Animal arena surface amendment

• US 6,810,831 B1
• Filed: 05/29/2002
• Issued: 11/02/2004
• Est. Priority Date: 05/29/2002
• Status: Expired due to Fees

• Current Assignee: Equidry Bedding Products LLC
• Original Assignee: Equidry Bedding Products LLC
• Inventors: Opfel, William
• Primary Examiner(s): ABBOTT, YVONNE RENEE
• Application Number:
  US10/158,676
• Time in Patent Office: 888 Days
• Field of Search: 119/171, 119/703, 119/172, 119/173, 106/900, 106/416, 106/486, 71/62, 71/63, 404/17, 404/20, 428/150, 428/143, 501/145, 501/150, 423/324, 432/13, 432/52
• US Class Current: 119/171
• CPC Class Codes: A01K 1/0107 Cat trays; Dog urinals; Toilets for pets
• CPC Class Codes: A01K 1/015 Floor coverings, e.g. bedding-down sheets ; Stable floors
• CPC Class Codes: A01K 1/0152 Litter
• CPC Class Codes: Y10T 428/2443 Sand, clay, or crushed rock or slate

Abstract

A soil amendment for use in the running surface of an animal competition arena comprises highly absorbent and durable calcined clay granules. The clay granules are porous and contain micropores and microstructures to capture and retain moisture for release over time. Additionally, because the clay granules are formed of a particularly hard calcined clay, they are sufficient to support the weight of even heavy animals even when mixed with soft soil such as sand. Methods of fabricating the soil amendment and amending soil include methods which provide the soil amendment granules and arena surface with selected hardness and porosity for the particular soil and use of the arena surface.

Claims

1. An animal competition arena surface comprising:

a subbase layer; and

a running surface layer located above the subbase layer and comprising calcined clay granules having at least 3% by weight of calcium bentonite clay and at least 3% by weight of at least one of illite clay and kaolinite clay.

2. The animal arena surface of claim 1, wherein the running surface layer comprises at least 10% by weight of the calcined clay granules.

3. The animal arena surface of claim 1, wherein the calcium bentonite clay and the one of the illite clay and the kaolinite clay are respectively combined in a percentage by weight of approximately 85%:

15% to approximately 15%;

85%.

4. The animal arena surface of claim 1, wherein the calcined clay granules have an LA Abrasion hardness value of approximately 3 to approximately 60.

5. The animal arena surface of claim 4, wherein the calcined clay granules have an LA Abrasion hardness value of approximately 20 to approximately 35.

6. The animal arena surface of claim 1, wherein the calcined clay granules have an absorption capacity of approximately 0.5 ml/g to approximately 2.5 ml/g.

7. The animal arena surface of claim 6, wherein the calcined clay granules have an absorption capacity of approximately 1.4 ml/g to approximately 1.9 ml/g.

8. The animal arena surface of claim 1, wherein the calcined clay granules have an absorption rate in a 52 mm diameter column of approximately 90 milliliters or more within 10 minutes.

9. The animal arena surface of claim 1, wherein the calcined clay granules have an absorption rate in a 52 mm diameter column of approximately 70 milliliters or more within 1 minute.

10. The animal arena surface of claim 1, wherein the calcined clay granules have a surface area of approximately 2,000,000 ft²/ft³ to approximately 75,000,000 ft²/ft³.

11. The animal arena surface of claim 10, wherein the calcined clay granules have a surface area of approximately 20,000,000 ft²/ft³ to approximately 40,000,000 ft²/ft³.

12. The animal arena surface of claim 1, wherein at least a portion of the granules each have interconnecting micropores, microchannels, and voids for providing permeability and porosity.

13. The animal arena surface of claim 12, wherein at least a portion of the micropores have an opening length of approximately 0.1 nm to approximately 30 nm, wherein each of the microchannels has an opening length of approximately 100 nm to approximately 600 nm, and wherein each of the voids has an opening length of approximately 30 nm to approximately 80 nm.

14. The animal arena surface of claim 1, wherein the granules further comprise a mixture of granules sized from approximately 4 mesh to approximately 14 mesh.

15. The animal arena surface of claim 14, wherein the mixture of granules is formed from a combination of granules sized from approximately 8 mesh to approximately 14 mesh and granules sized from approximately 4 mesh to approximately 8 mesh in a percentage by weight of approximately 60%:

40%.

16. The animal arena surface of claim 1, wherein the granules further comprise a mixture of granules sized from approximately 4 mesh to approximately 20 mesh.

17. The animal arena surface of claim 16, wherein the mixture of granules is formed from a combination of granules sized from approximately 8 mesh to approximately 20 mesh and granules sized from approximately 4 mesh to approximately 8 mesh in a percentage by weight of approximately 50%:

50%.

18. The animal arena surface of claim 1, wherein the granules further comprise a mixture of granules sized from approximately 4 mesh to approximately 50 mesh.

19. The animal arena surface of claim 18, wherein the mixture of granules is formed from a combination of granules sized from approximately 20 mesh to approximately 50 mesh and granules sized from approximately 4 mesh to approximately 20 mesh in a percentage by weight of approximately 50%:

50%.

20. The animal arena surface of claim 1, wherein the granules further comprise a mixture of granules sized from approximately 8 mesh to approximately 20 mesh.

21. The animal arena surface of claim 20, wherein the mixture of granules is formed from a combination of granules sized from approximately 14 mesh to approximately 20 mesh and granules sized from approximately 8 mesh to approximately 14 mesh in a percentage by weight of approximately 50%:

50%.

22. The animal arena surface of claim 1, wherein the granules further comprise a mixture of granules sized from approximately 8 mesh to approximately 50 mesh.

23. The animal arena surface of claim 22, wherein the mixture of granules is formed from a combination of granules sized from approximately 20 mesh to approximately 50 mesh and granules sized from approximately 8 mesh to approximately 20 mesh in a percentage by weight of approximately 50%:

50%.

24. The animal arena surface of claim 1, wherein the composition has a density of approximately 20 lbs/ft³ to approximately 70 lbs/ft³.

25. The composition of claim 1, wherein the calcined clay granules have a sodium sulfate soundness test weight percent loss total of approximately 10% or less.

26. The composition of claim 25, wherein the calcined clay granules have a sodium sulfate soundness test weight percent loss total of approximately 5% or less.

27. A soil amendment composition comprising granules each at least having at least 3% by weight of calcium bentonite clay, at least 3% by weight of illite clay, and at least 3% by weight of kaolinite clay.

28. The composition of claim 27;

wherein the calcium bentonite clay, the illite clay, and the kaolinite clay are respectively combined in a percentage by weight of approximately 72%;

17%;

11% to approximately 15%;

29%;

56%.

29. A soil amendment composition for an animal arena, the composition comprising calcined clay granules having at least 3% by weight of calcium bentonite clay and at least 3% by weight of at least one of illite clay and kaolinite clay.

30. The composition of claim 29, wherein the calcium bentonite clay and the one of the illite clay and the kaolinite clay are respectively combined in a percentage by weight of approximately 85%:

15% to approximately 15%;

85%.

31. The composition of claim 29, wherein the composition has an LA Abrasion hardness value of approximately 3 to approximately 60.

32. The composition of claim 31, wherein the composition has an LA Abrasion hardness value of approximately 20 to approximately 35.

33. The composition of claim 29, wherein the composition has an absorption capacity of approximately 0.5 ml/g to approximately 2.5 ml/g.

34. The composition of claim 33, wherein the composition has an absorption capacity of approximately 1.4 ml/g to approximately 1.9 ml/g.

35. The composition of claim 29, wherein the composition has an absorption rate in a 52 mm diameter column of approximately 90 milliliters or more within 10 minutes.

36. The composition of claim 29, wherein the composition has an absorption rate in a 52 mm diameter column of approximately 70 milliliters or more within 1 minute.

37. The composition of claim 29, wherein the composition has a surface area of approximately 2,000,000 ft²/ft³ to approximately 75,000,000 ft²/ft³.

38. The composition of claim 37, wherein the composition has a surface area of approximately 20,000,000 ft²/ft³ to approximately 40,000,000 ft²/ft³.

39. The composition of claim 29, wherein at least a portion of the granules each have interconnecting micropores, microchannels, and voids for providing permeability and porosity.

40. The composition of claim 39, wherein at least a portion of the micropores have an opening length of approximately 0.1 nm to approximately 30 nm, wherein each of the microchannels has an opening length of approximately 100 nm to approximately 600 nm, and wherein each of the voids has an opening length of approximately 30 nm to approximately 80 nm.

41. The composition of claim 29, wherein the granules further comprise a mixture of granules sized from approximately 4 mesh to approximately 14 mesh.

42. The composition of claim 41, wherein the mixture of granules is formed from a combination of granules sized from approximately 8 mesh to approximately 14 mesh and granules sized from approximately 4 mesh to approximately 8 mesh in a percentage by weight of approximately 60%:

40%.

43. The composition of claim 29, wherein the granules further comprise a mixture of granules sized from approximately 4 mesh to approximately 20 mesh.

44. The composition of claim 43, wherein the mixture of granules is formed from a combination of granules sized from approximately 8 mesh to approximately 20 mesh and granules sized from approximately 4 mesh to approximately 8 mesh in a percentage by weight of approximately 50%:

50%.

45. The composition of claim 29, wherein the granules further comprise a mixture of granules sized from approximately 4 mesh to approximately 50 mesh.

46. The composition of claim 45, wherein the mixture of granules is formed from a combination of granules sized from approximately 20 mesh to approximately 50 mesh and granules sized from approximately 4 mesh to approximately 20 mesh in a percentage by weight of approximately 50%:

50%.

47. The composition of claim 29, wherein the granules further comprise a mixture of granules sized from approximately 8 mesh to approximately 20 mesh.

48. The composition of claim 29, wherein the mixture of granules is formed from a combination of granules sized from approximately 14 mesh to approximately 20 mesh and granules sized from approximately 8 mesh to approximately 14 mesh in a percentage by weight of approximately 50%:

50%.

49. The composition of claim 29, wherein the granules further comprise a mixture of granules sized from approximately 8 mesh to approximately 50 mesh.

50. The composition of claim 49, wherein the mixture of granules is formed from a combination of granules sized from approximately 20 mesh to approximately 50 mesh and granules sized from approximately 8 mesh to approximately 20 mesh in a percentage by weight of approximately 50%:

50%.

51. The composition of claim 29, wherein the composition has a density of approximately 20 lbs/ft³ to approximately 70 lbs/ft³.

52. The composition of claim 29, wherein the composition has a sodium sulfate soundness test weight percent loss total of approximately 10% or less.

53. The composition of claim 52, wherein the composition has a sodium sulfate soundness test weight percent loss total of approximately 5% or less.

54. A method of fabricating a soil amendment composition comprising granules having a minimum hardness and a minimum porosity, wherein the method comprises the steps of:

admixing solid sacrificial material to a clay composition mixture;

forming the clay composition mixture into clay granules; and

flash kilning the clay granules at a temperature of approximately 1,800°

F. to approximately 2,000°

F. for a duration of approximately 5 minutes to approximately 30 minutes to release and burn out at least a portion of the solid sacrificial material, thereby bloating at least a portion of the clay granules and forming a porous microstructure of interconnecting micropores and microchannels in each of the at least a portion of the clay granules for providing the minimum porosity, and thereby partially vitrifying the at least a portion of the clay granules for providing the minimum hardness;

wherein the step of admixing sacrificial material further comprises admixing at least one of a gas forming material, an organic lint, and any combination thereof to the composition mixture.

55. The method of claim 54, wherein the step of flash kilning the granules further comprises forming each of the micropores with an opening length of approximately 0.1 nm to approximately 30 nm and forming each of the microchannels with an opening length of approximately 100 nm to approximately 600 nm.

56. The method of claim 54, wherein the step of flash kilning the granules further comprises flash kilning at a temperature and for a duration to obtain an LA Abrasion hardness value of approximately 3 to approximately 60.

57. The method of claim 54, wherein the step of flash kilning the granules further comprises flash kilning at a temperature and for a duration to obtain an absorption capacity of approximately 0.5 ml/g to approximately 2.5 ml/g.

58. The method of claim 54, wherein the step of kilning the granules further comprises flash kilning at a temperature and for a duration to obtain an absorption rate in a 52 mm diameter column of approximately 90 milliliters or more within 10 minutes.

59. A method of fabricating a soil amendment composition comprising granules having a minimum hardness and a minimum porosity, wherein the method comprises the steps of:

admixing sacrificial material to a composition mixture;

forming the composition mixture into the granules;

flash kilning the granules at a temperature of approximately 1,800°

F. to approximately 2,000°

F. for a duration of approximately 5 minutes to approximately 30 minutes to release and burn out at least a portion of the sacrificial material, thereby bloating at least a portion of the granules and forming a porous microstructure of interconnecting micropores and microchannels in each of the at least a portion of the granules for providing the minimum porosity, and thereby partially vitrifying the at least a portion of the granules for providing the minimum hardness;

wherein the step of admixing sacrificial material further comprises admixing at least one of a gas forming mineral, an organic lint, an organic dust, and any combination thereof to the composition mixture.

60. A method of fabricating a soil amendment composition comprising granules having a minimum hardness and a minimum porosity, wherein the method comprises the steps of:

admixing sacrificial material to a composition mixture;

forming the composition mixture into the granules;

flash kilning the granules at a temperature of approximately 1,800°

F. to approximately 2,000°

F. for a duration of approximately 5 minutes to approximately 30 minutes to release and burn out at least a portion of the sacrificial material, thereby bloating at least a portion of the granules and forming a porous microstructure of interconnecting micropores and microchannels in each of the at least a portion of the granules for providing the minimum porosity, and thereby partially vitrifying the at least a portion of the granules for providing the minimum hardness;

wherein the step of flash kilning the granules further comprises forming each of the micropores with an opening length of approximately 0.1 nm to approximately 30 nm and forming each of the microchannels with an opening length of approximately 100 nm to approximately 600 nm.

61. A method of fabricating a soil amendment composition comprising granules having a minimum hardness and a minimum porosity, wherein the method comprises the steps of:

admixing sacrificial material to a composition mixture;

forming the composition mixture into the granules;

flash kilning the granules at a temperature of approximately 1,800°

F. to approximately 2,000°

F. for a duration of approximately 5 minutes to approximately 30 minutes to release and burn out at least a portion of the sacrificial material, thereby bloating at least a portion of the granules and forming a porous microstructure of interconnecting micropores and microchannels in each of the at least a portion of the granules for providing the minimum porosity, and thereby partially vitrifying the at least a portion of the granules for providing the minimum hardness;

wherein the step of flash kilning the granules further comprises flash kilning at a temperature and for a duration to obtain an LA Abrasion hardness value of approximately 3 to approximately 60.

62. A method of fabricating a soil amendment composition comprising granules having a minimum hardness and a minimum porosity, wherein the method comprises the steps of:

admixing sacrificial material to a composition mixture;

forming the composition mixture into the granules;

flash kilning the granules at a temperature of approximately 1,800°

F. to approximately 2,000°

F. for a duration of approximately 5 minutes to approximately 30 minutes to release and bum out at least a portion of the sacrificial material, thereby bloating at least a portion of the granules and forming a porous microstructure of interconnecting micropores and microchannels in each of the at least a portion of the granules for providing the minimum porosity, and thereby partially vitrifying the at least a portion of the granules for providing the minimum hardness;

wherein the step of flash kilning the granules further comprises flash kilning at a temperature and for a duration to obtain an absorption capacity of approximately 0.5 ml/g to approximately 2.5 ml/g.

63. A method of fabricating a soil amendment composition comprising granules having a minimum hardness and a minimum porosity, wherein the method comprises the steps of:

admixing sacrificial material to a composition mixture;

forming the composition mixture into the granules;

flash kilning the granules at a temperature of approximately 1,800°

F. to approximately 2,000°

F. for a duration of approximately 5 minutes to approximately 30 minutes to release and bum out at least a portion of the sacrificial material, thereby bloating at least a portion of the granules and forming a porous microstructure of interconnecting micropores and microchannels in each of the at least a portion of the granules for providing the minimum porosity, and thereby partially vitrifying the at least a portion of the granules for providing the minimum hardness;

wherein the step of kilning the granules further comprises flash kilning at a temperature and for a duration to obtain an absorption rate in a 52 mm diameter column of approximately 90 milliliters or more within 10 minutes.