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.

What is claimed is: 
     
         1 . An animal litter comprising:
 a plurality of composite particles formed using at least (a) particles of sodium bentonite having a mean particle diameter of 3000 μm or less and (b) carbon particles having a mean particle diameter of less than 500 μm, wherein the carbon particles and sodium bentonite particles are bound together to form the composite particles; and   optionally, an absorbent material.   
     
     
         2 . The animal litter recited in  claim 1 , wherein said absorbent material is crushed or extruded bentonite. 
     
     
         3 . The animal litter recited in  claim 1 , wherein the carbon particles and sodium bentonite particles were bound together using an agglomeration process to form the composite particles. 
     
     
         4 . The animal litter recited in  claim 1 , wherein the mean particle diameter of the sodium bentonite is 25-150 μm. 
     
     
         5 . The animal litter recited in  claim 1 , wherein the carbon particles comprise powdered activated carbon (PAC). 
     
     
         6 . The animal litter recited in  claim 5 , wherein the mean particle diameter of the PAC is 25-150 μm. 
     
     
         7 . The animal litter recited in  claim 5 , wherein the mean particle diameter of the sodium bentonite is 25-150 μm and the mean particle diameter of the PAC is 25-150 μm. 
     
     
         8 . The animal litter recited in  claim 5 , wherein the mean particle diameter of the sodium bentonite is 25-150 μm, the mean particle diameter of the PAC is 25-150 μm, and the composite particles have a mean particle diameter of 2.5 mm or less. 
     
     
         9 . The animal litter recited in  claim 5 , wherein the mean particle diameter of the sodium bentonite is 25-150 μm, the mean particle diameter of the PAC is 25-150 μm, and the composite particles have a mean particle diameter of 400-1650 μm. 
     
     
         10 . The animal litter recited in  claim 1 , wherein the carbon particles are present in an amount of 5% or less based on the weight of the animal litter. 
     
     
         11 . The animal litter recited in  claim 1 , wherein the carbon particles are present in an amount from 0.3% to 1% based on the weight of the animal litter. 
     
     
         12 . The animal litter recited in  claim 1 , wherein the carbon particles are present in an amount less than 1% based on the weight of the animal litter. 
     
     
         13 . The animal litter recited in  claim 5 , wherein the PAC is present in an amount of 5% or less based on the weight of the animal litter. 
     
     
         14 . The animal litter recited in  claim 5 , wherein the PAC is present in an amount from 0.3% to 1% based on the weight of the animal litter. 
     
     
         15 . The animal litter recited in  claim 5 , wherein the PAC is present in an amount less than 1% based on the weight of the animal litter. 
     
     
         16 . The animal litter recited in  claim 9 , wherein the PAC is present in an amount from 0.3% to 1% based on the weight of the animal litter. 
     
     
         17 . The animal litter recited in  claim 9 , wherein the PAC is present in an amount less than 1% based on the weight of the animal litter. 
     
     
         18 . The animal litter recited in  claim 3 , wherein the agglomeration process is a tumble/growth agglomeration process. 
     
     
         19 . The animal litter recited in  claim 1 , further comprising other types of particles dry mixed with the composite particles and wherein the ratio of the composite particles to the other particles is between 75/25 and 25/75. 
     
     
         20 . The animal litter recited in  claim 1 , wherein the optional absorbent material comprises crushed or extruded bentonite.