CN101048276A - Thin ply laminates - Google Patents
Thin ply laminates Download PDFInfo
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- CN101048276A CN101048276A CN 200580032157 CN200580032157A CN101048276A CN 101048276 A CN101048276 A CN 101048276A CN 200580032157 CN200580032157 CN 200580032157 CN 200580032157 A CN200580032157 A CN 200580032157A CN 101048276 A CN101048276 A CN 101048276A
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Abstract
Fiber composite materials using thin plies with a thickness of less than 0.08 mm provide improved delamination resistance and thinner minimum gauge for laminates. Thin plies may be hybridized with conventional plies, interlaced for strength, and used with adhesives as reinforcement in bonding.
Description
The cross reference of related application
The application requires the priority of U.S. Provisional Application No.60/612740 (applying date is on September 24th, 2004) and U.S. Provisional Application No.60/668341 (applying date is on April 4th, 2005).
Technical field
The present invention relates generally to fibrous composite, particularly relate to and use thin layer (ply) so that the method that obtains the composite of improved physical characteristic and make this material.
Background technology
Common composite layer (by resin dipping or and can't help the resin dipping) is for 0.12mm is thick at least.The laminated material of composite layer solidifies and solidifies to handle and form by unidirectional ply being stacked in together and carrying out some subsequently.Need the layer of different directions, so that the mechanical property along a plurality of directions is provided.Like this, when minimum two the layer directions of needs, for example a layer is orientated with reference to 0 ° of angle, and another is 90 °.Hereinafter, usage flag [0/90] or [+45/-45] are described the layer direction of layer, and for example, one deck is laminated on the ground floor with 90 ° at 0 ° and another layer, perhaps one deck is in 45 ° and be laminated on another layer of-45 °, and expression is with respect to the direction of axis (unit is degree).In addition, laminated material is stacking symmetrically, to avoid warpage.Therefore, in the prior art, minimum (specification) gross thickness of minimum three layers (similar [0/90/0]) or four layers (similar [0/90/90/0]) is 0.36 or 0.48mm, no matter whether this thickness needs, because each layer is 0.12mm at least.Common employing direction is [0/90/45/-45] 4 layers.When forming symmetrically, need 8 layers, and minimum total laminate thickness is about 8 * 0.12mm, perhaps be about 1mm (using the common layer of 0.12mm at least).
Layering results from the free edge place of laminated material usually, perhaps at the some place that applies concentrated support load, perhaps is being subjected to side knock or forms the some place of stress in the laminated material solidification process.How let it be originates, and layering all is the fault pattern, and it has limited the utilization to the abundant potentiality of bearing capacity in the plane of the key of multi-direction laminated material usually.When composite was used for increasing important structure (for example Boeing 787 and airbus 350 and 380 aircrafts), composite material component can have hundreds of bed thickness.For a lot of purposes that receive composite, layering is serious threat.
A kind of common scheme is to make laminated material form 3 dimensional fabrics.This textile technology has multiple.They have at least two shortcomings: cost may be higher, and the reduction of plane internal characteristic, thereby be formed for the space of plane outer fiber.Use laterally stitching as a kind of optional substitute mode of this scheme.This method is not expensive, but also unreliable.Stitching causes the attach corruption to composite laminates.
Summary of the invention
In brief, the embodiment of the invention comprises a kind of laminated material, and this laminated material utilizes the thin layer of 0.08mm thickness or littler thickness to constitute.Optional embodiment comprises that thickness is less than the thin layer of 0.08mm and the combination of the thicker common layer of 0.12mm thickness at least.These combinations provide the performance of improved anti-micro rupture and layering, make the minimum gauge of laminated material thinner, chance thicker and that thinner layer mixes is provided, strengthened bonding connection, make interweaving product have the performance higher than common fabric, improved the direct reinforcement of pipe and container, and provide the fiber of chopping so that form stronger template die system mixture.The sublaminate (hereinafter being called " sublaminate ") of multi-direction layer can form the essential structure piece that is used for composite laminates, thereby has reduced assembly cost, keeps very high delamination resistance simultaneously.No matter whether carry out automation, the product that the product that is formed by thin layer sublaminate and laminated material constitutes with respect to the laminated material by the general thickness layer will be competitive on cost.
Utilize known fibre bundle to stretch and handle, the fibre bundle of common 12k carbon, glass or Kevlar fiber (approximately 0.12mm is thick) can stretch and form the thick ribbon of 0.02mm.By such thin layer, 3 layers of direction symmetric sublaminate for example of the present invention can have 0.12mm thickness, and are identical with common 0.12mm layer.Minimum gauge is decreased to the sixth (1/6) of the thickness of common layer.Press layer by layer in the material in symmetry 4, minimum gauge will be 0.16mm.This small dimension module provides by the conventional thick plies design alternative that is beyond one's reach, and higher delamination resistance is arranged.In fact, many designs of conventional composite structures are subjected to the domination of this layering standard.Therefore, utilize thin ply laminates can effectively design more high-performance or lighter weight structure.
Description of drawings
Fig. 1 has represented thin ply laminates of the present invention;
Fig. 2 has represented the more thick-layer of prior art;
Fig. 3 is the curve map as the normal stress of the function of bed thickness;
Fig. 4 is the curve map as the shear stress of the function of bed thickness;
Fig. 5 is the curve map that begins stress as the layering of the function of bed thickness;
Fig. 6 A has represented the use of thick-layer and thin layer;
Fig. 6 B has represented sublaminate;
Fig. 7 A is to use the perspective view of the composite of sublaminate;
Fig. 7 B is to use the side view of the composite of sublaminate, so that the expression joint;
Fig. 8 A is the curve map as the hardness of the function of bed thickness;
Fig. 8 B is the curve map as the maximum stress of the function of bed thickness;
Fig. 9 has represented the thin layer of doing;
Figure 10 has represented the lamellae of resin dipping;
Figure 11 has represented that three press material layer by layer;
Figure 12 has represented layer braiding and the angle in the crimp interchange zone;
Figure 13 A is each temperature for brittle adhesive, and load deformation is with respect to the curve map of bed thickness;
Figure 13 B is each temperature for ductile adhesive, and load deformation is with respect to the curve map of bed thickness;
It is two-layer that Figure 14 has represented that the use thin layer connects;
Figure 15 is the table of effect of the joint of expression Figure 14;
Figure 16 has represented that metal forming is used for a side of laminated material;
Figure 17 has represented that metal forming is used for the two sides of laminated material;
Figure 18 A has represented that metal forming is used on the two sides of laminated material and the center;
Figure 18 B is the amplification view of the part among Figure 18 A; And
Layer structure when Figure 19 has represented do not have paper tinsel at the center of laminated material.
The specific embodiment
The cross section of having represented composite 10 of the present invention among Fig. 1.Composite 10 has multilayer, comprises ground floor 12, and this ground floor 12 is with an expression, and along the first direction orientation.Ground floor 12 is separated by the second layer 14, and this second layer 14 is oriented along the second direction different with first direction.The second layer 14 any marks of no use are represented, so that they and ground floor 12 are distinguished.According to the present invention, the thickness " t " of layer 12,14 is less than 0.08mm, preferably from 0.02mm to 0.06mm.The laminated material that Fig. 2 just is used to represent common/prior art is made of the layer that replaces (for example 16,18), and the thickness of these layers is greater than the thickness of layer of the present invention, and the thickness of each layer " T " is 0.12mm or bigger roughly.
According to the present invention, thin ply laminates has improved delamination resistance.They do not need out-of-plane fiber, therefore keep good plane internal characteristic.For example, at the normal stress of the calculating at the free edge place of laminated material and shear stress as shown in Fig. 3 and 4, as the function of bed thickness.Bed thickness be common/prior art of 0.12mm at least shown in each figure right side, wherein, bed thickness is decreased to 0.02mm to the left.These measured values show: when bed thickness be decreased to 0.12mm prior art thick-layer laminated material 1/3 and 1/6 the time, normal stress and shear stress obviously reduce.This is the unforeseen result of prior art.Therefore, thin ply laminates provides the scheme of improved delamination resistance.
Fig. 5 has represented another example of the effect of thin layer when layering begins, and this Fig. 5 has represented as the stress function of effective layer thickness, that layering is required.When bed thickness reduced, delamination stress obviously increased once more.
As optional embodiment, the hybrid combining of thick-layer and thin layer can be provided at the balance between performance and the cost, and this combination is contained among the present invention.Thin layer has not only increased rigidity, but also has increased the flexibility when layer falls.This realizes wherein, having the thin layer of different directions or the thin layer of different directions and the module of thick-layer combination and be pre-formed to being used for the building block of laminated material by using sublaminate.The whereabouts of sublaminate has replaced the whereabouts of each layer.
Example 1: example of the present invention comprises that thickness is that thick-layer and the thickness of 0.12mm is the combination of the thin layer of 0.02mm.This is expressed as in Fig. 6 A has thin layer 21 and thick-layer 23.And the sublaminate 25 among Fig. 6 B can be the thickness mixture, and [0] 27 and thin layer [90] 29 of a thick-layer is arranged.The gross thickness of this sublaminate can be 0.12mm+0.02mm=0.14mm, and at this moment, the percentage of [0] should be 0.12/0.14=86%.Use such sublaminate construction mast or suspension rod that higher anisotropic structure will be provided, it has the inaccessiable rigidity of conventional laminates of only using thick-layer.For conventional laminates, the replicated blocks of thick-layer must have 9 layers [0] and 1 layer [90].The thickness of total sublaminate will be 1.20mm, and wherein the percentage of [0] equals 90%.This design is stacked in 9 layers [0] together, and this viewpoint from rigidity is very poor design.In fact this make the mast instability, and lost efficacy owing to fractureing easily.
Example 2: when hope has higher [0] percentage, two thick-layers [0] can be arranged, a thin layer [90] is arranged subsequently.At this moment, the percentage of [0] should be 0.24/0.26=92%.In three direction sublaminate with two [0] and [+/-45], [0] percentage is 0.24/0.28=86%.These two examples will make mast or suspension rod that the more laminated material of rigidity is arranged.This mixed structure also is used for driving shaft, reed and sports goods (for example pole vault bar, hockey stick, golf club etc.).
Example 3: another example of thick thin ply laminates is three direction sublaminate, and it has a 0.12mm thick-layer [0] and two 0.02mm angle thin layers [+/-30] or [+/-45], for example [+30/0/-30] or [+45/0/-45] module.The thickness of total sublaminate is 0.16mm, and it can be finished as a step in the decline of layer.Can make three direction modules of any thick-layer and thin layer combination.This design flexibility makes product have obvious improved laminated material performance, and obviously saves cost during fabrication.
Example 4: the multi-direction sublaminate of same thought can be designed for beam and rib, as the minor structure of composite structure.At this moment, the shear module in network is most important.The thickness mixture can have thick [+/-45] and the combination of thin [0].In all these purposes, the laminated processing of sublaminate can be along a direction, for example along beam axially.When being used for the covering of wing, laminated can be along wing axis.When being used for fuselage, laminated can be along both direction, one along the garter spring direction, another in axial direction, perhaps along two helical angles.This can save laminated machine capability and laminated time and work very significantly.
Composite of the present invention can be made of a plurality of sublaminate.Fig. 7 A has represented to comprise the composite 31 of sublaminate 33.Fig. 7 B is the planar side view with composite 35 of sublaminate 37, and it and Fig. 7 category-A seemingly are used to represent sublaminate joints 39.Sublaminate plate broad ways connects, and plate is carried out stacking, and blank area can not repeat along thickness direction.The sublaminate of Fig. 7 A, 7B can be all identical, and perhaps they can be different.Sublaminate can all be a thin layer, and the combination of thin layer and thick-layer is perhaps arranged, and/or sublaminate can have plies of interlaced fabric, as shown in figure 12.Use thin layer to make sublaminate thickness approximate identical with common bed thickness.Use this method, can obtain to have the large-sized composite material moulded product of excellent mechanical properties.
A kind of method that forms the thin layer fibre bundle is by making general fibre Shu Shenzhan.The cross section of the fibre bundle that stretches is a rectangle, and thickness is 0.04mm or littler, and width is about 20mm.The fibre bundle of these stretching, extensions can be easy to interweave, so that form fabric.The cross section of crossed fiber bundle as shown in Figure 12.Union provides high performance laminated material, and it is easy to be processed into complex geometric shapes.The gross thickness of this union will be the twice of thickness of thin layer, promptly be 0.04mm when using the thin layer of 0.02mm.Have thick-layer and thin layer union structural behaviour as shown in Figure 8A and 8B, wherein, the mechanical property of increase is expressed as bed thickness and reduces from right to left.When the layer that uses 0.02mm replaced the layer of 0.12mm, hardness increased by 35%, and maximum stress reduces 20%.
As an example, laminated material 28 has as shown in Figure 11 by a plurality of layer 36 three layer 30,32,34 of forming.Layer can position near 38 places, end and along sidepiece (for example at 40 places) and the layer place of meeting 42.Can be gapped between them.These gaps are very little to the mechanical performance influence of laminated material, because bed thickness is very little.
Figure 12 is the cutaway view of interlaced plies 41.Thin ply laminates has improved performance, because when bed thickness reduces, the size in the crimp interchange zone 42 shown in Figure 12 and the angle A of formation become littler.When the fibre bundle that stretches wove up and down because running into the fibre bundle of vertical direction, curling influence area was because more fine fibre Shu Ergeng is little.Exchange fiber Shu Bixu holds mutual thickness.Fibre bundle is thin more, and holding of needing in fibre bundle exchange place is more little.Therefore, the macrohardness of crossed fiber bundle and the stress that forms in the exchange place all are subjected to the influence of this thickness.Fibre bundle is thin more, and hardness is high more, and local stress is low more.
Bonding joint provides the best approach that connects two composite material components.The easier manufacturing of bonding joint, and the stress that causes in the joint is concentrated minimum.In a broad sense, two kinds of types of bonded joint adhesive are arranged: brittle adhesive and ductile adhesive.Figure 13 A and 13B show respectively at various temperatures brittle adhesive and the load-deformation curve of ductile adhesive.Load-the deformation curve of the hardest bonding agent is a room-temperature property.When increase in temperature, the performance of bonding agent will more and more resemble toughness material.Brittle adhesive shown in Figure 13 A is the epoxy resin that glass dust strengthens, and ductile adhesive is PMMA.
New bonded joint 43 can utilize thin layer to make as reinforcing material, as shown in Figure 14.The effect of this joint represents in the table of Figure 15, and it has represented the prediction that obtained by finite element analysis.Should be known in the stress with respect to the bonding agent that does not strengthen, stress reduces by 56% and 30%.In addition, this joint design obtained peel off and shear stress between balance, be not resemble not the bonding agent that strengthens a domination another.Strengthen bonding agent for thin layer, [0] direction is alignd with the axial force on being applied to bonded joint.
Template die system compound and pad can utilize the thin layer fiber of chopping to make.These products have very high-performance, because hardness and intensity are owing to reducing crimp interchange loss.In addition, thin layer has reduced bending hardness by cubic relationship: promptly 1/6 of thick-layer thickness will be 1/216 of original hardness.Therefore, by the template die system compound made of thin layer fibre bundle of chopping with the curvature of easier adaptation in moulding part and the unexpected variation of shape.The advantage of this processing is additional provide hardness and intensity.
Thin layer also helps the online quality of solidifying and the processing speed of the thermoplastic belt of carbon enhancing.When the thickness of band more hour, the common stiffness (high rigidity) of thick-layer band can be significantly reduced to more soft or submissive band.Cubic relationship same as described above also be used to flexural rigidity.In the online processing of using strip, do not need just in order to make the more soft preheating of band.This processing can be by filament winding moulding and is solidified subsequently and make pressure vessel.
Figure 16-18 has represented to comprise another embodiment of the laminated material of the present invention of metal and thin ply laminates.Figure 16 has represented that metal 44 is applied on the side of thin ply laminates 46.Figure 17 has represented that metal 48,50 is applied on the two sides of thin ply laminates 52.Product when Figure 16 and 17 has represented that metal matrix composite is bonded on side of thin ply laminates or the two sides.Metal level can produce in multiple mode known in the art, comprises that metal forming, steam deposition (CVD), metal embed in the polymer, plating etc.This laminated material of metal coating.In uncoated thin ply laminates, superficial layer is extremely thin.When the outside fiber in the laminated material is impaired (for example owing to impact or scraping), the fiber destruction in superficial layer can be easy to take place, and this can cause laminated material to lose efficacy.Product shown in Figure 16 and 17 helps to prevent this fiber destruction and inefficacy.Figure 18 A has represented in the two sides 54,56 of thin ply laminates 60,62 and 58 places, center metal is arranged.Figure 18 B is the cutaway view of Figure 18 A, is used for being illustrated in the direction (90 ° ,-45 °) of the fiber in the laminate ply of Figure 18 A.When metal matrix composite is inserted the thin ply laminates center, shown in Figure 18 A and 18B, with the double thickness that prevents in laminated material.This helps symmetrical lamination, and wherein, the double thickness at the laminated material center may cause matrix breakdown and layering.Figure 19 has represented the double thickness of central core when not having metal, and it makes laminated material be easy to crack and layering.
The newtype metal matrix composite materials of use metal and thin layer composite material can be with quite low cost manufacturing.Titanium-graphite) or copper (Cugr: high-temperature composite material copper-graphite) for example, can form and use thin carbon fiber reinforced plastics (CFRP) and in conjunction with titanium (Tigr:.This metal matrix composite materials has heat-resisting quantity and unique corrosion resistance, can be used for multiple use, comprises chemical reagent pipeline and container.
For pad and union, comprise that resin transmits molded (RTM) and vacuum-assisted resin transfer molded (VARTM) is handled, use layer material to make material easier to be mobile, and the adaptability to numerous and diverse surface is provided, keep good physical characteristic simultaneously.
The foregoing description is as example of the present invention.Those skilled in the art should know the version of these examples.These versions are included in the spirit of the present invention.
Claims (16)
1. a composite comprises thin layer, and the thickness of this thin layer is less than 0.08mm.
2. material according to claim 1, wherein: material comprises that thickness is the combination less than the thin layer of 0.08mm of the common layer of 0.12mm at least and thickness.
3. material according to claim 1, wherein: material comprises the combination of the sublaminate of thin layer.
4. material according to claim 2, wherein: material comprises the sublaminate of thin layer and the sublaminate of common layer.
5. material according to claim 2, wherein: material comprises the sublaminate with thin layer and common layer.
6. according to claim 1,2,3,4 or 5 described materials, wherein: thin layer interweaves or weaves.
7. according to claim 1,2,3,4 or 5 described materials, wherein: material uses resin to transmit molded and forms.
8. according to claim 1,2,3,4 or 5 described materials, wherein: thin layer and bonding agent combination so that the adhesives of enhancing is provided, are used to make composite and/or metal component to connect by bonding joint.
9. according to claim 1,2,3,4 or 5 described materials, wherein: thin layer and bonding agent combination so that the adhesives of enhancing is provided, are used to have the composite component of honeycomb or sandwich.
10. according to claim 1,2,3,4 or 5 described materials, wherein: thin layer is shredded, and reconstitute molded compound.
11. a product, comprise as claim 1,2,3,4 or 5 described materials, wherein: thin layer or sublaminate are included in thermosetting or the thermoplastic belt, and product forms by band method for arranging or band winding method, and band is solidified.
12. a fiber reinforced metal matrix composite comprises as claim 1,2,3,4 or 5 described material and metallic plates.
13. composite according to claim 12, wherein: metallic plate only is arranged as superficial layer.
14. composite according to claim 12, wherein: metallic plate is arranged between the thin layer with identical fibre direction.
15. according to claim 12,13 or 14 described matrix composites, wherein: thin layer comprises graphite linings.
16. matrix composite according to claim 15, wherein: metal is selected from the group that comprises titanium and copper.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201110428403.2A CN102514284B (en) | 2004-09-24 | 2005-09-23 | Thin ply laminates |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US61274004P | 2004-09-24 | 2004-09-24 | |
| US60/612,740 | 2004-09-24 | ||
| US60/668,341 | 2005-04-04 |
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| CN201110428403.2A Division CN102514284B (en) | 2004-09-24 | 2005-09-23 | Thin ply laminates |
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| CN101048276A true CN101048276A (en) | 2007-10-03 |
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN102777540A (en) * | 2011-05-11 | 2012-11-14 | 贝尔直升机泰克斯特龙公司 | Hybrid tape for robotic transmission |
| CN103140349A (en) * | 2010-10-15 | 2013-06-05 | 法国肯联铝业 | Aircraft wing and fiber metal laminate forming part of such an aircraft wing |
| CN104169059A (en) * | 2011-12-21 | 2014-11-26 | 吉凯恩航空服务结构公司 | Method and apparatus for forming a fabric preform for a composite material by separately tensioning tows |
| CN104736864A (en) * | 2012-10-22 | 2015-06-24 | H.E.F.公司 | Self-lubricating hinge assembly made from composite material and operating under high dynamic loads |
| CN107953624A (en) * | 2017-12-26 | 2018-04-24 | 宜兴市天宇世纪高新科技有限公司 | A kind of carbon fiber fire-proof plate |
| CN108045016A (en) * | 2017-12-26 | 2018-05-18 | 宜兴市天宇世纪高新科技有限公司 | A kind of high intensity, high modulus carbon fiber plate |
| CN108556383A (en) * | 2017-12-26 | 2018-09-21 | 宜兴市天宇世纪高新科技有限公司 | A kind of preparation method of Carbon fiber laminated board |
| CN110290919A (en) * | 2017-02-22 | 2019-09-27 | 三菱重工业株式会社 | The manufacturing method of composite material and composite material |
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2005
- 2005-09-23 CN CN 200580032157 patent/CN101048276A/en active Pending
Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103140349A (en) * | 2010-10-15 | 2013-06-05 | 法国肯联铝业 | Aircraft wing and fiber metal laminate forming part of such an aircraft wing |
| CN103140349B (en) * | 2010-10-15 | 2015-11-25 | 法国肯联铝业 | The fiber metal laminate of a part for wing and the described wing of formation |
| CN102777540A (en) * | 2011-05-11 | 2012-11-14 | 贝尔直升机泰克斯特龙公司 | Hybrid tape for robotic transmission |
| CN102777540B (en) * | 2011-05-11 | 2015-09-16 | 贝尔直升机泰克斯特龙公司 | For the hybrid driving belt of mechanical transmission |
| CN104169059A (en) * | 2011-12-21 | 2014-11-26 | 吉凯恩航空服务结构公司 | Method and apparatus for forming a fabric preform for a composite material by separately tensioning tows |
| CN104169059B (en) * | 2011-12-21 | 2016-06-08 | 吉凯恩航空服务结构公司 | Be formed for the method and apparatus of the fabric prefabricated component of composite by tensioning strands of material respectively |
| CN104736864A (en) * | 2012-10-22 | 2015-06-24 | H.E.F.公司 | Self-lubricating hinge assembly made from composite material and operating under high dynamic loads |
| CN104736864B (en) * | 2012-10-22 | 2018-07-06 | H.E.F.公司 | The self-lubricating hinge assembly for being made and being operated under high dynamic load by composite material |
| CN110290919A (en) * | 2017-02-22 | 2019-09-27 | 三菱重工业株式会社 | The manufacturing method of composite material and composite material |
| CN107953624A (en) * | 2017-12-26 | 2018-04-24 | 宜兴市天宇世纪高新科技有限公司 | A kind of carbon fiber fire-proof plate |
| CN108045016A (en) * | 2017-12-26 | 2018-05-18 | 宜兴市天宇世纪高新科技有限公司 | A kind of high intensity, high modulus carbon fiber plate |
| CN108556383A (en) * | 2017-12-26 | 2018-09-21 | 宜兴市天宇世纪高新科技有限公司 | A kind of preparation method of Carbon fiber laminated board |
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