Composite Absorbent Particles

Abstract

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

1 - 83 . (canceled) 
   
   
       84 . A plurality of porous composite particles comprising:
 a mixture of sodium bentonite, expanded perlite and activated carbon formed into a plurality of agglomerated porous composite particles suitable for use as an animal litter,   wherein substantially each agglomerated composite particle contains a percentage of sodium bentonite, a percentage of expanded perlite and a percentage of activated carbon, wherein at least a portion of the carbon is encapsulated within the pores of the composite particle,   wherein the clump strength, an indication of the percentage of particles retained in a clump after six hours upon addition of animal urine, is greater than 90%.   
   
   
       85 . The plurality of composite particles recited in  claim 84 , wherein the activated carbon is powdered activated carbon (PAC). 
   
   
       86 . The plurality of composite particles as recited in  claim 84 , wherein the activated carbon is present in about 5 weight percent or less. 
   
   
       87 . The plurality of composite particles as recited in  claim 84 , wherein said agglomerated composite particles range in size from 100 μm to 10 mm. 
   
   
       88 . The plurality of composite particles as recited in  claim 84 , wherein said agglomerated composite particles range in size from 400-1650 μm. 
   
   
       89 . The plurality of composite particles as recited in  claim 84 , wherein said agglomerated composite particles have a bulk density between 0.25 g/cc and 0.5 g/cc. 
   
   
       90 . The plurality of composite particles recited in  claim 84 , further comprising at least one of an antimicrobial, an odor control boron-containing material, a binder, a fragrance, a health indicating material, a color altering agent, a dust reducing agent, a nonstick release agent, a superabsorbent material, cyclodextrin, zeolite, a pH altering agent, a salt forming material, a ricinoleate and mixtures thereof. 
   
   
       91 . The plurality of composite particles recited in  claim 84 , wherein the composite particles have a moisture content of less than about 15% by weight based on a weight of the composite particle. 
   
   
       92 . The plurality of composite particles recited in  claim 84 , wherein the plurality of agglomerated composite particles have a hydraulic conductivity value of 0.25 cm/s or less. 
   
   
       93 . The plurality of composite particles recited in  claim 84 , wherein the composite particle is capable of absorbing a weight of water equaling at least about 90 percent of a weight of the composite particle. 
   
   
       94 . The plurality of composite particles recited in  claim 84 , wherein the composite particle is capable of absorbing a weight of water equaling at least about 75 percent of a weight of the composite particle 
   
   
       95 . The plurality of composite particles recited in  claim 84 , wherein the composite particles have a dusting attrition value of at most about 15% as measured by ASTM method E-728 Standard Test Method for Resistance to Attrition of Granular Carriers and Granular Pesticides. 
   
   
       96 . The plurality of composite particles recited in  claim 84 , wherein the composite particles have a malodor rating below about 15 as determined by a Malodor Sensory Method. 
   
   
       97 . The plurality of composite particles recited in  claim 84 , wherein the clump strength is greater than 95%.