[0014] The term "mesh," "U.S. sieve" or "Mesh U.S. Sieve Series" as used herein and in the appended claims is defined by ASTM E-11 U.S.A. Standard testing Seives.
[0015] Formulations of low density coated วัสดุรองคอกสัตว์ and methods for producing low density coated วัสดุรองคอกสัตว์ are described. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough
understanding of various exemplary รูปลักษณะ. It will be evident, however, to one of ordinary skill in the art that รูปลักษณะ of the การประดิษฐ์ may be practiced without
these specific details.
วัสดุรองคอก COMPOSITIONS
[0016] The วัสดุรองคอก compositions of the การเปิดเผยนี้ include เพอร์ไลต์ particles coated with a clumping agent. In one particular รูปลักษณะ, the particles are non-
agglomerated particles ซึ่งประกอบรวมด้วย a เพอร์ไลต์. In another particular รูปลักษณะ, the particles consist essentially of expanded เพอร์ไลต์. In yet another particular รูปลักษณะ, granules of วัสดุรองคอก include an expanded เพอร์ไลต์ core coated with a mixture of sodium
bentonite powder and กัวร์กัม.
[0017] เพอร์ไลต์ is a generic term for a naturally occurring siliceous rock. One
feature which sets เพอร์ไลต์ apart from other volcanic glasses is that when heated to a suitable point in its softening range, it expands from four to twenty times its original volume. This expansion is due, at least in part, to the presence of two to six percent combined water in the crude เพอร์ไลต์ rock. Firing, i.e., quickly heating to above 1600° F. (871° C.), causes the crude rock to pop in a manner similar to popcorn yielding a very open, highly porous structure referred to as expanded เพอร์ไลต์.
[0018] Where expanded เพอร์ไลต์ is employed in the วัสดุรองคอก compositions, the bulk density of expanded เพอร์ไลต์ is typically in the range of 25 to 200 kg/m3. In one
รูปลักษณะ, for example, the bulk density of the expanded เพอร์ไลต์ of a coated วัสดุรองคอก of the การประดิษฐ์ is in the range of 55 to 80 kg/Dl 3 (e.g., 55 kg/rin3 , 56 kg/m 3, 58 kg/m3, 60 kg/m3, 62 kg/m3, 64 kg/m3, 66 kg/m3, 68 kg/m3, 70 kg/m3, 72 kg/m3, 74 kg/m3, 76 kg/m3,
78 kg/m3, or 80 kg/m3). In another รูปลักษณะ, for example, the bulk density of the expanded เพอร์ไลต์ is in the range of 55 to 96 kg/m3 (e.g., 55 kg/m3, 56 kg/m3, 58 kg/m3,
60 kg/m3, 62 kg/m3, 64 kg/m3, 66 kg/m3, 68 kg/m3, 70 kg/m3, 72 kg/m3, 74 kg/m3, 76
kg/m3, 78 kg/m3, 80 kg/m3, 82 kg/m3, 84 kg/m3, 86 kg/m3, 88 kg/m3, or 90 kg/m3. In one particular รูปลักษณะ, for example, the bulk density of the expanded เพอร์ไลต์ is
approximately 72 kg/m3. In other particular รูปลักษณะ, for example, the bulk density of the expanded เพอร์ไลต์ is approximately 84 kg/m3 or approximately 88 kg/m3.
[0019] เพอร์ไลต์ can be further defined by its particle size. A range of particle sizes is preferred for the low density coated วัสดุรองคอกs described herein. In one รูปลักษณะ, the particle size of expanded เพอร์ไลต์ is in the range of U.S. sieve -8 to U.S. sieve 30. In
another รูปลักษณะ, the particle size of expanded เพอร์ไลต์ is in the range of U.S. sieve 6 to U.S. sieve 40. Preferably, the expanded เพอร์ไลต์ particles are not evenly distributed within the size range.
[0020] While typically at least some moisture is present in order to facilitate with the coating process, the moisture content of the วัสดุรองคอก material described herein is
relatively low. In one รูปลักษณะ, for example, the moisture content (expressed as a percentage by weight) of the expanded เพอร์ไลต์ of the low density coated วัสดุรองคอก is between approximately 0% and 3%. In another รูปลักษณะ, for example, the moisture content (expressed as a percentage by weight) is between approximately 2% and 3%. In yet another รูปลักษณะ, the moisture content (expressed as a percentage by weight) is approximately 0.5%.
[0021] In some รูปลักษณะ, the absorption of the expanded เพอร์ไลต์ particles is measured wt/wt from about 100% to about 800%, and measured by volume, is at least 20%. In one รูปลักษณะ, the absorption of the expanded เพอร์ไลต์ particles, measured wt/wt is approximately 600% and, measured by volume, is approximately 45%.
[0022] The core เพอร์ไลต์ materials are coated with a clumping agent; i.e., an agent when wetted results in the binding of adjacent particles. Representative clumping
agents include, for example, bentonite (such as sodium bentonite), กัวร์กัมs,
starches, xanthan gums, gum Arabic, gum acacia, silica gel, and other minerals, and mixtures a mixture thereof. In one รูปลักษณะ, the clumping agent ประกอบรวมด้วย
bentonite.
[0023] In one preferred รูปลักษณะ, the clumping agent ประกอบรวมด้วย sodium
bentonite. Sodium bentonite is described in the industry as a "swelling" clay because particles of sodium bentonite enlarge in size and volume when they absorb moisture. In addition, sodium bentonite particles exhibit gel-like qualities when wet that promote
clumping of the sodium bentonite particles when liquid (such as urine) is applied. In another รูปลักษณะ, the clumping agent ประกอบรวมด้วย a mixture of sodium bentonite and กัวร์กัม.
[0024] Where sodium bentonite is employed as or in the clumping agent, the bulk density of the bentonite is typically in the range of 600 to1125 kg/m3 (e.g., 600 kg/m3, 700 kg/m3, 800 kg/m3, 900 kg/m3, 1000 kg/nn3, or 1100 kg/m3). In one particular
รูปลักษณะ, for example, the bulk density of the sodium bentonite is approximately 1125 kg/m 3 (approximately 70 lb/ft3).
[0025] In one รูปลักษณะ, the moisture percentage of the sodium bentonite of
the low density วัสดุรองคอก is between about 6% and 7% (e.g., 6.1%, 6.2%, 6.3%, 6.4%, 6.5%,
6.6%, 6.7%, 6.8%, or 6.9%). In a particular รูปลักษณะ, the moisture percentage of the sodium bentonite is approximately 6.24%.
[0026] The bentonite of the low density coated วัสดุรองคอก is preferably provided as a powder or "fines" with a size range of 100 to 300 mesh. In an exemplary รูปลักษณะ, sodium bentonite particles are employed at approximately 200 mesh.
METHODS OF PREPARING วัสดุรองคอก COMPOSITIONS
[0027] In general, methods for preparing วัสดุรองคอก compositions in accordance with the การเปิดเผย involve coating a เพอร์ไลต์ (and/or an expanded เพอร์ไลต์) with a clumping agent. In the รูปลักษณะ illustrated in FIG. 1, for example, low density clumping วัสดุรองคอก is produced by a method 100 employing one or more of the following steps.
5
[0028] In step 101, เพอร์ไลต์ is screened to eliminate particles smaller than the
range of particle sizes selected for the particular รูปลักษณะ of วัสดุรองคอก. For example,
expanded เพอร์ไลต์ may be screened to eliminate particles smaller than 50 U.S. sieve,
more preferably smaller than approximately 40 U.S. sieve, still more preferably smaller than approximately 30 U.S. sieve. Commercially available shaker screens may be utilized.
[0014] The term "mesh," "U.S. sieve" or "Mesh U.S. Sieve Series" as used herein and in the appended claims is defined by ASTM E-11 U.S.A. Standard testing Seives.[0015] Formulations of low density coated วัสดุรองคอกสัตว์ and methods for producing low density coated วัสดุรองคอกสัตว์ are described. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of various exemplary รูปลักษณะ. It will be evident, however, to one of ordinary skill in the art that รูปลักษณะ of the การประดิษฐ์ may be practiced without these specific details.วัสดุรองคอก COMPOSITIONS[0016] The วัสดุรองคอก compositions of the การเปิดเผยนี้ include เพอร์ไลต์ particles coated with a clumping agent. In one particular รูปลักษณะ, the particles are non-agglomerated particles ซึ่งประกอบรวมด้วย a เพอร์ไลต์. In another particular รูปลักษณะ, the particles consist essentially of expanded เพอร์ไลต์. In yet another particular รูปลักษณะ, granules of วัสดุรองคอก include an expanded เพอร์ไลต์ core coated with a mixture of sodium bentonite powder and กัวร์กัม.[0017] เพอร์ไลต์ is a generic term for a naturally occurring siliceous rock. One feature which sets เพอร์ไลต์ apart from other volcanic glasses is that when heated to a suitable point in its softening range, it expands from four to twenty times its original volume. This expansion is due, at least in part, to the presence of two to six percent combined water in the crude เพอร์ไลต์ rock. Firing, i.e., quickly heating to above 1600° F. (871° C.), causes the crude rock to pop in a manner similar to popcorn yielding a very open, highly porous structure referred to as expanded เพอร์ไลต์.[0018] Where expanded เพอร์ไลต์ is employed in the วัสดุรองคอก compositions, the bulk density of expanded เพอร์ไลต์ is typically in the range of 25 to 200 kg/m3. In one รูปลักษณะ, for example, the bulk density of the expanded เพอร์ไลต์ of a coated วัสดุรองคอก of the การประดิษฐ์ is in the range of 55 to 80 kg/Dl 3 (e.g., 55 kg/rin3 , 56 kg/m 3, 58 kg/m3, 60 kg/m3, 62 kg/m3, 64 kg/m3, 66 kg/m3, 68 kg/m3, 70 kg/m3, 72 kg/m3, 74 kg/m3, 76 kg/m3,78 kg/m3, or 80 kg/m3). In another รูปลักษณะ, for example, the bulk density of the expanded เพอร์ไลต์ is in the range of 55 to 96 kg/m3 (e.g., 55 kg/m3, 56 kg/m3, 58 kg/m3,60 kg/m3, 62 kg/m3, 64 kg/m3, 66 kg/m3, 68 kg/m3, 70 kg/m3, 72 kg/m3, 74 kg/m3, 76kg/m3, 78 kg/m3, 80 kg/m3, 82 kg/m3, 84 kg/m3, 86 kg/m3, 88 kg/m3, or 90 kg/m3. In one particular รูปลักษณะ, for example, the bulk density of the expanded เพอร์ไลต์ is approximately 72 kg/m3. In other particular รูปลักษณะ, for example, the bulk density of the expanded เพอร์ไลต์ is approximately 84 kg/m3 or approximately 88 kg/m3.[0019] เพอร์ไลต์ can be further defined by its particle size. A range of particle sizes is preferred for the low density coated วัสดุรองคอกs described herein. In one รูปลักษณะ, the particle size of expanded เพอร์ไลต์ is in the range of U.S. sieve -8 to U.S. sieve 30. In another รูปลักษณะ, the particle size of expanded เพอร์ไลต์ is in the range of U.S. sieve 6 to U.S. sieve 40. Preferably, the expanded เพอร์ไลต์ particles are not evenly distributed within the size range.[0020] While typically at least some moisture is present in order to facilitate with the coating process, the moisture content of the วัสดุรองคอก material described herein is relatively low. In one รูปลักษณะ, for example, the moisture content (expressed as a percentage by weight) of the expanded เพอร์ไลต์ of the low density coated วัสดุรองคอก is between approximately 0% and 3%. In another รูปลักษณะ, for example, the moisture content (expressed as a percentage by weight) is between approximately 2% and 3%. In yet another รูปลักษณะ, the moisture content (expressed as a percentage by weight) is approximately 0.5%.[0021] In some รูปลักษณะ, the absorption of the expanded เพอร์ไลต์ particles is measured wt/wt from about 100% to about 800%, and measured by volume, is at least 20%. In one รูปลักษณะ, the absorption of the expanded เพอร์ไลต์ particles, measured wt/wt is approximately 600% and, measured by volume, is approximately 45%.[0022] The core เพอร์ไลต์ materials are coated with a clumping agent; i.e., an agent when wetted results in the binding of adjacent particles. Representative clumping agents include, for example, bentonite (such as sodium bentonite), กัวร์กัมs,starches, xanthan gums, gum Arabic, gum acacia, silica gel, and other minerals, and mixtures a mixture thereof. In one รูปลักษณะ, the clumping agent ประกอบรวมด้วย bentonite.[0023] In one preferred รูปลักษณะ, the clumping agent ประกอบรวมด้วย sodiumbentonite. Sodium bentonite is described in the industry as a "swelling" clay because particles of sodium bentonite enlarge in size and volume when they absorb moisture. In addition, sodium bentonite particles exhibit gel-like qualities when wet that promote clumping of the sodium bentonite particles when liquid (such as urine) is applied. In another รูปลักษณะ, the clumping agent ประกอบรวมด้วย a mixture of sodium bentonite and กัวร์กัม.[0024] Where sodium bentonite is employed as or in the clumping agent, the bulk density of the bentonite is typically in the range of 600 to1125 kg/m3 (e.g., 600 kg/m3, 700 kg/m3, 800 kg/m3, 900 kg/m3, 1000 kg/nn3, or 1100 kg/m3). In one particular รูปลักษณะ, for example, the bulk density of the sodium bentonite is approximately 1125 kg/m 3 (approximately 70 lb/ft3).[0025] In one รูปลักษณะ, the moisture percentage of the sodium bentonite ofthe low density วัสดุรองคอก is between about 6% and 7% (e.g., 6.1%, 6.2%, 6.3%, 6.4%, 6.5%,6.6%, 6.7%, 6.8%, or 6.9%). In a particular รูปลักษณะ, the moisture percentage of the sodium bentonite is approximately 6.24%.[0026] The bentonite of the low density coated วัสดุรองคอก is preferably provided as a powder or "fines" with a size range of 100 to 300 mesh. In an exemplary รูปลักษณะ, sodium bentonite particles are employed at approximately 200 mesh.
METHODS OF PREPARING วัสดุรองคอก COMPOSITIONS
[0027] In general, methods for preparing วัสดุรองคอก compositions in accordance with the การเปิดเผย involve coating a เพอร์ไลต์ (and/or an expanded เพอร์ไลต์) with a clumping agent. In the รูปลักษณะ illustrated in FIG. 1, for example, low density clumping วัสดุรองคอก is produced by a method 100 employing one or more of the following steps.
5
[0028] In step 101, เพอร์ไลต์ is screened to eliminate particles smaller than the
range of particle sizes selected for the particular รูปลักษณะ of วัสดุรองคอก. For example,
expanded เพอร์ไลต์ may be screened to eliminate particles smaller than 50 U.S. sieve,
more preferably smaller than approximately 40 U.S. sieve, still more preferably smaller than approximately 30 U.S. sieve. Commercially available shaker screens may be utilized.
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