Injection bonded articles and methods of fabrication and use thereof

Abstract

Injection bonded articles comprised of a rigid core and secured together with an elastomeric material network which also forms seals and encapsulates at least a portion of the rigid core. The elastomeric material is selected to be compatible with the material comprising the rigid core to create a chemical and mechanical bond therebetween. Injection bonding and over-molding techniques are used to fabricate an electrodeionization apparatus spacer comprised of mated rigid segments secured by a unitary elastomeric material network that also forms internal and external seals that fluidly isolate one or more of inlet ports, resin cavities, and outlet ports as well as throughports. Injection bonding and over-molding techniques can also be used to fabricate other articles comprised of multiple segments.

1 .- 23 . (canceled) 
     
     
         24 . A filter cartridge comprising a filter element supported between mating segments and a unitary elastomeric material network within the mated rigid segments and forming a seal disposed around at least a portion of a periphery of the mating segments. 
     
     
         25 . The filter cartridge of  claim 24 , further comprising a sheath comprised of the unitary elastomeric material and encapsulating at least a portion of an outer periphery of the mating segments. 
     
     
         26 . A method of fabricating an electrodeionization apparatus spacer comprising:
 providing a first segment and a second segment, the first and second segments having complementary features that allow mating assembly of the first and second segments in a predetermined arrangement;   mating the first and second segments to form a rigid core comprising a channel traversing at least a portion of an interface between the first and second segments and a resin cavity in communication with an inlet port and an outlet port; and   injecting an elastomeric material into the channel to form an elastomeric network between the first and second segments.   
     
     
         27 . The method of  claim 26 , further comprising a step of encapsulating at least a portion of the mated first and second segments with the elastomeric material. 
     
     
         28 . The method of  claim 26 , further comprising a step of forming a seal at a periphery of the mated first and second segments with the elastomeric material. 
     
     
         29 . The method of  claim 26 , further comprising a step of forming a resin cavity seal around the resin cavity with the elastomeric material. 
     
     
         30 . The method of  claim 26 , further comprising a step of forming an inlet port seal around the inlet port with the elastomeric material. 
     
     
         31 . The method of  claim 26 , further comprising a step of forming an outlet port seal around the outlet port with the elastomeric material. 
     
     
         32 . The method of  claim 26 , further comprising a step of forming an internal inlet seal with the elastomeric material at the interface and around an inlet manifold that fluidly connects the inlet port to the resin cavity. 
     
     
         33 . The method of  claim 26 , further comprising a step of forming an internal outlet seal with the elastomeric material at the interface and around an outlet manifold that fluidly connects the resin cavity to the outlet port. 
     
     
         34 . The method of  claim 26 , further comprising a step of forming a through port seal with the elastomeric material around a through port defined in the mated first and second segments, the through port seal fluidly isolates the through port from the inlet port, the outlet port, and the resin cavity. 
     
     
         35 . The method of  claim 26 , further comprising a step of forming an internal seal with the elastomeric material at the interface, the internal seal fluidly isolates the inlet port from the outlet port. 
     
     
         36 . The method of  claim 26 , wherein the first and second segments and the elastomeric material are comprised of a thermoplastic polymer. 
     
     
         37 . A method of fabricating an electrodeionization apparatus spacer comprising:
 mating a first complementary rigid segment to a second complementary rigid segment to form a rigid core comprising a resin cavity in communication with an inlet port and an outlet port; and   binding the first and second complementary segments with an elastomeric material.   
     
     
         38 . The method of  claim 37 , further comprising a step of forming a seal with the elastomeric material on an outer surface of the mated first and second complementary segments. 
     
     
         39 . The method of  claim 38 , further comprising a step of forming an inlet port seal with the elastomeric material around the inlet port. 
     
     
         40 . The method of  claim 40 , further comprising a step of forming an outlet port seal with the elastomeric material around the outlet port. 
     
     
         41 . The method of  claim 40 , further comprising a step of encapsulating at least a portion of a surface of the mated first and second complementary segments with the elastomeric material. 
     
     
         42 . The method of  claim 41 , further comprising a step of forming an internal inlet seal with the elastomeric material at the interface and around an inlet manifold that fluidly connects the inlet port and the resin cavity. 
     
     
         43 . The method of  claim 42 , further comprising a step of forming an internal outlet seal with the elastomeric material at the interface and around an outlet manifold that fluidly connects the outlet port and the resin cavity. 
     
     
         44 . A method of assembling an electrodeionization apparatus comprising positioning a depleting compartment spacer into an electrodeionization apparatus assembly, wherein the depleting compartment spacer is comprised of a rigid core and an elastomeric material seal disposed within the rigid core. 
     
     
         45 . A method of purifying water comprising:
 introducing water to be purified into an electrodeionization apparatus comprising a concentrating compartment defined by a concentrating compartment spacer and a depleting compartment disposed adjacent the concentrating compartment and defined by a depleting compartment spacer comprising a rigid core and an elastomeric material network disposed within the rigid core; and   applying an electrical potential across the electrodeionization apparatus to promote migration of undesirable species in the water from the depleting compartment into the concentrating compartment.