Caked dunnage and method of making low take-out caked dunnage

Abstract

The present invention provides a low take-out agglomerated dunnage having larger non-agglomerated dunnage particles having a particle size sufficiently large relative to smaller agglomerated dunnage particles such that substantially all of the smaller dunnage particles in a dunnage bowl are disposed below the dunnage surface, and the non-caking particles are accumulated in gaps between adjacent non-caking particles. This padding reduces take-out properties because the surface is composed of larger particles that are not easily taken away by cats, thereby minimizing the number of smaller particles that are more easily taken out on the top because the smaller particles that are more easily taken out are accumulated in the voids. This causes the urine to rapidly wet and swell the agglomerated particles, thereby capturing the urine to form agglomerates at the top. The dunnage has a take-out performance of less than 90 particles per square inch and the agglomerated particles are preferably composed of a water-soluble binder extruded on the basis of modified starch, which agglomerated particles produce scatter-resistant agglomerates, the agglomerate retention of which is preferably greater than 97%.

Description

[0001] Cross-referencing

[0002] This application claims priority and benefit to U.S. Provisional Patent Application No. 63 / 465916, filed May 12, 2023, the entire disclosure of which is expressly incorporated herein by reference. This application is also a continuation-in-part of U.S. Patent Application No. 18 / 372677, filed September 25, 2023, which claims priority and benefit to U.S. Provisional Patent Application No. 63 / 409755, filed September 24, 2022, the entire disclosure of which is expressly incorporated herein by reference. Technical Field

[0003] This invention relates to granular absorbents for use in animals, preferably bedding, and more specifically to a clumped bedding formulated to reduce bedding use and track animals from bedding containers containing the bedding. Background Technology

[0004] When cats use a litter box containing absorbent pellets, they often unintentionally carry some pellets out of the box when they leave. This typically happens in the following ways:

[0005] Entry and Digging: When a cat enters its litter box, it may get litter pellets stuck to its fur, especially if its fur is long. This is because cats instinctively dig to bury their waste, and this action can cause litter pellets to stick to their paws. During digging, the cat may also stir up the litter, causing some to scatter near the edge of the litter box or stick to its body.

[0006] Using a litter box: After a cat finishes its chores and buries its waste, it will often cover up its feces or urine by digging more litter. This action is another opportunity for the litter to stick to the cat's paws. Clumping litter is designed to absorb moisture and clump together, making it easier to stick to the paws than non-clumping varieties.

[0007] Leaving the litter box: When a cat leaves its litter box, it may bring out litter pellets stuck between its toes or attached to its fur. The texture and length of the cat's fur, as well as the moisture on its paws, can affect the amount of litter brought out. Longer, denser fur can trap more litter.

[0008] Cleaning after litter box: Cats often groom themselves after defecating, licking their paws and fur. During this grooming process, cats usually remove litter pellets from their paws, which then fall onto the floor outside the litter box.

[0009] Moving around the house: When a cat moves around the house, any remaining bedding particles on its paws or fur may be scattered by its movement. This causes the bedding particles to spread around the area near the litter box and may spread further depending on the cat's activity after using the litter box.

[0010] To mitigate this, many cat owners use mats around the litter box to catch any litter that falls off the cat when it leaves the box. Regular cleaning and maintenance of the litter box and surrounding area also helps minimize litter spillage outside the box. Despite using mats to catch spilled litter and regular cleaning and maintenance of the litter box, it remains very common for cats to take litter outside the mat's edge and then drop it off their bodies, requiring frequent cleaning by the owner.

[0011] In response, bedding manufacturers attempted to develop low-tracking bedding, but with little success. One type of low-tracking or low-trailing bedding introduced by manufacturers is made of silicone bedding crystals, because silicone crystals are less likely to stick to a cat's fur and paws. Other low-tracking bedding uses larger and heavier pellets or pellets than those used in standard bedding, because they are less likely to get stuck in a cat's paws or stick to its fur.

[0012] U.S. Patent Application Publication No. 20050160997 discloses a cat and small animal bedding material composed of yellow pine fiber and a nonionic surfactant, formed into pellets using a pellet mill. The pellets have a relatively large diameter, ranging from 4762 micrometers to 6350 micrometers (0.1875 inches to 0.250 inches). While the '997 publication discloses that pellets with these large diameters "can remain intact to limit the animal from carrying them out of the bedding tray," it teaches that using intact pellets may be uncomfortable for the animal and further discloses that the pellets "can be crushed and sifted to obtain a [softer] texture, thereby increasing the animal's comfort."

[0013] Attempting to create less clumpy bedding has proven more challenging because clumpy material particles (such as particles of sodium bentonite or another clumpy material) tend to be sticky by nature, making them more likely to stick not only to a cat's paws but also to its fur.

[0014] U.S. Patent No. 11,918,969 discloses an example of a clumping animal bedding material designed to reduce carryover. This bedding is made from composite bedding particles composed of sodium bentonite and activated carbon, with a particle size distribution of 16 / 50 mesh, ranging from 300 micrometers to 1180 micrometers. This bedding claims to reduce carryover by eliminating almost all fine particles (commonly referred to as “fine powder”) that would pass through a 100-mesh sieve (e.g., a 0.150 mm or 150 micrometer sieve), limiting the amount of fine powder in the bedding to no more than about 10%, about 5%, about 4%, about 3%, about 2.5%, about 2%, about 1.5%, or about 1% of the bedding. However, despite the significant reduction or even near elimination of fine powder in the bedding, carryover still occurs due to the relatively small particle size of the composite bedding particles constituting the bedding.

[0015] U.S. Patent No. 8,720,375 discloses another formulation for reducing carry-over agglomeration in a cushioning material, comprising particles of a clay-based liquid absorbent material such as sodium bentonite and particles of at least one filler, the filler being a non-absorbent, insoluble matrix coated with at least one agglomerating agent, which may also be sodium bentonite. The particle size of the clay-based liquid absorbent material is from 500 micrometers to 2000 micrometers (0.50 mm to 2.00 mm), preferably from 400 micrometers to 1600 micrometers (0.4 mm to 1.6 mm), more preferably from 400 micrometers to 1200 micrometers (0.4 mm to 1.2 mm). The particles of the clay-based liquid absorbent material constitute 40% to 99% of the weight of the cushioning material, preferably 50% to 95%, more preferably 40% to 85%. The clay-based liquid absorbent material is selected from agglomerating and non-agglomerating clay materials or mixtures of agglomerating and non-agglomerating clay materials. The filler particles have a particle size of 250 micrometers to 850 micrometers (0.25 mm to 0.85 mm) and account for 10% to 60% by weight of the bedding material, preferably 30% to 60% by weight, and more preferably 45% to 60% by weight. The binder can be agglomerating clay, such as sodium bentonite, polysaccharides, water-soluble gums, dry particulate cellulose ethers, water-absorbing polymers, or mixtures thereof. The binder content is 0.1% to 20% by weight of the bedding material, preferably 0.25% to 10% by weight, and more preferably 0.45% to 7.0% by weight. However, due to the relatively small particle size of the bedding material constituting this bedding material, carry-out phenomena can still occur.

[0016] Furthermore, because most clumping bedding, including those claiming to reduce carryover, primarily uses sodium bentonite for clumping, this bentonite absorbs urine during the clumping process, swells, and forms shrinking clumps upon drying. Unfortunately, sodium bentonite lacks the plasticity to prevent the tensile and compressive stresses generated within the clumps during drying and shrinkage, which can lead to cracks forming in the dried clumps. This cracking can cause the clumps to break or even collapse when scooped from the bedding bowl, resulting in the clumps scattering used bedding fragments that fall back into the bedding. This scattering is undesirable because it can lead to bedding contamination, requiring more frequent cleaning of the bedding bowl, and causing the bedding to run out faster. It can also cause unpleasant odors, as the scattered clumps returning to the bedding bowl can harbor odor-causing bacteria and other bacteria that may be harmful to the cat's health. This can even lead to the cat defecating outside the bedding bowl.

[0017] An improved caking bedding formulation is needed that minimizes carryover while maintaining good caking properties. Simultaneously, a low-carryover caking bedding formulation is also needed, which produces clumps that scatter minimally or not at all when removed from the bedding container. Summary of the Invention

[0018] This invention relates to a low-carryover clumping bedding formulation having larger non-clumping bedding particles, the particle size of which is sufficiently large relative to the smaller clumping particles to place substantially all of the smaller bedding particles in the bedding bowl below the bedding surface, filling the gaps between adjacent non-clumping particles. This reduces carryover because the surface consists of larger particles that are less likely to be carried away by the cat, and because the smaller, more easily carried-out particles are filled in the gaps, the number of smaller particles on top is minimized. This results in urine rapidly wetting and causing the clumping particles to swell, trapping urine on top and forming clumps. The bedding has a carryover efficiency of less than 90 particles / square inch, and the clumping particles are preferably composed of an extrusion-modified starch-based water-soluble binder, producing anti-scattering clumps with a clumping retention rate preferably greater than 97%. Attached Figure Description

[0019] The accompanying drawings illustrate one or more preferred exemplary embodiments of the invention, wherein like reference numerals denote like parts, and:

[0020] Figure 1 This is a partial cross-sectional front view of the agglomerated and non-agglomerated particles of the low-carryover agglomerated bedding material of the present invention, depicting smaller agglomerated particles filling between adjacent larger non-agglomerated particles, improving agglomeration while minimizing the number of smaller agglomerated particles that may be carried out of the bedding surface from the bedding basin.

[0021] Figure 2 This is a top view of another preferred low-carryover bedding material, which is a two-component bedding material with a pair of different types of agglomerated and non-agglomerated particles, wherein the particle size of both types of agglomerated particles is smaller than the particle size of both types of non-agglomerated particles to reduce carryover.

[0022] Figure 3 This is a front view of a tool used to evaluate the carry-out performance of bedding particles;

[0023] Figure 4 yes Figure 3 Rear view of the pad material particles leading out of the performance tool;

[0024] Figure 5 Table 1 shows the type of bedding material, the particle size range of the sieve, the bulk density, and the weight percentage of each of the low carry-out bedding test formulations 1-6.

[0025] Figure 6 Table 2 is shown, which provides the preferred non-caking and agglomerated bedding particle composition and particle size breakdown and weight percentage for low carry-out bedding test formulations 1-6;

[0026] Figure 7 Table 3 shows the density, clumping weight before drop, clumping weight after drops at 10 minutes and 30 minutes, and the corresponding clumping retention rate for low carry-out padding test formulations 1-6.

[0027] Figure 8 Table 4 is shown, which provides test results (in terms of particles per square inch) of the particle carry-out performance of low carry-out padding formulations 1-6 and four commercially available padding materials for comparison.

[0028] Before explaining one or more embodiments of the invention in detail, it should be understood that the invention is not limited to its application in the construction details and component arrangements set forth in the following description and drawings. The invention can be implemented or practiced in other embodiments or in various ways. Furthermore, it should be understood that the wording and terminology used herein are for descriptive purposes and should not be considered limiting. Detailed Implementation

[0029] introduction

[0030] There are two types of bedding materials: clumping bedding, which forms clumps when exposed to urine or other aqueous liquids (such as water) that wet the bedding particles; and non-clumping bedding, which does not clump when its particles are wetted by urine or other aqueous liquids.

[0031] Non-clumping bedding is typically formulated with larger-diameter bedding particles, usually larger than 2 millimeters or 2000 micrometers (10-mesh sieve). Therefore, when poured into the bedding bowl, the gaps between adjacent particles are large enough to define channels or pathways within the bedding so that urine can flow relatively quickly down through them to the bottom of the bowl when the cat uses it. Using such large-diameter particles results in a relatively loose packing of bedding in the bowl, creating relatively large gaps between adjacent particles, which hopefully prevents urine from pooling on the surface and forming sticky stains.

[0032] The relatively large-diameter pellets used in non-clumping bedding tend to reduce carry-out behavior because they are less likely to be carried out of the bedding bowl. This is because these larger pellets are large enough to be less likely to get stuck in the paws of cats using the bedding. Also, because these larger pellets are heavier, they are less likely to be carried away by the cat's fur during bedding use.

[0033] Clumping bedding is typically formulated with smaller particle sizes than non-clumping bedding. The need for smaller particle sizes is to block intentionally provided channels or pathways in non-clumping bedding during the clumping process. These channels typically allow urine to flow downwards through the bedding to the bottom of the bedding container. Using smaller particles in clumping bedding causes them to pack relatively tightly together in the container, reducing the size of gaps between adjacent particles. This allows rapidly expanding clumping particles to quickly block these gaps upon contact with urine, trapping the urine on or near the bedding surface. Trapping the urine on or near the bedding surface ensures that it is absorbed by the bedding material on or near the surface and forms clumps that can be easily scooped out.

[0034] When a cat urinates, the rate is typically about 1 milliliter of urine per second. Because the urine is trapped on or near the surface of the bedding using smaller bedding pellets, it causes the clumping material of the pellets to become thoroughly wetted by the urine, activating the clumping material and forming swollen, spherical clumps. During activation, the clumping material of each wetted pellet expands and becomes sticky, causing it to adhere to one or more adjacent bedding pellets, causing them to clump together. The urine is absorbed by the clump-forming pellets, locking it within the clumps and preventing it from flowing down to the bottom of the bedding bowl.

[0035] When urine comes into contact with the bedding, this must happen almost instantaneously; otherwise, the urine will flow down to the bottom of the bedding basin, causing a sticky stain. To promote caking and prevent urine from flowing to the bottom, the smaller particles used in caking bedding include caking granules, whose caking material expands immediately upon wetting to block the gaps between the granules. By blocking the gaps, it prevents urine from flowing down and redirects the flow, keeping it at or near the top of the bedding, where it wets more and more caking granules at or near the top of the bedding, forming an ever-expanding, spherical clump at the top of the bedding that is easy to scoop out.

[0036] Typically, caking bedding manufacturers create bedding particles with a particle size smaller than 3350 micrometers (3.35 mm or 0.132 inches) (see, for example, Hughes, U.S. Patent No. 5000115), and in other cases, particles smaller than 2000 micrometers (2.0 mm or 0.079 inches) (see, for example, Kuras, U.S. Patent No. 11026397). Both Hughes and Kuras teach the use of components with a primary particle size smaller than 3500 micrometers (3.5 mm or 0.138 inches), and both use similarly small-particle-size caking and non-caking components. Among other things, these patents teach the use of pre-mixture surface area proxies associated with components having similar particle sizes and similar shape assumptions. Most prior art caking bedding uses products with similar particle size distributions for its blended components to improve caking consistency and blending ease. Traditionally, attempts to manufacture caking bedding with large particles have resulted in inconsistent caking and are therefore commercially unfeasible.

[0037] Clumping bedding formulations typically include a caking agent, absorbent material, and non-absorbent components, and often also include non-caking components. Caking agents typically include, but are not limited to: sodium bentonite (a water-absorbing, swelling clay capable of absorbing up to six times its weight in water), gum, carboxymethyl cellulose, acrylics, and / or high-pressure extruded grains. Absorbent components of the bedding typically include, but are not limited to: calcium bentonite, starch, walnut shells, paper, cellulose-containing products, and perlite. Non-absorbent components include sand and various other types of non-absorbent products. Some caking agents are coated or coated onto other particles—for example, sodium bentonite coated onto perlite, or guar gum coated onto dried grains, or guar gum coated onto cellulose products.

[0038] Although the aforementioned clumping bedding materials can form easily removable clumps within the bedding when exposed to urine, the smaller particle size used in clumping bedding materials leads to increased carryover of the bedding material outside the bedding container. Therefore, improvements to clumping bedding materials are needed.

[0039] Therefore, it would be advantageous to obtain agglomerated bedding formulations with extremely low carry-out characteristics without sacrificing agglomerating capacity, agglomerating efficiency, or agglomerated integrity. It is also desirable to have agglomerated bedding that not only has low carry-out characteristics but also minimizes the amount of used bedding particles that scatter from the agglomerated material when it is removed from the bedding pan.

[0040] Low carryover reduces clumping of cat litter.

[0041] Figure 1 The present invention illustrates a low-carryover agglomerate bedding material 40, which is a dry blend (which may also be absorbent) of at least a plurality of pairs (i.e., at least three) of agglomerate particles 42 of a single type of agglomerate material 44 and at least a plurality of pairs of non-agglomerate particles 46 of a single type of non-agglomerate material 48. The bedding material 40 is formulated such that the agglomerate particles 42 are sufficiently smaller than the non-agglomerate particles 46, thereby configuring the bedding material 40 such that, when the bedding material 40 is placed in a bedding basin 50, substantially all of the smaller agglomerate particles 42 are distributed below the bedding surface 52 and fill the spaces between adjacent larger-diameter non-agglomerate particles 46, reducing carryover by minimizing the number of smaller particles 42 on the surface 52 that might be carried away by a cat using the bedding material 40. The bedding basin 50 is in Figure 1 The image, shown in dashed lines, shows a basin 50 containing a substrate 40. The basin 50 has a bottom wall 54 supporting the substrate 40, from which several opposite sidewalls typically extend vertically. Figure 1 Only a portion of a sidewall 56 is shown, which is described as being in contact with at least a plurality of agglomerated and non-agglomerated particles 42, 46 of the pad 40.

[0042] This bedding particle size formulation advantageously configures the bedding 40 to minimize carry-out by forming a top surface 52 of the bedding 40 poured into the bedding bowl 50, which is substantially composed entirely of larger-diameter particles 46 that are less likely to be carried away by a cat's claws when using the bedding 40. This advantageously minimizes the number of smaller-diameter particles 42 disposed on or along the top surface 52 of the bedding 40, as these smaller-diameter particles 42 are more easily carried away by a cat's claws when using the bedding. This non-clumping and clumping bedding particle formulation of the low-carry-out bedding 40 of the present invention advantageously configures the bedding 40 such that the larger bedding particles of the bedding 40 are non-clumping bedding particles 46, because they are less viscous than clumping particles 42, and therefore less likely to adhere to a cat's claws when using the bowl 50 compared to the smaller, more viscous clumping particles 42 of the bedding 40.

[0043] According to the tracking effectiveness test described in more detail herein, the formulation of the low-tracking bedding material 40 of the present invention has or is configured to have a tracking effectiveness of no more than 100 particles / square inch, preferably no more than 90 particles / square inch, and more preferably no more than about 60 particles / square inch. According to the clumping retention test procedure described in more detail below, this low-tracking bedding material 40 formulation of the present invention also preferably has reduced scattering during the removal of clumping formed by bedding particles 42, 46 from the bedding material 40 in the bedding basin 52, preferably by having or being configured to have a clumping retention rate of at least 90%, preferably at least 95%, and more preferably at least 97%. The agglomerates formed from the formulation of this low-carryover pad 40 of the present invention preferably also have or are configured to have a clumping compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi, wherein the agglomerates for which the clumping compressive strength test is performed are tested according to the clumping compressive strength test procedure described in more detail below.

[0044] refer to Figure 3 and Figure 4 The preferred padding carry-out performance testing tool 60 employs a generally flat or planar padding carry-out performance testing pad 61, which has a fiber surface 62 facing one direction and a handle 63 extending in the opposite direction on the other side. The pad 61 preferably has a fiber surface 62, which is a flocked fiber pad surface composed of upright-extending padding particle collecting fibers 64, and includes a padding particle carry-out collection area 66, typically rectangular (e.g., square). Figure 3 (shown in black in the image), preferably a one-inch by one-inch square. If desired, the fibrous surface 62 of the pad 61 of the tool 60 can be constrained to a one-inch by one-inch square.

[0045] refer to Figure 4 The pad 61 is preferably about a quarter inch thick and includes a base 68 from which fibers 64 extend outward, the base 68 being supported by a rigid backing 70 below. Figure 4 The pad 61 (shown in the image) is supported or rests on it, and the backing can be made of polystyrene foam (e.g., STYROFOAM) or a similar material, with the handle 62 extending outward from it. If desired, a layer of foam, such as an open-cell foam layer, can be placed between the fiber 64 and the backing 70. The pad 61 is approximately a quarter inch thick, and the fiber 64 is made of a synthetic material, preferably nylon, with a fiber length of approximately 0.150 inches, such that the fiber 64 extends approximately 0.150 inches from the base 68.

[0046] During the padding carry-out performance test, the user (e.g., the tester) manually grasps the handle of the tool and manipulates it so that the fibrous side of the pad is suspended above the surface 52 of the padding 40, then presses it straight down (not tilted), preferably at least slightly into the padding 40. The fibrous side of the pad is pressed against the padding 40 at surface 52 for five seconds with a pressure of 0.5 psi. Afterward, the tool 60 is lifted straight up, away from surface 52 and removed from the padding 40. The number of padding particles 42 and / or 46 adhering to a one-inch by one-inch test area is counted, and preferably removed to obtain the number of particles per square inch, i.e., the padding particle carry-out performance. The padding carry-out performance test procedure can and preferably is repeated at three other different locations on the outer surface 52 of the padding 40. The total number of padding particles 42 and / or 46 collected in a one-inch by one-inch square test pad area is calculated and divided by the number of test procedures performed to obtain the average padding particle carry-out performance, thereby enabling the evaluation of the uniformity of the padding blend or formulation. In a preferred embodiment, tool 60 is the 1500C HANDI PAINTR manufactured and sold by Shur-Line of Waukesha, Wisconsin, but the Shur-Line 1520C Trim and Touch Up Pad may also be used.

[0047] The agglomerated particles 42 are at least partially or entirely composed of or made of suitable agglomerating materials, including: agglomerating clay, such as preferably sodium bentonite; starch, starch-containing materials and / or starch-derived materials, such as preferably starch-containing grains or legumes extruded under sufficiently high pressure and temperature to cause at least a portion of the starch therein to be modified (e.g., physically, thermally and / or chemically modified) to form a water-soluble binder, which is a bedding agglomerating agent, in an amount sufficient to cause bedding agglomeration during the use of bedding 40; other starch-based agglomerating agents; cassava; cassava starch; gums or gum-based agglomerating agents, such as gum arabic, gum arabic, gum tragacanth, gum guar, gum arabic, and xanthan gum; alginates, such as sodium alginate; carrageenan, such as κ-carrageenan; pectin; Examples include high-methoxyl pectin (HMP), low-methoxyl pectin (LMP), or amidated low-methoxyl pectin; dextran, such as high molecular weight dextran, low molecular weight dextran, or cross-linked dextran; gelatin; gluten; vinyl polymers, including polyvinyl alcohol, polyethylene esters (such as polyvinyl acetate), polyvinylpyrrolidone, polyvinyloxazolidinone, polyvinylmethyloxazolidinone, copolymers thereof, or mixtures thereof; semi-synthetic polymers, including guar gum derivatives and cellulose ethers, such as methylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, ethyl hydroxyethylcellulose, methyl hydroxypropylcellulose, carboxymethylcellulose, preferably hydroxypropyl methylcellulose or mixtures thereof; and superabsorbent polymers that can be used as padding binders.

[0048] The non-caking particles 46 are at least partially or entirely composed of or made of suitable non-caking materials, including non-caking absorbent montmorillonite such as calcium bentonite, attapulgite, bleaching clay, sepiolite, and / or kaolin; plastics; rubber, such as crushed waste tires; glass, such as glass beads, granules, or pellets, preferably having a smooth surface or texture; wood, including wood pellets, sawdust, sawdust pellets, shavings, bark, and crushed wood particles, including particles at least partially made of wood. Pellet or sphere; paper, such as particles, pellets or spheres composed at least in part of paper; sand, such as quartz sand; perlite; ground plant shells or skins, such as those from walnuts (e.g., walnut shells), hazelnuts (e.g., hazelnut shells), cashews (e.g., cashew shells), almonds (e.g., almond shells), macadamia nuts (e.g., macadamia nut shells), peanuts (e.g., peanut shells or peanut skins), Brazil nuts (e.g., Brazil nut shells), pine nuts (e.g., pine nut shells or skins), and / or pecans (e.g., pecan shells or skins).

[0049] In a preferred low-carryover bedding embodiment and formulation, the agglomerated bedding pellets 42 are agglomerated bedding pellets extruded from a starch-containing material using an extruder, preferably a single-screw extruder. The starch-containing material is preferably a starch-containing admixture with a moisture content of no more than 22%, preferably no more than 20%, and more preferably no more than 18%. By weight of the admixture, the starch-containing material contains at least 40% starch, preferably at least 50% starch, and more preferably at least 60% starch. The extrusion process is carried out at at least 2000 psi, preferably at least 2500 psi, and more preferably at least 30 psi. The process is carried out at an extrusion pressure of 00 psi and an extrusion temperature of at least 100°C, preferably at least 120°C, more preferably at least 135°C. The process modifies, preferably, at least a portion of the starch in the extruded modified admixture, for example by physical modification and / or thermal modification, by applying extrusion pressure through the admixture in the extruder to form a water-soluble binder (preferably a cold water-soluble binder), which is an agglomerating agent, and in each agglomerated pad pellet extruded from the extruder, the amount is at least 5%, preferably at least 10%, more preferably at least 15% by weight of the pellet. The starch-containing admixture is preferably composed of one or more grains, such as wheat, corn, oats, rice, barley, sorghum and / or millet; one or more tubers, such as yam, sweet potato and / or another type of potato; and / or one or more legumes, such as lentils, chickpeas, peas, lupins and legumes such as butter beans, common beans (navy beans), white kidney beans, red kidney beans, adzuki beans, black-eyed beans and / or soybeans. Clumping bedding pellets 42 may be extruded clumping bedding pellets, such as those of extruded clumping bedding pellets of clumping lightweight natural grass bedding sold and distributed by Pioneer Pet Products, LLC of Cedarburg, Wisconsin, as SmartCat All Natural 100% Grass Lightweight Clumping Litter, which may be gray in color and whose composition, structure, configuration and / or manufacturing method are substantially the same as or similar to those of extruded clumping bedding pellets disclosed in the commonly owned U.S. Patents Nos. 1,101,3211, 1,108,3168 and 1,145,7605, the entire contents of which are expressly incorporated herein by reference.In the case of using extruded agglomerated pad pellets as agglomerated pad pellets 42 in the present invention of low-carryover pad 40, the agglomerating material 44 of each extruded pellet is or includes a starch-based extrudate extruded by the aforementioned starch-containing admixture via an extruder during pellet extrusion, containing at least 5%, preferably at least 10%, more preferably at least 15% of a water-soluble binder (preferably a cold water-soluble binder), which is formed from the aforementioned extrusion-modified starch, which is modified during and / or by extrusion of the pad pellets. When the pellets are wetted by an aqueous liquid (preferably urine), the binder at least partially dissolves into one or both of a gel and a flowable binder, wherein one or both are agglomerating agents, causing adjacent wetted pellets to aggregate and adhere to each other, forming a scoopable agglomerate. In at least one such preferred embodiment, the non-caking bedding particles 46 may be and preferably consist of one or more of the aforementioned non-caking materials, such as preferably calcium bentonite, crushed (e.g., ground) walnut shells, sand, paper particles, non-caking particles made of wood, cellulose particles, or another of the aforementioned non-caking materials.

[0050] It is also contemplated, within the scope of the low-carryover pad 40 of the present invention, the use of an extruded starch-based water-soluble binder containing agglomerating material 44, preferably an extruded starch-based agglomerating material 44, for example made from extruded agglomerate pellets (e.g., fine-sized extruded particles) and / or pulverized extruded agglomerate pellets, as agglomerating material 44, which is applied to the outer surface of matrix particles, for example by coating or plating, as disclosed in co-pending U.S. Application No. 18 / 372677, filed September 25, 2023, the entire contents of which are expressly incorporated herein by reference, thereby forming them into agglomerating particles 42 for use with or in connection with pad 40. The matrix particles may be agglomerated matrix particles (e.g., composed of agglomerated materials such as sodium bentonite), non-agglomerated matrix particles (e.g., composed of non-agglomerated materials such as calcium bentonite), non-absorbent matrix particles (e.g., composed of non-absorbent materials such as plastic, glass, rubber, or metal), absorbent matrix particles (e.g., composed of water-absorbing materials such as perlite or clays such as sodium bentonite and / or calcium bentonite), inorganic matrix particles (e.g., composed of inorganic materials), synthetic matrix particles (e.g., composed of synthetic materials, such as polymer materials), and / or organic matrix particles (e.g., composed of organic materials), preferably coated with extruded starch-based agglomerated material 44 to form agglomerated particles 42, which preferably have the particle size, particle size range, and / or particle size distribution disclosed elsewhere herein. In at least one preferred embodiment, a low-carryover pad 40 is made of agglomerated particles 42 consisting of such matrix particles coated or plated with extruded starch-based agglomerated material 44, wherein the non-agglomerated pad particles 46 may be and preferably consist of at least one of the aforementioned non-agglomerated materials, such as preferably calcium bentonite particles, crushed (e.g., ground) walnut shells, sand, perlite, paper particles, non-agglomerated particles composed of wood, cellulose particles, or particles (e.g., granules) of another of the aforementioned non-agglomerated materials.

[0051] Low-carryover bedding material with single agglomerated and non-agglomerated components

[0052] In a preferred embodiment, the padding material 40 is formulated such that the particle size of the largest agglomerated padding material particles 42 is at least 40%, preferably at least 45%, more preferably at least about 50% of the particle size of the smallest non-agglomerated padding material particles 46, such that the low-carryover padding material 40 of the present invention has and / or is configured to have an ideal low-carryover performance of no more than 100 particles / square inch, preferably no more than 90 particles / square inch, more preferably no more than about 60 particles / square inch. In such an embodiment, the padding material 40 is formulated such that the particle size of the largest agglomerated padding material particles 42 is between about 40% and about 60% of the particle size of the smallest non-agglomerated padding material particles 46, thereby configuring the padding material 40 to have an ideal low-carryover performance of no more than 100 particles / square inch, preferably no more than 90 particles / square inch, more preferably no more than about 60 particles / square inch. Such a bedding formulation preferably also forms bedding clumps during cat use of bedding 40, and these clumps are configured to reduce scattering by having (a) a clump retention rate of at least 90%, preferably at least 95%, more preferably at least 97% and / or (b) a clump compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi.

[0053] Procedure for testing the compressive strength of lumps

[0054] The following equipment was used to test the compressive strength of extruded granular absorbent (bedpan) lumps:

[0055] (1) 15mL plastic centrifuge tubes with screw caps

[0056] (2) 3.0mL disposable plastic pipette

[0057] (3) Distilled water

[0058] (4) Force gauge: Mark-10, model M7-500, serial number 3674412

[0059] (5) Electric test bench: Model ESM303, Serial number 3979431

[0060] (6) Digital control panel: Mark-10, model DC4060, serial number 3680222

[0061] (7) DREMEL handheld high-speed rotary power tool with deep cutting wheel

[0062] (8) Extruded granular absorbent material (extruded pellets) sample to be wetted to form agglomerates and subjected to compressive strength test.

[0063] Using the above equipment, the compressive strength of extruded granular absorbent (bedpan) lumps was tested using the following method:

[0064] (1) Saw off the conical end of the 15mL test tube and clean the burrs.

[0065] (2) Screw on the test tube cap and fill the test tube with the sample material to be tested.

[0066] (3) Add distilled water (1:1 weight ratio) to the sample material in the test tube to moisten the sample material.

[0067] (4) Wait 10 seconds

[0068] (5) Unscrew the test tube cap and use the ball end (tightly fitted) of the plastic pipette to gently push out the "mold" clump formed by wetting the sample material from the test tube.

[0069] (6) Allow the mold clumps to stand and dry at room temperature for 5 days.

[0070] (7) Using a deep cutting wheel attached to a DREMEL high-speed rotary tool (speed greater than 10000 RPM), cut the molded block into barrel-shaped sections, each section being approximately 0.5 inches thick or long.

[0071] (8) Measure the diameter and length of the cross section of each barrel-shaped mold block.

[0072] (9) Place the barrel-shaped (cylindrical) mold block cross section in the middle of the compression test platform, with the flat cut surface of the barrel-shaped mold block cross section facing up and down, so that the force gauge can perform the compression test.

[0073] (10) Using a compression rate of 0.5 inches per minute, the peak compressive strength of the barrel-shaped mold block section was determined by force gauge.

[0074] Clump retention rate test steps

[0075] (Clumping drop test)

[0076] The clumping retention rate was determined by adding 10 ml of water to pad material 40 to wet pellets 42 and 46 and form clumps in the pad material. After a predetermined time (ten minutes in one test group and thirty minutes in another), the clumps were removed from the pad material, weighed, and then dropped from a height of 18 inches onto a 10-mesh sieve. The remaining clumps after dropping onto the sieve were weighed. The clumping retention rate was calculated as the percentage obtained by dividing the weight of the clumps after the drop by the decimal result of the weight of the clumps before the drop, and then multiplying by 100.

[0077] In such a preferred embodiment, the minimum particle size of the non-clumping pad particles 46 of the pad 40 is at least 3000 micrometers, preferably at least 3250 micrometers, more preferably at least about 3350 micrometers, while the maximum particle size of the clumping pad particles 42 is no greater than 2000 micrometers, preferably no greater than 1850 micrometers, more preferably no greater than about 1700 micrometers. The minimum and maximum limits on the particle size of the non-clumping particles 46, as indicated by the relationship defined by the minimum percentages and / or percentage ranges described above, are crucial to ensuring that the maximum particle size of the clumping particles 42 is sufficiently small relative to the minimum particle size of the larger non-clumping particles 46, so that when the pad 40 is poured into the pad basin 50, substantially all the smaller clumping particles 42 are distributed below the top surface 52 of the pad, preferably relatively uniformly, filling the gaps between the non-clumping particles 46, which typically define the channels for urine to flow downwards away from the surface 52. By ensuring that the clumping particles 42 are distributed below the top surface 52 of the bedding 40, particularly placing them in the gaps between adjacent non-clumping particles 46 (which may form downward channels in the bedding 40), the clumping particles 42 located below but adjacent to surface 52 will be rapidly wetted and expanded by urine, blocking the gaps between adjacent non-clumping particles 46 before the urine can flow downward through the channels defined by the gaps to the bottom 56 of the bedding basin 50. This ensures that urine will be trapped at or near the bedding surface 52, rapidly activating the clumping material 44 in the clumping particles 42, quickly forming an expanded spherical agglomerate at or near surface 52, consisting of the wetted clumping particles 42 and non-clumping particles 46 of the bedding 40, which can be easily scooped out.

[0078] Because the relatively small agglomerated particles 42 arranged on and along the top surface 52 of the pad 40 are minimized, this results in a larger, more optimized number of agglomerated particles 42 being arranged below and between adjacent non-agglomerated particles 46. This helps ensure that the pad 40 of the present invention is not only low in carry-out, but also produces agglomerated particles with a clumping retention rate of at least 90%, preferably at least 95%, more preferably at least 97%, which minimizes and preferably substantially completely prevents scattering during agglomerated particle removal. Because the relatively small agglomerated particles 42 arranged on and along the top surface 52 of the padding 40 are minimized, this results in a larger, more optimized number of agglomerated particles 42 being arranged below and between adjacent non-agglomerated particles 46. The agglomerated particles produced by the low-carryover padding 40 of the present invention preferably also have a clumping compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi, which minimizes and preferably substantially prevents scattering during agglomeration removal.

[0079] In at least one of the above preferred embodiments, the low-carryover pad 40 has agglomerated particles 42 consisting of: (1) extruded starch-based agglomerated pellets containing at least 5%, preferably at least 10%, more preferably at least 15% of an extruded modified starch-based water-soluble binder, and / or (2) matrix particles coated or plated with extruded starch-based agglomerated material 44 containing at least 5%, preferably at least 10%, more preferably at least 15% of an extruded modified starch-based water-soluble binder, these particles absorbing at least five times, preferably at least six times, the weight of the extruded starch-based agglomerated material in the pellets or particles, and preferably expanding more rapidly when wetted by urine, more quickly clogging the gaps between adjacent non-agglomerated particles 46, trapping urine at or near the top surface 52 of the pad 40, more quickly activating the water-soluble binder in the extruded starch-based agglomerated material of each wetted pellet or particle, preferably rapidly forming pad clumps on the top surface 52 of the pad 40. The agglomerate particles 42 consist of: (1) extruded starch-based agglomerate pellets containing at least 5%, preferably at least 10%, more preferably at least 15% of an extruded modified starch-based water-soluble binder, and / or (2) matrix particles coated or plated with extruded starch-based agglomerate material 44 containing at least 5%, preferably at least 10%, more preferably at least 15% of an extruded modified starch-based water-soluble binder, preferably forming anti-scattering agglomerates that are harder, stronger, and do not crack, break, compress, or otherwise scatter. Such anti-scattering agglomerates preferably have a clumping retention rate of at least 90%, preferably at least 95%, more preferably at least 97%, and a clumping compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi.

[0080] The preferred low-carryover pad 40 formulation according to the invention can and preferably is further formulated to configure pad 40 such that the minimum particle size of the agglomerated particles 42 is between about 4% and about 10% of the minimum particle size of the non-agglomerated particles 46. This helps to ensure that the particle size of the minimum agglomerated particles 42 is sufficiently large relative to the minimum non-agglomerated particles 46 to minimize the number of agglomerated particles 42 adhering to the top of the non-agglomerated particles 46 on the surface 50 of pad 40, preferably resulting in even the smallest agglomerated particles 42 being distributed below the surface 50 of pad 40. This also reduces carryover, resulting in pad 40 having a carryover efficiency of no more than 100 particles / square inch, preferably no more than 90 particles / square inch, more preferably no more than about 60 particles / square inch. This preferred pad formulation preferably forms agglomerates with a retention rate of at least 90%, preferably at least 95%, more preferably at least 97%, which are minimized and preferably substantially completely prevented from scattering during removal. This preferred padding formulation can and preferably also form a clump compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi and is resistant to clumping.

[0081] In such preferred bedding formulations, the smallest agglomerated particles 42 preferably have a minimum particle size of at least 200 micrometers, more preferably at least about 250 micrometers, including ensuring that even the smallest agglomerated particles 42 are large enough to avoid becoming or turning into dust. In at least one such preferred bedding formulation, the smallest agglomerated particles 42 may have a minimum particle size of at least or about 500 micrometers. As previously mentioned, in such preferred formulations, the smallest non-agglomerated bedding particles 46 of the bedding 40 have a minimum particle size of at least 3000 micrometers, preferably at least 3250 micrometers, more preferably at least about 3350 micrometers. The relationship between the minimum diameter non-agglomerated particles 46 and the minimum diameter agglomerated particles 42, as defined by the minimum percentage mentioned above, is crucial to ensuring that the minimum diameter agglomerated particles 42 are not too small relative to the minimum diameter of the larger diameter non-agglomerated particles 46. This prevents the minimum diameter agglomerated particles 42 from becoming or manifesting as dust, and also ensures that they are large enough to be distributed below the top surface 52 of the bedding when the bedding 40 is poured into the bedding basin 50, filling the gaps between the non-agglomerated particles 46, which typically form channels for urine to flow unrestricted downwards from the bedding surface 52. By ensuring that even the minimum diameter agglomerated particles 42 are large enough to be distributed below the top surface 52 of the bedding 40 and fill the gaps in the downward channels formed between adjacent non-agglomerated particles 46 when the bedding 40 is poured into the bedding basin 50, it minimizes the number or amount of smaller agglomerated particles 42 that are ultimately carried or arranged on the surface 52 of the bedding 40, thereby reducing, minimizing, and preferably substantially completely preventing carryover. By ensuring that even the smallest clump particles 42 are large enough to be distributed below the bedding surface 52 and fill the gaps between and below adjacent non-clump particles 46, it ensures that even the smallest clump particles 42 will be quickly wetted and expanded by the urine of the cat using the bedding 40, blocking the gaps between adjacent non-clump particles 46, trapping urine on or near the bedding surface 52, and activating the clumping material 44 of the clump particles 42 to quickly form clumps of the bedding 42 on or near the surface 52.

[0082] In another preferred embodiment, the padding material 40 is formulated such that (a) the particle size of the largest agglomerated padding particles is at least 40%, preferably at least 45%, more preferably at least about 50% smaller than the particle size of the smallest non-agglomerated padding particles, and (b) the particle size of the smallest agglomerated particles is between about 4% and about 10% of the particle size of the smallest non-agglomerated particles. The padding material 40 is configured as the low-carryover padding material of the present invention, having a carryover efficiency of no more than 100 particles / square inch, preferably no more than 90 particles / square inch, more preferably no more than about 60 particles / square inch, and preferably also forming agglomerates with reduced scattering, these agglomerates having a retention rate of at least 90%, preferably at least 95%, more preferably at least 97%. Such low-scattering agglomerates can and preferably also have a clumping compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi.

[0083] In at least one of the above preferred embodiments, the low-carryover pad 40 has agglomerated particles 42 consisting of: (1) extruded starch-based agglomerated pellets containing at least 5%, preferably at least 10%, more preferably at least 15% of an extruded modified starch-based water-soluble binder, and / or (2) matrix particles coated or plated with extruded starch-based agglomerated material 44 containing at least 5%, preferably at least 10%, more preferably at least 15% of an extruded modified starch-based water-soluble binder, these particles absorbing at least five times, preferably at least six times, the weight of urine or water in the pellets or particles, and preferably expanding more rapidly when wetted by urine, more quickly clogging the gaps between adjacent non-agglomerated particles 46, trapping urine at or near the top surface 52 of the pad 40, more quickly activating the water-soluble binder in the extruded starch-based agglomerated material of each wetted pellet, preferably rapidly forming pad clumps on the top surface 52 of the pad 40. The agglomerate particles 42 consist of: (1) extruded starch-based agglomerate pellets containing at least 5%, preferably at least 10%, more preferably at least 15% of an extruded modified starch-based water-soluble binder, and / or (2) matrix particles coated or plated with extruded starch-based agglomerate material 44 containing at least 5%, preferably at least 10%, more preferably at least 15% of an extruded modified starch-based water-soluble binder, preferably forming anti-scattering agglomerates that are harder, stronger, and do not crack, break, compress, or otherwise scatter when scooped from the top surface 52 of the pad 40. Such anti-scattering agglomerates preferably have a clumping retention rate of at least 90%, preferably at least 95%, more preferably at least 97%, and a clumping compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi.

[0084] In yet another preferred embodiment, the bedding 40 is formulated such that the particle size of the largest diameter agglomerated particles 42 is between 30% and 50% of the particle size of the largest diameter non-agglomerated bedding particles 46, preferably between about 35% and about 45%, to ensure that even the largest diameter agglomerated particles 42 are sufficiently smaller than the largest diameter non-agglomerated particles 46, resulting in the agglomerated particles 42 being distributed between and below adjacent non-agglomerated particles 46, and sufficiently far from the surface 50 of the bedding 40, so that during use of the bedding bowl 50, a cat's paws stepping on the surface 50 of the bedding 40 cannot remove the agglomerated particles 42. This, in turn, ensures that the bedding 40 has, or is configured to have, a carry-out efficiency of no more than 100 particles / square inch, preferably no more than 90 particles / square inch, more preferably no more than about 60 particles / square inch. This embodiment preferably also produces bedding agglomerates with a retention rate of at least 90%, preferably at least 95%, more preferably at least 97%, which preferably have reduced scattering. This embodiment can and preferably also produces agglomerates with a mass compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi. The particle size of the agglomerated particles with the largest particle size is no greater than 2000 micrometers, preferably no greater than 1800 micrometers, and more preferably no greater than about 1700 micrometers. The particle size of the non-agglomerated particles 46 with the largest particle size is no greater than 5000 micrometers, preferably no greater than 4850 micrometers, and more preferably no greater than about 4750 micrometers.

[0085] In another preferred embodiment, the padding material 40 is formulated such that the particle size of the smallest agglomerated particles 42 is between 4% and 15% of the particle size of the largest non-agglomerated padding particles 46, preferably between about 4% and about 10%, resulting in a low-carryover padding material 40, which has and / or is configured to have a carryover efficiency of no more than 100 particles / square inch, preferably no more than 90 particles / square inch, more preferably no more than about 60 particles / square inch. The particle size of the largest non-agglomerated particles 46 is no more than 5000 micrometers, preferably no more than 4850 micrometers, more preferably no more than about 4750 micrometers. Such padding material 40 preferably forms a low-agglomeration agglomeration rate of at least 90%, preferably at least 95%, more preferably at least 97%. These agglomerates may have and preferably also have a clumping compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi.

[0086] The smallest agglomerated particle has a particle size of not less than 200 micrometers, preferably not less than 250 micrometers, and more preferably not less than about 500 micrometers. The largest non-agglomerated particle 46 has a particle size of not more than 5000 micrometers, preferably not more than 4850 micrometers, and more preferably not more than about 4750 micrometers.

[0087] In yet another preferred embodiment, the padding material 40 is formulated such that (a) the particle size of the largest diameter agglomerated particles 42 is between 30% and 50% of the particle size of the largest diameter non-agglomerated padding particles 46, preferably between about 35% and about 45%, and (b) the particle size of the smallest diameter agglomerated particles 42 is between 4% and 15% of the particle size of the largest diameter non-agglomerated particles 46, preferably between about 4% and about 10%, thus configuring the padding material 40 as a low-carryover padding material with a carryover efficiency of no more than 100 particles / square inch, preferably no more than 90 particles / square inch, and more preferably no more than about 60 particles / square inch. This embodiment also preferably produces a low-agglomeration padding material with a retention rate of at least 90%, preferably at least 95%, and more preferably at least 97%. These clumps can and preferably also have a clump compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi.

[0088] In at least one of the above preferred embodiments, the low-carryover pad 40 has agglomerated particles 42 consisting of: (1) extruded starch-based agglomerated pellets containing at least 5%, preferably at least 10%, more preferably at least 15% of an extruded modified starch-based water-soluble binder, and / or (2) matrix particles coated or plated with extruded starch-based agglomerated material 44 containing at least 5%, preferably at least 10%, more preferably at least 15% of an extruded modified starch-based water-soluble binder, these particles absorbing at least five times, preferably at least six times, the weight of the extruded starch-based agglomerated material in the pellets or particles, and preferably expanding more rapidly when wetted by urine, more quickly clogging the gaps between adjacent non-agglomerated particles 46, trapping urine at or near the top surface 52 of the pad 40, more quickly activating the water-soluble binder in each wetted pellet or particle of the extruded starch-based agglomerated material, preferably rapidly forming pad clumps on the top surface 52 of the pad 40. The agglomerate granules 42 consist of: (1) extruded starch-based agglomerate pellets containing at least 5%, preferably at least 10%, more preferably at least 15% of an extruded modified starch-based water-soluble binder, and / or (2) matrix granules coated or plated with an extruded starch-based agglomerate material 44 containing at least 5%, preferably at least 10%, more preferably at least 15% of an extruded modified starch-based water-soluble binder, preferably forming scatter-resistant agglomerates that are harder, stronger, and do not crack, break, compress, or otherwise scatter when scooped from the pad 40 with a pad shovel. When tested according to the corresponding agglomeration retention rate test and / or agglomeration compressive strength test procedures described in more detail herein, such anti-agglomeration preferably has an agglomeration retention rate of at least 90%, preferably at least 95%, more preferably at least 97%, and an agglomeration compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi.

[0089] At least one or more embodiments of the aforementioned padding material 40 may and preferably be formulated to include (a) at least 20%, preferably at least 25%, more preferably at least about 30% of agglomerated padding material particles 42 by weight of the padding material, and (b) no more than 45% and preferably no more than about 40% of agglomerated particles 42. At least one or more embodiments of the aforementioned padding material 40 may and preferably be formulated to include (a) at least 20%, preferably at least 25%, more preferably at least about 30% of non-agglomerated padding material particles 46 by weight of the padding material, and (b) no more than 80%, preferably no more than 75%, more preferably no more than about 70% of non-agglomerated particles 46 by weight of the padding material. In at least one preferred embodiment, the padding material 40 is formulated to include (a)(i) at least 20%, preferably at least 25%, more preferably at least about 30% of agglomerated padding material particles 42 by weight of the padding material, and (ii) no more than 45% and preferably no more than about 40% of agglomerated particles 42, and (b)(i) at least 20%, preferably at least 25%, more preferably at least about 30% of non-agglomerated padding material particles 46 by weight of the padding material, and (ii) no more than 80%, preferably no more than 75%, more preferably no more than about 70% of non-agglomerated particles 46 by weight of the padding material.

[0090] At least one or more of the above-disclosed bedding material 40 embodiments preferably have a larger diameter non-caking bedding material particles 46 having a particle size of at least 3000 micrometers, preferably at least 3250 micrometers, more preferably at least about 3350 micrometers, while the smaller diameter agglomerated bedding material particles 42 have a particle size of no more than 2000 micrometers, preferably no more than 1850 micrometers, more preferably no more than about 1700 micrometers. At least one or more of the above-disclosed bedding material 40 embodiments preferably have a larger diameter non-caking bedding material particles 46 having a particle size of no more than 5000 micrometers, preferably no more than 4850 micrometers, more preferably no more than about 4750 micrometers, while the smaller diameter agglomerated bedding material particles 42 have a particle size of at least 200 micrometers and preferably at least about 250 micrometers. In at least one embodiment, the smaller diameter agglomerated bedding material particles 42 have a particle size of at least 300 micrometers, preferably at least 400 micrometers, more preferably at least about 500 micrometers.

[0091] The non-caking bedding particles 46 of at least one or more of the bedding material 40 embodiments described herein preferably have a non-caking bedding particle size distribution of 3,000 micrometers to about 5,000 micrometers, or have a non-caking particle size of 3,000 micrometers to 5,000 micrometers. The agglomerated bedding particles 42 of at least one or more of the above embodiments preferably have an agglomerated bedding particle size distribution of 200 micrometers to 2,000 micrometers, or have a particle size of 200 micrometers to 2,000 micrometers. In at least one preferred bedding material formulation embodiment, (a) the agglomerated particles 42 have a particle size distribution of 200 micrometers to 1,800 micrometers and / or a particle size of 200 micrometers to 1,800 micrometers, and (b) the non-caking particles 46 have a particle size distribution of 3,250 micrometers to 4,850 micrometers and / or a particle size of 3,250 micrometers to 4,850 micrometers.

[0092] The non-caking bedding particles 46 of at least one or more of the above-described bedding material 40 embodiments preferably have a non-caking bedding particle size distribution of about 3350 micrometers to about 4750 micrometers, or have a non-caking particle size of about 3350 micrometers to about 4750 micrometers. The agglomerated bedding particles 42 of at least one or more of the above-described embodiments preferably have an agglomerated bedding particle size distribution of about 250 micrometers to about 1700 micrometers, or have a particle size of about 250 micrometers to about 1700 micrometers. In at least one preferred bedding material formulation embodiment, (a) the agglomerated particles 42 have a particle size distribution of 250 micrometers to 1700 micrometers and / or a particle size of 250 micrometers to 1700 micrometers, and (b) the non-caking particles 46 have a particle size distribution of 3350 micrometers to 4750 micrometers and / or a particle size of 3350 micrometers to 4750 micrometers.

[0093] In another preferred embodiment of the low carry-out padding material 40 of the present invention, at least one formulation of the padding material 40 comprises: (a) at least a plurality of, preferably at least a plurality of pairs (i.e., at least three) of non-agglomerated particles having a non-agglomerated particle size range, and (b) at least a plurality of, preferably at least a plurality of pairs (i.e., at least three) of agglomerated particles having agglomerated particle size range, wherein the particle size ratio of the non-agglomerated particles 46 to the agglomerated particles 42 ranges from about 2:1 to about 14:1, thereby configuring the padding material 40 to have an ideal low padding carry-out efficiency of no more than 100 particles / square inch, preferably no more than 90 particles / square inch, more preferably no more than about 60 particles / square inch. Such padding material 40 preferably also produces clumps with reduced breakage, the clumps having a clump retention rate of at least 90%, preferably at least 95%, more preferably at least 97%, and may have a clump compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi.

[0094] In one such preferred embodiment, the ratio of the smallest particle size of the non-agglomerated particles 46 to the smallest particle size of the agglomerated particles 42 ranges from about 7:1 to about 67:4 or about 16.75:1. For example, the smallest particle size of the non-agglomerated particles 46 is about 3350 micrometers, while the smallest particle size of the agglomerated particles 42 varies between 200 micrometers and 500 micrometers. In another such preferred embodiment, the ratio of the largest particle size of the non-agglomerated particles 46 to the largest particle size of the agglomerated particles ranges from 19:6 to 19:8. For example, the largest particle size of the non-agglomerated particles 46 is about 4750 micrometers, while the largest particle size of the agglomerated particles 42 varies between 1500 micrometers and 2000 micrometers.

[0095] Figure 2 Another preferred but exemplary clumping pad 40' is described, which forms clumps when wetted by urine. Its formulation comprises pad particles 42a, 42b, 46a, 46b of at least one non-clumping material, wherein the particle size of the non-clumping pad particles 46a, 46b is significantly larger than the particle size of the at least one clumping material pad particles 42a, 42b. This configures the clumping pad 40' to have such low pad particle carry-out efficiency that it produces a low-carry-out clumping pad 42 according to the invention. The pad 40' preferably has a pad carry-out efficiency of no more than 100 particles / square inch, preferably no more than 90 particles / square inch, and more preferably no more than about 60 particles / square inch (tested according to the pad particle carry-out efficiency test described in more detail below). The clumps formed using pad 40' exhibit reduced scattering when removed from the pad 40' from the pad trough by means of having or being configured to have a clump retention rate of at least 90%, preferably at least 95%, more preferably at least 97%. The clumps using pad 40' also preferably have or are configured to have a clump compressive strength of at least 40 psi, preferably at least 60 psi, more preferably at least 100 psi, and even more preferably at least 200 psi.

[0096] exist Figure 2 In the preferred low-carryover agglomeration bedding embodiment shown, bedding 40' may have (a) a plurality of different non-agglomerate bedding particles 46a, 46b, each preferably composed of a different type of non-agglomerate material, and the particle size of each non-agglomerate bedding particle 46a, 46b may fall within one of a plurality of particle size ranges, which may and preferably are different from each other, and (b) a plurality of different agglomerate bedding particles 42a, 42b, each preferably composed of a different type of agglomerate material, and the particle size of each different agglomerate bedding particle 42a, 42b may fall within one of a plurality of particle size ranges, which may and preferably are different from each other.

[0097] The present invention also relates to a clumping bedding material that minimizes bedding material carry-over when a cat leaves the bedding bowl, and preferably also minimizes the amount of used bedding material scattered from the clumping during removal, while ensuring high quality of the formed clumps and maximizing the absorbency of the bedding particles.

[0098] Refer again Figure 2 The clumping bedding material 40' comprises clumping bedding particles 42a, 42b of at least one clumping material, preferably multiple different clumping materials 44a, 44b, and non-clumping bedding particles 46a, 46b of at least one non-clumping material, preferably multiple different types of non-clumping materials 48a, 48b. In a preferred embodiment, the bedding material 40' comprises a blend of non-clumping calcium bentonite and clumping sodium bentonite, and may include another clumping material, which may be or contain an extruded starch-based clumping material, which preferably swells upon absorbing urine and activating the extruded modified starch-based water-soluble binder clumping agent. More preferably, the agglomerated bedding material comprises a blend of non-agglomerated calcium bentonite (non-agglomerated bedding particles 46a forming an agglomerated material 48a), agglomerated sodium bentonite (agglomerated particles 42a forming an agglomerated material 44a), and an expanded material (which is an extruded product, such as preferably high-pressure extruded cereal grains) containing at least 5% by weight, preferably at least 10% by weight, and more preferably at least 15% by weight of an extrusion-modified water-soluble binder agglomerating agent to form agglomerated bedding particles 42b of another agglomerated material 44b. The high-pressure extruded cereal grain agglomerated particles 42b (preferably in the form of extruded pellets) are water-activated and expand upon absorbing water. Although it dissolves at least partially upon wetting, the extruded agglomerate particles 42b swell upon rapid absorption of urine, wetting particles 42b and at least partially dissolving the extruded modified water-soluble binder agglomerate in each wetting particle 42b, substantially simultaneously forming and / or releasing a flexible, flowable adhesive that adapts to any shape upon flow and gelation, adhering, attaching, and / or preferably even bonding to any other component in the pad 40' that the flowable binder or adhesive comes into contact with, including adjacent pad particles 42a and / or 44. These flowable agglomerate binder or adhesive globules can be separated by the urine flow, which advantageously fills and preferably blocks downstream voids in the pad 40' as its viscosity rapidly thickens into a gel, which then solidifies, trapping urine above it at or near the top surface 52 of the pad. This preferably results in the formation of agglomerates of pad particles 42a, 42b, and / or 46a on the top 52 of the pad 40'.

[0099] This bedding formulation differs significantly from prior art bedding formulations in terms of particle size range and the weight percentage of each component. More specifically, the non-agglomerated particles 46a and / or 46b have larger particle sizes and ranges, with particle sizes at each range boundary larger than those of prior art agglomerated bedding. The particle size range of the bedding 40 or 40', the particle sizes of the agglomerated particles 42, 42a, and / or 42b relative to the significantly larger non-agglomerated particles 46, 46a, and / or 46b, can be varied, provided that the smaller agglomerated particles 42, 42a, and / or 42b are sufficiently small relative to the significantly larger non-agglomerated particles 46, 46a, and / or 46b, such that the smaller agglomerated particles 42, 42a, and / or 42b are substantially entirely disposed below the surface 52 of the bedding 40 or 42', away from contact with cat paws stepping on the bedding surface 52 during use of the bedding 40 or 40'. Provided that the particle size of the agglomerated particles 42, 42a and / or 42b is small enough relative to the non-agglomerated particles 46, 46a and / or 46b, such that the smaller agglomerated particles 42, 42a and / or 42b form a matrix when wetted by urine, resulting in a solid agglomerate with good agglomerate integrity and a high agglomerate retention rate (greater than 90%, preferably greater than 95%, more preferably greater than 97%), the particle size range of the pad material 40 or 40' of the present invention, the particle size of the agglomerated particles 42, 42a and / or 42b and the non-agglomerated particles 46, 46a and / or 46b can be varied. This configuration results in smaller clumping particles 42, 42a, and / or 42b being small enough to be contained within the voids of much larger non-clumping particles 46, 46a, and / or 46b, while the non-clumping particles 46, 46a, and / or 46b are large enough relative to the smaller clumping particles 42, 42a, and / or 42b in size to allow the clumping material (including its clumping agent) of urine-wetting clumping particles 42, 42a, and / or 42b to fill the channels created by the voids between adjacent non-clumping particles 46, 46a, and / or 46b. This prevents non-agglomerated particles from interrupting the formation of an interlocking matrix created by the release of an agglomerating agent, preferably comprising an extrusion-modified starch-based water-soluble binder present in the agglomerating material of agglomerated particles 42, 42a, and 42b (preferably extruded agglomerated particle 42b), which encapsulates agglomerated and non-agglomerated particles 42 and / or 46 or 42a, 42b, 46a, and / or 46b into a wet / moist spherical agglomerate. To facilitate this result, preferably, no more than 10% by weight of the particles 42, 42a, and / or 42b, 46, 46a, and / or 46b of the agglomerated and non-agglomerated materials 44 and 48 and / or 44a, 44b, 48a, and / or 48b overlap in particle size.Most preferably, in the agglomerated and non-agglomerated materials 44 and 48 and / or 44a, 44b, 48a and / or 48b, particles 42, 42a, 42b, 46, 46a and / or 46b, by weight, no more than 5% of the particles overlap in particle size.

[0100] In one embodiment of the invention, all non-caking particles have a larger particle size than the agglomerating particles. Due to this configuration, agglomeration occurs where smaller agglomerating particles fill the large voids between and around the non-caking particles. Because of the difference in particle size distribution between the non-caking particles and the agglomerating particles, the agglomerating particles are small enough to fit into the voids formed between and around adjacent non-caking particles. When urine enters the pad 50, this causes the agglomerating agent in the agglomerating particles to immediately expand and prevent urine from flowing downwards through the pad 40 or 40' to the bottom of the pad 50. The agglomerating agent from the urine-wetting agglomerating particles flows into the urine stream and blocks the pores and voids between and around the non-caking particles, preventing the urine from flowing downwards and trapping urine at or near the surface 52 of the pad 40 or 40', resulting in the formation of agglomerates on the top of the pad 40 or 40'.

[0101] See Figure 5Table 1 lists the weight percentages of various agglomerating materials 44a and / or 44b (agglomerating particles 42a and / or 42b) and non-agglomerating materials 48a and / or 48b (non-agglomerating particles 46a and / or 46b) contained in six test formulations of low-carryover bedding products prepared according to the present invention. Each formulation contains approximately 70% by weight of non-agglomerating material 48 (such as calcium bentonite 48) non-agglomerating particles 46, or non-agglomerating particles 46a of calcium bentonite 48a and walnut shell 48. A blend of non-caking pellets 46b and agglomerated pellets 42 of about 30% by weight of agglomerating material 44 (such as sodium bentonite 44), or agglomerated pellets 42a of sodium bentonite 44a and agglomerated pellets 42b of extruded starch-based material (consisting of at least 5%, preferably 10%, more preferably 15% by weight of extruded modified starch-based water-soluble binder 44b), such as lightweight natural grass / extruded grain 44b. In some preferred embodiments of the invention, non-caking pellets 46a and / or 46b and / or their non-caking material 48a and / or 48b constitute about 60%-70% by weight of the low-carryover bedding mixture, blend, or formulation. In a preferred embodiment of the invention, the non-caking particles 46 or 46a of calcium bentonite 48 or 48a constitute about 70%-80% by weight of a low-carryover bedding mixture, blend, or formulation. In other embodiments, the non-caking particles 46a and 46b consist of about 30%-40% by weight of calcium bentonite 48a and about 30%-40% by weight of walnut shells 48b, respectively. In some embodiments, the agglomerating particles 42a and 42b consist of about 10%-15% by weight of sodium bentonite 44a and about 10%-15% by weight of extruded grains. In other embodiments, the agglomerating material is about 5%-15% by weight of sodium bentonite and about 15%-25% by weight of extruded grains 44b, preferably an extruded starch-based material composed of at least 5%, preferably 10%, more preferably 15% by weight of extruded modified starch-based water-soluble binder agglomerating agent. In other embodiments, the agglomerated particles may also comprise or consist of guar gum coated on matrix particles (e.g., non-agglomerated and / or non-absorbent particles), having, for example, in a manner discussed above, one or more particle sizes smaller than the non-agglomerated pellets 46a and / or 46b used in padding 40 or 40'. The specific particle size distribution of each agglomerated particle and agglomerated material in these low-carryover padding product test numbers 1 to 6, as well as the specific particle size distribution of these non-agglomerated particles and non-agglomerated particles, is included in... Figure 6In Table 2. Due to the particle size distribution of the agglomerated and non-agglomerated particles in the respective formulation test numbers 1 to 6 of the present invention, the low carry-out bedding material 40 or 40' of the present invention is formulated such that in the bedding basin 50, about 70% or more of the surface area of ​​the top surface 52 of the bedding material 40 or 40' exposed to the cat's paws using the bedding material consists of non-agglomerated particles 46a and / or 46b with a particle size greater than 1700 micrometers, which are too large to adhere to the cat's paws and are carried out of the bedding material 40 or 40' from the bedding basin 50.

[0102] While serving as an effective agglomerating bedding material, the bedding formulation of the present invention also has the additional advantage of being lighter in weight compared to prior art agglomerating bedding materials. For example, the bulk density of agglomerating particles 42b composed of high-pressure extruded grains (preferably or comprising extruded starch-based material consisting of at least 5% by weight, preferably 10% by weight, or more preferably 15% by weight of extruded modified starch-based water-soluble binder agglomerating agent 44b) is approximately 1 / 5 that of sodium bentonite 44a used for agglomerating particles 42a, and is 1 / 3 that of the bulk density of non-agglomerating materials 48, 48a, and / or 48b used for non-agglomerating particles 46, 46a, and / or 46b. Therefore, by increasing the proportion of agglomerated particles 42 or 42a and non-agglomerated particles 46 or 46a (calcium bentonite 48 or 48a) made from high-pressure extruded grains (an extruded starch-based material consisting of at least 5% by weight, preferably 10% by weight, and more preferably 15% by weight of extruded modified starch-based water-soluble binder 44b of the pellet weight) and non-agglomerated particles 46 or 46a, the weight of the bedding 40 or 40' is reduced compared to conventional agglomerated bedding with a larger proportion of sodium bentonite bedding particles.

[0103] Although the low-carryover bedding test formulations 1-7 are lightweight, each formulation produced high-quality clumps, which is reflected in Figure 7 Table 3 contains the drop test results for each test formulation number. As shown in the figure, two clumps were formed and weighed for each padding formulation test number of the present invention. Subsequently, drop tests were performed on the clumps at time intervals of ten minutes and thirty minutes, after which the clumps were weighed again and compared with their weight before the drop. The percentage of clump retention was then calculated. These results are comparable to those of existing commercially available clump padding materials, but the weight of existing products is significantly higher than that of the low carry-out formulations 1-7 manufactured according to the present invention.

[0104] In addition, such as Figure 8As shown in Table 4, each of the six low-carryover bedding formulation test numbers exhibits excellent carryover characteristics, as evidenced by their respective bedding particle carryover efficiency values ​​in Table 4. These values ​​are significantly lower than those of several commercially available prior art agglomerated bedding materials also listed in Table 4—typically, their bedding particle carryover is less than half that of these commercially available prior art bedding material mixtures. This is because the particle size and type of agglomerated and non-agglomerated particles and materials used to manufacture the blends of formulation tests 1-6 were selected to maximize the amount of voids filled around the larger calcium bentonite particle 46a. This low-carryover bedding formulation, with voids filled around the calcium bentonite particle 46a, results in reduced movement of all bedding particles 42a, 42b, 46a, and / or 46b. In other words, this low carry-out formulation achieves this by minimizing the amount of deflection of particles 42b, 46a, and / or 46b when a cat steps on the surface 52 of the bedding 40 or 40' in the bedding bowl 50, which in turn minimizes the amount of particles 42a, 42b, 46a, and / or 46b carried out of the bowl 50.

[0105] The amount of moisture on a cat's paws also affects the amount of litter carried out. Wet paws are more likely to carry out clumps of litter pellets 42a and / or 42b, consisting of clumping materials 44a and / or 44b, from the litter bowl 50. Therefore, by increasing the weight percentage of non-clumping materials 46a and / or 46b (e.g., calcium bentonite 46a and / or walnut shells 46b), the amount of litter pellets 42a, 42b, 46a, and / or 46b carried out from the litter bowl 50 can be further reduced. Furthermore, static electricity (common due to the frequent charge generated by cat fur) also affects the amount carried out. Calcium bentonite 48a and walnut shells 48b advantageously do not carry a charge, so pellets 46a and / or 46b of these non-clumping materials 48a and / or 48b generally do not adhere to the cat's fur based on the charge in the fur. Figure 8 As shown in Table 4, all six low-carryover padding test formulations manufactured according to the present invention exhibited fewer particles on the test pads than commercially available prior art padding blends—they typically carried away less than half the number of padding particles as those commercially available prior art padding blends.

[0106] It should also be understood that, although the foregoing description and drawings detail and illustrate one or more preferred embodiments of the invention, this disclosure will also present various modifications, constructions, and alternatives, as well as different embodiments and applications, all of which are considered to be within the scope of the invention, to those skilled in the art. Therefore, the invention is intended to be limited only by the scope of the appended claims.

Claims

1. A low-carryover agglomeration bedding material, comprising a blend of agglomeration bedding material particles and non-agglomeration bedding material particles.

2. The low-carryover agglomeration bedding material according to claim 1, wherein the particle size of the non-agglomerate particles is larger than the particle size of the agglomerate particles.

3. The low-carryover agglomeration padding material according to claim 2, wherein the padding particle carryover efficiency of the low-carryover padding material is no more than 100 particles per square inch.

4. The low-carryover agglomeration padding material according to claim 3, wherein the padding particle carryover efficiency of the low-carryover padding material is no more than about 90 particles per square inch.

5. The low-carryover agglomeration padding material according to claim 3, wherein the padding particle carryover efficiency of the low-carryover padding material is no more than about 100 particles per square inch, said particles adhering to the outer padding particle collection surface of the low-carryover padding particle collection pad in contact with the low-carryover padding material.

6. The low-carryover caking bedding material according to claim 5, wherein the low-carryover bedding material particle collection pad is composed of a fiber pad attached to a backing layer and at least a handle carrying the fiber pad, wherein the outer bedding material particle collection surface of the fiber pad is pressed into and removed from the top surface of the low-carryover bedding material contained in the bedding basin, and wherein the number of non-caking bedding material and caking bedding material particles retained on the outer surface of the fiber pad is counted.

7. The low-carry-out agglomeration padding material according to claim 6, wherein the number of non-agglomerate and agglomerate particles remaining on the outer surface of the fibers of the pad is taken out and counted to obtain the padding particle carry-out efficiency of the low-carry-out padding material.

8. The low-carryover agglomeration pad material according to claim 2, wherein the non-agglomerate particles have a non-agglomerate particle size range consisting of non-agglomerate particles having a variety of particle sizes, and the agglomerate particles have an agglomerate particle size range consisting of agglomerate particles having a variety of particle sizes, wherein the particle size of the agglomerate particles is smaller than the particle size of the non-agglomerate particles in the non-agglomerate particle size range.

9. The low-carryover agglomeration pad according to claim 2, wherein the non-agglomerate particles have a non-agglomerate particle size range consisting of non-agglomerate particles having a variety of particle sizes, and the agglomerate particles have an agglomerate particle size range consisting of agglomerate particles having a variety of particle sizes, wherein the particle size of the agglomerate particles is smaller than the particle size of the non-agglomerate particles in the non-agglomerate particle size range, such that the agglomerate pad is configured such that its top surface is composed of larger non-agglomerate particles, and smaller agglomerate particles are arranged below the top surface of the agglomerate pad.

10. The low-carryover agglomeration padding material according to claim 9, wherein the agglomeration padding material is further configured in a stacked arrangement, the stacked arrangement comprising: (a) multiple pairs of non-agglomeration padding material particle layers defining multiple pairs of voids between non-agglomeration padding material particles in adjacent non-agglomeration padding material particle layers, and (b) multiple pairs of agglomeration particles disposed in the voids between adjacent non-agglomeration particles in each adjacent layer of non-agglomeration particles.

11. The low-carryover agglomeration pad material according to claim 10, wherein the ratio of the lower limit of the non-agglomerate particle size range to the lower limit of the agglomerate particle size range is not less than about 2:1, and the ratio of the upper limit of the non-agglomerate particle size range to the upper limit of the agglomerate particle size range is not greater than about 14:

1.

12. The low-carryover agglomeration bedding material according to claim 10, wherein the ratio of the particle size of the non-agglomerate particles to the particle size of the agglomerate particles is 2:1 to 14:

1.

13. The low-carryover agglomeration bedding material according to claim 1, wherein the agglomeration particles are composed of an extruded starch-based water-soluble binder containing agglomeration material, and the non-agglomeration particles are composed of one of calcium bentonite and crushed walnut shells.

14. The low-carryover agglomeration bedding material according to claim 1, wherein the agglomerating particles are composed of one of an extruded starch-based water-soluble binder containing agglomerating material and sodium bentonite, and the non-agglomerating particles are composed of one of calcium bentonite and crushed walnut shells.

15. The low-carryover agglomeration padding material according to claim 1, wherein there are agglomeration particles consisting of an extruded starch-based water-soluble binder containing agglomeration material and agglomeration particles consisting of sodium bentonite, and non-agglomeration particles consisting of calcium bentonite.

16. The low-carryover agglomeration bedding material according to claim 15, further comprising non-agglomerate particles composed of crushed walnut shells.

17. The low-carryover agglomeration padding material according to claim 1, wherein: At least a plurality of non-agglomerated particles have a particle size falling within the range of non-agglomerated particle size defined by the lower limit of non-agglomerated particle size and the upper limit of non-agglomerated particle size, and at least a plurality of agglomerated particles have a particle size falling within the range of agglomerated particle size defined by the lower limit of agglomerated particle size and the upper limit of agglomerated particle size. The ratio of non-agglomerated particle size to agglomerated particle size is approximately 2:1 to approximately 14:1; the ratio of non-agglomerated particle size to agglomerated particle size at the corresponding lower limit of the respective non-agglomerated and agglomerated particle size ranges is approximately 2:1; and the ratio of non-agglomerated particle size to agglomerated particle size at the corresponding upper limit of the respective non-agglomerated and agglomerated particle size ranges is approximately 14:1; and The low-carrying capacity of the low-carrying pad adhering to the low-carrying pad in contact with the low-carrying pad is no more than 100 particles per square inch.

18. The low-carryover agglomeration padding material according to claim 17, wherein the padding particle carryover efficiency of the low-carryover padding material is no more than about 90 particles per square inch.

19. The low-carryover agglomeration bedding material according to claim 17, wherein the agglomerating particles are composed of an extruded starch-based water-soluble binder containing agglomerating material, and the non-agglomerating particles are composed of one of calcium bentonite and crushed walnut shells.

20. The low-carryover agglomeration bedding material according to claim 17, wherein there are agglomeration particles consisting of an extruded starch-based water-soluble binder containing agglomeration material and agglomeration particles consisting of sodium bentonite, and non-agglomeration particles consisting of calcium bentonite and crushed walnut shells.

21. The low-carryover agglomeration bedding material according to claim 20, wherein non-agglomeration particles composed of calcium bentonite and non-agglomeration particles composed of crushed walnut shells are present.

22. A low-carryover agglomeration bedding material, comprising the following substances: Approximately 70% by weight of non-agglomerated clay material; and Approximately 30% by weight of agglomerated material; When urine is applied to the padding, the padding forms removable clumps.

23. The lightweight agglomerated granular bedding material according to claim 33, wherein the agglomerating material comprises one or more of sodium bentonite clay and cellulose materials.

24. The lightweight agglomerated granular bedding material according to claim 23, wherein the cellulose material is grain extruded under high pressure.

25. The lightweight agglomerated granular bedding material according to claim 24, wherein the non-agglomerated clay material is calcium bentonite clay.

26. The lightweight agglomerated granular bedding material according to claim 25, wherein the bulk density of the grains extruded under high pressure is lower than that of sodium bentonite clay and calcium bentonite clay.

27. The lightweight granular bedding material according to claim 25, wherein when urine is applied to the bedding material, the sodium bentonite clay particles and the high-pressure extruded grains expand and adhere to the calcium bentonite particles.

28. The lightweight agglomerated granular bedding material according to claim 25, wherein the average particle size of the calcium bentonite clay is greater than the average particle size of the sodium bentonite clay and the high-pressure extruded grains.

29. The lightweight agglomerated granular bedding material according to claim 28, wherein the particle size distribution of the bedding material minimizes the carry-out of both non-agglomerated clay material and agglomerated material outside the bedding basin.

30. The lightweight agglomerated granular bedding material according to claim 22, wherein the agglomerated material particles are about 250 micrometers to about 1680 micrometers.

31. The lightweight agglomerated granular bedding material according to claim 22, wherein the agglomerated material particles are about 250 micrometers to about 500 micrometers.

32. The lightweight agglomerated granular bedding material according to claim 22, wherein the non-agglomerated material particles are from about 1680 micrometers to about 4760 micrometers.

33. The lightweight agglomerated granular bedding material according to claim 1, wherein the particle size of the agglomerated particles is from about 250 micrometers to about 1680 micrometers.

34. The lightweight agglomerated granular bedding material according to claim 1, wherein the particle size of the agglomerated particles is from about 500 micrometers to about 1680 micrometers.

35. The lightweight agglomerated granular bedding material according to claim 1, wherein the particle size of the non-agglomerated particles is from about 1680 micrometers to about 4760 micrometers.

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