Processes for making a super-insulating core material for a vacuum insulated structure

A method for forming a pourable insulating material, the method comprising steps of:

• disposing a fine-particle insulating material within a rotating drum;
• disposing a binding material within the rotating drum;
• mixing the fine-particle insulating material and the binding material during a base mixing stage to define an adhering base material, wherein a plurality of interstitial spaces defined between particles of the fine-particle insulating material are partially occupied by the binding material;
• disposing a first insulating material within the rotating drum;
• mixing the adhering base material with the first insulating material to define an aggregate material;
• crushing the aggregate material during a crushing stage to define an insulating base;
• disposing a second insulating material within the rotating drum;
• and
• mixing the second insulating material with the insulating base to define a homogenous form of a super-insulating material, wherein the first and second insulating materials occupy substantially all of an interstitial volume defined by the plurality of interstitial spaces.

A method for forming a free-flowing insulating material, the method comprising steps of:

• disposing a fine-particle insulating material within a rotating drum;
• disposing a wax-based binder material within the rotating drum;
• mixing the fine-particle insulating material and the wax-based binder material within the rotating drum, wherein the wax-based binder material is mixed during a base mixing stage with the fine-particle insulating material to partially occupy a plurality of interstitial spaces between particles of the fine-particle insulating material and define an adhering base material;
• disposing a first insulating material within the rotating drum;
• mixing the adhering base material with the first insulating material to define an insulating base;
• disposing a second insulating material within the rotating drum;
• and
• mixing the second insulating material with the insulating base to define a homogenous form of a super-insulating material, wherein the first and second insulating materials occupy substantially all of an interstitial volume defined by the plurality of interstitial spaces.