Wet granulation for manufacture of thermal insulation material

A method for forming an insulated structure for use in an appliance, the method comprising steps of:

• combining a powder insulation material and temporary binder to define a partially wetted insulation material;
• mixing the partially wetted insulation material to define wetted insulation granules;
• evaporating the temporary binder from the wetted insulation granules to define dry insulation agglomerates;
• disposing the dry insulation agglomerates within a cavity defined within a structural envelope;
• expressing gas from the cavity to define an at least partial vacuum within the cavity.

An insulating structure for an appliance, the insulating structure comprising:

• a structural envelope having an exterior surface and an interior surface that defines an insulating cavity, wherein the insulating cavity defines an at least partial vacuum;
• dried silica-based agglomerates that are disposed within the insulating cavity, wherein each agglomerate of the dried silica-based agglomerates includes a silica-based powder insulation material that is water-densified and is at least substantially free of a material binder;
• and
• a secondary insulation material that is disposed within interstitial spaces defined between the dried silica-based agglomerates, wherein the dried silica-based agglomerates define an interior structure that resists inward compressive forces exerted as a result of the at least partial vacuum defined within the insulating cavity.