CN107450228B - 发光装置 - Google Patents

发光装置 Download PDF

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CN107450228B
CN107450228B CN201710399615.XA CN201710399615A CN107450228B CN 107450228 B CN107450228 B CN 107450228B CN 201710399615 A CN201710399615 A CN 201710399615A CN 107450228 B CN107450228 B CN 107450228B
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light
transmitting member
emitting element
substrate
emitting device
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CN107450228A (zh
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山田有一
山田元量
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Nichia Corp
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Abstract

本发明提供一种可抑制向上面方向的漏光且可得到所希望的配光特性的发光装置。发光装置具有:基板(25);发光元件(12),其载置在基板(25)上,且在上表面具有反射层(17);第一透光部件(16),其具有与发光元件(12)的侧面相接的第一面(16a)、朝向离开发光元件(12)的方向与基板(25)的距离变短的第二面(16b);第二透光部件(20),其与第二面(16b)相接,且将发光元件(12)覆盖,第一透光部件(16)的折射率比第二透光部件(20)的折射率小。

Description

发光装置
技术领域
本发明涉及发光装置。
背景技术
近年来,各种电子零件被提出且被实用化,对其要求的性能也提高。例如,在液晶显示器使用的背光灯或普通照明器件等,设计制造被重视,薄型化的要求更高,发光装置自身的小型化要求高。
例如在专利文献1中公开有如下的发光装置,即,将二维光学透镜与LED组合而实现蝙蝠翼配光的配光特性,通过使光在短的照射距离均匀地扩散而可实现器件的薄型化。
专利文献1:(日本)特开2006-114863号公报
但是,在将LED和透镜组合的方法中,若在透镜与空气层的界面的发射光及/或来自LED的直射光向在位于透镜下部的基板的上表面形成的扩散反射部射入,则通过由光散射形成的向透镜上面方向的射出光而使正上方的发光强度提高。由此,具有不能够使上面方向的发光强度充分降低,不能得到所希望的配光特性的情况。
发明内容
本发明是鉴于上述情况而设立的,提供可抑制向上面方向的漏光且可得到所希望的配光特性的发光装置。
本发明一方面的发光装置具有:基板;发光元件,其载置在所述基板上,且在上表面具有反射层;第一透光部件,其具有与所述发光元件的侧面相接的第一面、朝向离开所述发光元件的方向与所述基板的距离变短的第二面;第二透光部件,其与所述第二面相接,且将所述发光元件覆盖,所述第一透光部件的折射率比所述第二透光部件的折射率小。
根据本发明一方面的发光装置,能够抑制向上面方向的漏光,且可得到所希望的配光特性。
附图说明
图1是本发明第一实施方式的发光装置的概略俯视图;
图2是图1的A-A′线的概略剖面图;
图3是表示折射率的关系与第一实施方式不同时的光取出状态的概略图;
图4是表示折射率的关系与第一实施方式不同时的光取出状态的概略图;
图5是本发明第二实施方式的发光装置的概略剖面图;
图6是表示使用了实施方式的发光装置的面发光装置的一例的概略剖面图;
图7是表示使用了实施方式的发光装置的面发光装置的一例的概略俯视图;
图8是表示实施例及比较例的配光特性的图表。
标记说明
12:发光元件
13a、13b:配线部
15:保护层
16:第一透光部件
16a:第一面
16b:第二面
17:反射层
18:接合部件
20:第二透光部件
22:电线
24:基体
25:基板
30:光扩散板
32:波长转换层
33:反射部件
35:(反射部件的)端部
具体实施方式
以下,适当参照附图对发明的实施方式进行说明。但以下说明的发光装置用于将本发明的技术思想具体化,只要没有特别的记载,就不将本发明限定于此。另外,为了将说明明确,附图所示的部件的大小及位置关系等会夸大表示。
〈第一实施方式〉
图1是表示第一实施方式的发光装置的概略俯视图,图2是图1的A-A′线的概略剖面图。发光装置具有基板25、载置在基板25上且在其上表面具有反射层17的发光元件12、第一透光部件16、第二透光部件20。第一透光部件16具有与发光元件12的侧面相接的第一面16a、朝向从发光元件12离开的方向与基板25的距离变短的第二面16b。第二透光部件20与第一透光部件16的第二面16b相接,将发光元件12覆盖。第一透光部件16的折射率α比第二透光部件20的折射率β小。
1.基板25的构成
基板25例如如图2所示地具有基板24、配线部13a、13b、保护层15。基板24由绝缘材料构成,适合使用例如玻璃环氧树脂、双马来醯亚胺三嗪、聚酰亚胺(PI)、聚萘二甲酸乙二醇酯(PEN)、聚对苯二甲酸乙二醇酯(PET)等绝缘性树脂或者氧化铝等陶瓷。另外,基体24也可以利用绝缘性树脂覆盖铜箔或铝箔而构成。基体24的厚度例如可设为10μm~100μm左右。
配线部13a、13b配置在基体24的主面上。配线部13a及13b相互分开而配置。这样的配线部13a、13b例如由铜箔或铝等金属膜构成。配线部13a、13b的厚度例如可设为10μm~60μm左右。另外,在作为基体24而使用具有可挠性的材料的情况下,配线部的厚度只要为不损害作为基板25的可挠性的厚度即可,例如优选为8μm~150μm。
在本实施方式中,具有一对配线部13a、13b,但不限于此。基板25只要至少具有一对配线部即可,也可以具有三个以上的配线部。此时,发光元件12可以配置在三个以上的配线部上。
保护层15覆盖基体24及配线部13a、13b的表面。保护层15除了后述的开口部15S之外,还覆盖基板25的大致整个表面。保护层15优选通过将发光元件12的射出光(包含通过波长转换部件进行了波长转换的光)反射的材料而构成。作为保护层15的材料,例如适合使用在硅类树脂中含有氧化钛的称作白色抗蚀剂的绝缘性的白色墨。
另外,在保护层15至少形成有配置发光元件12的区域及在其附近开设的开口部15S。在图1中图示了跨越配线部13a、13b之上而形成的开口部15S。如图2所示,使两个配线部13a、13b的一部分在开口部15S的内侧露出。
开口部15S能够形成为俯视下包围发光元件12的圆形、四边形等任意的形状。在图1中,开口部15S形成为圆形。开口部15S在安装了发光元件12之后,被后述的第一透光部件16覆盖。另外,开口部15S不仅被第一透光部件16覆盖,也可以被第一透光部件16及第二透光部件20二者覆盖。
开口部15S的大小只要为可确保与发光元件12的电极连接的区域的大小即可,例如开口部15S的端部位于发光元件12的俯视下构成外形的一边的50~2000μm左右的外侧为好。在本实施方式中,开口部15S的端部形成在第二透光部件20的端部的外侧。
另外,保护层15可以延伸到发光元件12的下方而设置,开口部15S可以比发光元件12的俯视形状小。另外,保护层15以包围将发光元件12和基板25接合的接合部件18包围的方式设置,实质上也可以不具有开口部而设置。
另外,配线部13a、13b也可以作为与连接外部电源的外部配线连接的端子部而起作用。端子部优选形成在基板25的主面侧的端部,外部配线也可以与设于基板25上的公知的连接器等连接。
2.发光元件12的构成
发光元件12配置在基板25上。如图1所示,在基板25具有保护层15的情况下,配置在形成于保护层15的开口部15S的内侧。
发光元件12在其上表面具有反射层17。反射层17使来自发光元件12的光反射,通过配置反射层17而将来自发光元件12的射出光主要从未形成有反射层17的发光元件12的侧面射出。由此,能够抑制发光元件12正上方的光量,形成为蝙蝠翼型的配光特性。通过在发光元件12直接形成反射层17而不需要一次透镜或二次透镜,故而与使用一次透镜或二次透镜实现蝙蝠翼配光的情况相比,能够减小发光装置的厚度。
反射层17只要可将来自发光元件12的光反射即可。例如,优选将从发光元件发出的光反射70%以上,更优选反射80%以上。例如,既可以为金属膜,也可以为电介质多层膜(DBR膜)。
反射层17相对于发光元件12的发光波长,优选具有相对于入射角的反射率角度依赖性。具体地,反射层17的反射率优选以倾斜入射比垂直入射低的方式设定为好。由此,发光元件正上方的亮度的变化变缓,能够抑制发光元件的正上方变成暗点等极度变暗的情况。
在此,发光元件12如图2所示地在基板25上倒装片安装。发光元件12经由一对接合部件18与配线部13a、13b连接。接合部件18可由Sn-Ag-Cu类或Au-Sn类、Sn-Cu类等焊料或Au等金属、各向异性导电膏、Ag膏等构成。
发光元件12例如具有在具有透光性的蓝宝石基板上依次层积的n型层、活性层及p型层。n型层、活性层及p型层例如可通过氮化镓类半导体构成。与n型层连接的n侧电极及与p型层连接的p侧电极经由一对接合部件18而与一对配线部13a及13b连接。
3.第一透光部件16及第二透光部件20的构成
在本实施方式中,通过使用第一透光部件16及第二透光部件20,使从带光反射层17的发光元件12射出的光的取出方向变化,使光取出效率提高。
将从发光元件12的侧面射出的光射入的第一透光部件16与发光元件12的侧面相接而配置。将与发光元件12的侧面相接的第一透光部件16的面设为第一面16a。另外,第一透光部件16以朝向从发光元件12离开的方向而使与基板25的表面的距离变短的方式(换言之,以第一透光部件16的厚度朝向自发光元件12离开的方向而减薄的方式)形成有第二面16b。第二面16b相对于基板25或配线部13a、13b的表面倾斜。
发光元件12的上表面即反射层17的上表面从第一透光部件16露出。反射层17的侧面被第一透光部件16覆盖。另外,也可以将带反射层17的发光元件12的整体覆盖的方式配置有第一透光部件16。
第一透光部件16在俯视下如图1所示地优选其外缘为圆形。此时,如图1所示,优选以发光元件12为大致中心,由第一透光部件16将其周围包围而配置。
第二透光部件20配置在基板25之上,与第一透光部件16的第二面16b直接相接,将发光元件12间接地或直接地覆盖。第二透光部件20的形状可形成为圆柱状或半球状等。
第二透光部件20俯视下如图1所示地将第一透光部件16的整个上表面覆盖,比第一透光部件16大地形成。此时,在第一透光部件16的外周不隔着第一透光部件16而由第二透光部件20覆盖基板25的上表面。例如,俯视下,第二透光部件20的端部位于第一透光部件16的端部所处的部位的50~1000μm左右的外侧。
在本实施方式中,第一透光部件16的折射率α设定为比第二透光部件20的折射率β小。在此的折射率是指相对于发光元件12的发光波长的折射率。此时,如图2中箭头标记所示,从发光元件12的侧面射出的光从第一面16a向第一透光部件16射入,向第一透光部件16的第二面16b与第二透光部件20的界面方向行进。此时,从第一透光部件16向第二透光部件20行进的光L1从折射率小的介质向折射率大的介质行进,故而在第一透光部件16与第二透光部件的界面不产生全反射。另外,第一透光部件16的第二面16b、即第一透光部件16与第二透光部件20的界面以朝向从发光元件12离开的方向与基板25的距离变短的方式倾斜,故而在界面折射的光L2被向上方抬起。
由此,能够利用反射层17抑制向上面方向的漏光,能够提高光取出效率。因此,为了使光向上方折射,优选来自发光元件的光几乎全部通过第一透光部件16,优选利用第一透光部件16将发光元件的整个侧面覆盖。
图3是表示α>β时的来自发光元件12的光的取出状态的图。从发光元件侧12的侧面射出的光从第一面16a向第一透光部件16射入,并且向第一透光部件16的第二面16b与第二透光部件20的界面方向行进。此时,从第一透光部件16向第二透光部件行进的光L1从折射率大的介质向折射率小的介质行进,故而产生全反射。特别是,在从发光元件12的侧面射出光的情况下,射入第二面12b的光L1容易比临界角大,大部分光被全反射而如L3的箭头标记所示地向基板25侧反射,产生基板引起的光吸收而使光取出效率下降。
另外,为了抑制在基板25的光吸收,例如提高配线部13a、13b的反射率、将保护层15形成为反射性等而将全反射的光取出的情况下,由于光散射而使发光元件12的正上方的发光强度提高,反射层17的效率下降。
图4是表示α=β时的来自发光元件12的光的取出状态的图。此时,在第一透光部件16与第二透光部件20的界面不产生全反射。由于在界面也不产生折射,故而射入第二透光部件20的光L4以射入的角度在第二透光部件20内行进。在将光源排列多个而使用的情况下,向侧方射出的光向邻接的光源射入而被吸收。因此,如上述本实施方式那样地,需要使向横向射出的光在第一透光部件16与第二透光部件20的界面折射而将其向上方抬起。
另外,例如如图6所示,即使配置可将从发光元件12的侧面向横向射出的光反射的反射部件33的情况下,由于反射部件33具有厚度,通过与反射部件33的端部35碰撞而散射的光,使发光元件12的正上方的发光强度提高,反射层17的效果下降。因此,如本实施方式那样地,通过使向横向射出的光在第一透光部件16与第二透光部件20的界面折射而将其向上方抬起,能够降低发光元件侧的正上方的光量。
另外,考虑从发光元件12向第一透光部件16取出光时,例如在使用了蓝宝石基板的发光元件12的情况下,通常折射率比树脂高。此时,为了提高自发光元件12的光取出效率,优选尽可能地减小发光元件12与第一透光部件16的折射率差。在本实施方式中,在将第一透光部件16及第二透光部件20形成为树脂材料的情况下,发光元件12与第二透光部件20的折射率差比发光元件12与第一透光部件16的折射率差大。因此,从发光元件侧12向第一透光部件16的光取出效率变低,但在本实施方式中,由于能够抑制在基板25的光吸收,故而能够使直到第二透光部件20外侧(空气存在的部位)的光取出效率提高。
折射率例如能够由阿贝折射仪测定。另外,在根据部件的大小等而不能够由阿贝折射仪测定的情况下,能够特定部件,由与该特定的部件类似的部件的测定结果求出折射率。
第一透光部件16及第二透光部件20优选为树脂部件。通过使用树脂材料,能够选择所希望的折射率的材料。作为树脂材料,能够适合使用例如环氧树脂、脲醛树脂、硅酮树脂、氟树脂以及至少含有一种以上上述树脂的混合树脂等。另外,第一透光部件16及第二透光部件20实质上不含有例如光散射物质等阻碍光的直进性的物质。但是,为了调整树脂的粘度等,也可以含有纳米填充剂那样的几乎不产生光的散射的物质。
另外,第一透光部件16及第二透光部件20若为折射率α<β的关系,则不限于上述那样的树脂材料,可以由具有透光性的玻璃等构成。该情况下,也可以以将第一透光部件16设为树脂材料,将第二透光部件20设为玻璃的方式,由不同的材料形成第一透光部件16和第二透光部件20。
〈第二实施方式〉
本实施方式的发光装置不将发光元件12倒装片安装,将发光元件12的绝缘基板侧安装在基板25的上表面。
如图5所示,本实施方式的发光元件12以一对p侧电极和n侧电极位于上方的方式安装,各自的电极经由配线部13a、13b和电线22而电连接。在发光元件12的形成有电极一侧的面上形成有反射层17。例如,也可以将电极遮盖而在其以外的部分形成反射层17,还可以夹着保护膜而在大致同一面上形成反射膜17且在其上形成电极。在本实施方式中,保护层15以开口部15S比第二透光部件20的端部靠内侧的方式形成。
在发光元件12的侧面侧与第一实施方式同样地配置有第一透光部件16,电线22和配线部13a及13b的连接部位被第一透光部件16覆盖。另外,电线22与发光元件12的电极的连接部位被第二透光部件20覆盖。对于其他构成,实质上能够与第一实施方式相同,起到同样的效果。
以下,对第一实施方式及第二实施方式可适用的构成及部件进行说明。
(面发光装置)
本实施方式的发光装置优选将图1及图5所示的发光装置在一个基板上形成多个。由此,能够形成亮度不均少的面光源。也可以在该面光源上设置扩散板或波长转换片。作为这样的例子,在图6及图7中表示面发光装置。
图6是包含第一实施方式的发光装置的发光装置的概略剖面图。第一实施方式中说明的发光装置隔开规定的间隔而安装在共同的基板25上,在多个发光装置之间配置有反射部件33。即,面发光装置具有多个实施方式1的发光装置,在各发光装置之间且从第二透光部件20露出的区域的基板25上配置有可将来自发光元件12的光反射的反射部件33。反射部件33的高度设定为比第二透光部件20的高度还高。另外,在其上以与发光元件12的上表面大致平行的方式配置有用于将来自发光装置的光扩散的光扩散板30,进而在其上与光扩散板30大致平行地配置有将从发光装置发出的光的一部分转换成其他波长的光的波长转换层32。
通常,随着基板25与光扩散板30的距离(以后,光学距离也称为OD)/发光元件间隔(以后也称为Pitch)减小,在光扩散板30的面上,发光装置间的光量减少,产生暗部。但是,如本实施方式那样地形成为配置反射部件33的构成,从而利用反射部件33来弥补发光装置间的光量,在更小的OD/Pitch区域,光扩散板30的面上的亮度不均也减小。作为反射部件33的材料,若为至少将发光元件12的发光波长反射的材料,则不特别限定材料。能够适合使用例如金属箔、含有白色填充剂的树脂。
对于反射部件33的高度及相对于基板25的表面的光反射面的倾斜角度,可取得任意的值,另外,其反射面既可以为平面也可以曲面,以可得到所希望的配光特性的方式可适用最佳的构成。反射部件33的高度为发光元件间的距离的0.3倍以下,优选为0.2倍以下,由此能够降低亮度不均。
另外,反射部件33将多个反射部件33连接而形成为板状,优选形成为具有配置发光装置的贯通孔的板状。在图6中表示了包含两根发光装置的概略剖面图,但例如如图7的概略俯视图所示,也可以将数十~数百个发光装置矩阵状地排列。
〔实施例〕
(实施例1)
图1及图2表示实施例的发光装置的俯视图及剖面图。如图1所示,本实施例的基板25以跨过在基体24的上表面设置的正负一对配线部13a、13b的方式经由接合部件18将发光元件12倒装片安装。在配线部13a、13b中的不进行电连接的区域形成有保护层15。在发光元件12的上表面形成有反射层17。
第一透光部件16与发光元件12的侧面相接,以使位于发光元件12的上表面的光反射层17露出的方式在发光元件12的周围具有朝向从发光元件12离开的方向与基板25的距离变短的第二面16b而形成。另外,以与第一透光部件16的第二面16b及光反射层17直接相接的方式形成有第二透光部件20。第二透光部件20俯视为圆形,其表面具有曲面。另外,以第二透光部件20的高度比第二透光部件20的半径小的方式形成,以将发光元件侧12及第一透光部件16覆盖的方式形成为凸状。
在本实施例中,基体24为玻璃环氧基材,配线部13a、13b的厚度为35μm的Cu材料,保护层15为环氧树脂类白色抗蚀剂,具有光反射性。
另外,发光元件12是一边为600μm的正方形,使用厚度为150μm,在上表面作为反射层17而形成了电介质多层膜的发光峰值波长为450nm的氮化物类蓝色LED。
在此,第一透光部件16使用二甲基硅酮(折射率1.41),第二透光部件20使用苯基硅酮(折射率1.50)。在此的折射率记载了589nm时的值,但在发光元件12的发光波长为450nm时也满足“第一透光部件16的折射率α<第二透光部件的折射率β”的关系。
另外,本实施例的第二透光部件优选不具有光扩散性,但为了赋予用于形成凸形状的触变性,添加有几乎不产生光散射的硅石类纳米填充剂(平均粒径为12nm左右)。
(比较例1)
如图3所示,除了将第一透光部件16设为苯基硅酮(折射率1.50),将第二透光部件20设为二甲基硅酮(折射率1.41)之外,与实施例1同样。折射率为“第一透光部件16的折射率α>第二透光部件的折射率β”。
(比较例2)
如图4所示,除了将第一透光部件16及第二透光部件20设为苯基硅酮(折射率1.50)之外,与实施例1同样。折射率为“第一透光部件16的折射率α=第二透光部件的折射率β”。
(比较例3)
如图4所示,除了将第一透光部件16及第二透光部件20设为二甲基硅酮(折射率1.41)之外,与实施例1同样。折射率为“第一透光部件16的折射率α=第二透光部件的折射率β”。
图8表示实施例1、比较例1~比较例3的发光装置的配光特性。
由该图表,在α<β的实施例的情况下,使向横向射出的光折射而将其向上方抬起,由此,侧方的光量减少,伴随于此,峰值高度变高,由于峰值高度变高,相对地,发光元件的正上、即0°附近的光量降低。由此,与比较例1~3相比,能够抑制相对于上面方向的峰值发光强度的相对发光强度,可得到所希望的配光特性。
产业上的可利用性
能够利用于液晶显示器或电视机的背光灯等的显示装置使用的发光装置、照明装置等。

Claims (19)

1.一种发光装置,具有:
基板;
发光元件,其载置在所述基板上,且在上表面具有反射层;
第一透光部件,其具有与所述发光元件的侧面相接的第一面、朝向离开所述发光元件的方向与所述基板的距离变短的第二面;
第二透光部件,其与所述第二面相接,且将所述发光元件覆盖,
所述第一透光部件的折射率比所述第二透光部件的折射率小。
2.如权利要求1所述的发光装置,其中,
所述第一透光部件及所述第二透光部件由树脂材料构成。
3.如权利要求1或2所述的发光装置,其中,
所述第二透光部件在所述第一透光部件的外周将所述基板覆盖。
4.如权利要求1~3中任一项所述的发光装置,其中,
所述第二透光部件的表面具有曲面。
5.如权利要求1~4中任一项所述的发光装置,其中,
所述第二透光部件俯视为圆形,
所述第二透光部件的高度比所述第二透光部件的半径小。
6.如权利要求1~5中任一项所述的发光装置,其中,
所述发光元件倒装片安装在所述基板上。
7.如权利要求1~5中任一项所述的发光装置,其中,
所述发光元件经由电线与在所述基板上形成的配线电连接。
8.如权利要求1~7中任一项所述的发光装置,其中,
在所述基板上、在从所述第二透光部件露出的区域具有可将来自所述发光元件的光反射的反射部件。
9.如权利要求8所述的发光装置,其中,
所述反射部件的高度比所述第二透光部件的高度高。
10.一种面发光装置,具有:
基板;
多个发光装置,其隔开间隔而安装在所述基板上,其中,
所述发光装置的任一个具有:
发光元件,其载置在所述基板上,在其上表面具有反射层;
第一透光部件,其具有与所述发光元件的侧面相接的第一面、朝向离开所述发光元件的方向与所述基板的距离变短的第二面;
第二透光部件,其与所述第二面相接,且将所述发光元件覆盖,
所述第一透光部件的折射率比所述第二透光部件的折射率小,
在各发光装置之间,在从所述第二透光部件露出的区域的所述基板上,还具有可将来自发光元件的光反射的反射部件。
11.如权利要求10所述的面发光装置,其中,
所述第一透光部件及所述第二透光部件由树脂材料构成。
12.如权利要求10或11所述的面发光装置,其中,
所述第二透光部件在所述第一透光部件的外周将所述基板覆盖。
13.如权利要求10~12中任一项所述的面发光装置,其中,
所述第二透光部件的表面具有曲面。
14.如权利要求10~13中任一项所述的面发光装置,其中,
所述第二透光部件俯视为圆形,
所述第二透光部件的高度比所述第二透光部件的半径小。
15.如权利要求10~14中任一项所述的面发光装置,其中,
所述发光元件倒装片安装在所述基板上。
16.如权利要求10~15中任一项所述的面发光装置,其中,
所述发光元件经由电线与在所述基板上形成的配线电连接。
17.如权利要求10~15中任一项所述的面发光装置,其中,
在所述发光元件和所述发射部件上还配置光扩散板。
18.如权利要求10~15中任一项所述的面发光装置,其中,
在所述发光元件和所述发射部件上还配置波长变换层。
19.如权利要求10~15中任一项所述的面发光装置,其中,
所述反射部件的任一个配置在两个邻接的所述发光装置之间,具有两个倾斜面,该倾斜面分别朝向两个邻接的所述发光装置的各个逐渐接近而倾斜。
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