US 12,305,791 B2
Processes for making a super-insulating core material for a vacuum insulated structure
Lakshya J. Deka, Mishawaka, IN (US); and Nicole M. Ernat, St. Joseph, MI (US)
Assigned to Whirlpool Corporation, Benton Harbor, MI (US)
Filed by WHIRLPOOL CORPORATION, Benton Harbor, MI (US)
Filed on Mar. 8, 2024, as Appl. No. 18/599,615.
Application 18/599,615 is a continuation of application No. 18/302,128, filed on Apr. 18, 2023, granted, now 11,953,141.
Application 18/302,128 is a continuation of application No. 17/747,079, filed on May 18, 2022, granted, now 11,674,632, issued on Jun. 13, 2023.
Application 17/747,079 is a continuation of application No. 16/305,254, granted, now 11,365,843, issued on Jun. 21, 2022, previously published as PCT/US2017/021068, filed on Mar. 7, 2017.
Prior Publication US 2024/0209976 A1, Jun. 27, 2024
This patent is subject to a terminal disclaimer.
Int. Cl. F16L 59/02 (2006.01); C04B 14/06 (2006.01); C04B 24/34 (2006.01); F16L 59/065 (2006.01); F25D 23/06 (2006.01)
CPC F16L 59/028 (2013.01) [C04B 14/062 (2013.01); C04B 24/34 (2013.01); F16L 59/065 (2013.01); F25D 23/06 (2013.01); C04B 2235/528 (2013.01); F25D 2201/14 (2013.01)] 20 Claims
OG exemplary drawing
 
1. 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 at least one binder material within the rotating drum;
rotating the fine-particle insulating material and the at least one binder material within the rotating drum, wherein the at least one binder material is mixed with the fine-particle insulating material during a base mixing stage to partially occupy a plurality of interstitial spaces defined between particles of the fine-particle insulating material;
disposing a first insulating material within the rotating drum;
mixing the at least one binder material, the first insulating material and the fine-particle 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.
 
11. 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.