Low density pet litter and methods for making and using such pet litter

Abstract

Disclosed herein is an animal litter comprising a blend of compacted granules comprising expanded perlite fines and coated granules, each coated granule comprising non-agglomerated particles and a coating comprising a flocculating agent on the outer surface of the particle.

Description

Detailed Description of the Invention

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 126905, filed December 17, 2020, the entire disclosure of which is incorporated herein by reference.

[0002] [Background technology]

[0002] This disclosure relates generally to low-density absorbent materials that can be used to clump pet litter. More specifically, this disclosure relates to low-density pet litter comprising a blend of compacted granules comprising expanded perlite fines and coated granules comprising expanded perlite, as well as methods of making and using such pet litter.

[0003]

[0003] Animal litter boxes are used by pets, such as cats, to excrete urine and feces. The litter box contains a layer of pet litter that receives the urine and feces. Pet litter is granular, absorbent, and either non-clumping or clumping. Clumping pet litter is a litter product in which the granules promote clump formation after urine and feces adhere to the litter. The clumps are typically separated from the litter box using a litter scoop and then discarded. Non-clumping pet litter is typically better at absorbing urine and thus eliminating urine odors, but replacing soiled non-clumping pet litter without emptying the litter container can be difficult.

[0004]

[0004] Traditionally, mineral-based clumping litter has used swelling clay as a clumping agent. Incorporation of this component into the litter substrate has been achieved in a variety of ways, including grinding, sizing, and blending swelling and non-swelling clays of various particle sizes. Another approach involves coating an adsorbent core material with swelling clay.

[0005]

[0005] While swelling clays offer excellent absorption and granule-binding properties useful for clump formation, these properties can adversely affect the overall sorption capacity of the litter substrate as a whole. This apparent paradox arises because swelling clays have relatively low liquid permeability when hydrated. As the swelling clay absorbs liquid, a relatively liquid-impermeable barrier is formed at the absorption site, thereby preventing the liquid from further penetrating and absorbing deeper into the core of the granule. As a result, litter requires a large amount (by volume) of substrate to produce one or more clumps that are thin in shape or size, brittle, easily breakable, or so deep that they stick to the bottom of the box. These properties make clump removal more difficult.

[0006] Attempts to balance the mass loading level of swelling clay with the desired floc formation and acceptable floc properties have included various combinations of mass loading levels of swelling and non-swelling clay granules, various combinations of particle sizes of swelling and non-swelling clay granules, and coating agglomerated non-swelling clay with swelling clay. While these approaches have met with varying degrees of success, due to their reliance on the use of clay minerals, litter products are inherently high density (55-75 lb / ft). 3 ). Furthermore, even non-swelling clays have some inherent swelling capacity and, due to their clay structure, have a degree of plasticity when wet. The "mud" produced by non-swelling clays can also be relatively impermeable to liquids, and as a result, face the same agglomeration problems as those described above for swelling clays.

[0007]

[0007] Therefore, there is a need for a litter product that balances clump formation and liquid absorption, and also has a relatively low bulk density.

[0008] [Summary of the Invention]

[0008] Various aspects of the present disclosure generally involve the provision of an animal litter composition that benefits from the functional capabilities of swelling clay while maximizing the overall sorption and clumping capacity of the substrate. Furthermore, the litter has a relatively low density and is therefore lightweight.

[0009]

[0009] Briefly, therefore, the present disclosure relates to low-density pet litter comprising a blend of i) compacted granules comprising expanded perlite fines and ii) coated granules, each coated granule comprising non-agglomerated particles and a coating comprising a flocculant on the outer surface of the non-agglomerated particles, wherein the compacted granules are present in an amount of about 5% to about 25% by weight.

[0010] In some embodiments, the expanded perlite fines have a particle size of about 30 mesh or less.

[0011] In some embodiments, the compacted granules further comprise expanded perlite having a particle size of about 8 mesh or greater.

[0012] In some embodiments, the compacted granules containing expanded perlite fines have a viscosity of about 25 lb / ft 3 ~approx. 45 lb / ft 3 It has a density of

[0013] In some embodiments, the compacted granules further comprise a binder.

[0014] In some embodiments, the binder is selected from the group consisting of i) starch, ii) clay, and iii) starch and clay.

[0015] In some embodiments, the non-agglomerated particles comprise expanded perlite.

[0016] In some embodiments, the coated granules have a resistance of about 22 lb / ft 3 ~26lb / ft 3 It has a density of

[0017] In some embodiments, the animal litter has a water content of about 30 lb / ft 3 has a density of less than

[0018] In some embodiments, the dried compacted granules contain from about 1.0% to about 5.0% water by weight.

[0019] In some embodiments, the flocculant is selected from the group consisting of bentonite, guar gum, starch, xanthan gum, gum arabic, gum acacia, silica gel, and mixtures thereof. In some embodiments, the flocculant comprises sodium bentonite.

[0020]

[0020] In some embodiments, the animal litter further comprises additives selected from the group consisting of odor control agents, fragrances, antibacterial agents, anti-sticking agents, pH control agents, dyes, colorants, de-dusting agents, disinfectants, and combinations thereof.

[0021] In some embodiments, the animal litter has a clump-forming absorption volume of about 40% to about 50%.

[0022] In some embodiments, the animal litter has a clump volume of about 50 mL to about 60 mL.

[0023] In some embodiments, the animal litter has a clump thickness of from about 29 mm to about 34 mm.

[0024] An advantage of one or more embodiments provided by the present disclosure is that an improved pet litter is provided.

[0025] A further advantage of the present disclosure is that a pet litter having a low density is provided without sacrificing particle integrity or absorbency.

[0026] Yet another advantage of the present disclosure is that a pet litter is provided that has both low density and enhanced clumping efficiency.

[0027] Yet another advantage of the present disclosure is that it allows for lighter weight pet litter packaging without reducing its volume.

[0028] Another advantage of the present disclosure is that it makes pet litter packages easier for pet owners to purchase, carry, and use.

[0029] A further advantage of the present disclosure is that it provides a low density granular absorbent having good clump formation absorption, clump size and clump thickness.

[0030] Yet another advantage of the present disclosure is that it provides a clumping pet litter that allows for relatively easy removal of clumps from the animal litter box.

[0031]

[0031] Additional features and advantages are described herein, and will be apparent from the detailed description that follows.

[0032] [Mode for Carrying Out the Invention] As used in this disclosure and the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, reference to "an item" or "the item" includes two or more items.

[0033] The terms "comprise," "comprises," and "comprising" should be interpreted as inclusive rather than exclusive. Similarly, the terms "include," "including," and "or" should all be interpreted as inclusive unless such a construction is clearly prevented from occurring by the context.

[0034] However, the devices and compositions disclosed herein may lack any element not specifically disclosed. Accordingly, disclosure of an embodiment using the term "comprising" includes disclosure of embodiments "consisting essentially of" and "consisting of" the identified components. Similarly, methods disclosed herein may lack any step not specifically disclosed herein. Accordingly, disclosure of an embodiment using the term "comprising" includes disclosure of embodiments "consisting essentially of" and "consisting of" the identified steps. "Consisting essentially of" means that the embodiment contains more than 50% of the identified components, at least 75% of the identified components, at least 85% of the identified components, or at least 95% of the identified components, e.g., at least 99% of the identified components.

[0035]

[0035] The term "and / or" used in the context of "X and / or Y" should be interpreted as "X", or "Y", or "X and Y". As used herein, the terms "example" and "such as", particularly when followed by a listing of terms, are merely exemplary and illustrative and should not be considered exclusive or comprehensive. Unless otherwise stated, any embodiment disclosed herein can be combined with any other embodiment disclosed herein.

[0036] All percentages set forth herein are by weight of the total composition unless otherwise specified. As used herein, "about" and "approximately" are understood to refer to numbers within a numerical range, e.g., a range of -10% to +10% of the referenced number, preferably a range of -5% to +5% of the referenced number, more preferably a range of -1% to +1% of the referenced number, and most preferably a range of -0.1% to +0.1% of the referenced number. All numerical ranges herein should be understood to include all integers or fractions within that range. Furthermore, these numerical ranges should be interpreted as supporting claims directed to any number or subset of numbers within that range. For example, a disclosure of 1 to 10 should be interpreted as supporting ranges of 1 to 8, 3 to 7, 1 to 9, 3.6 to 4.6, 3.5 to 9.9, etc.

[0037] Quantifiers such as "first" and "second" are used merely to distinguish between components. These quantifiers do not imply the presence of other components, their relative positioning, or any chronological order of performance. In this regard, a "second widget" does not imply the necessary presence of a "first widget." Further in this regard, a "second widget" may be used before, after, or simultaneously with any "first widget."

[0038] The terms "pet" and "animal" are used interchangeably herein and refer to any animal capable of using an animal litter box, non-limiting examples of which include a cat, dog, rat, ferret, hamster, rabbit, iguana, pig, or bird. A pet can be any suitable animal, and the present disclosure is not limited to particular pet animals. The term "excretion" refers to urination and / or defecation by a pet.

[0039] As used herein, the term "litter" means any material that can absorb animal urine and / or reduce odors from animal urine and / or feces. "Clumping litter" forms clumps in the presence of moisture, which clumps are distinct from other litter in the animal litter box. "Non-clumping litter" does not form discernible clumps.

[0040]

[0040] The term "clump formation absorption" is a measure of the amount of litter required to absorb a given amount of liquid to form a clump, and is an assessment of the absorption efficiency of the litter. Clump formation absorption by mass is calculated using the following formula: Clump formation absorption by mass (%) = (mass of liquid added / (mass of clumps - mass of liquid added)) x 100. Clump formation absorption can also be measured by volume to compare the clumping efficiency of litter with different densities. Clump formation absorption by volume is calculated using the following formula: Clump formation absorption by volume (%) = (volume of liquid added / ((mass of clumps - mass of liquid added) x litter density)) x 100.

[0041]

[0041] The term "clump volume" or "clump litter volume" refers to the overall size of the clump and is calculated by dividing the mass of the litter by the density of the litter. Clump volume is another measure of the absorption efficiency of the litter, with smaller clumps indicating better absorption efficiency. When calculating clump litter volume, it is assumed that the clump volume is primarily litter volume and that the volume of water is absorbed within the litter.

[0042] The term "clump thickness" refers to the vertical measurement of the clump when it is resting on a horizontal surface. For example, flatter clumps have smaller clump thicknesses. If the clump is too thick, it may reach the bottom of the litter box and stick, making removal more difficult. If the clump is too thin, it may break apart during removal from the litter box.

[0043] The term "clump cohesion" refers to the ability of a clump to remain intact when an external force is applied, and provides a measure of the integrity of the clump. Clumps with lower clump cohesion values ​​are more likely to break during litter box use or clump removal, making the litter box more difficult to clean.

[0044] The term "animal litter" means any device capable of holding pet litter, such as a container having a bottom wall and one or more side walls, and / or any device configured for litter to be placed on, such as a mat or grid. As a non-limiting example, an animal litter box may be a rectangular box with side walls at least about 6 inches high.

[0045]

[0045] The term "mesh" is defined by the ASTM E-11 USA Standard specifications for sieves. As used herein, the "size" of a particle refers to the length of the particle's widest dimension.

[0046] The methods and apparatus and other advancements disclosed herein are not limited to particular methods, procedures, and reagents, as these may vary as will be recognized by those skilled in the art. Furthermore, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the disclosure or claims.

[0047]

[0047] Unless otherwise defined, all technical and scientific terms, terminology, and acronyms used herein have the meaning commonly understood by one of ordinary skill in the art of the disclosure or in the field where the term is used. Although any compositions, methods, articles of manufacture, or other techniques or materials similar or equivalent to those described herein can be used, the preferred devices, methods, articles of manufacture, or other techniques or materials are described herein.

[0048] The present inventors have discovered that a clumping litter composition having low density and high volumetric absorption is produced by blending i) compacted granules comprising expanded perlite fines with ii) coated granules, each coated granule comprising a non-agglomerated particle and a coating comprising a clumping agent on the outer surface of the particle. Furthermore, the present inventors have unexpectedly discovered that the high absorption, made possible in part by the presence of the non-swelling compacted granules comprising expanded perlite fines, does not reduce clump properties such as clump volume, clump thickness, and clump integrity.

[0049]

[0049] One aspect of the present disclosure is animal litter comprising a blend of i) compacted granules comprising expanded perlite fines and ii) coated granules, each coated granule comprising non-agglomerated particles and a coating comprising a flocculant on the outer surface of the particle; wherein the compacted granules are present in an amount of about 5% to about 25% by weight.

[0050] By adjusting the amount of compacted granules containing expanded perlite fines in the blend, the overall amount of litter (by volume) required to form clumps can be reduced. Ultimately, the clumps formed by the litter require less litter to form, and the clumps have a shape that makes them more resistant to collapse and less likely to stick to the bottom of the animal litter box.

[0051]

[0051] Compacted granules containing expanded perlite fines can be prepared using compaction rolls. Compaction can be carried out at a compaction roll back pressure of at least about 500 psi (3447 kPa), for example, from about 500 psi (3447 kPa) to about 1,300 psi (8963.18 kPa), for example, from about 500 psi (3447 kPa) to about 800 psi (5516 kPa) or from about 800 psi (5516 kPa) to about 1,300 psi (8963.18 kPa). In one embodiment, the expanded perlite fines have a size of about 30 mesh or less (i.e., a diameter of 595 microns or less). As a non-limiting example, about 95% or more of the perlite fines in the compacted granules may be less than 30 mesh (i.e., having a diameter less than 595 microns), and about 5% or less of the compacted granules may be up to 4 mesh (i.e., having a diameter greater than 4.76 mm).

[0052]

[0052] In one embodiment, compacted granules comprising expanded perlite fines are described in U.S. Patent Application Publication No. 2017 / 0112088 or U.S. Patent Application Publication No. 2017 / 0112089 (Huck et al.), the entire contents of which are incorporated herein by reference.

[0053] The present disclosure is not limited to any particular means of forming compacted granules, and other means of compacting or agglomerating perlite fines can be used in addition to or in place of compaction rolls. These other means include, for example, tumbling / growth agglomeration; low, medium, or high pressure agglomeration; punch and die; roller press; high shear mixer granulator; extrusion; and combinations thereof.

[0054]

[0054] Perlite is a generic name for a naturally occurring siliceous rock. One feature that distinguishes perlite from other volcanic glasses is that when perlite is heated to a suitable point within its softening range, it expands from 4 to 20 times its original volume. This expansion is due, at least in part, to the presence of 2 to 6% bound water in coarse perlite rock. Calcination, i.e., rapid heating to above 1,600°F (871°C), causes the coarse rock to pop like popcorn, resulting in a very open, highly porous structure called expanded perlite.

[0055] In one embodiment, the amount of expanded perlite fines in the compacted granules comprises a majority of the material in the granules. In one embodiment, the amount of expanded perlite fines in the compacted granules is about 80% to about 95% by weight. In one embodiment, the amount of expanded perlite fines in the compacted granules is about 90% to about 95%, about 93% to about 95%, e.g., about 93% to about 94%, or about 95% by weight of the material. In one embodiment, the expanded perlite fines comprise particles excluded in step 101 of method 100 disclosed in U.S. Patent Application Publication No. 2014 / 0174370.

[0056] In one embodiment, the compacted granules further comprise expanded perlite particles having a size of about 8 mesh or greater. In one embodiment, the expanded perlite particles having a size of about 8 mesh or greater comprise the particles excluded in step 101 of method 100 disclosed in U.S. Patent Application Publication No. 2014 / 0174370.

[0057] In one embodiment, the amount of water in the compacted granules is from about 1% to about 5% by weight of the material, for example, about 2% by weight of the material.

[0058] In one embodiment, the amount of binder in the compacted granules is about 3.0% to about 5.0% by weight of the material, e.g., about 3.0% to about 4.5% by weight or about 3.5% to about 4.0% by weight of the material. In some embodiments, the amount of binder is about 3.0%, about 4.0%, or about 5.0% by weight. The binder can be starch and / or clay. In some embodiments, the starch (if present) comprises cereal starch, e.g., starch derived from one or more of rice, millet, wheat, corn, or oats. In preferred embodiments, the starch (if present) comprises partially pregelled cereal starch, including any waxy or high amylose variant thereof. The clay can be swelling or non-swelling. In some embodiments, the clay (if present) comprises one or more clay minerals selected from the group consisting of kaolin, smectite, illite, chlorite, sepiolite, and attapulgite, hi one embodiment, the clay (if present) comprises a montmorillonite smectite, such as sodium montmorillonite or calcium montmorillonite.

[0059] At least a portion of the binder can be added to the expanded perlite fines as a dry mix prior to consolidation. Alternatively or additionally, at least a portion of the binder can be pre-blended with at least a portion of the water and then added to the expanded perlite fines prior to consolidation.

[0060] In one embodiment, consolidation forms a consolidated material, such as sheets and / or briquettes of consolidated expanded perlite fines. However, the consolidated material is not limited to a particular shape, size, or form. Furthermore, as noted above, the present disclosure is not limited to a particular means of consolidating or agglomerating the perlite fines to form the consolidated material. For example, the consolidated material may be in the form of pellets (e.g., flattened pellets), tablets, or pucks.

[0061] The consolidated material can then be crushed and / or pulverized, for example, by a mill grinding system or any other suitable device known to those skilled in the art, to obtain granules of the consolidated material containing expanded perlite. Granules of the consolidated material containing expanded perlite having a desired size can be obtained by separating particles having a desired size from the remaining particles using one or more sieves. The desired particle size is preferably about 30 mesh (595 microns) to about 8 mesh (2,380 microns). Preferably, the granules of the consolidated material containing expanded perlite are not uniformly distributed within the above size range. Commercially available shaker screens may also be utilized.

[0062] Granules of the compacted material containing expanded perlite having a desired size can be dried to remove moisture from the granules without substantially damaging the particles. For example, the granules can be transferred to a dryer, such as a fluidized bed dryer. The resulting moisture level can be about 1% to about 5%, e.g., about 2%.

[0063] The dried granules of compacted material containing expanded perlite fines have a viscosity of about 25 lb / ft 3 ~approx. 45 lb / ft 3 In some embodiments, the density is about 30 lb / ft 3 ~approx. 40 lb / ft 3 In another embodiment, the density is about 40 lb / ft 3 or about 0.65 g / mL.

[0064] Various additives may optionally be applied to the dried, compacted granules. Non-limiting examples of suitable additives include odor control agents, fragrances, antimicrobial agents, anti-sticking agents, agents for pH control, dyes, colorants, dust removal agents, disinfectants, and combinations thereof. In one embodiment, at least a portion of the dried, compacted granules is coated with a colorant.

[0065] In one embodiment, the coated granules comprise non-agglomerated particles and a coating comprising a flocculating agent on the outer surface of the non-agglomerated particles. In some embodiments, the non-agglomerated particles comprise expanded perlite. In another embodiment, the non-agglomerated particles consist essentially of expanded perlite. In some embodiments, the flocculating agent is selected from the group consisting of bentonite, guar gum, starch, xanthan gum, gum arabic, acacia gum, silica gel, and mixtures thereof. In one embodiment, the flocculating agent consists essentially of sodium bentonite. In another embodiment, the coated granules comprise non-agglomerated expanded perlite particles coated with sodium bentonite.

[0066] Generally, methods for preparing coated granules comprising non-agglomerated particles and a coating comprising a flocculating agent on the outer surface of the non-agglomerated particles include sieving the non-agglomerated particles to eliminate particles smaller than a particle size range selected for a particular embodiment. For example, the non-agglomerated particles may be sieved to eliminate particles smaller than 50 mesh (US sieve size), smaller than 40 mesh (US sieve size), or smaller than 30 mesh (US sieve size). Commercially available shaker screens may be utilized. In some embodiments, the non-agglomerated particles may be sieved to eliminate particles larger than 8 mesh.

[0067] In some embodiments, the method of preparing coated granules includes placing unagglomerated particles in an enrobing machine and agitating the particles. This aids in reducing fines and promotes dust reduction. The unagglomerated particles can then be wetted with water. Water may be added in the enrobing machine.

[0068] Next, the wet, unagglomerated particles are coated. The coating may include a flocculating agent, such as sodium bentonite. As an example, a centrifugal coating process may be used. For example, a batch of expanded perlite particles is metered by volume onto a feed belt and fed into a rotating coater. The perlite particles tumble in the direction of rotation within the coater chamber. In an optional preconditioning step, the perlite particles are spun in the coater for a set time (e.g., 30-60 seconds) before coating. A flocculating agent is then metered into the coater. Generally, the amount of flocculating agent added to the coater is based on the volume of the perlite particles. In one embodiment, for example, about 5 to about 25 pounds of sodium bentonite is added per cubic foot of expanded perlite. Other coating materials, such as guar gum, may be included in the coater in addition to or instead of the bentonite-based flocculating agent. Such materials may be added as a mixture with the bentonite or in a separate step.

[0069]

[0069] As the coating is metered into the chamber of the coater, it combines with the spinning particles in a wet state, forming a coating on the particles to form coated granules.

[0070] In some embodiments, the coated granules have a coating resistance of about 22 lb / ft 3 ~26lb / ft 3 It has a density of

[0071]

[0071] In some embodiments, the animal litter is prepared by dry blending i) compacted granules comprising expanded perlite fines and ii) coated granules, each coated granule comprising non-agglomerated particles and a coating comprising a flocculant on the outer surface of the non-agglomerated particles.

[0072] In one embodiment, the compacted granules comprising expanded perlite fines are present in the litter in an amount of about 5% to about 25% by weight. In some embodiments, the compacted granules are present in the litter in an amount of about 5%, about 10%, about 15%, about 20%, or about 25% by weight. In some embodiments, the compacted granules are present in the litter in an amount of about 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, or 25% by weight.

[0073] In some embodiments, the litter may contain various additives that are optionally applied to the animal litter, which may be compacted granules, coated granules, or a blend of compacted and coated granules. Non-limiting examples of suitable additives include odor control agents, fragrances, antimicrobial agents, anti-sticking agents, agents for pH control, dyes, colorants, dust removal agents, disinfectants, and combinations thereof. In one embodiment, at least a portion of the dried compacted granules are coated with a colorant.

[0074] In some embodiments, animal litter that is a blend of compacted granules and coated granules has a water content of about 30 lb / ft 3 has a density of less than

[0075] In one embodiment, the animal litter has a clumping absorption of about 40% to about 50%. Rate In some embodiments, the animal litter has a clump formation absorption of about 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, or 50%. Rate It has.

[0076] In one embodiment, the animal litter has a clump cohesion of about 95% to about 99%. In some embodiments, the animal litter has a clump cohesion of greater than about 97%, greater than about 98%, or greater than about 99%.

[0077] In one embodiment, the animal litter has a clump volume of about 55 mL to about 60 mL. In other embodiments, the animal litter has a clump volume of about 55 mL, about 56 mL, about 57 mL, about 58 mL, about 59 mL, or about 60 mL.

[0078] Another aspect of the present disclosure is a sealed package at least partially enclosing any of the pet litter embodiments disclosed herein, such as a sealed box or a sealed bag containing such pet litter. A further aspect of the present disclosure is a method of using pet litter, comprising placing at least a portion of the pet litter contained by the package into an animal litter box. This method can be used to manage animal waste, such as cat urine, prevent or treat cat litter, or treat or prevent feline lower urinary tract diseases, such as urethral plugs, struvite or oxalate stones, idiopathic cystitis, or reflux nephropathy. In one embodiment, one or more of the pet litter disclosed herein is used to treat a cat with a litter box problem. As used herein, a cat with an "out-litter box problem" is a cat that has eliminated outside the litter box at least once within the last month, and in one embodiment, a cat that has eliminated outside the litter box at least once within the last week.

[0079] [Example]

[0079] The following non-limiting examples illustrate embodiments and advantages of pet litter provided by the present disclosure.

[0080] Example 1: Preparation of compacted granules

[0080] Compacted granules were prepared using the following method.

[0081] 1. A 13.8% starch slurry was prepared by mixing starch and water using a tank agitator.

[0082] 2. Expanded perlite fines (76.8%) and starch slurry (23.2%) were continuously blended and fed into a set of compaction rolls.

[0083] 3. The compaction rolls had a back pressure setting of 500 psi to form briquettes from the feed.

[0084] 4. The briquettes were then crushed and sized to approximately 8 / 30 mesh (US sieve).

[0085] 5. The sieved material was then dried to a moisture content of about 2%.

[0086] The composition of the dried compacted granules was 94.1% expanded perlite fines, 3.9% starch, and 2% water.

[0087] Example 2: Preparation of coated granules

[0087] Coated granules were prepared using the following method.

[0088]

[0088] 1. Water was sprayed onto the expanded perlite while it was being transported from the bulk sack to the batch coater. When it reached the batch coater, the moisture content of the expanded perlite was about 14% by mass.

[0089]

[0089] 2. Approximately 4 ft from step 1 3 Or 23.62 lb of expanded perlite was added to a spinning batch type agricultural seed coater (Cimbria Heid).

[0090] 3. Water was added (22.34 lb) using a spray nozzle installed in the coater. The approximate addition time was 12 seconds.

[0091] 4. After the water addition, sodium bentonite (64 lb) was added to the coater over 30 seconds.

[0092] 5. Immediately after the bentonite addition, air atomized water (2.08 lb) was applied. The approximate addition time was 6.5 seconds.

[0093] 6. The material was spun for 5 seconds.

[0094]

[0094] 7. The discharge port of the coater was opened and the discharged material was collected.

[0095] 8. The material was dried using a fluid bed dryer (Carrier) and the final moisture content was recorded.

[0096] Example 3: Dry blending of compacted granules with coated granules Litter blends of compacted granules and coated granules were prepared using the following method.

[0097] 1. The desired amount of litter blend was determined to be 10 lbs.

[0098] The total target mass of 2.10 lb was multiplied by the desired percentage of compacted granules (eg, 5.0%) to determine the mass of compacted granules required for the final blend (eg, 0.50 lb).

[0099] 3. The mass of the compacted granules calculated in step 2 was subtracted from the total desired litter weight (10 lb) to determine the mass of coated granules required (9.50 lb).

[0100] 4. The compacted granules (0.5 lb) and the coated granules (9.5 lb) were combined in a benchtop tumble mixer and spun for approximately 30 seconds.

[0101] 5. After mixing, the blended compositions were removed from the tumbler and evaluated for density, cohesion and absorbency.

[0102]

[0102] 6. Using steps 1-5 above, additional litter compositions were prepared and evaluated by varying the % compacted granule content to 10%, 15%, 20%, 25%, and 50%.

[0103]

[0103] The masses of the blend components and the resulting properties are reported in Table 1.

[0104] Example 4: Loose fill bulk density measurements Bulk densities of compacted granules, coated granules, and blended litter were measured using a filling hopper (800 284-5779 Seedburo®; Part No. 151 Filling Hopper with 64P Pan), stand, and pint-sized (550.06 cm 3 The measurement was carried out using a sample cup of 1000 ml (dry volume) according to the following procedure.

[0105]

[0105] 1. The sample was poured into the filling hopper until it was full.

[0106] 2. An empty pint cup was then placed on the balance and the balance was zeroed.

[0107] 3. The cup was then placed under the filling hopper. The distance between the filling hopper outlet and the top of the cup was set at 2 inches.

[0108] 4. The fill hopper discharge slide was then opened and the product was allowed to fall into the empty sample cup. The sample was allowed to flow until the cup was full and then allowed to overflow for an additional 1-2 seconds.

[0109]

[0109] 5. A straightedge was then used to remove excess product from the top of the cup and the contents of the cup were leveled with the rim of the cup.

[0110]

[0110] 6. The cup containing the sample was then placed back on the balance and the weight of the sample was recorded.

[0111]

[0111] 7. Steps 1 to 6 were repeated three times.

[0112] 8. The mass value is 0.113358 (lg / dry pint = 113358 lb / ft 3 ) to get pounds per cubic foot (lb / ft 3 ) was converted to

[0113] 9. Average bulk density value in lb / ft 3 These values ​​were further converted to density units of g / mL by multiplying them by 0.01601846.

[0114] lb / ft for compacted granules, coated granules, and litter blends 3 and average bulk density values ​​in g / mL are reported in Table 1.

[0115] Example 5: Measurement of clump formation absorption rate and clump aggregation by volume

[0115] In order to compare the efficiency of the sample litters in a manner that reflects actual use, it was necessary to determine the amount of litter required to absorb a given volume of urine. Since litter can have different densities, values ​​were more relevant when considered on a volumetric basis (volume of urine absorbed per volume of litter). By expressing the values ​​as a percentage, it was possible to compare clump absorption rates between litter of different densities. The method used to calculate clump absorption rate by volume is shown below:

[0116] 1. An 8 inch diameter 3 / 4 inch mesh sieve was stacked on top of a sieve pan and placed at the bottom of a support stand.

[0117] 2. The trapdoor assembly was attached to a support stand and placed 10 inches above a 3 / 4 inch sieve.

[0118] 3. A representative sample of the litter material was placed into the litter test pan to a depth of 3 inches.

[0119] 4. A self-leveling burette was placed on a support stand 3 inches above the litter surface. This device was used to dispense 25 mL aliquots of cat urine onto the litter surface to form clumps in the litter. This process was repeated in various locations in the litter pan until the desired number of clumps had formed.

[0120] 5. At the end of the desired time interval (eg, 15 minutes or 24 hours), the clump was removed from the litter and its mass recorded as W1.

[0121] 6. The average mass of 25 mL portions of urine delivered by the self-leveling burette was determined by delivering (three) 25 mL portions to a container, measuring the mass, and dividing by (3). The value was 25.7 g.

[0122] 7. The mass of litter consumed in forming the clump or clump litter mass (CLM) was then determined by the formula: CLM = W1 - 25.7g.

[0123] 8. The volume of litter consumed during clump formation or clump litter volume (CLV) was then determined using the formula: CLV = CLM / Litter density (g / mL).

[0124] 9. The clump litter volume was recorded.

[0125] 10. The rate of clump formation absorption by volume was determined using the following formula: Aggregate formation absorption rate (%) = (25 mL / CLV) x 100

[0126] 11. The clump from step 5 was placed in the center of the trapdoor mechanism assembled in step 2.

[0127] 12. The lever was activated to release the trap door, allowing the clumps to fall onto the 3 / 4 inch test sieve.

[0128] 13. The agglomerates were carefully removed from the screen so that any loose material would fall out of the agglomerates but would not cause further damage to the agglomerates. If the agglomerates broke into small pieces, the largest piece remaining on the 3 / 4 inch screen was selected. If nothing remained on the screen, the result was a zero (0) weight.

[0129]

[0129] 14. The chunk or largest piece was weighed and the mass recorded as W2.

[0130] The percent clump cohesion was calculated by the following formula: percent clump cohesion = [(W2, final weight) / (W1, initial weight)] x 100

[0131] Example 6: Agglomerate Thickness Measurement

[0132] Table 1: Summary of test results [Table 1]

[0133] conclusion The results show that blended litter compositions containing 5-25% compacted granules containing expanded perlite fines have acceptable densities comparable to those of basic litter containing only coated granules. Litter Blends 1-5 have good clump volumes and good absorption rates. Specifically, clump volumes are less than 58.3 and clump absorption rates are greater than about 43%. Blends 1-3 demonstrate increased absorption rates compared to basic litter containing only coated granules. Furthermore, litter Blends 1-5 have surprisingly good particle integrity, with clump cohesion of 97.3% or greater. In other words, the benefits achieved by using compacted granules containing expanded perlite fines in the litter of the present disclosure (e.g., increased absorption rates) are not offset by a decrease in litter performance (e.g., clump litter volume and clump cohesion).

[0134]

[0133] It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. Accordingly, it is intended that such changes and modifications be covered by the appended claims.

Claims

1. i) compacted granules containing expanded perlite fines; ii) coated granules, each coated granule comprising non-agglomerated particles and a coating comprising a flocculating agent on the outer surface of the non-agglomerated particles; wherein the compacted granules are present in an amount of 5% to 25% by weight. Animal litter.

2. 2. The animal litter according to claim 1, wherein the expanded perlite fine powder has a particle size of 30 mesh or less.

3. 10. The animal litter of claim 1, wherein the compacted granules further comprise expanded perlite particles having a size of 8 mesh or greater.

4. The compacted granules have a density of 25 lb / ft. ３ ~45 lb / ft ３ 2. The animal litter of claim 1, having a density of

5. 10. The animal litter of claim 1, wherein the compacted granules further comprise a binder.

6. 6. The animal litter of claim 5, wherein the binder is selected from the group consisting of: (i) starch, (ii) clay, and (iii) starch and clay.

7. 10. The animal litter of claim 1, wherein said non-agglomerated particles comprise expanded perlite.

8. The coated granules are 22 lb / ft ３ ~26 lb / ft ３ 2. The animal litter of claim 1, having a density of

9. 30lb / ft ３ 2. The animal litter of claim 1 having a density of less than 1000 .mu.m.

10. 2. The animal litter of claim 1, wherein the compacted granules contain 1% to 5.0% by weight of water.

11. 2. The animal litter of claim 1, wherein the clumping agent is selected from the group consisting of bentonite, guar gum, starch, xanthan gum, gum arabic, acacia gum, silica gel, and mixtures thereof.

12. 12. The animal litter of claim 11, wherein the clumping agent comprises sodium bentonite.

13. 2. The animal litter of claim 1, wherein the animal litter has a clump formation absorption rate of 40% to 50%.

14. 10. The animal litter of claim 1, wherein said animal litter has a clump formation absorption rate of 43% to 45%.

15. 10. The animal litter of claim 1, wherein the animal litter has a clump volume of 50 mL to 60 mL.

16. 10. The animal litter of claim 1, wherein the animal litter has a clump volume of 55 mL to 59 mL.

17. 10. The animal litter of claim 1, wherein said animal litter has a clump thickness of from 29 mm to 34 mm.

18. 2. The animal litter of claim 1, further comprising an additive selected from the group consisting of odor control agents, fragrances, antibacterial agents, anti-sticking agents, pH control agents, dyes, colorants, dust removal agents, disinfectants, and combinations thereof.

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