) are formed as a single piece integrated output adapter (322). By way of a non- limiting example, in such a case, the single piece integrated output adapter (322) may comprise 12 to 24 output adapters (3041, 3042, …304i, …304n). In an embodiment of the present invention, the output adapters (3041, 3042, …304i, …304n) may comprise 12F LC adapters or the like.

[0106] The protective cassette module (104) furthermore comprises a first sidewall (314a) and a second side wall (314b) projecting perpendicularly from the base unit (308). In a non- limiting embodiment of the invention the second side wall (314b) may be disposed so as to be opposite to the first side wall (314a). As can be particularly seen from Figure 6, the first side wall (314a) comprises a first protruded region (316a), a second protruded region (316b) and a first lever portion (318a) while the second side wall (314b) comprises at least a third protruded region (316c). The second side wall (314b) may additionally comprise a fourth protruded region (316d) and a second lever portion (318b).

[0107] By way of a non-limiting example, the first protruded region (316a) and the second protruded region (316b) are spaced along a height direction of the protective cassette module (104). By way of a non-limiting example, the second protruded region (316b) and the first lever portion (318a) are substantially co-located. Similarly, by way of a non-limiting example, the third protruded region (316c) and the fourth protruded region (316d) are spaced along a height direction of the protective cassette module (104). By way of a non-limiting example, the fourth protruded region (316d) and the second lever portion (318b) are substantially co-located.

[0108] The first protruded region (316a), the second protruded region (316b), the first lever portion (318a), the third protruded region (316c) and optionally the fourth protruded region (316d) and the second lever portion (318b) play a crucial role in forming a portable bulkhead unit(502), whose construction is shown in Figures 7 to 11. Instead of mounting the protective cassette modules (1041, 1042, … 104i, … 104n) individually within the fiber enclosure (100), it is preferable to form the portable bulkhead unit (502) that comprises plurality of protective cassette modules (1041, 1042, … 104i, … 104n) and then to mount the portable bulkhead unit (502) within the fiber enclosure (100). In fact, Figure 1 shows plurality of portable bulkhead unit (502) being mounted within the fiber enclosure (100) with each of the portable bulkhead unit (502) comprising plurality of protective cassette modules (1041, 1042, … 104i, … 104n).

[0109] Now referring to Figure 7, there is illustrated a first perspective view of the portable bulkhead unit (502) constructed in accordance with an embodiment of the invention; referring to Figure 8, there is illustrated a second perspective view of the portable bulkhead unit (502) constructed in accordance with an embodiment of the invention; referring to Figure 9, there is illustrated a first exploded view of the portable bulkhead unit (502) constructed in accordance with an embodiment of the invention; and referring to Figure 10, there is illustrated a first perspective view of the portable bulkhead unit (502) constructed in accordance with an embodiment of the invention. It can be seen from the aforesaid figures that the portable bulkhead unit (502) comprises a plurality of protective cassette modules (1041, 1042, … 104i, … 104n) vertically stacked and held between a frame (504) and a removable locking piece (506). In an embodiment of the invention, the frame (504) and the removable locking piece (506) are separate elements and are coupled to the plurality of protective cassette modules (1041, 1042, … 104i, … 104n). It can be seen that the frame (504) comprises a plurality of slots (5081, 5082, …508i, …508n) and a plurality of openings (5101, 5102, …510i, …510n) and the removable locking piece (506) comprises a plurality of apertures (5121, 5122, …512i, …512n).

[0110] Each of the plurality of slots (5081, 5082, …508i, …508n) is adapted to receive the first protruded region (316a) provided on adjacently stacked protective cassette modules (104). Each of the plurality of openings (5101, 5102, …510i, …510n) is adapted to receive the second protruded region (316b) and the first lever portion (318a) provided on adjacently stacked protective cassette modules (104). It may be noted here that the lever portion (318a) is configured to be pressed inward during coupling to the frame (504) and returns to an original position upon full engagement with the frame (504). Thus, the plurality of protective cassette modules (1041, 1042, … 104i, … 104n) are held within the frame (504). To ensure that one or more of the plurality of protective cassette modules (1041, 1042, … 104i, … 104n) do not inadvertently fall out of the frame (504), the removable locking piece (506) is coupled to the plurality of protective cassette modules (1041, 1042, … 104i, … 104n). This is done by locating the removable locking piece (506) with respect to the plurality of protective cassette modules (1041, 1042, … 104i, … 104n)in such a way that each of the plurality of apertures (5121, 5122, …512i, …512n) receive the third protruded region (316c) provided on adjacently stacked protective cassette modules (104).

[0111] It may be noted that while in Figures 7 to 10, the portable bulkhead unit (502) is shown to comprise about 6 protective cassette modules stacked vertically, it may be noted that the portable bulkhead unit (502) may comprise lesser (less than 6) or greater (greater than 6) number of protective cassette modules (1041, 1042, … 104i, … 104n). To illustrate the above, reference is drawn to Figure 11 which shows the portable bulkhead unit (502) to be composed of 2 protective cassette modules (1041, 1042) stacked vertically. It may be noted that all other construction aspects of the portable bulkhead unit (502) shown in Figure 11 is substantially similar to the portable bulkhead unit (502) shown in Figures 7 to 10. Also, referring back to Figure 1, it may be noted that the fiber enclosure (100) can comprise two or more portable bulkhead units (502), wherein the two or more portable bulkhead units (502) comprise different numbers of protective cassette modules (1041, 1042, … 104i, … 104n).

[0112] In an embodiment of the present invention, a method for forming the portable bulkhead unit (502) comprises: providing a plurality of protective cassette modules (1041, 1042, … 104i, … 104n), wherein each of the protective cassette modules (104) comprises the base unit (308), the removable cover unit (310), the first sidewall (314a) and the second side wall (314b) projecting perpendicularly from the base unit (308); at least one input port (3021, 3022, … 302i, … 302n) to receive one or more of the IBR bundle segments (2061, 2062, …206i, …206n); plurality of output adapters (3041, 3042, …304i, …304n), the plurality of output adapters (3041, 3042, …304i, …304n) being aligned for mating with downstream optical connections. As stated above, the first side wall (314a) comprises the first protruded region (316a), the second protruded region (316b) and the first lever portion (318a); and the second side wall (314b) comprises at least the third protruded region (316c). The method further comprises providing the frame (504) and the removable locking piece (506). The method further comprises attaching the plurality of protective cassette modules (1041, 1042, … 104i, … 104n) between the frame (504) and the removable locking piece (506) to form the portable bulkhead unit (502). Each of the plurality of protective cassette modules (1041, 1042, … 104i, … 104n) is slidably inserted into the frame (504) and thereafter, the removable locking piece (506) is attached to the plurality of protective cassette modules (1041, 1042, … 104i, … 104n).

[0113] In particular, each of the plurality of slots (5081, 5082, …508i, …508n) being adapted to receive the first protruded region (316a) provided on adjacently stacked protective cassette modules (104) and each of the plurality of openings (5101, 5102, …510i, …510n) being adapted to receive the second protruded region (316b) and the first lever portion (318a) providedon adjacently stacked protective cassette modules (104); and each of the plurality of apertures (5121, 5122, …512i, …512n) being adapted to receive the third protruded region (316c) provided on adjacently stacked protective cassette modules (104).

[0114] Now coming to the aspect of mounting the bulkhead unit (502) within the fiber enclosure, the bulkhead unit (502) comprises a frame (504), a removable locking piece (506), and a plurality of protective cassette modules (1041, 1042, … 104i, … 104n) that are vertically stacked and mounted between the frame (504) and the removable locking piece (506). The frame (504) of the bulkhead unit (502) is provided with one or more anchor points (514) at the bottom of the frame (504) configured to receive fastening means (e.g., a fastener, a screw, a bolt, or a nail) for removably mounting the bulkhead unit (502) within the fiber enclosure (100).

[0115] Further for removing a protective cassette module (104) or a stack of protective cassette modules (1041, 1042, … 104i, … 104n) from the frame (504). First, the removable locking piece (506) is removed by disengaging it in an upward direction. Subsequently, the lever portion (318a) of the protective cassette module (104) or the stack (1041, 1042, … 104i, … 104n), which is engaged within the openings (510) of the frame (504), is manually pressed. Concurrently, the protective cassette module (104) or the stack (1041, 1042, ...104i, ...104n) is pulled upward. These sets of actions allow the removal of the protective cassette module (104) or the stack (1041, 1042, ...104i, ...104n) from the removable mountable frame.

[0116] In an alternative embodiment of the invention, the fiber enclosure (100) includes one or more splitter cassettes (1061, 1062, … 106i, … 106n) to receive an output from the single piece integrated output adapter (322) (which has at least 12 output adapters as output) associated with the protective cassette modules (1041, 1042, … 104i, … 104n). The splitter cassette (1061, 1062, … 106i, … 106n) is designed to house and manage optical splitters (not shown). The optical splitters are used in fiber optic networks to divide a single fiber input into multiple outputs, which is essential for distributing optical signals to multiple locations. The one or more splitter cassette can be, for example, but not limited to 1 / 8 splitter, 1 / 16 splitter, and 1 / 32 splitter. The 1 / 8 splitter divides one input fiber into eight output fibers. This is commonly used in scenarios where the signal input needs to be distributed to eight different locations or devices. The 1 / 16 splitter divides one input fiber into sixteen output fibers.1 / 32 splitter divides one input fiber into thirty-two output fibers. The 1 / 32 splitter is used in large-scale deployments where a single input needs to be distributed to many endpoints.

[0117] In an embodiment of present invention, a method for terminating one or more input cables (2021, 2022, …202i, …. 202n) to the fiber enclosure (100), the method comprises providing, as an input to the fiber enclosure (100), the one or more input cables (2021, 2022,…202i, …. 202n). The method further comprises receiving one or more IBR bundles (2041, 2042,…204i, …204n) at one or more breakout assemblies (1021, 1022, … 102i, … 102n). As mentioned above, each breakout assembly (102) divides an IBR bundle (204) into a plurality of IBR bundle segments (2061, 2062, …206i, …206n) while preserving intermittent bonding within each IBR (208) forming part of the IBR bundle segment (206). The method further comprises providing at least one of the plurality of IBR bundle segments (206) to an input port (302) forming part of a protective cassette module (104). The method furthermore comprises providing a plurality of output adapters (3041, 3042, …304i, …304n), the plurality of output adapters (3041, 3042, …304i, …304n) being aligned for mating with downstream optical connections. In a further aspect of the invention, the method of terminating further comprises performing a mass fusion splicing so as to connect each individual optical fiber of the at least one IBR bundle segment (206) to a corresponding pigtail (3201, 3202, … 320i, … 320n) of the protective cassette module (104). In an embodiment of the invention, each of the corresponding pigtails (3201, 3202, … 320i, … 320n) of the protective cassette module (104) may be coupled to a corresponding port (332) of the plurality of output adapters (3041, 3042, …304i, …304n). Each pigtail is a short length of optical fiber that has a connector (330) installed on one end, while the other end is left unterminated (bare fiber). In an exemplary embodiment, the connector (330) at the one end of the pigtail may comprise an LC connector or the like.

[0118] An advantage of the invention is that the fiber enclosure enables organized, scalable distribution of high-count fiber cables through structured breakout and cassette modules. This organization reduces the potential for cable congestion and confusion during installation or maintenance. The structured layout ensures that each fiber route is clearly defined, improving manageability and reducing the risk of accidental disconnections or damage. Scalability is achieved by allowing additional modules or fibers to be added without overhauling the existing system. This is particularly important in environments where network capacity needs to grow rapidly, such as data centers or metro fiber networks. The modular design promotes clean routing and future-proof infrastructure planning, allowing seamless expansion without significant disruption to existing services. Ultimately, the structured and scalable nature of the enclosure supports long-term operational efficiency and simplifies both initial setup and future modifications.

[0119] The invention is specifically designed for Intermittently Bonded Ribbon (IBR) fibers, allowing high-density fiber management while preserving bonding integrity. IBR fibers are engineered to combine the benefits of both individual and ribbon fibers, offering flexibility in splicing and routing while maintaining high packing density. This invention accommodates theunique structure of IBR fibers, preventing damage to bonding points during handling, routing, or splicing. As high-density networks become increasingly necessary for modern bandwidth demands, preserving the integrity of bonded fibers is essential. The tailored design also enhances compatibility with mass fusion splicing techniques, improving installation efficiency. Furthermore, by specifically addressing the physical characteristics of IBR fibers, the invention mitigates issues such as delamination or breakage that can occur when generic enclosures are used. This compatibility ensures reliable performance in both current and future high-density optical environments.

[0120] The invention minimizes traditional splicing and cable handling challenges, especially in ribbonized fiber structures, by allowing segment-level breakout. Traditional splicing methods often require the full ribbon to be spliced or routed together, which can be cumbersome and risky if only a subset of fibers needs to be accessed. This invention enables technicians to selectively break out specific fiber segments (e.g., 12 or 24 fibers) without disturbing the entire ribbon, significantly improving handling efficiency and reducing potential errors. Segment-level breakout also supports more customized deployment scenarios, such as node-specific connections or patching in distributed architectures. It further reduces strain on the remaining fibers, thereby enhancing physical longevity and maintaining signal quality. By improving accessibility and reducing the risk associated with handling tightly packed ribbons, the invention streamlines installation and maintenance, ensuring quicker turnaround and better long-term reliability.

[0121] The invention supports fiber bundles from 24 to 10800 fibers, with segment outputs of 12, 16, or 24 fibers, suitable for current and future network needs. This flexibility allows network designers to choose configurations that match their specific bandwidth and capacity requirements. For smaller deployments, such as those in rural areas or small businesses, a 24-fiber bundle may suffice, while large enterprise campuses or urban FTTH rollouts may demand full 288-fiber capacity. Segmenting outputs into manageable groupings ensures that scalability does not come at the cost of manageability. Technicians can address individual sections without disrupting the entire bundle. This granularity is critical as networks evolve toward higher fiber counts to support 5G, data center interconnects, and dense passive optical networks (PONs). The design thus ensures that installations today remain compatible with the bandwidth demands of tomorrow, without requiring total infrastructure replacement.

[0122] The protective cassette modules are self-contained and stackable, enabling flexible installation and removal without disturbing the system. Each cassette is designed to function independently, with its own protective housing and routing features, which means that modules can be added, replaced, or removed without impacting adjacent units. This is especially useful indynamic network environments where capacity may need to change regularly or where maintenance needs to occur without causing service interruptions. The stackable design saves valuable rack or wall space, allowing high fiber density in compact installations. Furthermore, the self-contained nature of the modules reduces the risk of fiber tangling or damage during handling, as each module maintains internal organization. This design philosophy promotes modularity and service continuity, two critical factors for efficient operation in large-scale network infrastructures like central offices and data centers.

[0123] The snap-fit latching and lever-based design simplify module access and maintenance, reducing downtime and the need for special tools. Traditional fiber enclosures often require screwdrivers or other tools to open and access internal components, which increases service time and introduces risks such as overtightening or accidental damage. With the invention’s tool-less snap-fit and lever mechanisms, technicians can quickly and safely access internal components for inspection, maintenance, or upgrades. This design facilitates faster troubleshooting, especially in time-sensitive environments such as emergency restorations or during peak network loads. The intuitive mechanical interface also reduces the training required for field personnel, enabling faster ramp-up of new technicians. Additionally, the secure but easily releasable locking system maintains enclosure integrity while still allowing swift intervention, enhancing both operational uptime and safety.

[0124] The invention reduces production and installation costs by offering mass-fusion splicing compatibility, reusable modules, and a simplified enclosure design. Mass fusion splicing allows multiple fibers to be spliced simultaneously, drastically reducing labor time and improving consistency across connections. The ability to reuse modules means that installers can repurpose existing components for different projects, reducing material waste and inventory costs. Furthermore, the simplified enclosure reduces manufacturing complexity, making it cheaper to produce at scale. These savings extend throughout the product lifecycle—from factory assembly to field deployment and even during future network upgrades. In environments where cost-per- fiber is a critical metric, such as in competitive FTTH deployments, these efficiencies translate to significant overall savings. The reduced need for specialized tools and training further contributes to lower operational costs and faster time-to-market for service providers.

[0125] The protective cassette modules shield fibers during splicing and routing, minimizing breakage and micro-bending, especially for 250µm / 900µm fibers. These fiber types are especially susceptible to mechanical stress, which can cause signal degradation over time. By enclosing and guiding the fibers within protective housings, the invention ensures consistent bend radius and secure anchoring, thereby preserving optical performance. During splicing, thecassettes prevent unintended movement or tension that could compromise splice quality. Additionally, by housing the fibers in a controlled environment, the modules reduce the risk of contamination by dust, moisture, or other foreign particles. Over time, this protection extends the operational lifespan of the fibers, reducing the need for repairs and improving service quality. The overall design helps maintain a clean, stress-free fiber layout, which is essential for high- performance and long-haul optical networks.

[0126] The integrated output adapters and controlled routing reduce unnecessary on field splicing, leading to lower optical signal loss. Every connector or splice point in an optical network introduces potential signal attenuation, reflection, or contamination. By integrating adapters directly into the enclosure modules and carefully guiding fiber routing, the invention minimizes the number of required interconnects. This streamlined signal path maintains higher optical integrity, which is especially important for high-speed or long-distance transmissions where loss budgets are tight. Fewer connections also translate to faster installation and lower maintenance overhead, as there are fewer points that might require cleaning or replacement. The use of high- quality integrated components further ensures that optical alignment is preserved, which enhances signal fidelity and reduces bit error rates. This makes the invention ideal for applications where performance and uptime are critical, such as in core transport networks or cloud data centers.

[0127] The stackable modular cassettes allow easy scaling from small deployments to large centralized networks by simply adding modules. This design enables network operators to expand capacity incrementally without the need to redesign or replace existing infrastructure. A small business or remote site can begin with just one or two modules, then scale up as demand grows. For large-scale installations, dozens of cassettes can be stacked in a rack-mounted or wall- mounted format to support hundreds of fibers. The uniform mechanical interface between modules ensures that additions are plug-and-play, without disrupting the existing layout. This flexibility is particularly advantageous for service providers and enterprises that anticipate growth but must manage current budgets efficiently. The result is a cost-effective, future-proof system that adapts as network requirements evolve, without requiring significant downtime or re-cabling.

[0128] The use of pre-defined protrusions, apertures, and slots enables quick and secure assembling of a plurality of protective cassette modules without additional fasteners or adhesives. This design approach not only simplifies the mechanical assembly process but also improves structural reliability by minimizing the number of loose components. By aligning and locking the cassettes into position using built-in features, installers can quickly stack or reconfigure modules on-site with minimal effort. The absence of external fasteners eliminates the need for tools, further speeding up deployment. It also reduces the chances of mechanical failure due to missing or loosescrews. In high-vibration environments or locations where space is limited, this snap-fit assembly ensures stable, repeatable installations. Moreover, it streamlines manufacturing processes and packaging, contributing to lower costs and better consistency in quality across large production volumes.

[0129] The protective cassette modules can be standardized, which streamlines production and assembly, increasing throughput at manufacturing and installation levels. Standardization reduces variation and complexity in both design and supply chains. Manufacturers can produce a single module form factor in large quantities, achieving economies of scale and reducing part costs. In the field, installers benefit from familiarity with a consistent module layout, which reduces training time and potential errors during installation or servicing. Standardized modules also facilitate easier inventory management, as the same unit can be deployed across different projects or customer environments. For network planners, standardization enables repeatable deployment models, simplifying documentation and quality control. This consistency across the board—from production to operation—translates to better reliability, lower operational expenditures, and faster deployment times in competitive network markets.

[0130] The invention can be adapted for use with various downstream optical systems due to standardized output adapter interfaces. These interfaces allow seamless integration with a wide range of existing fiber equipment, such as patch panels, transceivers, optical splitters, and multiplexers. By using industry-standard connectors (e.g., LC, SC, MPO), the system avoids compatibility issues and supports rapid field deployment. This adaptability ensures the enclosure can be used across different use cases, whether in data centers, central offices, or FTTH environments. It also reduces the need for custom adapters or cables, simplifying both logistics and procurement. Network architects gain flexibility in designing systems that can evolve over time without being locked into proprietary technologies. This promotes long-term investment protection, operational agility, and improved overall network performance due to standardized connectivity practices.

[0131] The IBR bundles and modular breakouts reduce the need for excessive cable clamping and fixation, simplifying internal cable routing. Traditional fiber management often requires numerous clamps, ties, and fixtures to keep cables organized and within bend radius limits. This can create clutter, increase installation time, and put unnecessary strain on the fibers. The invention’s support for Intermittently Bonded Ribbon bundles, along with structured breakout points, allows for natural, strain-free routing of fiber segments. The reduced need for fixation hardware leads to cleaner installations and makes it easier to modify or reconfigure the layout in the future. This not only improves airflow and accessibility within the enclosure but also lowersthe risk of damage during maintenance. Ultimately, it enhances technician efficiency while maintaining high standards of optical performance and physical protection.

[0132] The guided separation channels and internal routing ensure clean paths and bend- radius control, aiding long-term reliability. One of the most common causes of fiber signal degradation is micro-bending and macro-bending, which occur when fibers are bent beyond their specified radius. This invention incorporates carefully engineered routing paths and separation guides that maintain optimal bend geometry throughout the enclosure. These features provide visual and mechanical guidance for technicians, reducing the likelihood of poor routing practices during installation or servicing. By preserving fiber geometry and minimizing stress points, the system extends the service life of the optical cables and ensures consistent signal quality. In environments where space is tight or fiber density is high, this structured guidance becomes essential to maintaining both performance and compliance with industry standards. The result is a robust and highly maintainable fiber network.

[0133] The splitter cassettes allow signal distribution within the same enclosure, reducing the need for external splitter boxes. By integrating optical splitters directly into the modular cassettes, the invention eliminates the need to route fibers to separate distribution points for signal splitting. This consolidation saves space, reduces material costs, and shortens installation time. It also improves overall system reliability by minimizing fiber runs and potential connection points. Technicians benefit from having all components—input, splitter, and output—within a single accessible unit, simplifying both initial setup and future troubleshooting. The integrated design also enables more compact installations, which is particularly beneficial in high-density environments like multi-dwelling units or edge data centers. Whether the application involves GPON, XGS-PON, or other PON technologies, the internal splitter capability supports efficient signal branching without external hardware.

[0134] The complete system forms a portable, pre-assembled bulkhead, ideal for rapid deployment in FTTH networks or data centers. Pre-assembly means the enclosure can be configured and tested off-site, then delivered ready for installation. This significantly reduces on- site labor, shortens installation timelines, and improves consistency in quality. The portability of the system allows it to be easily transported and installed in remote or space-constrained environments, such as outdoor cabinets, telecom shelters, or on utility poles. This is particularly advantageous for FTTH deployments where speed and consistency are critical. For data centers, the pre-assembled nature simplifies rack integration and minimizes disruption to live environments. In emergency scenarios or temporary setups, the ability to quickly deploy a functional, high-capacity fiber bulkhead ensures service continuity and network resilience.

[0135] The invention supports mass fusion splicing (e.g., 4N where N = 1–10), significantly reducing the time and skill required for fiber termination. Mass fusion splicing allows multiple fibers—typically in ribbons or groups of 4, 8, or 12—to be spliced in a single operation, greatly accelerating the splicing process compared to single-fiber methods. This is especially beneficial for large-scale rollouts where thousands of terminations are required. The system’s compatibility with these high-efficiency splicing techniques means that less experienced technicians can still achieve consistent, low-loss results. It also reduces the need for long training periods or reliance on highly specialized labor. The inclusion of splice holder(s), routing channels, and alignment features within the cassettes ensures that fibers are securely positioned during and after splicing. Overall, the invention dramatically improves deployment speed and reduces operational costs.

[0136] The invention is suitable for indoor, outdoor, aerial, or wall-mounted installations, increasing its utility across various FTTH topologies. Versatility in installation environments is critical in modern fiber networks, which often span multiple terrains and building types. The enclosure is designed with robust materials and weather-resistant features that make it suitable for outdoor or aerial use. At the same time, its compact form factor and modularity allow for clean wall-mounted or rack-mounted installations indoors. Whether in a residential basement, a telecom cabinet, or atop a utility pole, the system maintains the same performance and reliability. This adaptability reduces the need for different enclosure types across deployment scenarios, simplifying inventory and logistics. It also allows service providers to deploy a consistent fiber management solution across varied geographical and architectural conditions, streamlining both planning and maintenance.

[0137] The pre-configured modules and simplified routing accelerate field installation, reducing labor costs and increasing deployment speed. Because the modules come with a pre- installed routing path, splice holder(s), and adapter ports, technicians spend less time preparing the system in the field. Installation becomes more of a plug-and-play process, where fibers are simply routed through predefined channels and snapped into place. This reduces both the skill threshold and time required, enabling faster network rollouts with fewer errors. Simplified routing also helps maintain bend radius and optical integrity, preventing costly service disruptions. In large-scale fiber-to-the-home (FTTH) or metropolitan network projects, this speed and efficiency can translate into significant cost savings and faster return on investment. For contractors and service providers, the ability to install more connections per day improves workforce productivity and reduces project timelines.

[0138] The portable bulkhead unit offers a vertically stacked architecture, allowing multiple protective cassette modules to be efficiently housed within a minimal footprint. This vertical stacking optimizes space usage, making the unit highly suitable for space-constrained installations such as wall-mounted FTTH cabinets, aerial closures, or inside crowded data center racks. The use of a frame and removable locking piece to secure the modules eliminates the need for external housing, adhesives, or complex fixtures. The plurality of protective cassette modules can be mounted and removed from the portable bulkhead unit without any tool. Also, an individual protective cassette module can be removed from the portable bulkhead unit without any tool. This structural design enables quick assembly and disassembly, which is particularly advantageous during rapid deployments, field upgrades, or emergency network restoration. Additionally, the portability of the entire bulkhead unit simplifies transportation, staging, and handling, as it can be pre-assembled off-site and moved to the installation site as a single, ready-to-use component. This configuration not only saves time and labor during setup but also improves installation consistency and reduces error margins in complex fiber installations.

[0139] The portable bulkhead unit can be made purely by mechanical interlocking of protective cassette modules through a precision alignment system involving protrusions, slots, openings, and apertures. This design eliminates the need for screws, adhesives, or external clamping mechanisms by using structural geometry to hold the protective cassette modules securely in place. Each protruded region—strategically placed on the sidewalls of the protective cassette module —interfaces with corresponding slots and openings in the frame and removable locking piece, creating a highly stable and vibration-resistant structure. This not only ensures mechanical reliability in fixed or mobile environments (such as aerial deployments or field transport) but also accelerates the assembly process. The inclusion of lever portions further supports tool-less access and maintenance, allowing technicians to unlock or reposition individual modules without disassembling the entire stack. This level of modular integrity combined with intuitive physical interlocks contributes to faster service operations, lower training requirements for technicians, and reduced likelihood of fiber disturbance during module removal or replacement

[0140] The systematic method for constructing the portable bulkhead unit, ensures an ease of modular integration from pre-fabricated cassette components. By breaking down the process into defined steps—such as providing pre-molded cassette modules, inserting IBR bundle segments, and aligning output adapters—the invention supports repeatable, high-efficiency production or field assembly. This structured methodology lends itself well to both factory pre- assembly and on-site configuration, enabling operators to customize the fiber breakout pattern asper deployment needs without redesigning the enclosure. The ability to align the output adapters for direct downstream connectivity ensures that field splicing or patching is minimized. The perpendicular orientation of sidewalls with protruded regions supports a snug vertical fit, locking the modules between the frame and the removable locking piece with high precision. This eliminates guesswork, reduces assembly errors, and ensures that the final unit maintains mechanical integrity and optical performance. The result is faster time-to-service and significant labor cost savings during deployment. Also, The portable bulkhead unit as well as the protective cassette module can be placed inside any other type of enclosure.

[0141] It will be apparent to those skilled in the art that other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention. While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above-described embodiment, method, and examples, but by all embodiments and methods within the scope of the invention. It is intended that the specification and examples be considered as exemplary, with the true scope of the invention being indicated by the claims.

[0142] Conditional language used herein, such as, among others, “can”, “may”, “might”, “may”, “e.g.”, and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain alternatives include, while other alternatives do not include, certain features, elements and / or steps. Thus, such conditional language is not generally intended to imply that features, elements and / or steps are in any way required for one or more alternatives or that one or more alternatives necessarily include logic for deciding, with or without other input or prompting, whether these features, elements and / or steps are included or are to be performed in any particular alternative. The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list.

[0143] Disjunctive language such as the phrase “at least one of X, Y, Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and / orZ). Thus, such disjunctive language is not generally intended to, and should not, imply that certain alternatives require at least one of X, at least one of Y, or at least one of Z to each be present.

[0144] While the detailed description has shown, described, and pointed out novel features as applied to various alternatives, it can be understood that various omissions, substitutions, and changes in the form and details of the devices or algorithms illustrated can be made without departing from the scope of the disclosure. As can be recognized, certain alternatives described herein can be embodied within a form that does not provide all of the features and benefits set forth herein, as some features can be used or practiced separately from others.

Claims

CLAIMS We Claim:

1. A fiber enclosure (100) adapted to receive and manage one or more input cables (2021, 2022, …202i, …. 202n), wherein each input cable (202) comprising at least one intermittently bonded ribbon (IBR) bundle (2041, 2042,…204i, …204n), wherein each IBR (208) comprising plurality of optical fibers (2101, 2102, … 210i, … 210n) such that adjacent optical fibers are bonded intermittently with a matrix material in a staggered bonding pattern, wherein a pitch at a bonded region (214a) at the adjacent optical fibers is in a range of 150 to 250 micrometers, the fiber enclosure (100) comprising: one or more breakout assemblies (1021, 1022, … 102i, … 102n), each breakout assembly (102) configured to divide an IBR bundle (204) into a plurality of IBR bundle segments (2061, 2062, …206i, …206n) while preserving intermittent bonding within each IBR (208) forming part of the IBR bundle segment (206); and one or more protective cassette modules (1041, 1042, … 104i, … 104n), wherein each protective cassette module (1041, 1042, … 104i, … 104n) being a self-contained unit mountable and demountable within the fiber enclosure (100) using a frame (504), each protective cassette module (1041, 1042, … 104i, … 104n) and the frame (504) being configured to be portable and mountable within different enclosure formats, including an aerial closure, a pedestal, or a cabinet housing, wherein each protective cassette module (104) comprising: at least one input port (3021, 3022, … 302i, … 302n) configured to receive one or more of the IBR bundle segments (2061, 2062, …206i, …206n) from one or more breakout assemblies (1021, 1022, … 102i, … 102n); and a plurality of output adapters (3041, 3042, …304i, …304n) aligned for mating with downstream optical connections; and an internal routing path (328) configured to route the received IBR bundle segments with a bend radius of at least 30 millimeters.

2. The fiber enclosure (100) as claimed in claim 1, wherein each breakout assembly (102) comprises a housing (402) having a first opening (404) sized and configured to receive an IBR bundle (204) having fiber count between 24 and 10800 fibers, and a plurality of through holes (406) sized and configured to output an IBR bundle segment (206) having 12 optical fibers, 16 optical fibers, or 24 optical fibers.

3. The fiber enclosure (100) as claimed in claim 1, wherein each breakout assembly (102) comprises: a guided separation channel (408) configured to receive and internally route the IBR bundle (204); and a transition fixture (410) configured to divide the IBR bundle (204) into the plurality of IBR bundle segments (2061, 2062, …206i, …206n) without disrupting the pitch at the bonded region (214a) of the IBR (208) forming part of the IBR bundle segment (206).

4. The fiber enclosure (100) as claimed in claim 1, further comprising at least one portable bulkhead unit (502), wherein a plurality of protective cassette modules (1041, 1042, … 104i, … 104n) are vertically stacked and secured between a frame (504) and a removable locking piece (506) to form the at least one portable bulkhead unit (502).

5. The fiber enclosure (100) as claimed in claim 4, wherein each protective cassette module (104) comprises at least one splice sleeve (306) configured to store mass fusion splices of at least one IBR bundle segment (206) to a plurality of pigtails (3201, 3202, … 320n), the pigtails being connected to corresponding ports (332) of the plurality of output adapters (3041, 3042, … 304n).

6. The fiber enclosure (100) as claimed in claim 5, wherein each input port (302) is configured to receive one or more IBR bundle segments (2061, 2062, …206i, …206n) having 12, 16, or 24 optical fibers, and each splice sleeve (306) is configured to store mass fusion splices of 4N fibers, where N is an integer from 1 to 10.

7. The fiber enclosure (100) as claimed in claim 4 to 6, wherein each protective cassette module (104) comprises: a base unit (308); a removable cover unit (310) coupled to the base unit via a locking mechanism (312), wherein the locking mechanism (312) is at least one of a snap fit mechanism or a hinged mechanism; a first sidewall (314a) having a first protruded region (316a), a second protruded region (316b), and a first lever portion (318a); and a second sidewall (314b) opposite the first sidewall, comprising at least a third protruded region (316c).

8. The fiber enclosure (100) as claimed in claim 7, wherein the frame (504) comprises a plurality of slots (5081, 5082, … 508n) configured to receive the first protruded region (316a), a plurality of openings (5101, 5102, … 510n) configured to receive the second protruded region (316b) and the first lever portion (318a), and the removable locking piece(506) comprises a plurality of apertures (5121, 5122, … 512n) configured to receive the third protruded region (316c).

9. The fiber enclosure of any one of claims 1, wherein the plurality of output adapters (3041, 3042, … 304n) are formed as a single piece integrated output adapter (322) comprising 12 to 24 output adapters.

10. The fiber enclosure of claim 9, further comprising at least one splitter cassette (1061, 1062, … 106n) configured to receive an input from the single piece integrated output adapter (322) and divide a single fiber input into multiple outputs.

11. A method for terminating one or more input cables (2021, 2022, …202i, ….202n) at a fiber enclosure (100), wherein each input cable (202) comprising at least one intermittently bonded ribbon (IBR) bundle (2041, 2042,…204i, …204n), wherein each IBR bundle (204) comprising at least one of IBR bundle segment (2061, 2062, …206i,…206n), wherein each of the IBR bundle segment (206) comprises at least one IBR (208), wherein each IBR (208) comprising plurality of optical fibers (2101, 2102, … 210i, … 210n) such that the adjacent optical fibers are bonded intermittently with a matrix material in a staggered bonding pattern, wherein a pitch at a bonded region (214a) of the adjacent optical fibers is between150 to 250 micrometers, the method comprising: providing, as an input to the fiber enclosure (100), the one or more input cables (2021, 2022, …202i, ….202n); receiving one or more IBR bundles (2041, 2042,…204i, …204n) at one or more breakout assemblies (1021, 1022, … 102i, … 102n), wherein at least one breakout assembly (102) is configured to divide the one or more IBR bundles (2041, 2042,…204i, …204n) into a plurality of IBR bundle segments (2061, 2062, …206i, …206n) while preserving intermittent bonding within each IBR (208) forming part of the IBR bundle segment (206); providing at least one of the plurality of IBR bundle segments (206) an input port (302) forming part of a protective cassette module (104); performing a mass fusion splicing to connect each individual optical fiber of the plurality of IBR bundle segments (206) to a corresponding pigtail (3201… 320n) of the protective cassette module (104).

12. A protective cassette module (104), comprising: a base unit (304);a removable cover unit (308); a first sidewall (314a), wherein the first side wall (314a) comprising a first protruded region (316a), a second protruded region (316b) and a first lever portion (318a); a second side wall (314b), wherein first sidewall (314a) and the second side wall (314b) projecting perpendicularly from the base unit (304), wherein the second side wall (314b) comprising at least a third protruded region (316c); at least one input port (3021, 3022, … 302i, … 302n) to receive one or more IBR bundle segments (2061, 2062, …206i, …206n); and a plurality of output adapters (3041, 3042, …304i, …304n), wherein the plurality of output adapters (3041, 3042, …304i, …304n) being aligned for mating with downstream optical connections, wherein; the first protruded region (316a), the second protruded region (316b), the first lever portion (318a) being adapted to be joined to a frame (504) and the third protruded region (316c) being adapted to be joined to a removable locking piece (506) to form a portable bulkhead unit (502).

13. The protective cassette module as claimed in claim 15, wherein the first lever portion (318a) is configured to be pressed inward during coupling to the frame (504) and returns to an original position upon full engagement with the frame (504).

14. A portable bulkhead unit (502) comprising: a plurality of protective cassette modules (1041, 1042, … 104i, … 104n) vertically stacked and held between a frame (504) and a removable locking piece (506).

15. The portable bulkhead unit (502) as claimed in claim 17, wherein the protective cassette module (104) comprising: a) a first sidewall (314a) having a first protruded region (316a), a second protruded region (316b) and a first lever portion (318a); b) a second side wall (314b) being opposite to the first side wall (314a), wherein the second side wall (314b) comprising at least a third protruded region (316c).

16. The portable bulkhead unit (502) as claimed in claim 17 and 18, wherein the frame (504) comprises a plurality of slots (5081, 5082, …508i, …508n) and a plurality of openings (5101, 5102, …510i, …510n) and the removable locking piece (506) comprises a plurality of apertures (5121, 5122, …512i, …512n), wherein each of the plurality of slots (5081, 5082, …508i, …508n) being adapted to receive the first protruded region (316a), wherein each of the plurality of openings (5101, 5102, …510i, …510n) being adapted to receive the secondprotruded region (316b) and the first lever portion (318a), wherein each of the plurality of apertures (5121, 5122, …512i, …512n) being adapted to receive the third protruded region (316c).

17. A method of forming a portable bulkhead unit (502), said method comprising: providing a plurality of protective cassette modules (1041, 1042, … 104i, … 104n), wherein each of the protective cassette modules (104) comprises: a base unit (304); a removable cover unit (308); a first sidewall (314a) and a second side wall (314b) projecting perpendicularly from the base unit (304); at least one input port (3021, 3022, … 302i, … 302n) to receive one or more of the IBR bundle segments (2061, 2062, …206i, …206n); and a plurality of output adapters (3041, 3042, …304i, …304n), wherein the plurality of output adapters (3041, 3042, …304i, …304n) being aligned for mating with downstream optical connections, wherein the first side wall (314a) comprising a first protruded region (316a), a second protruded region (316b) and a first lever portion (318a) and the second side wall (314b) comprising at least a third protruded region (316c); providing a frame (504) and a removable locking piece (506); vertically stacking the plurality of protective cassette modules (1041, 1042, … 104i, … 104n) and attaching the vertically stacked plurality of protective cassette modules (1041, 1042, … 104i, … 104n) between the frame (504) and the removable locking piece (506) to form the portable bulkhead unit (502).

18. The method as claimed in claim 20, wherein the frame (504) comprising a plurality of slots (5081, 5082, …508i, …508n) and a plurality of openings (5101, 5102, …510i, …510n); and the removable locking piece (506) comprising a plurality of apertures (5121, 5122, …512i, …512n), wherein each of the plurality of slots (5081, 5082, …508i, …508n) being adapted to receive the first protruded region (316a), wherein each of the plurality of openings (5101, 5102, …510i, …510n) being adapted to receive the second protruded region (316b) and the first lever portion (318a), wherein each of the plurality of apertures (5121, 5122, …512i, …512n) being adapted to receive the third protruded region (316c).

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