Refrigerator and method for manufacturing refrigerator door

Abstract

A refrigerator and a method for manufacturing a refrigerator door are provided. The refrigerator comprises: a main body for forming storage chambers; and a door opened or closed to open or close each of the storage chambers. The door includes: an outer frame; an inner frame which is coupled to the outer frame, and which includes a flat part and a door protruding part that is disposed at the circumference of the flat part and protrudes from the flat part so as to protrude toward the storage chamber when the door is closed; and a door insulating material disposed between the outer frame and the inner frame. The door insulating material includes: a vacuum insulating panel in contact with the outer frame and the flat part of the inner frame; and a foam insulating material disposed along the circumference of the vacuum insulating material between the door protruding part of the inner frame and the outer frame.

Description

Method for manufacturing refrigerators and refrigerator doors

[0001] The present disclosure relates to a method for manufacturing a refrigerator and a door of the refrigerator.

[0002] A refrigerator is a device that maintains food freshness by including a main body with a storage compartment and a cooling system that supplies cold air to the storage compartment. The storage compartment includes a refrigerator, which maintains a temperature of approximately 0 to 5 degrees Celsius, for refrigerated storage, and a freezer, which maintains a temperature of approximately -17 to -23 degrees Celsius, for frozen storage. The storage compartment is designed with an open front for food entry and exit.

[0003] A refrigerator uses a compressor, condenser, expander, and evaporator to repeat the cooling cycle of compressing, condensing, expanding, and evaporating the refrigerant. A single evaporator located in the freezer can cool both the freezer and refrigerator compartments, or the freezer and refrigerator can each have their own evaporators, allowing for independent cooling.

[0004] The refrigerator body includes an inner case forming a storage compartment and an outer case forming the exterior of the refrigerator. Since the temperature of the storage compartment must be maintained within a certain range required to keep food fresh, insulation may be placed between the inner and outer cases for thermal insulation. Additionally, insulation may be placed inside the door that closes the front of the storage compartment.

[0005] Examples of insulation materials include polyurethane-based foam insulation, vacuum insulation materials formed by wrapping a core material with micro-pores, such as glass wool or silica powder, with an outer covering material, and then sealing the inside of the outer covering material under reduced pressure.

[0006] One aspect of the present disclosure provides a method of manufacturing a refrigerator and a refrigerator door that is improved to simplify the manufacturing process and equipment.

[0007] One aspect of the present disclosure provides an improved method of manufacturing a refrigerator and a refrigerator door so as to shorten the manufacturing time.

[0008] One aspect of the present disclosure provides a method of manufacturing a refrigerator and a refrigerator door improved to improve insulation efficiency.

[0009] The technical problems to be achieved in this document are not limited to the technical problems mentioned above, and other technical problems not mentioned can be clearly understood by a person having ordinary skill in the technical field to which the present invention belongs from the description below.

[0010] A refrigerator according to one embodiment of the present disclosure may include a main body forming a storage compartment, and a door configured to open or close to open or close the storage compartment, respectively. 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 the periphery of the flat portion, the door protrusion protruding from the flat portion and protruding toward the storage compartment when the door is closed, and a door insulation material disposed between the outer frame and the inner frame. The door insulation material may include a vacuum insulation panel in contact with the flat portion of the outer frame and the inner frame, and a foam insulation material disposed along the periphery of the vacuum insulation panel between the door protrusion of the inner frame and the outer frame.

[0011] A method for manufacturing a door of a refrigerator according to one 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 foam liquid into the inner side of the outer frame along the perimeter of the vacuum insulation panel, and joining the inner frame and the outer frame so that the vacuum insulation panel comes into contact with a flat portion of the outer frame and the inner frame of the door and the foam liquid is foamed and hardened to form a foam insulation material along the perimeter of the vacuum insulation panel between the door protrusion of the inner frame and the outer frame.

[0012] A refrigerator according to one embodiment of the present disclosure may include a main body forming a storage compartment, and a door configured to open or close to open or close the storage compartment, respectively. The door may include an outer frame, an inner frame coupled to the outer frame, the inner frame having a flat portion formed in the center of the inner frame, and a door insulation material disposed between the outer frame and the inner frame. The door insulation material may include a vacuum insulation panel having one surface attached to the outer frame and the other surface attached to the flat portion of the inner frame, and a foam insulation material disposed in an outer direction around the periphery of the vacuum insulation panel.

[0013] FIG. 1 is a perspective view of a refrigerator according to one embodiment of the present disclosure.

[0014] FIG. 2 is an exploded perspective view showing a door included in a refrigerator according to one embodiment of the present disclosure, viewed from one direction.

[0015] FIG. 3 is an exploded perspective view showing a door included in a refrigerator according to one embodiment of the present disclosure, viewed from another direction.

[0016] FIG. 4 is a cross-sectional view of a door included in a refrigerator according to one embodiment of the present disclosure.

[0017] Figure 5 is an enlarged cross-sectional view showing A of Figure 4.

[0018] Figure 6 is an enlarged cross-sectional view showing B of Figure 5.

[0019] FIG. 7 is a drawing illustrating a step of forming a first adhesive layer on the inner surface of an outer frame in a method of manufacturing a door of a refrigerator according to one embodiment of the present disclosure.

[0020] FIG. 8 is a drawing illustrating a step of attaching a vacuum insulation panel to an outer frame in a method of manufacturing a door of a refrigerator according to one embodiment of the present disclosure.

[0021] FIG. 9 is a drawing illustrating a step of forming a second adhesive layer on a vacuum insulation panel and injecting a foaming liquid along the perimeter of the vacuum insulation panel in a method for manufacturing a door of a refrigerator according to one embodiment of the present disclosure.

[0022] FIG. 10 is a drawing illustrating a step of combining an outer frame and an inner frame in a method of manufacturing a door of a refrigerator according to one embodiment of the present disclosure.

[0023] FIG. 11 is a drawing illustrating a step of pressing an inner frame toward an outer frame with a mold in a method of manufacturing a door of a refrigerator according to one embodiment of the present disclosure.

[0024] It should be understood that the various embodiments of the present disclosure and the terminology used therein are not intended to limit the technical features described in the present disclosure to specific embodiments, but rather to encompass various modifications, equivalents, or alternatives of the embodiments.

[0025] In connection with the description of the drawings, similar reference numerals may be used for similar or related components.

[0026] The singular form of a noun corresponding to an item may include one or more of said items, unless the relevant context clearly indicates otherwise.

[0027] In this disclosure, each of the phrases "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 of the items listed together in the corresponding phrase, or all possible combinations thereof.

[0028] The term “and / or” includes any combination of a plurality of related described elements or any one of a plurality of related described elements.

[0029] Terms such as "first," "second," or "first" or "second" may be used simply to distinguish one component from another and do not qualify the components in any other respect (e.g., importance or order).

[0030] In addition, terms such as 'front', 'rear', 'top', 'bottom', 'side', 'left', 'right', 'upper', and 'lower' used in the present disclosure are defined based on the drawings, and the shape and position of each component are not limited by these terms.

[0031] The terms “include” or “have” are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in the present disclosure, but do not preclude the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

[0032] When a component is said to be “connected,” “coupled,” “supported,” or “in contact with” another component, this includes not only cases where the components are directly connected, coupled, supported, or in contact, but also cases where the components are indirectly connected, coupled, supported, or in contact through a third component.

[0033] When we say that a component is "on" another component, this includes not only cases where the component is in contact with the other component, but also cases where there is another component between the two components.

[0034] A refrigerator according to one embodiment may include a body.

[0035] The “body” may include an inner case, an outer case placed on the outside of the inner case, and an insulating material provided between the inner case and the outer case.

[0036] The "inner case" may include at least one of a case, plate, panel, or liner forming a 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 the outer appearance of the body, and may be joined to the outer side of the inner case so that insulation is placed between the inner case and the outer case.

[0037] "Insulation" can insulate the interior and exterior of a storage room so that the temperature inside the storage room can be maintained at a set temperature without being affected by the external environment. In one embodiment, the insulation can include foam insulation. The foam insulation can be formed by injecting and foaming urethane foam, a mixture of polyurethane and a foaming agent, between the inner and outer layers.

[0038] In one embodiment, the insulation may include a vacuum insulation material in addition to the foam insulation, or the insulation may consist solely of the vacuum insulation material instead of the foam insulation. The vacuum insulation material may include a core material and an outer shell material that accommodates the core material and seals the interior under a vacuum or near-vacuum pressure. However, the insulation material is not limited to the foam insulation or vacuum insulation material described above, and may include various materials that can be used for insulation.

[0039] A "storage room" may include a space defined by an interior wall. The storage room may further include an interior wall defining a corresponding space. The storage room may store various items, such as food, medicine, and cosmetics, and the storage room may be configured to be open on at least one side for the entry and exit of items.

[0040] A refrigerator may include one or more storage compartments. When a refrigerator includes two or more storage compartments, each compartment may have a different purpose and be maintained at different temperatures. To achieve this, each storage compartment may be separated from the others by a partition wall containing insulation.

[0041] The storage room may be provided to be maintained at an appropriate temperature range depending on the intended use, and may include a "refrigerator," a "freezer," or a "variable temperature room," which are distinguished according to the intended use and / or temperature range. The refrigerator room may be maintained at a temperature appropriate for refrigerating items, and the freezer room may be maintained at a temperature appropriate for freezing items. "Refrigeration" may mean cooling items to a temperature that does not freeze them, and for example, a refrigerator room may be maintained at a temperature ranging from 0 degrees Celsius to +7 degrees Celsius. "Freezing" may mean cooling items to freeze them or keep them in a frozen state, and for example, a freezer room may be maintained at a temperature ranging from -20 degrees Celsius to -1 degree Celsius. The variable temperature room may be used as either a refrigerator room or a freezer room, at the user's option or not.

[0042] In addition to names such as "refrigerator," "freezer," and "variable temperature room," a storage room may also be called by various other names such as "vegetable room," "fresh room," "cooling room," and "ice room." The terms "refrigerator," "freezer," and "variable temperature room" used hereinafter should be understood to encompass storage rooms having corresponding uses and temperature ranges.

[0043] In one embodiment, the refrigerator may include at least one door configured to open and close an open side of a storage compartment. The door may be configured to open and close one or more storage compartments, or a single door may be configured to open and close multiple storage compartments. The door may be installed on the front of the main body in a pivotal or sliding manner.

[0044] The “door” may be configured to seal the storage compartment when the door is closed. The door may include insulation, similar to the body, to insulate the storage compartment when the door is closed.

[0045] According to one embodiment, the door may include a door outer panel forming the front of the door, a door inner panel forming the back of the door and facing the storage compartment, an upper cap, a lower cap, and door insulation provided on the interior of these.

[0046] The door inner panel may be provided with a gasket that seals the storage compartment by contacting the front of the body when the door is closed. The door inner panel may include a dyke that protrudes rearward to accommodate a door basket for storing items.

[0047] In one embodiment, the door may include a door body and a front panel detachably coupled to the front side of the door body and forming the front of the door. The door body may include a door outer panel forming the front of the door body, a door inner panel forming the rear of the door body and facing the storage compartment, an upper cap, a lower cap, and door insulation provided inside these.

[0048] Depending on the arrangement of the door and storage compartment, refrigerators can be classified into French door type, side-by-side type, bottom mounted freezer (BMF), top mounted freezer (TMF), or single-door refrigerator.

[0049] According to one embodiment, the refrigerator may include a cold air supply device configured to supply cold air to the storage compartment.

[0050] A “cold air supply device” may include a system of machines, devices, electronic devices and / or combinations thereof that can generate cold air and guide the cold air to cool a storage room.

[0051] In one embodiment, the cold air supply device can generate cold air through a refrigeration cycle that includes the processes of compression, condensation, expansion, and evaporation of a refrigerant. To this end, the cold air supply device can include a refrigeration cycle device having a compressor, a condenser, an expansion device, and an evaporator capable of driving the refrigeration cycle. In one embodiment, the cold air supply device can include a semiconductor, such as a thermoelectric element. The thermoelectric element can cool a storage compartment by generating heat and cooling through the Peltier effect.

[0052] According to one embodiment, the refrigerator may include a machine room in which at least some components belonging to the cold air supply device are arranged.

[0053] The "machine room" may be designed to be partitioned and insulated from the storage room to prevent heat generated by components placed within the machine room from being transferred to the storage room. The interior of the machine room may be configured to be connected to the exterior of the main body to dissipate heat from components placed within the machine room.

[0054] In one embodiment, the refrigerator may include a dispenser provided on the door to provide water and / or ice. The dispenser may be provided on the door so that it is accessible to a user without having to open the door.

[0055] In one embodiment, a refrigerator may include an ice-making device configured to produce ice. The ice-making device may include an ice-making tray configured to store water, an ice-separating device configured to separate ice from the ice-making tray, and an ice bucket configured to store ice produced in the ice-making tray.

[0056] According to one embodiment, the refrigerator may include a control unit for controlling the refrigerator.

[0057] The “control unit” may include a memory that stores or memorizes a program and / or data for controlling the refrigerator, and a processor that outputs a control signal for controlling a cold air supply device, etc. according to the program and / or data memorized in the memory.

[0058] Memory stores or records various information, data, commands, programs, etc. necessary for the operation of the refrigerator. Memory can store temporary data generated during the generation of control signals for controlling components within the refrigerator. Memory may include at least one of volatile memory and non-volatile memory, or a combination thereof.

[0059] The processor controls the overall operation of the refrigerator. The processor can control the components of the refrigerator by executing programs stored in memory. The processor may include a separate NPU that performs the operations of an artificial intelligence model. The processor may also include a central processing unit (CPU), a graphics processing unit (GPU), or the like. The processor may generate control signals to control the operation of the cooling system. For example, the processor may receive temperature information about the storage compartment from a temperature sensor and generate a cooling control signal to control the operation of the cooling system based on the temperature information.

[0060] Additionally, the processor may process user input of the user interface and control the operation of the user interface based on programs and / or data stored / stored in the memory. The user interface may be provided using an input interface and an output interface. The processor may receive user input from the user interface. Additionally, the processor may transmit display control signals and image data to the user interface for displaying an image on the user interface in response to the user input.

[0061] The processor and memory may be provided as a single unit or separately. The processor may include one or more processors. For example, the processor may include a main processor and at least one subprocessor. The memory may include one or more memories.

[0062] In one embodiment, a refrigerator may include a processor and memory that control all components within the refrigerator, and may include multiple processors and multiple memories that individually control the components within the refrigerator. For example, the refrigerator may include a processor and memory that control the operation of a cooling device based on the output of a temperature sensor. Additionally, the refrigerator may separately include a processor and memory that control the operation of a user interface based on user input.

[0063] The communication module can communicate with external devices, such as servers, mobile devices, and other home appliances, via a nearby access point (AP). The AP can connect the local area network (LAN) to which the refrigerator or user device is connected to the wide area network (WAN) to which the server is connected. The refrigerator or user device can then connect to the server via the WAN.

[0064] The input interface may include keys, a touchscreen, a microphone, etc. The input interface may receive user input and transmit it to the processor.

[0065] The output interface may include a display, a speaker, etc. The output interface may output various notifications, messages, information, etc. generated by the processor.

[0066] Hereinafter, a refrigerator according to various embodiments of the present disclosure will be described in detail with reference to the attached drawings.

[0067] In describing various embodiments of the present disclosure with reference to FIGS. 1 to 11, the terms “upper,” “lower,” “front,” “rear,” “left,” “right,” etc. 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 mean upper in the Z direction and lower in the Z direction, respectively, based on the drawings. The terms “front” and “rear” below may mean front and rear in the X direction, respectively, based on the drawings. The terms “left” and “right” below may mean left in the Y direction and right in the Y direction, respectively, based on the drawings.

[0068] FIG. 1 is a perspective view of a refrigerator according to one embodiment of the present disclosure.

[0069] Referring to FIG. 1, a refrigerator (1) according to one 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 and closing the storage compartment (20), and a cooling system for supplying cold air to the storage compartment (20).

[0070] The main body (10) may include an inner case (11) forming a storage compartment (20) and an outer case (12) forming the exterior of the refrigerator (1). The outer case (12) may be formed to have a shape of a box with an approximately open front. The outer case (12) may form the top, bottom, left and right sides, and the rear of the refrigerator (1). The inner case (11) may be open at the front. The inner case (11) may have a storage compartment (20) provided therein, which may be provided on the inner side of the outer case (12). The inner wall of the inner case (11) may form the inner wall of the storage compartment (20).

[0071] A body insulation material may be provided between the inner case (11) and the outer case (12) to insulate the inner case (11) and the outer case (12). The body insulation material may be foamed between the inner case (11) and the outer case (12). The body insulation material may connect the inner case (11) and the outer case (12) to each other. The body insulation material may prevent heat exchange between the inside of the storage compartment (20) and the outside of the body (10), thereby improving the cooling efficiency inside the storage compartment (20). For example, the body insulation material may include insulation materials of various materials such as urethane foam insulation, expanded polystyrene insulation (EPS insulation), and vacuum insulation.

[0072] A storage compartment (20) may be formed inside the main body (10). For example, the storage compartment (20) may include a refrigerator that is maintained at approximately 0 to 5 degrees Celsius and used to refrigerate food. For example, the storage compartment (20) may include a freezer that is maintained at approximately -23 to -17 degrees Celsius and used to freeze food.

[0073] In various embodiments, the storage compartment (20) may be partitioned into a plurality of regions. The storage compartment (20) may be partitioned into a plurality of regions by partitions (15). For example, the storage compartment (20) may be partitioned into a first storage compartment (21) at the top and a second storage compartment (22, 23) at the bottom by a first partition (17) extending in the horizontal direction. In addition, the second storage compartment (22, 23) at the bottom of the storage compartment (20) may be partitioned into a second storage compartment (22) at the left and a third storage compartment (23) at the right by a second partition (19) extending in the vertical direction. In this case, as an example, the first storage compartment (21) may be used as a refrigerator, and both the second storage compartment (22) and the third storage compartment (23) may be used as a freezer, or one of the two may be used as a freezer and the other of the two may be used as a refrigerator.

[0074] The above-described division method of the storage room (20) and the use of each of the divided storage rooms (21, 22, 23) are only an example and are not limited thereto.

[0075] Inside the storage room (20), a shelf (24) for placing food and a drawer (26) for storing food may be provided.

[0076] A refrigerator (1) may include a cooling system that generates cold air using a cooling cycle and supplies the generated cold air to a storage compartment (20). The cooling system may generate cold air using a cooling cycle that compresses, condenses, expands, and evaporates a refrigerant. For example, the cooling system may include a compressor, a condenser, an expansion valve, an evaporator, a blower fan, and the like. The cold air generated by the cooling system may be supplied to the storage compartment (20) through a cold air supply duct formed at the rear portion of the inner case (11).

[0077] A door (30) may be provided to open and close the storage room (20). The door (30) may be provided to open and close an opening formed on one side of the main body (10). The door (30) may be provided to be rotatable with respect to the main body (10).

[0078] The outer surface of the door (30) may form a part of the exterior of the refrigerator (1). When the door (30) is closed, the outer surface of the door (30) may form at least a part of the front exterior of the refrigerator (1). When the door (30) is closed, the inner surface of the door (30) may face the interior of the storage compartment (20). The inner surface of the door (30) referred to herein means one side of the door (30) that faces the storage compartment (20) when the door (30) closes the storage compartment (20). In addition, the outer surface of the door (30) referred to herein means the other side opposite to the inner surface of the door (30) that faces the storage compartment (20) when the door (30) closes the storage compartment (20), and means the front of the door (30) that is visible when the refrigerator (1) is viewed from the front.

[0079] A door shelf (36) for storing food may be provided on the inner surface of the door (30). For example, the door shelf (36) may be supported by a dyke provided on the door protrusion (35b) of the door (30). The door shelf (36) may be mounted on the dyke provided on the door protrusion (35b) of the door (30).

[0080] A door gasket (37) may be provided on the inner surface of the door (30). The door gasket (37) may be provided to cover the gap between the door (30) and the main body (10) to prevent leakage of cold air from the storage compartment (20). The door gasket (37) may include various elastic materials such as rubber or silicone to enable elastic deformation.

[0081] The refrigerator (1) may include an upper door and a lower door that are arranged side by side in a vertical direction (Z). The refrigerator (1) may include a left door and a right door that are arranged side by side in a horizontal direction (Y). The refrigerator (1) may include a plurality of doors (30A, 30B, 30C, 30D) that open and close each of the partitioned storage compartments (21, 22, 23).

[0082] The first storage compartment (21) can be opened and closed by a pair of upper doors (30A, 30B). The refrigerator (1) may include a first door (30A) for opening and closing a portion of the first storage compartment (21), and a second door (30B) for opening and closing another 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 parallel to each other in the horizontal direction (Y direction). For example, the first door (30A) may be provided to open and close the left portion of the first storage compartment (21), and the second door (30B) may be provided to open and close the right portion of the first storage compartment (21).

[0083] A rotation bar (50) may be provided on one of the pair of upper doors (30A, 30B) (e.g., the first door (30A)) so as to be rotatable relative to that one door and to cover the gap between the pair of upper doors (30A, 30B) when the first storage compartment (21) is closed.

[0084] The second storage compartment (22) can be opened and closed by the lower left door (30C). The refrigerator (1) may include a third door (30C) provided to open and close the second storage compartment (22). The third door (30C) may be provided to be rotatable with respect to the main body (10). For example, the first door (30A) and the third door (30C) may be arranged parallel to each other in the vertical direction (Z).

[0085] The third storage compartment (23) can be opened and closed by the lower right door (30D). The refrigerator (1) may include a fourth door (30D) provided to open and close the third storage compartment (23). The fourth door (30D) may be provided to be rotatable with respect to the main body (10). For example, the second door (30B) and the fourth door (30D) may be arranged parallel to each other in the vertical direction (Z). In addition, the third door (30C) and the fourth door (30D) may be arranged parallel to each other in the horizontal direction (Y).

[0086] The structure or features of the door (30) described below can be applied to each of a plurality of doors (30A, 30B, 30C, 30D).

[0087] The refrigerator (1) may include a hinge (40) connecting the main body (10) and the door (30). The hinge (40) may be respectively coupled to the main body (10) and the door (30). The hinge (40) may be provided so that the door (30) can rotate relative 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).

[0088] The refrigerator (1) may include a plurality of hinges (41, 42, 43) provided to support each of the plurality of doors (30A, 30B, 30C, 30D). For example, the refrigerator (1) may include a pair of upper door hinges (41) that are coupled to the upper portion of the main body (10) and 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) that are coupled to the lower portion of the main body (10) and rotatably support the third door (30C) and the fourth door (30D), respectively. For example, the refrigerator (1) may include a pair of middle hinges (42) that are arranged between the upper door hinge (41) and the lower door hinge (43) and are coupled to the middle portion of the main body (10) (specifically, the first partition (17)) to rotatably support each of the first door (30A), the second door (30B), the third door (30B), and the fourth door (30D).

[0089] The configuration of the refrigerator (1) described above with reference to FIG. 1 is merely an example of the present disclosure, and the present disclosure is not limited thereto. A refrigerator according to various embodiments of the present disclosure may be provided to include various configurations for performing the function of supplying cold air to a storage compartment for storing food.

[0090] For example, in FIG. 1, a refrigerator (1) according to one embodiment is described as being of the French Door Type, but 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 BMF (Bottom Mounted Freezer) type in which a refrigerator compartment is arranged on the upper side and a freezer compartment is arranged on the lower side, a TMF (Top Mounted Freezer) type in which a freezer compartment is arranged on the upper side and a refrigerator compartment is arranged on the lower side, and a side-by-side type in which a refrigerator and a freezer compartment are arranged on the left and right.

[0091] FIG. 2 is an exploded perspective view showing a door included in a refrigerator according to one embodiment of the present disclosure, viewed from one direction, disassembled. FIG. 3 is an exploded perspective view showing a door included in a refrigerator according to one embodiment of the present disclosure, viewed from another direction, disassembled.

[0092] Referring to FIGS. 2 and 3, a door (30) according to one embodiment of the present disclosure may include an outer frame (31) and an inner frame (35).

[0093] The outer frame (31) can form the outer surface of the door (30). Here, the outer surface of the outer frame (31) can mean a surface different from the inner surface of the outer frame (31) that faces the storage compartment (20) when the door (30) closes the storage compartment (20). The outer frame (31) can form the front, upper, lower, left, right, etc. of the door (30). The outer frame (31) can cover the internal space of the door (30) from the front, upper, lower, left, right, etc.

[0094] The outer frame (31) may include a plate (32). The plate (32) may form the front of the door (30). The plate (32) may form the front of the outer frame (31). The front of the door (30) as referred to here means one side of the door (30) that faces the front of the refrigerator (1) when the door (30) is closed. Hereinafter, in defining the positional relationship of the components included in the door (30), the direction in which the plate (32) faces is defined as the front of the door (30), and the opposite direction is defined as the rear of the door (30).

[0095] The plate (32) may have a flat shape. The plate (32) may have a roughly flat rectangular plate shape. The plate (32) may have a plate shape that is roughly perpendicular to the front-back direction (X direction). The plate (32) may have a plate shape that is roughly parallel to the lateral direction (Y direction) and the up-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).

[0096] The outer frame (31) may include an upper door cap (33a). The upper door cap (33a) may form an upper surface of the door (30). The upper door cap (33a) may form an upper surface of the outer frame (31). For example, the upper door cap (33a) may be disposed on an upper side of the plate (32) and a side frame (34) to be described later. For 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 formed integrally with at least a portion of the plate (32) and the side frame (34).

[0097] For example, a hinge (40) may be coupled to the upper door cap (33a).

[0098] The outer frame (31) may include a lower door cap (33b). The lower door cap (33b) may form the bottom surface of the door (30). The lower door cap (33b) may form the bottom surface of the outer frame (31). For example, the lower door cap (33b) may be positioned on the lower side of the plate (32) and the side frame (34). For example, the lower door cap (33b) may be coupled to the lower portion of the plate (32) and / or the side frame (34). Alternatively, in various embodiments, the lower door cap (33b) may be formed integrally with at least a portion of the plate (32) and the side frame (34).

[0099] For example, a hinge (40) may be coupled to the lower door cap (33b).

[0100] The outer frame (31) may include a side frame (34). The side frames (34) may be provided as a pair, each forming a left side or a right side of the door (30). The pair of side frames (34) may each form a left side or a right side of the outer frame (31). For example, the side frames (34) may be arranged at left side or a right side of the plate (32), the upper door cap (33a), and the lower door cap (33b). For example, the side frames (34) may be coupled to left side or a right side 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 formed integrally with at least a portion of the plate (32), the upper door cap (33a), and the lower door cap (33b).

[0101] In the above, an embodiment in which a plate (32), an upper door cap (33a), a lower door cap (33b), and a side frame (34) are combined with each other to form an outer frame (31) has been described. However, according to various embodiments, the outer frame (31) may be formed integrally with a plate (32), an upper door cap (33a), a lower door cap (33b), and a side frame (34).

[0102] The inner frame (35) may be arranged 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 arranged at the rear of the outer frame (31).

[0103] The inner frame (35) can be coupled to the outer frame (31). The inner frame (35) can be coupled to the side frame (34) of the outer frame (31). The inner frame (35) can be coupled to the upper door cap (33a) of the outer frame (31). The inner frame (35) can be coupled to the lower door cap (33b) of the outer frame (31). Alternatively, for example, the inner frame (35) and the outer frame (31) may be formed integrally with each other.

[0104] The inner frame (35) may include a flat portion (35a).

[0105] 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 that is substantially perpendicular to the front (X direction). The flat portion (35a) may have a plate shape that is substantially parallel to the lateral direction (Y direction) and the up-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).

[0106] The flat portion (35a) can form the rear surface of the door (30). The flat portion (35a) can 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.

[0107] The flat portion (35a) can be placed in the center of the inner frame (35).

[0108] 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. The approximate center portion of the plate (32) may face the flat portion (35a), and a portion adjacent to the edge of the plate (32) may face the edge of the door protrusion (35b) or the inner frame (35), which will be described later.

[0109] The inner frame (35) may include a door protrusion (35b) protruding from the flat portion (35a). The door protrusion (35b) may protrude rearward 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).

[0110] The door protrusion (35b) may be positioned along the edge of the inner frame (35). The door protrusion (35b) may be positioned adjacent to the edge of the inner frame (35). The door protrusion (35b) may be positioned around the periphery of the flat portion (35a). The door protrusion (35b) may be positioned further outward than the flat portion (35a). The door protrusion (35b) may be positioned closer to the edge of the inner frame (35) than the flat portion (35a).

[0111] For example, a portion of the door protrusion (35b) may be formed approximately parallel to the vertical direction (Z). For example, a portion of the door protrusion (35b) may be arranged approximately parallel to the lateral direction (Y).

[0112] A dyke may be provided on the door protrusion (35b), and the dyke may support the door shelf (36) described above.

[0113] The edge portion of the inner frame (35) may be positioned outside the door protrusion (35b). The inner frame (35) may extend outward from the door protrusion (35b) in a vertical direction (Z) or a lateral direction (Y). The edge portion of the inner frame (35) may be combined with an upper door cap (33a), a lower door cap (33b), a side frame (34), etc. A door gasket (37) may be mounted on the edge portion of the inner frame (35).

[0114] According to one embodiment, the flat portion (35a) and the door protrusion (35b) of the inner frame (35) may be formed integrally. However, this is not limited thereto, and in various embodiments, the flat portion (35a) and the door protrusion (35b) may not be formed integrally.

[0115] The door (30) may have a space formed between the outer frame (31) and the inner frame (35). A door insulation material (100, see FIG. 4) may be placed between the outer frame (31) and the inner frame (35). The door insulation material (100) may prevent heat exchange between the inside and the outside of the storage compartment (20) through the door (30) when the door (30) is closed. The door insulation material (100) may improve the insulation performance between the inside of the storage compartment (20) and the outside of the door (30).

[0116] Fig. 4 is a cross-sectional view of a door included in a refrigerator according to one 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.

[0117] Referring to FIGS. 4 to 6, a door (30) of a refrigerator (1) according to one embodiment of the present disclosure may include a door insulation material (100) disposed in an inner space of the door (30). The door insulation material (100) may be disposed in an inner space of the door (30) formed between an outer frame (31) and an inner frame (35). The inner space of the door (30) may be formed by a plate (32), an upper door cap (33a), a lower door cap (33b), a side frame (34), and an inner frame (35). The door insulation material (100) may fill the inner space of the door (30).

[0118] The door insulation (100) may include a vacuum insulation panel (VIP) (110). The vacuum insulation panel (110) may be placed inside the door (30). The vacuum insulation panel (110) may be placed between the outer frame (31) and the inner frame (35).

[0119] The vacuum insulation panel (110) may include a core material (111) and an outer covering material (112) surrounding the core material (111). According to one embodiment, the core material (111) may include a porous core material having fine pores inside, such as glass wool or silica powder. According to one embodiment, the outer covering material (112) may include a gas barrier outer covering material and may be configured to completely surround the core material (111) and seal the core material (111). According to one embodiment, the vacuum insulation panel (110) may be formed by a process of wrapping the porous core material (111) with the gas barrier outer covering material (112) and decompressing and sealing the inside of the outer covering material (112) at a vacuum or a pressure close to a vacuum.

[0120] The vacuum insulation panel (110) may include an absorbent material that is pressure-sealed on the inside of the outer covering (112) together with the core material (111). The absorbent material may be configured to remove heat transfer media such as water vapor, oxygen, or nitrogen that penetrate into the outer covering (112) so as to maintain the excellent insulation performance of the vacuum insulation panel (110) for a long period of time. For example, the absorbent material may include a chemical absorbent such as calcium oxide (CaO) that irreversibly fixes and absorbs moisture, or a metal absorbent such as a barium getter or a ternary alloy of zirconium-vanadium-iron that adsorbs oxygen or nitrogen.

[0121] With this configuration, the vacuum insulation panel (110) can have excellent insulation efficiency. For example, the vacuum insulation panel (110) can have a low thermal conductivity of approximately 2 mW / mk.

[0122] As a type of foam insulation material used by being foamed into the interior of a door (30), a urethane-based insulation material mainly used may have a high thermal conductivity of approximately 20 mK / mK or more. That is, the foam insulation material may have lower insulation efficiency than the vacuum insulation panel (110). Therefore, when a urethane-based insulation material is mainly used as a door insulation material used into the interior of a door (30), a problem may arise in that sufficient insulation efficiency is not obtained, or the volume of the foam insulation material increases in order to obtain sufficient insulation efficiency, and the thickness of the door (30) becomes thicker.

[0123] In one embodiment of the present disclosure, the door insulation (100) can have excellent insulation efficiency since it includes a vacuum insulation panel (110) having excellent insulation efficiency, and it can be possible to obtain sufficient insulation efficiency even if the door (30) is formed to have a thin thickness.

[0124] According to one embodiment, the vacuum insulation panel (110) can be in contact with the outer frame (31) and the inner frame (35). The vacuum insulation panel (110) can be in contact with the inner surface of the outer frame (31) facing the inner frame (35). The vacuum insulation panel (110) can be in contact with the plate (32) of the outer frame (31). The vacuum insulation panel (110) can be in contact with the inner surface of the inner frame (35) facing the outer frame (31). The vacuum insulation panel (110) can be in contact with the flat portion (35a) of the inner frame (35). The vacuum insulation panel (110) can include a first surface (110a) in contact with the inner surface (32a) of the plate (32) facing the inner frame (35) and a second surface (110b) in contact with the inner surface (35aa) of the flat portion (35a) facing the outer frame (31).

[0125] The vacuum insulation panel (110) may have a substantially flat plate shape. The first surface (110a) of the vacuum insulation panel (110) may have a flat shape so as to be in contact with the inner surface (32a) of the flat plate (32). The second surface (110b) of the vacuum insulation panel (110) may have a flat shape so as to be in contact with the inner surface (35aa) of the flat portion (35a). The first surface (110a) and the second surface (110b) of the vacuum insulation panel (110) may be opposite surfaces. The first surface (110a) and the second surface (110b) of the vacuum insulation panel (110) may each be a portion having a relatively large area among the outer surfaces of the vacuum insulation panel (110).

[0126] As the first surface (110a) of the vacuum insulation panel (110) contacts the plate (32) and the second surface (110b) contacts the flat portion (35a), the vacuum insulation panel (110) may have a thickness corresponding to the distance between the inner surface (32a) of the plate (32) and the inner surface (35aa) of the flat portion (35a). For example, the vacuum insulation panel (110) may have a thickness substantially equal to the distance between the inner surface (32a) of the plate (32) and the inner surface (35aa) of the flat portion (35a).

[0127] According to one embodiment, the vacuum insulation panel (110) can contact approximately the entire area of ​​the flat portion (35a). The second surface (110b) of the vacuum insulation panel (110) can contact approximately the entire area of ​​the flat portion (35a). For example, approximately the central portion of the second surface (110b) of the vacuum insulation panel (110) can contact approximately the entire area of ​​the flat portion (35a), and the remaining portion of the second surface (110b) can be positioned between the plate (32) and the door protrusion (35b) without contacting the inner frame (35).

[0128] In one embodiment, the vacuum insulation panel (110) can contact a portion of the plate (32) facing the flat portion (35a). In one embodiment, the vacuum insulation panel (110) can contact a portion of the plate (32) facing the door protrusion (35b). A portion of the first surface (110a) of the vacuum insulation panel (110) located approximately in the center can contact a portion of the plate (32) facing the flat portion (35a), and another portion of the first surface (110a) of the vacuum insulation panel (110) adjacent to the edge can contact another portion of the plate (32) facing the door protrusion (35b).

[0129] The vacuum insulation panel (110) can be coupled to the outer frame (31). The vacuum insulation panel (110) can be attached to the inner surface of the outer frame (31) facing the inner frame (35). The vacuum insulation panel (110) can be attached to the plate (32) of the outer frame (31). The vacuum insulation panel (110) can be attached to the inner surface (32a) of the plate (32).

[0130] For example, the door (30) may include a first adhesive layer (ad1) provided to attach a vacuum insulation panel (110) to an inner surface facing the inner frame (35) of the outer frame (31). The vacuum insulation panel (110) may be attached to the plate (32) by the first adhesive layer (ad1). The vacuum insulation panel (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 vacuum insulation panel (110) may be attached 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 side (110a) of the vacuum insulation panel (110) can be bonded to another part of the inner surface (35aa) of the plate (32) facing the door protrusion (35b) by the first adhesive layer (ad1).

[0131] The first adhesive layer (ad1) may include an adhesive. For example, the first adhesive layer (ad1) may include a thermosetting adhesive. The thermosetting adhesive may have temporary adhesive properties before heat curing, and may have excellent fixing properties and heat resistance after heat curing. Since the thermosetting adhesive is used as the first adhesive layer (ad1), even if heat is applied to the door (30), the shape of the first adhesive layer (ad1) does not change, and the vacuum insulation panel (110) can be stably fixed to the outer frame (31). The first adhesive layer (ad1) may include various types of thermosetting adhesives, such as a PUR (Polyurethane Reactive) adhesive.

[0132] Alternatively, for example, the first adhesive layer (ad1) may include a double-sided adhesive tape that is provided to adhere the inner surface (32a) of the plate (32) and the first surface (110a) of the vacuum insulation panel (110) to each other.

[0133] The vacuum insulation panel (110) can be coupled to the inner frame (35). The vacuum insulation panel (110) can be attached to the inner surface of the inner frame (35) facing the outer frame (31). The vacuum insulation panel (110) can be attached to the flat portion (35a) of the inner frame (35). The vacuum insulation panel (110) can be attached to the inner surface (35aa) of the flat portion (35a).

[0134] For example, the door (30) may include a second adhesive layer (ad2) provided to attach the vacuum insulation panel (110) to the flat portion (35a) of the inner frame (35). The vacuum insulation panel (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 vacuum insulation panel (110) may be attached to approximately the entire area of ​​the inner surface (35aa) of the flat portion (35a) by the second adhesive layer (ad2).

[0135] The second adhesive layer (ad2) may include an adhesive. For example, the second adhesive layer (ad2) may include a thermosetting adhesive. The thermosetting adhesive may have temporary adhesive properties before heat curing, and may have excellent fixing properties and heat resistance after heat curing. Since the thermosetting adhesive is used as the second adhesive layer (ad2), even if heat is applied to the door (30), the shape of the second adhesive layer (ad2) does not change, and the vacuum insulation panel (110) can be stably fixed to the inner frame (35). The second adhesive layer (ad2) may include various types of thermosetting adhesives, such as a PUR (Polyurethane Reactive) adhesive.

[0136] The first side (110a) and the second side (110b) of the vacuum insulation panel (110) may be provided on the outer surface of the outer covering material (112) of the vacuum insulation panel (110) described above. The outer covering material (112) may be in contact with the flat portion (35a) of the outer frame (31) and the inner frame (35). The outer covering material (112) may be in contact with the inner surface (32a) of the plate (32) and the inner surface (35aa) of the flat portion (35a). The outer covering material (112) may be attached to the inner surface (32a) of the plate (32) and the inner surface (35aa) of the flat portion (35a). The outer covering material (112) can be attached to the inner surface (32a) of the plate (32) by the first adhesive layer (ad1) and can be attached to the flat portion (35a) of the inner frame (35) by the second adhesive layer (ad2).

[0137] In this way, as the first side (110a) of the vacuum insulation panel (110) contacts the plate (32) of the outer frame (31) and the second side (110b) contacts the flat portion (35a), the vacuum insulation panel (110) can fill the space between the plate (32) and the flat portion (35a).

[0138] Meanwhile, according to one embodiment, although a part of the vacuum insulation panel (110) is disposed between the plate (32) and the door protrusion (35b) with the first surface (110a) attached to the plate (32), since the vacuum insulation panel (110) has a substantially flat plate shape, a gap may be formed between the second surface (110b) and the door protrusion (35b), and the vacuum insulation panel (110) may not be disposed. In addition, as illustrated in FIG. 5, a gap may also be formed between the vacuum insulation panel (110) and the inner surface of the side frame (34), and thus the vacuum insulation panel (110) may not be disposed in a part of the inner area of ​​the door (30) adjacent to the edges (e.g., left edge, right edge, upper edge, lower edge) of the door (30).

[0139] In this way, there may be areas in the interior space of the door (30) where the vacuum insulation panel (110) is not provided, and so that the door insulation (100) may include a foam insulation (120) so that the insulation function can be provided to those areas as well. The foam insulation (120) may be placed in an area other than the area where the vacuum insulation panel (110) is placed in the interior space of the door (30). The foam insulation (120) may be placed in an area other than the area where the vacuum insulation panel (110) is placed in the space between the outer frame (31) and the inner frame (35).

[0140] For example, the foam insulation (120) may be arranged along the perimeter of the vacuum insulation panel (110). The foam insulation (120) may be arranged between the inner frame (35) and the outer frame (31), outside the flat portion (35a) of the inner frame (35). The foam insulation (120) may be arranged along the perimeter of the flat portion (35a) between the inner frame (35) and the outer frame (31).

[0141] For example, the foam insulation (120) can be placed between the door protrusion (35b) of the inner frame (35) and the outer frame (31). The foam insulation (120) can be placed between the door protrusion (35b) and the plate (32). The foam insulation (120) can be placed between the door protrusion (35b) and the second surface (110b) of the vacuum insulation panel (110). The foam insulation (120) can fill the space between the outer frame (31), the door protrusion (35b), and the vacuum insulation panel (110). The foam insulation (120) can include a protrusion filling portion (120a) that fills the inside of the door protrusion (35b). The protrusion filling portion (120a) can fill the space between the outer frame (31), the door protrusion (35b), and the vacuum insulation panel (110).

[0142] For example, the foam insulation (120) can be placed between the portion adjacent to the edge of the inner frame (35) and the outer frame (31). The foam insulation (120) can be placed between the portion adjacent to the edge of the inner frame (35) and the plate (32), 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) can 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 vacuum insulation panel (110). The foam insulation (120) can include a edge filling portion (120b) that fills an area adjacent to the edge of the door (30) among the interior spaces of the door (30). The edge filling portion (120b) can fill the space between the portion adjacent to the edge of the inner frame (35) and the plate (32), 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) can 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 vacuum insulation panel (110).

[0143] The foam insulation (120) can be formed by injecting and foaming a foaming agent into the interior space of the door (30), i.e., between the outer frame (31) and the inner frame (35). When the foaming agent is injected and foamed into the interior space of the door (30) and then hardened, the foam insulation (120) can be formed. For example, the foaming agent can include urethane foam in which a urethane material and a foaming agent are mixed. The foam insulation (120) can include a urethane material. The foam insulation (120) can provide an insulating function by forming a large number of pores inside it during the foaming process.

[0144] According to one embodiment, the foam insulation (120) can be formed by a low-pressure foaming method using a foaming agent composed of water and not including pentane series such as cyclopentane. The foam insulation (120) formed in this manner has, for example, a foam density of approximately 75 kg / m 3 It can have a high density. If the foam insulation (120) has a high density like this, the overall rigidity of the door (30) can increase.

[0145] In this way, the foam insulation (120) is formed through a process in which a fluid foaming liquid is injected into the foaming space, foamed, and then hardened, and therefore, unlike the vacuum insulation panel (110), it can be formed into various shapes depending on the foaming space. That is, the foam insulation (120) can have a shape corresponding to the shape of the foaming space. Areas other than the area where the vacuum insulation panel (110) is not placed within the interior space of the door (30), such as the area between the outer frame (31) and the door protrusion (35b), or the area adjacent to the edge within the interior space of the door (30), can be filled without any empty space by the foam insulation (120) even though they have a shape that is not flat but curved.

[0146] Since the foam insulation (120) is filled in an area of ​​the interior space of the door (30) other than an area where the vacuum insulation panel (110) is not placed, the foam insulation (120) can be bonded to the vacuum insulation panel (110). The foam insulation (120) can be bonded to the vacuum insulation panel (110) during the process of the foaming liquid hardening. The foam insulation (120) can be bonded to the periphery of the vacuum insulation panel (110). The foam insulation (120) can be bonded to a portion of the outer covering (112) of the vacuum insulation panel (110).

[0147] As described above, by simultaneously contacting the vacuum insulation panel (110) with the outer frame (31) and the flat portion (35a), the volume occupied by the vacuum insulation panel (110) between the outer frame (31) and the inner frame (35) can be improved. Since the insulation efficiency of the vacuum insulation panel (110) (e.g., thermal conductivity of approximately 2 mW / mK) is higher than that of the foam insulation (120) (e.g., thermal conductivity of approximately 20 mW / mK or more), the thickness of the door (30) can be prevented from increasing, while the overall insulation efficiency of the door (30) can be further improved.

[0148] In addition, in areas where it is difficult to place a vacuum insulation panel (110), such as the inner area of ​​the door protrusion (35b) in the interior space of the door (30) and the area adjacent to the edge of the door (30), a foam insulation material (120) is placed instead of the vacuum insulation panel (110), so that the door insulation material (100) can be provided in almost all of the interior space of the door (30), and the overall insulation efficiency can be improved.

[0149] As described above, the vacuum insulation panel (110) can simplify the process and equipment for manufacturing the door (30) and reduce the manufacturing time by having the first side (110a) attached to the plate (32) and the second side (110b) attached to the flat portion (35a). If the vacuum insulation panel (110) does not contact either the plate (32) or the flat portion (35a) but is spaced apart from it, leaving the space between them as an empty space may lower the insulation efficiency, so there is a need to fill the space with a foam insulation material (120). In this case, in addition to the problem that the insulation efficiency may be lowered as the thickness of the vacuum insulation panel (110) is reduced, there is also the problem that the process efficiency may be lowered because a process of injecting, foaming, and curing a foaming agent must be performed in the space between them in order to fix the vacuum insulation panel (110) to the plate (32) or the flat portion (35a).

[0150] However, in the embodiment of the present disclosure, the vacuum insulation panel (110) can be easily attached to both the plate (32) and the flat portion (35a) through a simple process of attaching the first side (110a) of the vacuum insulation panel (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). In addition, as described above, as the volume occupied by the vacuum insulation panel (110) inside the door (30) increases, the volume occupied by the foam insulation (120) decreases, so the relatively complicated process and equipment for injecting, foaming, and curing the foaming liquid to form the foam insulation (120) can be simplified, and the process time therefor can be reduced.

[0151] Hereinafter, with reference to FIGS. 7 to 11, a method for manufacturing a door (30) of a refrigerator (1) according to one embodiment of the present disclosure will be described in detail.

[0152] FIG. 7 is a drawing illustrating a step of forming a first adhesive layer on the inner surface of an outer frame in a method for manufacturing a refrigerator door according to an embodiment of the present disclosure. FIG. 8 is a drawing illustrating a step of attaching a vacuum insulation panel to an outer frame in a method for manufacturing a refrigerator door according to an embodiment of the present disclosure. FIG. 9 is a drawing illustrating a step of forming a second adhesive layer on a vacuum insulation panel and injecting a foaming liquid along the perimeter of the vacuum insulation panel in a method for manufacturing a refrigerator door according to an embodiment of the present disclosure. FIG. 10 is a drawing illustrating a step of joining an outer frame and an inner frame in a method for manufacturing a refrigerator door according to an embodiment of the present disclosure. FIG. 11 is a drawing illustrating a step of pressing an inner frame toward an outer frame with a mold in a method for manufacturing a refrigerator door according to an embodiment of the present disclosure.

[0153] Referring to FIGS. 7 to 11, in a step of manufacturing a door (30) of a refrigerator (1) according to one embodiment of the present disclosure, a step of positioning an outer frame (31) on a support device (M1) may be performed first. The outer frame (31) may be positioned on the support device (M1) such that the inner surface (32a) of the plate (32) faces upward while the plate (32), the upper door cap (33a), the lower door cap (33b), and the side frame (34) are connected to each other.

[0154] Thereafter, as illustrated in FIG. 7, a step of forming a 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). For example, the first adhesive layer (ad1) may include a thermosetting adhesive such as a PUR adhesive. For example, the first adhesive layer (ad1) may include a double-sided adhesive tape.

[0155] In one embodiment, the first adhesive layer (ad1) may be formed of a plurality of rows spaced apart from each other. For example, the first adhesive layer (ad1) may be formed of a plurality of rows spaced apart at regular intervals. The length of one row of the first adhesive layer (ad1) may approximately correspond to the length of the vacuum insulation panel (110).

[0156] Thereafter, a step of positioning the vacuum insulation panel (110) on the inner surface of the outer frame (31) as illustrated in FIG. 8 may be performed. The vacuum insulation panel (110) may be positioned on the inner surface (32a) of the plate (32). The vacuum insulation panel (110) may be positioned so as to be approximately in the center of the plate (32).

[0157] Since a first adhesive layer (ad1) is formed on the inner surface (32a) of the plate (32), when the vacuum insulation panel (110) is positioned on the inner surface (32a) of the plate (32), the vacuum insulation panel (110) can be attached to the plate (32). For example, when the first adhesive layer (ad1) includes a thermosetting adhesive, the thermosetting adhesive positioned between the inner surface (32a) of the plate (32) and the vacuum insulation panel (110) is exposed to heat and hardens after a certain period of time, so that the vacuum insulation panel (110) can be attached to the plate (32). The time for the thermosetting adhesive to harden and the vacuum insulation panel (110) to be bonded to the outer frame (31) may vary depending on the heating conditions, the application area of ​​the thermosetting adhesive, etc., but it is expected to be significantly shorter than the time for the urethane-based foam to harden and form a foam insulation material under general conditions.

[0158] After the vacuum insulation panel (110) is positioned on the inner surface of the outer frame (31), a step of forming a second adhesive layer (ad2) on the second surface (110b) of the vacuum insulation panel (110) and a step of filling the inner surface of the outer frame (31) along the perimeter of the vacuum insulation panel (110) can be performed, as shown in FIG. 9.

[0159] According to one embodiment, the step of forming the second adhesive layer (ad2) may include applying an adhesive to the second surface (110b) of the vacuum insulation panel (110). For example, the adhesive may include a thermosetting adhesive such as a PUR adhesive.

[0160] In one embodiment, the second adhesive layer (ad2) may be formed of a plurality of rows spaced apart from each other. For example, the second adhesive layer (ad2) may be formed of a plurality of rows spaced apart at regular intervals. The length of one row of the second adhesive layer (ad2) may roughly correspond to the length of the flat portion (35a) of the inner frame (35).

[0161] For example, after a thermosetting adhesive for forming a second adhesive layer (ad2) is applied to the second surface (110b) of the vacuum insulation panel (110), a foaming liquid (121) for forming a foam insulation material (120) may be injected. However, this is not limited thereto, and according to various embodiments, the step of forming the second adhesive layer (ad2) and the step of filling the inner side of the outer frame (31) with the foaming liquid (121) may be performed simultaneously, or either one of the two may be performed first.

[0162] The foaming liquid (121) can be sprayed by a nozzle (N) and injected into the inside of the outer frame (31). For example, the nozzle (N) can be configured to be movably mounted on a rail (R) and to spray the foaming liquid (121) while moving along the perimeter of the vacuum insulation panel (110). For example, at least two rails (R) can be provided so that the nozzle (N) can move along at least two axes.

[0163] As illustrated in FIG. 9, according to one embodiment, the step of filling the foaming liquid (121) into the inside of the outer frame (31) may be performed by injecting the foaming liquid (121) while leaving the inside of the outer frame (31) open without connecting the inner frame (35) to the outer frame (31) or connecting a foaming mold to the outer frame (31).

[0164] The foaming liquid (121) may include a urethane material and a foaming agent. According to one embodiment, the foaming agent included in the foaming liquid (121) may be composed of water without including a pentane-based material such as cyclopentane. This foaming liquid (121) may be formed under low pressure (for example, approximately 0.2 to 0.4 kg / cm 2 When fired at a pressure of about 75 kg / m, the density is high (for example, about 75 kg / m). 3A foam insulation material (120) having a density of about 100 MPa and high rigidity (e.g., an elastic modulus of about 42.5 MPa) can be formed (hereinafter referred to as the 'low-pressure foaming method'). The numerical values ​​of pressure, density, elastic modulus, etc. explained above with respect to the low-pressure foaming method are only examples, and may vary depending on various conditions, such as the mixing ratio of the foaming liquid (121), the presence or absence of additives such as catalysts, etc.

[0165] In contrast, the foaming agent included in the foaming liquid (121) contains a pentane series material such as cyclopentane and water and is heated under high pressure (e.g., approximately 0.8 to 1 kg / cm). 2 When fired at a pressure of about 25 kg / m, the density is relatively low (e.g., about 25 kg / m). 3 A foam insulation material (120) having a density of about 100 MPa and high rigidity (e.g., an elastic modulus of about 5.5 MPa) can be formed (hereinafter referred to as the 'high-pressure foaming method'). The numerical values ​​of pressure, density, elastic modulus, etc. explained above with respect to the high-pressure foaming method are only examples, and may vary depending on various conditions, such as the mixing ratio of the foaming liquid (121), the presence or absence of additives such as catalysts, etc.

[0166] In this way, compared to the case where the foam insulation (120) is formed using a high-pressure foaming method, it is possible to form a high-density, high-strength foam insulation (120) using a low-pressure foaming method, thereby improving the overall durability of the door (30).

[0167] Thereafter, a step of combining the inner frame (35) and the outer frame (31) as illustrated in Fig. 10 may be performed. The inner frame (35) may be combined with the outer frame (31) in a state where the inner surface (35aa) of the flat portion (35a) is positioned so that the second surface (110b) of the vacuum insulation panel (110) is directed. This allows the vacuum insulation panel (110) to come into contact with the flat portion (35a).

[0168] Since a second adhesive layer (ad2) is formed on the second surface (110b) of the vacuum insulation panel (110), when the flat portion (35a) of the inner frame (35) and the vacuum insulation panel (110) come into contact, the flat portion (35a) and the vacuum insulation panel (110) can be attached to each other. For example, the second adhesive layer (ad2) may include an adhesive, and a step of pressing the inner frame (35) toward the vacuum insulation panel (110) and the outer frame (31) for a predetermined period of time required for the adhesive to harden and for the flat portion (35a) and the vacuum insulation panel (110) to be joined may be performed. For example, as illustrated in FIG. 11, a step of pressing the inner frame (35) toward the vacuum insulation panel (110) and the outer frame (31) using a jig (M2) may be performed during the time that the adhesive hardens. The step of the jig (M2) pressurizing the inner frame (35) can be determined to be at least a time sufficient for the adhesive to harden and for the flat portion (35a) and the vacuum insulation panel (110) to be attached to each other by the second adhesive layer (ad2), and the time can be determined experimentally or empirically, for example.

[0169] For example, the second adhesive layer (ad2) may include a thermosetting adhesive such as a PUR adhesive, in which case the thermosetting adhesive may be exposed to heat and hardened after a certain period of time, thereby attaching the flat portion (35a) and the vacuum insulation panel (110). The time it takes for the thermosetting adhesive to harden and the vacuum insulation panel (110) to be bonded to the flat portion (35a) may vary depending on heating conditions, the application area of ​​the thermosetting adhesive, etc., but it is expected to be significantly shorter than the time it takes for a urethane-based foam to harden and form a foam insulation under general conditions.

[0170] In a state where the inner frame (35) is coupled to the outer frame (31), a step of foaming and curing the foaming liquid (121) injected into the inside of the outer frame (31) can be performed. When the foaming liquid (121) foams, its volume increases, and thus, the foaming insulation (120) can fill even areas of the interior space of the door (30) where the vacuum insulation panel (110) is not arranged, such as the door protrusion (35b) and the area adjacent to the edge of the door (30).

[0171] Through these steps, when the thermosetting adhesive is cured and the vacuum insulation panel (110) is 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 foaming insulation (120), the step of pressurizing the inner frame (35) using the jig (M2) can be completed, and the manufacturing step of the door (30) can be completed.

[0172] According to one embodiment of the present disclosure, a refrigerator may include a main body forming a storage compartment, and a door provided 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 the periphery of the flat portion and protruding from the flat portion toward the storage compartment, and a door insulation material disposed between the outer frame and the inner frame. The door insulation material may include a vacuum insulation panel in contact with the flat portion of the outer frame and the inner frame, and a foam insulation material disposed along the periphery of the vacuum insulation panel and disposed between the door protrusion of the inner frame and the outer frame.

[0173] The above vacuum insulation panel may have a thickness corresponding to the distance between the inner surface of the outer frame and the inner surface of the flat portion.

[0174] The above vacuum insulation panel can be attached to the flat portion by an adhesive.

[0175] The above adhesive may include a thermosetting adhesive.

[0176] The above 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 be in contact with an inner surface of the plate facing the inner frame.

[0177] The above vacuum insulation panel can fill the space between the plate of the outer frame and the flat portion of the inner frame.

[0178] A portion of the above plate may face the door protrusion. The vacuum insulation panel may contact the portion of the above plate facing the door protrusion.

[0179] The above vacuum insulation panel can be attached to the inner surface of the outer frame facing the inner frame.

[0180] The above foam insulation can fill the space between the outer frame, the door protrusion of the inner frame, and the vacuum insulation panel.

[0181] The above foam insulation can fill the space between the inner surface of the frame of the door and the perimeter of the vacuum insulation panel.

[0182] The above foam insulation can be bonded to the above vacuum insulation panel.

[0183] The above vacuum insulation panel may include a porous core material and an outer covering material surrounding the porous core material. The outer covering material may be in contact with the outer frame and the flat portion.

[0184] The above foam insulation may include a urethane material.

[0185] According to one embodiment of the present disclosure, a method for 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 foam liquid into the inner side of the outer frame along the perimeter of the vacuum insulation panel, and joining the inner frame and the outer frame so that the vacuum insulation panel contacts a flat portion of the inner frame of the door.

[0186] The above method may further include applying an adhesive to one surface of the vacuum insulation panel provided to contact the flat portion.

[0187] The method may further include pressing the inner frame toward the vacuum insulation panel and the outer frame using a jig while the adhesive is curing.

[0188] The method may further include forming an adhesive layer for adhering the vacuum insulation panel to the inner surface of the outer frame.

[0189] The method may further include foaming and curing the foam to fill the inner side of a door protrusion provided around the flat portion of the inner frame and protruding from the flat portion.

[0190] According to one embodiment of the present disclosure, a refrigerator may include a main body forming a storage compartment, and a door provided to 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 formed in the center of the inner frame, and a door insulation material disposed between the outer frame and the inner frame. The door insulation material may include a vacuum insulation panel having one surface attached to the outer frame and the other surface attached to the flat portion of the inner frame, and a foam insulation material disposed in an outer direction around the vacuum insulation panel.

[0191] The above outer frame may include a plate facing the flat portion of the inner frame and parallel to the flat portion. The one side of the vacuum insulation panel may be attached to the inner surface of the plate facing the inner frame.

[0192] According to the idea of ​​the present disclosure, the refrigerator door occupies a large volume within the insulation space inside the door by placing the vacuum insulation panels in contact with the plates of the outer frame and the flat portion of the inner frame, respectively, and since foam insulation is formed only in the remaining portion where the vacuum insulation panels are not placed, the manufacturing process and equipment, such as the foaming process, can be simplified.

[0193] According to the idea of ​​the present disclosure, when manufacturing a refrigerator door, the manufacturing process, such as the foaming process, is simplified, and the curing time of the adhesive layer that attaches the vacuum insulation panel to the plate of the outer frame and the flat part of the inner frame is shorter than the curing time of the foam insulation, so that the manufacturing time can be shortened.

[0194] According to the idea of ​​the present disclosure, a vacuum insulation panel having a high insulation efficiency per volume can occupy a large volume within the insulation space inside the door, thereby improving the overall insulation efficiency of the refrigerator.

[0195] The effects according to the idea of ​​the present disclosure are not limited to the effects mentioned above, and other effects not mentioned will be clearly understood by those skilled in the art to which the present invention pertains from the description below.

[0196] The above illustrates and describes specific embodiments. However, the invention is not limited to the above-described embodiments, and those skilled in the art will readily appreciate that various modifications and implementations can be made without departing from the spirit and scope of the invention as set forth in the claims below.

Claims

1. A main body forming a storage room; and A door configured to be opened or closed to open or close the storage room, respectively; The above door, Outer frame; An inner frame coupled to the outer frame and including a flat portion and a door protrusion disposed around the flat portion, the door protrusion protruding from the flat portion and protruding toward the storage compartment when the door is closed; and A door insulation material disposed between the outer frame and the inner frame; The above door insulation, A vacuum insulation panel in contact with the flat portion of the outer frame and the inner frame; and A refrigerator comprising: a foam insulation material arranged along the perimeter of the vacuum insulation panel between the door protrusion of the inner frame and the outer frame; 2. In paragraph 1, A refrigerator in which the vacuum insulation panel has a thickness substantially equal to the distance between the inner surface of the outer frame and the inner surface of the flat portion of the inner frame.

3. In paragraph 1, A refrigerator wherein the above vacuum insulation panel is attached to the flat portion of the inner frame by an adhesive.

4. In paragraph 3, The above adhesive is a refrigerator containing a thermosetting adhesive.

5. In paragraph 1, The above outer frame includes a plate having an inner surface facing the flat portion of the inner frame and being parallel to the flat portion of the inner frame, A refrigerator in which the above vacuum insulation panel is in contact with the inner surface of the above plate.

6. In paragraph 5, A refrigerator in which the vacuum insulation panel fills the space between the plate of the outer frame and the flat portion of the inner frame.

7. In paragraph 5, A portion of the above plate faces the inside of the above door protrusion, A refrigerator wherein the vacuum insulation panel is in contact with the part of the plate facing the inside of the door protrusion.

8. In paragraph 1, A refrigerator in which the vacuum insulation panel is attached to the inner surface of the outer frame facing the inner frame.

9. In paragraph 1, A refrigerator in which the foam insulation fills the space between the outer frame, the door protrusion of the inner frame, and the vacuum insulation panel.

10. In paragraph 1, A refrigerator wherein the foam insulation fills the space between the inner surface of the frame of the door and the perimeter of the vacuum insulation panel.

11. In paragraph 1, A refrigerator in which the above foam insulation is bonded to the above vacuum insulation panel.

12. In paragraph 1, The above vacuum insulation panel includes a porous core material and an outer covering material surrounding the porous core material, A refrigerator in which the above outer material is in contact with the flat portion of the outer frame and the inner frame.

13. In paragraph 1, The above foam insulation is a refrigerator containing urethane material.

14. A method for manufacturing a door configured to open or close to open or close a storage compartment of the refrigerator when installed in the refrigerator, as a door of the refrigerator, Positioning a vacuum insulation panel on the inner surface of the outer frame of the above door; Filling the foam liquid into the inner side of the outer frame along the perimeter of the vacuum insulation panel; A method for manufacturing a door of a refrigerator, comprising: combining an inner frame of the door with the outer frame, the inner frame including a flat portion and a door protrusion disposed around the flat portion, the door protrusion protruding from the flat portion so as to face the storage compartment when the door is installed in the storage compartment and closed; and combining the inner frame and the outer frame such that the vacuum insulation panel comes into contact with the outer frame and the flat portion of the inner frame, and the foaming liquid is foamed and hardened to form a foam insulation material along the perimeter of the vacuum insulation panel between the door protrusion of the inner frame and the outer frame.

15. In paragraph 14, A method for manufacturing a refrigerator door, further comprising: applying an adhesive to one surface of the vacuum insulation panel that is in contact with the flat portion of the inner frame.

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