REFRIGERATOR AND METHOD FOR MANUFACTURING REFRIGERATOR DOOR

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation application, under 35 U.S.C. § 111 (a), of international application No. PCT/KR2025/010950, filed Jul. 24, 2025, which claims priority under 35 U.S.C. § 119 to Korean Patent Application No. 10-2024-0116259, filed Aug. 28, 2024, and to Korean Patent Application 10-2024-0171552 filed Nov. 26, 2024 the disclosures of which are incorporated herein by reference in their entireties.

TECHNICAL FIELD

The disclosure to a refrigerator and a method of manufacturing a door of the refrigerator.

BACKGROUND ART

A refrigerator is an appliance for keeping food fresh, including a main body having a storage compartment and a cold air supply system for supplying cold air to the storage compartment. The storage compartment includes a refrigerating compartment in which the food is kept refrigerated at a temperature of about 0° C. to 5° C., and a freezing compartment in which the food is kept frozen at a temperature of about 0° C. to −30° C. The storage compartment is typically arranged to have an open front for receiving food, and the open front of the storage compartment is opened and closed by a door.

The refrigerator uses a compressor, a condenser, an expander, and an evaporator to repeat a cooling cycle in which the refrigerant is compressed, condensed, expanded, and evaporated. At this time, both the freezing compartment and the refrigerating compartment may be cooled by one evaporator installed on the freezing compartment side, or the freezing compartment and the refrigerating compartment may each be provided with an evaporator and cooled independently.

The main body of the refrigerator includes an inner case forming the storage compartment and an outer case forming an exterior of the refrigerator. Since the storage compartment needs to be maintained at a temperature within a certain range required for keeping the food fresh, an insulating material for thermal insulation may be disposed between the inner case and the outer case. In addition, an insulating material for thermal insulation may be disposed inside a door for closing a front side of the storage compartment.

The insulating material may include, for example, a polyurethane-based foam insulation, or a vacuum insulation formed by enclosing a core material having fine pores, such as glass wool or silica powder, with an envelope and sealing an inner side of the envelope under reduced pressure.

DISCLOSURE

Technical Problem

An aspect of the present disclosure provides a refrigerator and a method of manufacturing a door of the refrigerator, which are improved to simplify a manufacturing process and equipment.

An aspect of the present disclosure provides a refrigerator and a method of manufacturing a door of the refrigerator, which are improved to shorten a manufacturing time.

An aspect of the present disclosure provides a refrigerator and a method of manufacturing a door of the refrigerator, which are improved to enhance heat insulation efficiency.

Technical tasks to be achieved in this document are not limited to the technical tasks mentioned above, and other technical tasks not mentioned will be clearly understood by those skilled in the art from the description below.

Technical Solution

A refrigerator according to an embodiment of the present disclosure may include a main body forming a storage compartment, and a door configured to open or close to respectively open or close the storage compartment. The door may include an outer frame, an inner frame coupled to the outer frame, the inner frame having a flat portion and a door protrusion around a perimeter of the flat portion, the door protrusion protruding from the flat portion such that the door protrusion protrudes toward the storage compartment while the door is closed, and a door insulation between the outer frame and the inner frame. The door insulation may include a vacuum insulation panel in contact with the outer frame and the flat portion of the inner frame, and a foam insulation between the door protrusion of the inner frame and the outer frame along a perimeter of the vacuum insulation panel.

A method of manufacturing a door of a refrigerator according to an embodiment of the present disclosure may include positioning a vacuum insulation panel on an inner surface of an outer frame of the door, filling a foaming liquid into an inner side of the outer frame along a perimeter of the vacuum insulation panel, and coupling an inner frame of the door and the outer frame so that the vacuum insulation panel contacts the outer frame and a flat portion of the inner frame and the foaming liquid foams and cures to form a foam insulation between the door protrusion of the inner frame and the outer frame along the perimeter of the vacuum insulation panel.

A refrigerator according to an embodiment of the present disclosure may include a main body forming a storage compartment, and a door configured to open or close to respectively open or close the storage compartment. The door may include an outer frame, an inner frame coupled to the outer frame, wherein a flat portion having a flat shape is formed at a center of the inner frame, and a door insulation between the outer frame and the inner frame. The door insulation may include a vacuum insulation panel having a first surface attached to the outer frame and a second surface attached to the flat portion of the inner frame, and a foam insulation on an outer side of a perimeter of the vacuum insulation panel.

DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a refrigerator according to an embodiment of the present disclosure.

FIG. 2 is an exploded perspective view illustrating a door included in the refrigerator according to an embodiment of the present disclosure, viewed from one direction.

FIG. 3 is an exploded perspective view illustrating the door included in the refrigerator according to an embodiment of the present disclosure, viewed from another direction.

FIG. 4 is a cross-sectional view of the door included in the refrigerator according to an embodiment of the present disclosure.

FIG. 5 is an enlarged cross-sectional view illustrating A of FIG. 4.

FIG. 6 is an enlarged cross-sectional view illustrating B of FIG. 5.

FIG. 7 is a view illustrating a step of forming a first adhesive layer on an inner surface of an outer frame in a method of manufacturing the door of the refrigerator according to an embodiment of the present disclosure.

FIG. 8 is a view illustrating a step of attaching a vacuum insulation panel to the outer frame in the method of manufacturing the door of the refrigerator according to an embodiment of the present disclosure.

FIG. 9 is a view illustrating a step of forming a second adhesive layer on the vacuum insulation panel and injecting a foaming liquid along a perimeter of the vacuum insulation panel in the method of manufacturing the door of the refrigerator according to an embodiment of the present disclosure.

FIG. 10 is a view illustrating a step of coupling the outer frame and an inner frame in the method of manufacturing the door of the refrigerator according to an embodiment of the present disclosure.

FIG. 11 is a view illustrating a step of pressing the inner frame toward the outer frame with a mold in the method of manufacturing the door of the refrigerator according to an embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Various embodiments of the present document and terms used therein are not intended to limit the technical features described in this document to specific embodiments, and should be understood to include various modifications, equivalents, or substitutes of the corresponding embodiments.

In connection with the description of the drawings, similar reference numerals may be used for similar or related components.

The singular form of a noun corresponding to an item may include one or a plurality of the items unless clearly indicated otherwise in a related context.

In this document, phrases, such as “A or B”, “at least one of A and B”, “at least one of A or B,” “A, B or C,” “at least one of A, B and C,” and “at least one of A, B, or C”, may include any one or all possible combinations of items listed together in the corresponding phrase among the phrases.

As used herein, the term “and/or” includes any and all combinations of one or more of associated listed items.

Terms such as “1st”, “2nd”, “primary”, or “secondary” may be used simply to distinguish a component from other components, without limiting the component in other aspects (e.g., importance or order).

Further, as used in the disclosure, the terms “front”, “rear”, “top”, “bottom”, “side”, “left”, “right”, “upper”, “lower”, and the like are defined with reference to the drawings, and are not intended to limit the shape and position of each component.

It will be understood that when the terms “includes,” “comprises,” “including,” and/or “comprising,” when used in this specification, specify the presence of stated features, figures, steps, operations, components, members, or combinations thereof, but do not preclude the presence or addition of one or more other features, figures, steps, operations, components, members, or combinations thereof.

It will be understood that when a certain component is referred to as being “connected to”, “coupled to”, “supported by” or “in contact with” another component, it can be directly or indirectly connected to, coupled to, supported by, or in contact with the other component. When a component is indirectly connected to, coupled to, supported by, or in contact with another component, it may be connected to, coupled to, supported by, or in contact with the other component through a third component.

It will also be understood that when a component is referred to as being “on” another component, it can be directly on the other component or intervening components may also be present.

A refrigerator according to an embodiment of the disclosure may include a main body.

The main body may include an inner case, an outer case disposed outside the inner case, and an insulation between the inner case and the outer case.

The “inner case” may include at least one of a case, a plate, a panel, and a liner forming the storage compartment. The inner case may be formed as a single body, or may be formed by assembling a plurality of plates. The “outer case” may form an outer appearance of the main body, and may be coupled to the outside of the inner case such that an insulation is placed between the inner case and the outer case.

The insulation may insulate inside of a storage compartment from outside of the storage compartment to maintain inside temperature of the storage compartment at appropriate temperature without being influenced by an external environment of the storage compartment. According to an embodiment of the disclosure, the insulation may include a foaming insulation. The foaming insulation may be formed by injecting and foaming a urethane form, in which polyurethane and a foaming agent are mixed, between the inner case and the outer case.

According to an embodiment of the disclosure, the insulation may include a vacuum insulation in addition to a foaming insulation, or may be configured only with a vacuum insulation instead of a forming insulation. The vacuum insulation may include a core material and an envelope that accommodates the core material and seals the interior at a vacuum or a pressure close to vacuum. However, the insulation is not limited to the foaming insulation or vacuum insulation described above, and may include various materials that can be used for insulation.

The “storage compartment” may include a space defined by the inner case. The storage compartment may further include the inner case defining a space corresponding to the storage compartment. The storage compartment may store a variety of items, such as foods, medicines, cosmetics, and the like, and the storage compartment may be formed to be open on at least one side for storing or removing items.

The refrigerator may include one or more storage compartments. In a case in which two or more storage compartments are formed in the refrigerator, the respective storage compartments may have different purposes of use, and may be maintained at different temperature. To this end, the storage compartments may be partitioned by a partition wall including an insulation.

The storage compartment may be maintained within an appropriate temperature range according to a purpose of use, and include a “refrigerating compartment”, a “freezing compartment”, and a “temperature conversion compartment” according to purposes of use and/or temperature ranges. The refrigerating compartment may be maintained at appropriate temperature to keep food refrigerating, and the freezing compartment may be maintained at appropriate temperature to keep food frozen. The “refrigerating” may be keeping food cold without freezing the food, and for example, the refrigerating compartment may be maintained within a range of 0 degrees Celsius to 7 degrees Celsius. The “freezing” may be freezing food or keeping food frozen, and for example, the freezing compartment may be maintained within a range of −20 degrees Celsius to −1 degrees Celsius. The temperature conversion compartment may be used as any one of a refrigerating compartment or a freezing compartment according to or regardless of a user's selection.

The storage compartment may also be called various other terms, such as “vegetable compartment (also referred to as room)”, “freshness compartment”, “cooling compartment”, and “ice-making compartment”, in addition to “refrigerating compartment”, “freezing compartment”, and “temperature conversion compartment”, and the terms, such as “refrigerating compartment”, “freezing compartment”, “temperature conversion compartment”, etc., as used below need to be understood to represent storage compartments having the corresponding purposes of use and the corresponding temperature ranges.

The refrigerator according to an embodiment of the disclosure may include at least one door configured to open or close the open side of the storage compartment. The respective doors may be provided to open and close one or more storage compartments, or a single door may be provided to open and close a plurality of storage compartments. The door may be rotatably or slidably mounted on the front of the main body.

The door may seal the storage compartment in a closed state. The door may include an insulation, like the main body, to insulate the storage compartment in the closed state.

According to an embodiment, the door may include an outer door plate forming the front surface of the door, an inner door plate forming the rear surface of the door and facing the storage compartment, an upper cap, a lower cap, and a door insulation provided therein.

A gasket may be provided on the edge of the inner door plate to seal the storage compartment by coming into close contact with the front surface of the main body when the door is closed. The inner door plate may include a dyke that protrudes rearward to allow a door basket for storing items to be fitted.

According to an embodiment, the door may include a door body and a front panel that is detachably coupled to the front of the door body and forms the front surface of the door. The door body may include an outer door plate that forms the front surface of the door body, an inner door plate that forms the rear surface of the door body and faces the storage compartment, an upper cap, a lower cap, and a door insulator provided therein.

The refrigerator may be classified as French Door Type, Side-by-side Type, Bottom Mounted Freezer (BMF), Top Mounted Freezer (TMF), or One Door Refrigerator depending on the arrangement of the doors and the storage compartments.

The refrigerator according to an embodiment of the disclosure may include a cold air supply device for supplying cold air to the storage compartment.

The cold air supply device may include a machine, an apparatus, an electronic device, and/or a combination system thereof, capable of generating cold air and guiding the cold air to cool the storage compartment.

According to an embodiment of the disclosure, the cold air supply device may generate cold air through a cooling cycle including compression, condensation, expansion, and evaporation processes of refrigerants. To this end, the cold air supply device may include a cooling cycle device having a compressor, a condenser, an expander, and an evaporator to drive the cooling cycle. According to an embodiment of the disclosure, the cold air supply device may include a semiconductor such as a thermoelectric element. The thermoelectric element may cool the storage compartment by heating and cooling actions through the Peltier effect.

The refrigerator according to an embodiment of the disclosure may include a machine compartment where at least some components belonging to the cold air supply device are installed.

The machine compartment may be partitioned and insulated from the storage compartment to prevent heat generated from the components installed in the machine compartment from being transferred to the storage compartment. To dissipate heat from the components installed inside the machine compartment, the machine compartment may communicate with outside of the main body.

The refrigerator according to an embodiment of the disclosure may include a dispenser provided on the door to provide water and/or ice. The dispenser may be provided on the door to allow access by the user without opening the door.

The refrigerator according to an embodiment of the disclosure may include an ice-making device that produces ice. The ice-making device may include an ice-making tray that stores water, an ice-moving device that separates ice from the ice-making tray, and an ice-bucket that stores ice generated in the ice-making tray.

The refrigerator according to an embodiment of the disclosure may include a controller for controlling the refrigerator.

The controller may include a memory for storing and/or memorizing data and/or programs for controlling the refrigerator, and a processor for outputting control signals for controlling the cold air supply device, etc. according to the programs and/or data memorized in the memory.

The memory may store or record various information, data, commands, programs, and the like necessary for operations of the refrigerator. The memory may store temporary data generated while generating control signals for controlling components included in the refrigerator. The memory may include at least one of volatile memory or non-volatile memory, or a combination thereof.

The processor may control the overall operation of the refrigerator. The processor may control the components of the refrigerator by executing programs stored in memory. The processor may include a separate neural processing unit (NPU) that performs an operation of an artificial intelligence (AI) model. In addition, the processor may include a central processing unit (CPU), a graphics processor (GPU), and the like. The processor may generate a control signal to control the operation of the cold air supply device. For example, the processor may receive temperature information of the storage compartment from a temperature sensor, and generate a cooling control signal for controlling an operation of the cold air supply device based on the temperature information of the storage compartment.

Furthermore, the processor may process a user input of a user interface and control an operation of the user interface according to the programs and/or data memorized/stored in the memory. The user interface may be provided using an input interface and an output interface. The processor may receive the user input from the user interface. In addition, the processor may transmit a display control signal and image data for displaying an image on the user interface to the user interface in response to the user input.

The processor and memory may be provided integrally or may be provided separately. The processor may include one or more processors. For example, the processor may include a main processor and at least one sub-processor. The memory may include one or more memories.

The refrigerator according to an embodiment of the disclosure may include a processor and a memory for controlling all the components included in the refrigerator, and may include a plurality of processors and a plurality of memories for individually controlling the components of the refrigerator. For example, the refrigerator may include a processor and a memory for controlling the operation of the cold air supply device according to an output of the temperature sensor. In addition, the refrigerator may be separately equipped with a processor and a memory for controlling the operation of the user interface according to the user input.

A communication module may communicate with external devices, such as servers, mobile devices, and other home appliances via a nearby access point (AP). The AP may connect a local area network (LAN) to which a refrigerator or a user device is connected to a wide area network (WAN) to which a server is connected. The refrigerator or the user device may be connected to the server via the WAN.

The input interface may include keys, a touch screen, a microphone, and the like. The input interface may receive the user input and pass the received user input to the processor.

The output interface may include a display, a speaker, and the like. The output interface may output various notifications, messages, information, and the like generated by the processor.

Hereinafter, various embodiments according to the disclosure will be described in detail with reference to the accompanying drawings.

In describing various embodiments of the present disclosure with reference to FIGS. 1 to 11, terms such as “upper”, “lower”, “front”, “rear”, “left”, and “right” used in the following description are defined based on the drawings, and the shape and position of each component are not limited by these terms. For example, the terms “upper” and “lower” below may refer to upward in a Z direction and downward in the Z direction, respectively, based on the drawings. The terms “front” and “rear” below may refer to forward in an X direction and rearward in the X direction, respectively, based on the drawings. The terms “left” and “right” below may refer to leftward in a Y direction and rightward in the Y direction, respectively, based on the drawings.

FIG. 1 is a perspective view of a refrigerator according to an embodiment of the present disclosure.

Referring to FIG. 1, a refrigerator 1 according to an embodiment of the present disclosure may include a main body 10, a storage compartment 20 provided inside the main body 10, a door 30 for opening or closing the storage compartment 20, and a cooling system for supplying cold air to the storage compartment 20.

The main body 10 may include an inner case 11 forming the storage compartment 20 and an outer case 12 forming an exterior of the refrigerator 1. The outer case 12 may be formed to have a box shape with a substantially open front. The outer case 12 may form an upper surface, a lower surface, left and right side surfaces, a rear surface, and the like of the refrigerator 1. The inner case 11 may have an open front. The inner case 11 may have the storage compartment 20 provided therein and may be provided on an inner side of the outer case 12. An inner wall of the inner case 11 may form an inner wall of the storage compartment 20.

A body insulation may be provided between the inner case 11 and the outer case 12 to thermally insulate between the inner case 11 and the outer case 12. The body insulation may be foamed between the inner case 11 and the outer case 12. The body insulation may couple the inner case 11 and the outer case 12 to each other. The body insulation may prevent heat exchange from occurring between an inside of the storage compartment 20 and an outside of the main body 10, thereby improving cooling efficiency inside the storage compartment 20. For example, the body insulation may include insulation of various materials, such as urethane foam insulation, expanded polystyrene (EPS) insulation, vacuum insulation, and the like.

The storage compartment 20 may be formed on an inner side of the main body 10. In an example, the storage compartment 20 may include a refrigerating compartment maintained at approximately 0 to 5 degrees Celsius for keeping food items refrigerated. In an example, the storage compartment 20 may include a freezing compartment maintained at approximately minus 23 to minus 17 degrees Celsius for keep the food items frozen.

In various embodiments, the storage compartment 20 may be partitioned into a plurality of areas. The storage compartment 20 may be partitioned into a plurality of areas by a partition 15. For example, the storage compartment 20 may be partitioned into an upper first storage compartment 21 and lower storage compartments 22 and 23 by a first partition 17 extending in a horizontal direction. In addition, the lower storage compartments 22 and 23 of the storage compartment 20 may be partitioned into a left second storage compartment 22 and a right third storage compartment 23 by a second partition 19 extending in a vertical direction. In this case, for example, the first storage compartment 21 may be used as a refrigerating compartment, and both the second storage compartment 22 and the third storage compartment 23 may be used as freezing compartments, or one of them may be used as a freezing compartment and the other may be used as a refrigerating compartment.

The partitioning of the storage compartment 20 as described above and the respective uses of the partitioned storage compartments 21, 22 and 23 are by way of example only and are not limited thereto.

A shelf 24 on which food items may be placed and a drawer 26 for storing food items may be provided inside the storage compartment 20.

The refrigerator 1 may include a cooling system configured to generate cold air using a cooling cycle and supply the generated cold air to the storage compartment 20. The cooling system may generate cold air using a refrigeration cycle of compressing, condensing, expanding, and evaporating a refrigerant. In an example, the cooling system may include a compressor, a condenser, an expansion valve, an evaporator, a blowing fan, and the like. The cold air generated by the cooling system may be supplied to the storage compartment 20 via a cold air supply duct formed in a rear portion of the inner case 11.

The door 30 may be configured to open or close the storage compartment 20. The door 30 may be configured to open or close an opening formed on one side of the main body 10. The door 30 may be arranged to be rotatable with respect to the main body 10.

An outer surface of the door 30 may form a portion of an exterior of the refrigerator 1. In a closed position of the door 30, the outer surface of the door 30 may form at least a portion of a front exterior of the refrigerator 1. In the closed position of the door 30, an inner surface of the door 30 may face an interior of the storage compartment 20. As used herein, the inner surface of the door 30 may refer to one surface of the door 30 facing the storage compartment 20 when the door 30 is closing the storage compartment 20. Also, the outer surface of the door 30 may refer to the other surface opposite to the inner surface of the door 30 facing the storage compartment 20 when the door 30 is closing the storage compartment 20, and refer to a front surface of the door 30 that is visible when the refrigerator 1 is viewed from the front.

The inner surface of the door 30 may be provided with a door shelf 36 for storing food items. For example, the door shelf 36 may be supported by a dyke provided in a door protrusion 35b of the door 30. The door shelf 36 may be mounted to the dyke provided on the door protrusions 35b of the door 30.

A door gasket 37 may be provided on the inner surface of the door 30. The door gasket 37 may be configured to cover a gap between the door 30 and the main body 10 to prevent cold air from leaking out of the storage compartment 20. The door gasket 37 may include a variety of elastic materials, such as rubber, silicone, or the like, to be elastically deformable.

The refrigerator 1 may include an upper door and a lower door arranged side by side in a vertical direction Z. The refrigerator 1 may include a left door and a right door arranged next to each other in a horizontal direction Y. The refrigerator 1 may include a plurality of doors 30A, 30B, 30C and 30D for opening or closing each of the partitioned storage compartments 21, 22 and 23.

The first storage compartment 21 may be opened and closed by a pair of upper doors 30A and 30B. The refrigerator 1 may include a first door 30A that opens and closes a portion of the first storage compartment 21 and a second door 30B that opens and closes a different portion of the first storage compartment 21. The first door 30A and the second door 30B may be provided to be rotatable independently of each other with respect to the main body 10. The first door 30A and the second door 30B may be arranged side by side in the horizontal direction (Y direction). In an example, the first door 30A may be arranged to open and close a left portion of the first storage compartment 21, and the second door 30B may be arranged to open and close a right portion of the first storage compartment 21.

One of the pair of upper doors 30A and 30B (e.g., the first door 30A) may be provided with a rotation bar 50 that is rotatably provided with respect to the one door and provided to cover a gap between the pair of upper doors 30A and 30B when the pair of upper doors 30A and 30B close the first storage compartment 21.

The second storage compartment 22 may be opened and closed by a left lower door 30C. The refrigerator 1 may include a third door 30C arranged to open or close the second storage compartment 22. The third door 30C may be provided to be rotatable with respect to the main body 10. In an example, the first door 30A and the third door 30C may be arranged side by side in the vertical direction Z.

The third storage compartment 23 may be opened and closed by a right lower door 30D. The refrigerator 1 may include a fourth door 30D arranged to open or close the third storage compartment 23. The fourth door 30D may be rotatably arranged with respect to the main body 10. In an example, the second door 30B and the fourth door 30D may be arranged side by side in the vertical direction Z. In addition, the third door 30C and the fourth door 30D may be arranged side by side in the horizontal direction Y.

The structure or features of the door 30 described herein may be applied correspondingly to each of the plurality of doors 30A, 30B, 30C and 30D.

The refrigerator 1 may include a hinge 40 connecting the main body 10 and the door 30. The hinge 40 may be coupled to the main body 10 and the door 30, respectively. The hinge 40 may be configured such that the door 30 is rotatable with respect to the main body 10. The hinge 40 may be coupled to the outer case 12. The door 30 may be rotatably coupled to the main body 10 by the hinge 40.

The refrigerator 1 may include a plurality of hinges 41, 42, and 43 configured to support each of the plurality of doors 30A, 30B, 30C and 30D. For example, the refrigerator 1 may include a pair of upper door hinges 41 coupled to an upper portion of the main body 10 to rotatably support the first door 30A and the second door 30B, respectively. For example, the refrigerator 1 may include a pair of lower door hinges 43 coupled to a lower portion of the main body 10 to rotatably support the third door 30C and the fourth door 30D, respectively. For example, the refrigerator 1 may include a pair of intermediate hinges 42 disposed between the upper door hinge 41 and the lower door hinge 43 and coupled to a middle portion of the main body 10 (particularly, to the first partition 17) to rotatably support each of the first door 30A, the second door 30B, the third door 30C, and the fourth door 30D.

The configuration of the refrigerator 1 described above with reference to FIG. 1 is only an example of the present disclosure, and the present disclosure is not limited thereto. The refrigerator according to various embodiments of the present disclosure may be configured to include various configurations to perform a function of supplying cold air to a storage compartment for storing food items.

For example, although FIG. 1 illustrates an example in which the refrigerator 1 according to an embodiment is a French Door Type, the present disclosure is not limited thereto. In various embodiments of the present disclosure, the refrigerator may include various types of refrigerators, such as a one-door type, a Bottom Mounted Freezer (BMF) type in which a refrigerating compartment is disposed on an upper side and a freezing compartment is disposed on a lower side, a Top Mounted Freezer (TMF) type in which a freezing compartment is disposed on an upper side and a refrigerating compartment is disposed on a lower side, and a Side-by-side type in which a refrigerating compartment and a freezing compartment are disposed in a left-to-right.

FIG. 2 is an exploded perspective view illustrating a door included in the refrigerator according to an embodiment of the present disclosure, viewed from one direction. FIG. 3 is an exploded perspective view illustrating the door included in the refrigerator according to an embodiment of the present disclosure, viewed from another direction.

Referring to FIGS. 2 and 3, the door 30 according to an embodiment of the present disclosure may include an outer frame 31 and an inner frame 35.

The outer frame 31 may form the outer surface of the door 30. Here, the outer surface of the outer frame 31 may refer to a different surface from an inner surface of the outer frame 31 facing the storage compartment 20 when the door 30 closes the storage compartment 20. The outer frame 31 may form a front surface, an upper surface, a lower surface, a left side surface, a right side surface, and the like of the door 30. The outer frame 31 may cover an internal space of the door 30 from a front side, an upper side, a lower side, a left side, a right side, and the like.

The outer frame 31 may include a plate 32. The plate 32 may form the front surface of the door 30. The plate 32 may form the front surface of the outer frame 31. As used herein, the front surface of the door 30 may refer to one surface of the door 30 facing the front side of the refrigerator 1 when the door 30 is closed. Hereinafter, in defining a positional relationship of configurations included in the door 30, a direction in which the plate 32 faces may be defined as the front side of the door 30, and the opposite direction may be defined as the rear side of the door 30.

The plate 32 may have a flat shape. The plate 32 may have a substantially flat rectangular plate shape. The plate 32 may have a plate shape substantially perpendicular to a front-to-back direction (X direction). The plate 32 may have a plate shape substantially parallel to a lateral direction (Y direction) and an up-and-down direction (Z direction). The plate 32 may have a flat outer surface (i.e., one surface of the plate 32 facing forward) and a flat inner surface (i.e., one surface of the plate 32 facing rearward).

The outer frame 31 may include an upper door cap 33a. The upper door cap 33a may form the upper surface of the door 30. The upper door cap 33a may form the upper surface of the outer frame 31. In an example, the upper door cap 33a may be disposed on an upper side of the plate 32 and a side frame 34, which will be described later. In an example, the upper door cap 33a may be coupled to an upper portion of the plate 32 and/or the side frame 34. Alternatively, in various embodiments, the upper door cap 33a may be integrally formed with at least a portion of the plate 32 and the side frame 34.

In an example, the upper door cap 33a may be coupled with the hinge 40.

The outer frame 31 may include a lower door cap 33b. The lower door cap 33b may form the lower surface of the door 30. The lower door cap 33b may form the lower surface of the outer frame 31. In an example, the lower door cap 33b may be disposed on a lower side of the plate 32 and the side frame 34. In an example, the lower door cap 33b may be coupled to a lower portion of the plate 32 and/or the side frame 34. Alternatively, in various embodiments, the lower door cap 33b may be integrally formed with at least a portion of the plate 32 and the side frame 34.

In an example, the lower door cap 33b may be coupled with the hinge 40.

The outer frame 31 may include the side frame 34. The side fames 34 may be provided in a pair, each forming the left side surface or right side surface of the door 30. The pair of side frames 34 may each form the left side surface or right side surface of the outer frame 31. In an example, the side frames 34 may be disposed on a left portion and right portion of the plate 32, the upper door cap 33a, and the lower door cap 33b. In an example, the side frames 34 may be coupled to the left portion and right portion of the plate 32, the upper door cap 33a, and the lower door cap 33b. Alternatively, in various embodiments, the side frames 34 may be integrally formed with at least a portion of the plate 32, the upper door cap 33a, and the lower door cap 33b.

While an embodiment in which the plate 32, the upper door cap 33a, the lower door cap 33b, and the side frame 34 are joined together to form the outer frame 31 has been described above, in accordance with various embodiments, the outer frames 31 may be integrally formed of the plate 32, the upper door cap 33a, the lower door cap 33b, and the side frames 34.

The inner frame 35 may be disposed to face the main body 10 and/or the storage compartment 20 when the door 30 is closed. The inner frame 35 may cover at least a portion of the main body 10 and/or the storage compartment 20 when the door 30 is closed. The inner frame 35 may form the inner surface of the door 30. The inner frame 35 may form the rear surface of the door 30. The inner frame 35 may be disposed on a rear side of the outer frame 31.

The inner frame 35 may be coupled to the outer frame 31. The inner frame 35 may be coupled to the side frames 34 of the outer frame 31. The inner frame 35 may be coupled to the upper door cap 33a of the outer frame 31. The inner frame 35 may be coupled to the lower door cap 33b of the outer frame 31. Alternatively, in an example, the inner frame 35 and the outer frame 31 may be integrally formed with each other.

The inner frame 35 may include a flat portion 35a.

The flat portion 35a may have a flat shape. The flat portion 35a may have a substantially flat rectangular plate shape. The flat portion 35a may have a plate shape substantially perpendicular to the front direction (X direction). The flat portion 35a may have a plate shape substantially parallel to the lateral direction (Y direction) and the up-and-down direction (Z direction). The flat portion 35a may have a flat outer surface (i.e., one surface of the flat portion 35a facing rearward) and a flat inner surface 35aa (see FIG. 6) (i.e., one surface of the flat portion 35a facing forward).

The flat portion 35a may form the rear surface of the door 30. The flat portion 35a may form the inner surface of the door 30 facing the main body 10 and/or the storage compartment 20 when the door 30 is closed.

The flat portion 35a may be disposed at a center of the inner frame 35.

The plate 32 and the flat portion 35a may be parallel to each other. The plate 32 and the flat portion 35a may face each other. A substantially central portion of the plate 32 may face the flat portion 35a, and a portion of the plate 32 that is adjacent to an edge of the plate 32 may face the door protrusion 35b, which will be described later, or an edge portion of the inner frame 35.

The inner frame 35 may include the door protrusion 35b protruding from the flat portion 35a. The door protrusion 35b may protrude rearwardly from the flat portion 35a. The door protrusion 35b may protrude from the flat portion 35a in a direction toward the main body 10 and/or the storage compartment 20.

The door protrusion 35b may be disposed along an edge of the inner frame 35. The door protrusion 35b may be disposed adjacent to the edge of the inner frame 35. The door protrusion 35b may be disposed around a perimeter of the flat portion 35a. The door protrusion 35b may be disposed in an outward direction from the flat portion 35a. The door protrusion 35b may be disposed closer to the edge of the inner frame 35 than the flat portion 35a.

In an example, a portion of the door protrusion 35b may be formed substantially in line with the vertical direction Z. In an example, a portion of the door protrusion 35b may be disposed to substantially align with the lateral direction Y.

The door protrusion 35b may be provided with a dyke, and the dyke may support the door shelf 36 described above.

The edge portion of the inner frame 35 may be disposed further outward than the door protrusion 35b. The inner frame 35 may extend outwardly from the door protrusion 35b in the vertical direction Z or the lateral direction Y. The edge portion of the inner frame 35 may be coupled to the upper door cap 33a, the lower door cap 33b, the side frame 34, and the like. The door gasket 37 may be mounted on the edge portion of the inner frame 35.

According to an embodiment, the flat portion 35a and the door protrusion 35b of the inner frame 35 may be integrally formed. However, the present disclosure is not limited thereto, and in various embodiments, the flat portion 35a and the door protrusion 35b may not be integrally formed.

The door 30 may include a space formed between the outer frame 31 and the inner frame 35. A door insulation 100 (see FIG. 4) may be disposed between the outer frame 31 and the inner frame 35. The door insulation 100 may prevent heat exchange from occurring between an inside and outside of the storage compartment 20 through the door 30 when the door 30 is closed. The door insulation 100 may improve heat insulation performance between the inside of the storage compartment 20 and the outside of the door 30.

FIG. 4 is a cross-sectional view of the door included in the refrigerator according to an embodiment of the present disclosure. FIG. 5 is an enlarged cross-sectional view illustrating A of FIG. 4. FIG. 6 is an enlarged cross-sectional view illustrating B of FIG. 5.

Referring to FIGS. 4 to 6, the door 30 of the refrigerator 1 according to an embodiment of the present disclosure may include the door insulation 100 disposed in the internal space of the door 30. The door insulation 100 may be disposed in the internal space of the door 30 formed between the outer frame 31 and the inner frame 35. The internal space of the door 30 may be formed by the plate 32, the upper door cap 33a, the lower door cap 33b, the side frames 34, and the inner frame 35. The door insulation 100 may fill the internal space of the door 30.

The door insulation 100 may include a vacuum insulation panel (VIP) 110. The VIP 110 may be disposed inside the door 30. The VIP 110 may be disposed between the outer frame 31 and the inner frame 35.

The VIP 110 may include a core material 111 and an envelope 112 enclosing the core material 111. According to an embodiment, the core material 111 may include a porous core material having microscopic pores within, such as glass wool or silica powder. According to an embodiment, the envelope 112 may include a gas barrier envelope and may be configured to completely enclose the core material 111 to seal the core material 111. According to an embodiment, the VIP 110 may be formed by surrounding the porous core material 111 with the gas barrier envelope 112 and sealing an inner side of the envelope 112 to with a vacuum or near-vacuum pressure.

The VIP 110 may include an adsorbent material that, together with the core material 111, is sealed on the inner side of the envelope 112 under reduced pressure. The adsorbent material may be configured to remove heat transfer media, such as water vapor, oxygen, or nitrogen that penetrate into the envelope 112 to allow excellent heat insulation performance of the VIP 110 to be maintained over a long period of time. For example, the adsorbent material may include a chemical adsorbent such as calcium oxide (CaO) that irreversibly and fixedly adsorbs moisture, and a metal adsorbent such as a barium getter or a ternary alloy of zirconium-vanadium-iron that adsorbs oxygen or nitrogen.

With such a configuration, the VIP 110 may have an excellent heat insulation efficiency. For example, the VIP 110 may have a low thermal conductivity of about 2 mW/mk.

A urethane-based insulation, which is often used as a type of foam insulation material that is foamed on the interior of the door 30, may have a high thermal conductivity of about 20 mW/mK or more. In other words, the foam insulation may have a lower heat insulation efficiency than the VIP 110. Thus, when a urethane-based insulation material is primarily used as the door insulation used on the interior of the door 30, sufficient heat insulation efficiency may not be obtained, or a volume of the foam insulation may be increased in order to obtain sufficient heat insulation efficiency, thereby increasing the thickness of the door 30.

In an embodiment of the present disclosure, the door insulation 100 may include the VIP 110 having an excellent heat insulation efficiency, it may have an excellent heat insulation efficiency, and it may be possible to obtain a sufficient heat insulation efficiency even though the thickness of the door 30 is formed with a thin thickness.

According to an embodiment, the VIP 110 may be in contact with the outer frame 31 and the inner frame 35. The VIP 110 may be in contact with the inner surface of the outer frame 31 facing the inner frame 35. The VIP 110 may be in contact with the plate 32 of the outer frame 31. The VIP 110 may be in contact with the inner surface of the inner frame 35 facing the outer frame 31. The VIP 110 may be in contact with the flat portion 35a of the inner frame 35. The VIP 110 may include a first surface 110a that contacts an inner surface 32a of the plate 32 facing the inner frame 35 and a second surface 110b that contacts an inner surface 35aa of the flat portion 35a facing the outer frame 31.

The VIP 110 may have a substantially flat plate shape. The first surface 110a of the VIP 110 may have a flat shape to contact the inner surface 32a of the flat plate 32. The second surface 110b of the VIP 110 may have a flat shape to contact the inner surface 35aa of the flat portion 35a. The first surface 110a and the second surface 110b of the VIP 110 may be opposite surfaces to each other. The first surface 110a and the second surface 110b of the VIP 110 may each be a portion of a relatively large area of the outer surface of the VIP 110.

With the first surface 110a of the VIP 110 contacting the plate 32 and the second surface 110b contacting the flat portion 35a, the VIP 110 may have a thickness corresponding to a distance between the inner surface 32a of the plate 32 and the inner surface 35aa of the flat portion 35a. For example, the VIP 110 may have a thickness substantially equal to a distance between the inner surface 32a of the plate 32 and the inner surface 35aa of the flat portion 35a.

According to an embodiment, the VIP 110 may contact substantially the entire area of the flat portion 35a. The second surface 110b of the VIP 110 may contact substantially the entire area of the flat portion 35a. For example, a substantially central portion of the second surface 110b of the VIP 110 may contact substantially the entire area of the flat portion 35a, and a remaining portion of the second surface 110b may be disposed between the plate 32 and the door protrusion 35b without contacting the inner frame 35.

According to an embodiment, the VIP 110 may contact a portion of the plate 32 facing the flat portion 35a. According to an embodiment, the VIP 110 may contact a portion of the plate 32 facing the door protrusion 35b. A portion located substantially at a center of the first surface 110a of the VIP 110 may contact a portion of the plate 32 facing the flat portion 35a, and another portion adjacent to an edge of the first surface 110a of the VIP 110 may contact another portion of the plate 32 facing the door protrusion 35b.

The VIP 110 may be coupled to the outer frame 31. The VIP 110 may be attached to the inner surface of the outer frame 31 facing the inner frame 35. The VIP 110 may be attached to the plate 32 of the outer frame 31. The VIP 110 may be attached to the inner surface 32a of the plate 32.

For example, the door 30 may include a first adhesive layer ad1 configured to attach the VIP 110 to the inner surface of the outer frame 31 facing the inner frame 35. The VIP 110 may be attached to the plate 32 by the first adhesive layer ad1. The VIP 110 may be attached to the inner surface 32a of the plate 32 by the first adhesive layer ad1. The first surface 110a of the VIP 110 may be adhered to a portion of the inner surface 35aa of the plate 32 facing the flat portion 35a by the first adhesive layer ad1. The first surface 110a of the VIP 110 may be adhered to another portion of the inner surface 35aa of the plate 32 facing the door protrusion 35b by the first adhesive layer ad1.

The first adhesive layer ad1 may include an adhesive. In an example, the first adhesive layer ad1 may include a thermosetting adhesive. The thermosetting adhesive may have temporary adhesiveness before being thermally cured, and may have an excellent fixing force and heat resistance after being thermally cured. As the thermosetting adhesive is used as the first adhesive layer ad1, a shape or the like of the first adhesive layer ad1 does not change even when heat is applied to the door 30, and the VIP 110 may be reliably fixed to the outer frame 31. The first adhesive layer ad1 may include various types of thermosetting adhesives, such as polyurethane reactive (PUR) adhesives.

Alternatively, in an example, the first adhesive layer ad1 may include a double-sided adhesive tape configured to bond the inner surface 32a of the plate 32 and the first surface 110a of the VIP 110 to each other.

The VIP 110 may be coupled to the inner frame 35. The VIP 110 may be attached to the inner surface of the inner frame 35 facing the outer frame 31. The VIP 110 may be attached to the flat portion 35a of the inner frame 35. The VIP 110 may be attached to the inner surface 35aa of the flat portion 35a.

For example, the door 30 may include a second adhesive layer ad2 configured to attach the VIP 110 to the flat portion 35a of the inner frame 35. The VIP 110 may be attached to the inner surface 35aa of the flat portion 35a by the second adhesive layer ad2. The second surface 110b of the VIP 110 may be attached to substantially the entire area of the inner surface 35aa of the flat portion 35a by the second adhesive layer ad2.

The second adhesive layer ad2 may include an adhesive. In an example, the second adhesive layer ad2 may include a thermosetting adhesive. The thermosetting adhesive may have temporary adhesiveness before being thermally cured, and may have an excellent fixing force and heat resistance after being thermally cured. As the thermosetting adhesive is used as the second adhesive layer ad2, a shape or the like of the second adhesive layer ad2 does not change even when heat is applied to the door 30, and the VIP 110 may be reliably fixed to the inner frame 35. The second adhesive layer ad2 may include various types of thermosetting adhesives, such as PUR adhesives.

The first surface 110a and the second surface 110b of the VIP 110 may be provided on an outer surface of the envelope 112 of the aforementioned VIP 110. The envelope 112 may contact the outer frame 31 and the flat portion 35a of the inner frame 35. The envelope 112 may contact the inner surface 32a of the plate 32 and the inner surface 35aa of the flat portion 35a. The envelope 112 may be attached to the inner surface 32a of the plate 32 and the inner surface 35aa of the flat portion 35a. The envelope 112 may be attached to the inner surface 32a of the plate 32 by the first adhesive layer ad1 and may be attached to the flat portion 35a of the inner frame 35 by the second adhesive layer ad2.

As such, with the first surface 110a of the VIP 110 contacting the plate 32 of the outer frame 31 and the second surface 110b contacting the flat portion 35a, the VIP 110 may fill a space between the plate 32 and the flat portion 35a.

On the other hand, although a portion of the VIP 110 is disposed between the plate 32 and the door protrusion 35b in a state where the first surface 110a is attached to the plate 32 in accordance with an embodiment, the VIP 110 may have a substantially flat plate shape, such that a gap space may be formed between the second surface 110b and the door protrusion 35b and the VIP 110 may not be disposed. Furthermore, as shown in FIG. 5, a gap space may be formed between the VIP 110 and an inner surface of the side frame 34, and thus the VIP 110 may not be disposed on a portion of an internal region of the door 30 adjacent to an edge (e.g., a left edge, a right edge, an upper edge, a lower edge) of the door 30.

As such, a region where the VIP 110 cannot be provided may be present within the internal space of the door 30. To provide an insulation function to such a region, the door insulation 100 may include a foam insulation 120. The foam insulation 120 may be disposed in a region of the internal space of the door 30 other than the region where the VIP 110 is disposed. The foam insulation 120 may be disposed in a region of the space between the outer frame 31 and the inner frame 35 other than the region where the VIP 110 is disposed.

For example, the foam insulation 120 may be disposed along a perimeter of the VIP 110. The foam insulation 120 may be disposed further outwardly than the flat portion 35a of the inner frame 35, between the inner frame 35 and the outer frame 31. The foam insulation 120 may be disposed along the perimeter of the flat portion 35a, between the inner frame 35 and the outer frame 31.

For example, the foam insulation 120 may be disposed between the door protrusion 35b of the inner frame 35 and the outer frame 31. The foam insulation 120 may be disposed between the door protrusion 35b and the plate 32. The foam insulation 120 may be disposed between the door protrusion 35b and the second surface 110b of the VIP 110. The foam insulation 120 may fill a space between the outer frame 31, the door protrusion 35b, and the VIP 110. The foam insulation 120 may include a protrusion filling portion 120a that fills an interior of the door protrusion 35b. The protrusion filling portion 120a may fill the space between the outer frame 31, the door protrusion 35b, and the VIP 110.

For example, the foam insulation 120 may be disposed between a portion of the inner frame 35 adjacent to the edge thereof and the outer frame 31. The foam insulation 120 may be disposed between a portion of the inner frame 35 adjacent to the edge thereof, the plate 32, and the edge of the door 30 (e.g., the side frame 34 or the upper door cap 33a or the lower door cap 33b). The foam insulation 120 may fill a space between an inner surface of the edge of the door 30 (e.g., the inner surface of the side frame 34 or the upper door cap 33a or the lower door cap 33b) and the perimeter of the VIP 110. The foam insulation 120 may include an edge filling portion 120b that fills a region of the internal space of the door 30 adjacent to the edge of the door 30. The edge filling portion 120b may fill the space between a portion of the inner frame 35 adjacent to the edge thereof, the plate 32, and the edge of the door 30 (e.g., the side frame 34 or the upper door cap 33a or the lower door cap 33b). The edge filling portion 120b may fill the space between the inner surface of the edge of the door 30 (e.g., the inner surface of the side frame 34 or the upper door cap 33a or the lower door cap 33b) and the perimeter of the VIP 110.

The foam insulation 120 may be formed by injecting and foaming a foaming liquid into the internal space of the door 30, i.e., between the outer frame 31 and the inner frame 35. After the foaming liquid is injected and foamed into the internal space of the door 30 and then cured, the foam insulation 120 may be formed. For example, the foaming liquid may include urethane foam, which is a mixture of a urethane material and a foaming agent. The foam insulation 120 may include a urethane material. The foam insulation 120 may provide an insulation function by forming a plurality of pores therein during a foaming process.

According to an embodiment, the foam insulation 120 may be formed by a low-pressure foaming method using a foaming agent composed of water without including a pentane series, such as Cyclopentane. The foam insulation 120 formed in such a manner may have a high density of, for example, about 75 kg/m³. When the foam insulation 120 has such a high density, an overall rigidity of the door 30 may increase.

Since the foam insulation 120 is formed through a process in which a flowable foaming liquid is injected into a foam cavity, foamed, and then cured, unlike the VIP 110, the foam insulation 120 may be formed into various shapes depending on the foam cavity. In other words, the foam insulation 120 may have a shape corresponding to a shape of the foam cavity. A region between the outer frame 31 and the door protrusion 35b, which is a region of the internal space of the door 30 other than the region where the VIP 110 is not disposed, or a region of the internal space of the door 30 adjacent to the edge thereof, and the like, may be filled by the foam insulation 120 without any empty space despite having a curved shape rather than a flat shape.

As the foam insulation 120 is filled in the region of the internal space of the door 30 other than the region where the VIP 110 is not disposed, the foam insulation 120 may be coupled to the VIP 110. The foam insulation 120 may be coupled to the VIP 110 as the foaming liquid is cured. The foam insulation 120 may be coupled to the perimeter of the VIP 110. The foam insulation 120 may be coupled to a portion of the envelope 112 of the VIP 110.

As described above, as the VIP 110 simultaneously contacts the outer frame 31 and the flat portion 35a, a volume occupied by the VIP 110 between the outer frame 31 and the inner frame 35 may be improved. Since heat insulation efficiency of the VIP 110 (e.g., thermal conductivity of about 2 mW/mk) is higher than heat insulation efficiency of the foam insulation 120 (e.g., thermal conductivity of about 20 mW/mK or more), an overall heat insulation efficiency of the door 30 may be further improved while preventing the thickness of the door 30 from increasing.

In addition, since the foam insulation 120 is disposed instead of the VIP 110 in regions where it is difficult to dispose the VIP 110, such as an inner region of the door protrusion 35b and a region adjacent to an edge of the door 30 among the internal space of the door 30, the door insulation 100 may be provided in almost all of the internal space of the door 30, thereby improving the overall heat insulation efficiency of the door 30.

As described above, the VIP 110 may have the first surface 110a attached to the plate 32 and the second surface 110b attached to the flat portion 35a, which may simply the process and equipment for manufacturing the door 30, and may reduce manufacturing time. When the VIP 110 is separated apart without contacting either the plate 32 or the flat portion 35a, there may be a need to fill a region therebetween with the foam insulation 120, as leaving the region therebetween as an empty space may reduce the heat insulation efficiency. In this case, in addition to the problem that heat insulation efficiency may be reduced due to the reduced thickness of the VIP 110, a problem that process efficiency may be reduced because a process of injecting, foaming, and curing a foaming liquid is required to fix the VIP 110 to the plate 32 or the flat portion 35a in the region therebetween may also occur.

However, in an embodiment of the present disclosure, the VIP 110 may be easily attached to both the plate 32 and the flat portion 35a through a simple process of attaching the first surface 110a of the VIP 110 to the plate 32 with the first adhesive layer ad1 and attaching it to the flat portion 35a with the second adhesive layer ad2. Furthermore, as described above, since the volume occupied by the foam insulation 120 decreases as the volume occupied by the VIP 110 in the interior of the door 30 increases, a relatively complex process and equipment for injecting, foaming, and curing a foaming liquid for forming the foam insulation 120 may be simplified, and a process time therefor may also be reduced.

Hereinafter, a method of manufacturing the door 30 of the refrigerator 1 according to an embodiment of the present disclosure will be described in detail with reference to FIGS. 7 to 11.

FIG. 7 is a view illustrating a step of forming a first adhesive layer on the inner surface of the outer frame in a method of manufacturing the door of the refrigerator according to an embodiment of the present disclosure. FIG. 8 is a view illustrating a step of attaching the VIP to the outer frame in the method of manufacturing the door of the refrigerator according to an embodiment of the present disclosure. FIG. 9 is a view illustrating a step of forming a second adhesive layer on the VIP and injecting the foaming liquid along the perimeter of the VIP in the method of manufacturing the door of the refrigerator according to an embodiment of the present disclosure. FIG. 10 is a view illustrating a step of coupling the outer frame and the inner frame in the method of manufacturing the door of the refrigerator according to an embodiment of the present disclosure. FIG. 11 is a view illustrating a step of pressing the inner frame toward the outer frame with a mold in the method of manufacturing the door of the refrigerator according to an embodiment of the present disclosure.

Referring to FIGS. 7 to 11, according to an embodiment of the present disclosure, a step of manufacturing the door 30 of the refrigerator 1 may preferentially include a step of positioning the outer frame 31 on a support device M1. The outer frame 31 may be positioned on the support device M1 such that the inner surface 32a of the plate 32 faces upward in a state in which the plate 32, the upper door cap 33a, the lower door cap 33b, and the side frame 34 are coupled together.

Thereafter, as shown in FIG. 7, the step of forming the first adhesive layer ad1 on the inner surface of the outer frame 31 may be performed. For example, the first adhesive layer ad1 may be formed on the inner surface 32a of the plate 32. In an example, the first adhesive layer ad1 may include a thermosetting adhesive, such as a PUR adhesive. In an example, the first adhesive layer ad1 may include a double-sided adhesive tape.

According to an embodiment, the first adhesive layer ad1 may be formed in a plurality of rows spaced apart from each other. In an example, the first adhesive layer ad1 may be formed in a plurality of rows spaced apart at regular intervals. A length of one row of the first adhesive layer ad1 may substantially correspond to a length of the VIP 110.

Thereafter, as shown in FIG. 8, a step of positioning the VIP 110 on the inner surface of the outer frame 31 may be performed. The VIP 110 may be positioned on the inner surface 32a of the plate 32. The VIP 110 may be arranged to be positioned substantially at the center of the plate 32.

Since the first adhesive layer ad1 is formed on the inner surface 32a of the plate 32, the VIP 110 may be attached to the plate 32 once the VIP 110 is positioned on the inner surface 32a of the plate 32. For example, when the first adhesive layer ad1 includes a thermosetting adhesive, the thermosetting adhesive located between the inner surface 32a of the plate 32 and the VIP 110 may be exposed to heat and cured after a certain period of time has elapsed, so that the VIP 110 may be attached to the plate 32. The time for the thermosetting adhesive to cure and the VIP 110 to be coupled to the outer frame 31 may vary depending on heating conditions, an application area of the thermosetting adhesive, and the like, but it is expected to be meaningfully shorter than the time for a urethane-based foaming liquid to cure and form a foam insulation under typical conditions.

After the VIP 110 is positioned on the inner surface of the outer frame 31, as shown in FIG. 9, the step of forming the second adhesive layer ad2 on the second surface 110b of the VIP 110 and the step of filling a foaming liquid 121 inside the outer frame 31 along the perimeter of the VIP 110 may be performed.

According to an embodiment, the step of forming the second adhesive layer ad2 may include applying an adhesive to the second surface 110b of the VIP 110. In an example, the adhesive may include a thermosetting adhesive, such as a PUR adhesive.

According to an embodiment, the second adhesive layer ad2 may be formed in a plurality of rows spaced apart from each other. In an example, the second adhesive layer ad2 may be formed in a plurality of rows spaced apart at regular intervals. A length of one row of the second adhesive layer ad2 may substantially correspond to a length of the flat portion 35a of the inner frame 35.

In an example, after a thermosetting adhesive for forming the second adhesive layer ad2 is applied to the second surface 110b of the VIP 110, the foaming liquid 121 for forming the foam insulation 120 may be injected. However, the present disclosure is not limited thereto, and according to various embodiments, the step of forming the second adhesive layer ad2 and the step of filling the foaming liquid 121 inside the outer frame 31 may be performed simultaneously, or either one of them may be performed first.

The foaming liquid 121 may be injected into the inner side of the outer frame 31 by being sprayed by a nozzle N. For example, the nozzle N may be movably mounted on a rail R and configured to spray the foaming liquid 121 while moving along the perimeter of the VIP 110. In an example, the rail R may be provided in at least two or more such that the nozzle N may move along at least two or more axes.

As shown in FIG. 9, in accordance with an embodiment, the step of filling the foaming liquid 121 inside the outer frame 31 may be performed by injecting the foaming liquid 121 while the inner frame 35 is coupled to the outer frame 31 or otherwise leaving the interior of the outer frame 31 open without coupling the mold for foaming to the outer frame 31.

The foaming liquid 121 may include a urethane material and a foaming agent. According to an embodiment, the foaming agent included in the foaming liquid 121 may consist of water and not include a pentane-based material such as cyclopentane. When the foaming liquid 121 is foamed at a low pressure (e.g., a pressure of about 0.2 to 0.4 kg/cm²), the foam insulation 120 having a high density (e.g., a density of about 75 kg/m³) and a high rigidity (e.g., an elastic modulus of about 42.5 MPa) may be formed (hereinafter referred to as a ‘low-pressure foaming method’). The numerical values of pressure, density, elastic modulus, and the like described above as examples regarding the low-pressure foaming method are only examples and may vary depending on various conditions, such as a formulation ratio of the foaming liquid 121 and the presence or absence of additives, such as a catalyst.

In contrast, when the foaming agent included in the foaming liquid 121 includes a pentane-based material, such as cyclopentane, and water, and is foamed at a high pressure (e.g., a pressure of about 0.8 to 1 kg/cm²), the foam insulation 120 having a relatively low density (e.g., a density of about 25 kg/m³) and a high rigidity (e.g., an elastic modulus of about 5.5 MPa) may be formed (hereinafter referred to as a ‘high-pressure foaming method’). The numerical values of pressure, density, elastic modulus, and the like described above as examples regarding the high-pressure foaming method are only examples and may vary depending on various conditions, such as a formulation ratio of the foaming liquid 121 and the presence or absence of additives, such as a catalyst.

As such, when forming the foam insulation 120 by the low-pressure foaming method compared to forming the foam insulation 120 by the high-pressure foaming method, it is possible to form the foam insulation 120 with a high density and a high rigidity, thereby improving the overall durability of the door 30.

Thereafter, as shown in FIG. 10, the step of coupling the inner frame 35 and the outer frame 31 may be performed. The inner frame 35 may be coupled to the outer frame 31 in a state where the inner surface 35aa of the flat portion 35a is disposed to face the second surface 110b of the VIP 110. This may allow the VIP 110 to contact the flat portion 35a.

The second adhesive layer ad2 may be formed on the second surface 110b of the VIP 110, so that when the flat portion 35a of the inner frame 35 and the VIP 110 come into contact, the flat portion 35a and the VIP 110 may be attached to each other. For example, the second adhesive layer ad2 may include an adhesive, and the step of pressing the inner frame 35 toward the VIP 110 and the outer frame 31 for a predetermined time required for the adhesive to cure and join the flat portion 35a and the VIP 110 may be performed. For example, as shown in FIG. 11, the step of pressing the inner frame 35 toward the VIP 110 and the outer frame 31 using a jig M2 during the time the adhesive is cured may be performed. The step of pressing the inner frame 35 by the jig M2 may be determined to be at least a time sufficient for the adhesive to cure and for the flat portion 35a and the VIP 110 to be attached to each other by the second adhesive layer ad2, and for example, the time may be determined experimentally or empirically.

In an example, the second adhesive layer ad2 may include a thermosetting adhesive, such as a PUR adhesive, and in this case, the flat portion 35a and the VIP 110 may be attached by the thermosetting adhesive being exposed to heat and curing over a period of time. The time for the thermosetting adhesive to cure to bond the VIP 110 to the flat portion 35a may vary depending on heating conditions, an application area of the thermosetting adhesive, and the like, but is expected to be substantially less than the time for a urethane-based foaming liquid to cure to form a foam insulation under typical conditions.

In a state where the inner frame 35 is coupled to the outer frame 31, the step of forming and curing of the foaming liquid 121 injected into the inner side of the outer frame 31 may be performed. As the foaming liquid 121 is foamed, its volume increases, and as a result, the foam insulation 120 may fill the region where the VIP 110 is not disposed among the internal space of the door 30, such as the door protrusion 35b and the region adjacent to the edge of the door 30.

When such steps, once the thermosetting adhesive is cured to allow the VIP 110 to be attached to the plate 32 of the outer frame 31 and the flat portion 35a of the inner frame 35 and the foaming liquid 121 is foamed and cured to form the foam insulation 120, the step of pressing the inner frame 35 using the jig M2 may be terminated, and the step of manufacturing the door 30 may be terminated.

According to an embodiment of the present disclosure, a refrigerator may include a main body forming a storage compartment, and a door configured to open or close the storage compartment. The door may include an outer frame, an inner frame coupled to the outer frame and including a flat portion and a door protrusion disposed around a perimeter of the flat portion and protruding from the flat portion toward the storage compartment, and a door insulation disposed between the outer frame and the inner frame. The door insulation may include a vacuum insulation panel in contact with the outer frame and the flat portion of the inner frame, and a foam insulation disposed along a perimeter of the vacuum insulation panel and disposed between the door protrusion of the inner frame and the outer frame.

The vacuum insulation panel may have a thickness corresponding to a distance between an inner surface of the outer frame and an inner surface of the flat portion.

The vacuum insulation panel may be attached to the flat portion by an adhesive.

The adhesive may include a thermosetting adhesive.

The outer frame may include a plate facing the flat portion of the inner frame and parallel to the flat portion. The vacuum insulation panel may contact an inner surface of the plate facing the inner frame.

The vacuum insulation panel may fill a space between the plate of the outer frame and the flat portion of the inner frame.

A portion of the plate may face the door protrusion. The vacuum insulation panel may contact the portion of the plate facing the door protrusion.

The vacuum insulation panel may be attached to an inner surface of the outer frame facing the inner frame.

The foam insulation may fill a space between the outer frame, the door protrusion of the inner frame, and the vacuum insulation panel.

The foam insulation may fill a space between an inner surface of an edge of the door and a perimeter of the vacuum insulation panel.

The foam insulation may be coupled to the vacuum insulation panel.

The vacuum insulation panel may include a porous core material and an envelope enclosing the porous core material. The envelope may contact the outer frame and the flat portion.

The foam insulation may include a urethane material.

According to an embodiment of the present disclosure, a method of manufacturing a door of a refrigerator may include positioning a vacuum insulation panel on an inner surface of an outer frame of the door, filling a foaming liquid into an inner side of the outer frame along a perimeter of the vacuum insulation panel, and coupling an inner frame and the outer frame to allow the vacuum insulation panel to contact a flat portion of the inner frame of the door.

The method may further include applying an adhesive to one surface of the vacuum insulation panel provided to contact the flat portion.

The method may further include pressing the inner frame toward the vacuum insulation panel and the outer frame using a jig for a period of time during which the adhesive is cured.

The method may further include forming an adhesive layer on an inner surface of the outer frame to bond the vacuum insulation panel.

The method may further include foaming and curing the foaming liquid to fill an inner side of a door protrusion provided around a perimeter of the flat portion of the inner frame and protruding from the flat portion.

According to an embodiment of the present disclosure, a refrigerator may include a main body forming a storage compartment, and a door configured to open or close the storage compartment. The door may include an outer frame, an inner frame coupled to the outer frame, wherein a flat portion having a flat shape is formed at a center of the inner frame, and a door insulation disposed between the outer frame and the inner frame. The door insulation may include a vacuum insulation panel having a first surface attached to the outer frame and a second surface attached to the flat portion of the inner frame, and a foam insulation disposed on an outer side of a perimeter of the vacuum insulation panel.

The outer frame may include a plate facing the flat portion of the inner frame and parallel to the flat portion. The first surface of the vacuum insulation panel may be attached to an inner surface of the plate facing the inner frame.

According to the concept of the present disclosure, the door of the refrigerator may be configured such that the vacuum insulation panel contacts the plate of the outer frame and the flat portion of the inner frame, respectively, thereby occupying a large volume within an insulation space inside the door, and the foam insulation may formed only in a remaining portion where the vacuum insulation panel is not disposed, thereby simplifying a manufacturing process, such as a foaming process and equipment.

According to the concept of the present disclosure, when manufacturing the door of the refrigerator, the manufacturing process, such as the foaming process, may be simplified, and the curing time of the adhesive layer to attach the vacuum insulation panel to the plate of the outer frame and the flat portion of the inner frame may be shorter than the curing time of the foam insulation, thereby shortening a manufacturing time.

According to the concept of the present disclosure, the vacuum insulation panel having a high heat insulation efficiency to volume ratio may occupy a large volume within the insulation space inside the door, thereby improving the overall heat insulation efficiency of the refrigerator.

The effects to be obtained from the present disclosure are not limited to those mentioned above, and other effects not mentioned will be apparent to those of skilled in the art from the following description.

Although the above technical ideas of the disclosure have been described by way of specific embodiments, the scope of the disclosure is not limited to these embodiments. Various modifications and variations that can be made by those skilled in the art without departing from the technical ideas of the disclosure as set forth in the claims of the patent will be deemed to be within the scope of the disclosure.