Patent ID: 12196474

MODE FOR CARRYING OUT THE INVENTION

Hereinafter, a refrigerator according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

FIG.1is a perspective view illustrating an outer appearance of a refrigerator according to an embodiment of the present invention,FIG.2is a perspective view illustrating an internal structure of the refrigerator, andFIG.3is a longitudinal cross-sectional view taken along line3-3ofFIG.1.

Referring toFIGS.1to3, a refrigerator10according to an embodiment of the present invention may include a cabinet11including a refrigerating compartment114and a freezer compartment115therein, a pair of refrigerating compartment doors20that are rotatably connected to a front surface of the refrigerating compartment114, and a freezer compartment door that opens and closes the freezer compartment115.

Specifically, the cabinet11may include an inner case111defining the refrigerating compartment114and the freezer compartment115, an outer case112surrounding the outside of the inner case111, and an insulation material113filled between the inner case111and the outer case112.

A cool air duct18including a supply duct181and a return duct182may be disposed between the inner case111and the outer case112, and the cool air duct may be surrounded by the insulation material113. An evaporation chamber116in which an evaporator is provided is defined in a rear side of the freezer compartment115.

The cool air duct18may be defined as a main body-side cool air duct or a cabinet-side cool air duct, and the supply duct181and the return duct182may be defined as a main body-side supply duct and a main body-side return duct or a cabinet-side supply duct and a cabinet-side return duct.

A machine room117in which a portion of a refrigeration cycle including a compressor, a condenser, and a condensation fan is accommodated may be defined in a rear lower side of the cabinet11.

An inlet of the supply duct181communicates with a cool air hole (see reference numeral111cofFIG.3) defined in a side surface of the inner case111, which corresponds to the evaporation chamber116. An outlet of the supply duct181communicates with a cool air supply hole111adefined in the side surface of the inner case111, which defines the refrigerating compartment114.

An inlet of the return duct182communicates with a cool air return hole111bdefined in a side surface of the inner case111, which defines the refrigerating compartment114. An outlet of the return duct182communicates with a cool air hole111ddefined in a side surface of the inner case111, which defines the freezer compartment115.

Also, the freezer compartment door may include a first freezer compartment door12and a second freezer compartment door13. That is, the freezer compartment115may be vertically partitioned into a plurality of regions, and the plurality of freezer compartments115may be opened and closed by the plurality of freezer compartment doors12and13. However, a single freezer compartment and a single freezer compartment door may be provided. The freezer compartment door may be provided as a drawer type door. However, the freezer compartment door may be provided as a pair of rotation-type doors, like the refrigerating compartment door.

The pair of refrigerating compartment doors20may be rotatably connected to left and right edges of a front surface part of the cabinet11by hinge assemblies40by using a vertical axis as a center, respectively.

Also, one or all of the pair of refrigerating compartment doors20may include a main door22having an opening therein and a sub door21disposed on a front surface of the main door22to selectively open and close the opening. A housing23communicating with the opening and having a storage space therein may be provided in the main door22. The housing23may be mounted on a back surface of the main door22as a separate component or integrated with the main door22. That is, the main door22may include a rectangular frame of which the inside is opened and a housing extending from a back surface of the rectangular frame to define a storage space therein.

The sub door21is rotatably coupled to the main door22on the front surface of the main door22. Here, the main door22may be defined as a first door, and the sub door21may be defined as a second door.

Specifically, the main door22may be rotatably connected to the left or right edge of the front surface part of the cabinet11to selectively open and close a portion of the front surface of the refrigerating compartment114.

The inside of the housing23may be vertically partitioned by a partition wall207to define an ice making room201and a chiller room202. Here, the ice making room201may be defined above the chiller room202.

An ice maker24making ice and an ice bin25in which the ice is stored may be accommodated in the ice making room201. The ice bin25is disposed below the ice maker24to receive and store ice dropping down from the ice maker24.

A cool air inflow hole511and a cool air discharge hole522are defined in a side surface of the housing23. Specifically, the cool air inflow hole511and the cool air discharge hole522may communicate with the cool air supply hole111aand the cool air return hole, which are defined in the inner case111, when the main door22is closed, respectively. The cool air inflow hole511and the cool air discharge hole522may be portions that are defined in a cool air supply duct (that will be described later) and a cool air return duct (that will be described later) constituting a door duct assembly (that will be described later), respectively.

The sub door21is rotatably coupled to the front surface of the main door22. Specifically, a rotation shaft of the sub door21is disposed at a position that is adjacent to a rotation shaft of the main door22. The rotation shafts of the sub door21and the main door22may rotate for opening or closing in the same direction. That is to say, the rotation shafts of the main door22and the sub door21may be disposed on the same side surface.

The dispenser30for dispensing water and ice is mounted on the front surface of the sub door21. A structure of the dispenser30will be described in more detail with reference to the following drawings.

As described above, since the ice making room201is defined in the main door22, and the dispenser30is provided in the sub door21, stability of the door hinge may be secured through dispersion of a load.

FIG.4is an enlarged view illustrating a portion A ofFIG.3.

Referring toFIG.4, in the refrigerator10according to an embodiment of the present invention, one of the pair of rotation-type refrigerating compartment doors20has a door-in-door structure.

Specifically, the door-in-door structure may be defined to be represented as a door assembly which opens and close the storage space (e.g., the refrigerating compartment) defined in the main body or cabinet of the refrigerator and includes a main door having a separate storage space with an opened front surface and a sub door rotatably connected to the main door to open and close the opened front surface of the separate storage space. The rotation direction of the main door for opening the storage space defined in the main body of the refrigerator and the rotation direction of the sub door for opening the separate storage space defined in the main door may be the same.

More specifically, the main door22may be rotatably connected to the left or right edge of the front surface of the cabinet11, and the sub door21may be rotatably connected to the left or right edge of the front surface of the main door22. The lateral edge on which the rotation shaft of the sub door21is disposed and the lateral edge on which the rotation shaft of the main door22may be the same.

The housing23may be provided in the main door22, and the ice making room201and the chiller room202may be defined in the housing23. The front surface of the main door22may be opened so that the ice making room201and the chiller room202are accessible by opening the sub door21. An ice making room door80is separately provided in a front opening of the ice making room201so that the ice making room201is exposed to external air although the sub door21is opened.

The dispenser30for dispensing ice made in the ice making room201and drinking water is installed in the sub door21. The drinking water may be supplied from a water tank26mounted inside the cabinet11or the main door22. The water tank26may be connected to a water source that is provided outside the refrigerator by a water supply hose.

A space203ain which the water tank26is mounted is defined in a lower side of the main door22, and a space in which the water tank26is accommodated is defined below the chiller room202. The space in which the water tank26is accommodated may be selectively opened and closed by a water tank cover203.

The dispenser30may be provided in a shape that is inserted into a hole for mounting the dispenser provided in the sub door21. An upper end of the dispenser30may be disposed at a point that is spaced a predetermined distance downward from an upper end of the sub door21. Specifically, the upper end of the dispenser30may be disposed on the same line as a horizontal surface that equally divides sub door21in a vertical direction or disposed at a point that is slightly higher than the horizontal surface. However, the installed position of the dispenser30may change according to the position of the lower end of the ice making room201provided in the main door22.

Specifically, the dispenser30may include a front casing31, a rear casing32, a dispensing button33, a micro switch34, a water faucet (or a drinking water dispensing hole), an outer funnel36, an inner funnel37, a duct cap38, and a discharge duct39.

The outer funnel36and the inner funnel37may have a shape in which separate components are coupled to each other or be injection-molded in a single body. An assembly of the outer funnel36and the inner funnel37may be defined as an ice funnel.

Also, an assembly of the front casing31and the rear casing32may be defined as a dispenser casing.

More specifically, the front casing31is inserted into a dispenser mounting hole defined in the sub door21and fixed to the sub door21. The front casing31may be recessed backward by a predetermined depth to accommodate a container for receiving water or ice. The rear casing32may be fixed to the sub door21in a manner in which the rear casing32is coupled to a rear side of the front casing31. A dispenser liner211may protrudes from a back surface of the sub door21, which corresponds to a portion of the dispenser30. An insulation material may be foamed and filled between the rear casing32and the dispenser liner211.

The dispensing button33may be coupled to the front casing31so as to be tiltable in a front/rear direction. The micro switch34is mounted on the rear casing32that corresponds to a rear side of the dispensing button33. Thus, when a user pushes the dispensing button33, the dispensing button33may contact the micro switch34to generate a signal for dispensing one or all of water and ice.

The dispensing button33may be provided as one button as illustrated in the drawings and be designed to select a water dispensing mode and an ice dispensing mode through a control panel300mounted on the front surface of the sub door21, which corresponds to an upper side of the dispenser30. That is, the user may push a mode selection button provided on the control panel300to select one of the water or ice dispensing modes. Here, when the user pushes the dispensing button33, one of the water and ice may be dispensed.

In another method, the water dispensing button and the ice dispensing button are installed on the dispenser30in a vertical or horizontal direction so that the user pushes a desired button.

The water faucet35may protrude forward from any point of the front casing31, which corresponds to an upper side of the water dispensing button33. The ice funnel may be installed to be tiltable in a front/rear direction at an upper side of the front casing31.

A guide duct207dguiding discharge of ice extends inside the partition wall207, and an inlet of the guide duct207dcommunicates with an ice discharge hole (see reference numeral207aofFIG.6) defined in a front side of the bottom of the ice making room201. An outlet of the guide duct207dis exposed to the bottom surface of the partition wall207and closely attached to an inlet of the discharge duct39in a state in which the sub door21is closed. As illustrated in the drawings, gaskets391and207efor sealing the cool air may be mounted on an edge of the inlet of the discharge duct39and an edge of the outlet of the guide duct207d, respectively. The gaskets391and207emay be closely attached to each other in a state in which the sub door21is closed. Here, the guide duct207dand the discharge duct39may communicate with only the ice making room201, but do not communicate with the chiller room202.

The ice funnel is rotatably connected to the outlet of the discharge duct39, and the outlet of the ice funnel communicates with an opening defined in the upper end of the front casing31and is exposed to the outside of the dispenser30.

The outlet of the discharge duct39is selectively opened and closed by the duct cap38, and the duct cap38is rotatably installed inside the dispenser30. When the duct cap38rotates to open the outlet of the discharge duct39, the ice stored in the ice bin25is discharged to the outside of the dispenser30.

The ice funnel37and the ice dispensing button33may be provided in one body.

Although the structure that is capable of accommodating both the ice maker24and the ice bin25into the ice making room201is described in an embodiment of the present invention, the present invention is not limited thereto.

According to another embodiment, only the ice maker24may be accommodated in the ice making room201, and the ice bin25may be disposed on the back surface of the sub door21. In this case, the ice bin25may be disposed above the dispenser, i.e., above the discharge duct39. A separate insulation wall structure for accommodating the ice bin25may be installed on the back surface of the sub door21.

FIG.5is a perspective view of the door-in-door assembly in a state in which the sub door is opened,FIG.6is a front exploded perspective view of the door-in-door assembly, andFIG.7is a rear exampled perspective view of the door-in-door assembly.

Referring toFIGS.5to7, the door-in-door assembly constituting the refrigerating compartment door20of the refrigerator10according to an embodiment of the present invention includes the main door22and the sub door21.

Specifically, the sub door21and the main door22may be rotatably coupled to the cabinet11by the hinge assembly40.

More specifically, the hinge assembly40includes a main door hinge unit (or a first door hinge unit) connecting the cabinet11to the main door22and a sub door hinge unit (or a second door hinge unit) connecting the main door22to the sub door21.

Specifically, the main door hinge unit includes a main door upper hinge unit (or a first door upper hinge unit)41connecting the cabinet11to a top surface of the main door22and a main door lower hinge unit (or a first door lower hinge unit) connecting the cabinet11to a bottom surface of the main door22.

The sub door hinge unit includes a sub door upper hinge unit (or a second door upper hinge unit)42connecting the main door22to a top surface of the sub door21and a sub door lower hinge unit (or a second door lower hinge unit) connecting the main door22to a bottom surface of the sub door21.

As illustrated in the drawings, when the sub door21is opened, the inlet of the discharge duct39is exposed to the outside, and the gasket391is disposed around an edge of the inlet of the discharge duct39.

The dispenser liner211may further protrude from the back surface of the sub door21, and the inlet of the discharge duct39may be disposed on a top surface of the dispenser liner211.

As illustrated inFIG.4, a top surface of the dispenser liner211on which the inlet of the discharge duct39is disposed is gradually inclined backward. Also, a bottom surface of the partition wall207on which the outlet of the guide duct207dis disposed may be inclined at an angle corresponding to the inclined angle of the top surface of the dispenser liner211. As a result, when the sub door21is closed, the pushing due to shearing force generated while the gasket391disposed around the inlet of the discharge duct39and the gasket207edisposed around the outlet of the guide duct207dare closely attached to each other may be minimized.

A sealing member210is disposed around the back surface of the sub door21. The sealing member210is closely attached to an edge of an opening defined in the front surface of the main door22when the sub door21is closed. As a result, introduction of external air into the housing23through a gap between the sub door21and the main door22or leakage of the cool air within the housing23to the outside may be prevented.

Specifically, the housing23may include an inner housing231and an outer housing232coupled to a rear side of the inner housing231. Also, a door duct assembly (see reference numeral50ofFIG.8) for moving the cool air is installed in an outer surface of the inner housing231. The door duct assembly50is covered by the outer housing232and thus is not exposed to the outside. However, a cool air inflow hole511and a cool air discharge hole522of the door duct assembly50may be exposed to the outside by passing through a side surface of the outer housing232. The door duct assembly50may be defined as a door-side cool air duct assembly. A structure of the door duct assembly50will be described in more detail with reference to the following drawings.

One or plurality of door baskets205may be mounted on the back surface of the outer housing232. A portion of the housing23, which corresponds to the back surface of the chiller room202, may be opened, and the opened portion of the housing23may be selectively opened and closed by a chiller room cover208. A lateral end of the chiller room cover208may be rotatably connected to the housing23. The front opening of the chiller room202is opened and closed by the sub door21.

As described above, the inside of the inner housing231may be partitioned into the upper ice making room201and the lower chiller room202by the partition wall207. The front opening of the ice making room201may be may be opened and closed by the ice making room door80. The ice making room door80may be rotatably hinge-coupled to an edge of the side surface of the front opening of the ice making room201.

The ice discharge hole207amay be defined in the partition wall207. Specifically, the ice discharge hole207amay be disposed closer to a front end of the partition wall207than a rear end of the partition wall207. Particularly, a vertical surface that cut the ice discharge hole207athat equally divides the ice discharge hole207ain the front/rear direction may be disposed at a front side of the vertical surface that equally divides the partition wall207in the front/rear direction. Thus, an inclined angle of the discharge duct39that is closely attached to the ice discharge hole207amay be reduced. As a result, a width of the dispenser30in the front/rear direction may be reduced.

The inclined angle of the discharge duct39may represent an angle between the vertical surface and the discharge duct39. When the ice discharge hole207ais disposed closer to the front end of the partition wall207, the discharge duct39may be substantially vertically inclined.

Specifically, when the sub door21is closed, the dispenser30is accommodated in the chiller room202. Since the more the dispenser decreases in thickness, the more the chiller room202increases in volume, it is advantageous that the inclined angle of the discharge duct39decreases.

A vertical surface that equally divides the ice discharge hole207ain a left/right direction may correspond to a vertical surface that equally divides the partition wall207in the left/right direction.

The guide duct207dis mounted inside the partition wall207, and the inlet of the guide duct207dcommunicates with the ice discharge hole207a. When the ice discharge hole207ais disposed closer to the front end of the partition wall207, i.e., the front end of the ice making room201, the inclined angle of the guide duct207dwith respect to the vertical surface may decrease.

A communication hole207bmay be defined in the partition wall207so that the ice making room201and the chiller room202fluidly communicate with each other. The communication hole207bmay be defined in a left or right edge of the partition wall207to prevent an interference with the ice discharge hole207aand also be defined at a point that is spaced a predetermined distance backward from the ice discharge hole207a. It is preferable that the communication hole207bmay be defined at a point that is closer to a side surface opposite to the side surface of the inner housing231on which the door duct assembly50is mounted. Thus, since the communication hole207bis defined at a point to which the cool air discharged into the ice making room201through the door duct assembly50drops, the cool air may be easily supplied to the chiller room202. A damper assembly may be mounted inside the communication hole207bto adjust an amount of cool air supplied from the ice making room201to the chiller room202. That is, an amount of cool air may be controlled by the damper assembly so that the chiller room202has a temperature greater than that of the ice making room201and less than that of the refrigerating compartment.

FIG.8is a rear perspective of the main door from which the outer housing is removed,FIG.9is an exploded perspective view of the main door ofFIG.8, andFIG.10is an exploded perspective view of the door duct assembly.

Referring toFIGS.8to10, the housing23coupled to the back surface of the main door22may include the inner housing231and the outer housing232. The door duct assembly50may be mounted in a space between an outer surface of the inner housing231and an inner surface of the outer housing232. The insulation material may be foamed and filled into the space between the inner housing231and the outer housing232to prevent the cool air from leaking.

Also, cool air holes through which the cool air is introduced or discharged may be defined in the side surface of the inner housing231on which the door duct assembly50is mounted.

Specifically, the cool air holes defined in the side surface of the inner housing231may include a cool air inflow hole231a, an ice making room-side cool air discharge hole231b, and a chiller room-side cool air discharge hole231c.

More specifically, the cool air inflow hole231amay be defined in the side surface of the inner housing231that defines the ice making room201and disposed in an upper space of the ice making room201.

The ice making room-side cool air discharge hole231bmay be defined in the side surface of the inner housing that defines the ice making room201and disposed in a lower portion of the ice making room201.

The chiller room-side cool air discharge hole231cmay be defined in the side surface of the inner housing231that defines the chiller room202and disposed in a lower portion of the chiller room202.

The door duct assembly50may include a cool air supply duct51and a cool air return duct52. The cool air supply duct51and the cool air return duct52may be disposed to overlap each other in a lateral direction of the inner housing231.

The cool air supply duct51may be a duct that is connected to the supply duct181extending from the side surface of the cabinet11to supply the cool air within the evaporation chamber116into the ice making room201. The cool air return duct52may be a duct that is connected to the return duct182extending from the side surface of the cabinet11to supply the cool air discharged from the chiller room202into the freezer compartment115.

Specifically, the cool air inflow hole511is defined in a lower end of an outer surface of the cool air supply duct51. When the main door22is closed, the cool air inflow hole511may communicate with the cool air supply hole111adefined in the side surface of the inner case111.

The cool air discharge hole512is defined in an upper end of the inner surface of the cool air supply duct51. The cool air discharge hole512communicates with the cool air inflow hole231a.

An upper cool air inflow hole521is defined in an upper end of the inner surface of the cool air return duct52. The upper cool air inflow hole521communicates with the ice making room-side cool air discharge hole231b.

A lower cool air inflow hole523is defined in a lower end of the inner surface of the cool air return duct52. The lower cool air inflow hole523communicates with the chiller room-side cool air discharge hole231c.

The cool air discharge hole522is defined in a lower end of the outer surface of the cool air return duct52. The cool air discharge hole522communicates with the cool air return hole111bdefined in the side surface of the inner case111when the main door22is closed.

Here, the upper cool air inflow hole521may be defined as a first inlet, and the lower cool air inflow hole523may be defined as a second inlet.

FIG.11is a partial longitudinal cross-sectional view taken along line11-11ofFIG.6.

Referring toFIG.11, the partition wall207is disposed between the ice making room201and the chiller room202, and the guide duct207dand the damper assembly200are mounted inside the partition wall207.

Specifically, a bottom surface of the partition wall207in which the outlet of the guide duct207dis disposed is inclined downward. The communication hole207bpasses through the partition wall207at a point that is spaced apart from the guide duct207din the lateral and backward directions. The damper assembly200may be mounted inside the communication hole207bto adjust an amount of cool air supplied from the ice making room201to the chiller room202.

As illustrated in the drawing, the partition wall207may be provided as a portion of the housing23by filling foam into the space between the inner housing231and the outer housing232. Alternatively, the partition wall207may be provided as a separate part and coupled to the inside of the inner housing231.

FIG.12is an exploded perspective view of the damper assembly installed in the partition wall that separates an ice making room from a chiller room.

Referring toFIG.12, the damper assembly200may include an outer box200a, a middle box200b, an inner box200c, a damper200d, and a discharge grille200f.

Specifically, cool air holes200g,200h, and200icorresponding to the communication holes207bmay be defined in the outer box200a, the middle box200b, and the inner box200c, respectively. The middle box200bmay be an insulation member such as Styrofoam.

The damper200dmay be rotatably mounted inside the inner box200cby a damper shaft200eto open and close the cool air hole200idefined in the top surface of the inner box200c. Of course, the damper shaft200emay be connected to a driving motor M that provides rotation force.

The discharge grille200fmay be inserted into a lower end of the outer box200aand then coupled to the middle box200b. A grille having a lattice shape may be disposed on the discharge grille200fto prevent foreign substances within the ice making room201from being introduced into the chiller room202. The discharge grille200fmay be exposed to the chiller room202so that the user or a service man put a hand thereof into the chiller room202to separate the discharge grille200ffrom the chiller room202. That is, after the discharge grille200fis separated from the chiller room202, the damper200dmay be repaired or replaced.

Hereinafter, a circulation structure of the cool air supplied from the evaporation chamber116to the inside of the housing23of the main door22will be described with reference to the accompanying drawings.

FIG.13is a view illustrating a state in which cool air is supplied into and collected from the ice making room and the chiller room, which are provided in the main door.

Referring toFIG.13, the cool air of the evaporation chamber116is supplied into the ice making room201through the cool air supply duct51. Also, ice is made in the ice maker24by using the cool air supplied into the ice making room201, and ice stored in the ice bin25disposed below the ice maker24is maintained in a state in which the ice are not melted or clogged.

A portion of the cool air supplied into the ice making room201is discharged to the cool air return duct52through the ice making room-side cool air discharge hole231b. Also, the rest of the cool air supplied into the ice making room201is supplied into the chiller room202through the communication hole207bdefined in the partition wall207.

Here, an amount of cool air supplied into the chiller room202may be adjusted by an operation of the damper200dthat opens and closes the communication hole207b. For example, a temperature sensor may be mounted on a portion of the inside of the chiller room202. If it is determined that a temperature detected by the temperature sensor is less than a set temperature, the damper200dmay operate by a control unit of the refrigerator to close the communication hole207b. Thus, supercooling of the chiller room202to a temperature of the ice making room may be prevented.

A heater (not shown) may be buried in a wall constituting the chiller room202to operate when the chiller room202is supercooled. Particularly, the heater may be buried in a space between a portion of the inner housing231and a portion of the outer housing232, which define the chiller room202.

The chiller room202may be maintained at a temperature that is greater than that of the freezer compartment and less than that of the refrigerating compartment so that the user utilizes the chiller room202as a purpose for quickly cooling beverages, alcoholic beverages, or water for a short time. The chiller room202may be maintained within a temperature range of about 3 degrees below zero to about 5 degrees below zero.

The cool air supplied to the chiller room202cools items received in the chiller room202and then is discharged to the cool air return duct52through the chiller room-side cool air discharge hole231cdefined in the side surface of the chiller room202.

Here, since the inside of the cool air return duct52has a pressure less than that of the chiller room202, the cool air discharged from the ice making room201to flow along the cool air return duct52may be prevented from being reintroduced into the chiller room202.

FIGS.14and15are a partial perspective view and a partial plan view illustrating a connection structure between a water tube and a power cable of the refrigerator according to an embodiment of the present invention, respectively.

Referring toFIGS.14and15, water supplied from the water source is supplied along a main water supply tube61. The main water supply tube61extends along the inside of the top surface of the cabinet11and then is exposed to the outside by passing through the top surface of the cabinet11.

Specifically, the main water supply tube61extends along the space between the inner case111and the outer case112, which define the top surface of the cabinet11, and then is exposed to the outside by passing through the outer case112at a point that is close to the front end of the cabinet11. Also, the main water supply tube61exposed to the outside of the cabinet11extends into the main door22through the main door upper hinge unit41.

The hinge assembly40includes the main door hinge unit and the sub door hinge unit. The main door hinge unit includes the main door upper hinge unit41and the main door lower hinge unit. Also, the sub door hinge unit includes the sub door upper hinge unit42and the sub door lower hinge unit.

The main door upper hinge unit41includes an upper hinge bracket411and an upper hinge shaft412. The upper hinge bracket411has one end fixed to the top surface of the cabinet11and the other end that further protrudes forward from the front surface of the cabinet11. The upper hinge shaft412extends downward from the other end of the upper hinge bracket411. The upper hinge shaft412has an empty cylindrical shape. Alternatively, the upper hinge shaft412may have a circular transverse section or a C shape in which a slit is defined in one side thereof. Also, the upper hinge shaft412is inserted into the top surface of the main door22.

Specifically, a recess part221into which the main door upper hinge unit41and the sub door upper hinge unit42are seated is defined in the top surface of the main door22. The recess part221may be recessed by a predetermined depth from the top surface of the main door22, and a recessed bottom part may be flat. The recess part221may be disposed in the vicinity of an edge of one surface on which the upper hinge units41and42are seated.

The sub door upper hinge unit42includes an upper hinge bracket421of which one end is fixed to the top surface of the main door22, i.e., the recess part221and an upper hinge shaft422extending downward from the other end of the upper hinge bracket421.

A stepped part212on which the sub door upper hinge unit42is seated is also disposed on the top surface of the sub door21. The stepped part212may have a width that is equal to or less than that of the recess part221. The stepped part212may have a flat bottom that is disposed on the same plane as the bottom of the recess part221. A front end of the stepped part212is disposed at a point that is spaced apart backward from the front surface of the sub door21. Thus, the hinge units41and42may not be seen from the front surface of the sub door21.

The upper hinge shaft412of the main door upper hinge unit41has a diameter greater than that of the upper hinge shaft422of the sub door upper hinge unit42. This is done because the main door upper hinge unit41has to support all loads of the main door22and the sub door21, whereas the sub door upper hinge unit42is enough to support only the load of the sub door21.

Each of the upper hinge shafts312and322is inserted into a position that is closer to the front end than the rear end of each of the main door22and the sub door21. That is to say, a center of the hinge shaft412of the main door upper hinge unit41is disposed at a point that is lean forward from a position that equally divides a distance between the front end and the rear end of the main door22. Of course, the hinge shaft422of the sub door upper hinge unit42may also be disposed at a position that is lean forward from a point that equally divides a distance between the front end and the rear end of the sub door21.

When a rotation center of the main door22approaches the rear end of the main door22, a trace defined by rotation of the edge of the rear end of the main door22approaches the front surface of the cabinet11when the main door22is opened, and thus, possibility of jamming of the user's hand becomes high. In the same point of view, when the sub door21is opened, a trace defined by rotation of the rear end of the sub door21approaches the front surface of the main door22, and thus, the possibility of the jamming of the user's hand becomes high.

Since the hinge shaft412of the main door upper hinge unit41has a diameter greater than that of the hinge shaft422of the sub door upper hinge unit42, a protrusion222may be disposed on the front surface part of the main door22, which corresponds to a portion in which the hinge shaft412of the main door upper hinge unit41is inserted.

Also, a cable through hole220may be defined in any point of the recess part221. The cable through hole220may be defined in a point that is spaced apart from the sub door upper hinge unit42.

Also, a main controller C is mounted on the top surface of the cabinet11, and a cable unit CL extends from the main controller C. The cable unit CL is inserted into the upper hinge shaft412of the main door upper hinge unit41.

A main door controller for controlling operations of the temperature sensor (not shown) and the heater (not shown), which are installed in the ice maker24and the chiller room202within the ice making room201may be provided on the main door22.

The control panel300for controlling an operation of the dispenser30and an operation condition of the refrigerator may be provided on the sub door21.

The cable unit CL includes a main door cable unit CL1(or a first door cable unit) extending from the main controller C up to the main door22and a sub door cable unit CL2(or a second door cable unit) extending from the main controller C up to the sub door21via the main door22. The main door cable unit CL1and the sub door cable unit CL2may be inserted into a single cable hose.

The cable unit CL extending from the main controller C is inserted into the upper hinge shaft412of the main door upper hinge unit41to extend into the main door22. Since the upper hinge shaft412of the main door upper hinge unit41has an inner diameter greater than that of the upper hinge shaft422of the sub door upper hinge unit42, all the main water supply tube61and the cable unit CL may be inserted into the upper hinge shaft412.

The cable unit CL may be divided into the main door cable unit CL1and the sub door cable unit CL2in the main door22. The main door cable unit CL1extends to a controller (not shown) provided in the main door22. The sub door cable unit CL2is taken again out of the main door2through the cable through hole220defined in the top surface of the main door22.

The sub door cable unit CL taken out through the cable through hole220is inserted into the upper hinge shaft422of the sub door upper hinge unit42. Since the upper hinge shaft422has a relatively less diameter, only the second sub cable unit CL1may be inserted into the upper hinge shaft422.

FIG.16is a rear perspective view of the door-in-door assembly according to an embodiment of the present invention,FIG.17is a front partial perspective view of the main door,FIG.18is an enlarged perspective view of a portion D ofFIG.17, andFIG.19is a cross-sectional view taken along line19-19ofFIG.17.

Referring toFIGS.16to19, the main water supply tube61inserted through the upper hinge shaft412of the main door upper hinge unit41extends downward along the edge of the side surface of the main door22.

Specifically, the main door22may include a front part22adefining the front surface thereof and a rear part22bdefining the back surface thereof. The door duct assembly50and the water supply tubes may be accommodated in a space defined between the front part22aand the rear part22b. Also, a foamed insulation material is filled into the space between the front part22aand the rear part22b.

The inner housing231constituting the housing23may be a portion of the front part22a, and the outer housing232may be a portion of the rear part22b.

Specifically, the water tank26is mounted on the lower end of the main door22, and the main water supply tube61is connected to the water tank26. The water tank26may be disposed at a point that is close to a side surface opposite to the side surface of the main door22from which the main water supply tube61extends. That is, the water tank26may be disposed at a position that is close to a side surface opposite to the side surface in which the rotation center is defined.

Specifically, a space for accommodating the water tank26, i.e., a water tank accommodation part203ais defined in a lower end of a back surface of the rear part22bconstituting the main door22, i.e., a point corresponding to a lower side of the outer housing232defining the chiller room202. The water tank26is accommodated into the water tank accommodation part, and the water tank accommodation part is covered by the water tank cover203.

An opening232ais defined in a portion of the rear part22b, which corresponds to a side of the water tank accommodation part. Thus, the main water supply tube61may be connected to the water tank26. Also, the opening232amay also be covered by the water tank cover203and thus not be exposed to the outside. The main water supply tube61is connected to an inlet of the water tank26, and a switching valve V2is mounted on an outlet of the water tank26. Since only the water tank cover203is opened so as to repair the water tank26and the switching valve V2, it is unnecessary to disassemble the main door22.

The main water supply tube61passes through the upper hinge shaft412of the main door upper hinge unit41to extend up to the lower end of the main door22and then is bent. The main water supply tube61passes through the opening232aand is connected to the inlet of the water tank26.

The switching valve V2may be a three-way valve. A dispenser water supply tube62may be connected to one of two outlets, and an ice maker water supply tube63may be connected to the other outlet

Specifically, the ice maker water supply tube63passes through the opening232ato extend up to the ice maker24along the edge of the side surface of the main door22. That is, all the ice maker water supply tube63and the main water supply tube61extend along an edge of a hinge-side side surface of the main door22.

The dispenser water supply tube62extends from the outlet of the switching valve V2to pass through the opening232a. Then, the dispenser water supply tube62passes through the front part22aand is exposed to the lower end of the front surface of the main door22.

Although the housing23constituting the ice making room201and the chiller room202is integrated with the main door22as one body in the current embodiment, the housing23may be provided as a separate component and then mounted on the main door.

As illustrated inFIGS.17and18, a stepped part213is disposed on the bottom surface of the sub door21. The stepped part213is stepped upward from a point that is spaced apart backward from the front surface of the sub door21, like the stepped part212disposed on the top surface of the sub door21.

Specifically, the main door lower hinge unit43constituting the main door upper hinge unit includes a lower hinge bracket431and a lower hinge shaft432. The sub door lower hinge unit44constituting the sub door hinge unit includes a lower hinge bracket441and a lower hinge shaft442. The lower hinge shaft432may have the same diameter as the upper hinge shaft422.

More specifically, the lower hinge bracket431of the main door lower hinge unit43is fixed to the front surface of the cabinet11, and the lower hinge shaft432is inserted into the edge of the bottom surface of the main door22. An auto closing module (not shown) is provided in the lower hinge shaft432to automatically close the main door22when the main door22is opened at an angle less than about 90 degrees.

The lower hinge bracket441constituting the sub door lower hinge unit44has one end fixed to the front surface of the main door22and the other end in which the lower hinge shaft442is disposed. The lower hinge bracket441may include a vertical part fixed to the front surface of the main door22, i.e., the lower end of the front surface of the front part22aand a horizontal part horizontally bent forward from an upper end of the vertical part to extend. The lower hinge shaft442extends upward from a front end of the horizontal part, and the lower hinge shaft442has an empty cylindrical shape.

The vertical part of the lower hinge bracket441is fixed to a seat part disposed on the front surface of the main door22. The lower hinge shaft442passes through a top surface of the stepped part213and is inserted into the sub door21. A bracket member made of a metal material may be mounted on the top surface of the stepped part213. The lower hinge shaft442may pass through the bracket member and then pass through the top surface of the stepped part213and be inserted into the sub door21.

A guide groove223for guiding the dispenser water supply tube62is recessed and defined in a lower portion of the front part22adefining the front surface of the main door22. A recess surface223cthat is further recessed than other portions may be designed to be defined in the front surface of the main door22to which the vertical part of the lower hinge bracket441is fixed.

The dispenser water supply tube62extending from the switching valve V is inserted into the lower hinge shaft442of the sub door lower hinge unit44and then led into the sub door21. Then, the dispenser water supply tube62led into the sub door21extends upward along the edge of the side surface of the sub door21to extend up to the water faucet35of the dispenser30.

Specifically, the guide groove223may be provided to minimize possibility of bending of the dispenser water supply tube62while the dispenser water supply tube62passes through the front surface of the main door22to extend up to the lower hinge shaft442.

A folding prevention member621may be disposed around an outer circumferential surface of the dispenser water supply tube62extending up to the lower hinge shaft442by passing through the front surface of the main door22. The folding prevention member621may be a spring member that has predetermined elasticity and is wound around the circumferential surface of the dispenser water supply tube62. The folding prevention member621may be a plastic tube member having predetermined rigidity.

As illustrated inFIG.19, a guide groove223may be recessed in the front part22adefining the front surface of the main door22.

Specifically, the guide groove223includes a first recess surface223ainclined at a predetermined angle with respect to the front surface of the front part22aand a second recess surface223binclined in a direction opposite to the first recess surface223a. The first recess surface223aand the second recess surface223bmay form a V-shaped recess part having a predetermined angle θ therebetween.

More specifically, the angle θ defined by the first recess surface223aand the second recess surface223bmay be defined as the sum of a first inclination angle θ1defined by a vertical surface k, which passes through a point at which the first recess surface223aand the second recess surface223bcontact each other and is parallel to the side surface of the main door22, and the first recess surface223aand a second inclination angle θ2defined by the second recess surface223band the vertical surface k. The first inclination angle θ1may be greater than the second inclination angle θ2.

When the second recess surface223bis parallel to the vertical surface k, the dispenser water supply tube62may pass through the guide groove223to extend up to the lower hinge shaft442in a bent state. To minimize this possibility, the second recess surface223bmay be inclined somewhat.

A tube through hole220dmay be defined in the second recess surface223b. Thus, the dispenser water supply tube62extending from the switching valve V2may extend up to the lower hinge shaft442.

A portion of the dispenser water supply tube62extending from the switching valve V2up to the tube through hole220dmay pass through a guide pipe600so as to be minimized in bending thereof. An end of the guide pipe600, which corresponds to a lead-out side of the dispenser water supply tube62, may be fixed to a back surface of the second recess surface223b.

FIG.20is a view illustrating an arranged structure of a water supply tube and a cable of the refrigerator according to an embodiment of the present invention.

Referring toFIG.20, a main valve v1is mounted at any point of a water source tube60extending from an external water surface such as a faucet. The main valve v1may be installed in the machine room117of the refrigerator10. The main valve v1may be a pilot valve.

Specifically, the water source tube60extending from an outlet of the main valve v1may extend upward along the inside of the rear wall of the cabinet11or the outer circumferential surface of the rear wall of the cabinet11. Also, the water source tube60may pass through the inner case111of the cabinet11defining the rear wall of the refrigerating compartment114and be connected to a filter assembly f mounted inside the refrigerating compartment114.

The main water supply tube61extending from an outlet of the filter assembly f passes through the top surface of the cabinet11and is exposed to the outside. Then, the main water supply tube61is led into the main door22through the upper hinge shaft412of the main door upper hinge unit41. The main water supply tube61led into the main door22is connected to the inlet of the water tank26. The dispenser water supply tube62branched from the switching valve V2passes through the front surface of the lower end of the main door22and is exposed to the outside. Then, the dispenser water supply tube62is led into the sub door21through the lower hinge shaft442of the sub door lower hinge unit44. The dispenser water supply tube62led into the sub door21extends up to the water faucet35disposed on the top surface of the dispenser30.

The ice maker water supply tube63branched from the switching valve V2extends up to a water supply part of the ice maker along the side surface of the main door22.

The cable unit CL extending from the main controller C is led into the main door22through the upper hinge shaft412of the main door upper hinge unit41. The main door cable unit CL1constituting the cable unit CL is connected to a main door controller Cl provided in the main door22.

The sub door cable unit CL2constituting the cable unit CL passes through the top surface of the main door22and is exposed to the outside. Then, the cable unit CL is led into the sub door21through the upper hinge shaft422of the sub door upper hinge unit42. The sub door cable unit LC2led into the sub door21may be connected to the control panel provided on the sub door21.

As described above, the water supply tube and the power cable, which extend from the cabinet11, may be respectively led into the doors through the hinge shafts constituting the door hinges, and the plurality of water supply tubes may be divided and led into the upper hinge shaft and the lower hinge shaft. Thus, the hinge according to the related art may be used as it is without changing in diameter.

FIG.21is a perspective view illustrating a connection structure between an ice making assembly and the door duct assembly according to an embodiment of the present invention, andFIG.22is a perspective view of the ice making assembly according to an embodiment of the prevent invention.

Referring toFIGS.21and22, an ice making assembly I according to an embodiment of the present invention is provided a DID door assembly. Particularly, the ice making assembly I may be installed in the ice making room201provided in the upper side of the main door22.

Specifically, supply of cool air into the ice making room201may be performed through the door duct assembly50installed in the side surface of the main door22. The door duct assembly50is connected to a supply duct181and the return duct182, which are buried in the side surface of the cabinet11, to perform circulation of cool air between the evaporation chamber116, the ice making room201, and the freezer compartment115.

The ice making assembly I may include the ice maker24making ice, the cool air guide duct28mounted on the bottom surface of the ice maker24to spread the cool air supplied from the cool air supply duct51toward the ice maker24, the ice bin25storing the ice made in the ice maker24, and an ice discharge adjustment module250installed in the ice bin25to adjust a shape of the discharged ice.

A mounting plate27is mounted inside the ice making room201. The mounting plate27is closely attached to the bottom and the rear wall of the ice making room201. The ice maker24is fixed to an upper portion of the mounting plate27, and the ice bin25is separably disposed below the ice maker24.

A fixing bracket29may be disposed on a rear side of an upper end of the mounting plate27. A water supply hose guide part291guiding an outlet of the ice maker water supply tube63to the ice maker24may be disposed on the fixing bracket29. The fixing bracket29is fixed and mounted on the outer rear surface of the ice making room201. That is, a hole covered by the fixing bracket29and a hole through which the water supply hose guide part291passes are defined in the rear surface of the ice making room201. The fixing bracket29may be fixed and mounted in the holes.

FIG.23is an exploded perspective view of the ice making assembly,FIG.24is a rear perspective view of an ice bin constituting the ice making assembly,FIG.25Ais a plan view of the ice bin,FIG.25Bis an enlarged perspective view illustrating the inside of the ice bin,FIG.25Cis a front view illustrating the inside of the ice bin, andFIG.26is a longitudinal cross-sectional view taken along line26-26ofFIG.23.

Each of components constituting the ice making assembly will be described with reference toFIGS.23to26.

First, the mounting plate27will be described.

When the ice maker24is directly fixed and mounted on the rear surface of the ice making room201, the wall defining the ice making room201may be bent in an uneven shape by heat while the insulation material is filled into the main door22. As a result, the ice maker may not be mounted at a regular position, and also, the discharge hole of the water supply tube connected to the ice maker may not be disposed at a regular position.

To solve the above-described limitations, after the insulation material is completely foamed into the main door22, the mounting plate27is mounted on the wall of the ice making room201, and then, the ice maker24is mounted on the mounting plate27.

In addition, since the mounting plate27is provided, a blade motor (that will be described later) and a gear assembly (that will be described later) may be hidden behind the mounting plate27. Thus, although the ice bin25is separated, the blade motor and the gear assembly are not exposed to the outside.

Specifically, the mounting plate27includes a bottom part271disposed on the bottom of the ice making room201and a rear surface part272bent upward from a rear end of the bottom part271to extend and then closely attached to the rear wall of the ice making room201.

An ice discharge hole276is defined in a center of a front end of the bottom part271to communicate with the cool air discharge hole277defined in the bottom of the ice making room201.

Also, a stepped part278is disposed on a rear edge of the bottom part271, and the cool air discharge hole277is defined in the stepped part278. The cool air discharge hole277communicates with the communication hole207bdefined in the partition wall207.

The stepped part278may protrude upward from the bottom part271to prevent ice pieces dropping onto the bottom part271or water generated by melted ice from being introduced into the cool air discharge hole277.

A blade motor cover part273protrudes from an edge portion at which the bottom part271and the rear surface part272contact each other. The blade motor cover part273is disposed on an edge of a side surface opposite to the cool air discharge hole277. That is, when the blade motor cover part273is disposed on one side of the left and right edges of the mounting plate27, the cool air discharge hole277may be defined in the other side of the left and right edges. Thus, a portion of cool air supplied to the ice making room201may be smoothly supplied to the chiller room202through the communication hole207b.

A gear accommodation part274into which the gear assembly is accommodated is defined in the rear surface part272. The gear accommodation part274slightly protrudes forward from the configuration of the gear assembly. A gear shaft hole275through which a gear shaft passes is defined in any point of the gear accommodation part274.

The ice maker24is mounted on an upper end of a front surface of the mounting plate27. Specifically, the ice maker24includes an ice tray241in which a plurality of cells2412for making ice are provided, an ejector244provided above the ice tray241to eject the ice made in the cells2412, an ice separating motor243mounted on one surface (a left surface inFIG.22) of the ice tray241to rotate the ejector244, a water supply part245disposed above the other surface (a right surface inFIG.22) of the ice tray241, and an ice separating guide242(or called a tray cover) covering a portion or entire surface of the top surface of the ice tray241.

The ice separating guide242includes a top surface part2423extending from a front side of the ejector244to a front end of the ice tray241and a front surface part2421bent from an end of the top surface part2423to cover an entire surface of the ice tray241. A plurality of cool air holes2422may be defined in the front surface part2421.

The front surface part2421is spaced apart from the front surface of the ice tray241, and the top surface part2423is a surface along which the ice ejected by the ejector244is slid.

The cool air guide duct28is fixed to a bottom surface of the ice tray241. Specifically, the cool air discharge hole512defined in the upper end of the cool air supply duct51constituting the door duct assembly50is connected to the cool air inflow hole231adefined in the side surface of the ice making room201. A suction hole of the cool air guide duct28is closely attached to the cool air inflow hole231awithin the ice making room201.

In the related art, the cool air guide duct28for guiding the cool air to the ice maker is disposed above the ice maker24. The cool air introduced to the side surface of the ice making room201through the cool air supply duct51flows to a side surface opposite to the ice making room201and then is bent to a rear side of the ice maker24. Then, the cool air collides with the rear surface part272of the mounting plate27to descend to a lower side of the ice making room201and then flows again to a front side of the ice making room201.

When the cool air guide duct28is disposed above the ice maker24, the ice maker24has to be designed so that a vertical width between the top surface of the ice making room201and the ice maker24is greater than a height of the cool air guide duct28. As a result, it is limited to increase a height of the ice bin25. Particularly, in the structure in which the separate chiller room is added to the lower side of the ice making room, it is very disadvantageous that the cool air guide duct28is disposed above the ice maker24.

The ice bin25is mounted below the cool air guide duct28. Here, the ice bin25is separable from the ice making room201.

Specifically, the ice bin25includes a case and the ice discharge adjustment module250installed in the case. The case may include a front case251and a rear case252coupled to a rear side of the front case251. According to design conditions, the front case251may include an upper part251aand a lower part251b, but the present invention is not limited thereto. For example, the front case251may be provided as a single body. The upper part251amay have a structure that is inserted slidably from an upper side of the lower part251b. The upper part251is made of a transparent material and also designed so that the user is capable of confirming the inside of the ice bin25.

Although the front case251defines front and side surfaces of the ice bin25, the present invention is not limited thereto. For example, the rear case252may be designed to define the rear surface, both side surfaces, and the bottom part of the ice bin25. Of course, the case may be provided as a single injection-molded part.

The rear case may include a back surface part2521, a bottom part disposed on a lower end of a front surface of the back surface part2521, and an ice discharge hole252bdefined in an approximate center of the bottom part.

The bottom part may include a left inclination part2522, a right inclination part2523, a blade accommodation part disposed between the left inclination part2522and the right inclination part2523, and an ice storage part2529. The left inclination part2522is inclined downward from a lower end of a left surface of the case to a center of the case, and the right inclination part2523is inclined downward from a lower end of a right surface of the case to a center of the case. The ice storage part2529and the blade accommodation part are disposed between the lower ends of the left and right inclination parts2522and2523.

The ice storage part2529is disposed at a rear side of the blade accommodation part. As illustrated inFIG.26, the bottom part of the ice storage part2529is inclined downward toward the blade accommodation part.

A blocking wall2528is disposed between the ice storage part2529and the blade accommodation part. The blocking wall blocks only a portion of the vertical surface that separates the ice storage part2529from the blade accommodation part. The vertical surface that is not blocked by the blocking wall2528is opened to define an ice through hole252a. That is, ice, which is received in the ice storage part2529, of ice dropping from the ice maker24is guided to the blade accommodation part through the ice through hole252a.

Here, the ice storage part2529may be defined as an ice storage region, and the blade accommodation part may be defined as an ice discharge region. A portion of a boundary surface between the ice storage region and the ice discharge region is partitioned by the blocking wall2528, and the other portion of the boundary surface is opened to define the ice through hole252a.

A left edge of the blade accommodation part is defined by a discharge guide part2524that extends at a predetermined curvature from a front end of the blocking wall2528of the lower end of the left inclination part2522. The discharge guide part2524may be rounded at the same curvature as a rotation trace of the rotation blade that will be described later.

A shutter256that will be described later is rotatably mounted on a right edge of the blade accommodation part. A space between a lower end of the discharge guide part2524and a lower end of the shutter256is defined as the ice discharge hole252b. The ice discharge hole252bmay ascend or descend according to a position of the lower end of the shutter.

That is, in a crushed ice dispensing mode, an end of the discharge guide part2524and an end of the shutter256may be closest to each other, i.e., a left/right width of the ice discharge hole252bmay be minimized. In a cubed ice dispensing mode, the shutter256may rotate to become a state in which the end of the discharge guide part2524and the end of the shutter256are farthest away from each other, i.e., the left/right width of the ice discharge hole252bmay be maximized.

The ice discharge adjustment module250mounted inside the case of the ice bin25may include a shaft253extending from the rear surface to the front surface of the ice bin25, a mixing blade257and a plurality of rotatable blades255, which rotate together with the shaft253, a plurality of fixed blades254having one end fixed to an end of the discharge guide part2524and the other end fixed to the shaft253, and a shutter256selectively rotating according to the ice dispensing modes.

Specifically, the mixing blade257is disposed within the ice storage part2529. When the shaft253rotates, the mixing blade257rotates together with the shaft253to stir ices stored in the ice storage part2529, thereby preventing the ices from being clogged.

In the ice bin mounted on the door ice maker assembly according to the related art, the front/rear width of the ice bin, which corresponds to the extension direction of the shaft, decreases to realize a slim refrigerator door. As a result, only the accommodation part in which the fixed blades and the rotatable blades are accommodated is provided, but the ice storage part2529is not provided.

However, in the structure in which the ice making room and the chiller room are vertically disposed in one door according to the present invention, the vertical width of the ice making room may be slightly reduced by the chiller room. In the above-described conditions, it is preferable that the front/rear width of the ice bin increase so as to maintain an ice storage amount of ice bin to the same level. As a result, the storage space corresponding to the ice storage part2529may be secured. The bottom part of the ice storage part2529is designed to be inclined downward toward the blade accommodation part so that ices are not accumulated in the ice storage part2529, but moved to the blade accommodation part through the ice through hole252a.

A spaced space is defined between the bottom part of the ice storage part2529and the rearmost rotatable blade of the plurality of rotatable blades255. In an mode except for the ice dispensing mode, the ice stored in the ice storage part2529may be discharged through the ice discharge hole252bvia the spaced space. To prevent this phenomenon from occurring, the blocking wall2528is disposed at a portion corresponding to the boundary surface between the ice storage part2529and the blade accommodation part.

The blocking wall2528may not block the entire boundary surface and thus be not disposed at the ice through hole252a. Thus, the ice may be discharged through the spaced space between the ice through hole252aand the rearmost rotatable blade at the ice through hole252a. However, since the shutter256is disposed at the front of the ice through hole252a, the ice may not be discharged by the shutter256.

The plurality of fixed blades254are disposed between the plurality of rotatable blades255and also disposed on one side of the left and right sides with respect to a center of the shaft253. The shutter256is rotatably installed at a side opposite to the fixed blade254. The fixed blade254and the rotatable blade255are disposed in the blade accommodation part to allow ice guided to the blade accommodation part through the ice through hole252aor ice directly dropping from the ice maker24to the blade accommodation part to be discharged through the ice discharge hole252bin one state of the cubed ice or crushed ice.

The shaft253may include a shaft body253a, a plurality of spacers253csurrounding an outer circumferential surface of the shaft body253a, and a cap253bfixed to an end of the shaft body253a. The plurality of spacers253cmay be inserted between the members to always maintain a designed space between the mixing blade257, the fixed blades254, and the rotatable blades255.

Referring toFIG.25, the shutter256may include a shutter body2561and a protrusion2562protruding from a top surface of the shutter body2561. The protrusion2562is disposed between the plurality of rotatable blades255to prevent ice from being discharged through a space between the plurality of rotatable blades255in the mode except for the ice dispensing mode.

The shutter body2561may include one end on which the shutter shaft256ais disposed and the other end opposite to the one end. Also, the shutter body2561may include a first side edge adjacent to the ice through hole252aand a second side edge adjacent to a back surface of the front case251. That is, the second side edge may be an edge opposite to the first side edge.

The protrusion2562may protrude from any point of a top surface of the shutter body2561to extend up to the other end. The protrusion2562is disposed between the rotatable blades255adjacent to each other. Here, the protrusion2562has to be disposed at a point between the first side edge and the rotatable blades255.

The shutter256may be provided in plurality that are disposed parallel to each other. Alternatively, a single shutter having a relatively large width may be provided. The plurality of protrusions2562may protrude from the top surface of the shutter body2561.

When the protrusion2562is not provided at a point corresponding to the space between the first side edge and the rotatable blade255that is closest to the first side edge, ice may be broken in a cubed ice discharge mode.

Specifically, referring to an ice piece picture expressed by a dotted line, when the protrusion2562is not provided, one end of an ice piece may be disposed below the mixing blade257, and the other end may be disposed below the rotatable blade255. In this state, when the shaft253rotates in a clockwise direction in the drawing so as to discharge the cubed ice, the other end of the ice piece may be compressed downward by the rotatable blade255.

Simultaneously, since the mixing blade257rotates in the same direction as the rotatable blade255, the one end of the ice piece may be compressed downward. Thus, when the rotatable blade255continuously rotates, both ends of the rotatable blade255and the mixing blade257may break the ice piece jammed therebetween.

To minimize this limitation, the protrusion2562has to be provided on the edge of the top surface of the shutter body2561that is adjacent to the portion in which the ice through hole252ais defined. Thus, possibility in which the ice pieces disposed on the bottom of the ice storage part2529pass through the ice through hole252amay be minimized by the protrusion2562.

Although a region in which the protrusion2562is not provided between the rotatable blades adjacent to each other exists in the drawings, this may be a matter of selection in design. As expressed by the dotted line, the protrusion2562may be provided in the empty region.

Referring toFIG.24, a stepped part or recess part for forming a cool air descending passage R may be provided on rear edges of the cases251and252constituting the ice bin25.

Specifically, when the ice bin25is disposed on the mounting plate27, the cool air discharge hole277is disposed at the rear edge of the ice bin25. To smoothly supply a portion of cool air supplied to the ice making room201to the chiller room202through the cool air discharge hole277, the cool air descending passage R may be defined above the cool air discharge hole277.

For this, the rear edge of the ice bin25(or the case) corresponding to a direct upper side of the cool air discharge hole277may be bent or recessed into the ice bin25.

In the current embodiment, a first bent part2525in which the rear end of the side surface of the ice bin25is bent to the inside of the ice bin25and a second bent part2526in which the edge of the rear surface of the ice bin25is bent to the inside of the ice bin25are provided. However, the present invention is not limited thereto. The bent part may be smoothly rounded at a predetermined curvature and recessed. Thus, when the ice bin25is mounted on the mounting plate27, the cool air descending passage R may be completely formed by the bent parts2525and2526, the rear surface part272of the mounting plate27, and the side surface of the ice making room201.

One or plurality of cool air holes2527(or cool air slits) may be defined in upper portions of the first and second bent parts2525and2526. Thus, a portion of cool air descending into the ice bin25is discharged through the cool air hole2527and then descends along the cool air descending passage R.

Here, the formation point of the cool air descending passage R may change according to the position of the cool air discharge hole277. For example, the cool air discharge hole277may be defined in a point that is spaced apart from the rear edge toward a center of the rear surface of the ice bin25, but not the rear edge of the ice bin25. Thus, the rounded part or bent part for defining the cool air descending passage R may have a U-shaped transverse section or an arc-shaped transverse section, but not an L-shape transverse cross-section. That is to say, only the rear surface part of the case may be bent, stopped, or recessed according to the position of the cool air discharge hole277in addition to the bending of the edge portion at which the side surface and the back surface part of the case defining the ice bin25contact each other.

To form the cool air descending passage R, a portion at which a portion of the case of the ice bin25is deformed may be defined as a recess part, a stepped part, or a cool air descending passage formation part.

Here, although the case of the ice bin25is completely assembled by being coupled to the front case251and the rear case252, the case of the ice bin25may be provided as a single part. Thus, when the shape of the ice bin25is generally defined, the ice bin25may be defined to be provided with a front surface part, a back surface part, a left surface part, a right surface part, a bottom part, and an opened top surface part. The bottom part may be defined as a left inclination part that is inclined downward from a lower end of the left surface, a right inclination part that is inclined downward from a lower end of the right surface, and the ice storage part and ice discharge part, which are disposed between ends of the left and right inclination parts. The structure in which the ice storage part is disposed at a rear side of the ice discharge hole, and the bottom part is inclined downward toward the ice discharge hole may be described.

Also, the structure in which the cool air descending passage formation part including the first and second bent parts is disposed on the edge portion at which the side surface and the back surface part of the ice bin25contact each other may be described. The cool air descending passage formation part may be disposed on the back surface part of the ice bin25according to the position of the communication hole.

Referring toFIG.26, a gear assembly G is disposed at a rear side of the rear case252of the ice bin25. Although not shown in the cross-sectional view ofFIG.26, as described above, the gear assembly G is disposed between the mounting plate27and the rear wall of the ice making room201.

The blade motor (see reference symbol M1ofFIG.33) supplying rotation force to the gear assembly G is disposed at a front side of the gear assembly G and covered by the blade motor cover part273disposed on the mounting plate27. The rear case252of the ice bin25is disposed at a front side of the mounting plate27.

A gear shaft G1protruding from the gear assembly G passes through the gear shaft hole275defined in the mounting plate27to extend to the rear surface of the ice bin25. A connector G2is connected to the gear shaft G1and engaged with a connector receiver258mounted on the rear surface of the ice bin25to rotate in one body.

A rear end of the shaft body253aof the shaft253is fixed to the connector receiver258to rotate together with the connector receiver258in one body. A mounting hole in which the connector receiver258is mounted is defined in the rear case252of the ice bin25. The connector receiver258is covered by the receiver cover259. The shaft body253apasses through the receiver cover259to extend to the front surface of the ice bin25.

FIG.27is a front view of the mixing blade constituting the ice discharge adjustment module installed in the ice bin according to an embodiment of the present invention.

Referring toFIG.27, as described above, a blade accommodation part in which, so-called, a blade unit including the rotatable blade255and the fixed blade254is accommodated and an ice storage part2529disposed at a rear side of the blade accommodation part are disposed in the ice bin25according to an embodiment of the present invention.

Specifically, the ice directly dropping into the blade accommodation part may be discharged in a cubed ice state or crushed ice state according to the rotation direction of the rotatable blade255. On the other hand, the ice dropping into the ice storage part2529may be stored for a predetermined time without directly moving to the blade accommodation part.

Also, a phenomenon in which the ices are clogged for the storage period may be prevented. To prevent this phenomenon from occurring, the mixing blade257is disposed within the ice storage part2529. The mixing blade257is mounted on the shaft253and then rotates together with the shaft253in one body in a clockwise direction or counterclockwise direction.

The mixing blade may include a center part2571, a first extension part2573extending from the center part2571, and a second extension part extending from the center part2571in a direction opposite to the extension direction of the first extension part2573.

Specifically, a shaft hole2572may be defined in the center part2571. The shaft253passing through the shaft hole2572may have a non-circular cross-section. This is done for preventing the mixing blade257from being stopped or idling when the shaft253rotates.

A catching recess2575that is concavely recessed is defined in each of both edges of each of the first and second extension parts2573and2574. The mixing blade257rotates in a first direction (for example, a clockwise direction) in a cubed ice mode and rotates in a second direction (for example, a counterclockwise direction) in a crushed ice mode. Thus, since it is necessary to mix the ices stored in the ice storage part2529regardless of the modes, the catching recesses may be provided on all both sides of the first and second extension parts2573and2574.

Each of the first extension part2573and the second extension part2574has an end that is rounded at a curvature corresponding to the rotation trace of the mixing blade257. Also, a portion at which the catching recess2575and each of the extension parts2573and2574contact each other may be rounded.

FIG.28is a bottom perspective view of the ice maker according to an embodiment of the present invention.

Referring toFIG.28, the ice making assembly according to an embodiment of the present invention is characterized in that the cool air guide duct28is mounted on the bottom surface of the ice maker24.

Specifically, cool air ascending along the cool air supply duct51is discharged through the cool air discharge hole512to flow along the cool air guide duct28. The cool air flowing along the cool air guide duct28directly collides with the bottom surface of the ice tray241to cool the ice tray241. In case of the ice making assembly in which the cool air guide duct28is disposed above the ice tray241according to the related art, cool air guided along the cool air guide duct28may flows to a rear side of the ice tray241. Then, the cool air descends along the rear wall of the ice making room, and then, flows to the front side of the ice making room to cool the bottom portion of the ice tray241. As a result, cooling efficiency may be deteriorated.

However, according to the present invention, the cool air guide duct28may be directly mounted on the bottom surface of the ice tray241to directly collide with the bottom surface of the ice tray. Thus, ice making efficiency may be improved.

FIG.29is a perspective view of the cool air guide according to an embodiment of the present invention, andFIG.30is a longitudinal cross-sectional view taken along line30-30ofFIG.29.

Referring toFIGS.29and30, the cool air guide duct28according to an embodiment of the present invention may include a suction duct part having a duct shape and a tray coupling part282disposed on an outlet side of the suction duct part281.

Specifically, a suction hole2811is defined in a side surface of the suction duct part281. The suction hole2811is closely attached to the cool air supply duct51to communicate with the cool air discharge hole512.

Also, a top surface of the tray coupling part282is opened to allow the cool air passing through the suction duct part281to collide with the bottom surface of the ice tray241.

The tray coupling part282includes a bottom part2824and a wall part2822extending upward along an edge of the bottom part2824. An upper end of the wall part2822is fixed to the bottom surface of the ice tray241.

The bottom part2824may include an inclination part2820extending upward from an end of the bottom part constituting the suction duct part and a horizontal part2821horizontally extending from an end of the inclination part2820.

A coupling boss2823protrudes from the end of the tray coupling part282, and a coupling member is inserted into the coupling boss2823. The coupling member may be fixed to the bottom surface of the ice tray241.

FIG.31is a bottom perspective view of the ice tray constituting the ice maker according to an embodiment of the present invention.

Referring toFIG.31, the ice tray241according to an embodiment of the present invention includes a left surface on which the ice separating motor243is mounted, a right surface corresponding to a surface opposite to the left surface and on which the water supply part2415is disposed, a front surface part connecting a front end of the left surface to a front end of the right surface, a rear surface part connecting a rear end of the left surface to a rear end of the right surface, and a bottom part connecting a lower end of the left surface to a lower end of the right surface.

A plurality of cells2412for making ice are provided inside the ice tray241, and a plurality of cool air guide ribs2413are disposed on the bottom part of the ice tray241.

The plurality of cool air guide ribs2413are made of the same aluminum material as the ice tray241. Also, the plurality of cool air guide ribs may be heat-exchanged with cool air supplied along the cool air guide duct28to perform a function of a heat-exchange fin. Thus, the cool air guide rib2413may be defined as a heat-exchange fin or cool guide fin.

The plurality of cool air guide ribs2413vertically extend from the front surface part and are disposed to be spaced a predetermined distance from the left surface to the right surface. A flange2411protrudes forward by a predetermined width from an upper end of the front surface part.

The cool air guide ribs2413disposed on the bottom part have a length from the left surface to the right surface and are disposed to be spaced a predetermined distance from the front surface part to the rear surface part. An end of the cool air guide rib2413has a length at which the cool air guide rib2413does not contact the bottom part2824of the cool air guide duct28in a state in which the cool air guide duct28is mounted on the bottom surface of the ice tray241.

An ice separating heater h is mounted on the bottom part of the ice tray241. The ice separating heater h may be a sheath heater having a U shape as illustrated in the drawings. Thus, the ice separating heater h may extend along an edge of the bottom part of the ice tray241. Particularly, a right edge of the bottom surface of the ice tray241may be rounded along the shape of the ice separating heater h.

FIG.32is a cut-away perspective taken along line32-32ofFIG.21.

Referring toFIG.32, cool air supplied from the cool air supply duct51to the cool air guide duct28flows from a left end of the ice tray241to a right end of the ice tray241along the cool air guide passage defined between the cool air guide ribs2413that are adjacent to each other. The cool air flowing through the inside of the cool air guide duct28collides with the bottom part of the ice tray241to cool the ice tray241.

The ice separating guide242is mounted on the front surface part of the ice tray241, and the front surface part2421of the ice separating guide242is closely attached to the flange2411. Thus, the front surface part2421of the ice separating guide242is spaced a predetermined distance from the front surface part of the ice tray241.

A lower end of the front surface part2421of the ice separating guide242is seated on an upper end of the front surface of the tray coupling part282constituting the cool air guide duct28. Thus, the cool air flowing along a space defined between the bottom part of the cool air guide duct28and the plurality of cool air guide ribs2413ascends to a space between the front surface part of the ice tray241and the front surface part2421of the ice separating guide242.

Specifically, the cool air ascending along the front surface part of the ice separating guide242ascends along a space defined between the plurality of cool air guide ribs2414disposed on the front surface of the ice tray241. The ascending cool air is discharged into the ice making room201through cool air holes2422defined in the front surface part2421of the ice separating guide242. The cool air colliding with the flange2411is switched in flow direction and discharged into the ice making room201through the cool air holes2422.

The cool air holes2422may be defined in the front of the space defined between the plurality of cool air guide ribs2414adjacent to each other so that the cool air is smoothly discharged.

As described above, since the cool air guide duct28is mounted on the button surface of the ice tray241, until the cool air collides with the button surface of the ice tray241, the number of cool air flowing direction switching may be reduced to improve air pressure drop due to flow resistance. Particularly, in the related art, the cool air flowing direction is switched five times to six times. According to the present invention, the switching number is reduced to two times to three times. As described above, since the air pressure drop is improved, an amount of air supplied to the ice maker24increases to reduce an ice making time. Thus, an amount of made ice per unit time may increase.

A mounted position of the ice maker24within the ice making room201may be higher. That is, the ice maker24may be mounted on the upper end of the ice making room201. As a result, since the ice bin25increases in height, an amount of ice to be stored may increase.

The upper end of the front surface part of the ice bin25may be higher than that of the cool air guide duct28. Thus, the cool air discharged through the cool air hole2422descends within the ice bin25. As a result, the ices stored in the ice bin25may be prevented from being melted and clogged.

In addition, a portion of the cool air supplied into the ice bin25is discharged through the cool air hole2527. The discharged cool air may descend along the cool air descending passage R to pass through the communication hole207band then be supplied to the chiller room202.

FIG.33is a partial perspective view of the ice making room provided in the main door according to an embodiment of the present invention, andFIG.34is an enlarged cross-sectional view of a portion B ofFIG.3.

Referring toFIGS.33and34, the ice making room201and the chiller room202are provided in the main door22constituting the door-in-door assembly according to an embodiment of the present invention. The ice making room201and the chiller room202are vertically partitioned by the partition wall207.

Specifically, the front surface part of the chiller room202is opened, and the opened front surface part is covered by the sub door21. Particularly, when the sub door21is closely attached to the front surface of the main door22, the dispenser liner211further protruding from the back surface of the sub door21is led into the chiller room202.

Although the front surface part of the ice making room is opened also, like the chiller room202, a separate ice making room door80may be provided. Although the sub door21is opened, since the ice making room201is not opened, external air may be prevented from being introduced into the ice making room201.

A gear seat groove2011is defined in the rear surface of the ice making room201. The gear assembly G is seated in the gear seat groove2011. The blade motor M1is mounted on a front surface of the gear assembly G. The gear assembly G and the blade motor M1are covered by the mounting plate27.

The gear shaft G1extends from the front surface of the gear assembly G, and the connector G2is mounted on the gear shaft G1. The rotation shaft of the blade motor M1is connected to a driving gear shaft (not shown) of the gear assembly G. The rotation force transmitted to the driving shaft is reduced by reduction gears provided in the gear assembly G, and thus, the reduced rotation force may be transmitted to the gear shaft G1. The rotation force transmitted to the gear shaft G1is transmitted to the shaft253. Thus, the gear shaft G1may be defined as a transmission gear shaft.

The driving shaft of the gear assembly G is disposed on an end of one side of the gear assembly G, and the gear shaft G1, i.e., the transmission shaft is disposed on an end of the other side that is away from the driving shaft. The blade motor M1is disposed on a rear edge portion of the ice making room, and the gear shaft G1is disposed at an approximate center of the rear surface of the ice making room201, which corresponds to a point that equally divides the ice making room201in half.

As illustrated inFIG.34, since the gear assembly G is mounted on the rear surface (or the rear wall) of the ice making room201, when the ice bin25is mounted on the ice making room201, the blade unit is disposed at a position that is close to the front surface of the main door22. Thus, the ice discharge hole207adefined in the partition wall207may also be disposed at a position that is close to the front end of the partition wall207.

In addition, since the ice discharge hole207aand the guide duct207dare disposed close to the front end of the partition wall207, an angle defined by the discharge duct39and the vertical surface may be significantly reduced. As a result, since the front/rear width of the dispenser30is reduced, the capacity of the chiller room202may increase.

In the door ice making structure according to the related art, in which the front surface of the ice making room201is closed, and the ice making room door80is mounted on the rear surface of the ice making room201, the blade motor M1and the gear assembly G have to be mounted to the inside of the door, which corresponds to the front surface of the ice making room. When the ice bin25according to the present invention is mounted inside the ice making room, the blade unit may be disposed at a position that is farthest away from the back surface of the door. Thus, the inclined angle of the discharge duct39may increase, and also, the dispenser may increase in front/rear thickness. As a result, the capacity of the chiller room202may be reduced.

FIG.35is a left perspective view of the ice making room door according to an embodiment of the present invention,FIG.36is a right perspective view of the ice making room door, andFIG.37is an exploded perspective view of the ice making room door.

Referring toFIGS.35to37, the ice making room door80according to an embodiment of the present invention is mounted on the front surface of the main door22.

In the refrigerator according to the related art, in which the ice making room is provided in the refrigerating compartment door, since the ice making room door is mounted on the rear surface of the ice making room, an insulation thickness of the ice making room door may be sufficiently secured to improve insulation performance.

However, in case of the present invention, since the opening of the ice making room is defined in the front surface of the main door22, it is limited to sufficiently secure the insulation thickness of the ice making room door.

To solve this limitation and improve the insulation performance, a vacuum insulation material may be mounted inside the ice making room door80.

Specifically, the ice making room door80may include a front cover81, a rear cover83, a vacuum insulation panel82, a frame, a handle86, a gasket87, and an ice making room door hinge assembly85.

Specifically, the frame84may have a rectangular frame shape having an opened inside. The gasket87is mounted on a back surface of the frame84. When the ice making room door80is closed, cool air within the ice making room may be prevented from leaking to the outside. The rear cover83is seated on a front surface of the frame84, and the front cover81is coupled to a front surface of the rear cover83.

The vacuum insulation panel (VIP) may be disposed between the front cover81and the rear cover83. Each of the front cover81, the rear cover83, and the frame84may be made of a plastic material.

Here, a coupled body of the front cover81, the rear cover83, the vacuum insulation panel82, the frame84, and the gasket87may be defined as a door part. The ice making room door hinge assembly85is mounted on a left edge of the door part, and the handle86is mounted on a right edge of the door part. Thus, the ice making room door80may include the door part, a hinge part including the ice making room door hinge assembly85, and a handle part including the handle86.

The ice making room door hinge assembly85may be fixed to one side of the left edge and right edge of the ice making room201. Preferably, the ice making room door hinge assembly85may be disposed on the same side surface as that in which the rotation center of the sub door21is defined. That is to say, when the rotation center of the sub door21is defined in the left edge, the ice making room door hinge assembly85may also be attached to the left edge of the door part.

As a result, although the sub door21is closed in the state in which the ice making room door80is opened, since the ice making room door80is closed together with the sub door21, damage of the ice making room door80may be prevented. When the rotation shaft of the sub door21is disposed on the left edge, and the rotation shaft of the ice making room door80is disposed on the right edge, if the user closes the sub door21in a state in which the ice making room door80is opened at an angle of about 90 degrees or more, the damage of the ice making room door80may occur.

Thus, the ice making room door80and the sub door21may rotate in the same direction and be opened.

The ice making room door hinge assembly85may include a hinge bracket851fixed to the front surface of the main door22, which corresponds to the left edge of the ice making room201, and a hinge shaft852inserted into the hinge bracket851.

Specifically, the hinge bracket851includes a bracket body8511mounted on an edge of the side surface of the ice making room201to extend by a predetermined length along an edge of the side surface of the door part and a plurality of hinge shaft accommodation parts8512protruding from a front surface of the bracket body8511and having holes into which the hinge shaft852is inserted. The plurality of hinge shaft accommodation parts8512are spaced a predetermined distance from each other in a longitudinal direction of the bracket body8511.

Also, a plurality of hinge shaft accommodation parts814are provided in an edge of a side surface of the front cover81, i.e., a side surface on which the ice making room door hinge assembly85is provided. The plurality of hinge shaft accommodation parts814may be disposed between the plurality of hinge shaft accommodation parts8512constituting the hinge bracket851. Particularly, one or plurality of hinge shaft accommodation parts814may be disposed between the hinge shaft accommodation parts8512of the hinge brackets851adjacent to each other. Here, for convenience of description, the hinge shaft accommodation part8512may be defined as a first hinge shaft accommodation part, and the hinge shaft accommodation part814may be defined as a second hinge shaft accommodation part.

The hinge shaft852passes through the hinge shaft accommodation parts8512and814, and the front cover81and the ice making room door hinge assembly85are coupled to each other to form one body. The door part of the ice making room door80rotates about the hinge shaft852of the ice making room door hinge assembly85to open or close the front opening of the ice making room201.

The hinge shaft accommodation parts814and8512are disposed on the side surface of the door part, and the hinge shaft852passes through the hinge shaft accommodation parts814and8512to couple the hinge bracket851to the door part. Thus, the rotation center of the door part is vertically defined on the side surface of the door part.

Specifically, the rotation center of the ice making room door80is defined outside the side surface of the door part. Thus, while the door part of the ice making room door80rotates, interference between the rear edge of the door part and the front surface of the main door22may not occur.

More specifically, the rotation center of the door part of the ice making room door80is defined at a point that corresponds to a vertical axis between a vertical surface passing through the front surface of the door part and a vertical surface passing through the rear surface of the door part and is spaced apart outward from the side surface of the door part.

In case of the main door22or the sub door21, the rotation center is defined inside the door, i.e., at a point that is spaced apart from the edge of the side surface of the door in a center direction of the door. As a result, a spaced space for preventing fingers from being jammed may be defined between the edge of the rear surface of the main door22and the front surface part of the cabinet11or between the front surface of the main door22and the edge of the rear surface of the sub door21.

However, in case of the ice making room door hinge assembly85, the hinge shaft852that serves as the rotation center is disposed outside the door part, i.e., at a point that is spaced apart outward from the side surface of the door part. Thus, the spaced space may not be provided between the door part and the edge of the front surface of the ice making room.

Since the hinge structure is applied as described above, it is unnecessary to design the sub door21so that the back surface of the sub door21corresponding to the mounted position of the ice making room door hinge assembly85is recessed or stepped to prevent the sub door21from interfering with the ice making room door hinge assembly85. Thus, deterioration in insulation performance of the sub door21may be prevented.

When the hinge assembly such as the main door upper hinge unit41or the sub door upper hinge unit42is used as the ice making room door hinge assembly85, the back surface of the sub door21may be recessed or stepped by the hinge bracket portion that protrudes forward.

Also, a stopper813and a hinge groove812are provided on the side surface (right surface in the drawing) of the front cover81, which corresponds to a side opposite to the side surface on which the hinge shaft accommodation part814is disposed. Also, a handle hinge88is inserted into the hinge groove812.

Also, a handle groove811may be recessed in an edge of a right side of the front surface part of the front cover81, which is close to the side surface in which the stopper813and the hinge groove812are provided.

Also, a handle groove832corresponding to the handle groove811of the front cover81may be recessed from a right edge of the front surface part of the rear cover83. Thus, when the front cover81is coupled to the front surface of the rear cover83, the handle groove811of the front cover81is seated in the handle groove832of the rear cover83.

The vacuum insulation panel may not be provided at the portion in which the handle grooves811and832are defined. That is, as illustrated in the drawings, an edge of a side surface of the vacuum insulation panel82corresponding to the portion in which the handle grooves811and832are defined may be cut to prevent the interference with the handle grooves811and832.

An insulation panel seat part831on which the vacuum insulation panel82is seated is stepped on the front surface of the rear cover83.

The handle86may be rotatably mounted on the right surface of the front cover81. Specifically, the handle86may include a grip part861, a latch part862extending laterally from an edge of a side surface of the grip part861and then bent backward, a hinge hole865defined in a lower end of the latch part862, a stopper hole863rounded at a predetermined curvature on an upper end of the latch part862, and a hook protrusion864disposed on a rear end of the latch part862.

More specifically, the handle hinge88passes through the hinge hole865of the handle86and is inserted into the hinge groove812of the front cover81. Thus, the handle86is rotatable in a front/rear direction with respect to a center of the handle hinge88.

The stopper813is inserted into the stopper hole863to set a rotation limitation of the handle86. That is, a rotation angle of the handle86in a front direction may be determined by a length of the stopper hole863.

The hook protrusion864is selectively hooked with a hook part (not shown) to be disposed on a front end of the side surface of the ice making room201. For example, when the grip part861is pushed backward, the handle86rotates backward, and the hook protrusion864is hooked with the hook part disposed on the side surface of the ice making room201. In this state, the grip part861is seated in the handle groove811.

FIG.38is an enlarged perspective view of the dispenser provided in the door of the refrigerator according to an embodiment of the present invention, andFIGS.39and40are exploded perspective views of a dispenser casing constituting the dispenser according to an embodiment of the present invention.

Referring toFIGS.38to40, the dispenser30according to an embodiment of the present invention is disposed on the front surface of the door.

Hereinafter, a structure in which the dispenser is disposed in the sub door21, which is disposed at a front side, of the main door and the sub door, which constitute the door-in-door assembly, and the ice making room is provided in the main door22will be described as an example.

However, the present invention is not limited to a refrigerator in which the dispenser and the ice making room according to an embodiment of the present invention are provided in a different door. For example, the ice making room and the dispenser may be provided in one door.

Specifically, the dispenser30according to an embodiment of the present invention may include a dispenser casing including a front casing31and a rear casing32, a discharge duct39connected to an upper portion of the dispenser casing, a discharge duct switching module73driving a duct cap (that will be described later) for opening and closing an outlet of the discharge duct39, and a dispensing button33disposed on a front surface of the dispensing casing, and a funnel S that is tilted forward from the front surface of the dispenser casing.

A control panel300including a display part may be mounted above the dispenser30, i.e., on an upper end of the dispenser casing. Although the control panel300is mounted on the dispenser casing as illustrated in the drawings, the control panel300may be disposed on an outer edge of the dispenser casing.

The control panel300may include a touch screen-type display part. An item desired to be dispensed may be selected through the control panel300by touching a button image or icon for a water or ice dispensing command input that is displayed on the display part. The item desired to be dispensed may include water and ice. The use may select one of the water and the ice through manipulation of the control panel300. Furthermore, if it is desired to dispense the ice, one of cubed ice and crushed ice may be additionally selected.

Also, temperatures of the refrigerating compartment, the freezer compartment, and the chiller room may be set through the display part provided on the control panel300.

The front casing31has a container accommodation part301in which a portion of the front surface of the front casing31is recessed backward. As the container accommodation part301increases in depth, the dispenser30increases in thickness in a front/rear direction. Thus, to realize a slim dispenser30, it is important that the container accommodation part301decreases in recessed depth.

A rear surface of the container accommodation part301is obliquely inclined so that the recessed depth increases from a lower end to an upper end of the container accommodation part301. A funnel hole314is defined in a top surface of the container accommodation part301. A funnel S including an inner funnel37and an outer funnel36may be disposed in the funnel hole314. The funnel S is rotatably coupled to a back surface of the front casing31.

The outer funnel36constituting the funnel S may be exposed to the front surface of the door as illustrated in the drawing. That is, the front surface part of the front casing31and a front surface of the outer funnel36are designed to be disposed on the same plane. The funnel S may be tilted forward in the ice dispensing process. Here, a tilting operation method will be described later.

An outlet of the funnel S is exposed to the container accommodation part301through the funnel hole314defined in the top surface of the container accommodation part301. Thus, a container such as a cup contacts the container accommodation part301to receive ice dispensed through the funnel S.

Specifically, a dispensing button accommodation groove313is recessed from a portion of the front casing31on which an inclined surface of the container accommodation part301is disposed, and the dispensing button33is rotatably disposed in the dispensing button accommodation groove313. A switch mounting part312is disposed on a back surface of the dispensing button accommodation groove313. A micro switch34is mounted on the switch mounting part312.

Thus, the user manipulates the control panel300to select one of the water dispensing mode and the ice dispensing mode. Then, when the dispensing button33is pushed, the micro switch34is turned on to dispense a selected item of the water and the ice.

Here, the selection of the water dispensing mode and the ice dispensing mode is performed through an input unit provided on the control panel300. Although the dispensing button33is used as a unit for inputting a dispensing command of the selected item, the dispensing button may be used for various methods.

For example, the water dispensing button and the ice dispensing button may be separately installed on the inclined surface of the container accommodation part301. The water dispensing button and the ice dispensing button may be disposed to overlap each other in a stair shape at upper front and lower rear sides. When being manipulated, the dispensing buttons may be disposed so that the dispensing buttons do not interfere with each other. Thus, the user may push a button for dispensing a desired item. Thus, it is unnecessary to select the dispensing mode through the control panel.

A water faucet (or drinking water dispensing hole)35protrudes from an upper end of the container accommodation part301. Specifically, an end of the dispenser water supply tube62extending along a space between the rear casing32and the dispenser liner211is connected to the water faucet35to dispense drinking water through the water faucet35. The water faucet35protrudes forward from the inclined surface on which the container accommodation part301is disposed. When the user pushes the dispensing button33by using a container in which the water or the ice is received, the water dispensed from the water faucet35or the ice discharged through the funnel S may be received.

A spring support rib311protrudes from a portion corresponding to the top surface of the container accommodation part301on the back surface of the front casing31. One end of a return spring301that will be described later is connected to the spring support rib311, and the other end of the return spring301is connected to a spring hook part363of the outer funnel36.

The duct cap38for selectively opening and closing the outlet of the discharge duct39is disposed on the funnel hole314. The duct cap38is connected to the front surface of the rear casing32by the discharge duct switching module73.

A dispenser controller310may be mounted on a rear edge of the container accommodation part301. The dispenser controller310may be a controller for controlling an operation of the micro switch34.

The rear casing32constituting the dispenser casing is coupled to the back surface of the front casing31to cover the micro switch34, the dispenser controller310, the duct cap38, and the discharge duct switching module73. A switch cover part322is recessed backward along the shape of the container accommodation part301to protrude backward at the portion corresponding to the mounted position of the micro switch34.

A guide sleeve321extends by a predetermined length on the back surface of the rear casing32on which the duct cap38is disposed. An upper end of the guide sleeve321is connected to an outlet of the discharge duct39, i.e., a lower end, and the guide sleeve321is selectively opened and closed by the duct cap38.

In the detailed description and claims of the present invention, although the duct cap38selectively opens and closes the discharge duct39, the duct cap38may exactingly open and close a lower end of the guide sleeve321. However, the opening/closing of the discharge duct39through the duct cap38may represent opening/closing of an end of the ice discharge passage defined in the door or an outlet of the ice discharge passage. That is, the discharge duct39may represent the ice discharge passage including the guide sleeve321.

FIG.41is a front exploded perspective of the dispenser in a state in which the dispenser casing is removed according to an embodiment of the present invention, andFIG.42is a rear exploded perspective view of the dispenser.

Referring toFIGS.41and42, the dispenser30according to an embodiment of the present invention may include a portion of all of the dispensing casing31, the dispensing button33, the funnel S including the inner funnel37and the outer funnel36, the discharge duct switching module73, and the water faucet35. The dispenser30may further include a micro switch34disposed at a rare side of the dispensing button33.

Specifically, the funnel S may include the outer funnel36and the inner funnel37disposed at a rear side of the outer funnel36. The outer funnel36is made of an opaque material, and the inner funnel37is made of a transparent material. Thus, the inside of the funnel S is not seen from a front side of the dispenser30. When a lighting unit provided in the funnel S is turned on, the funnel S may be recognized by the user at night to improve use convenience.

The front surface of the outer funnel36may be disposed on the same plane as that of the front casing31. Thus, when the dispenser30is viewed from the front side of the refrigerator, the front surface of the outer funnel36is exposed to the outside. The front surface of the outer funnel36may be used as the display part. That is to say, an image or moving picture for displaying the ice dispensing mode or the ice dispensing state may be displayed on the front surface of the outer funnel36.

The outer funnel36may include a front surface and left and right surface parts which respectively extend backward from left and right edges of the front surface part. A rotation shaft362protrudes from an upper end of each of the left and right surface parts of the outer funnel36. The rotation shaft362is rotatably connected to the back surface of the front casing31.

The spring hook part363extends from a rear end of each of the left and right surface parts, and a front end of the return spring is connected to the spring hook part363. As described above, the rear end of the return spring301is connected to the spring support rib311protruding from the back surface of the front casing31. When the outer funnel36rotates forward about the center of the rotation shaft362, restoring force is accumulated while the return spring301is expanded. When force for rotating the outer funnel36is removed, the return spring301is contracted by the restoring force, and then the outer funnel36is returned to its original position.

A guide protrusion366protrudes one side or each of both sides of the left and right surface parts of the outer funnel36. Although the guide protrusion366is disposed on only one side of the left and right surface parts in the drawing, the present invention is not limited thereto. For example, the guide protrusions366may be disposed on both side surfaces, respectively.

The guide protrusion366is interlocked with a push link, which will be described later, constituting the discharge duct switching module73to allow the outer funnel36to be tilted in the front/rear direction. This will be described in detail with reference to the accompanying drawings.

A hook rib364is bent from each of left and right edges of the back surface of the outer funnel36. The coupling boss365may be disposed on each of the left and right edges of the back surface of the outer funnel36, which correspond to the lower side of the hook rib364.

The inner funnel37is integrally coupled to the outer funnel36to form the funnel S.

Specifically, the inner funnel37may have an opened front upper surface, a front lower surface, and left and right surfaces. Since the front upper surface of the inner funnel37is opened, interference between the inner funnel37and the duct cap38may be prevented.

A guide hole guiding discharge of ice is defined in a lower end of the inner funnel37. The guide hole may extend in a shape of which a width gradually decreases toward the lower end thereof.

A hook end372is disposed on the inner funnel37. Particularly, the hook end372may be disposed on an edge portion at which the front surface part and both side surfaces of the inner funnel37contact each other and also disposed at an upper end point of the inner funnel37. The hook end372may be inserted into the hook rib364disposed in the back surface of the outer funnel36.

A coupling rib371extends from each of the left and right edges of the lower end of the front surface part of the inner funnel37. A coupling hole may be defined in the coupling rib371. A coupling member may pass through the coupling hole of the coupling rib371and then be inserted into the coupling boss365. Thus, in the inner funnel37, the hook end372is hooked with the hook rib364, and the coupling rib371is fixed to the coupling boss365by the coupling member. Thus, the inner funnel37may be coupled to the back surface of the outer funnel36to form one body. A method for integrally coupling the inner funnel37to the outer funnel36may be variously performed in addition to the method described in the current embodiment.

FIG.43is a front perspective view of the discharge duct switching module constituting the dispenser according to an embodiment of the present invention, andFIG.44is a rear perspective view of the discharge duct switching module.

Referring toFIGS.43and44, the discharge duct switching module73according to an embodiment of the present invention includes a duct cap driving motor70, a rack gear71connected to a driving shaft of the duct cap driving motor70, and a duct cap support72interlocked with the rack gear71to rotate.

The duct cap38is mounted on the duct cap support72, and the duct cap support72and the duct cap38rotate in one body.

Specifically, the duct cap support72may include a cap holder721coupled to a front surface of the duct cap38, a holder shaft722extending from an upper end of the cap holder721in a left/right direction, a rotation arm723extending from an end of the holder shaft722in a direction crossing the holder shaft722, and a push link725extending in a direction crossing the holder shaft722and angled at a predetermined angle with respect to the rotation arm723. The push link725may further extend than the rotation arm723.

The return spring is wound around the holder shaft722. When rotation force applied to the holder shaft722is removed, restoring force may be provided so that the duct cap support72is returned to its original position. Here, the original position of the duct cap support72may represent a position at which the duct cap38closes a lower end of the guide sleeve321, i.e., a lower end of the ice discharge passage.

The cap holder721extends in the direction crossing the holder shaft722to cover a top surface of the duct cap38and then extends after being bent downward to be closely attached to a front surface of the duct cap38. Specifically, a plurality of coupling holes may be defined in a portion of the cap holder721to which the front surface of the duct cap38is closely attached.

The duct cap38may include a duct cap body381having a predetermined thickness and also having a size and shape that are enough to cover the lower end of the guide sleeve321and a duct cap cover382mounted on the front surface of the duct cap body381. A plurality of coupling protrusions383protrude from the front surface of the duct cap cover382and are respectively inserted into the plurality of coupling holes defined in the cap holder721. Thus, when the holder shaft722rotates, the duct cap38rotates together with the duct cap support72in one body.

The rack gear71may include a gear body710having a fan shape, a gear part711disposed on a circumferential surface of the gear body710, a rack gear shaft712disposed at a center of the gear body710, and an extension end713extending parallel to the holder shaft722from the back surface of the gear body710.

Specifically, the extension end713is disposed at a point that is spaced apart from the rack gear shaft712and has a shape in which the duct cap support72crosses the rotation arm723and is placed on a top surface of the rotation arm723.

A driving gear (not shown) is mounted on the rotation shaft of the duct cap driving motor70and engaged with the gear part711of the rack gear71on an outer circumferential surface of the driving gear. When the duct cap driving motor70is driven, the driving gear rotates, and then, the gear part711rotates together with the driving gear.

When the duct cap driving motor70is driven, the rack gear shaft712rotates, and then, the extension end713rotates about the rack gear shaft712. The extension end713compresses the rotation arm723to allow the rotation arm723to rotate about the holder shaft722.

Hereinafter, a process in which the ice discharge passage is opened, and the ice shutter is tilted according to an operation of the discharge duct switching module will be described with reference to the accompanying drawings.

FIG.45is a side view of the dispenser in a state in which the discharge duct switching module is stopped, andFIG.46is a side cross-sectional view of the dispenser.

Referring toFIGS.45and46, in a state in which the ice dispensing command is not inputted, the ice discharge passage connecting the dispenser30to the ice making room201is maintained in a closed state by the duct cap38.

Specifically, the duct cap38is maintained in a state in which the duct cap38closes the outlet of the guide sleeve321. In this state, a state in which the push link725is spaced apart from the guide protrusion366disposed on the rear end of the side surface of the outer funnel36may be maintained.

Also, the front surface of the outer funnel36may be disposed on the same plane as that of the front casing31.

FIG.47is a side view of the dispenser in a state in which a duct cap rotates at a predetermined angle, andFIG.48is a side cross-sectional view of the dispenser.

Referring toFIGS.47and48, when the user pushes the dispensing button33to input the ice dispensing command, power is applied to the duct cap driving motor70to allow the driving shaft (or the rotation shaft) of the duct cap driving motor70to rotate.

Specifically, when the driving gear connected to the driving shaft of the duct cap driving motor70rotates, the rack gear71engaged with the driving gear rotates. As the rack gear71rotates, the extension end713rotates.

When the extension end713rotates, the rotation arm723placed on the bottom surface of the extension end713rotates together with the extension end713in a direction crossing the extension end713. As a result, the push link725rotates together.

Only the duct cap rotates, and the funnel S is maintained in the former state until the push link725contacts the guide protrusion366of the outer funnel36.

When the duct cap38and the funnel S rotate at the same time, a rotation amount of funnel S may excessively increase, and thus, the outer funnel36may excessively protrude from the front surface of the sub door21. Thus, a time difference between a rotation start time point of the funnel S and a rotation start time point of the duct cap38may be set.

FIG.49is a side view of the dispenser in a state in which the duct cap maximally rotates, andFIG.50is a side cross-sectional view of the dispenser.

Referring toFIGS.49and50, in a state in which the push link725rotates until the push link725contacts the guide protrusion366, when the push link725further rotates, the outer funnel36may also rotate together with the duct cap38.

When the outer funnel36rotates forward, the inner funnel37coupled to the back surface of the outer funnel36rotates in one body. Thus, the outer funnel36is tilted about the rotation shaft362of the outer funnel36by a predetermined angle from the front surface of the dispenser casing, i.e., the front casing31.

As a result, the ice discharge hole defined in the lower end of the inner funnel37may rotate forward. The ice discharge hole defined in the lower end of the inner funnel37may be further expanded forward on the top surface of the container accommodation part301disposed on the front surface of the dispenser30. Thus, the inner funnel37may more easily receive ice through the ice discharge hole.

That is, since the ice discharge hole moves to the front side of the dispenser while the ice discharge hole increases in transverse cross-sectional area, it is unnecessary to deeply push a container into the container accommodation part301so as to receive the ice.

In addition, since the funnel S is tilted to the front side of the dispenser casing in the ice dispensing mode, the container accommodation part301may have a thinner depth in the front/rear direction when compared to the related art, thereby realizing the slim dispenser.

Since a dead volume that is secured for accommodating the rear protrusion of the dispenser may be reduced through the slim dispenser30. Thus, an effective storage volume of the chiller room202may increase.

An inclination of the ice discharge passage constituted by the discharge duct39and the guide sleeve321, i.e., an angle inclined backward from the vertical surface may decrease when compared to the related art. Thus, the thickness of the door in which the dispenser30is provided may decrease.

When the duct cap driving motor70rotates reversely after the dispensing of ice is completed, the rack gear71may also reversely rotate to return to its original position.

Specifically, when the rack gear71rotates reversely, pressing force applied to the rotation arm723is removed. Thus, the duct cap support72may rotate reversely to return to its original position by the restoring force of the return spring724that is wound around the holder shaft722. Since the duct cap support72rotates reversely, the duct cap38closes the outlet of the guide sleeve321.

As the push link725rotates reversely, pressing force applied to the funnel S is removed. The outer funnel36may rotate to return its original position by the restoring force accumulated in the return spring301connected to the rear end of both side surfaces of the outer funnel36. Thus, the outer funnel36and the inner funnel37may return together to its original position. Since separate driving force for returning the duct cap38to its original position is unnecessary by the return spring301, a power consumption reduction effect may be obtained.

As described above, although the rack gear71is connected to the rotation shaft of the duct cap driving motor70, and the duct cap support72rotates by the rack gear71, the present invention is not limited thereto.

Particularly, the rack gear71may be removed, and the holder shaft722of the duct cap support72may be directly connected to the rotation shaft of the duct cap driving motor70.

FIGS.51to53are views successively illustrating operations of a discharge duct switching module according to another embodiment of the present invention.

Referring toFIG.51, in a discharge duct cap module according to another embodiment of the present invention, the driving motor for rotating the duct cap38to open the ice discharge passage is not provided.

Specifically, the discharge duct switching module according to another embodiment is the same as that according to the foregoing embodiment except for a driving unit that is substitute for the duct cap driving motor70according to the foregoing embodiment.

Specifically, the driving unit that is substitute for the duct cap driving motor70may include a transmission link332connected to a hinge shaft331of the dispensing button33. The transmission link332may be a separate link extending from an upper end of the dispensing button33or an injection-molded single body in which the dispensing button33and the transmission link332are angled at a predetermined angle. The hinge shaft331may be disposed at a point at which the dispensing button and the transmission link332contact each other.

The transmission link332may have a length that is enough to rotate the push link725forward at a predetermined angle.

When the transmission link332is connected to the dispensing button33through a separate part, the main gear may be mounted on the hinge shaft of the dispensing button33, and the sub gear may be mounted on a lower end of the transmission link332. An intermediate gear is disposed between the main gear and the sub gear so that the rotation direction of the main gear is equal to that of the sub gear. Thus, the transmission link332rotates in the same direction as the rotation direction of the dispensing button33to press the push link725.

The main gear has a diameter greater than the sub gear. Although a rotation amount of dispensing button33is less, the push link725may sufficiently rotate. That is, the duct cap38may sufficiently rotate through only the rotation amount of dispensing button33to completely open the ice discharge passage.

As illustrated inFIG.51, in a state in which the dispensing button33is not pushed to dispense ice, the dispensing button33is maintained in a state of being spaced a predetermined angle φ1from a horizontal line passing through the hinge shaft331.

Referring toFIG.52, when the use press the front surface of the dispensing button33to dispense ice, the dispensing button rotates at a predetermined angle to form a predetermined angle (φ2, φ2>φ1) with respect to the horizontal line.

Referring toFIG.53, in a state in which the dispensing button33rotates at an angle φ2described inFIG.52, when the dispensing button33is further pressed, the transmission link332allows the push link725to further rotate at a predetermined angle forward. When the dispensing button33is fully pushed, i.e., when an angle (φ3, φ3>φ2) between the dispensing button33and the horizontal line is maximized, the duct cap may maximally rotate forward, and the funnel S may be tilted forward.

According to the above-described structure, it is unnecessary to provide a separate power source so as to open the ice discharge passage by rotating the duct cap38. Thus, the user may sufficiently push the dispensing button33by only using physical force thereof.

FIG.54is a side cross-sectional view illustrating a structure of a dispenser according to further another embodiment of the present invention.

Referring toFIG.54, a dispenser30according to further another embodiment of the present invention is the same as that according to the foregoing embodiment except for a position of the water faucet35. Thus, their duplicated descriptions with respect to the same parts will be omitted.

Specifically, although the water faucet35is fixed to the upper portion of the rear surface of the container accommodation part301in the foregoing embodiment, the water faucet35may also be tilted together with the funnel S in the current embodiment.

That is, the dispenser water supply tube62may extend along the space between the front surface of the sub door21and the front surface of the discharge duct39, and the water faucet35may be disposed on a lower end of the funnel S.

More specifically, the water faucet35may be disposed on the lower end of the funnel S, which corresponds between the inner funnel37and the outer funnel36, and the dispenser water supply tube62may extend to the water faucet35along the inside of the sub door21.

Although the ice making room201supplying ice to the dispenser is installed in the main door22in an embodiment, the ice making room may be installed in one of the main door22, the cabinet11, and the refrigerating compartment114. That is, the dispenser according to an embodiment of the present invention may be applied to the refrigerator in which the ice making room is installed in the cabinet. In addition, the dispenser according to an embodiment of the present invention may be provided in a door different from the door in which the ice making room is installed or provided in the door in which the ice making room is installed.

FIG.55is an exploded perspective view of the sub door constituting the door-in-door assembly according to an embodiment of the present invention, andFIG.56is a side cross-sectional view of the sub door.

Referring toFIGS.55and56, the sub door21may include a front plate214defining an outer appearance of a front surface thereof, a rear plate215coupled to a back surface of the front plate214, and an upper decor216and lower decor217, which are respectively coupled to top and bottom surfaces of the front plate214and the rear plate215.

Specifically, a dispenser hole2141may be defined in the front plate214, and the dispenser30may be mounted in the dispenser hole2141. A process of foam-filling an insulation material into the sub door21so as to manufacture the sub door21is needed. The foam-filling process is performed in a state in which the rear casing32of the components constituting the dispenser30is mounted in the dispenser hole2141.

The dispenser liner211protrudes from the back surface of the rear plate215, and the rear casing32is disposed at a front side of the dispenser liner211. A duct hole2152is defined in a top surface of the dispenser liner, and an inlet of the discharge duct39is connected to the duct hole2152. An outlet of the discharge duct39is connected to a guide sleeve321disposed on the top surface of the rear casing32.

A foamed solution injection hole2151(or a foamed solution injection port) is defined in any point of the rear plate215corresponding to an upper side of the dispenser liner211. The foamed solution injection hole2151may be covered by an injection hole cover218.

The foamed solution injection hole2151may be defined in a point that is spaced apart upward from a front end of the top surface of the dispenser liner211. The foamed solution injection hole2151may be defined in a point that is closer to the front end of the top surface of the dispenser liner211than an upper end of the sub door21, i.e., an upper end of the rear plate215.

As described above, in a state in which all the components that have to be mounted between the front plate214and the rear plate215are mounted to block a hole or gap through which the insulation material leaks, the foamed insulation material is injected into the sub door21.

When the foamed insulation material (or the foamed solution) is injected through the foamed solution injection hole2151, the liquefied foamed thermal insulation material may be filled into a sub door front part defined by the front plate214and the rear casing32, a sub door rear part defined by the rear plate215, and a space defined by the upper decor216and the lower decor217. The liquefied foamed thermal insulation material is hardened as time goes on.

While the foamed insulation material is injected through the foamed solution injection hole2151to fill the inner space of the sub door21with the foamed solution, air corresponding to a volume of the filled foamed solution has to be discharged to the outside of the sub door21. If the air within the sub door21is not quickly discharged to the outside of the sub door21during the foaming process, a foamed solution non-filled space may occur in the sub door21.

To quickly discharge the air during the foamed solution filling process, a plurality of vent holes2153may be provided in a portion of the dispenser liner211. Particularly, the plurality of vent holes2153may be vertically arranged at a central portion of the dispenser liner211. The vent hole2153has a diameter of about 0.5 mm to about 1.5 mm, preferably, 1 mm. A distance between the vent holes adjacent to each other may range of about 7 mm to about 15 mm, preferably, about 10 mm. 25 to 35 vent holes, preferably, 30 vent holes2153may be provided in the dispenser liner211. A reason in which the vent hole2153is defined in the dispenser liner211is because of being determined according to the filled appearance of the foamed solution. That is, the vent hole2153may be defined in a portion at which the foamed solution is filled late. This will be described in detail with reference to the accompanying drawings.

FIG.57is a bottom view of the lower decor defining a bottom surface of the sub door.

Referring toFIG.57, a hinge hole2172through which the hinge shaft passes is defined in an edge of one side of the lower decor217, and a plurality of vent holes2171are defined in a point that is spaced a predetermined distance from the hinge hole2172to an edge of the other side of the lower decor217.

Specifically, the plurality of vent holes2171may be arranged from the edge of one surface to the edge of the other surface of the lower decor217at a central portion of the lower decor217. Thus, the foamed solution may flow to the lower decor217in the foamed solution filling process of the sub door. Since the foamed solution is filled the latest at the lower decor217, the vent holes2171may be defined in the lower decor217.

FIGS.58to61are simulations illustrating a state in which the foamed solution is filled in the process of filling the foamed solution into the sub door.

Referring toFIG.58, in order to fill the foamed solution into the sub door21, the sub door21is seated on a jig (not shown) in a state in which the front surface of the sub door21is overturned to face a lower side. The sub door21may be inclined at a predetermined angle from the horizontal surface so that the foamed solution is spread far through the foamed solution injection hole2151. Here, the sub door21may be inclined at an angle of about 4 degrees to about 6 degrees.

Particularly, the sub door21may be inclined so that the foamed solution injection hole1251is disposed at a position that is higher than the lower end of the sub door21. When the foamed solution is injected in a state in which the sub door21is horizontally disposed, the foamed solution is not uniformly spread far, but is hardened.

FIG.58illustrates a state in which a diffused state of the foamed solution when 5 seconds are elapsed after the foamed solution is injected. Here, a filling rate is about 5%.

It can be seen that the foamed solution injected through the foamed solution injection hole2151is spread in all directions from a center of the sub door21to flow to the door handle. This is done due to a transverse cross-section shape of the sub door21. That is, a side surface opposite to the sub door, i.e., a side surface to which the handle is attached may have a thickness greater than that of the side surface of the sub door to which the hinge shaft is connected.

Thus, when the foamed solution is injected through the foamed solution injection hole2151defined in the back surface of the sub door21in the state in which the front surface of the sub door21is overturned to face the lower side, the foamed solution may be concentrated into the side surface to which the handle is attached.

FIG.59illustrates a state in which a diffused state of the foamed solution when 16 seconds are elapsed after the foamed solution is injected. Here, a filling rate is about 30%.

Referring toFIG.59, it can be seen that the foamed solution is filled first up to the upper end of the sub door21and then gradually filled into a portion of the dispenser liner211.

FIG.60illustrates a state in which a diffused state of the foamed solution when 19 seconds are elapsed after the foamed solution is injected. Here, a filling rate is about 55%.

Referring toFIG.60, it can be seen that the foamed solution is filled to the bottoms of the left and right surfaces of the dispenser liner211at almost the same rate and then is concentrated into the central portion of the dispenser liner211. Thus, the air existing in the sub door21may be concentrated in a central direction of the dispenser liner211.

Due to the above-described filled appearance, the plurality of vent holes2153may be defined in the central portion of the dispenser liner211and be arranged at a predetermined distance from the upper end to the lower end of the dispenser liner211.

FIG.61illustrates a state in which a diffused state of the foamed solution when 32 seconds are elapsed after the foamed solution is injected. Here, a filling rate is about 97%.

Referring toFIG.61, the foamed solution is filled into the dispenser liner211at the same time while flowing to the lower end of the sub door21. Thus, it can be seen that the lower end of the sub door21is filled later. Due to this filled appearance, the plurality of vent holes2171may be defined in the lower decor217.

FIG.62is an exploded perspective view of the main door according to an embodiment of the present invention, andFIG.63is a side cross-sectional view of the main door.

Referring toFIGS.62and63, the main door22according to an embodiment of the present invention may include a front part22a, a rear part22bcoupled to a rear surface of the front part22a, an upper decor22cand lower decor22d, which are respectively coupled to top and bottom surfaces of the front part22a, and a pair of side decors22erespectively coupled to left and right surfaces of the front part22a.

The front part22amay include a door frame224and an inner housing231protruding from a back surface of the door frame224. The door frame224and the inner housing231may be provided in one body through injection molding.

The rear part22bmay include a flange part233coupled to the back surface of the door frame224to define the rear surface of the door frame224and an outer housing232protruding backward from the flange part233to surround the inner housing231.

An opening225is defined in the front surface part of the inner housing231, and the inside of the inner housing231is partitioned into the ice making room201that is an upper storage space and the chiller room202that is a lower storage space by the partition wall207.

To inject the foamed insulation material into the main door22, the door duct assembly50is coupled to an outer surface of the inner housing231to prevent the foamed solution from leaking through the cool air inflow hole231a, the ice making room-side cool air discharge hole231b, and the chiller room-side cool air discharge hole231c. The guide duct207dis mounted on the partition wall207, and the damper assembly200is mounted on the communication hole207bto prevent the foamed solution from leaking through a hole or gap defined in the inner housing231.

Then, the outer housing232is coupled to the back surface of the inner housing231, and the side decor22eis coupled. Then, the foamed solution is injected into the space defined between the inner housing231and the outer housing232.

In the state in which the rear part22bis coupled to a rear side of the front part22a, the main door22may be largely defined to be constituted by a door frame and a housing protruding backward from the door frame. An opening is defined inside the door frame so as to be accessible to the inside of the housing.

FIG.64is a front perspective view of the front part constituting the main door.

Referring toFIG.64, the front part22amay be defined to be constituted by a door frame224and an inner housing231protruding backward from the door frame224.

Specifically, the door frame224has a rectangular frame shape to define a door part of the main door22. An opening225is defined inside the door frame224. The opening225is defined as an opened front surface part of the inner housing231. A stepped part224ais recessed by a predetermined depth from the front surface of the door frame224. The stepped part224amay have a predetermined width along an edge of the opening225. A gasket210around the back surface of the sub door21is closely attached to an outer edge of the stepped part224a.

A foamed solution injection hole226may be defined in a portion of the stepped part224acorresponding to a lower edge of the opening225. The foamed solution injection hole226may be defined in each of left and right edge points of the stepped part224a.

A plurality of vent holes227may be defined in a rear surface of the inner housing defining the rear surface of the ice making room201. The plurality of vent holes227may be disposed at a predetermined distance from an upper end to a lower end of the ice making room. Each of the plurality of vent holes227may have the same diameter as each of the vent holes defined in the sub door21, and a distance between the vent holes adjacent to each other may be the same as that between the vent hole defined in the sub door21. The number of vent holes227may be about 30. However, the number of vent holes227may be changed according to the vertical width of the rear surface of the ice making room201.

The main door22may have a structural characteristic in that portions at which a flow direction of the foamed solution is switched when the foamed solution is injected is large in number when compared to the sub door21. That is, the structure of the main door22may be relatively complicated when compared to the structure of the sub door21. Thus, in the process of injecting the foamed solution into the main door22, the foamed solution may be injected through at least two or more points so that a region that is not filled with the foamed solution does not exist.

FIG.65is a plan view of the front part constituting the main door, andFIG.66is a bottom view of the front part.

Referring toFIGS.65and66, a plurality of vent holes228and229may be defined in a top surface of the main door22, particularly, top and bottom surfaces of the door frame224constituting the main door22.

Specifically, the diameter of each of the above-described different vent holes and the distance between the vent holes adjacent to each other may be equally applied to the vent holes228and229defined in the door frame224. The number of vent holes228defined in the top surface of the door frame224may be about 20 to about 25. The number of vent holes defined in the bottom surface of the door frame224may be about 25 to about 30. However, the number of vent holes228and229may be changed according to the dimensions in design of the door frame224.

FIGS.67to70are simulations illustrating a state in which the foamed solution is filled in the process of filling the foamed solution into the main door.

FIG.67illustrates a state in which a diffused state of the foamed solution when 5 seconds are elapsed after the foamed solution is injected. Here, a filling rate is about 5%.FIG.68illustrates a state in which a diffused state of the foamed solution when 17 seconds are elapsed after the foamed solution is injected. Here, a filling rate is about 30%.FIG.69illustrates a state in which a diffused state of the foamed solution when 20 seconds are elapsed after the foamed solution is injected. Here, a filling rate is about 55%.FIG.70illustrates a state in which a diffused state of the foamed solution when 32 seconds are elapsed after the foamed solution is injected. Here, a filling rate is about 97%.

Like the sub door21, the foamed solution may be injected into the main door in a state in which the main door is inclined also at an angle of about 4 degrees to about 6 degrees with respect to the horizontal plane so that the foamed solution smoothly flows and is smoothly diffused in the foamed solution filling process.

Unlike the sub door21, the main door22may become a state in which the lower end in which the foamed solution injection hole226is defined is lifted upward in a state in which the front surface part faces an upper side. This is done because the foamed solution injection hole226is defined in the lower side of the front surface of the main door22.

Referring toFIG.67, it can be seen that the foamed solution injected through two foamed solution injection holes226is diffused along the bottom part and the side surface of the housing23. Referring toFIG.68, it can be seen that the foamed solution flows to the upper end of the main door22while being filled into the left and right surfaces of the housing23.

Referring toFIGS.68and69, it can be seen that the foamed solutions meet each other while being gradually filled from the left and right edges of the housing23toward the center of the housing23. Particularly, it can be seen that the foamed solution flows from the left and right edges of the ice making room201toward the center of the rear surface of the ice making room201. Thus, the plurality of vent holes227may be defined in any point of the inner housing231defining the rear surface of the ice making room201. The plurality of vent holes227may be disposed to be spaced a predetermined distance from the bottom to the top surface of the ice making room201.

Also, referring toFIG.70, it can be seen that the foamed solution is filled the latest at the upper and lower ends of the main door22. Thus, the plurality of vent holes228and229may be defined in the top and bottom surface of the main door22, i.e., the top and bottom surfaces of the door frame224, respectively.

Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.