WO2018184148A1 - Litière pour animaux légère et colorée - Google Patents

Litière pour animaux légère et colorée Download PDF

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Publication number
WO2018184148A1
WO2018184148A1 PCT/CN2017/079431 CN2017079431W WO2018184148A1 WO 2018184148 A1 WO2018184148 A1 WO 2018184148A1 CN 2017079431 W CN2017079431 W CN 2017079431W WO 2018184148 A1 WO2018184148 A1 WO 2018184148A1
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WIPO (PCT)
Prior art keywords
particles
composition
core
less
equal
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PCT/CN2017/079431
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English (en)
Inventor
Jianjun Zhao
Wenfang Xu
Yanming GU
Lei Sun
Original Assignee
Specialty Minerals ( Michigan) Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Application filed by Specialty Minerals ( Michigan) Inc. filed Critical Specialty Minerals ( Michigan) Inc.
Priority to CN201780089133.2A priority Critical patent/CN110944506A/zh
Priority to PCT/CN2017/079431 priority patent/WO2018184148A1/fr
Publication of WO2018184148A1 publication Critical patent/WO2018184148A1/fr

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    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01K—ANIMAL HUSBANDRY; AVICULTURE; APICULTURE; PISCICULTURE; FISHING; REARING OR BREEDING ANIMALS, NOT OTHERWISE PROVIDED FOR; NEW BREEDS OF ANIMALS
    • A01K1/00—Housing animals; Equipment therefor
    • A01K1/015—Floor coverings, e.g. bedding-down sheets ; Stable floors
    • A01K1/0152—Litter

Definitions

  • the present invention is directed to an absorbent composition useful as an animal litter, and which may be a clumping animal litter. More particularly, the present invention is directed to an animal litter composition comprising composite particles of a core at least partially coated with an outer coating.
  • House-broken animals such as cats, are trained into the habit of urinating and defecating in a specially provided litter box.
  • untrained and caged animals such as guinea pigs, urinate and defecate on the floor of their cage, often in approximately the same floor area of the cage. Consequently, pet owners, homeowners, veterinarians and laboratory personnel have added absorbent materials to the litter box or cage to collect the urine and feces. After a relatively short period of time, the dross-soiled absorbent emits objectionable odors because of the presence of the urine and fecal matter.
  • clumping animal litters allow for clumps to be removed rather than exchanging all of the litter in the box for new litter.
  • many clumping animal litters are made of clay. The high density of clay based litters has long been recognized as a drawback to these litters (see U.S. Patent No. 3,789,797) .
  • Embodiments of the present invention address some of these issues.
  • Embodiments of the present invention are directed to methods of producing an absorbent composition and an absorbent composition.
  • the absorbent composition may be used as an animal litter, but it is not limited to this use.
  • Embodiments of the present invention encompass methods of forming an absorbent composition, the methods include applying an outer coating to a plurality of particles (core particles) , optionally colored, such that the outer coating covers at least a portion of the surface of the core particles, thus forming composite particles. In some embodiments, the outer coating does not cover all of the surface of the core particles.
  • Embodiments of the present invention encompass absorbent compositions including a plurality of composite particles, the composite particles including core particles, optionally colored, and an outer coating, the outer coating at least partially coating the cores.
  • the outer coating does not cover all of the surface of the core particles.
  • the core particles are colored. In some of the embodiments of the present invention, the outer coating does not cover all of the surface of the core particles so that the color of the core particles shows through, or in other words, the color of the core particles is visible.
  • the core particles include an organic substance
  • the outer coating includes a clay
  • both the core particles include an organic substance and the outer coating includes a clay.
  • the core particle is a particle of corn cob coated with a coating including a coloring agent.
  • the clay of the outer coating is a bentonite clay.
  • the outer coating covers about 50%to about 80%of the surface area of the core particles which may be colored.
  • At least 98 wt%of the core particles, before any optional coating is applied are of a diameter of less than or equal to 2.5 mm and greater than 0.5 mm, as determined by sieving, and of the particles of a diameter less than or equal to 2.5 mm and greater than 0.5 mm, at least 5 wt%are less than or equal to 1.0 mm and greater than 0.5 mm, at least 5 wt%are less than or equal to 1.5 mm and greater than 1.0 mm, at least 5 wt%are less than or equal to 2.0 mm and greater than 1.5 mm, and at least 1 wt%are less than or equal to 2.5 mm and greater than 2.0 mm; also as determined by sieving.
  • between 30 wt%and 80 wt%of the core particles, before any optional coating is applied are less than or equal to 2.0 mm and greater than 1.0 mm, as determined by sieving.
  • FIG. 1 depicts a cross-section of a generic composite particle as defined by the present invention.
  • FIGs. 2A and 2B depict the cross-section of two types of composite particles of embodiments of the present invention.
  • FIGs. 3A and 3B depict an exemplary process flow chart for an embodiment of the present invention.
  • any words of approximation such as without limitation, “about, ” “essentially, ” “substantially, ” and the like mean that the element so modified need not be exactly what is described but can vary from the description. The extent to which the description may vary will depend on how great a change can be instituted and have one of ordinary skill in the art recognize the modified version as still having the properties, characteristics and capabilities of the unmodified word or phrase.
  • a numerical value herein that is modified by a word of approximation may vary from the stated value by ⁇ 15%in some embodiments, by ⁇ 10%in some embodiments, by ⁇ 5%in some embodiments, or in some embodiments, may be within the 95%confidence interval.
  • any ranges presented are inclusive of the end-points.
  • a temperature between 10 °C and 30 °C or “a temperature from 10 °C to 30 °C” includes 10 °Cand 30 °C, as well as any temperature in between.
  • various aspects of this invention may be presented in a range format. The description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range.
  • a description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6.
  • a description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges 1.5 to 5.5, etc., and individual values such as 3.25, etc. that is non-integer individual values and ranges beginning with, ending with or both beginning with and ending with non-integer value (s) . This applies regardless of the breadth of the range.
  • a range may be expressed as from “about” one particular value and/or to “about” another particular value. When such a range is expressed, another embodiment is included, the embodiment being from one particular value and/or to the other particular value. Similarly when values are expressed as approximations by use of the antecedent “about, ” it will be understood that the particular value forms another embodiment. As a non-limiting example, if “from about 1 to about 4” is disclosed, another embodiment is “from 1 to 4, ” even if not expressly disclosed. Likewise, if one embodiment disclosed is “a temperature of about 30 °C, ” then another embodiment is “a temperature of 30 °C, ” even if not expressly disclosed.
  • numbers or ranges presented as a specific value or specific range also encompass another embodiment in which the number or the ends of the range are preceded by “about. ”
  • a temperature of 30 °C is expressly disclosed
  • another embodiment is “a temperature of about 30 °C, ” even if not expressly disclosed.
  • another embodiment is “from about 1 to about 4, ” even if not expressly disclosed.
  • any combination of A, B, C, and D (as does “a combination of A, B, C, and D” ) encompasses the following combinations: A and B; A and C; A and D; B and C; B and D; C and D; A, B, and C; A, B, and D; A, C, and D; B, C, and D; A, B, C, and D.
  • X is selected from the group consisting of A, B, C, D, and combinations thereof” means X is an individual member of the group or X is a combination of members of the group, that is X is A, X is B, X is C, X is D, or X is “any combination of A, B, C, and D” where the above definition of “any combination of” applies.
  • a phrase such as “X is A, B, C, D, or a combination thereof” means X is A, X is B, X is C, X is D, or X is “a combination of A, B, C, and D” where the above definition of “a combination of” applies.
  • X is A, B, and/or C
  • X is any combination of A, B, and C (A and B; A and C; B and C; A, B, and C) .
  • wt% refers to percent by weight. As used herein, percent by weight will be used interchangeably with percent by mass.
  • moisture content or “%moisture” refers to the weight (mass) loss expressed as a percent of the initial weight (mass) when tested in a standard moisture analyzer at 105 °C until a constant weight (constant mass) is obtained (in other words, for a non-specified time or unlimited time) . The calculation would be 100* [ (initial mass –final mass) /initial mass] .
  • moisture is generally used to refer to water, the moisture content as defined here includes all components that are volatilized at 105 °C.
  • the “%” for the moisture content is therefore a wt%or a mass%.
  • a non-limiting example of a moisture analyzer is a moisture analyzer.
  • the wt% is the wt%after the composition has been dried such that there is 5 wt%, or a lower content, of moisture.
  • the term “exclusive of moisture, ” means that the moisture content is about equal to 1 wt%or is less than 1 wt%.
  • a reference to screening through a particular mesh size screen refers to Standard mesh sizes in China.
  • particle is a piece of matter held together by physical bonding of molecules, an agglomeration of pieces of matter ( “particles” ) held together by colloidal forces and/or surface forces, a piece of matter which is held together by chemical bonds such as a cross-linked polymer network or a piece of a larger material (for example ground wood or ground stone) , a piece of matter formed by ionic interactions, or a piece of matter held together by any combination of agglomeration, surface forces, colloidal forces, ionic interactions, and chemical bonds.
  • a particle will be defined as ranging in size from less than a one tenth of a nanometer to several centimeters in size.
  • a particle need not be spherical, but may be irregularly shaped.
  • the polydispersity of a plurality of particles represents the distribution of sizes, usually expressed as particle diameters, within a plurality of particles.
  • the distribution of particles by diameters is represented as a histogram, or in other words the particles are divided into smaller groups encompassing a smaller range of diameters and each of these groups is assigned a diameter near the center of that range.
  • a computer performs an integration over all particle sizes (diameters) .
  • the surface area average diameter is determined by ( ⁇ i f i d i 2 ) 1/2
  • the volume average diameter is determined by ( ⁇ i f i d i 3 ) 1/3 , where f i is n i / ⁇ i n i .
  • the weighting factor is the surface area represented by the class of particles of diameter d i
  • the weighting factor is the volume represented by each class of particles of diameter d i . Since the surface area increases with diameter squared and the volume increases with diameter cubed, the surface area average diameter is greater than the number average diameter, and the volume average diameter exceeds the surface area average diameter.
  • the mass or weight average diameter is the same as the volume average diameter if the density of all of the particles is the same. Similarly, distributions of particle sizes may be based on the number, surface area, or volume of the particles.
  • Another means for determining the average diameter is by the use of dynamic light scattering, which is also called photon correlation spectroscopy, and measures the diffusion of the particles in solution.
  • the average diameter is the mean hydrodynamic diameter, and is close to the volume-average diameter.
  • ISO International Standards Organization
  • the distribution of the particle sizes in a plurality may be represented by the standard deviation, which is a well-known statistical measurement.
  • the standard deviation may be suitable for a narrow particle size distribution.
  • Other measures of polydispersity include the d10 and d90 which refer to the diameters representing the threshold where 10%of the distribution falls below, and 90%of the distribution falls below, respectively.
  • the average may be referred to as a d50.
  • half or 50%of the number of particles have a diameter less than the d50 and half have a diameter greater than the d50.
  • the d50 represents the diameter where half the volume represented by the plurality is in particles having a diameter smaller than d50, or in other words, the intersection of the 50%line on a plot of the cumulative volume of the particles as a function of diameter.
  • Another method of determining particle size is by using a number of screens or sieves.
  • a fixed quantity, typically a fixed mass or weight, of particles is placed in a stack of sieves with the largest opening on the top and a pan at the bottom, and the stack of sieves is shaken or agitated to help distribute the particles.
  • the mass of particles retained on each screen is determined.
  • the particle size distribution is represented as a histogram with the weight percent to the total falling between different screen sizes.
  • the particles retained on each screen are just larger than the screen size opening, and equal to or smaller than the screen above.
  • the particles on the pan are equal to or smaller than the smallest screen opening, and those on the largest top screen are greater in size than the largest screen opening.
  • a reference to an average or mean particle diameter refers to a particle diameter as determined by sieving.
  • a material that is described as a layer or a film (e.g., a coating) “disposed over” an indicated substrate refers to, e.g., a coating of the material deposited directly or indirectly over at least a portion of the surface of the substrate.
  • Direct depositing means that the coating is applied directly to the surface of the substrate.
  • Indirect depositing means that the coating is applied to an intervening layer that has been deposited directly or indirectly over the substrate.
  • a coating is supported by a surface of the substrate, whether the coating is deposited directly, or indirectly, onto the surface of the substrate.
  • the term “coating” will be used to refer to a layer, film, or coating as described in this paragraph.
  • a coating need not be continuous, and need not be smooth or of constant thickness.
  • a coating may include multiple layers and each layer may be formed by multiple applications of a coating material.
  • a reference to an average molecular weight of a polymer (or macromolecule) refers to the weight average molecular weight.
  • Embodiments of the present invention are directed to absorbent compositions and methods of producing absorbent compositions.
  • the absorbent compositions may be used as an animal litter, but the compositions are not limited in use to use as an animal litter.
  • Embodiments of the present invention encompass methods of forming an absorbent composition, the methods including applying an outer coating onto a plurality of core particles, optionally colored (colored core particles) , such that the outer coating covers at least a portion of the surface of the core particles to form composite particles.
  • Embodiments of the present invention encompass absorbent compositions including a plurality of composite particles, the composite particles including core particles, optionally colored, and an outer coating, the outer coating at least partially coating the cores.
  • the embodiments of the invention are not limited to colored core particles, and that where logically possible, the description also encompasses alternative embodiments in which the core particles are not colored.
  • the outer coating does not cover all of the surface of the core particles so that the color of the core particles shows through, or in other words, the color of the core particles is visible.
  • the core particles include an organic substance
  • the outer coating includes a clay
  • both the core particles include an organic substance and the outer coating includes a clay
  • the outer coating does not cover cover all of the surface of the core particles.
  • composite particles is used herein to refer to particles with a distinct core and an outer coating of a different composition than the core.
  • the core and outer coating are of different materials.
  • the core and the outer coating include at least one material in common, although the compositions of the core and the outer coating are not identical.
  • the particle and the core need not be spherical but may be irregularly shaped.
  • the coating may cover the entire surface of the core or the coating may only cover a portion of the surface of the core.
  • Figure 1 is depicts the cross-section of an example of a generic composite particle as defined above which shows a particle with a core 10 and an outer coating 30 where the coating thickness is not necessarily drawn to scale.
  • the material of the core particles may be any one or any combination of materials typically used in animal litter compositions including both absorbent materials and those materials which have no absorption capacity or limited absorption capacity (where “limited” is not more than 5 wt%by weight gain, that is the final mass after absorption of a liquid is 105%of the initial weight) , as well as other materials like binders, surfactants, processing aids, etc.
  • Non-limiting examples include clays, porous polymeric beads, sand, silica gel, water-insoluble inorganic salts (such as such as calcium sulfate) , and organic substances.
  • Organic substances include, without limitation, sawdust, wood chips, wood shavings, shredded paper, paper derivatives, paper sludge, pulp residue, agricultural byproducts, bark, cloth, ground corn husks, cellulose, cellulosic plants, cellulosic plant stalks, roots, grains, grass straw, corn cob, corn, corn meal, soybean, soybean meal, wheat meal, straw, alfalfa meal, alfalfa, peanut hulls, rice hulls, walnut shells, flax, rye, barley, oats, wheat, durm, triticle, pulp, beans, and mung beans.
  • Other materials which may be used include, without limitation, limestone, sand, calcite, dolomite, recycled waste materials, zeolites, aggregates, cement, and gypsum. Any of these materials may be used individually, or in combination with one or more other materials, including, but not limited to, those materials specifically listed herein.
  • the core particles include an organic substance, and in some embodiments, the core particles include at least 90 wt%organic substance. In some embodiments, the core particles include at least 95 wt%organic substance. In preferred embodiments, the organic substance includes cellulose or is a material including cellulose. In a more preferred embodiment, the core particles include corn cob, and in some embodiments, the core particles include at least 90 wt%corn cob. In some embodiments, the corn cob is at least 95 wt%of the core particles. As used here, “corn cob” refers to the center of an ear of corn on which the grains, or corn kernels, grow. Some incidental corn kernels may be included with the corn cob. In some embodiments, incidential corn kernels is about 2 wt%or less than 2 wt%. In some embodiments, incidential corn kernels is about 5 wt%or less than 5 wt%.
  • a binder is also present in the core particle.
  • binders include film forming polymers, surfactants, fibrillated polytetrafluoro-ethylene, water-soluble lignin, lignosulfate, lignosol, starches, gluten, gluten containing material, corn starch, dextran, maltodextrins, sugars, cellulosic adhesive, wheat paste (apre-gelatinized starch) , polysaccharide gum, guar gum, xanthan gum, gum arabic, gum karaya, gum tragacanth, gum ghatti, locust bean gum, alginates, carrageenan, pectins, guar gum derivative, locust bean gum derivative (such as an ether derivative) , carrageenan gum, galactomannan gum, gelatin, cellulose derivatives including, but not limited to, hydroxyethyl cellulose, hydroxy-propylmethyl cellulose, methyl cellulose
  • binders include, without limitation polyvinyl alcohol, polyvinyl esters such polyvinyl acetate, polyvinylpyrrolidone, polyvinyloxazolidone, polyvinylmethyloxazolidone, polyethylene glycol, copolymers thereof, and mixtures thereof.
  • Some of the above materials such as and without limitation, the polysaccharide gums, guar gum, xanthan gum, and carrageenan gum, may also contribute to the clumping of the litter particles. Any of these binders may be used individually, or in combination with one or more other binders, including, but not limited to, those binders specifically listed herein.
  • the core includes a binder and the binder is about 0.01 wt%to 20 wt%of the core. In some embodiments, the core includes a binder and the binder is about 0.1 wt%to 10 wt%of the core. In some embodiments, the core includes a binder and the binder is about 0.2 wt%to 5 wt%of the core. In some embodiments, the core includes a binder and the binder is about 0.1 wt%to 3 wt%of the core.
  • the core particles are colored.
  • colored core particles refer to core particles with a color other than the naturally occurring color, where the color results from addition of a coloring agent for the purpose of changing or altering the color.
  • the naturally occurring color is the color that the core particles would have without the addition of a coloring agent.
  • the addition of the coloring agent is at a level such that it does not impact the function of the particles, and in some embodiments, this level is between 0.01 wt%and 10 wt%.
  • the colored core particles are particles with a color other than gray or brown, where the color results from addition of a coloring agent for the purpose of changing or altering the color.
  • the colored core particles are particles with a color other than black, white, or gray, where the color results from addition of a coloring agent for the purpose of changing or altering the color.
  • the colored core particles are particles with a color resulting from addition of a coloring agent with a specific color of red, green, blue, yellow or a combination thereof, or a combination of coloring agents where at least one coloring agent is member of the group of red, green, blue, and yellow, which is combined with black, white, or both black and white.
  • the color results from adding a dye or other coloring agent to a blend which is agglomerated, granulated, or otherwise combined to form core particles, in which the coloring agent is distributed throughout the core particle.
  • Figure 2A illustrates the cross-section of such a composite particle with core (11) which includes coloring agent, and an outer coating (31) which does not completely cover the surface of the core and again where the thickness of the outer coating relative to the core is not necessarily drawn to scale.
  • the coloring agent is distributed throughout the core particle, and the coloring agent is about 0.1 wt%to about 20 wt%of the core particle.
  • the coloring agent is distributed throughout the core particle, and the coloring agent is about 0.5 wt% to about 10 wt%of the core particle.
  • the coloring agent is distributed throughout the core particle, and the coloring agent is about 1 wt%to about 8 wt%of the core particle. In some embodiments, the coloring agent is distributed throughout the core particle, and the coloring agent is about 0.5 wt%to about 5 wt%of the core particle. In some embodiments, the coloring agent is distributed throughout the core particle, and the coloring agent is about 0.1 wt%to about 3 wt%of the core particle. In some embodiments, such as, but not limited to, those described in this paragraph, the coloring agent is homogeneously or substantially homogeneously ( ⁇ 10%variation in concentration) distributed throughout the core.
  • the coloring agent is added to a coating on the exterior surface of the core particles.
  • Figure 2B illustrates such a composite particle with core (12) which includes coloring agent in a coating (22) on the exterior of the surface of the core, and an outer coating (32) which does not completely cover the surface of the colored core where again the relative dimensions of the core, coating including a coloring agent, and outer coating are not necessarily drawn to scale.
  • a coloring agent is added to a blend which is agglomerated, granulated, or otherwise combined to form the core particles, and in some of these embodiments, a coloring agent, which may be the same or a different coloring agent than the coloring agent of the core particles, is added to a coating on the exterior surface of the core particles.
  • the color coating applied to the core particles may include other ingredients in addition to the coloring agent to allow the coloring agent to stick to the particle, and/or to suspend the coloring agent in a solvent.
  • the application of the coating with the coloring agent may use a solvent, which may be water, an organic solvent, or a combination of water and an organic solvent.
  • the coating including the coloring agent is about 0.5 wt%to about 5 wt%of the colored core particles, exclusive of moisture.
  • the coating including the coloring agent is about 0.75 wt%to 4.5 wt%of the colored core particles, exclusive of moisture.
  • the coating including the coloring agent is about 1 wt%to 4 wt%of the colored core particles, exclusive of moisture.
  • the coating including the coloring agent is about 1.5 wt%to 3.5 wt%of the colored core particles, exclusive of moisture. In some embodiments, the coating including the coloring agent is about 0.5 wt%to about 5 wt%of the colored core particles, when the moisture is not more than 10%. In some embodiments, the coating including the coloring agent is about 0.75 wt%to 4.5 wt%of the colored core particles, when the moisture is not more than 10%. In some embodiments, the coating including the coloring agent is about 1 wt%to 4 wt%of the colored core particles, when the moisture is not more than 10%. In some embodiments, the coating including the coloring agent is about 1.5 wt%to 3.5 wt%of the colored core particles, when the moisture is not more than 10%.
  • the coloring agent or dye may be non-toxic when touched, may not easily be rubbed off the core particles, may not be water soluble (less than 0.1 wt%dissolves in water after applied to the core particles) , may have low water solubility (less than 2 wt%of applied pigment is washed off with water) , may be non-volatile (less than 100 Torr at 20 to 25 C°) , or may be any combination of the preceding.
  • Non-limiting examples of coloring agents include direct dyes, vat dyes, sulfur dyes, acid dyes, mordant acid dyes, premetalized acid dyes, basic dyes, dispersed dyes, reactive dyes, azo dyes, phthalocyanine dyes, anthraquinone dyes, quinolone dyes, monoazo, disazo and polyazo dyes, and pigments, including but not limited to, carbon pigments, iron oxide pigments, cobalt pigments, copper pigments, titanium pigments, ultramarine pigments, zinc pigments, clay earth pigments (which include iron oxides) , and pigments of biological origin.
  • coloring agents of specific colors include, without limitation, red, blue, yellow, and green, as well as mixtures of any of two or more of these colors with each other, mixtures any one of these colors with black, mixtures of any of two or more of these colors with each other and with black, mixtures any one of these colors with white, mixtures of any of two or more of these colors with each other and with white, mixtures any one of these colors with both black and white, and mixtures of any of two or more of these colors with each other and with both black and white.
  • the coloring agent (pigment and/or dye) is white, black, or a combination of black and white.
  • the coloring agent is a commercially available pigment or dye in combination with other ingredients.
  • Coloring agents and pigments are well known in the art and are readily available from companies such as (and without limitation) Clariant (Clariant Pigments (Tianjin) Ltd., Tianjin, China) , and Milliken Inc., USA. Any of these coloring agents may be used individually, or in combination with one or more other coloring agents, including, but not limited to, those coloring agents specifically listed herein.
  • the colored core particles include a coloring agent, as part of the core, in a coating on the outer surface of the core, or both, and the coloring agent is between 0.1 wt%and 8 wt%of the colored core particle and the coloring agent does not include carbon pigments, iron oxide pigments, cobalt pigments, copper pigments, titanium pigments, ultramarine pigments, zinc pigments, clay earth pigments, or any combination of the preceding.
  • the colored core particles include a coloring agent, as part of the core, in a coating on the outer surface of the core, or both, and the coloring agent is between 0.1 wt% and 8 wt%of the colored core particle and the coloring agent does not include carbon pigments, clay earth pigments, or any combination of the preceding.
  • the colored core particles include a coloring agent, as part of the core, a coating on the outer surface of the core, or both, includes at least one coloring agent selected from the group consisting of carbon pigments, iron oxide pigments, cobalt pigments, copper pigments, titanium pigments, ultramarine pigments, zinc pigments, clay earth pigments (which include iron oxides) , and combinations thereof wherein the level (in wt%) in the core particles is above the level that would occur by use of clay or other core materials that include some of these pigments as a natural part of the composition (in other words, the pigments are due to addition of the pigment itself and not the incidential inclusion by use of a material for the core including some limited amout ( ⁇ 2 wt%) of these pigments) .
  • a coloring agent selected from the group consisting of carbon pigments, iron oxide pigments, cobalt pigments, copper pigments, titanium pigments, ultramarine pigments, zinc pigments, clay earth pigments (which include iron oxides) , and combinations thereof wherein the level (
  • the size of the core particles, before an optional coating including a coloring agent is applied may range in size from 0.02 mm to 6 mm in size, preferably in the range of 0.05 mm to 4 mm, and even more preferably in the range of 0.1 mm to 3.5 mm.
  • At least 98 wt%of the core particles, before an optional coating including a coloring agent is applied are of a diameter of less than or equal to 2.5 mm and greater than 0.5 mm, as determined by sieving, and of the particles of a diameter less than or equal to 2.5 mm and greater than 0.5 mm, at least 5 wt%are less than or equal to 1.0 mm and greater than 0.5 mm, at least 5 wt%are less than or equal to 1.5 mm and greater than 1.0 mm, at least 5 wt%are less than or equal to 2.0 mm and greater than 1.5 mm, and at least 1 wt%are less than or equal to 2.5 mm and greater than 2.0 mm.
  • between 30 wt%and 80 wt%of the core particles, before an optional coating including a coloring agent is applied are less than or equal to 2.0 mm and greater than 1.0 mm.
  • at least 98 wt%of the core particles, after an optional coating including a coloring agent is applied are of a diameter of less than or equal to 2.5 mm and greater than 0.5 mm, as determined by sieving, and of the particles of a diameter less than or equal to 2.5 mm and greater than 0.5 mm, at least 5 wt%are less than or equal to 1.0 mm and greater than 0.5 mm, at least 5 wt%are less than or equal to 1.5 mm and greater than 1.0 mm, at least 5 wt%are less than or equal to 2.0 mm and greater than 1.5 mm, and at least 1 wt%are less than or equal to 2.5 mm and greater than 2.0 mm.
  • between 30 wt%and 80 wt%of the core particles, after an optional coating including a coloring agent is applied, are less than or equal to 2.0 mm and greater than 1.0 mm. It has been found that the size distribution of the core particles (before optional color coating) used in forming the composite particles has an impact on the clumping cohesion of the plurality of composite particles.
  • the outer coating does not cover all of the surface of the colored particles so that the color of the particles shows through, or in other words, the color of the core particles is visible.
  • the outer coating includes an absorbent material.
  • the outer coating includes a clay.
  • absorbent materials include porous polymeric beads, diatomateous earths, water-insoluble inorganic salts (such as such as calcium sulfate) , and organic substances.
  • Non-limiting examples of clays include opal clay, attapulgite, Fuller's earth, palygorskite, sepiolite, kaolinite, diatomite, perlite, expanded perlite, illite, halloysite, hormite, smectite, vermiculite, montmorillonite, and bentonite, including bentonites with sodium, potassium, lithium, ammonium, calcium and magnesium, and mixtures thereof, as the exchangeable cation, and also including synthetic clays.
  • the outer coating includes a combination of a clay and another material.
  • the outer coating includes a bentonite clay, or a bentonite clay in combination with another material.
  • the bentonite clay used in the outer coating is calcium bentonite, at least partially activated calcium bentonite, sodium bentonite, or a combination thereof.
  • activated calcium bentonite refers to calcium bentonite in which some of the calcium ions (and/or other non-sodium exchangeable ions) have been exchanged with sodium ions. The activation of the calcium bentonite may result from exposure of the clay to soda ash (Na 2 CO 3 ) , but other techniques may be used as well. In some embodiments, the wet activated calcium bentonite is also extruded.
  • the bentonite soda ash (Na 2 CO 3 )
  • about 2 –4 wt%soda ash (2 –4 g soda ash per 100 g of calcium bentonite)
  • the bentonites may be montmorillonite, beidellite, nontronite, hectorite, saponite, or any combination thereof.
  • the bentonite is predominantly (at least 50 wt%, and preferably, at least 60 wt%) montmorillonite clay mineral.
  • a binder and/or clumping agent is used in addition to the clay and/or other material.
  • the binder, clumping agent, or combination of binder and clumping agent are between 0.01 wt%and 50 wt%of the outer coating, and preferably, between 0.1 wt%and 25 wt%of the outer coating.
  • the outer coating only partially covers the colored core particle, or in other words, some of the exterior surface of the colored core particle is visible.
  • the outer coating covers at least 30 %of the surface area of the colored core particles and not more than 90%of the surface area of colored core particles.
  • the outer coating covers at least 35 %of the surface area of the colored core particles and not more than 85%of the surface area of colored core particles.
  • the outer coating covers at least 40 %of the surface area of the colored core particles and not more than 80%of the surface area of colored core particles.
  • the outer coating covers at least 50 %of the surface area of the colored core particles and not more than 80%of the surface area of colored core particles.
  • the outer coating covers at least 60 %of the surface area of the colored core particles and not more than 75%of the surface area of colored core particles.
  • the outer coating covers at least 95%of the surface area of the core particles, which may be colored or may not be colored. In some embodiments, the outer coating covers at least 98%of the surface area of the core particles, which may be colored or may not be colored. In some embodiments, the outer coating covers at least 99%of the surface area of the core particles, which may be colored or may not be colored.
  • Non-limiting examples of analytical techniques include X-ray Photoelectron Spectroscopy (XPS) , dynamic SIMS (Secondary Ion Mass Spectroscopy) , ToF SIMS (Time-of-Flight Secondary Ion Mass Spectrometry) , Scanning Electron Microscopy (SEM) including Three Dimensional SEM and SEM used in conjuction with Energy Dispersive Analysis (SEM/EDX) , X-ray diffraction, Powder X-ray Diffraction, Fourier Transform Infrared Analysis (FTIR) , Atomic Force Microscopy (AFM) , Transmission Electron Microscopy (TEM) , and Raman Spectroscopy.
  • XPS X-ray Photoelectron Spectroscopy
  • dynamic SIMS Secondary Ion Mass Spectroscopy
  • ToF SIMS Time-of-Flight Secondary Ion Mass Spectrometry
  • Scanning Electron Microscopy SEM including Three Dimensional SEM and SEM used
  • Image analysis software may be used in conjunction with other imaging techniques such as but not limited to photography (cameras, digital cameras, etc. ) , digital cameras with a zoom lens, cameras attached to a microscope, etc. For a photograph that is not made using a digital means, the photograph may be digitized prior to use with image analysis software.
  • image analysis software A non-limiting example of image analysis software that may be used is ImageJ TM supplied free of charge by the United States National Institute of Health, which will count the number of pixels of specific colors in a digital image.
  • Another non-limiting example of image analysis software is Adobe Photoshop TM from Adobe Systems Incorporated, San Jose, California, USA.
  • the photograph, or a digitized version of the photograph may be converted to a gray scale image and then a threshold for dark or light gray is used to differentiate the outer coating from the core.
  • a threshold for dark or light gray is used to differentiate the outer coating from the core.
  • image analysis software is used with photographs taken with a zoom lens and/or attached to a microscope to determine the %surface area that is coated.
  • the percent (%) of the surface area of the colored core particles that is covered by the outer coating is determined by analysis of a representative number of photographs of the composite particles which have been magnified sufficiently to differentiate the colored core from the outer coating where the analysis uses image analysis software.
  • sufficient magnification is at least 3X and not more than 1000X.
  • sufficient magnification is at least 10X and not more than 200X.
  • the image analysis uses grayscale conversion.
  • the plurality of composite particles is of a density in the range of 450 g/liter to 700 g/liter, with the majority of the particles being between 0.5 mm and 4 mm, and having a cohesion of at least 85 wt%. In some embodiments, the plurality of composite particles is of a density of around 550 to 650 g/liter, with the majority of the particles being between 1.0 mm and 3.0 mm, and having a cohesion of at least 85 wt%. As used in this paragraph, “majority of the particles” means at least 50 wt%of the particles, and in some embodiments, at least 80 wt%of the particles.
  • the term “cohesion” is the ability of the particles to form a cohesive clump when wetted.
  • the cohesion is measured by dispensing 10 ml saline (saline includes sodium chloride, NaCl, at a concentration of approximately 2 wt%NaCl) from 2 inches height above the plurality of particles, and then waiting 5 minutes.
  • the clump formed after 5 minutes is weighed, and then subsequently dropped from a height of 10 inches (25.4 centimeter) height onto a sieve, the sieve having 3/4 inch (19 millimeter) openings.
  • the weight of the clump (or the largest piece if multiple pieces) is weighed.
  • the ratio of the final weight to the initial weight when expressed as a percent is the cohesion.
  • the bulk density of the plurality of composite particles is in the range of 450 to 700 g/liter. In some embodiments, the bulk density of the plurality of composite particles is in the range of 450 to 600 g/liter. In some embodiments, the bulk density of the plurality of composite particles is in the range of 450 to 550 g/liter. In some embodiments, the bulk density of the plurality of composite particles is in the range of 540 to 660 g/liter. In some embodiments, the bulk density of the plurality of composite particles is in the range of 570 to 630 g/liter. In some embodiments, the bulk density of the plurality of composite particles is in the range of 575 to 620 g/liter.
  • At least 90 wt%of the composite particles are of a diameter of less than or equal to 4.5 mm and greater than 0.25 mm. In some embodiments, the at least 95 wt%of the composite particles are of a diameter of less than or equal to 4.5 mm and greater than 0.25 mm. In some embodiments, the at least 98 wt%of the composite particles are of a diameter of less than or equal to 4.5 mm and greater than 0.25 mm. In some embodiments, at least 90 wt%of the composite particles are of a diameter of less than or equal to 4.0 mm and greater than 0.5 mm.
  • the at least 95 wt%of the composite particles are of a diameter of less than or equal to 4.0 mm and greater than 0.5 mm. In some embodiments, the at least 98 wt%of the composite particles are of a diameter of less than or equal to 4.0 mm and greater than 0.5 mm. In some embodiments, the at least 90 wt%of the composite particles are of a diameter of less than or equal to 3.0 mm and greater than 1.0 mm. In some embodiments, the at least 95 wt%of the composite particles are of a diameter of less than or equal to 3.0 mm and greater than 1.0 mm. In some embodiments, the at least 98 wt%of the composite particles are of a diameter of less than or equal to 3.0 mm and greater than 1.0 mm.
  • the moisture content of the plurality of composite particles is in the range of 1 wt%to 10 wt%. In some embodiments, the moisture content of the plurality of composite particles is in the range of 3 wt%to 9 wt%. In some embodiments, the moisture content of the plurality of composite particles is in the range of 6 wt%to 8 wt%.
  • the cohesion of the plurality of composite particles is at least 85%. In some embodiments, the cohesion of the plurality of composite particles is at least 90%. In some embodiments, the cohesion of the plurality of composite particles is at least 92%. In some embodiments, the cohesion of the plurality of composite particles is at least 95%. Obviously, the cohesion cannot exceed 100%, so the maximum cohesion is 100%.
  • not more than 3 wt%of the plurality of composite particles are of a diameter of less than or equal to 0.25 mm. In some embodiments, not more than 2 wt%of the plurality of composite particles are of a diameter of less than or equal to 0.25 mm. In some embodiments, not more than 1 wt%of the composite particles are of a diameter of less than or equal to 0.25 mm. In some embodiments, not more than 0.95 wt%of the composite particles are of a diameter of less than or equal to 0.25 mm.
  • Dustiness is determined as the weight percent of the product passing through a screen with a 0.25 mm opening when a 25 gram sample is agitated on the screen for 5 minutes where agitation may be by hand or by a machine (shaker) .
  • Low dustiness being about 1 wt%or less than 1 wt%of the sample falls through the screen with a 0.25 mm opening.
  • the dustiness is about 0.9 wt%or less than 0.9 wt%of the sample falls through the screen with a 0.25 mm opening.
  • the colored core particles and the outer coating are at least 90 wt%of the composite particles, excluding moisture. In some embodiments, the colored core particles and the outer coating are at least 95 wt%of the composite particles, excluding moisture. In some embodiments, the colored core particles and the outer coating are at least 98 wt%of the composite particles, excluding moisture.
  • the plurality of composite particles has at least one function (water absorption, clumping/cohesion) which is within a 95%confidence interval of the function of a plurality of composite particles made with the same materials and made in the same manner except the coloring agent.
  • the plurality of composite particles has at least one function (water absorption, clumping/cohesion) which is within a 95%confidence interval of the function of a plurality of composite particles made with the same materials and made in the same manner except the coloring agent and other ingredients needed for coating and/or addition of the coloring agent.
  • the core is a corn cob particle
  • the color is added by coating the corn cob with a coating including a coloring agent, and subsequently, a coating including (at least 90 wt%, at least 95 wt%, or at least 98 wt%) clay, and more preferably, bentonite clay or a combination of bentonite clay and a second clay, is applied over the color coated corn cob cores and the applied outer coating does not cover the entire surface of the colored corn cob cores, preferably, not more than 80 %of the surface (and at least 15 %of the surface) .
  • the process of manufacturing the composite particles is not limited.
  • the core particles may be obtained as particles from a supplier or the core particles may be manufactured.
  • the core particles may be obtained by grinding a material or otherwise breaking up a material to form the core particles, and/or agglomerating or combining smaller particles to form the core particles.
  • Examples of means of agglomerating or combining smaller particles to form larger particles include using a pan agglomeration process, a high shear agglomeration process, a low shear 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, a pelletization process, and fluid bed processes, with or without a Wurster insert.
  • Agglomeration processes may also be referred to granulation processes.
  • water and/or another solvent is added during the agglomeration or granulation process.
  • the agglomeration process may be followed by an optional drying and/or a sizing step.
  • the sizing step may involve grinding or breaking up a material, and/or screening or sieving a material.
  • binders, clumping agents, or both may be added to the materials of the core particle.
  • the core particles are obtained by grinding of a material to form the core particles which are screened to an appropriate size.
  • the coloring of the core particles may occur concurrently with the agglomeration if the core particles are formed by combining or agglomerating smaller particles.
  • the core particles may be coated with a coating including the coloring agent.
  • the coating including a coloring agent may be applied by any of numerous methods including, but not limited to, blending, spraying, brushing, and mixing.
  • the equipment used includes various blenders and mixers including ribbon blenders, V-shell blenders, Marion mixers, and Norda mixers, as well as various spraying equipment including, but not limited to including, air brushers and atomizers which may be used with a mixer, pan coater, or rotary drum.
  • Another option is a fluid bed optionally including a Wurster insert.
  • the core particles may be optionally dried at the end of the coating application process.
  • an outer coating is applied to at least partially cover the colored core particles, and in some embodiments, an outer coating is applied to substantially cover the entire surface of the core particles (where substantially is at least 95%up to 100%) .
  • the outer coating is applied in a separate piece of equipment than the application of the coating including a coloring agent.
  • the outer coating may be applied by use of any of the equipment described above in reference to the application of a coating including the coloring agent.
  • the outer coating is applied by use of a pan agglomerator or rotary drum.
  • the composite particles may be dried, and/or may also be sieved or screened, before being packaged. Before being packaged, the composite particles may be blended with additional particles of absorbent material.
  • other additives commonly used with animal litter including, but not limited to fragrances, odor control agents, odor absorbing agents, dust control agents, antibactierials, and others, may be blended with the composite particles or a blend of particles including the composite particles.
  • the core particles are not agglomerated particles, but are particles resulting from grinding of a material including cellulose.
  • the core particles, prior to addition of an optional coating are ground corn cob, and at least 98 wt%of the core particles are of a diameter of less than or equal to 2.5 mm and greater than 0.5 mm, as determined by sieving, and of the particles of a diameter less than or equal to 2.5 mm and greater than 0.5 mm, at least 5 wt%are less than or equal to 1.0 mm and greater than 0.5 mm, at least 5 wt%are less than or equal to 1.5 mm and greater than 1.0 mm, at least 5 wt%are less than or equal to 2.0 mm and greater than 1.5 mm, and at least 1 wt%are less than or equal to 2.5 mm and greater than 2.0 mm.
  • the core particles are colored by applying a coating including a coloring agent.
  • the coating is accomplished with a spray coating operation which involves a solvent, typically water, but which may be an organic solvent or a mixture of an organic solvent and water.
  • the spray coating may be executed in a pan granulator, a rotary drum granulator or mixer, a pan coater, a fluid bed (with or without a Wurster insert) , or a combination thereof.
  • the colored core particles are of a moisture content of about 10 wt%to 35 wt%at the end of the coating operation. In some embodiments, the colored core particles are of a moisture content of about 10 wt%to 25 wt%at the end of the coating operation. In some embodiments, the colored core particles are of a moisture content of about 18 wt%to 22 wt%at the end of the coating operation. In some embodiments of the present invention, at the end of the process of color coating the core particles, the moisture content is in the range of about 12%to about 28%. If the moisture content is too high, the particles begin to agglomerate. If the moisture is too low, the coating may not be sufficient.
  • the outer coating includes a clay powder.
  • the clay powder may have a size such that not less than 60 wt%of the powder passes through a screen with a 75 micrometer opening (#200 mesh) .
  • the clay powder has a size such that 60 –90 wt%pass through a screen with a 75 micrometer opening (#200 mesh) .
  • the size may be measured by hand sieving or using an auto-siever (shaker) .
  • water and/or another solvent is added during the application of the outer coating.
  • the composite particles are of a moisture content 15 wt%to 37 wt%. In some embodiments, at the end of the outer coating operation, the composite particles are of a moisture content 20 wt%to 35 wt%. In some embodiments, at the end of the outer coating operation, the composite particles are of a moisture content 25 wt%to 30 wt%.
  • the process further includes drying the composite particles after the application of the outer coating.
  • the drying may be accomplished in a fluid bed dryer, rotary drum dryer, tray dryer, or the like.
  • the composite particles are of a moisture content of 1%to 10%at the end of the drying operation.
  • the composite particles are of a moisture content of 3%to 9%at the end of the drying operation.
  • the composite particles are of a moisture content of 6%to 8%at the end of the drying operation.
  • the process further includes sizing the composite particles. If the particles are dried, sizing occurs after drying.
  • the sizing includes screening the particles to remove the over-size particles of a diameter greater than a first diameter ( “overs” ) and removing particles of a diameter equal to or less than a second diameter ( “fines” or “unders” ) .
  • the first diameter is 3 mm and the second diameter is 1 mm.
  • the first diameter is 6 mm and the second diameter is 2 mm.
  • the first diameter is 5 mm and the second diameter is 0.5 mm.
  • the first diameter is 4.5 mm and the second diameter is 0.25 mm.
  • the first diameter is 4 mm and the second diameter is 0.5 mm.
  • additives may be blended with the plurality of composite particles.
  • the sum of all of the additives, where additives are those materials other than absorbent materials that are commonly added to animal litter is between 0.05 wt%and 35 wt%of the composition.
  • the sum of all of the additives, where additives are those materials other than absorbent materials that are commonly added to animal litter is between 0.1 wt%and 25 wt%of the composition.
  • the sum of all of the additives, where additives are those materials other than absorbent materials that are commonly added to animal litter is between 0.05 wt%and 12 wt%of the composition.
  • the sum of all of the additives, where additives are those materials other than absorbent materials that are commonly added to animal litter is between 0.05 wt%and 5 wt%of the composition.
  • the plurality of composite particles is not less than 90 wt%of the packaged composition. In some embodiments, the plurality of composite particles is not less than 95 wt%of the packaged composition. In some embodiments, the plurality of composite particles is not less than 98 wt%of the composition. In the embodiments of the present invention described in this paragraph, reference to the plurality of composite particles encompasses all of the composite particles if there is a blend of two or more pluralities of composite particles.
  • the plurality of composite particles is blended with a second plurality of particles, and optionally additives, to form the final composition, which is subsequently packaged.
  • the second plurality of particles may include particles of any of the absorbent materials described herein.
  • the composition includes a second plurality of particles blended with the plurality of composite particles.
  • the second plurality of particles comprises at least 0.5 wt%of the blend, and not more than 99.5 wt%of the blend.
  • the second plurality of particles comprises at least 5 wt%of the blend, and not more than 95 wt%of the blend. In some embodiments, for the blend of the composite particles and the second plurality of particles, the second plurality of particles comprises at least 15 wt%of the blend, and not more than 85 wt%of the blend. In some embodiments, for the blend of the composite particles and the second plurality of particles, the second plurality of particles comprises at least 10 wt%of the blend, and not more than 50 wt%of the blend.
  • the second plurality of particles comprises at least 20 wt%of the blend, and not more than 60 wt%of the blend.
  • reference to the second plurality of particles encompasses all of the additional non-composite particles if there is a blend of two or more pluralities of non-composite particles (asecond plurality, a third plurality, etc. ) .
  • reference to the plurality of composite particles encompasses all of the composite particles if there is a blend of two or more pluralities of composite particles.
  • the second plurality of particles comprises at least 0.5 wt%of the packaged composition, and not more than 99.5 wt%of the packaged composition. In some embodiments, the second plurality of particles comprises at least 5 wt%of the packaged composition, and not more than 95 wt%of the packaged composition. In some embodiments, the second plurality of particles comprises at least 15 wt%of the packaged composition, and not more than 85 wt%of the packaged composition. In some embodiments, the second plurality of particles comprises at least 10 wt%of the packaged composition, and not more than 50 wt%of the packaged composition. In some embodiments, the second plurality of particles comprises at least 20 wt%of the packaged composition, and not more than 60 wt%of the packaged composition.
  • reference to the second plurality of particles encompasses all of the additional non-composite particles if there is a blend of two or more pluralities of non-composite particles (asecond plurality, a third plurality, etc. ) .
  • reference to the plurality of composite particles encompasses all of the composite particles if there is a blend of two or more pluralities of composite particles.
  • the particles of the second plurality of particles comprise an absorbent material.
  • the absorbent material of the particles of the second plurality may be any one or any combination of these listed for use in the core particles.
  • the absorbent material of the particles of the second plurality of particles is selected from the group consisting of clays, porous polymeric beads, sand, silica gel, water-insoluble inorganic salts (such as such as calcium sulfate) , and organic substance.
  • the organic substances are selected from the group consisting of sawdust, wood chips, wood shavings, shredded paper, paper derivatives, paper sludge, pulp residue, agricultural byproducts, bark, cloth, ground corn husks, cellulose, cellulosic plants, cellulosic plant stalks, roots, grains, grass straw, pulp, beans, mung beans, corn cob, corn, corn meal, soybean, soybean meal, wheat meal, straw, alfalfa meal, alfalfa, peanut hulls, rice hulls, walnut shells, flax, rye, barley, oats, wheat, durm, triticle, and combinations thereof.
  • the particles of the second plurality of particles include a filler material, such as but not limited to, limestone, sand, calcite, dolomite, recycled waste materials, zeolites, cement, gypsum, and combinations thereof. Filler materials are typically not absorbent or of limited absorption capacity.
  • the particles of the second plurality of particles include a clay material selected from the group consisting of opal clay, attapulgite, Fuller's earth, palygorskite, sepiolite, kaolinite, diatomite, perlite, expanded perlite, illite, halloysite, hormite, smectite, vermiculite, montmorillonite, beidellite, nontronite, hectorite, saponite, bentonite, synthetic clays, and mixtures thereof.
  • a clay material selected from the group consisting of opal clay, attapulgite, Fuller's earth, palygorskite, sepiolite, kaolinite, diatomite, perlite, expanded perlite, illite, halloysite, hormite, smectite, vermiculite, montmorillonite, beidellite, nontronite, hectorite, saponite, benton
  • the particles of the second plurality of particles may include any of the materials described herein used individually, or in combination with one or more other materials, including, but not limited to, those materials specifically listed herein. In the embodiments to the present invention, the particles of the second plurality of particles may a combination of materials. In the embodiments to the present invention, the individual particles of the second plurality of particles may a combination of materials.
  • the particles of the second plurality include a clay.
  • the particles of the second plurality include bentonite.
  • the bentonite is calcium bentonite, sodium bentonite, activated calcium bentonite, mixed ion bentonite, or a combination thereof.
  • a “mixed ion” bentonite is a bentonite with a mixture of exchangeable cations such that one does not predominate, and may be a mixture of sodium and calcium ions. In some embodiments, an ion does not predominate if it represents less than 80%of the total milli-equivalents of the clay.
  • Embodiments of the present invention encompass a composition, including, but not limited to including, a plurality of composite particles, the composite particles comprising core particles comprising an organic substance, where the core particles are optionally colored, and the composite particles further including an outer coating comprising a clay, the outer coating at least partially coating the cores (optionally colored) .
  • the composition is absorbent.
  • the outer coating does not cover all of the surface of the core particles.
  • the core particles are colored.
  • the color of the core particles results from a coloring agent.
  • the coloring agent is included in a coating on the core particles.
  • At least 90 wt%of the composite particles, excluding moisture is an organic substance, a clay, and a coloring agent. In some embodiments, at least 95 wt%of the composite particles, excluding moisture, is an organic substance, a clay, and a coloring agent. In some embodiments, at least 98 wt%of the composite particles, excluding moisture, is an organic substance, a clay, and a coloring agent. In some embodiments, the composite particles, excluding moisture, include 15%to 60%organic substance, 37%to 85%clay, and 0.1%to 4.5%coloring agent, subject to the constraint that the sum does not exceed 100%.
  • the composite particles, excluding moisture include 20%to 60%organic substance, 37%to 80%clay, and 0.1%to 3.5%coloring agent, subject to the constraint that the sum does not exceed 100%. In some embodiments, the composite particles, excluding moisture, include 25%to 60%organic substance, 37%to 75%clay, and 0.25%to 3.5%coloring agent, subject to the constraint that the sum does not exceed 100%. In some embodiments, the organic substance is corn cob.
  • the weight percent (wt%) of corn cob, or other organic substance is measured by a loss of ignition test at 1010 °C for 4 hours.
  • a non-limiting example of a loss-of-ignition method involves preparing a calibration curve using dried samples of 100%, 80%, 60%, 40%, 20%, and 0%by weight of the clay used in the outer coating, and the balance being the core material, and in this case, the corn cob used in the core.
  • drying of the clay, the core material (in this case corn cob) , and the composite particles (in this case, clay partially coating the corn cob cores) involves leaving the samples in an over at 105 °C for 4 hours followed by 30 minutes cooling at room temperature (20 to 25 °C) , and storage in plastic bags until use.
  • the samples are then prepared by determining the crucible mass (m 1 ) and then adding 5.000 grams of sample (calibration sample or test sample) with sand (1 gram below, add sample, remainder above sample) such that the sample and sand is 10.000 grams.
  • the crucibles with sand and sample are then placed in a muffle furnace, which is turned on and set to reach a furnace temperature of 1010 °C within 20 minutes, and then the samples remain in the furnace at 1010 °C for 4 hours. After four hours, the furnace is turned off, and the samples cooled by remaining in the furnace, slightly open door for 10 minutes, a further 20 minutes remaining in the furnace with a wide open door, and finally the crucibles are removed from the muffle furnace and allowed to cool for 30 minutes at room temperature (20 to 25 °C) . The final mass (m 2 ) is determined and a calibration curve of y vs.
  • the organic matter, in this case corn cob, is the balance or 100 –x%. If one of the calibration samples is off, it can be eliminated.
  • wt%of corn cob is measured by a water wash method.
  • the water wash method involves determining the weight of material (core material) remaining on a sieve when the outer coating material has been washed off and passes through the sieve.
  • the sieve (0.25 mm opening) and a sample of the composite particles are placed in an oven at 105 °C for 4 hours followed by 30 minutes cooling at room temperature (20 to 25 °C) after removal from the oven, and storage in plastic bags until use.
  • the initial weight of the sieve is recorded (m 3 ) .
  • the core material wt%, or in this instance corn cob, corn cob wt% 100%–clay (wt%) .
  • the water wash method and the Loss of Ignition method yielded the same value for the wt%core particles when the core particles were corn cob particles where “not the same” means that less than a 5%probability that the difference is due to chance alone according to the Student T-Test.
  • Some non-limiting embodiments of the invention include:
  • Embodiment 1 A method of forming a composition, the method comprising: applying an outer coating to a plurality of core particles, optionally colored, such that the outer coating covers at least a portion of the surface of the core particles to form composite particles.
  • Embodiment 2 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 described above, at least 98 wt%of the core particles, before application of any optional color coating, are of a diameter of less than or equal to 2.5 mm and greater than 0.5 mm, as determined by sieving, and of the particles of a diameter less than or equal to 2.5 mm and greater than 0.5 mm, at least 5 wt%are less than or equal to 1.0 mm and greater than 0.5 mm, at least 5 wt%are less than or equal to 1.5 mm and greater than 1.0 mm, at least 5 wt%are less than or equal to 2.0 mm and greater than 1.5 mm, and at least 1 wt%are less than or equal to 2.5 mm and greater than 2.0 mm.
  • Embodiment 3 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 and 2 described above, at least 99 wt%of the core particles, before application of any optional color coating, are of a diameter of less than or equal to 2.5 mm and greater than 0.5 mm, as determined by sieving, and of the particles of a diameter less than or equal to 2.5 mm and greater than 0.5 mm, at least 5 wt%are less than or equal to 1.0 mm and greater than 0.5 mm, at least 5 wt%are less than or equal to 1.5 mm and greater than 1.0 mm, at least 5 wt%are less than or equal to 2.0 mm and greater than 1.5 mm, and at least 1 wt%are less than or equal to 2.5 mm and greater than 2.0 mm.
  • Embodiment 4 In some embodiments of the present invention, such as but not limited to embodiment (s) 3 described above, between 30 wt%and 80 wt%of the core particles are less than or equal to 2.0 mm and greater than 1.0 mm.
  • Embodiment 5 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –4 described above, the application of the outer coating includes applying particles to the surface of the core particles, optionally colored, to form the outer coating.
  • Embodiment 6 In some embodiments of the present invention, such as but not limited to embodiment (s) 5 described above, at least 60 wt%of the particles applied to form the outer coating pass through a screen with a 75 micrometer opening.
  • Embodiment 7 In some embodiments of the present invention, such as but not limited to embodiment (s) 5 described above, 60 wt%to 90 wt%of the particles applied to form the outer coating pass through a screen with a 75 micrometer opening.
  • Embodiment 8 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –7 described above, water is added during outer coating application.
  • Embodiment 9 In some embodiments of the present invention, such as but not limited to embodiment (s) 8 described above, at the end of the outer coating application, the composite particles are of a moisture content of 10 %to 35 %.
  • Embodiment 10 In some embodiments of the present invention, such as but not limited to embodiment (s) 8 described above, at the end of the outer coating application, the composite particles are of a moisture content 10 %to 25 %.
  • Embodiment 11 In some embodiments of the present invention, such as but not limited to embodiment (s) 8 described above, at the end of the outer coating application, the composite particles are of a moisture content 18 %to 22 %.
  • Embodiment 12 In some embodiments of the present invention, such as but not limited to embodiment (s) 8 described above, at the end of the outer coating application, the composite particles are of a moisture content 20 %to 35 %.
  • Embodiment 13 In some embodiments of the present invention, such as but not limited to embodiment (s) 8 described above, at the end of the outer coating application, the composite particles are of a moisture content 15 %to 37 %.
  • Embodiment 14 In some embodiments of the present invention, such as but not limited to embodiment (s) 8 described above, at the end of the outer coating application, the composite particles are of a moisture content 25 %to 30 %.
  • Embodiment 15 In some embodiments of the present invention, such as but not limited to embodiment (s) 8 –14 described above, the methods further include drying the composite particles after the application of the outer coating.
  • Embodiment 16 In some embodiments of the present invention, such as but not limited to embodiment (s) 15 described above, the composite particles are of a moisture content of 1%to 10%at the end of the drying operation.
  • Embodiment 17 In some embodiments of the present invention, such as but not limited to embodiment (s) 15 described above, the composite particles are of a moisture content of 3%to 9%at the end of the drying operation.
  • Embodiment 18 In some embodiments of the present invention, such as but not limited to embodiment (s) 15 described above, the composite particles are of a moisture content of 6%to 8%at the end of the drying operation.
  • Embodiment 19 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –18 described above, the composite particles are sized.
  • Embodiment 20 In some embodiments of the present invention, such as but not limited to embodiment (s) 19 described above, sizing includes screening the particles to remove the over-size particles of a diameter greater than a first diameter and removing particles of a diameter equal to or less than a second diameter.
  • Embodiment 21 In some embodiments of the present invention, such as but not limited to embodiment (s) 20 described above, the first diameter is 4.5 mm and the second diameter is 0.25 mm.
  • Embodiment 22 In some embodiments of the present invention, such as but not limited to embodiment (s) 20 described above, the first diameter is 4 mm and the second diameter is 0.5 mm.
  • Embodiment 23 In some embodiments of the present invention, such as but not limited to embodiment (s) 20 described above, the first diameter is 3 mm and the second diameter is 1 mm.
  • Embodiment 24 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –23 described above, the particles are optionally blended with a second plurality of particles, and then packaged.
  • Embodiment 25 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –24 described above, the methods further include coating core particles with a color coating comprising a coloring agent to form colored core particles.
  • Embodiment 26 In some embodiments of the present invention, such as but not limited to embodiment (s) 25 described above, the color coating is applied by spray coating.
  • Embodiment 27 In some embodiments of the present invention, such as but not limited to embodiment (s) 26 described above, the spray coating is executed using a pan granulator, a drum, a fluid bed, or a combination thereof.
  • Embodiment 28 In some embodiments of the present invention, such as but not limited to embodiment (s) 25 –27 described above, the colored core particles are of a moisture content of about 10 %to 35 %at the end of the color coating application.
  • Embodiment 29 In some embodiments of the present invention, such as but not limited to embodiment (s) 25 –27 described above, the colored core particles are of a moisture content of about 10 %to 25 %at the end of the color coating application.
  • Embodiment 30 In some embodiments of the present invention, such as but not limited to embodiment (s) 25 –27 described above, the colored core particles are of a moisture content of about 12 %to 25 %at the end of the color coating application.
  • Embodiment 31 In some embodiments of the present invention, such as but not limited to embodiment (s) 25 –27 described above, the colored core particles are of a moisture content of about 15 %to 25 %at the end of the color coating application.
  • Embodiment 32 In some embodiments of the present invention, such as but not limited to embodiment (s) 25 –27 described above, the colored core particles are of a moisture content of about 18 %to 22 %at the end of the color coating application.
  • Embodiment 33 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –32 described above, the outer coating is applied in a separate piece of equipment than the application of the color coating.
  • Embodiment 34 A composition comprising: a plurality of composite particles, the composite particles comprising core particles, where the core particles are optionally colored, and the composite particles further include an outer coating, the outer coating at least partially coating the cores (which are optionally coated) .
  • Embodiment 35 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –34 described above, the composition is absorbent.
  • Embodiment 36 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –35 described above, the outer coating covers all (at least 99%) or substantially all (at least 98%) of the surface are of the cores of the composite particles or at least 95%of the surface of the cores of the composite particles.
  • Embodiment 37 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –35 described above, the outer coating covers at least 30 %of the surface area of the cores of the composite particles and not more than 90%of the surface area of the cores of the composite particles.
  • Embodiment 38 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –35 described above, the outer coating covers at least 35 %of the surface area of the cores of the composite particles and not more than 85%of the surface area of the cores of the composite particles.
  • Embodiment 39 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –35 described above, the outer coating covers at least 40 %of the surface area of the cores of the composite particles and not more than 80%of the surface area of the cores of the composite particles.
  • Embodiment 40 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –35 described above, the outer coating covers at least 50 %of the surface area of the cores of the composite particles and not more than 80%of the surface area of the cores of the composite particles.
  • Embodiment 41 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –35 described above, the outer coating covers at least 60 %of the surface area of the cores of the composite particles and not more than 76%of the surface area of the cores of the composite particles.
  • Embodiment 42 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –41 described above, the percent (%) of the surface area of the colored core particles that is covered by the outer coating is determined by analysis of a representative number of photographs of the composite particles which have been magnified sufficiently to differentiate the colored core from the outer coating and where the analysis uses image analysis software.
  • Embodiment 43 In some embodiments of the present invention, such as but not limited to embodiment (s) 42 described above, sufficient magnification is at least 3X and not more than 1000X.
  • Embodiment 44 In some embodiments of the present invention, such as but not limited to embodiment (s) 42 described above, sufficient magnification is at least 10X and not more than 200X.
  • Embodiment 45 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –44 described above, the moisture content of the plurality of composite particles is in the range of 1 wt%to 10 wt%.
  • Embodiment 46 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –44 described above, the moisture content of the plurality of composite particles is in the range of 3 wt%to 9 wt%.
  • Embodiment 47 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –44 described above, the moisture content of the plurality of composite particles is in the range of 6 wt%to 8 wt%.
  • Embodiment 48 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –47 described above, the bulk density of the plurality of composite particles is in the range of 450 to 700 g/liter.
  • Embodiment 49 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –47 described above, the bulk density of the plurality of composite particles is in the range of 450 to 600 g/liter.
  • Embodiment 50 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –47 described above, the bulk density of the plurality of composite particles is in the range of 450 to 550 g/liter.
  • Embodiment 51 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –47 described above, the bulk density of the plurality of composite particles is in the range of 540 to 660 g/liter.
  • Embodiment 52 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –47 described above, the bulk density of the plurality of composite particles is in the range of 570 to 630 g/liter.
  • Embodiment 53 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –47 described above, the bulk density of the plurality of composite particles is in the range of 575 to 620 g/liter.
  • Embodiment 54 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –53 described above, at least 90 wt%of the composite particles are of a diameter of less than or equal to 4.5 mm and greater than 0.25 mm.
  • Embodiment 55 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –53 described above, at least 95 wt%of the composite particles are of a diameter of less than or equal to 4.5 mm and greater than 0.25 mm.
  • Embodiment 56 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –53 described above, at least 98 wt%of the composite particles are of a diameter of less than or equal to 4.5 mm and greater than 0.25 mm.
  • Embodiment 57 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –53 described above, at least 90 wt%of the composite particles are of a diameter of less than or equal to 4.0 mm and greater than 0.5 mm.
  • Embodiment 58 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –53 described above, at least 95 wt%of the composite particles are of a diameter of less than or equal to 4.0 mm and greater than 0.5 mm.
  • Embodiment 59 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –53 described above, at least 98 wt%of the composite particles are of a diameter of less than or equal to 4.0 mm and greater than 0.5 mm.
  • Embodiment 60 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –53 described above, at least 90 wt%of the composite particles are of a diameter of less than or equal to 3.0 mm and greater than 1.0 mm.
  • Embodiment 61 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –53 described above, at least 95 wt%of the composite particles are of a diameter of less than or equal to 3.0 mm and greater than 1.0 mm.
  • Embodiment 62 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –53 described above, at least 98 wt%of the composite particles are of a diameter of less than or equal to 3.0 mm and greater than 1.0 mm.
  • Embodiment 63 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –62 described above, the cohesion of the plurality of composite particles is at least 90%.
  • Embodiment 64 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –62 described above, the cohesion of the plurality of composite particles is at least 92%.
  • Embodiment 65 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –62 described above, the cohesion of the plurality of composite particles is at least 95%.
  • Embodiment 66 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –65 described above, not more than 3 wt%of the composite particles are of a diameter of less than or equal to 0.25 mm.
  • Embodiment 67 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –65 described above, not more than 2 wt%of the composite particles are of a diameter of less than or equal to 0.25 mm.
  • Embodiment 68 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –65 described above, not more than 1 wt%of the composite particles are of a diameter of less than or equal to 0.25 mm.
  • Embodiment 69 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –65 described above, not more than 0.95 wt%of the composite particles are of a diameter of less than or equal to 0.25 mm.
  • Embodiment 70 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –65 described above, not more than 0.9 wt%of the composite particles are of a diameter of less than or equal to 0.25 mm.
  • Embodiment 71 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –70 described above, the core particles include an organic substance.
  • Embodiment 72 In some embodiments of the present invention, such as but not limited to embodiment (s) 71 described above, at least 90 wt%of the core particles is organic substance.
  • Embodiment 73 In some embodiments of the present invention, such as but not limited to embodiment (s) 71 and 72 described above, at least 95 wt%of the core particles is organic substance.
  • Embodiment 74 In some embodiments of the present invention, such as but not limited to embodiment (s) 70 –73 described above, the organic substance includes cellulose.
  • Embodiment 75 In some embodiments of the present invention, such as but not limited to embodiment (s) 70 –73 described above, the organic substance is selected from the group consisting of wood, an agricultural byproduct, paper, a paper derivative, cellulosic plants, cellulosic plant stalks, roots, and combinations thereof.
  • Embodiment 76 In some embodiments of the present invention, such as but not limited to embodiment (s) 70 –73 described above, the organic substance is corn cob, corn, corn meal, soybean, soybean meal, wheat meal, wheat straw, alfalfa meal, alfalfa, peanut hulls, rice hulls, walnut shells, paper, paper sludge, pulp residue, sawdust, wood, pulp, beans, mung bean, and combinations thereof.
  • Embodiment 77 In some embodiments of the present invention, such as but not limited to embodiment (s) 76 described above, the organic substance includes corn cob.
  • Embodiment 78 In some embodiments of the present invention, such as but not limited to embodiment (s) 76 described above, at least 90 wt%of the core is corn cob.
  • Embodiment 79 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –78 described above, the core particles are colored.
  • Embodiment 80 In some embodiments of the present invention, such as but not limited to embodiment (s) 79 described above, the color of the core particles results from a coloring agent.
  • Embodiment 81 In some embodiments of the present invention, such as but not limited to embodiment (s) 80 described above, the coloring agent is at a level (wt%) such that the coloring agent does not impact the function of the particles, where the function may be cohesion, saline absorption, or both.
  • Embodiment 82 In some embodiments of the present invention, such as but not limited to embodiment (s) 79 –81 described above, the colored core particles are particles with a color other than gray or brown.
  • Embodiment 83 In some embodiments of the present invention, such as but not limited to embodiment (s) 79 –81 described above, the colored core particles are particles with a color other than black, white, or gray.
  • Embodiment 84 In some embodiments of the present invention, such as but not limited to embodiment (s) 79 –81 described above, the coloring agent is a pigment and/or dye of the color red, blue, yellow, green, or a mixture thereof.
  • Embodiment 85 In some embodiments of the present invention, such as but not limited to embodiment (s) 79 –81 described above, the coloring agent (pigment and/or dye) is a specific color, the specific color being red, blue, yellow, green, or a mixture of any of two or more of these colors; a mixture of black with red, blue, yellow, green, or a mixture of any of two or more of the colors, red, blue, yellow, and green; a mixture of white with red, blue, yellow, green, or a mixture of any of two or more of the colors, red, blue, yellow, and green; or a mixture of black and white with red, blue, yellow, green, or a mixture of any of two or more of the colors, red, blue, yellow, and green.
  • Embodiment 86 In some embodiments of the present invention, such as but not limited to embodiment (s) 79 –81 described above, the coloring agent (pigment and/or dye) is a specific color, the specific color being black, white, or a combination of black and white.
  • the coloring agent pigment and/or dye
  • Embodiment 87 In some embodiments of the present invention, such as but not limited to embodiment (s) 79 –81 described above, the color of the core particles is red, pink, yellow, green, blue, or a mixture of any of these colors with black.
  • Embodiment 88 In some embodiments of the present invention, such as but not limited to embodiment (s) 79 –81 described above, the color of the core particles is red, pink, yellow, green, blue, or a mixture of any of these colors with white.
  • Embodiment 89 In some embodiments of the present invention, such as but not limited to embodiment (s) 79 –81 described above, the color of the core particles is red, pink, yellow, green, blue, or a mixture of any of these colors with black and white.
  • Embodiment 90 In some embodiments of the present invention, such as but not limited to embodiment (s) 80 –89 described above, the coloring agent is distributed throughout the core particle, and the coloring agent is about 0.1 wt%to about 20 wt%of the core particle.
  • Embodiment 91 In some embodiments of the present invention, such as but not limited to embodiment (s) 80 –89 described above, the coloring agent is distributed throughout the core particle, and the coloring agent is about 0.5 wt%to about 10 wt%of the core particle.
  • Embodiment 92 In some embodiments of the present invention, such as but not limited to embodiment (s) 80 –89 described above, the coloring agent is distributed throughout the core particle, and the coloring agent is about 1 wt%to about 8 wt%of the core particle.
  • Embodiment 93 In some embodiments of the present invention, such as but not limited to embodiment (s) 80 –89 described above, the coloring agent is distributed throughout the core particle, and the coloring agent is about 0.5 wt%to about 5 wt%of the core particle.
  • Embodiment 94 In some embodiments of the present invention, such as but not limited to embodiment (s) 80 –89 described above, the coloring agent is distributed throughout the core particle, and the coloring agent is about 0.1 wt%to about 3 wt%of the core particle.
  • Embodiment 95 In some embodiments of the present invention, such as but not limited to embodiment (s) 80 –94 described above, the coloring agent is homogeneously or substantially homogeneously ( ⁇ 10%variation in concentration) throughout the core particle.
  • Embodiment 96 In some embodiments of the present invention, such as but not limited to embodiment (s) 80 –95 described above, there is a coating on the core particles, and the coating includes the coloring agent, which may be the same coloring agent as the core if the core particle includes a coloring agent, or may be a different coloring agent than the coloring agent of the core.
  • the coloring agent may be the same coloring agent as the core if the core particle includes a coloring agent, or may be a different coloring agent than the coloring agent of the core.
  • Embodiment 97 In some embodiments of the present invention, such as but not limited to embodiment (s) 96 described above, the coating including the coloring agent is about 0.5 wt%to 5 wt%of the colored core particles, exclusive of moisture or when the moisture content is not more than 10%.
  • Embodiment 98 In some embodiments of the present invention, such as but not limited to embodiment (s) 96 described above, the coating including the coloring agent is about 0.75 wt%to 4.5 wt%of the colored core particles, exclusive of moisture or when the moisture content is not more than 10%.
  • Embodiment 99 In some embodiments of the present invention, such as but not limited to embodiment (s) 96 described above, the coating including the coloring agent is about 1 wt%to 4 wt%of the colored core particles, exclusive of moisture or when the moisture content is not more than 10%.
  • Embodiment 100 In some embodiments of the present invention, such as but not limited to embodiment (s) 96 described above, the coating including the coloring agent is about 1.5 wt%to 3.5 wt%of the colored core particles, , exclusive of moisture or when the moisture content is not more than 10%.
  • Embodiment 101 In some embodiments of the present invention, such as but not limited to embodiment (s) 79 –100 described above, the colored core particles include a coloring agent, as part of the core or in a coating on the outer surface of the core, or both, and the coloring agent is between 0.1 wt%and 8 wt%of the colored core particle and the coloring agent does not include carbon pigments, iron oxide pigments, cobalt pigments, copper pigments, titanium pigments, ultramarine pigments, zinc pigments, clay earth pigments, or any combination of the preceding.
  • the coloring agent is between 0.1 wt%and 8 wt%of the colored core particle and the coloring agent does not include carbon pigments, iron oxide pigments, cobalt pigments, copper pigments, titanium pigments, ultramarine pigments, zinc pigments, clay earth pigments, or any combination of the preceding.
  • Embodiment 102 In some embodiments of the present invention, such as but not limited to embodiment (s) 79 –100 described above, the colored core particles include a coloring agent, as part of the core or in a coating on the outer surface of the core, or both, and the coloring agent is between 0.1 wt%and 8 wt%of the colored core particle and the coloring agent does not include carbon pigments, clay earth pigments, or any combination of the preceding.
  • a coloring agent as part of the core or in a coating on the outer surface of the core, or both
  • the coloring agent is between 0.1 wt%and 8 wt%of the colored core particle and the coloring agent does not include carbon pigments, clay earth pigments, or any combination of the preceding.
  • the colored core particles include a coloring agent, as part of the core or in a coating on the outer surface of the core, or both, and the coloring agent is between 0.1 wt%and 8 wt%of the colored core particle and the coloring agent includes carbon pigments, iron oxide pigments, cobalt pigments, copper pigments, titanium pigments, ultramarine pigments, zinc pigments, clay earth pigments, or any combination of the preceding, where the level of the pigment (s) is greater than the level which occurs in a naturally occurring clay, and/or other absorbent material of the core particle.
  • Embodiment 104 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –103 described above, the outer coating includes a clay.
  • Embodiment 105 In some embodiments of the present invention, such as but not limited to embodiment (s) 104 described above, at least 90 wt%of the outer coating is clay.
  • Embodiment 106 In some embodiments of the present invention, such as but not limited to embodiment (s) 104described above, at least 95 wt%of the outer coating is clay.
  • Embodiment 107 In some embodiments of the present invention, such as but not limited to embodiment (s) 104 described above, at least 98 wt%of the outer coating is clay.
  • Embodiment 108 In some embodiments of the present invention, such as but not limited to embodiment (s) 104 –107 described above, the clay is selected from the group consisting of opal clay, attapulgite, Fuller's earth, palygorskite, sepiolite, kaolinite, diatomite, perlite, expanded perlite, illite, halloysite, hormite, smectite, vermiculite, montmorillonite, bentonite, synthetic clays, and combinations thereof.
  • the clay is selected from the group consisting of opal clay, attapulgite, Fuller's earth, palygorskite, sepiolite, kaolinite, diatomite, perlite, expanded perlite, illite, halloysite, hormite, smectite, vermiculite, montmorillonite, bentonite, synthetic clays, and combinations thereof.
  • Embodiment 109 In some embodiments of the present invention, such as but not limited to embodiment (s) 104 –107 described above, the clay is bentonite or a combination of bentonite and a second clay.
  • Embodiment 110 In some embodiments of the present Invention, such as but not limited to embodiment (s) 109 described above, the exchangeable cation (s) of bentonite include, but are not limited to including, sodium, potassium, lithium, ammonium, calcium, magnesium, or a mixture thereof.
  • Embodiment 111 In some embodiments of the present invention, such as but not limited to embodiment (s) 109 described above, the bentonite is calcium bentonite, sodium bentonite, activated calcium bentonite, mixed ion bentonite, or a combination thereof.
  • Embodiment 112 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –111 described above, wherein if the core includes an organic substance, and the outer coating includes a clay, the organic substance, if present, the clay, and the coloring agent are at least 90 wt%of the composite particles, exclusive of moisture.
  • Embodiment 113 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –111 described above, wherein if the core includes an organic substance, and the outer coating includes a clay, the organic substance, the clay, and the coloring agent are at least 95 wt%of the composite particles, exclusive of moisture.
  • Embodiment 114 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –111 described above, wherein if the core includes an organic substance, and the outer coating includes a clay, the organic substance, the clay, and the coloring agent are at least 98 wt%of the composite particles, exclusive of moisture.
  • Embodiment 115 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –111 described above, wherein if the core includes an organic substance, and the outer coating includes a clay, the composite particles, excluding moisture, comprise 15%to 60%organic substance, 37%to 85%clay, and 0.1%to 4.5%coloring agent, subject to the constraint that the sum does not exceed 100%.
  • Embodiment 116 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –111 described above, wherein if the core includes an organic substance, and the outer coating includes a clay, the composite particles, excluding moisture, comprise 20%to 60%organic substance, 37%to 80%clay, and 0.1%to 3.5%coloring agent, subject to the constraint that the sum does not exceed 100%.
  • Embodiment 117 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –111 described above, wherein if the core includes an organic substance, and the outer coating includes a clay, the composite particles, excluding moisture, comprise 25%to 60%organic substance, 37%to 75%clay, and 0.25%to 3.5%coloring agent, subject to the constraint that the sum does not exceed 100%.
  • Embodiment 118 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –111 described above, the core particles, including any optional color coating, and the outer coating are at least 90 wt%of the composite particles, exclusive of moisture.
  • Embodiment 119 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –111 described above, the core particles, including any optional color coating, and the outer coating are at least 95 wt%of the composite particles, exclusive of moisture.
  • Embodiment 120 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –111 described above, the core particles, including any optional color coating, and the outer coating are at least 98 wt%of the composite particles, exclusive of moisture.
  • Embodiment 121 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –120 described above, the plurality of composite particles is not less than 90 wt%of the composition.
  • Embodiment 122 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –120 described above, the plurality of composite particles is not less than 95 wt%of the composition.
  • Embodiment 123 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –120 described above, the plurality of composite particles is not less than 98 wt%of the composition.
  • Embodiment 124 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –123 described above, if the cores are colored, the plurality of composite particles has at least one function, such as but not limited to water absorption, clumping/cohesion, or both, which are within a 95%confidence interval of the function of a comparator plurality of composite particles, the comparator plurality of composite particles made with the same materials and made in the same manner except the coloring agent is not included.
  • the function such as but not limited to water absorption, clumping/cohesion, or both, which are within a 95%confidence interval of the function of a comparator plurality of composite particles, the comparator plurality of composite particles made with the same materials and made in the same manner except the coloring agent is not included.
  • Embodiment 125 In some embodiments of the present invention, such as but not limited to embodiment (s) 1 –124 described above, the composition includes, but is not limited to including, a second plurality of particles blended with the plurality of composite particles.
  • Embodiment 126 In some embodiments of the present invention, such as but not limited to embodiment (s) 125 described above, the second plurality of particles is at least 0.5 wt%of the composition, and not more than 99.5 wt%of the composition.
  • Embodiment 127 In some embodiments of the present invention, such as but not limited to embodiment (s) 125 described above, the second plurality of particles is at least 5 wt%of the composition, and not more than 95 wt%of the composition.
  • Embodiment 128 In some embodiments of the present invention, such as but not limited to embodiment (s) 125 described above, the second plurality of particles is at least 15 wt%of the composition, and not more than 85 wt%of the composition.
  • Embodiment 129 In some embodiments of the present invention, such as but not limited to embodiment (s) 125 described above, the second plurality of particles comprises at least 10 wt%of the composition, and not more than 50 wt%of the composition.
  • Embodiment 130 In some embodiments of the present invention, such as but not limited to embodiment (s) 125 described above, the second plurality of particles is at least 20 wt%of the composition, and not more than 60 wt%of the composition.
  • Embodiment 131 In some embodiments of the present invention, such as but not limited to embodiment (s) 125 –130 described above, the particles of the second plurality of particles comprise an absorbent material.
  • Embodiment 132 In some embodiments of the present invention, such as but not limited to embodiment (s) 131 described above, the absorbent material of the particles of the second plurality of particles is selected from the group consisting of diatomateous earth, wood, an agricultural byproduct, paper, a paper derivative, cellulosic plants, cellulosic plant stalks, roots, and combinations thereof.
  • Embodiment 133 In some embodiments of the present invention, such as but not limited to embodiment (s) 131 described above, the absorbent material of the particles of the second plurality of particles is selected from the group consisting of corn cob, corn, corn meal, soybean, soybean meal, wheat meal, wheat straw, alfalfa meal, alfalfa, peanut hulls, rice hulls, walnut shells, paper, paper sludge, pulp residue, sawdust, wood, pulp, beans, mung beans, and combinations thereof.
  • Embodiment 134 In some embodiments of the present invention, such as but not limited to embodiment (s) 125 –130 described above, wherein the material of the particles of the second plurality of particles is a clay material selected from the group consisting of opal clay, attapulgite, Fuller's earth, palygorskite, sepiolite, kaolinite, diatomite, perlite, expanded perlite, illite, halloysite, hormite, smectite, vermiculite, montmorillonite, bentonite, synthetic clays, and combinations thereof.
  • opal clay attapulgite, Fuller's earth
  • palygorskite sepiolite
  • kaolinite diatomite
  • perlite expanded perlite
  • illite halloysite
  • hormite smectite
  • vermiculite montmorillonite
  • bentonite synthetic clays, and combinations thereof.
  • Embodiment 135 In some embodiments of the present invention, such as but not limited to embodiment (s) 134 described above, the absorbent material of the particles of the second plurality of particles is bentonite.
  • Embodiment 136 In some embodiments of the present invention, such as but not limited to embodiment (s) 135 described above, the exchangeable cation (s) of bentonite include, but are not limited to including, sodium, potassium, lithium, ammonium, calcium, magnesium, or a mixture thereof.
  • Embodiment 137 In some embodiments of the present invention, such as but not limited to embodiment (s) 135 described above, the bentonite is calcium bentonite, sodium bentonite, activated calcium bentonite, mixed ion bentonite, or a combination thereof.
  • Corn cob particles were received from a supplier, Gongyi Jiujiu (Henan, China) .
  • the corn cob particles were obtained by grinding and crushing corn cobs. The initial moisture of the corn cob particles was 7.92%and the density was 519 g/Liter.
  • the corn cob particles were used as the core particles.
  • the core particles of corn cob were coated with a coloring agent in a pan granulator.
  • the coloring agents used were: Colanyl Red FBB 100-CN, Colanyl Blue A2R 100-CN, and Colanyl Green GG 131-CN, from Clariant Pigments (Tianjin) Ltd., Tianjin, China.
  • the moisture content was in the range of about 15%to about 25%.
  • the moisture content at the end of the core particle coating operation was about 20%.
  • an outer coating of clay was added in a laboratory pan granulator.
  • the color coated core particles were added to the pan granulator along with clay powder and water to partially coat the colored core particles with clay.
  • the clay used was a bentonite clay, and specifically a partially activated calcium bentonite.
  • the bentonite was obtained from the Dongming Plant of Minerals Technology Inc. (Liaoning, China) .
  • During the milling of the of the natural occurring calcium bentonite about 2 –4 wt%soda ash (Na 2 CO 3 ) (2 –4 g soda ash per 100 g bentonite) was added which resulted in a partial activation of the calcium bentonite.
  • the resulting bentonite product had some sodium ions exchanged for some of the calcium ions (or other non-sodium exchangeable cations) , and thus had a mixture of calcium and sodium as the exchangeable ions (as well as some amount of other naturally occurring ions) .
  • the bentonite powder (at least 60 wt%pass through a 200 mesh screen (about 75 micrometers) , and preferably 60 wt%to 90 wt%pass through a 200 mesh screen) had a moisture content of 8.18%and a density of 758 g/Liter.
  • the particles were dried to a moisture content of about 6%to about 8%, and then screened. In these laboratory samples, screening was done to remove particles greater than 2.5 mm and equal to or less than 0.5 mm (those passing through a 2.5 mm screen and retained on a 0.5 mm screen were selected) .
  • the final product was about 50 wt%clay and 50 wt%corn cob.
  • the weight percent corn cob was determined by use of a loss of ignition test at 1010 °C for 4 hours, the water wash method, or both. The two methods of measuring the weight percent corn cob provided the same or essentially the same result according to the Student T-Test.
  • the size ranges in Table 1 above were determined by sieving, so the above size ranges refer to particles retained on the smaller sieve size but passing through the larger sieve size.
  • 0.5 mm –1.0 mm refers to particles slightly greater than 0.5 mm and equal to or less than 1.0 mm.
  • the comparator product, Bentonite litter is composed of partially activated calcium benotonite, that is calcium bentonite milled with 2 wt%Na 2 CO 3 added (2 g Na 2 CO 3 added to 100 g calcium bentonite) .
  • dustiness is determined as the weight percent of the product passing through a screen with a 0.25 opening when a 25 gram sample is agitated the screen for 5 minutes. Low dustiness is defined as being about 1 wt%or less than 1 wt%of the sample falls through the screen with a 0.25 mm opening.
  • the clumps of the litter formed from the composite particle of the narrow PSD (particle size distribution) cores were not good clumps because the clumps were not compact with an aspect ratio (length to width) was approximately 2 to 2.5 or slightly more than 2.5.
  • the clumps of the litter formed from the composite particle of the wide PSD cores were good clumps having an aspect ratio closer to 1, that is the aspect ratio was less than 1.5, at about 1.35. This is reflected in the cohesion strength in Table 2 above.
  • the final product still appears to be colored because the outer coating does not completely cover the surface of the colored core particles thus allowing the color to be visible.
  • a pilot scale manufacture of the composite particles without color coating of the cores was performed using the same raw materials and similar processes (outer coating with a bentonite clay powder, and then drying and screening and sizing) using a wide particle size corn cob particles as the initial core particles.
  • Table 3 summarizes the particle size distribution (PSD) of the core particles of used for the laboratory manufacture and the pilot scale manufacture:
  • the size ranges in Table 6 above were determined by sieving, so the above size ranges refer to particles retained on the smaller sieve size but passing through the larger sieve size.
  • Sample 3 was from a lot manufactured on March 8, 2017, and Sample 4 was from a lot manufactured on March 9, 2017.
  • Samples F and G were from lots manufactured on March 8, 2017. Samples H –O were from lots manufactured on March 9, 2017.

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  • Life Sciences & Earth Sciences (AREA)
  • Environmental Sciences (AREA)
  • Zoology (AREA)
  • Animal Husbandry (AREA)
  • Biodiversity & Conservation Biology (AREA)
  • Housing For Livestock And Birds (AREA)

Abstract

Des modes de réalisation de la présente invention concernent des procédés de production d'une composition absorbante et une composition absorbante. La composition absorbante peut être utilisée comme litière pour animaux, mais elle n'est pas limitée à cette utilisation. Des modes de réalisation comprennent des procédés de formation d'une composition absorbante par application d'un revêtement externe sur une pluralité de particules centrales de telle sorte que le revêtement externe recouvre au moins partiellement la surface des particules centrales, formant ainsi des particules composites. Dans des modes de réalisation préférés, les particules centrales sont colorées et le revêtement externe ne recouvre pas la totalité de la surface des particules centrales.
PCT/CN2017/079431 2017-04-05 2017-04-05 Litière pour animaux légère et colorée WO2018184148A1 (fr)

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JP2000300102A (ja) * 1999-04-21 2000-10-31 Kunimine Industries Co Ltd ペット用排泄物処理剤
US20110174228A1 (en) * 2010-01-21 2011-07-21 F&R Enterprises, Inc. Hybrid animal litter composition
US20150181831A1 (en) * 2013-12-31 2015-07-02 Nestec Sa Hybrid composite coated animal litter compositions
CN105393924A (zh) * 2015-11-19 2016-03-16 兰州坤仑环保科技有限公司 一种多彩凹凸棒天然矿物猫砂
US9549532B2 (en) * 2012-12-18 2017-01-24 Green Products Company Organically based animal litter and manufacturing process
US9549533B2 (en) * 2013-11-08 2017-01-24 Green Products Company Organically based animal litter and manufacturing process

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US20070017453A1 (en) * 2005-07-25 2007-01-25 Fritter Charles F Animal litter containing activated carbon
RU2521670C2 (ru) * 2008-11-17 2014-07-10 Нестек С.А. Наполнитель для туалета животных
JP6001358B2 (ja) * 2012-07-02 2016-10-05 ユニ・チャーム株式会社 動物用トイレ砂

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JP2000300102A (ja) * 1999-04-21 2000-10-31 Kunimine Industries Co Ltd ペット用排泄物処理剤
US20110174228A1 (en) * 2010-01-21 2011-07-21 F&R Enterprises, Inc. Hybrid animal litter composition
US9549532B2 (en) * 2012-12-18 2017-01-24 Green Products Company Organically based animal litter and manufacturing process
US9549533B2 (en) * 2013-11-08 2017-01-24 Green Products Company Organically based animal litter and manufacturing process
US20150181831A1 (en) * 2013-12-31 2015-07-02 Nestec Sa Hybrid composite coated animal litter compositions
CN105393924A (zh) * 2015-11-19 2016-03-16 兰州坤仑环保科技有限公司 一种多彩凹凸棒天然矿物猫砂

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