Method for preparing a densified insulation material for use in appliance insulated structure

A method of preparing a core material for installation into an insulated structure, the method comprising steps of:

• blending a plurality of insulating components to form a powder insulation material having a bulk density, wherein the insulating components include at least one of silica powder, aerogel powder, insulating fibers, insulating spheres, perlite, rice husk ash, diatomaceous earth and at least one opacifier;
• pre-densifying the powder insulation material using a roller compactor to form a pre-densified insulation base;
• crushing the pre-densified insulation base using a separate roller compactor to further densify the powder insulation material and to define adhered granules of a granular core insulation having a core density, wherein the adhered granules are adhered particles of the powder insulation material;
• and
• coating the adhered granules of the granular core insulation with a binder to increase a compressive strength of the adhered granules and to define the granular core insulation to be a flowable material;
• disposing the granular core insulation into a cavity of an insulating structure having an outer wrapper and an inner liner;
• and
• sealing the cavity of the insulating structure to contain the granular core insulation therein.