Refrigerator door having vacuum insulation assembly and method for manufacturing the same

1 . A refrigerator door comprising:

a first door body;

a second door body coupled to the first door body to form a heat insulating space between the first door body and the second door body, the first door body and the second door body defining an exterior of the refrigerator door;

a vacuum insulation assembly provided inside the heat insulating space, the vacuum insulation assembly having a sealed vacuum chamber; and

a foam filled part provided inside the heat insulating space and surrounding at least a portion of an edge of the vacuum insulation assembly,

wherein the vacuum insulation assembly includes:

a coupling part provided along the edge of the vacuum insulation assembly to maintain a vacuum state in the sealed vacuum chamber of the vacuum insulation assembly;

a first casing facing the first door body; and

a second casing coupled to the first casing to form the sealed vacuum chamber between the first casing and the second casing, the second casing facing the second door body,

wherein the coupling part is surrounded by the foam filled part while being spaced apart from a peripheral part inside the heat insulating space,

wherein a gap space is formed between the coupling part and the heat insulating space,

wherein the coupling part couples an edge of the first casing to an edge of the second casing,

wherein the second door body includes:

a first plate defining a side surface of a storage space; and

a second plate connected to the first plate and defining a rear surface of the storage space, the second plate facing the vacuum insulation assembly,

wherein a first end of the second door body extends from the first plate and is located in a filling space provided with the foam filled part, and

wherein a first gap space is formed between the coupling part and the first end of the second door body.

2 . The refrigerator door of claim 1 , wherein the refrigerator door is attached to a refrigerator,

wherein the second door body includes:

the storage space formed in a direction towards a storage compartment of the refrigerator; and

a dyke part protruding from a lower portion of the second door body and defining a bottom of the storage space, and

wherein at least a portion of the dyke part is overlapped with a frame of the refrigerator or a main door of the refrigerator.

3 . The refrigerator door of claim 2 , further comprising a gasket provided between the second door body and the frame of the refrigerator or between the second door body and the main door,

wherein an end of the dyke part protrudes more towards the storage space than the gasket.

4 . The refrigerator door of claim 2 , wherein the dyke part extends to the side surface of the storage space.

5 . The refrigerator door of claim 1 , wherein the vacuum insulation assembly further includes:

a radiant heat shield film provided inside the sealed vacuum chamber, the radiant heat shield film having a coupling hole; and

a pair of spacers respectively provided at opposite sides of the radiant heat shield film, the pair of spacers being assembled to each other through the coupling hole to allow the radiant heat shield film to be spaced apart from both of the first casing and the second casing.

6 . The refrigerator door of claim 1 , wherein a portion where the first plate and the second plate are connected to each other is spaced apart from the second casing of the vacuum insulation assembly to form a second gap space between the second casing and the portion where the first plate and the second plate are connected to each other, and

wherein a width of the first gap space is larger than a width of the second gap space.

7 . The refrigerator door of claim 1 , wherein the first casing is fixed to an inner surface of the first door body, and

wherein the coupling part is provided on the edge of the first casing spaced apart from the inner surface of the first door body.

8 . The refrigerator door of claim 5 , wherein the pair of spacers comprise:

a first spacer on which a boss part protrudes and passes through the coupling hole; and

a second spacer having an assembly groove,

wherein an end of the boss part that passes through the coupling hole is coupled to the assembly groove of the second spacer, and

wherein the boss part has a width widening gradually toward a surface of the first spacer.

9 . The refrigerator door of claim 8 , wherein the radiant heat shield film includes a burring part formed along a rim of the coupling hole, and

wherein the burring part extends in a longitudinal direction of the boss part to cover a surface of the boss part.

10 . The refrigerator door of claim 8 , wherein the second spacer includes a flange part protruding in a direction of the first spacer,

wherein the assembly groove is formed inside the flange part, and

wherein an external diameter of the flange part is larger than an internal diameter of the coupling hole.

11 . The refrigerator door of claim 5 , wherein the radiant heat shield film includes a bead part protruding in a direction of an inner surface of the first casing or an inner surface of the second casing.

12 . The refrigerator door of claim 1 , further comprising an exhaust port connected to the vacuum insulation assembly to connect the sealed vacuum chamber to an external space,

wherein an end of the exhaust port is received in the second door body or is surrounded by the foam filled part.

13 . A refrigerator comprising:

a cabinet;

a main door rotatably provided on the cabinet; and

a sub door provided on the cabinet and rotatable independently from the main door, the sub door being connected to a storage compartment of the cabinet through the main door when opened, the sub door including:

a first door body;

a second door body coupled to the first door body to form a heat insulating space between the first door body and the second door body, the first door body and the second door body defining an exterior of the sub door;

a vacuum insulation assembly provided inside the heat insulating space, the vacuum insulation assembly having a sealed vacuum chamber; and

a foam filled part provided inside the heat insulating space and surrounding at least a portion of an edge of the vacuum insulation assembly,

wherein the vacuum insulation assembly includes:

a coupling part provided along the edge of the vacuum insulation assembly to maintain a vacuum state in the sealed vacuum chamber of the vacuum insulation assembly;

a first casing facing the first door body; and

a second casing coupled to the first casing to form the sealed vacuum chamber between the first casing and the second casing, the second casing facing the second door body,

wherein the coupling part is surrounded by the foam filled part while being spaced apart from a peripheral part inside the heat insulating space,

wherein a gap space is formed between the coupling part and the heat insulating space,

wherein the coupling part couples an edge of the first casing to an edge of the second casing,

wherein the second door body includes:

a first plate defining a side surface of a storage space; and

a second plate connected to the first plate and defining a rear surface of the storage space, the second plate facing the vacuum insulation assembly,

wherein a first end of the second door body extends from the first plate and is located in a filling space provided with the foam filled part, and

wherein a first gap space is formed between the coupling part and the first end of the second door body.

14 . The refrigerator of claim 13 , further comprising a gasket provided between the main door and the sub door,

wherein the second door body further includes:

the storage space formed in a direction towards the storage compartment of the cabinet; and

a dyke part protruding from a lower portion of the second door body and defining a bottom of the storage space,

wherein the dyke part blocks a space between the main door and the sub door, and

wherein the gasket is disposed in the space between the main door and the sub door.