# US 2014/0360044 A1 · Thermal insulation products and production of thermal insulation products > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0360044 A1 - Document ID: US20140360044A1 - Status: Published application - Kind: A1 - Application number: 14/154,704 - Filed: 2014-01-14 - Published: 2014-12-11 - Earliest claimed: 2013-01-14 - Assignees: Nanopore, Inc. - Applicants: Nanopore, Inc. - Inventors: Douglas M. Smith - Web page: https://patentgrep.com/patent/US20140360044A1 ## CPC - B01D 5/0057: {in combination with other processes} - B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} - B32B 5/18: characterised by features of a layer {of} foamed material - B32B 5/24: one layer being a fibrous or filamentary layer - E04B 1/803: {with vacuum spaces included in the slab} - F16L 59/065: using vacuum (F16L59/075 takes precedence) - B32B 2307/304: Insulating - B32B 2457/00: Electrical equipment - B32B 2509/00: Household appliances - B32B 2597/00: Tubular articles, e.g. hoses, pipes - Y02A 30/24: Structural elements or technologies for improving thermal insulation - Y02A 30/242: Slab shaped vacuum insulation - Y02B 80/10: Insulation, e.g. vacuum or aerogel insulation - Y10T 29/49353: Heat pipe device making - Y10T 29/49359: Cooling apparatus making, e.g., air conditioner, refrigerator - B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - F16L: PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL - Y02A: TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE - Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract Methods of making thermal insulation products that may be usable to provide insulation in high temperature applications. One method includes sealing a support material (e.g., a nanoporous core such as fumed silica, an aerogel powder, etc.) and at least one vapor within an interior portion of a substantially gas-impermeable envelope (e.g., a metallic and/or polymeric film), and then condensing at least a portion of the vapor after the sealing step to reduce the pressure within the gas-impermeable envelope from a first pressure before the condensing to a lower second pressure after the condensing. The disclosed methods limit or eliminate the need for pumping mechanisms to draw the vacuum within the products, drying of the core before the sealing, and the like. ## Claims ### Claim 1 A method for making a thermal insulation product, the method comprising the steps of: sealing a support material and a vapor within an interior portion of a substantially gas-impermeable envelope, wherein the interior portion of the gas-impermeable envelope comprises a first pressure during the sealing step, wherein the vapor has a boiling point that is different than the boiling point of water under ambient pressure; and condensing at least a portion of the vapor after the sealing step to reduce the first pressure within the gas-impermeable envelope to a second pressure less than the first pressure. ### Claim 2 (depends on 1) The method of claim 1, wherein the vapor comprises at least one of an organic compound and a silicone-based compound. ### Claim 3 (depends on 2) The method of claim 2, wherein the organic compound comprises at least one alcohol. ### Claim 4 (depends on 3) The method of claim 3, wherein the at least one alcohol comprises at least one diol. ### Claim 5 (depends on 4) The method of claim 4, wherein the at least one diol comprises at least one glycol. ### Claim 6 (depends on 1) The method of claim 1, wherein the silicone-based compound comprises a dimethyl polysiloxane compound. ### Claim 7 (depends on 1) The method of claim 1, wherein the vapor comprises a boiling point that is at least about 100° C. at about 1000 mbar of pressure. ### Claim 8 (depends on 1) The method of claim 1, wherein the vapor comprises a boiling point that is at least about 150° C. at about 1000 mbar of pressure. ### Claim 9 (depends on 8) The method of claim 8, wherein the interior portion of the gas-impermeable envelope comprises a temperature that is at least about 125° C. after the condensing step. ### Claim 10 (depends on 1) The method of claim 1, wherein the vapor comprises a boiling point that is at least about 200° C. at about 1000 mbar of pressure. ### Claim 11 (depends on 10) The method of claim 10, wherein the interior portion of the gas-impermeable envelope comprises a temperature that is at least about 150° C. after the condensing step. ### Claim 12 (depends on 10) The method of claim 10, wherein the interior portion of the gas-impermeable envelope comprises a temperature that is at least about 175° C. after the condensing step. ### Claim 13 (depends on 1) The method of claim 1, wherein the vapor comprises a maximum molecular weight of not greater than about 200. ### Claim 14 (depends on 1) The method of claim 1, wherein the vapor comprises a maximum molecular weight of not greater than about 150. ### Claim 15 (depends on 1) The method of claim 1, wherein the vapor comprises at least one selected from the group consisting of ethylene glycol, diethylene glycol, triethylene glycol, trimethylene glycol, Decan-1-ol, and Dodecan-1-ol. ### Claim 16 (depends on 1) The method of claim 1, wherein the vapor further comprises water. ### Claim 17 (depends on 1) The method of claim 1, wherein the support material is disposed within a gas-permeable enclosure. ### Claim 18 (depends on 17) The method of claim 17, further comprising: injecting the support material into the gas-permeable enclosure. ### Claim 19 (depends on 17) The method of claim 17, further comprising: injecting the vapor into the gas-permeable enclosure. ### Claim 20 (depends on 17) The method of claim 17, further comprising: contacting the support material with a liquid; and heating, before the sealing step, the support material above the boiling point of the liquid to convert at least a portion of the liquid into the vapor. ### Claim 21 (depends on 17) The method of claim 17, wherein the sealing step further includes: sealing the gas-permeable enclosure containing the support material and the vapor within the interior portion of the gas-impermeable envelope. ### Claim 22 (depends on 21) The method of claim 21, further comprising before the sealing: adding at least one desiccant into the interior portion of the gas-impermeable envelope, wherein the at least one desiccant is disposed between the gas-permeable enclosure and gas-impermeable envelope after the adding step. ### Claim 23 (depends on 18) The method of claim 18, wherein the sealing and injecting steps occur at a pressure substantially equal to an ambient pressure. ### Claim 24 (depends on 1) The method of claim 1, wherein the condensing step comprises: cooling the vapor to a temperature below a boiling point of the vapor after the sealing step. ### Claim 25 (depends on 24) The method of claim 24, wherein the gas impermeable envelope comprises spaced apart first and second sidewalls, and wherein the cooling step comprises: contacting the first and second sidewalls with first and second surfaces, respectively, wherein each of the first and second surfaces comprises a temperature below the boiling point of the vapor. ### Claim 26 (depends on 24) The method of claim 24, wherein the cooling step comprises: contacting an outer surface of the gas-impermeable envelope with a cooling liquid. ### Claim 27 (depends on 24) The method of claim 24, wherein the cooling step comprises: passively cooling the gas-impermeable envelope under a substantially ambient temperature. ### Claim 28 (depends on 24) The method of claim 24, further comprising: forming a thermal insulation product into a desired non-planar shape during the cooling step. ### Claim 29 (depends on 1) The method of claim 1, wherein the interior portion of the gas-impermeable envelope comprises a second temperature that is not greater than about 60° C. after the condensing step. ### Claim 30 (depends on 1) The method of claim 1, wherein the interior portion of the gas-impermeable envelope comprises a second temperature that is not greater than about 25° C. after the condensing step. ### Claim 31 (depends on 1) The method of claim 1, wherein a time between the completion of the sealing step and the reduction of the first pressure to the second pressure during the condensing step is not greater than about 60 minutes. ### Claim 32 (depends on 1) The method of claim 1, wherein a number of molecules in a gaseous state within the interior portion of the gas-impermeable envelope is at least about 90% less after a completion of the condensing step compared to before a start of the condensing step. ### Claim 33 (depends on 1) The method of claim 1, wherein after the condensing step, the sealed interior portion comprises at least about 4 grams of a liquid per liter of a total volume of the sealed interior portion. ### Claim 34 (depends on 1) The method of claim 1, wherein the first pressure is substantially equal to or greater than an ambient pressure. ### Claim 35 (depends on 1) The method of claim 1, wherein a difference between the first and second pressures is at least about 250 mbar. ### Claim 36 (depends on 1) The method of claim 1, wherein a difference between the first and second pressures is at least about 500 mbar. ### Claim 37 (depends on 1) The method of claim 1, wherein a difference between the first and second pressures is at least about 800 mbar. ### Claim 38 (depends on 1) The method of claim 1, wherein the second pressure is not greater than about 400 mbar. ### Claim 39 (depends on 1) The method of claim 1, wherein the second pressure is not greater than about 100 mbar. ### Claim 40 (depends on 1) The method of claim 1, wherein the pressure within the gas-impermeable envelope is reduced from the first pressure to the second pressure free of pumping mechanisms. ### Claim 41 (depends on 1) The method of claim 1, wherein the support material comprises a particulate blend. ### Claim 42 (depends on 1) The method of claim 1, wherein the support material comprises a fine powder selected from at least one of silica powder and an aerogel powder. ### Claim 43 (depends on 42) The method of claim 42, wherein the fine powder comprises fumed silica. ### Claim 44 (depends on 42) The method of claim 42, wherein the support material comprises at least about 60 wt % of the fine powder. ### Claim 45 (depends on 42) The method of claim 42, wherein the support material comprises at least about 90 wt % of the fine powder. ### Claim 46 (depends on 1) The method of claim 1, wherein the support material comprises an infrared (IR) opacifier. ### Claim 47 (depends on 46) The method of claim 46, wherein the IR opacifier comprises at least one of titania, aluminum, iron oxide, silicon carbide, and carbon. ### Claim 48 (depends on 46) The method of claim 46, wherein the support material comprises at least about 5 wt % of the IR opacifier. ### Claim 49 (depends on 1) The method of claim 1, wherein the support material comprises not greater than about 0.1 wt % of fibrous materials. ### Claim 50 (depends on 1) The method of claim 1, wherein the support material comprises at least about 10 wt % of a structural filler. ### Claim 51 (depends on 1) The method of claim 1, wherein the support material comprises not greater than about 70 wt % of a structural filler. ### Claim 52 (depends on 1) The method of claim 1, wherein the structural filler comprises perlite. ### Claim 53 (depends on 1) The method of claim 1, wherein the support material comprises at least about 0.01 wt % of a getter. ### Claim 54 (depends on 1) The method of claim 1, wherein the support material comprises not greater than about 1 wt % of a getter. ### Claim at position 55 55-145. (canceled)