WO2015033335A1 - Vermiculite molded matrix - Google Patents

Vermiculite molded matrix Download PDF

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Publication number
WO2015033335A1
WO2015033335A1 PCT/IL2014/050777 IL2014050777W WO2015033335A1 WO 2015033335 A1 WO2015033335 A1 WO 2015033335A1 IL 2014050777 W IL2014050777 W IL 2014050777W WO 2015033335 A1 WO2015033335 A1 WO 2015033335A1
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WO
WIPO (PCT)
Prior art keywords
tray
molded matrix
vermiculite
group
agent
Prior art date
Application number
PCT/IL2014/050777
Other languages
French (fr)
Inventor
Gideon INSLER
Original Assignee
Insler Gideon
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Insler Gideon filed Critical Insler Gideon
Publication of WO2015033335A1 publication Critical patent/WO2015033335A1/en
Priority to IL244444A priority Critical patent/IL244444A0/en

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Classifications

    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01K—ANIMAL HUSBANDRY; CARE OF BIRDS, FISHES, INSECTS; FISHING; REARING OR BREEDING ANIMALS, NOT OTHERWISE PROVIDED FOR; NEW BREEDS OF ANIMALS
    • A01K1/00—Housing animals; Equipment therefor
    • A01K1/01—Removal of dung or urine, e.g. from stables
    • A01K1/0107—Cat trays; Dog urinals; Toilets for pets
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01K—ANIMAL HUSBANDRY; CARE OF BIRDS, FISHES, INSECTS; FISHING; REARING OR BREEDING ANIMALS, NOT OTHERWISE PROVIDED FOR; NEW BREEDS OF ANIMALS
    • A01K1/00—Housing animals; Equipment therefor
    • A01K1/015—Floor coverings, e.g. bedding-down sheets ; Stable floors
    • A01K1/0152—Litter
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01K—ANIMAL HUSBANDRY; CARE OF BIRDS, FISHES, INSECTS; FISHING; REARING OR BREEDING ANIMALS, NOT OTHERWISE PROVIDED FOR; NEW BREEDS OF ANIMALS
    • A01K1/00—Housing animals; Equipment therefor
    • A01K1/015—Floor coverings, e.g. bedding-down sheets ; Stable floors
    • A01K1/0152—Litter
    • A01K1/0154—Litter comprising inorganic material
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01K—ANIMAL HUSBANDRY; CARE OF BIRDS, FISHES, INSECTS; FISHING; REARING OR BREEDING ANIMALS, NOT OTHERWISE PROVIDED FOR; NEW BREEDS OF ANIMALS
    • A01K1/00—Housing animals; Equipment therefor
    • A01K1/015—Floor coverings, e.g. bedding-down sheets ; Stable floors
    • A01K1/0152—Litter
    • A01K1/0155—Litter comprising organic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
    • B01J20/10—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
    • B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
    • B01J20/28042—Shaped bodies; Monolithic structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
    • B01J20/3007—Moulding, shaping or extruding

Definitions

  • the present invention relates to animal litter articles, and more particularly, this invention relates to inorganic litter articles which are made from an inorganic binder absorbent material.
  • Those animal litter articles comprise only a layer or a fraction of the overall inorganic material, or partially constitutes the article mass.
  • the litter box models known in the art are typically a plastic or a plastic liners tray which comprises a mineral or any absorbent material .
  • the elaborate models are covered in order to facilitate emptying and cleaning a litter box.
  • Some models have electric combing mechanisms that automatically scoop the clumps out of the litter box into a sealed, disposable-bag- lined container after the animal has used it. These models use a pressure pad or an infrared light to determine when the cat has left the box and will comb the box after so many minutes have passed, to avoid disturbing the cat.
  • Other designs take this further, and connect directly to a home's plumbing so they can wash, rinse and dry the permanent litter pellets automatically.
  • Other designs known in the art require the owner to manually shake the clumps into an easy-to-remove tray.
  • Another variant has an enclosed sphere which rotates as it sifts out the clumps and deposits them in a drawer below the
  • US patent No. 3590111 discloses shaped articles for construction or insulation comprising vermiculite or expanded perlite, or mixture thereof compounded by a quasi-colloidal binding agent made up from perlite dust and containing mixed crystals of calcium, silicate hydrate, calcium aluminosilicate hydrate, and calcium aluminate hydrate produced by the reaction of calcium oxide or dry hydrated calcium oxide with finally divided perlite.
  • US patent No. 5830305 describes compositions for manufacturing articles, particularly containers and packaging materials, having a highly inorganically filled matrix.
  • the inorganically filled mixtures are prepared by mixing together an organic polymer binder, water, one or more aggregate materials, fibers, and optional admixtures in the correct proportions in order to form an article which has the desired performance criteria.
  • the inorganically filled mixtures are molded to fashion a portion of the mixture into a form stable shape for the desired article. Once the article has obtained form stability, the article is removed from the mold and allowed to harden to gain strength.
  • the articles may have properties substantially similar to articles presently made from traditional materials like paper, paperboard, polystyrene, plastic, or metal. They have especial utility in the mass production of containers, particularly food and beverage containers.
  • It is one embodiment of the present invention to provide a shaped molded matrix for absorbing animal litter comprising: at least one inorganic binder absorbent material; wherein the shaped molded matrix is formed from the absorbent material comprising vermiculite at the range of about 50% to about 100% by weight. It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein the molded matrix is with a shape of a sliding tray.
  • the absorbent material further comprises at least one mineral selected from the group consisting of Georgia White clay, sepiolite, zeolite, calcite, dolomite, slate, pumice, tobermite, marls, attapulgite, bentonite, kaolinite, halloysite, montmorillonite, smectite, hectorite, diatomaceous earth, Fuller's earth, fossilized plant materials, expanded perlites and gypsum or any other similar minerals and a mixture thereof.
  • the absorbent material further comprises at least one mineral selected from the group consisting of Georgia White clay, sepiolite, zeolite, calcite, dolomite, slate, pumice, tobermite, marls, attapulgite, bentonite, kaolinite, halloysite, montmorillonite, smectite, hectorite, diatomaceous earth, Fuller's earth, fossilized plant materials, expanded perlite
  • the binding agent comprises (i) natural polymers and synthetic derivatives thereof selected from the group consisting of lignins, gums, starches , polysaccharides, such as lignin sulfonate, carboxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, ethylhydroxyethyl cellulose, methylhydroxypropylcellulose, guar gum, alginates, starch, xanthan gum, gum acacia, gum Arabic, and any combination thereof;
  • synthetic polymers selected from the group consisting of polyvinylpyrrolidone, polyethylene glycol, polyethyleneoxide, acrylate polymers and copolymers, acrylic emulsions, polyvinyl alcohol, polyvinyl acetate, polyvinyl pyrrolidine, polyacrylic acid, latexes,neoprene latex, superabsorbent polymers,cross-linked polyacrylates, flocculating agents , polycarboxylates, fluorinated polymers,polytetrafluoroethylene and any combination thereof, and (iii) inorganic agglomerating agents selected from the group consisting of silicates and phosphates, pyrophosphates, aluminates and any combination thereof.
  • a slidable tray formed from at least one inorganic binder material; the tray is located at the lower part of the container;
  • the lower slidable tray comprises at least 50% of vermiculite configured to absorb secretions of the animal and further to be drawn out for fertilization means. It is another object of the present invention to provide the article as defined in any of the above, wherein the article further comprises an upper slidable tray.
  • the odor agent is selected from the group consisting of bicarbonate compounds, boron compounds, carbonates, cyclodextrins, zeolites, activated carbon, kieselguhr, chelating agents, chitin and pH buffered materials, such as carboxylic acids and any mixture thereof.
  • the absorbent material is a mineral selected from the group consisting of Georgia White clay, sepiolite, zeolite, calcite, dolomite, slate, pumice, tobermite, marls, attapulgite, bentonite, kaolinite, halloysite, montmorillonite, smectite, hectorite, diatomaceous earth, Fuller's earth, fossilized plant materials, expanded perlites and gypsum or any other similar minerals, or mixture thereof.
  • the absorbent material is a mineral selected from the group consisting of Georgia White clay, sepiolite, zeolite, calcite, dolomite, slate, pumice, tobermite, marls, attapulgite, bentonite, kaolinite, halloysite, montmorillonite, smectite, hectorite, diatomaceous earth, Fuller's earth, fossilized plant materials, expanded perlites and gy
  • slidable tray further comprising natural processed materials selected from the group consisting of paper, cellulosic webs, polymeric fibrous webs, wood chips, alfalfa, bark, straw, sand, grain hulls, synthetic foams, recycled materials, pelletized absorbing litter materials and any mixture thereof.
  • the slidable tray further comprises at least one component selected from the group consisting of supplemental absorbent material, a fixing agent, colorant agent, anti-bacterial agent, a fragrance and any combination thereof.
  • the binding agent comprises (i) natural polymers and synthetic derivatives thereof selected from the group consisting of lignins, gums, starches , polysaccharides, such as lignin sulfonate, carboxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, ethylhydroxyethyl cellulose, methylhydroxypropylcellulose, guar gum, alginates, starch, xanthan gum, gum acacia, gum Arabic, and any combination thereof;
  • synthetic polymers selected from the group consisting of polyvinylpyrrolidone, polyethylene glycol, polyethyleneoxide, acrylate polymers and copolymers, acrylic emulsions, polyvinyl alcohol, polyvinyl acetate, polyvinyl pyrrolidine, polyacrylic acid, latexes,neoprene latex, superabsorbent polymers,cross-linked polyacrylates, flocculating agents , polycarboxylates, fluorinated polymers,polytetrafluoroethylene and any combination thereof, and (iii) inorganic agglomerating agents seelclted from the group consisting of silicates and phosphates, pyrophosphates, aluminates and any combination thereof.
  • the slidable tray is formed by manner selected from a group consisting of: agglomeration technique, molding technique, compaction technique, coating technique, embedding technique, dispersing technique, filling technique and any combination thereof.
  • the container shape is selected from a group consisting of tray, spherical shape, non- spherical shapes, ovals, flattened spheres, hexagons, triangles, squares, square with a flat form, rectangular with a flat form, square, rectangular, diamond, cupped, star, bagel, mesh-like, angled, cone, tetrahedron, pyramid and any combination thereof.
  • slidable tray formed from at least one inorganic binder material; the binder material is vermiculite; and
  • odor agent selected from the group consisting of bicarbonate compound or boron compound.
  • the odor agent selected from the group consisting of carbonates, bicarbonates, cyclodextrins, zeolites, activated carbon, kieselguhr, chelating agents, chitin and pH buffered materials, such as carboxylic acids and any mixture thereof.
  • FIG. 1 illustrates a cuboid configuration of the animal litter article of the present invention
  • FIG. 2 illustrates an upper view of the open configuration of the animal litter article of the present invention
  • FIG. 3 illustrates a side view of the animal litter article of the present invention
  • FIG. 4 illustrates a bottom view of the animal litter article of the present invention.
  • the present invention relates to litter molded matrix made from at least one inorganic binder absorbent material with improved physical, chemical properties and further greater absorption capability.
  • the composition may further comprise malodor controlling materials and optional performance-enhancing additives.
  • a preferred use for the absorbent material is for adsorbing and absorbing animal litter or any secretion or excretion, and may further be useful for air and water filtration, fertilizer, waste remediation, etc., and should not be limited to the context of an animal litter.
  • the molded matrix may be "engineered” to preferentially exhibit specific characteristics including but not limited to improved odor control, lower density, easier scooping, better particle/active consistency, higher clump strength, etc.
  • the molded matrix comprising vermiculite is further configured to control leakage or flow-through of fluids.
  • the present invention relates to an animal litter article for recycling purposes comprising: a container composed of polystyrene and a slidable tray formed from at least one inorganic binder material; the tray is located at the lower part of the container.
  • the slidable tray comprises at least 50% of vermiculite configured to absorb secretions of the animal and further to be ejected or drawn out for fertilization means.
  • the container composed of polystyrene(PS) may be in its foam form and at least one inorganic binder absorbent material.
  • the tray is a molded matrix composed of vermiculite as a substrate which can be heated and further expands greatly such that it can be formed into any desired shape.
  • the molded matrix process may involve mixing exfoliated vermiculite with inorganic bonding agents such as sodium silicate and potassium to produce a mixture.
  • This vermiculite is then hydraulically pressed into shape in a mold, and then heat cured at temperatures up to 180 °C for up to 24 hours depending upon the thickness of the molded part.
  • Such parts can withstand service temperatures of up to 1150 °C.
  • the article of the present invention comprises polystyrene or expanded polystyrene which is injection molded or extruded. Polystyrene can further be recycled. Polystyrene is chemically inert, being resistant to acids and bases but is easily dissolved by d-limonene, chlorinated solvents, and further aromatic hydrocarbon solvents. Resulting from its resilience and inertness characteristics , Polystyrene may be attacked by organic solvents, which dissolve the polymer. Polystyrene foams are good thermal insulators and are may be further used as building insulation materials, such as in insulating concrete forms and structural insulated panel building systems. Polystyrene incorporating graphite has superior insulation properties.
  • the article of the present invention may comprise an expanded polystyrene (EPS) form which is a rigid and tough, closed-cell foam. It is made of pre-expanded polystyrene beads and may further be used as a disposable containers, trays, plates and/or bowls for accommodating a vermiculite layer.
  • EPS expanded polystyrene
  • the article of the present invention may further comprise an extruded polystyrene foam (XPS) consists of closed cells, which provides improved surface roughness and higher stiffness and reduced thermal conductivity. The density range is about 28-45 kg/m .
  • molded matrix as used herein should be understood to mean a layer, a tray or any article configured to contain and absorb animal litter.
  • the molded matrix comprises at least one inorganic binding substrate preferably expanded vermiculite which may be exfoliated.
  • the molded matrix may be formed of plurality of material and layers.
  • the slidable tray is composed of at least 50% of vermiculite configured to absorb secretions of the animal and further to be ejected or/and drawn out for fertilization means. Furthermore, the container composed of polystyrene(PS) may be in its foam form and at least one inorganic binder absorbent material.
  • the article of the present invention may further comprise an additional upper moveable tray 12 which slides and therefore allows opening and closing of the cuboid.
  • the tray may be composed of a material selected from the group consisting of PS, vermiculite, an odor material and any mixture thereof.
  • the external layer of the article may be composed of polystyrene and the slidable tray configured as a drawer as the interior layer is composed of at vermiculite in the range of about 50 to about 100% by weight.
  • the vermiculite may be employed up to approximately 50% by weight of the tray.
  • the vermiculite is employed up to approximately 70% by weight of the tray.
  • the container may further comprise beads of vermiculite having a particle size smaller than 15 mm which may be coated or impregnated upon the tray or a thick solid coating layer of vermiculite uniformly distributed having a thickness of more than about 25.0 % of tray thickness.
  • the size of the tray is designed according to the size of the pet whilst the width of the cuboid is in the range of approximately 25 to 50cm.
  • the length is in the range of approximately 35 to 70 cm and the height is in the range of approximately 7 to 40cm.
  • the vermiculite filling may be in the volume of about 3L to 17L, according to the cuboid size.
  • the tray is a slidably member which may be mounted to the container in a locking mechanism for releasably retaining or/and drawing the tray at various longitudinal positions along the container base surface. Furthermore the slidable tray may comprise pivoting slidable hooks or/and a slidable assist handle.
  • Fig 2 illustrates an open configuration of the animal litter article 20 comprising a polystyrene container 22 moveable vermiculite tray 21 which slide along the upper section of the cuboid container.
  • the tray 21 is operatively engaged to the container such that it can be pulled out and inserted back easily.
  • Fig 3-4 illustrates the cuboid structure of the animal litter article 30,40 comprising a cuboid container having a slide vermiculite tray 31,41 on the bottom of the cuboid container .
  • the tray is quite light in weight, configured to be removable and may further be replaceable and reused for recycling purposes, process and needs such as fertilization for agriculture, ecological means and the like.
  • the tray may further be treated for reuse by soaking in water and heating in a temperature of 100°C to 150°C in an oven ,autoclave or any sterilizer device.
  • the slidable tray is based upon any known slide mechanism.
  • the inorganic material may have a concentration in a range from about 95% to about 100% by volume of the total solids in the vermiculite mixture, more preferably from about 90% to about 98%. Additional components, such as organic aggregates and dispersants, can be selectively added.
  • vermiculite molded matrix configured as a tray is with the properties of flexibility, tensile strength, toughness, moldability, and mass-producibility. Vermiculite has a trioctahedral 2: 1 layer, and an interlayer containing both Mg 2+ and Al 3+ , which are able to hold two water molecules in the interlayer.
  • Vermiculite has a higher layer charge and a high cation exchange capacity (1000-1500 meq/kg). The layers are strongly held together, so the basal spacing is smaller. On heating, the water can be expelled, collapsing the structure to 12.5 A and then to 10 A. If a large vermiculite crystal is rapidly heated, the steam physically blows some of the layers apart and accordion-like "worms" are formed. Therefore due to Vermiculite physical properties a litter article can be formed in a desired shape or structure suitable to the need.
  • the cation exchange capacity (up to 1000 milliequivalents per kg) of vermiculite allows it to be used in fluid purification processes for waste water, chemical processing and the pollution control of air and gases in industrial processes. In addition to its ion exchange properties exfoliated vermiculite will retain liquids within the inter-laminar voids of the individual particles as well as between the particles themselves.
  • the preferred absorbent material is vermiculite additional liquid- absorbing materials may be used without departing from the scope of the present invention.
  • Illustrative absorbent materials include but are not limited to plurality of granules, minerals, fly ash, absorbing pelletized materials, perlite, silicas, other absorbent materials and mixtures thereof.
  • Preferred minerals include: bentonites, zeolites, fullers earth, attapulgite, montmorillonite diatomaceous earth, opaline silica, crystalline silica, silica gel, alumina, Georgia White clay, sepiolite, calcite, dolomite, slate, pumice, tobermite, marls, attapulgite, kaolinite, halloysite, smectite, vermiculite, hectorite, Fuller's earth, fossilized plant materials, expanded perlites, gypsum and other similar minerals and mixtures thereof.
  • the molded matrix may comprise additional additives such as Silica gel litter, or "crystal litter", a porous granular form of sodium silicate, having high absorbency of any litter, and has excellent moisture control and complete odor elimination for an extended period of time when compared to other litters.
  • additional additives such as Silica gel litter, or "crystal litter", a porous granular form of sodium silicate, having high absorbency of any litter, and has excellent moisture control and complete odor elimination for an extended period of time when compared to other litters.
  • the slidable tray further comprises at least one component selected from the group consisting of supplemental absorbent material, a fixing agent, colorant agent, anti-bacterial agent, a fragrance and any combination thereof.
  • the molded matrix may further contains bentonite clay particles.
  • Bentonite is known as a water-swellable clay which, upon contact with moist animal waste, is able to agglomerate with other moistened bentonite clay particles. This thus isolates the moist animal waste by the agglomeration of the moist clay particles. The agglomerations form an isolatable clump, which can be removed from the litter
  • the molded matrix may comprise boron-containing compounds, especially boric acid, which are effective additives to both clumping and non-clumping clay-based animal litters.
  • borax in a animal litter in which a water soluble polymer present is caused to gel or harden by the presence of borax as a reaction initiator or catalyst, but not as an odor control agent.
  • Another embodiment of the present invention may include various buffering agents, including sodium borate, in a litter in which a strong oxidant, sodium or ammonium persulfate is present to reduce odors in animal litters.
  • buffering agents including sodium borate
  • Another embodiment of the present invention may include activated alumina which is known as a desiccant in gas-phase processes and applications.
  • vermiculite is with the characters and the ability to be molded into a variety of structures.
  • the vermiculite molded matrix preferably may have a tray or a box structure but variety of other configuration and shapes may be formed, selected from a group consisting of :
  • spherical shape non- spherical shapes such as ovals, flattened spheres, hexagons, triangles, squares, square with a flat form, rectangular with a flat form, square, rectangular, diamond, cupped, star, bagel, mesh-like, angled, cone, tetrahedron, pyramid, and combinations thereof.
  • the container preferably may have a cuboid or a box structure but variety of other configuration and shapes may be formed, selected from a group consisting of: spherical shape, non- spherical shapes such as ovals, flattened spheres, hexagons, triangles, squares, square with a flat form, rectangular with a flat form, square, rectangular, diamond, cupped, star, bagel, meshlike, angled, cone, tetrahedron, pyramid, and combinations thereof.
  • spherical shape non- spherical shapes such as ovals, flattened spheres, hexagons, triangles, squares, square with a flat form, rectangular with a flat form, square, rectangular, diamond, cupped, star, bagel, meshlike, angled, cone, tetrahedron, pyramid, and combinations thereof.
  • the preferred structural matrix of the vermiculite molded matrix is formed from the interaction between inorganic aggregate particles, a water-dispersable organic binder. These are made into a highly moldable, workable, and uniform mixture by adding an appropriate amount of water and thoroughly mixing the components together. Preferably, the amount of added water is just enough to provide adequate workability and moldability, while maintaining a mixture that is form stable; that is, a mixture which will maintain its shape after being molded into the desired shape, including post-molding handling of the article.
  • the present invention further provides a method for manufacturing and further recycling an animal litter article comprising the steps of (a)providing a container composed of foamed polystyrene, (b)forming a slidable tray comprising at least one inorganic binder material; the binder material is vermiculite and (c)imiformly distributing along the tray at least one odor agent selected from the group consisting of bicarbonate compound or boron compound.
  • the method of the present invention further comprising step of forming the slidable tray by at least one of the following steps distributing ,filing, coating dispersing, embedding, admixing molding and compacting the vermiculite into a predefined shape .
  • the method of the present invention further comprising the step of coating the tray with at least one layer of exfoliated expanded vermiculite
  • the method of the present invention further comprising step of dispersing the bicarbonate compound upon the vermiculite.
  • the method of the present invention further comprising step of providing the tray composed of at least 50% of vermiculite by weight.
  • the method of the present invention further comprising step of employing the vermiculite up to approximately 100% by weight of the tray.
  • the method of the present invention further comprising step of employing the vermiculite more than approximately 70% by weight of the tray.
  • the method of the present invention further comprising step of providing slidable tray which is removable and replaceable after absorbing the litter of the animal.
  • the method of the present invention further comprising step of providing the odor agent selected from the group consisting of carbonates, bicarbonates, cyclodextrins, zeolites, activated carbon, kieselguhr, chelating agents, chitin and pH buffered materials, carboxylic acids and any mixture thereof.
  • the odor agent selected from the group consisting of carbonates, bicarbonates, cyclodextrins, zeolites, activated carbon, kieselguhr, chelating agents, chitin and pH buffered materials, carboxylic acids and any mixture thereof.
  • the method of the present invention further comprising step of heating the
  • vermiculite to produce a layer of an absorbent material and dispersing thereto a layer of the odor agent upon the vermiculate layer.
  • the present invention further provides the production of foamed polystyrene articles according to the following steps: Making styrene
  • the basic unit of polystyrene is styrene, which is the product of a two-fold reaction.
  • Ethylene and benzene in the presence of a catalyst such as aluminum chloride, form ethylbenzene (C 8 3 ⁇ 4 ), which is then dehydrogenated (hydrogen is removed) at 1,112- 1,202 degrees Fahrenheit (600-650 degrees Celsius) to form styrene (CgHg).
  • Polystyrene is formed from styrene through suspension polymerization, a process by which tiny drops of the monomer, styrene are completely surrounded by water and a mucilaginous substance. Supporting and surrounding the styrene globules, the suspension agent produces uniform droplets of polystyrene.
  • a polymerization initiator is added to the droplets, which are suspended by heat radiation of about 212 degrees Fahrenheit (100 degrees Celsius). This results in free radicals, a group of atoms particularly likely to react with others because they contain unpaired electrons which are available for molecular bonding. Free radicals then combine at randomly to form chains of polystyrene. Terminators are introduced to the process to end it at the appropriate time. Though variable, chain length must fall within a certain range, because polystyrene with overly long chains won't melt readily, and polystyrene with short chains will be brittle.
  • the mixture consisting of beads made up of polystyrene chains is cooled. These beads are then washed out and dried. Uniform bead size is achieved by sorting the beads through meshes which filter out over and undersized beads.
  • the beads of polystyrene must be expanded to achieve the proper density.
  • This process is known as pre-expansion, and involves heating the polystyrene either with steam or hot air (for high density foam, ), the heating is carried out in a vessel holding anywhere from 50 to 500 gallons (189 to 1,892 liters).
  • an agitator is used to keep the beads from fusing together. Since expanded beads are lighter than unexpanded beads, they are forced to the top of the vessel's cavity and discharged. This process lowers the density of the beads to three percent of their original value and yields a smooth-skinned, closed cell EPF that is excellent for detailed molding.
  • the pre-expanded beads are "aged" for at least 24 hours in mesh storage silos. This allows air to diffuse into the beads, cooling them and making them harder.
  • the beads After aging, the beads are fed into a mold of the desired shape. Low-pressure steam is then injected into and between the beads, expanding them once more and fusing them together. The mold is then cooled, either by circulating water through it or by spraying water on the outside. EPF is such a good insulator that it is hard to cool the mold down. Using small molds can reduce both the heating and cooling time and thereby speed up the process.
  • This process yields EPF with small cell size that can be used to manufacture boards used for insulation.
  • the beads are melted, and a blowing agent is added.
  • the molten polystyrene is then extruded into the proper shape under conditions of high temperature and pressure. Additional steps such as cutting, bonding, and coating the polystyrene to a predefined structure.
  • Polystyrene is extruded with foaming agents and preferably in the presence of nucleating agents, e.g. talc or chemical foaming agents.
  • the foaming agents can be either a physical foaming agent, e.g. a gas like C0 2 , N 2 , isopentane, hydrofluorocarbons, or a chemical foaming agent which decomposes in the melted polymer during processing liberating a gas, e.g. C02 or N 2 . In both processes the gas has to be thoroughly dispersed and dissolved in the polymer melt under pressure in the extruder barrel.
  • Foam extruded polystyrene articles produced in the so called direct gassed extrusion can achieve foam densities of from 5 kg/m 3 to 500 kg/m 3.
  • the slidable tray composed of vermiculite is formed by manner selected from a group consisting of: agglomeration technique, molding technique, compaction technique, coating technique, embedding technique, dispersing technique, filling technique and any combination thereof.
  • the tray may further comprise polystyrene sheet and at least one coating layer of vermiculite dispersions which is either chemically or physically very finely delaminated vermiculite in a fluid medium.
  • the dispersions technique can be used to make vermiculite film sheet by simply pouring on to a piece of smooth low surface of polystyrene and allowing to dry, the resulting sheet may further be peeled off the polystyrene sheet.
  • Typical end uses for vermiculite dispersions include in high temperature coatings or binders for construction materials, oxidation resistant coating on carbon based composites, and as barrier coatings for films.
  • the tray may further comprise exfoliated vermiculite and additional odor agent or supplemental additives as disclosed, which are dewatered by pressing or by using one of the Fourdriner/Magnani/Hatschek processes to form a flat board which is then heat cured under pressure (typically 10-15 bar) for periods up to 24 hours.

Abstract

The present invention discloses a shaped molded matrix, an article and a method thereof for absorbing animal litter comprising: at least one inorganic binder absorbent material. The shaped molded matrix is formed from an absorbent material comprising vermiculate at the range of about 50% to about 100% by weight.

Description

VERMICULITE MOLDED MATRIX
FIELD OF INVENTION
The present invention relates to animal litter articles, and more particularly, this invention relates to inorganic litter articles which are made from an inorganic binder absorbent material.
BACKGROUND
There are variety of compositions and attempts to form animal litter articles.
Those animal litter articles comprise only a layer or a fraction of the overall inorganic material, or partially constitutes the article mass.
The litter box models known in the art are typically a plastic or a plastic liners tray which comprises a mineral or any absorbent material .The elaborate models are covered in order to facilitate emptying and cleaning a litter box. Further more, there are attempts and developments in litter box technology to simplify the litter box emptying procedure. Some models have electric combing mechanisms that automatically scoop the clumps out of the litter box into a sealed, disposable-bag- lined container after the animal has used it. These models use a pressure pad or an infrared light to determine when the cat has left the box and will comb the box after so many minutes have passed, to avoid disturbing the cat. Other designs take this further, and connect directly to a home's plumbing so they can wash, rinse and dry the permanent litter pellets automatically. Other designs known in the art require the owner to manually shake the clumps into an easy-to-remove tray. Another variant has an enclosed sphere which rotates as it sifts out the clumps and deposits them in a drawer below the sphere.
US patent No. 3590111 discloses shaped articles for construction or insulation comprising vermiculite or expanded perlite, or mixture thereof compounded by a quasi-colloidal binding agent made up from perlite dust and containing mixed crystals of calcium, silicate hydrate, calcium aluminosilicate hydrate, and calcium aluminate hydrate produced by the reaction of calcium oxide or dry hydrated calcium oxide with finally divided perlite. US patent No. 3,778,28 ldiscloses a fusion bonded vermiculite molding material prepared from vermiculite, sodium borate, sodium met phosphate and clay is used to prepare a variety of materials and structures.
US patent No. 5830305 describes compositions for manufacturing articles, particularly containers and packaging materials, having a highly inorganically filled matrix. The inorganically filled mixtures are prepared by mixing together an organic polymer binder, water, one or more aggregate materials, fibers, and optional admixtures in the correct proportions in order to form an article which has the desired performance criteria. The inorganically filled mixtures are molded to fashion a portion of the mixture into a form stable shape for the desired article. Once the article has obtained form stability, the article is removed from the mold and allowed to harden to gain strength. The articles may have properties substantially similar to articles presently made from traditional materials like paper, paperboard, polystyrene, plastic, or metal. They have especial utility in the mass production of containers, particularly food and beverage containers.
There is therefore a long unmet need for improved compositions, products and methods for manufacturing highly inorganically filled mixtures that can be molded into articles.
SUMMARY OF THE INVENTION
It is one embodiment of the present invention to provide a shaped molded matrix for absorbing animal litter comprising: at least one inorganic binder absorbent material; wherein the shaped molded matrix is formed from the absorbent material comprising vermiculite at the range of about 50% to about 100% by weight. It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein the molded matrix is with a shape of a sliding tray.
It is another object of the present invention to provide the molded matrix as defined in any of the above, further comprising an odor absorbing agent adapted as an antibacterial agent for absorbing odors, inhibiting odors, controlling and stabilizing the pH value and preventing any static electricity effects. It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein the odor agent is selected from the group consisting of bicarbonate compounds, boron compounds, carbonates, cyclodextrins, zeolites, activated carbon, kieselguhr, chelating agents, chitin and pH buffered materials, such as carboxylic acids and any combination thereof.
It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein further comprising Polystyrene is in its foam form.
It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein the molded matrix is of a biodegradable material.
It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein the molded matrix is used as fertilizer or for recycling means or processes.
It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein the vermiculite is employed up to approximately 50% by weight of the molded matrix.
It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein the vermiculite is employed up to approximately 70% by weight of the molded matrix
It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein further comprising supplemental additives which may be introduced into the molded matrix mixture.
It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein the absorbent material further comprises at least one mineral selected from the group consisting of Georgia White clay, sepiolite, zeolite, calcite, dolomite, slate, pumice, tobermite, marls, attapulgite, bentonite, kaolinite, halloysite, montmorillonite, smectite, hectorite, diatomaceous earth, Fuller's earth, fossilized plant materials, expanded perlites and gypsum or any other similar minerals and a mixture thereof.
It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein further comprising natural processed materials selected from the group consisting of paper, cellulosic webs, polymeric fibrous webs, wood chips, alfalfa, bark, straw, sand, grain hulls, synthetic foams, recycled materials, pelletized absorbing litter materials and any mixture thereof. It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein the molded matrix further comprises at least one component selected from the group consisting of supplemental absorbent material, a fixing agent, colorant agent, anti-bacterial agent, a fragrance and any combination thereof.
It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein the component is in an amount of about 1% to about 5% of the molded matrix.
It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein further comprising at least one binding agent to induce or facilitate agglomeration; the binding agent comprises (i) natural polymers and synthetic derivatives thereof selected from the group consisting of lignins, gums, starches , polysaccharides, such as lignin sulfonate, carboxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, ethylhydroxyethyl cellulose, methylhydroxypropylcellulose, guar gum, alginates, starch, xanthan gum, gum acacia, gum Arabic, and any combination thereof;
(ii) synthetic polymers selected from the group consisting of polyvinylpyrrolidone, polyethylene glycol, polyethyleneoxide, acrylate polymers and copolymers, acrylic emulsions, polyvinyl alcohol, polyvinyl acetate, polyvinyl pyrrolidine, polyacrylic acid, latexes,neoprene latex, superabsorbent polymers,cross-linked polyacrylates, flocculating agents , polycarboxylates, fluorinated polymers,polytetrafluoroethylene and any combination thereof, and (iii) inorganic agglomerating agents selected from the group consisting of silicates and phosphates, pyrophosphates, aluminates and any combination thereof.
It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein the matrix is formed by at least one technique selected from the group consisting of: agglomeration technique, molding technique, compaction technique, coating technique, embedding technique, dispersing technique, filling technique and any combination thereof.
It is another object of the present invention to provide the molded matrix as defined in any of the above, wherein the matrix shape is selected from a group consisting of tray, spherical shape , non- spherical shapes ,ovals, flattened spheres, hexagons, triangles, squares, square with a flat form, rectangular with a flat form, square, rectangular, diamond, cupped, star, bagel, mesh-like, angled, cone, tetrahedron, pyramid and any combination thereof.
It is another object of the present invention to disclose an animal litter article for recycling purposes comprising:
a. a container composed of polystyrene; and
b. a slidable tray formed from at least one inorganic binder material; the tray is located at the lower part of the container;
wherein the lower slidable tray comprises at least 50% of vermiculite configured to absorb secretions of the animal and further to be drawn out for fertilization means. It is another object of the present invention to provide the article as defined in any of the above, wherein the article further comprises an upper slidable tray.
It is another object of the present invention to provide the article as defined in any of the above, wherein the vermiculite is uniformly distributed upon surface of the tray at a thickness of more than about 25.0 % of the tray.
It is another object of the present invention to provide the article as defined in any of the above, wherein the slidable tray further comprising an odor absorbing agent adapted as an antibacterial agent for absorbing odors, inhibiting odors , controlling and stabilizing the pH value and preventing any static electricity effects.
It is another object of the present invention to provide the article as defined in any of the above, wherein the odor agent is selected from the group consisting of bicarbonate compounds, boron compounds, carbonates, cyclodextrins, zeolites, activated carbon, kieselguhr, chelating agents, chitin and pH buffered materials, such as carboxylic acids and any mixture thereof.
It is another object of the present invention to provide the article as defined in any of the above, wherein container is composed from Polystyrene is in its foam form.
It is another object of the present invention to provide the article as defined in any of the above, wherein the container is of a biodegradable material.
It is another object of the present invention to provide the article as defined in any of the above, wherein the molded matrix is used as fertilizer or for recycling needs or processes.
It is another object of the present invention to provide the article as defined in any of the above, wherein the vermiculite is employed up to approximately 100% by weight of the tray. It is another object of the present invention to provide the article as defined in any of the above, wherein the vermiculite is employed up to approximately 70% by weight of the tray.
It is another object of the present invention to provide the article as defined in any of the above, wherein the slidable tray further comprising supplemental additives which may be introduced into the molded matrix mixture.
It is another object of the present invention to provide the article as defined in any of the above, wherein the absorbent material is a mineral selected from the group consisting of Georgia White clay, sepiolite, zeolite, calcite, dolomite, slate, pumice, tobermite, marls, attapulgite, bentonite, kaolinite, halloysite, montmorillonite, smectite, hectorite, diatomaceous earth, Fuller's earth, fossilized plant materials, expanded perlites and gypsum or any other similar minerals, or mixture thereof.
It is another object of the present invention to provide the article as defined in any of the above, wherein slidable tray further comprising natural processed materials selected from the group consisting of paper, cellulosic webs, polymeric fibrous webs, wood chips, alfalfa, bark, straw, sand, grain hulls, synthetic foams, recycled materials, pelletized absorbing litter materials and any mixture thereof.
It is another object of the present invention to provide the article as defined in any of the above, wherein the slidable tray further comprises at least one component selected from the group consisting of supplemental absorbent material, a fixing agent, colorant agent, anti-bacterial agent, a fragrance and any combination thereof.
It is another object of the present invention to provide the article as defined in any of the above, wherein the component is in an amount of about 1% to about 5% of the molded matrix.
It is another object of the present invention to provide the article as defined in any of the above, wherein further comprising at least one binding agent to induce or facilitate agglomeration; the binding agent comprises (i) natural polymers and synthetic derivatives thereof selected from the group consisting of lignins, gums, starches , polysaccharides, such as lignin sulfonate, carboxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, ethylhydroxyethyl cellulose, methylhydroxypropylcellulose, guar gum, alginates, starch, xanthan gum, gum acacia, gum Arabic, and any combination thereof;
(ii) synthetic polymers selected from the group consisting of polyvinylpyrrolidone, polyethylene glycol, polyethyleneoxide, acrylate polymers and copolymers, acrylic emulsions, polyvinyl alcohol, polyvinyl acetate, polyvinyl pyrrolidine, polyacrylic acid, latexes,neoprene latex, superabsorbent polymers,cross-linked polyacrylates, flocculating agents , polycarboxylates, fluorinated polymers,polytetrafluoroethylene and any combination thereof, and (iii) inorganic agglomerating agents seelclted from the group consisting of silicates and phosphates, pyrophosphates, aluminates and any combination thereof.
It is another object of the present invention to provide the article as defined in any of the above, wherein the slidable tray is formed by manner selected from a group consisting of: agglomeration technique, molding technique, compaction technique, coating technique, embedding technique, dispersing technique, filling technique and any combination thereof.
It is another object of the present invention to provide the article as defined in any of the above, wherein the container shape is selected from a group consisting of tray, spherical shape, non- spherical shapes, ovals, flattened spheres, hexagons, triangles, squares, square with a flat form, rectangular with a flat form, square, rectangular, diamond, cupped, star, bagel, mesh-like, angled, cone, tetrahedron, pyramid and any combination thereof.
It is another object of the present invention to provide a method of manufacturing a litter animal article for recycling, comprising steps of:
a. providing a container composed of polystyrene;
b. forming slidable tray formed from at least one inorganic binder material; the binder material is vermiculite; and
c. uniformly distributing along the tray at least one odor agent selected from the group consisting of bicarbonate compound or boron compound.
It is another object of the present invention to provide the method as defined in any of the above, wherein the method further comprising step of forming the slidable tray by at least one of the following steps distributing, filing, coating dispersing, embedding, admixing, molding, compacting the vermiculite into a predefined shape .
It is another object of the present invention to provide the method as defined in any of the above, wherein the method further comprising step of coating shaped molded matrix with at least one layer of exfoliated expanded vermiculite . It is another object of the present invention to provide the method as defined in any of the above, wherein the method further comprising step of dispersing the bicarbonate compound upon the tray.
It is another object of the present invention to provide the method as defined in any of the above, wherein the method further comprising step of providing the tray composed of at least 50% of vermiculite by weight.
It is another object of the present invention to provide the method as defined in any of the above, wherein the method further comprising step of employing the vermiculite up to approximately 100% by weight of the tray.
It is another object of the present invention to provide the method as defined in any of the above, wherein the method further comprising step of employing the vermiculite more than approximately 70% by weight of the tray.
It is another object of the present invention to provide the method as defined in any of the above, wherein the step of providing slidable tray which is removable and replaceable after absorbing the litter of the animal.
It is another object of the present invention to provide the method as defined in any of the above, wherein the method further comprising step of providing the odor agent selected from the group consisting of carbonates, bicarbonates, cyclodextrins, zeolites, activated carbon, kieselguhr, chelating agents, chitin and pH buffered materials, such as carboxylic acids and any mixture thereof.
It is another object of the present invention to provide the method as defined in any of the above, wherein the method further comprising step of heating the vermiculite to produce a layer of an absorbent material and dispersing thereto a layer of the odor agent upon the vermiculite.
BRIEF DESCRIPTION
In order to understand the invention and to see how it may be implemented in practice, a few preferred embodiments will now be described, by way of non-limiting example only, with reference to be accompanying drawings, in which:
FIG. 1 illustrates a cuboid configuration of the animal litter article of the present invention: FIG. 2 illustrates an upper view of the open configuration of the animal litter article of the present invention;
FIG. 3 illustrates a side view of the animal litter article of the present invention; and, FIG. 4 illustrates a bottom view of the animal litter article of the present invention.
DETAILED DESCRIPTION
The following description is provided so as to enable any person skilled in the art to make use of the invention and sets forth the best modes contemplated by the inventor of carrying out this invention. Various modifications, however, will remain apparent to those skilled in the art, since the generic principles of the present invention have been defined specifically to provide a product and a method for a vermiculite litter molded matrix.
The present invention relates to litter molded matrix made from at least one inorganic binder absorbent material with improved physical, chemical properties and further greater absorption capability. The composition may further comprise malodor controlling materials and optional performance-enhancing additives. A preferred use for the absorbent material is for adsorbing and absorbing animal litter or any secretion or excretion, and may further be useful for air and water filtration, fertilizer, waste remediation, etc., and should not be limited to the context of an animal litter.
By using various processes described herein, the molded matrix may be "engineered" to preferentially exhibit specific characteristics including but not limited to improved odor control, lower density, easier scooping, better particle/active consistency, higher clump strength, etc. The molded matrix comprising vermiculite is further configured to control leakage or flow-through of fluids.
The present invention relates to an animal litter article for recycling purposes comprising: a container composed of polystyrene and a slidable tray formed from at least one inorganic binder material; the tray is located at the lower part of the container.
The slidable tray comprises at least 50% of vermiculite configured to absorb secretions of the animal and further to be ejected or drawn out for fertilization means. The container composed of polystyrene(PS) may be in its foam form and at least one inorganic binder absorbent material. In another embodiment of the present invention, the tray is a molded matrix composed of vermiculite as a substrate which can be heated and further expands greatly such that it can be formed into any desired shape.
In another embodiment of the present invention, the molded matrix process may involve mixing exfoliated vermiculite with inorganic bonding agents such as sodium silicate and potassium to produce a mixture. This vermiculite is then hydraulically pressed into shape in a mold, and then heat cured at temperatures up to 180 °C for up to 24 hours depending upon the thickness of the molded part. Such parts can withstand service temperatures of up to 1150 °C.
The article of the present invention comprises polystyrene or expanded polystyrene which is injection molded or extruded. Polystyrene can further be recycled. Polystyrene is chemically inert, being resistant to acids and bases but is easily dissolved by d-limonene, chlorinated solvents, and further aromatic hydrocarbon solvents. Resulting from its resilience and inertness characteristics , Polystyrene may be attacked by organic solvents, which dissolve the polymer. Polystyrene foams are good thermal insulators and are may be further used as building insulation materials, such as in insulating concrete forms and structural insulated panel building systems. Polystyrene incorporating graphite has superior insulation properties. PS foams also exhibit good damping properties, therefore it may further be used as a packaging material. The article of the present invention may comprise an expanded polystyrene (EPS) form which is a rigid and tough, closed-cell foam. It is made of pre-expanded polystyrene beads and may further be used as a disposable containers, trays, plates and/or bowls for accommodating a vermiculite layer. The article of the present invention may further comprise an extruded polystyrene foam (XPS) consists of closed cells, which provides improved surface roughness and higher stiffness and reduced thermal conductivity. The density range is about 28-45 kg/m .
The term "molded matrix " as used herein should be understood to mean a layer, a tray or any article configured to contain and absorb animal litter. The molded matrix comprises at least one inorganic binding substrate preferably expanded vermiculite which may be exfoliated. The molded matrix may be formed of plurality of material and layers.
As used herein the term "about X" or "approximately X" or "substantially X" usually refers to a range 25% less than to 25% more than of X (X +- 25%), at times X +- 20%, X +- 15% and preferably X +- 10%. Reference is now made to Fig. 1 which illustrates a close configuration of the animal litter article 10 comprises: a container having a cuboid shape 11 composed of polystyrene and a molded matrix as a slidable tray 13 formed from at least one inorganic binder material. As illustrated, the tray 13 is located at the lower part of the container. The slidable tray is composed of at least 50% of vermiculite configured to absorb secretions of the animal and further to be ejected or/and drawn out for fertilization means. Furthermore, the container composed of polystyrene(PS) may be in its foam form and at least one inorganic binder absorbent material.
The article of the present invention may further comprise an additional upper moveable tray 12 which slides and therefore allows opening and closing of the cuboid. The tray may be composed of a material selected from the group consisting of PS, vermiculite, an odor material and any mixture thereof. As further illustrated, the external layer of the article may be composed of polystyrene and the slidable tray configured as a drawer as the interior layer is composed of at vermiculite in the range of about 50 to about 100% by weight.
In another embodiment of the present invention, the vermiculite may be employed up to approximately 50% by weight of the tray.
In another embodiment of the present invention, the vermiculite is employed up to approximately 70% by weight of the tray.
In another embodiment of the present invention, the container may further comprise beads of vermiculite having a particle size smaller than 15 mm which may be coated or impregnated upon the tray or a thick solid coating layer of vermiculite uniformly distributed having a thickness of more than about 25.0 % of tray thickness. . The size of the tray is designed according to the size of the pet whilst the width of the cuboid is in the range of approximately 25 to 50cm. The length is in the range of approximately 35 to 70 cm and the height is in the range of approximately 7 to 40cm. The vermiculite filling may be in the volume of about 3L to 17L, according to the cuboid size. The tray is a slidably member which may be mounted to the container in a locking mechanism for releasably retaining or/and drawing the tray at various longitudinal positions along the container base surface. Furthermore the slidable tray may comprise pivoting slidable hooks or/and a slidable assist handle.
Fig 2 illustrates an open configuration of the animal litter article 20 comprising a polystyrene container 22 moveable vermiculite tray 21 which slide along the upper section of the cuboid container. The tray 21 is operatively engaged to the container such that it can be pulled out and inserted back easily.
Fig 3-4 illustrates the cuboid structure of the animal litter article 30,40 comprising a cuboid container having a slide vermiculite tray 31,41 on the bottom of the cuboid container . The tray is quite light in weight, configured to be removable and may further be replaceable and reused for recycling purposes, process and needs such as fertilization for agriculture, ecological means and the like. The tray may further be treated for reuse by soaking in water and heating in a temperature of 100°C to 150°C in an oven ,autoclave or any sterilizer device. The slidable tray is based upon any known slide mechanism.
In another embodiment of the present invention, the inorganic material may have a concentration in a range from about 95% to about 100% by volume of the total solids in the vermiculite mixture, more preferably from about 90% to about 98%. Additional components, such as organic aggregates and dispersants, can be selectively added. In another embodiment of the present invention, vermiculite molded matrix configured as a tray is with the properties of flexibility, tensile strength, toughness, moldability, and mass-producibility. Vermiculite has a trioctahedral 2: 1 layer, and an interlayer containing both Mg2+ and Al3+, which are able to hold two water molecules in the interlayer. Vermiculite has a higher layer charge and a high cation exchange capacity (1000-1500 meq/kg). The layers are strongly held together, so the basal spacing is smaller. On heating, the water can be expelled, collapsing the structure to 12.5 A and then to 10 A. If a large vermiculite crystal is rapidly heated, the steam physically blows some of the layers apart and accordion-like "worms" are formed. Therefore due to Vermiculite physical properties a litter article can be formed in a desired shape or structure suitable to the need. The cation exchange capacity (up to 1000 milliequivalents per kg) of vermiculite allows it to be used in fluid purification processes for waste water, chemical processing and the pollution control of air and gases in industrial processes. In addition to its ion exchange properties exfoliated vermiculite will retain liquids within the inter-laminar voids of the individual particles as well as between the particles themselves.
In another embodiment of the present invention, the preferred absorbent material is vermiculite additional liquid- absorbing materials may be used without departing from the scope of the present invention. Illustrative absorbent materials include but are not limited to plurality of granules, minerals, fly ash, absorbing pelletized materials, perlite, silicas, other absorbent materials and mixtures thereof. Preferred minerals include: bentonites, zeolites, fullers earth, attapulgite, montmorillonite diatomaceous earth, opaline silica, crystalline silica, silica gel, alumina, Georgia White clay, sepiolite, calcite, dolomite, slate, pumice, tobermite, marls, attapulgite, kaolinite, halloysite, smectite, vermiculite, hectorite, Fuller's earth, fossilized plant materials, expanded perlites, gypsum and other similar minerals and mixtures thereof.
In another embodiment of the present invention , the molded matrix may comprise additional additives such as Silica gel litter, or "crystal litter", a porous granular form of sodium silicate, having high absorbency of any litter, and has excellent moisture control and complete odor elimination for an extended period of time when compared to other litters.
In another embodiment of the present invention, the slidable tray further comprises at least one component selected from the group consisting of supplemental absorbent material, a fixing agent, colorant agent, anti-bacterial agent, a fragrance and any combination thereof.
In another embodiment of the present invention, in order to solve and further control the malodor problem arising from used animal litter the molded matrix may further contains bentonite clay particles. Bentonite is known as a water-swellable clay which, upon contact with moist animal waste, is able to agglomerate with other moistened bentonite clay particles. This thus isolates the moist animal waste by the agglomeration of the moist clay particles. The agglomerations form an isolatable clump, which can be removed from the litter
In another embodiment of the present invention, the molded matrix may comprise boron-containing compounds, especially boric acid, which are effective additives to both clumping and non-clumping clay-based animal litters. The use of borax in a animal litter in which a water soluble polymer present is caused to gel or harden by the presence of borax as a reaction initiator or catalyst, but not as an odor control agent.
Another embodiment of the present invention may include various buffering agents, including sodium borate, in a litter in which a strong oxidant, sodium or ammonium persulfate is present to reduce odors in animal litters.
Another embodiment of the present invention may include activated alumina which is known as a desiccant in gas-phase processes and applications. By using various processes described herein, vermiculite is with the characters and the ability to be molded into a variety of structures. The vermiculite molded matrix preferably may have a tray or a box structure but variety of other configuration and shapes may be formed, selected from a group consisting of :
spherical shape , non- spherical shapes such as ovals, flattened spheres, hexagons, triangles, squares, square with a flat form, rectangular with a flat form, square, rectangular, diamond, cupped, star, bagel, mesh-like, angled, cone, tetrahedron, pyramid, and combinations thereof.
In another embodiment of the present invention, the container preferably may have a cuboid or a box structure but variety of other configuration and shapes may be formed, selected from a group consisting of: spherical shape, non- spherical shapes such as ovals, flattened spheres, hexagons, triangles, squares, square with a flat form, rectangular with a flat form, square, rectangular, diamond, cupped, star, bagel, meshlike, angled, cone, tetrahedron, pyramid, and combinations thereof.
According to the present invention, the preferred structural matrix of the vermiculite molded matrix is formed from the interaction between inorganic aggregate particles, a water-dispersable organic binder. These are made into a highly moldable, workable, and uniform mixture by adding an appropriate amount of water and thoroughly mixing the components together. Preferably, the amount of added water is just enough to provide adequate workability and moldability, while maintaining a mixture that is form stable; that is, a mixture which will maintain its shape after being molded into the desired shape, including post-molding handling of the article.
Due to environmental needs and impacts of indisposed materials on the environment, there is a need for articles which are from biodegradable material.
In the foregoing description, embodiments of the invention, including preferred embodiments, have been presented for the purpose of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principals of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth they are fairly, legally, and equitably entitled.
The present invention further provides a method for manufacturing and further recycling an animal litter article comprising the steps of (a)providing a container composed of foamed polystyrene, (b)forming a slidable tray comprising at least one inorganic binder material; the binder material is vermiculite and (c)imiformly distributing along the tray at least one odor agent selected from the group consisting of bicarbonate compound or boron compound.
The method of the present invention further comprising step of forming the slidable tray by at least one of the following steps distributing ,filing, coating dispersing, embedding, admixing molding and compacting the vermiculite into a predefined shape .
The method of the present invention further comprising the step of coating the tray with at least one layer of exfoliated expanded vermiculite
The method of the present invention further comprising step of dispersing the bicarbonate compound upon the vermiculite.
The method of the present invention further comprising step of providing the tray composed of at least 50% of vermiculite by weight.
The method of the present invention further comprising step of employing the vermiculite up to approximately 100% by weight of the tray.
The method of the present invention further comprising step of employing the vermiculite more than approximately 70% by weight of the tray.
The method of the present invention further comprising step of providing slidable tray which is removable and replaceable after absorbing the litter of the animal.
The method of the present invention further comprising step of providing the odor agent selected from the group consisting of carbonates, bicarbonates, cyclodextrins, zeolites, activated carbon, kieselguhr, chelating agents, chitin and pH buffered materials, carboxylic acids and any mixture thereof.
The method of the present invention further comprising step of heating the
vermiculite to produce a layer of an absorbent material and dispersing thereto a layer of the odor agent upon the vermiculate layer.
The present invention further provides the production of foamed polystyrene articles according to the following steps: Making styrene
The basic unit of polystyrene is styrene, which is the product of a two-fold reaction. Ethylene and benzene, in the presence of a catalyst such as aluminum chloride, form ethylbenzene (C8 ¾ ), which is then dehydrogenated (hydrogen is removed) at 1,112- 1,202 degrees Fahrenheit (600-650 degrees Celsius) to form styrene (CgHg).
Making polystyrene
Polystyrene is formed from styrene through suspension polymerization, a process by which tiny drops of the monomer, styrene are completely surrounded by water and a mucilaginous substance. Supporting and surrounding the styrene globules, the suspension agent produces uniform droplets of polystyrene.
Next, a polymerization initiator is added to the droplets, which are suspended by heat radiation of about 212 degrees Fahrenheit (100 degrees Celsius). This results in free radicals, a group of atoms particularly likely to react with others because they contain unpaired electrons which are available for molecular bonding. Free radicals then combine at randomly to form chains of polystyrene. Terminators are introduced to the process to end it at the appropriate time. Though variable, chain length must fall within a certain range, because polystyrene with overly long chains won't melt readily, and polystyrene with short chains will be brittle.
Preparing the beads
After polymerization is complete, the mixture consisting of beads made up of polystyrene chains is cooled. These beads are then washed out and dried. Uniform bead size is achieved by sorting the beads through meshes which filter out over and undersized beads.
Making expanded polystyrene foam
First, the beads of polystyrene must be expanded to achieve the proper density. This process is known as pre-expansion, and involves heating the polystyrene either with steam or hot air (for high density foam, ), the heating is carried out in a vessel holding anywhere from 50 to 500 gallons (189 to 1,892 liters). During pre-expansion, an agitator is used to keep the beads from fusing together. Since expanded beads are lighter than unexpanded beads, they are forced to the top of the vessel's cavity and discharged. This process lowers the density of the beads to three percent of their original value and yields a smooth-skinned, closed cell EPF that is excellent for detailed molding. Next, the pre-expanded beads are "aged" for at least 24 hours in mesh storage silos. This allows air to diffuse into the beads, cooling them and making them harder.
Molding
After aging, the beads are fed into a mold of the desired shape. Low-pressure steam is then injected into and between the beads, expanding them once more and fusing them together. The mold is then cooled, either by circulating water through it or by spraying water on the outside. EPF is such a good insulator that it is hard to cool the mold down. Using small molds can reduce both the heating and cooling time and thereby speed up the process.
Making extruded, expanded polystyrene foam
This process yields EPF with small cell size that can be used to manufacture boards used for insulation. The beads are melted, and a blowing agent is added. The molten polystyrene is then extruded into the proper shape under conditions of high temperature and pressure. Additional steps such as cutting, bonding, and coating the polystyrene to a predefined structure.
In another embodiment of the present invention, Polystyrene is extruded with foaming agents and preferably in the presence of nucleating agents, e.g. talc or chemical foaming agents. The foaming agents can be either a physical foaming agent, e.g. a gas like C02, N2, isopentane, hydrofluorocarbons, or a chemical foaming agent which decomposes in the melted polymer during processing liberating a gas, e.g. C02 or N2. In both processes the gas has to be thoroughly dispersed and dissolved in the polymer melt under pressure in the extruder barrel. When the melt exits the extruder through the die, the pressure drops and the gas expands the melt creating a cellular structure in the polymer. Foam extruded polystyrene articles produced in the so called direct gassed extrusion can achieve foam densities of from 5 kg/m 3 to 500 kg/m 3.
In another embodiment of the present invention, the slidable tray composed of vermiculite is formed by manner selected from a group consisting of: agglomeration technique, molding technique, compaction technique, coating technique, embedding technique, dispersing technique, filling technique and any combination thereof. The tray may further comprise polystyrene sheet and at least one coating layer of vermiculite dispersions which is either chemically or physically very finely delaminated vermiculite in a fluid medium. The dispersions technique can be used to make vermiculite film sheet by simply pouring on to a piece of smooth low surface of polystyrene and allowing to dry, the resulting sheet may further be peeled off the polystyrene sheet. Typical end uses for vermiculite dispersions include in high temperature coatings or binders for construction materials, oxidation resistant coating on carbon based composites, and as barrier coatings for films.
The tray may further comprise exfoliated vermiculite and additional odor agent or supplemental additives as disclosed, which are dewatered by pressing or by using one of the Fourdriner/Magnani/Hatschek processes to form a flat board which is then heat cured under pressure (typically 10-15 bar) for periods up to 24 hours.

Claims

1. A shaped molded matrix for absorbing animal litter comprising:
at least one inorganic binder absorbent material;
wherein said shaped molded matrix is formed from said absorbent material comprising vermiculite at the range of about 50% to about 100% by weight.
2. The molded matrix according to claim 1, wherein said molded matrix is with a shape of a sliding tray.
3. The molded matrix according to claiml, further comprising an odor absorbing agent adapted as an anti bacterial agent for absorbing and/or inhibiting odors , controlling and stabilizing the pH value and preventing any static electricity effects.
4. The molded matrix according to claim 3, wherein said odor agent is selected from the group consisting of bicarbonate compounds , boron compounds, carbonates, cyclodextrins, zeolites, activated carbon, kieselguhr, chelating agents, chitin and pH buffered materials, carboxylic acids and any
combination thereof.
5. The molded matrix according to claim 1, wherein further comprising
Polystyrene is in its foam form.
6. The molded matrix according to claiml, wherein said molded matrix is of a biodegradable material.
7. The molded matrix according to claiml, wherein said molded matrix is used as fertilizer or for recycling means or processes.
8. The molded matrix according to claiml, wherein said vermiculite is employed up to approximately 50% by weight of said molded matrix.
9. The molded matrix according to claim 1, wherein said vermiculite is employed up to approximately 70% by weight of said molded matrix
10. The molded matrix according to claim 1, wherein further comprising
supplemental additives which may be introduced into said molded matrix mixture.
11. The molded matrix according to claim 1, wherein said absorbent material further comprises at least one mineral selected from the group consisting of Georgia White clay, sepiolite, zeolite, calcite, dolomite, slate, pumice, tobermite, marls, attapulgite, bentonite, kaolinite, halloysite, montmorillonite, smectite, hectorite, diatomaceous earth, Fuller's earth, fossilized plant materials, expanded perlites and gypsum or any other similar minerals and a mixture thereof.
12. The molded matrix according to claim 1, wherein further comprising natural processed materials selected from the group consisting of paper, cellulosic webs, polymeric fibrous webs, wood chips, alfalfa, bark, straw, sand, grain hulls, synthetic foams, recycled materials, pelletized absorbing litter materials and any mixture thereof.
13. The molded matrix according to claiml, wherein said molded matrix further comprises at least one component selected from the group consisting of supplemental absorbent material, a fixing agent, colorant agent, anti-bacterial agent, a fragrance and any combination thereof.
14. The molded matrix according to claim 13, wherein said component is in an amount of about 1% to about 5% of said molded matrix.
15. The molded matrix according to claim 1, wherein further comprising at least one binding agent to induce or facilitate agglomeration; said binding agent comprises (i) natural polymers and synthetic derivatives thereof selected from the group consisting of lignins, gums, starches , polysaccharides, lignin sulfonate, carboxymethylcellulose, hydroxyethylcellulose,
hydroxypropylcellulose, ethylhydroxyethyl cellulose,
methylhydroxypropylcellulose, guar gum, alginates, starch, xanthan gum, gum acacia, gum Arabic, and any combination thereof;
(ii) synthetic polymers selected from the group consisting of
polyvinylpyrrolidone, polyethylene glycol, polyethyleneoxide, acrylate polymers and copolymers, acrylic emulsions, polyvinyl alcohol, polyvinyl acetate, polyvinyl pyrrolidine, polyacrylic acid, latexes, neoprene latex, superabsorbent polymers,cross-linked polyacrylates, flocculating agents , polycarboxylates, fluorinated polymers,polytetrafluoroethylene and any combination thereof, and (iii) inorganic agglomerating agents selected from the group consisting of silicates and phosphates, pyrophosphates,aluminates and any combination thereof.
16. The molded matrix according to claiml, wherein said matrix is formed by at least one technique selected from the group consisting of: agglomeration technique, molding technique, compaction technique, coating technique, embedding technique, dispersing technique, filling technique and any combination thereof.
17. The molded matrix according to claiml, wherein said matrix shape is selected from a group consisting of tray, spherical shape , non- spherical shapes ,ovals, flattened spheres, hexagons, triangles, squares, square with a flat form, rectangular with a flat form, square, rectangular, diamond, cupped, star, bagel, mesh-like, angled, cone, tetrahedron, pyramid and any combination thereof.
18. An animal litter article for recycling purposes ,comprising:
a. a container composed of polystyrene; and
b. a slidable tray formed from at least one inorganic binder material; said tray is located at the lower part of said container;
wherein said lower slidable tray comprises at least 50% of vermiculite by weight configured to absorb secretions of said animal and further to be drawn out for fertilization means.
19. The article according to claim 18, wherein said article further comprises an upper slidable tray.
20. The article according to claim 18, wherein said vermiculite is uniformly
distributed upon surface of said tray at a thickness of more than about 25.0 % of said tray.
21. The article according to claim 18, wherein said slidable tray further
comprising an odor absorbing agent adapted as an antibacterial agent for absorbing and/or inhibiting odors , controlling and stabilizing the pH value and preventing any static electricity effects.
22. The article according to claim 20, wherein said odor agent is selected from the group consisting of bicarbonate compounds, boron compounds, carbonates, , cyclodextrins, zeolites, activated carbon, kieselguhr, chelating agents, chitin and pH buffered materials, carboxylic acids and any mixture thereof.
23. The article according to claim 18, wherein container is composed from
Polystyrene is in its foam form.
24. The article according to claim 18, wherein said container is of a biodegradable material.
25. The article according to claim 18, wherein said molded matrix is used as
fertilizer or for recycling needs or processes.
26. The article according to claim 18, wherein said vermiculite is employed up to approximately 100% by weight of said tray.
27. The article according to claim 18, wherein said vermiculite is employed up to approximately 70% by weight of said tray.
28. The article according to claim 18, wherein said slidable tray further
comprising supplemental additives which may be introduced into said molded matrix mixture.
29. The article according to claim 18, wherein said absorbent material is a mineral selected from the group consisting of Georgia White clay, sepiolite, zeolite, calcite, dolomite, slate, pumice, tobermite, marls, attapulgite, bentonite, kaolinite, halloysite, montmorillonite, smectite, hectorite, diatomaceous earth, Fuller's earth, fossilized plant materials, expanded perlites and gypsum or any other similar minerals, or mixture thereof.
30. The article according to claim 18, wherein slidable tray further comprising natural processed materials selected from the group consisting of paper, cellulosic webs, polymeric fibrous webs, wood chips, alfalfa, bark, straw, sand, grain hulls, synthetic foams, recycled materials, pelletized absorbing litter materials and any mixture thereof.
31. The article according to claim 18, wherein said slidable tray further comprises at least one component selected from the group consisting of supplemental absorbent material, a fixing agent, colorant agent, anti-bacterial agent, a fragrance and any combination thereof.
32. The article according to claim 31, wherein said component is in an amount of about 1% to about 5% of said molded matrix.
33. The article according to claim 18, wherein further comprising at least one binding agent to induce or facilitate agglomeration; said binding agent comprises (i) natural polymers and synthetic derivatives thereof selected from the group consisting of lignins, gums, starches , polysaccharides, lignin sulfonate, carboxymethylcellulose, hydroxyethylcellulose,
hydroxypropylcellulose, ethylhydroxyethyl cellulose,
methylhydroxypropylcellulose, guar gum, alginates, starch, xanthan gum, gum acacia, gum Arabic, and any combination thereof;
(ii) synthetic polymers selected from the group consisting of
polyvinylpyrrolidone, polyethylene glycol, polyethyleneoxide, acrylate polymers and copolymers, acrylic emulsions, polyvinyl alcohol, polyvinyl acetate, polyvinyl pyrrolidine, polyacrylic acid, latexes, neoprene latex, superabsorbent polymers,cross-linked polyacrylates, flocculating agents , polycarboxylates, fluorinated polymers,polytetrafluoroethylene and any combination thereof, and (iii) inorganic agglomerating agents seelclted from the group consisting of silicates and phosphates, pyrophosphates,aluminates and any combination thereof.
34. The article according to claim 18, wherein said slidable tray is formed by manner selected from a group consisting of : agglomeration technique, molding technique, compaction technique, coating technique, embedding technique, dispersing technique, filling technique and any combination thereof.
35. The article according to claim 18, wherein said container shape is selected from a group consisting of tray, spherical shape , non- spherical shapes, ovals, flattened spheres, hexagons, triangles, squares, square with a flat form, rectangular with a flat form, square, rectangular, diamond, cupped, star, bagel, mesh-like, angled, cone, tetrahedron, pyramid and any combination thereof.
36. A method of manufacturing a litter animal article for recycling, comprising steps of;
a. providing a container composed of foamed polystyrene;
a. forming a slidable tray comprising at least one inorganic binder
material; said binder material is vermiculite; and
b. uniformly distributing along said tray at least one odor agent selected from the group consisting of bicarbonate compound or boron compound.
37. The method according to claim 36, wherein said method further comprising step of forming said slidable tray by at least one of the following steps distributing ,filing, coating dispersing, embedding, admixing molding and compacting said vermiculite into a predefined shape .
38. The method according to claim 36, wherein said method further comprising step of coating said tray with at least one layer of exfoliated expanded
vermiculite
39. The method according to claim 36, wherein said method further comprising step of dispersing said bicarbonate compound upon said vermiculite.
40. The method according to claim 36, wherein said method further comprising step of providing said tray composed of at least 50% of vermiculite by weight.
41. The method according to claim 36, wherein said method further comprising step of employing said vermiculite up to approximately 100% by weight of said tray.
42. The method according to claim 36, wherein said method further comprising step of employing said vermiculite more than approximately 70% by weight of said tray.
43. The method according to claim 36, wherein said step of providing slidable tray which is removable and replaceable after absorbing said litter of said animal.
44. The method according to claim 36, wherein said method further comprising step of providing said odor agent selected from the group consisting of carbonates, bicarbonates, cyclodextrins, zeolites, activated carbon, kieselguhr, chelating agents, chitin and pH buffered materials, carboxylic acids and any mixture thereof.
45. The method according to claim 36, wherein said method further comprising step of heating said vermiculite to produce a layer of an absorbent material and dispersing thereto a layer of said odor agent upon said vermiculite.
PCT/IL2014/050777 2013-09-08 2014-08-27 Vermiculite molded matrix WO2015033335A1 (en)

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US61/875,037 2013-09-08

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3796188A (en) * 1972-10-12 1974-03-12 S Bradstreet Reusable sanitary pet lavatory
US3921581A (en) * 1974-08-01 1975-11-25 Star Kist Foods Fragrant animal litter and additives therefor
US4881490A (en) * 1988-02-19 1989-11-21 Ducharme Cyril L Absorbent composition, and method of making same
US5819688A (en) * 1997-04-21 1998-10-13 Walker; Robert T. Pet animal odor adsorbing and liquid absorbing mat
US6523495B1 (en) * 2001-09-18 2003-02-25 Gaye A. Rydman Cat litter box apparatus
US20060243212A1 (en) * 2005-04-29 2006-11-02 Jenkins Dennis B Composite particle animal litter and method thereof
US20100307422A1 (en) * 2006-10-20 2010-12-09 Nathan Huck Waste collection mats

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3796188A (en) * 1972-10-12 1974-03-12 S Bradstreet Reusable sanitary pet lavatory
US3921581A (en) * 1974-08-01 1975-11-25 Star Kist Foods Fragrant animal litter and additives therefor
US4881490A (en) * 1988-02-19 1989-11-21 Ducharme Cyril L Absorbent composition, and method of making same
US5819688A (en) * 1997-04-21 1998-10-13 Walker; Robert T. Pet animal odor adsorbing and liquid absorbing mat
US6523495B1 (en) * 2001-09-18 2003-02-25 Gaye A. Rydman Cat litter box apparatus
US20060243212A1 (en) * 2005-04-29 2006-11-02 Jenkins Dennis B Composite particle animal litter and method thereof
US20100307422A1 (en) * 2006-10-20 2010-12-09 Nathan Huck Waste collection mats

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