Composite absorbent particles

Abstract

Composite particles and methods for making the same. An absorbent material is formed into a particle. An optional performance-enhancing active is coupled to the absorbent material before, during, or after the particle-forming process, homogeneously and / or in layers. Additionally, the composite absorbent particle may include a core material. Preferred methods for creating the absorbent particles include a pan agglomeration process, a high shear agglomeration process, a low shear agglomeration process, a high pressure agglomeration process, a low pressure agglomeration process, a rotary drum agglomeration process, a mix muller process, a roll press compaction process, a pin mixer process, a batch tumble blending mixer process, an extrusion process, and a fluid bed process.

Description

FIELD OF THE INVENTION The present invention relates to composite absorbent particles, and more particularly, this invention relates to a composite absorbent particle having improved clumping and odor-inhibiting properties. BACKGROUND OF THE INVENTION Clay has long been used as a liquid absorbent, and has found particular usefulness as an animal litter. Because of the growing number of domestic animals used as house pets, there is a need for litters so that animals may micturate, void or otherwise eliminate liquid or solid waste indoors in a controlled location. Many cat litters use clay as an absorbent. Typically, the clay is mined, dried, and crushed to the desired particle size. Some clay litters have the ability to clump upon wetting. For example, sodium bentonite is a water-swellable clay which, upon contact with moist animal waste, is able to agglomerate with other moistened sodium bentonite clay particles. The moist animal waste is contained by the agglomeration of the mo...

AI Technical Summary

Benefits of technology

The processing technology disclosed herein allows the “engineering” of the individual composite particles so that the characteristics of the final product can be predetermined. The composite particles are particularly useful as an animal litter. Favorable characteristics for a litter product such as odor control, active optimization, low density, low tracking, low dust, strong clumping, etc. can be optimized to give the specific performance required. Another aspect of the invention is the use of encapsulated actives, i.e., formed into the particle itself and accessible via pores or discontinuities in the particles. Encapsulation of actives provides a slow release mechanism such that the actives are in a useful form for a longer period of time. A further aspect of the invention provides control over granule strength, and therefore, degradation and / or disintegration properties. Controlling the rate at which granules degrade, for example when the granules disintegrate due to urine deposition, provides another mechanism to slowly release actives from the granule's interior and surface, and in so doing, optimize performance. Thus, the present invention's engineered composite particle optimizing the performance enhancing actives is novel in light of the prior art.

Problems solved by technology

However, the clump strength of clay litters described above is typically not strong enough to hold the clump shape upon scooping, and inevitably, pieces of the litter break off of the clump and remain in the litter box, allowing waste therein to create malodors.

Another problem inherent in typical litters is the inability to effectively control malodors.

Clay has very poor odor-controlling qualities, and inevitably waste build-up leads to severe malodor production.

However, the GAC is usually dry blended with the litter, making the litter undesirably dusty.

Activated carbon is very expensive, and the need for such high concentrations greatly increases production costs.

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