Refrigerator and method for manufacturing refrigerator door

Abstract

Disclosed herein are a refrigerator and a method of manufacturing a door of the refrigerator. The refrigerator includes 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 and including a flat portion and a door protrusion around a perimeter of the flat portion protruding from the flat portion such that the door 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 (VIP) 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 VIP.

1 . A refrigerator, comprising:
 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 including:
 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 including:
 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. 
 
   
     
     
         2 . The refrigerator of  claim 1 , wherein the vacuum insulation panel has a thickness substantially equal to a distance between an inner surface of the outer frame and an inner surface of the flat portion of the inner frame. 
     
     
         3 . The refrigerator of  claim 1 , wherein the vacuum insulation panel is attached to the flat portion of the inner frame by an adhesive. 
     
     
         4 . The refrigerator of  claim 3 , wherein the adhesive comprises a thermosetting adhesive. 
     
     
         5 . The refrigerator of  claim 1 , wherein:
 the outer frame includes a plate having an inner surface facing the flat portion of the inner frame and parallel to the flat portion of the inner frame, and   the vacuum insulation panel contacts the inner surface of the plate.   
     
     
         6 . The refrigerator of  claim 5 , wherein the vacuum insulation panel fills a space between the plate of the outer frame and the flat portion of the inner frame. 
     
     
         7 . The refrigerator of  claim 5 , wherein:
 a portion of the plate faces an interior of the door protrusion, and   the vacuum insulation panel contacts the portion of the plate facing the interior of the door protrusion.   
     
     
         8 . The refrigerator of  claim 1 , wherein the vacuum insulation panel is attached to an inner surface of the outer frame facing the inner frame. 
     
     
         9 . The refrigerator of  claim 1 , wherein the foam insulation fills a space between the outer frame, the door protrusion of the inner frame, and the vacuum insulation panel. 
     
     
         10 . The refrigerator of  claim 1 , wherein the foam insulation fills a space between an inner surface of an edge of the door and a perimeter of the vacuum insulation panel. 
     
     
         11 . The refrigerator of  claim 1 , wherein the foam insulation is coupled to the vacuum insulation panel. 
     
     
         12 . The refrigerator of  claim 1 , wherein:
 the vacuum insulation panel includes a porous core material and an envelope enclosing the porous core material, and   the envelope contacts the outer frame and the flat portion of the inner frame.   
     
     
         13 . The refrigerator of  claim 1 , wherein the foam insulation includes a urethane material. 
     
     
         14 . A method of manufacturing a door of a refrigerator, the door configured to, while installed on the refrigerator, open or close to respectively open and close a storage compartment of the refrigerator, the method comprising:
 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, wherein the inner frame has a flat portion and a door protrusion around a perimeter of the flat portion such that the door protrusion protrudes from the flat portion toward the storage compartment while the door is installed on the refrigerator and is closed, and the coupling couples the inner frame and the outer frame so that the vacuum insulation panel contacts the outer frame and the 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.   
     
     
         15 . The method of  claim 14 , further comprising:
 applying an adhesive to a surface of the vacuum insulation panel contacting the flat portion of the inner frame.