CN1787904B - 氟树脂叠层膜及其制造方法 - Google Patents
氟树脂叠层膜及其制造方法 Download PDFInfo
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- CN1787904B CN1787904B CN200480012952XA CN200480012952A CN1787904B CN 1787904 B CN1787904 B CN 1787904B CN 200480012952X A CN200480012952X A CN 200480012952XA CN 200480012952 A CN200480012952 A CN 200480012952A CN 1787904 B CN1787904 B CN 1787904B
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Abstract
本发明提供一种氟树脂叠层膜的制造方法,其特征在于,一边将氟树脂层(1)和可以与该氟树脂层(1)剥离的树脂层(2)进行共挤出,一边使该共挤出的膜的氟树脂层(1)一侧面与拉伸聚对苯二甲酸乙二醇酯膜对置地进行挤出层压。
Description
技术领域
本发明涉及氟树脂叠层膜的制造方法,详细地说,涉及通过挤出层压法将挤出的氟类树脂层压在聚对苯二甲酸乙二醇酯薄膜上的方法。
背景技术
氟树脂叠层膜一般可通过干式层压来制作。可是,在干式层压法中容易在叠层的薄膜层之间混入杂质,由于该杂质以及在其周围产生的空隙,存在损害膜的外观的问题。另外,在干式层压法中,有必要预先通过电晕处理等对层压的膜的表面进行前处理,不仅工序繁琐而且成本增高。
为了避免上述干式层压法的问题,本发明者们发现,可以通过使用四氟乙烯-六氟丙烯-偏二氟乙烯(ビニリデンフロォラィド)3元共聚物树脂(THV),用挤出层压法制造氟树脂叠层膜(特愿2002-05910号、特愿2003-51017号)。
参照图1说明用上述挤出层压法制作氟树脂3层膜的方法。将氟树脂层(1)和树脂层(2)在例如315℃的温度下通过T型模进行共挤出,将氟树脂层(1)一侧与拉伸聚对苯二甲酸乙二醇酯(PET)膜3相对,在夹持辊5和冷却辊6之间压合该共挤出的层,卷取得到的叠层膜(4)。
按照上述方法可以得到没有杂质混入的氟树脂叠层膜。可是,当氟树脂层(1)为约10μm或10μm以下的薄层时,存在不能稳定地层压的问题。
发明内容
发明要解决的课题
因此,为了解决上述问题,本发明的目的在于提供一种即使在氟树脂层的厚度很薄时仍可以稳定地层压的挤出层压方法。
解决课题的方法
即,一种氟树脂叠层膜的制造方法,其特征在于,将氟树脂层(1)和可以与该氟树脂层(1)剥离的树脂层(2)进行共挤出,并且使该共挤出的氟树脂层一侧与拉伸聚对苯二甲酸乙二醇酯膜3相对,在该拉伸聚对苯二甲酸乙二醇酯膜的至少单面上进行挤出层压。
在上述方法中,通过在树脂层(2)中配合填料,可以将氟树脂层(1)的在树脂层(2)侧的表面进行粗糙化。
另外,在上述方法中,在树脂层(2)和氟树脂层(1)之间,还可以进一步共挤出含有与构成层(1)的氟树脂不同种类的氟树脂并且可以与树脂层(2)剥离的氟树脂层(3)。
在上述本发明的方法中,优选氟树脂层(1)包含四氟乙烯-六氟丙烯-偏二氟乙烯3元共聚物(THV)、树脂层(2)含有聚乙烯、氟树脂层(3)含有选自包含四氟乙烯-乙烯共聚物树脂、四氟乙烯-六氟丙烯共聚物树脂以及聚偏氟乙烯树脂的组中的树脂。
另外,填料优选选自包含玻璃纤维、云母以及碳酸钙的组中的至少1种。另外,其粒径为1μm~1000μm,并且相对于树脂层(2)的总重量,含有5重量%~30重量%的该填料。
另外,本发明涉及一种叠层膜,其特征在于,在拉伸聚对苯二甲酸乙二醇酯膜的至少一侧面上叠层了氟树脂膜的叠层膜上,在与挤出方向成直角的方向的上述叠层膜的最大厚度与最小厚度的差(R)为2μm/75cm或2μm/75cm以下。
发明的效果
按照本发明的方法,由于树脂层(2)与氟树脂层(1)共挤出,因此可以稳定地挤出薄的氟树脂层(1)。另外,由于具有树脂层(2),可防止氟树脂层(1)的表面温度的降低,并可获得与聚对苯二甲酸乙二醇酯的良好的粘接。
另外,本发明的叠层膜的厚度精度高,适用于要求厚度精度的用途。
附图的简单说明
[图1]是示出本发明中的挤出层压方法的流程图。
符号的说明
1氟树脂层(1)
2树脂层(2)
3拉伸聚脂膜
4叠层膜
5夹持辊
6冷却辊
实施发明的最佳方案
作为构成氟树脂层(1)的氟树脂,可以使用四氟乙烯-六氟丙烯-偏二氟乙烯3元共聚物(THV)、聚偏氟乙烯、或它们的衍生物,例如在高分子链的末端导入羧基而改性的树脂。优选使用THV。
上述各氟树脂的结晶化温度虽然依共聚比、改性程度等而不同,但约为90~180℃。THV的结晶化温度主要依赖于其3元聚合比,但为约90~约160℃的范围,优选使用约95~约140℃的物质。
本发明的特征为一边将氟树脂层(1)和可以与该氟树脂剥离的树脂层(2)进行共挤出,一边进行层压。虽然不是限定本发明的主旨,但可以认为该树脂层(2)作为保温层起作用,维持氟树脂层的表面温度比其结晶化温度高变得容易,故可以得到牢固的粘接。另外,由于该树脂层(2)作为挤出支持层起作用,故即使是在氟树脂层薄至2~5μm的场合,也可以得到稳定地挤出的效果。
作为树脂层(2),只要是可以与氟树脂层共挤出并可以剥离的物质,则可以使用任意的树脂。在此,所谓的「可以剥离」是指用手挤可以容易地剥离的意思。从价格方面看,优选使用不含氟的树脂,例如,可以举出各种聚乙烯、聚丙烯、聚酯、聚氯乙烯、三乙酰纤维素、再生纤维素、聚酰胺、聚碳酸酯、芳香族聚酰胺、聚酰亚胺、聚醚酰亚胺、聚苯硫醚、聚砜、聚醚砜等膜。其中,由于价格低,故优选聚乙烯。
在树脂层(2)和氟树脂层(1)之间,可以进一步共挤出含有与构成层(1)的氟树脂不同种类的氟树脂层(3)。这里,所说的「不同种类」,也包含即使是含有相同构成成分的氟树脂但各成分比不同的物质。作为该不同种类氟树脂,可以举出,例如聚四氟乙烯(PTFE)、四氟乙烯-全氟烷基乙烯基醚共聚物(PFA)、四氟乙烯-乙烯共聚物(ETFE)、四氟乙烯-六氟丙烯共聚物(FEP)、聚三氟氯乙烯(CTFE)、聚偏氟乙烯(PVdF)、与氟树脂层(1)的THV不同组成比的THV等。优选使用ETFE、FEP或PVdF。
通过在树脂层(2)中含有填料,例如玻璃纤维、云母、碳酸钙,可以进一步提高树脂层(2)的保温效果。
另外,通过适当设定填料的大小以及配合量,可以在树脂层(1)的在树脂层(2)侧的表面形成凹凸。即,在树脂层(2)的表面可形成由填料引起的凹凸,该凹凸可以在具有氟树脂层(1)或树脂层(3)时转印到树脂层(3)上。由此,可以使氟树脂层(1)或(3)的表面粗糙化(消光)。在将氟树脂叠层膜作为冲压成型用脱模膜使用时,希望粗糙化用于容易地进行排气。另外,将氟树脂叠层膜作为涂膜形成用载体膜使用时,希望通过对涂膜面进行粗糙加工。可是,由于氟树脂一般是高熔点的,因此,在膜成型后通过热加工进行粗糙化是困难的。与此相反,按照本发明的方法,可以在挤出的同时容易地进行粗糙化。在以粗糙化作为目的时,填料的大小为5μm~1000μm,优选20μm~100μm,另外,相对于树脂层(2)的重量,填料的含量为5重量%~30重量%,优选10重量%~25重量%。另一方面,使用比上述下限值小的物质作为填料、或通过配合更加少量,从而不进行粗糙化,可以提高树脂层(2)的保温效果。
树脂层(2)虽然可以在使用叠层膜之前剥离,但剥离时期也可以是从制造后立即到使用叠层膜时的任意时刻。通过直到使用叠层膜时仍不剥离,可以作为氟树脂层(1)或(3)的保护膜起作用。
在本发明中,氟树脂层(1)的厚度可以对应于该氟树脂的结晶化温度、用途等进行适当设定,但通常为2~10μm,优选2~5μm。如果比上述下限值薄,由于膜厚度不均匀,存在产生氟树脂层欠缺的部分的可能性,故不为优选。另一方面,如果比上述上限值厚,则不能获得与成本提高相称的性能的提高。
树脂层(2)的厚度可以依据使用的氟树脂层(1)的结晶化温度、厚度、挤出机的口模温度等进行适当设定,但在使用THV作为氟树脂,且该THV树脂层的厚度为2~10μm时,树脂层(2)的厚度通常为5~500μm,优选8~20μm。厚度低于上述下限值时,维持氟树脂层的温度的效果不充分,另一方面,如果超过上述上限值,层压后的冷却时间变长,另外,有时从氟树脂上的剥离变得困难。
氟树脂层(3)的厚度可以视其用途适当设定,如果是用于脱模,其厚度为2μm~10μm,优选2μm~5μm。
作为本发明中的PET膜,可以使用已知的各种拉伸PET膜。另外,不仅可以将氟树脂层层压在PET的单面,也可以层压在两面。该PET膜的厚度为5~300μm,优选25~100μm。如果比上述下限值薄,得到的叠层膜的操作性差。另一方面,如果比上述上限值厚,PET膜的厚度精度变差,另外还存在制造成本和废弃物变多等问题。
在PET膜的表面预先涂布粘合剂,例如丙烯酸改性类、异氰酸酯类、聚乙烯亚胺类、聚氨酯类、硅烷偶合剂。如果使用在表面涂布了这些粘合剂的易粘接性PET膜,例如特开平2000-229394号中记载的膜,可以节省涂布工序,故优选。
本发明还涉及厚度精度高的氟树脂叠层膜。该膜的特征是从氟树脂膜表面上的任意的位置在与挤出方向,即机械方向成直角的方向上用连续厚度计的前端的端子径5mm经过75cm的长度而测定的厚度的最大值和最小值的差(R)为2μm或2μm以下。
薄壁的氟树脂膜一般厚度精度差,特别是与挤出方向(机械方向)成直角的方向的厚度精度差。作为提高这样的薄壁氟树脂膜的厚度精度的方法,已知有在厚度精度良好的聚酯膜上叠层薄壁的氟树脂的方法(特开平2002-67241号公报)。可是,在该方法中,由于叠层膜是将预先制膜的聚酯膜和氟树脂膜进行干式层压,因此,容易引起掺入杂质、气泡等,使R不足3μm是困难的。可是,令人惊异的是按照本发明的挤出层压法,发现可以使R为2μm或2μm以下。可以认为这是由于在挤出中可以进行厚度的微调节,另外,即使在膜上有杂质,挤出的熔融树脂在该杂质的周围也不会残留气泡,容易形成圆滑平坦的表面。具有这样的厚度精度的本发明的氟树脂叠层膜适合于例如制膜用载体膜等要求厚度精度的用途。在本发明中,对于R的测定方法,在实施例中详细叙述。
该氟树脂叠层膜中的拉伸聚酯膜和氟树脂膜,与作为本发明的方法中涉及的PET膜以及氟树脂层(1)分别与上面叙述的物质是同样的。另外,在氟树脂膜上也可以叠层与该氟树脂膜不同种类的氟树脂膜,该不同种类的氟树脂膜可以是本发明的方法中涉及的作为含有氟树脂的层(3)所叙述的物质。
以下,通过实施例详细地说明本发明。
(1)以下示出使用的膜和填料。各树脂名称后面的括号内表示在表1中的简称。
拉伸聚对苯二甲酸乙二醇酯膜(PET-1):三菱化学聚酯社制造
易粘接性拉伸聚对苯二甲酸乙二醇酯膜(PET-2):UV4(商品名),ュニチカ(株)制造
四氟乙烯-六氟丙烯-偏二氟乙烯3元共聚物树脂(THV):THV220(ダィニォン社制造,结晶化温度98℃)
四氟乙烯-乙烯共聚物(ETFE):テフゼル290(商标),三井·デュポンフロロケミカル(株)社制造
聚偏氟乙烯(PVDF):カィナ一720(商品名),ェルファトケム社制造
四氟乙烯-六氟丙烯共聚物(FEP):ネォフロンFEP NP-100(商品名),大金(ダィキン)工业(株)社制造
低密度聚乙烯(PE):日本ポリケム社制造,密度0.95,MFR 3g/10分
球状云母:クラレ社制造,平均粒径50μm
(2)膜的制造
制造表1所示的各种构成的膜。在实施例4以及实施例5中,使用在聚乙烯树脂中混炼了10重量%的填料的树脂。在实施例6中,使用了易粘接性拉伸聚对苯二甲酸乙二醇酯膜。在挤出机口模温度315℃下通过T型模共挤出树脂层(1)和树脂层(2),在实施例4以及5中共挤出树脂层(2)和(3),并在设定为温度90℃的冷却辊和夹持辊之间在预先涂布了丙烯酸改性粘合剂的PET膜,但在实施例中为未涂布任何物质的原样的PET膜的单面上,边用X射线连续厚度计(横河电机制造,WEBFLEX2)监测膜的厚度边叠层,从而制造了叠层膜。参考例的膜除了不共挤出树脂层(2)的PE这点以外,与实施例同样地制造。另外,比较例1的膜通过干式层压法制造。对制造的膜进行下述的评价,结果示于表1。
(3)评价方法
(i)层压稳定性:将能够稳定层压的作为A,将膜起皱等不能稳定层压的作为B。
(ii)粘接强度:氟树脂层(1)和PET的粘接强度基于JIS Z-0237,以5mm/分测定180度剥离。该强度为4N/cm或4N/cm以上的作为A,低于4N/cm的作为B。
(iii)粗糙性:剥离树脂层(2)后,通过目视观察树脂层(3)的表面,确认了没有斑点并呈粗糙状(消光状态)的作为A。
(iv)厚度差(R)的测定
用膜厚度测试仪(FILM THCKNESS TESTER)(Anritsu社制造),与膜的机械(挤出)方向成直角的方向上以前端的端子径5mm经过75cm(全幅)的长度测定连续的厚度,求出其最大值和最小值的差的平均值,按下述标准进行评价。
A:R为2μm或2μm以下的
B:R超过2μm的
C:R超过5μm的
[表1]
膜构成膜厚(μm)) | 挤出层压稳定剂 | 粘接强度 | 粗糙化 | R(μm) | |
实施例1实施例2实施例3实施例4实施例5实施例6 | PE/THV/PET-1(10/3/50)PE/ETFE/THV/PET-1(10/3/3/50)PE/PVDF/PET-1(10/3/50)PE(10%云母)/ETFE/THV/PET-1(10/3/3/50)PE(10%云母)/FEP/THV/PET-1(10/3/3/50)PE/ETFE/THV/PET-2(10/3/3/50) | AAAAAA | AAAAAA | ---AA- | AAAAAA |
参考例1参考例2参考例3 | THV/PET-1(3/50)PVDF/PET-1(3/50)ETFE/THV/PET-1(3/3/50) | BBB | BBB | --- | BBB |
比较例1 | ETFE/PET-1(3/50) | - | A | - | C |
由上表可知,按照本发明的挤出层压法,可以以强的粘接强度叠层薄壁的氟树脂膜,粗糙化也可以容易地进行。在参考例中,稳定地挤出氟树脂膜是困难的,并且得到的膜的粘接强度以及厚度精度差。另外,通过干式层压法的比较例1的膜有由于混入杂质、气泡等而引起的凸部,厚度精度大幅变差。
工业实用性
按照本发明的方法,可以通过挤出层压叠层的膜稳定地制造薄的氟树脂层。另外,可以容易地将氟树脂层表面进行粗糙化。本发明的膜,厚度精度优异,适用于涂膜制造用载体膜等。
Claims (25)
1.一种氟树脂叠层膜的制造方法,其特征在于,将第一氟树脂层和可以与该第一氟树脂层剥离的树脂层(2)进行共挤出,并且使该共挤出的第一氟树脂层一侧与拉伸聚对苯二甲酸乙二醇酯膜对置地挤出层压在该拉伸聚对苯二甲酸乙二醇酯膜的至少单面上,第一氟树脂层和拉伸聚对苯二甲酸乙二醇酯膜的粘接强度基于JIS Z-0237,以5mm/分测定180度剥离,为至少4N/cm。
2.按照权利要求1记载的方法,其特征在于,树脂层(2)含有填料,并且将第一氟树脂层的在树脂层(2)侧的表面进行粗糙化。
3.按照权利要求1记载的方法,其特征在于,在树脂层(2)和第一氟树脂层之间,进一步共挤出由与构成层(1)的氟树脂不同种类的氟树脂构成并且可以与树脂层(2)剥离的第二氟树脂层。
4.按照权利要求3记载的方法,其特征在于,树脂层(2)含有填料,并且将第二氟树脂层的在树脂层(2)侧的表面进行粗糙化。
5.按照权利要求1记载的方法,其特征在于,第一氟树脂层包含四氟乙烯-六氟丙烯-偏二氟乙烯3元共聚物(THV)。
6.按照权利要求2记载的方法,其特征在于,第一氟树脂层包含四氟乙烯-六氟丙烯-偏二氟乙烯3元共聚物(THV)。
7.按照权利要求3记载的方法,其特征在于,第一氟树脂层包含四氟乙烯-六氟丙烯-偏二氟乙烯3元共聚物(THV)。
8.按照权利要求4记载的方法,其特征在于,第一氟树脂层包含四氟乙烯-六氟丙烯-偏二氟乙烯3元共聚物(THV)。
9.按照权利要求1~8中的任一项记载的方法,其特征在于,树脂层(2)包含不含氟的树脂。
10.按照权利要求9记载的方法,其特征在于,不含氟的树脂为聚乙烯。
11.按照权利要求3、4、7和8中的任一项记载的方法,其特征在于,第二氟树脂层含有选自包含四氟乙烯-乙烯共聚物树脂、四氟乙烯-六氟丙烯共聚物树脂以及聚偏氟乙烯树脂的组中的树脂。
12.按照权利要求2记载的方法,其特征在于,填料为选自包含玻璃纤维、云母以及碳酸钙的组中的至少1种。
13.按照权利要求4记载的方法,其特征在于,填料为选自包含玻璃纤维、云母以及碳酸钙的组中的至少1种。
14.按照权利要求2记载的方法,其特征在于,填料的粒径为1μm~1000μm,并且相对于树脂层(2)的总重量,含有该填料为5重量%~30重量%。
15.按照权利要求4记载的方法,其特征在于,填料的粒径为1μm~1000μm,并且相对于树脂层(2)的总重量,含有该填料为5重量%~30重量%。
16.按照权利要求12记载的方法,其特征在于,填料的粒径为1μm~1000μm,并且相对于树脂层(2)的总重量,含有该填料为5重量%~30重量%。
17.按照权利要求13记载的方法,其特征在于,填料的粒径为1μm~1000μm,并且相对于树脂层(2)的总重量,含有该填料为5重量%~30重量%。
18.按照权利要求9记载的方法,其特征在于,树脂层(2)的厚度为8~20μm。
19.按照权利要求10记载的方法,其特征在于,树脂层(2)的厚度为8~20μm。
20.按照权利要求11记载的方法,其特征在于,树脂层(2)的厚度为8~20μm。
21.按照权利要求12~17中的任一项记载的方法,其特征在于,树脂层(2)的厚度为8~20μm。
22.一种叠层膜,其特征在于,该叠层膜是在拉伸聚对苯二甲酸乙二醇酯膜的至少一侧叠层了氟树脂膜的叠层膜,其中,在与挤出方向成直角的方向的上述叠层膜的最大厚度与最小厚度的差(R)为2μm/75cm或2μm/75cm以下,第一氟树脂层和拉伸聚对苯二甲酸乙二醇酯膜的粘接强度基于JISZ-0237,以5mm/分测定180度剥离,为至少4N/cm。
23.按照权利要求22记载的叠层膜,其特征在于,上述氟树脂为四氟乙烯-六氟丙烯-偏二氟乙烯3元共聚物(THV)。
24.按照权利要求23记载的叠层膜,其特征在于,上述氟树脂四氟乙烯-六氟丙烯-偏二氟乙烯3元共聚物(THV)的结晶化温度为95~140℃。
25.按照权利要求22~24中的任一项记载的叠层膜,其特征在于,上述氟树脂的膜的厚度为2~10μm,拉伸聚对苯二甲酸乙二醇酯膜的厚度为5~300μm。
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PCT/JP2004/006534 WO2004101256A1 (ja) | 2003-05-14 | 2004-05-14 | フッ素系積層フィルム及びその製造方法 |
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US (1) | US7744715B2 (zh) |
JP (1) | JP4300215B2 (zh) |
KR (1) | KR20060013396A (zh) |
CN (1) | CN1787904B (zh) |
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JP4727998B2 (ja) * | 2005-01-12 | 2011-07-20 | 三菱樹脂株式会社 | 金属被覆用積層フィルム |
JP2006192668A (ja) * | 2005-01-12 | 2006-07-27 | Mitsubishi Plastics Ind Ltd | 金属被覆用積層フィルム |
WO2006121070A1 (ja) * | 2005-05-10 | 2006-11-16 | Mitsubishi Plastics, Inc. | 金属被覆用積層フィルム、スクリーンボード用金属被覆用積層フィルム |
FR2896445B1 (fr) * | 2006-01-25 | 2010-08-20 | Arkema | Film flexible a base de polymere fluore |
US20070202311A1 (en) * | 2006-02-28 | 2007-08-30 | Saint-Gobain Performance Plastics Corporation | Multi-layer release films |
US8445102B2 (en) * | 2007-11-05 | 2013-05-21 | Laird Technologies, Inc. | Thermal interface material with thin transfer film or metallization |
US8545987B2 (en) | 2007-11-05 | 2013-10-01 | Laird Technologies, Inc. | Thermal interface material with thin transfer film or metallization |
US9795059B2 (en) | 2007-11-05 | 2017-10-17 | Laird Technologies, Inc. | Thermal interface materials with thin film or metallization |
JP5531390B2 (ja) * | 2008-09-24 | 2014-06-25 | 住友化学株式会社 | 多層構造体 |
CN102039664B (zh) * | 2009-10-10 | 2013-11-27 | E.I.内穆尔杜邦公司 | 多层膜的叠合方法和用该方法制成的太阳能电池背板 |
JP5730039B2 (ja) * | 2011-01-27 | 2015-06-03 | キヤノン株式会社 | 定着用回転体及びこの定着用回転体を搭載する定着装置 |
FR2982796A1 (fr) * | 2011-11-23 | 2013-05-24 | Arkema France | Procede de fabrication d'un film fluore mat |
JP6137192B2 (ja) * | 2012-10-30 | 2017-05-31 | 旭硝子株式会社 | 樹脂フィルム、太陽電池モジュールのバックシートおよび太陽電池モジュール |
KR101596725B1 (ko) * | 2013-05-22 | 2016-02-24 | 삼성디스플레이 주식회사 | 충전 필름 및 이를 이용한 유기 발광 디스플레이 장치의 제조 방법 |
CN105751615B (zh) * | 2015-06-05 | 2017-12-05 | 捷欣企业股份有限公司 | 功能性皮料合成方法 |
CN109454845B (zh) * | 2018-11-06 | 2020-09-01 | 江门市辉隆塑料机械有限公司 | 一种高剥离强度无胶水复合材料的挤出复合设备及工艺 |
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CN1787904A (zh) | 2006-06-14 |
WO2004101256A1 (ja) | 2004-11-25 |
JP4300215B2 (ja) | 2009-07-22 |
DE112004000834T5 (de) | 2006-03-30 |
US20060292359A1 (en) | 2006-12-28 |
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