CN109263173B - 一种亚麻复合地板及其制备方法 - Google Patents
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Abstract
本发明属于地面装饰材料技术领域,特别涉及一种亚麻复合地板,包括顺次粘接的亚麻秆碎屑复合层、碳酸钙复合层和黄麻粗布层;所述亚麻秆碎屑复合层的组分包括亚麻秆碎屑、水性聚氨酯、亚麻籽油和松香;所述碳酸钙复合层的组分包括碳酸钙、水性聚氨酯、亚麻籽油和松香。本发明提供的亚麻复合地板中的组分材料无污染物挥发,真正达到绿色环保的目的;本发明的三层复合结构使得复合材料结构优化,符合实际使用要求;同时,本发明通过优化各原料含量,使复合地板具有较高的断裂强力和较低的表面渗透性。因此,本发明提供的产品无污染物挥发,实现了亚麻复合地板的绿色环保。
Description
技术领域
本发明属于地面装饰材料技术领域,特别涉及一种亚麻复合地板及其制备方法。
背景技术
地板,即房屋地面或楼面的表面层,由木料或其他材料做成。地板的分类有很多,按结构分类有:实木地板、强化复合木地板、三层实木复合地板、竹木地板、防腐地板、软木地板以及目前最流行的多层实木复合地板等。目前市场上流行着品种繁多、性能各异的地板,包括实木地板、大理石地板等。然而这些地板都存在着各种各样的不足与缺陷:大理石地板往往含有放射性物质,长期接触会对身体产生不良影响;强化复合木地板由高密度纤维基材和印刷纸面组成,其缺点是怕水怕潮,且易产生甲醛等有害物质;多层实木复合地板采用板条镶嵌或整副木板和多层胶合板作为基材,其不足是防火防潮性能较差,且胶合板中所含胶质VOC易超标;实木地板品质优良但价格较高,制造过程中需要消耗大量原木,对环境不友好且容易产生噪音,对人体健康不利,故一般铺设的木地板对人体或对环境均有不利影响,不符合和谐社会下绿色环保的理念。
发明内容
有鉴于此,本发明的目的在于提供一种亚麻复合地板。本发明由亚麻秆碎屑、碳酸钙、水性聚氨酯、亚麻籽油、松香和黄麻粗布复合得到一种亚麻复合地板,消除了复合地板对环境和人体健康的不利影响,达到了绿色环保的需求。
为了实现上述发明的目的,本发明提供以下技术方案:
本发明提供了一种亚麻复合地板,包括顺次粘接的亚麻秆碎屑复合层、碳酸钙复合层和黄麻粗布层;所述亚麻秆碎屑复合层包括亚麻秆碎屑、水性聚氨酯、亚麻籽油和松香;所述碳酸钙复合层包括碳酸钙、水性聚氨酯、亚麻籽油和松香。
优选的,以质量份计,所述亚麻秆碎屑复合层包括亚麻秆碎屑15~18份、水性聚氨酯30~33份、亚麻籽油3~5份以及松香2~4份;以所述亚麻秆碎屑复合层中亚麻秆碎屑的质量份为基准计,所述碳酸钙复合层包括碳酸钙30~35份、水性聚氨酯14~18份、亚麻籽油3~5份以及松香3~5份;以所述亚麻秆碎屑复合层中亚麻秆碎屑的质量为基准,黄麻粗布层的用量为(9~11cm2)/(31~33g)。
优选的,所述亚麻秆碎屑复合层、碳酸钙复合层和黄麻粗布层的厚度比为(1~1.5):(1~1.5):0.5。
优选的,所述黄麻粗布层由黄麻纤维经纺织得到;所述黄麻粗布层中经纱和纬纱的细度独立地为40~50tex,经纬密度为15~18根/5cm。
本发明还提供了上述技术方案所述亚麻复合地板的制备方法,包括以下步骤:
(1)将亚麻秆碎屑、水性聚氨酯、亚麻籽油和松香混合,得到亚麻秆复合原料;
(2)将碳酸钙、水性聚氨酯、亚麻籽油和松香混合,得到碳酸钙复合原料;
(3)将黄麻粗布和所述步骤(2)得到的碳酸钙复合原料以及所述步骤(1)得到的亚麻秆复合原料依次堆叠后模压成型,得到亚麻复合地板;
所述步骤(1)和(2)没有时间先后顺序。
优选的,所述步骤(1)中亚麻秆碎屑的粒径为0~100μm,所述步骤(2)中碳酸钙的粒径为0~5μm。
优选的,所述步骤(1)和步骤(2)中水性聚氨酯的密度为1.3g/mL。
优选的,所述步骤(1)中亚麻杆碎屑的含水率低于2%;所述步骤(2)中碳酸钙的含水率低于1%。
优选的,所述步骤(2)和步骤(3)中混合方式为搅拌混合;所述搅拌混合的转速为200~220r/min,搅拌混合的时间为10~12min。
优选的,所述步骤(4)模压成型的参数设置为:压力12~15MPa,加热温度为80~100℃,加热时间为10~15min。
本发明提供了一种亚麻复合地板,包括顺次粘接的亚麻秆碎屑复合层、碳酸钙复合层和黄麻粗布层,其中所述亚麻秆碎屑复合层包括亚麻秆碎屑、水性聚氨酯、亚麻籽油和松香,所述碳酸钙复合层包括碳酸钙、水性聚氨酯、亚麻籽油和松香。
本发明提供的亚麻复合地板中的组分材料包括亚麻秆碎屑、碳酸钙、水性聚氨酯、亚麻籽油、松香和黄麻粗布,无污染物挥发,真正达到了绿色环保的目的;本发明的三层复合结构以水性聚氨酯为粘结剂,实现各层物质及层间粘结;同时,本发明的三层复合结构使得复合材料结构优化,符合实际使用要求。同时,本发明通过优化各原料含量,使复合地板具有较高的断裂强度和较低的表面渗透性,因此,本发明提供的产品无污染物挥发,实现了亚麻复合地板的绿色环保。
实验数据表明,本发明提供的亚麻复合地板的密度为0.946~1.174g/cm2;材料含水率为2.14~3.12%,含水率低,不易变质;表面渗透性为正面(亚麻秆碎屑复合层面)的渗透(甲苯在材料表面的渗透痕迹长度)为4.8~7.8cm,反面(黄麻粗布层面)的渗透(甲苯在材料表面的渗透痕迹长度)为4.6~9.3cm,表面渗透性低,能有效控制实际使用过程中液体对复合地板的渗透影响,提高复合地板寿命;断裂强力为5.45~5.96MPa,具有较高的抗断裂能力,力学性能稳定;各原料无有毒有害污染物挥发,绿色环保。本发明高效实现了复合地板的绿色环保需求,具有可观的经济效益。
附图说明
图1为本发明亚麻复合地板的三层结构示意图,其中1为亚麻秆碎屑复合层,2为碳酸钙复合层,3为黄麻粗布层;
图2为本发明复合材料模压加工示意图,其中1为亚麻秆碎屑复合层,2为碳酸钙复合层,3为黄麻粗布层,4为上模,5为下模,6为硫化机上板,7为硫化机下板;
图3为本发明实施例1制备的亚麻复合地板的实物图;
图4为本发明实施例1制备的亚麻复合地板的扫描电镜图。
具体实施方式
本发明提供了一种亚麻复合地板,包括顺次粘接的亚麻秆碎屑复合层、碳酸钙复合层和黄麻粗布层;所述亚麻秆碎屑复合层包括亚麻秆碎屑、水性聚氨酯、亚麻籽油和松香;所述碳酸钙复合层包括碳酸钙、水性聚氨酯、亚麻籽油和松香。
在本发明中,若无特殊说明,所有的组分均为本领域技术人员熟知的市售商品。
在本发明中,所述亚麻复合地板包括顺次粘接的亚麻秆碎屑复合层、碳酸钙复合层和黄麻粗布层。如图1所示,所述亚麻复合地板包括亚麻秆碎屑复合层1、碳酸钙复合层2和黄麻粗布层3。
在本发明中,所述亚麻秆碎屑复合层包括亚麻秆碎屑、水性聚氨酯、亚麻籽油和松香。
以质量份计,本发明所述亚麻秆碎屑复合层优选包括亚麻秆碎屑15~18份,进一步优选为16~17份。本发明中,亚麻秆碎屑作为亚麻秆碎屑层复合材料中的增强体,主要起到和水性聚氨酯结合并增加材料力学性能的功能。
以所述亚麻秆碎屑复合层中亚麻秆碎屑的质量份为基准,本发明所述亚麻秆碎屑复合层优选包括水性聚氨酯30~33份,进一步优选为31~32份。本发明中水性聚氨酯作为一种绿色环保的高分子树脂材料,在复合地板中作为基体,不仅起到粘结层中各组分材料的作用,还在压制成型过程中实现各层之间的粘接;同时赋予亚麻复合地板一定的韧性与形变回复能力。
以所述亚麻秆碎屑复合层中亚麻秆碎屑的质量份为基准,本发明所述亚麻秆碎屑复合层优选包括亚麻籽油3~5份,进一步优选为4份。本发明中亚麻籽油在复合地板中主要起到对亚麻秆碎屑表面处理的作用,可减低其表面能以提高各复合层的界面结合能力,与松香和水性聚氨酯协同作用下实现复合地板良好粘结作用。
以所述亚麻秆碎屑复合层中亚麻秆碎屑的质量份为基准,本发明所述亚麻秆碎屑复合层优选包括松香2~4份,进一步优选为3份。本发明中松香作为粘合剂,在复合地板中有效粘结亚麻秆碎屑组分。
本发明所述亚麻复合地板包括碳酸钙复合层,所述碳酸钙复合层包括碳酸钙、水性聚氨酯、亚麻籽油和松香。
以所述亚麻秆碎屑复合层中亚麻秆碎屑的质量份为基准,本发明所述碳酸钙复合层优选包括碳酸钙30~35份,进一步优选为31~34份。本发明中碳酸钙作为碳酸钙复合层的增强体,主要起到和水性聚氨酯结合,并增加复合地板的尺寸稳定性,以及提高复合地板的断裂拉伸强力。
以所述亚麻秆碎屑复合层中亚麻秆碎屑的质量份为基准,本发明所述碳酸钙复合层优选包括水性聚氨酯14~18份,进一步优选为15~17份。本发明中水性聚氨酯作为一种绿色环保的高分子树脂材料,在亚麻复合地板中作为基体,主要起到粘结各组分材料的作用,同时赋予复合地板一定的韧性与形变能力。
以所述亚麻秆碎屑复合层中亚麻秆碎屑的质量份为基准,本发明所述碳酸钙复合层优选包括亚麻籽油3~5份,进一步优选为4份。本发明中亚麻籽油在复合地板中主要起到对碳酸钙表面处理的作用,可减低其表面能以提高各复合层之间的界面结合能力,与松香和水性聚氨酯协同作用下实现复合地板良好粘结作用。
以所述亚麻秆碎屑复合层中亚麻秆碎屑的质量份为基准,本发明所述碳酸钙复合层优选包括松香3~5份,进一步优选为4份。本发明中松香作为粘合剂,在复合地板中有效粘结碳酸钙组分。
以所述亚麻秆碎屑复合层中亚麻秆碎屑的质量为基准,黄麻粗布层的用量为(9~11cm2)/(31~33g)。本发明中黄麻粗布层作为复合地板的基体,提供复合地板衬底,同时在复合地板中起到一定增强体的作用。
在本发明中,所述黄麻粗布层优选由黄麻纤维经纺织得到。在本发明中,所述黄麻纤维优选经纺织形成纱线,用于黄麻粗布的织造。在本发明中所述黄麻粗布层中经纱和纬纱的细度独立地优选为40~50tex,经纬密度优选为15~18根/5cm。
在本发明中,所述亚麻秆碎屑复合层、碳酸钙复合层和黄麻粗布层的厚度比优选为(1~1.5):(1~1.5):0.5,进一步优选为(1~1.2):(1.2~1.4):0.5。
本发明还提供了上述技术方案所述的亚麻复合地板的制备方法,包括以下步骤:
(1)将亚麻秆碎屑、水性聚氨酯、亚麻籽油和松香混合,得到亚麻秆复合原料;
(2)将碳酸钙、水性聚氨酯、亚麻籽油和松香混合,得到碳酸钙复合原料;
(3)将黄麻粗布和所述步骤(2)得到的碳酸钙复合原料以及所述步骤(1)得到的亚麻秆复合原料依次堆叠后模压成型,得到亚麻复合地板;
所述步骤(1)和(2)没有时间先后顺序。
在本发明中,所述制备方法中各组分的用量与前述亚麻复合地板的技术方案中组分的用量一致,在此不再赘述。
本发明将所述亚麻秆碎屑、水性聚氨酯、亚麻籽油和松香混合,得到亚麻秆复合原料。本发明对所述亚麻秆碎屑、水性聚氨酯、亚麻籽油和松香的混合方式没有特殊限定,采用本领域技术人员熟知的混合方式即可。在本发明中,所述混合的方式优选为搅拌混合。在本发明中,所述搅拌混合中搅拌的转速优选为200r/min,搅拌的时间优选为10min。
在本发明中,所述亚麻杆碎屑的含水率优选低于2%。在本发明中,亚麻秆碎屑含水率较高时,优选将亚麻秆碎屑进行干燥,得到含水率符合上述范围的亚麻秆碎屑。本发明对所述干燥没有特殊限制,采用本领域技术人员熟知的干燥方法进行干燥即可。在本发明中,所述干燥优选为真空干燥。在本发明中,所述真空干燥的真空度优选为0.01~0.03MPa,真空干燥的温度优选为75~85℃,进一步优选为79~81℃,真空干燥的时间优选为24~30h。
所述干燥前,本发明优选对亚麻秆碎屑依次进行细化和筛选。本发明对所述亚麻秆碎屑的细化和筛选没有特殊限制,采用本领域技术人员熟知的细化和筛选方式即可。在本发明中,所述细化优选在粉碎机中完成;所述细化时粉碎机的转速优选为6000转/min,细化的时间优选为2min。在本发明中,所述细化的设备优选为高速万能粉碎机;所述高速万能粉碎机的型号优选为FW-100。在本发明中,所述筛选的筛网优选为40目。在本发明中,经过筛后颗粒较大未能过筛的亚麻秆碎屑优选再次进行细化和筛选,以提高亚麻秆碎屑利用率。在本发明中,所述亚麻秆碎屑的筛后粒径优选为0~100μm,进一步优选为0~50μm。
本发明将所述碳酸钙、水性聚氨酯、亚麻籽油和松香混合,得到碳酸钙复合原料。本发明对所述碳酸钙、水性聚氨酯、亚麻籽油和松香的混合方式没有特殊限定,采用本领域技术人员熟知的混合方式即可。在本发明中,所述混合的方式优选为搅拌混合。在本发明中,所述搅拌混合中搅拌的转速优选为200r/min,搅拌的时间优选为10min。在本发明中,所述碳酸钙的粒径优选为0~5μm,进一步优选为1~4μm。
在本发明中,所述碳酸钙的含水率优选低于1%。在本发明中,碳酸钙含水率较高时,优选将碳酸钙进行干燥,得到含水率符合上述范围的碳酸钙。本发明对所述干燥没有特殊限制,采用本领域技术人员熟知的干燥方法进行干燥即可。在本发明中,所述干燥优选为真空干燥。在本发明中,所述真空干燥的真空度优选为0.01~0.03MPa,真空干燥的温度优选为75~85℃,进一步优选为79~81℃,真空干燥的时间优选为24~30h。
在本发明中,所述亚麻秆复合原料和碳酸钙复合原料的混合没有时间先后顺序。
得到亚麻秆复合原料和碳酸钙复合原料后,本发明将黄麻粗布、碳酸钙复合原料和亚麻秆复合原料依次堆叠后模压成型,得到亚麻复合地板。各层间关系如图1所示,顺次为黄麻粗布、碳酸钙复合层和亚麻秆碎屑复合层。本发明对所述模压成型没有特殊限制,采用本领域技术人员熟知的模压成型技术进行模压成型即可。在本发明中,所述模压成型的设备优选使用平板硫化机。在本发明中,所述平板硫化机的压力优选为12~15MPa,加热温度优选为80~100℃,加热时间优选为10~15min。本发明在模压成型过程中,通过加热加压,促进水性聚氨酯粘结性能的提升,实现黄麻粗布、碳酸钙复合层和亚麻秆复合层之间紧密粘结,同时使亚麻复合地板结构致密。
为了进一步说明本发明,下面结合实施例对本发明提供的亚麻复合地板及其制备方法进行详细地描述,但不能将它们理解为对本发明保护范围的限定。显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1
将亚麻秆碎屑在80℃下干燥24h,将碳酸钙在80℃下干燥24h。将8g干燥后的亚麻秆碎屑和10g水性聚氨酯、2g亚麻籽油和2g松香,于转速为200r/min条件下搅拌混合10min,得到亚麻秆复合原料;将20g干燥后的碳酸钙和6g水性聚氨酯、2g亚麻籽油和2g松香,于转速为200r/min条件下搅拌混合10min,得到碳酸钙复合原料。如图2所示物料与平板硫化机相对关系,将面积为10cm2的黄麻粗布(黄麻粗布的尺寸主要取决于平板硫化机模具的尺寸,即黄麻粗布的大小应适应模具的长和宽)、碳酸钙复合原料和亚麻秆复合原料依次铺设在平板硫化机模具下的矩形内凹空腔中,利用压辊对内凹空腔复合原料的表面进行碾压,使原料填满空腔,并使原料表面平整,将模具的上下模对齐合拢并放入平板硫化机中,设置硫化机参数,加热温度设置为80℃,压力为14MPa,热压时间10min,复合地板厚3mm,将模具取出后打开,使样品冷却至室温,即得到亚麻复合地板,如图3,其中图a为亚麻复合地板反面(黄麻粗布面)实物图;图b为正面(亚麻秆碎屑面)实物图,所得复合地板外形平整。
使用扫描电子显微镜对实施例1所得亚麻复合地板进行微观结构的观察,观察结果见图4,其中图a是亚麻复合地板中亚麻秆碎屑复合层的断面SEM形貌图,图b是亚麻复合地板中碳酸钙复合层的断面SEM形貌图。依据GB/T 17657-2013对实施例1所得亚麻复合地板的密度、含水率、表面渗透性和拉伸断裂强力进行测试,测试结果见表1。
实施例2
将亚麻秆碎屑在80℃下干燥24h,将碳酸钙在80℃下干燥24h。将7g干燥后的亚麻秆碎屑和12g水性聚氨酯、2g亚麻籽油和2g松香,于转速为200r/min条件下搅拌混合10min,得到亚麻秆复合原料;将18g干燥后的碳酸钙和10g水性聚氨酯、2g亚麻籽油和2g松香,于转速为200r/min条件下搅拌混合10min,得到碳酸钙复合原料。将面积为10cm2的黄麻粗布、碳酸钙复合原料和亚麻秆复合原料依次铺设在平板硫化机模具下的矩形内凹空腔中,利用压辊对内凹空腔复合原料的表面进行碾压,使原料填满空腔,并使原料表面平整,将模具的上下模对齐合拢并放入平板硫化机中,设置硫化机参数,加热温度设置为80℃,压力为14MPa,热压时间10min,复合地板厚3mm,将模具取出后打开使样品冷却至室温,即得到亚麻复合地板。
依据GB/T 17657-2013对实施例1所得亚麻复合地板的密度、含水率、表面渗透性和拉伸断裂强力进行测试,测试结果见表1。
实施例3
将亚麻秆碎屑在80℃下干燥24h,将碳酸钙在80℃下干燥24h。将6g干燥后的亚麻秆碎屑和15g水性聚氨酯、2g亚麻籽油和2g松香,于转速为200r/min条件下搅拌混合10min,得到亚麻秆复合原料;将16g干燥后的碳酸钙和12g水性聚氨酯、2g亚麻籽油和2g松香,于转速为200r/min条件下搅拌混合10min,得到碳酸钙复合原料。将面积为10cm2的黄麻粗布、碳酸钙复合原料和亚麻秆复合原料依次铺设在平板硫化机模具下的矩形内凹空腔中,利用压辊对内凹空腔复合原料的表面进行碾压,使原料填满空腔,并使原料表面平整,将模具的上下模对齐合拢并放入平板硫化机中,设置硫化机参数,加热温度设置为80℃,压力为14MPa,热压时间10min,复合地板厚3mm,将模具取出后打开使样品冷却至室温,即得到亚麻复合地板。
依据GB/T 17657-2013对实施例1所得亚麻复合地板的密度、含水率、表面渗透性和拉伸断裂强力进行测试,测试结果见表1。
表1亚麻复合地板测试结果
由表1可以看到,本发明提供的亚麻复合地板密度为0.9~1.2g/cm3,质轻;含水率为2.7~3.2%,含水量低,复合地板质量稳定,不易变质;表面渗透性正面(亚麻秆碎屑层)为4.5~8cm,反面(碳酸钙层)为4.5~9.5cm,复合材料内部结构致密,抗渗透性强;拉伸断裂强力达到5.4~6.0MPa,力学性能高,体现了复合地板良好的使用性能。
由图4的a图可以看到,亚麻秆碎屑颗粒的断裂面较为齐整而没有出现结构的松散,说明亚麻秆碎屑层材料的结构较为紧密,水性聚氨酯等材料起到了很好的粘结作用;由b图可以看到,材料断面中出现了树脂在外力作用下被拉伸变形所产生的丝状形貌,说明水性聚氨酯在复合材料体系中起到了连接和增强的作用;由a图结合b图可以得出,水性聚氨酯等材料很好的粘结了各复合层材料,亚麻复合地板结构紧密,力学性能佳。
以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (7)
1.一种亚麻复合地板,其特征在于,包括顺次粘接的亚麻秆碎屑复合层、碳酸钙复合层和黄麻粗布层;所述亚麻秆碎屑复合层包括亚麻秆碎屑、水性聚氨酯、亚麻籽油和松香;所述碳酸钙复合层包括碳酸钙、水性聚氨酯、亚麻籽油和松香;
以质量份计,所述亚麻秆碎屑复合层包括亚麻秆碎屑15~18份、水性聚氨酯30~33份、亚麻籽油3~5份以及松香2~4份;以所述亚麻秆碎屑的质量份为基准计,所述碳酸钙复合层包括碳酸钙30~35份、水性聚氨酯14~18份、亚麻籽油3~5份以及松香3~5份;以所述亚麻秆碎屑复合层中亚麻秆碎屑的质量为基准,黄麻粗布层的用量为(9~11cm2)/(31~33g);
所述亚麻秆碎屑复合层、碳酸钙复合层和黄麻粗布层的厚度比为(1~1.5):(1~1.5):0.5;
所述黄麻粗布层由黄麻纤维经纺织得到;所述黄麻粗布层中经纱和纬纱的细度独立地为40~50tex,经纬密度为15~18根/5cm。
2.一种权利要求1所述亚麻复合地板的制备方法,包括以下步骤:
(1)将亚麻秆碎屑、水性聚氨酯、亚麻籽油和松香混合,得到亚麻秆复合原料;
(2)将碳酸钙、水性聚氨酯、亚麻籽油和松香混合,得到碳酸钙复合原料;
(3)将黄麻粗布和所述步骤(2)得到的碳酸钙复合原料以及所述步骤(1)得到的亚麻秆复合原料依次层铺后模压成型,得到亚麻复合地板;
所述步骤(1)和(2)没有时间先后顺序。
3.根据权利要求2所述的制备方法,其特征在于,所述步骤(1)中亚麻秆碎屑的粒径为0~100μm,所述步骤(2)中碳酸钙的粒径为0~5μm。
4.根据权利要求2或3所述的制备方法,其特征在于,所述步骤(1)和步骤(2)中水性聚氨酯的密度为1.3g/mL。
5.根据权利要求2或3所述的制备方法,其特征在于,所述步骤(1)中亚麻杆碎屑的含水率低于2%;所述步骤(2)中碳酸钙的含水率低于1%。
6.根据权利要求4所述的制备方法,其特征在于,所述步骤(1)和步骤(2)中混合方式为搅拌混合;所述搅拌混合的转速为200~220r/min,搅拌混合的时间为10~12min。
7.根据权利要求4所述的制备方法,其特征在于,所述步骤(3)模压成型的参数设置为:压力12~15MPa,加热温度为80~100℃,加热时间为10~15min。
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