CA2172108A1 - Fiberglass preform compression process - Google Patents
Fiberglass preform compression processInfo
- Publication number
- CA2172108A1 CA2172108A1 CA 2172108 CA2172108A CA2172108A1 CA 2172108 A1 CA2172108 A1 CA 2172108A1 CA 2172108 CA2172108 CA 2172108 CA 2172108 A CA2172108 A CA 2172108A CA 2172108 A1 CA2172108 A1 CA 2172108A1
- Authority
- CA
- Canada
- Prior art keywords
- tubular form
- accordance
- ram
- preform
- along
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Landscapes
- Moulding By Coating Moulds (AREA)
Abstract
A method for forming a fiber preform for use in a resin transfer molding process, the method comprising the steps of providing a hollow form having open first and second opposite ends, placing in the form a predetermined amount of fibrous material and binder, closing the first end of the form with an end cap, compressing the fibrous material and binder by inserting a ram into the second end of the form and moving the ram through a predetermined distance, and curing the binder to produce the preform.
Description
217~08 VXo~
FTR~RGr~ S PREPORM COMPRESSION PROC~SS
BAC~GROUND OF THE INVENTION
The invention relates generally to the molding of plastic parts. More particularly, the invention relates to fiberglass reinforced parts, and still more particularly, to molding of preforms therefor, i . e ., to forming of the reinforcement to be used in the molding of the final product.
Attention is directed to the following U. S.
patents:
FTR~RGr~ S PREPORM COMPRESSION PROC~SS
BAC~GROUND OF THE INVENTION
The invention relates generally to the molding of plastic parts. More particularly, the invention relates to fiberglass reinforced parts, and still more particularly, to molding of preforms therefor, i . e ., to forming of the reinforcement to be used in the molding of the final product.
Attention is directed to the following U. S.
patents:
2,751,626 - Issued June 26, 1956 2,949,054 - Issued August 16, 1960 3,621,092 - Issued November 16, 1971 4,407,772 - Issued October 4, 1983 4,463,959 - Issued August 7, 1984 5,213,821 - Issued May 25, 1993 SUMMARY OF THE INVENTION
The invention provides a method for forming a fiber preform for use in a resin transfer molding process, the method comprising the steps of providing a hollow form having a closed first end and an opposite second open end, placing in the form a predet~rm;n~,l amount of fibrous material and binder, compressing the fibrous material and binder by inserting a ram into the second end of the form and moving the ram through a predet~rmi nPr~ distance, and curing the binder to produce the preform.
The invention also provides tooling for forming a part having an outer endless p~r; ~h~ry with a predet~rmin~fi length, a first end surface extending from along the entire length of the outer periphery, and a second end surface extending from along the entire length of the outer perlphery in spaced relation to the first end surface, the tooling comprising a tubular form including opposite ends and an endless inner periphery defining the outer periphery of a part 2l 72ta~
--2-- 2~5Q ,o to be formed, an end cap closing one of the opposite ends of the tubular form and including an end face which is located in the one end, which extends from along the entirety of the inner periphery, and which defines the first end surface of the part to be formed, and a ram enterable into the other of the opposite ends of the tubular form, and including an end face extending from along the entirety of the inner periphery in spaced relation to the end face of the end cap, and defining the second end surface of the part to be f ormed .
The invention also provides a process for forming a part having an outer endless periphery, a f irst end surface extending from along the entirety of the outer periphery, and a second end surface extending from along the entirety of the outer periphery in spaced relation to the first end surface, the process comprising the steps of providing a tubular form having first and second opposite ends and including an inner periphery defining the outer periphery of the part to be formed, placing in the tubular form a predet~ n~
amount of fibrous material and binder, closing the first end of the tubular form with an end cap including an end face which extends into the first end and from along the entire length of the inner periphery, and which defines the first end surface of the part to be formed, compressing the fibrous material and binder by inserting into the second end of the tubular form and through a predetermined distance a ram having an end face extending from along the entirety of the inner periphery and defining the second end surface of the part to be formed, and curing the binder to produce the f ormed part .
A principal feature of the invention is the provision of a method for manufacturing fiber preforms with structural features such as bosses and ribs.
2l ?~ a~
Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detalled description, claims and drawings.
DBSCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of an outboard motor cover~ portion constructed in accordance with the method or process of the invention.
Figure 2 is a sectional view of apparatus embodying the invention and at one stage in the process .
Figure 3 is a sectional view similar to Figure 2 at another stage in the process.
Figure 4 is a perspective view of a preform formed by the process shown in Figs. 2 and 3.
Figure 5 is a sectional view of a mold containing the pre f orm .
Before one embodiment of the inventLon is explained in detail, it is to be understood that the invention is not limited Ln its application to the details of the construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is f or the purpose of description and should not be regarded as limiting.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Shown in Fig. 1 is a fiber-reinforced polymer or fiberglass ob~ect 10 to be formed in a resin transfer molding process. The illustrated ob~ect 10 is a lower, half engine cover for an outboard motor (not shown).
However, it should be understood that the method or process of the invention is applicable to a wide variety of fiber-reinforced plastic end parts or 2t72ita~
--4-- 2,6000 products which have a compound shape. The cover 10 includes a pair of bosses 11 used ln a known manner to mount the cover 10 on an outboard motor.
Shown in Fig. 4 i5 a fiber preform 12 to be used in manufacturing the engine cover 10. More particularly, and as described below, the preform 12 is used in the resin trans~er molding process to form one of the bosses 11. The preform 12 has an endless or generally cylindrical outer periphery 13, a first or outer face surface 15 which extends continuously from the outer periphery 13, and a second or Lnner face surface 17 which also extends from the outer periphery 13 .
Shown in Figures 2 and 3 of the drawings is tooling or apparatus 41 for compressing and molding the fiberglass preform 12 shown in Figure 4. The tooling or apparatus 41 includes a hollow or tubular form or member 51 having a longitudinal axis 52 and a hollow interior with opposite first and second ends 53 and 55.
The form 51 also has an inner, endless peripheral wall or surface 57 which has an axially constant shape and preferably extends recti 1 inf~Arly between the ends 53 and 55 and corresponds to the shape of the outer periphery 13 of the preform 12 to be compressed and 2 5 mo lded .
The tooling or apparatus 41 also includes an end cap or member 61 which is movable between a first position (shown in Figure 2) closing the first end 53 of the tubular form 51 and a second position (shown in Figure 3 ) remote from or spaced from the first end 53 of the tubular form 51. The end cap 61 includes an end face 63 which, when the end cap 61 is in the closing position, extends into the first end 53 of the tubular form 51 and continuously from the inne~ peripheral surface 57 of the tubular form 51. The end face 63 can have any desired compound or non-planar shape, including being convex as shown, to form or define one ~ 2~72108 of the surfaces 15 and 17 of the preform 12 to be c ompre s s ed a nd mo lded .
Means 69 (shown schematically in the form of a pneumatic or hydraulic ram) is also provided for displacLng the end cap 61 between the closing position and the remote position. Any suitable means can be employed .
The tooling or apparatus 41 also includes a ram or member 71 which is insertable into the second end 55 of the tubular form 51 and which includes an end face 73 which, when the ram 71 is inserted into the tubular form 51, extends continuously from the inner peripheral wall or surface 57 of the tubular form 51. The end face 73 can have any compound shape to form or define the other of the surfaces 15 and 17 of the preform 12 to be compressed and molded. In the illustrated construction, the end face 73 is angled or extends in non-perpendicular relationship to the axis 52.
~eans 79 (shown schematically in the form of a pneumatic or hydraulic ram) is also provided for displacing the ram 71 along the axis 52 and into and from the second end 55 of the tubular form 51. The means 79 moves the ram 71 between a first position (not shown) spaced to the left in the drawings from the second end 55 of the tubular form 51, a second position shown in Figure 2 and located in the tubular form 51 at a first distance from the second end 55, and a third position shown in Figure 3 and located in the tubular form 51 at a second distance greater than the first distance from the second end 55 such that the preform 12 is removed from the tubular part or member 51. Any suitable means can be employed.
The prQcess or method of the invention comprises:
(a) providing a hollow or tubular form (such as the form 51) having first and second opposite ends and including an inner periphery defining the outer periphery of the preform to be formed;
~ 2t721Q~
(b) closing the first end of the tubular form by moving a member (such as the end cap 61) to a position which closes the first end of the tubular fDrm Sl, the member including an end face (such as the end face 63) which extends into the first end and from along the entLre length of the Lnner perLphery, and whLch defines the first end surface of the piece or part to be molded;
(c) placLng in the tubular form, preferably through the second end thereof and while the ram 71 is in the remote or spaced first position, a predet.orm;n-~
amount of fibrous material (or fiberglass) and binder;
(d) compressing the fiberglass and binder by inserting a member ( such as the ram 71 ) into the second end 55 of the tubular form and moving the ram through a first distance, the ram having an end face 73 extending from along the entire length of the inner periphery and spaced from the end face of the end cap to define both the second end surface of the preform and the distance between the end surfaces of the preform;
(e) curing the binder to produce the molded or f o~med pref orm;
( f ) removing the end cap 61 from the first end of the tubular form 51 to the remote or spaced position;
and (g) displacing the preform from the tubular form by further inserting the ram 71 into the tubular form 51 to the third position so as to effect removal of the preform from the tubular form 51. The process can then be recycled.
It should be noted that any suitable fibrous material, any suitable binder, and any suitable amounts thereof can be employed. Also, the fibrous material can be placed in the form 51 either before or after the end of the form 51 is closed by the end cap 61, although it is preferred to place the fibrous material in the form 51 after the end of the form 51 is closed by the end cap 61.
2t721~8 .
--7-- z,~oo Fiqure 5 shows how the preform 12 is used in the resin transfer molding process. A mold cavity lO0 is formed by mold halves 104 and 108. The cavity 104 has the shape of the cover 10 to be formed. ~he mold half 104 has therein a recess 112 corresponding to one of the })osses 11 on the cover 10. The preform 12 is placed in the recess 112, and additional fibrous material ( such as continuous strand mat or chopped fiber) 116 is placed in the l~ ;n~ r of the cavity.
Resin i6 then in~ected or otherwise introduced into the cavity, and the resin is cured to provide the fiber-reinforced polymer cover 10 comprised of the preform 12, any other preforms required (such as for the other boss 12), and the cured resin.
various of the features of the invention are set forth in the following claims.
The invention provides a method for forming a fiber preform for use in a resin transfer molding process, the method comprising the steps of providing a hollow form having a closed first end and an opposite second open end, placing in the form a predet~rm;n~,l amount of fibrous material and binder, compressing the fibrous material and binder by inserting a ram into the second end of the form and moving the ram through a predet~rmi nPr~ distance, and curing the binder to produce the preform.
The invention also provides tooling for forming a part having an outer endless p~r; ~h~ry with a predet~rmin~fi length, a first end surface extending from along the entire length of the outer periphery, and a second end surface extending from along the entire length of the outer perlphery in spaced relation to the first end surface, the tooling comprising a tubular form including opposite ends and an endless inner periphery defining the outer periphery of a part 2l 72ta~
--2-- 2~5Q ,o to be formed, an end cap closing one of the opposite ends of the tubular form and including an end face which is located in the one end, which extends from along the entirety of the inner periphery, and which defines the first end surface of the part to be formed, and a ram enterable into the other of the opposite ends of the tubular form, and including an end face extending from along the entirety of the inner periphery in spaced relation to the end face of the end cap, and defining the second end surface of the part to be f ormed .
The invention also provides a process for forming a part having an outer endless periphery, a f irst end surface extending from along the entirety of the outer periphery, and a second end surface extending from along the entirety of the outer periphery in spaced relation to the first end surface, the process comprising the steps of providing a tubular form having first and second opposite ends and including an inner periphery defining the outer periphery of the part to be formed, placing in the tubular form a predet~ n~
amount of fibrous material and binder, closing the first end of the tubular form with an end cap including an end face which extends into the first end and from along the entire length of the inner periphery, and which defines the first end surface of the part to be formed, compressing the fibrous material and binder by inserting into the second end of the tubular form and through a predetermined distance a ram having an end face extending from along the entirety of the inner periphery and defining the second end surface of the part to be formed, and curing the binder to produce the f ormed part .
A principal feature of the invention is the provision of a method for manufacturing fiber preforms with structural features such as bosses and ribs.
2l ?~ a~
Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detalled description, claims and drawings.
DBSCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of an outboard motor cover~ portion constructed in accordance with the method or process of the invention.
Figure 2 is a sectional view of apparatus embodying the invention and at one stage in the process .
Figure 3 is a sectional view similar to Figure 2 at another stage in the process.
Figure 4 is a perspective view of a preform formed by the process shown in Figs. 2 and 3.
Figure 5 is a sectional view of a mold containing the pre f orm .
Before one embodiment of the inventLon is explained in detail, it is to be understood that the invention is not limited Ln its application to the details of the construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is f or the purpose of description and should not be regarded as limiting.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Shown in Fig. 1 is a fiber-reinforced polymer or fiberglass ob~ect 10 to be formed in a resin transfer molding process. The illustrated ob~ect 10 is a lower, half engine cover for an outboard motor (not shown).
However, it should be understood that the method or process of the invention is applicable to a wide variety of fiber-reinforced plastic end parts or 2t72ita~
--4-- 2,6000 products which have a compound shape. The cover 10 includes a pair of bosses 11 used ln a known manner to mount the cover 10 on an outboard motor.
Shown in Fig. 4 i5 a fiber preform 12 to be used in manufacturing the engine cover 10. More particularly, and as described below, the preform 12 is used in the resin trans~er molding process to form one of the bosses 11. The preform 12 has an endless or generally cylindrical outer periphery 13, a first or outer face surface 15 which extends continuously from the outer periphery 13, and a second or Lnner face surface 17 which also extends from the outer periphery 13 .
Shown in Figures 2 and 3 of the drawings is tooling or apparatus 41 for compressing and molding the fiberglass preform 12 shown in Figure 4. The tooling or apparatus 41 includes a hollow or tubular form or member 51 having a longitudinal axis 52 and a hollow interior with opposite first and second ends 53 and 55.
The form 51 also has an inner, endless peripheral wall or surface 57 which has an axially constant shape and preferably extends recti 1 inf~Arly between the ends 53 and 55 and corresponds to the shape of the outer periphery 13 of the preform 12 to be compressed and 2 5 mo lded .
The tooling or apparatus 41 also includes an end cap or member 61 which is movable between a first position (shown in Figure 2) closing the first end 53 of the tubular form 51 and a second position (shown in Figure 3 ) remote from or spaced from the first end 53 of the tubular form 51. The end cap 61 includes an end face 63 which, when the end cap 61 is in the closing position, extends into the first end 53 of the tubular form 51 and continuously from the inne~ peripheral surface 57 of the tubular form 51. The end face 63 can have any desired compound or non-planar shape, including being convex as shown, to form or define one ~ 2~72108 of the surfaces 15 and 17 of the preform 12 to be c ompre s s ed a nd mo lded .
Means 69 (shown schematically in the form of a pneumatic or hydraulic ram) is also provided for displacLng the end cap 61 between the closing position and the remote position. Any suitable means can be employed .
The tooling or apparatus 41 also includes a ram or member 71 which is insertable into the second end 55 of the tubular form 51 and which includes an end face 73 which, when the ram 71 is inserted into the tubular form 51, extends continuously from the inner peripheral wall or surface 57 of the tubular form 51. The end face 73 can have any compound shape to form or define the other of the surfaces 15 and 17 of the preform 12 to be compressed and molded. In the illustrated construction, the end face 73 is angled or extends in non-perpendicular relationship to the axis 52.
~eans 79 (shown schematically in the form of a pneumatic or hydraulic ram) is also provided for displacing the ram 71 along the axis 52 and into and from the second end 55 of the tubular form 51. The means 79 moves the ram 71 between a first position (not shown) spaced to the left in the drawings from the second end 55 of the tubular form 51, a second position shown in Figure 2 and located in the tubular form 51 at a first distance from the second end 55, and a third position shown in Figure 3 and located in the tubular form 51 at a second distance greater than the first distance from the second end 55 such that the preform 12 is removed from the tubular part or member 51. Any suitable means can be employed.
The prQcess or method of the invention comprises:
(a) providing a hollow or tubular form (such as the form 51) having first and second opposite ends and including an inner periphery defining the outer periphery of the preform to be formed;
~ 2t721Q~
(b) closing the first end of the tubular form by moving a member (such as the end cap 61) to a position which closes the first end of the tubular fDrm Sl, the member including an end face (such as the end face 63) which extends into the first end and from along the entLre length of the Lnner perLphery, and whLch defines the first end surface of the piece or part to be molded;
(c) placLng in the tubular form, preferably through the second end thereof and while the ram 71 is in the remote or spaced first position, a predet.orm;n-~
amount of fibrous material (or fiberglass) and binder;
(d) compressing the fiberglass and binder by inserting a member ( such as the ram 71 ) into the second end 55 of the tubular form and moving the ram through a first distance, the ram having an end face 73 extending from along the entire length of the inner periphery and spaced from the end face of the end cap to define both the second end surface of the preform and the distance between the end surfaces of the preform;
(e) curing the binder to produce the molded or f o~med pref orm;
( f ) removing the end cap 61 from the first end of the tubular form 51 to the remote or spaced position;
and (g) displacing the preform from the tubular form by further inserting the ram 71 into the tubular form 51 to the third position so as to effect removal of the preform from the tubular form 51. The process can then be recycled.
It should be noted that any suitable fibrous material, any suitable binder, and any suitable amounts thereof can be employed. Also, the fibrous material can be placed in the form 51 either before or after the end of the form 51 is closed by the end cap 61, although it is preferred to place the fibrous material in the form 51 after the end of the form 51 is closed by the end cap 61.
2t721~8 .
--7-- z,~oo Fiqure 5 shows how the preform 12 is used in the resin transfer molding process. A mold cavity lO0 is formed by mold halves 104 and 108. The cavity 104 has the shape of the cover 10 to be formed. ~he mold half 104 has therein a recess 112 corresponding to one of the })osses 11 on the cover 10. The preform 12 is placed in the recess 112, and additional fibrous material ( such as continuous strand mat or chopped fiber) 116 is placed in the l~ ;n~ r of the cavity.
Resin i6 then in~ected or otherwise introduced into the cavity, and the resin is cured to provide the fiber-reinforced polymer cover 10 comprised of the preform 12, any other preforms required (such as for the other boss 12), and the cured resin.
various of the features of the invention are set forth in the following claims.
Claims (21)
1. A method for forming a fiber preform for use in a resin transfer molding process, said method comprising the steps of providing a hollow form having a closed first end and an opposite second open end, placing in the form a predetermined amount of fibrous material and binder, compressing the fibrous material and binder by inserting a ram into the second end of the form and moving the ram through a predetermined distance, and curing the binder to produce the preform.
2. A method in accordance with Claim 1 wherein said providing step includes the steps of providing the hollow form with an open first end, and closing the first end of the form with an end cap.
3. A method in accordance with Claim 2 and further comprising the steps of removing the end cap from the first end of the tubular form, and displacing the preform from the form by further moving the ram into the form beyond the predetermined distance.
4. A method as set forth in Claim 2 wherein the preform has an outer endless periphery, a first end surface extending from along the entirety of the outer periphery, and a second end surface extending from along the entirety of the outer periphery in spaced relation to the first end surface, wherein said form includes an inner periphery defining the outer periphery of the preform, wherein said end cap includes an end face which extends into the first end and from along the entire length of the inner periphery, and which defines the first end surface of the preform, wherein said ram has an end face extending from along the entirety of said inner periphery and defining the second end surface of the preform.
5. A method in accordance with Claim 4 wherein one of said end faces is non-planar.
6. A method in accordance with Claim 5 wherein said one of said end faces is convex.
7. A method in accordance with Claim 4 wherein said tubular form has a longitudinal axis, and wherein one of said end faces extends in non-perpendicular relationship to said axis.
8. A method in accordance with Claim 2 wherein said placing step is performed after said closing step.
9. A method in accordance with Claim 1 and further comprising the steps of placing the preform in a mold cavity, introducing a resin into the mold cavity, and curing the resin to provide a fiber-reinforced polymer object comprised of the preform and the cured resin.
10. Tooling for forming a part having an outer endless periphery with a predetermined length, a first end surface extending from along the entire length of said outer periphery, and a second end surface extending from along the entire length of said outer periphery in spaced relation to said first end surface, said tooling comprising a tubular form including opposite ends and an endless inner periphery defining the outer periphery of a part to be formed, an end cap closing one of said opposite ends of said tubular form and including an end face which is located in said one end, which extends from along the entirety of said inner periphery, and which defines the first end surface of the part to be formed, and a ram enterable into the other of said opposite ends of said tubular form, and including an end face extending from along the entirety of said inner periphery in spaced relation to said end face of said end cap, and defining the second end surface of the part to be formed.
11. Tooling in accordance with Claim 10 and further including means for moving said end cap between a first position closing said first end of said tubular form and a second position remote from said first end of said tubular form, and means for moving said ram between a first position spaced from said second end of said tubular form and a second position located in said tubular form at a first distance from said second end.
12. Tooling in accordance with Claim 11 wherein said means for moving said ram is also operable to move said ram to and from a third position located in said tubular form at a second distance from said second end greater than said first distance.
13. Tooling in accordance with Claim 10 wherein one of said end faces is non-planar.
14. Tooling in accordance with Claim 13 wherein said one of said end faces is convex.
15. Tooling in accordance with Claim 10 wherein said tubular form has a longitudinal axis, and wherein one of said end faces extends in non-perpendicular relationship to said axis.
16. A process for forming a part having an outer endless periphery, a first end surface extending from along the entirety of the outer periphery, and a second end surface extending from along the entirety of the outer periphery in spaced relation to the first end surface, said process comprising the steps of providing a tubular form having first and second opposite ends and including an inner periphery defining the outer periphery of the part to be formed, placing in the tubular form a predetermined amount of fibrous material and binder, closing the first end of the tubular form with an end cap including an end face which extends into the first end and from along the entire length of the inner periphery, and which defines the first end surface of the part to be formed, compressing the fibrous material and binder by inserting into the second end of the tubular form and through a predetermined distance a ram having an end face extending from along the entirety of said inner periphery and defining the second end surface of the part to be formed, and curing the binder to produce the formed part.
17. A forming process in accordance with Claim 16 and further including the steps of removing the end cap from the first end of the tubular form, and displacing the formed part from the tubular form by further inserting the ram into the tubular form beyond the predetermined distance.
18. A forming process in accordance with Claim 16 wherein one of said end faces is non-planar.
19. A forming process in accordance with Claim 18 wherein said one of said end faces is convex.
20. A forming process in accordance with Claim 16 wherein said tubular form has a longitudinal axis, and wherein one of said end faces extends in non-perpendicular relationship to said axis.
21. A forming process in accordance with Claim 16 wherein said placing step is performed after said closing step.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US42863195A | 1995-04-25 | 1995-04-25 | |
| US08/428,631 | 1995-04-25 | ||
| US61066696A | 1996-03-04 | 1996-03-04 | |
| US08/610,666 | 1996-03-04 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2172108A1 true CA2172108A1 (en) | 1996-10-26 |
Family
ID=27027848
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2172108 Abandoned CA2172108A1 (en) | 1995-04-25 | 1996-03-19 | Fiberglass preform compression process |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2172108A1 (en) |
-
1996
- 1996-03-19 CA CA 2172108 patent/CA2172108A1/en not_active Abandoned
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Legal Events
| Date | Code | Title | Description |
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| FZDE | Dead |