DE102012109346A1 - Internal heat exchanger with external manifolds - Google Patents

Abstract

A heat exchanger includes a plurality of first plate groups nested with a plurality of second plate groups in a stacked form. Each of the plate groups includes an upper plate and a lower plate remote therefrom that form an intermediate flow path. The flow paths of the disk groups take up the respective working fluids. Terminals formed in the plate groups are aligned to form an external influent header and an external effluent header in fluid communication with the flow paths. The plate groups are arranged such that the planar surfaces of the first plate and the second plate of the first plate group substantially contact the substantially planar surfaces of the first plate and the second plate of the second plate group. By separating the flow paths of the respective working fluids through adjacent double walls and by providing separate external collecting pipes for the working fluids leakage and contamination of the working fluids are minimized.

Description

FIELD OF THE INVENTION

The present invention relates to a heat exchanger having at least one external header.

GENERAL PRIOR ART

Plate heat exchangers are used to transfer thermal energy between heat-exchanging working fluids. At least two heat exchanging working fluid streams flow through separate flow channels between the heat exchanger plates in the plate heat exchanger. The heat exchanger plates are normally arranged one above the other and form part of the plate heat exchanger. The separate flow channels are usually defined by working fluid ports formed in the heat exchanger plates and flow paths formed between the plates.

Heat transfer between the working fluid streams takes place in the region of a central heat transfer part of the heat exchanger plates. To transfer thermal energy, a first working fluid stream flows through the ports on one side of the heat exchanger into a plurality of first flow paths formed by alternate heat exchanger plates. At the same time, a second working fluid stream flows through the ports on the opposite side of the heat exchanger into a plurality of second flow paths, which are also formed by the alternating heat exchanger plates and run separately from the first flow paths. In this way heat is exchanged between the two working fluid streams flowing in opposite directions through the heat exchanger.

It would be desirable to develop a heat exchanger having an internal structure and at least one external header that prevents contamination of the working fluid and damage to the external systems while reducing costs and optimizing the manufacturability of the heat exchanger, regardless of orientation the line, the working fluid circuit and the size of the heat exchanger.

BRIEF SUMMARY OF THE INVENTION

In accordance with and in accordance with the present invention, surprisingly, a heat exchanger having an internal structure and at least one external header has been discovered which prevents contamination of the working fluid and damage to the external systems while reducing costs and optimizing the manufacturability of the heat exchanger.

In one embodiment, the heat exchanger includes: a plurality of first plate groups, including a top plate, a bottom plate, and a first flow path; between the first plate and the second plate of the first plate groups to trap a first working liquid therein, wherein each of the first plate and the second plate of the first plate groups includes a first surface and a substantially planar second surface, and wherein the first Plate and the second plate of the respective first plate groups are arranged so that the first surfaces face each other; and a plurality of second plate groups including an upper plate, a lower plate and a second flow path formed between the first plate and the second plate of the second plate groups to trap a second working liquid therein, the first plate and the second plate the second plate groups having a first surface and a substantially planar second surface, and wherein the first plate and the second plate of the respective second plate groups are arranged with the opposing first surfaces such that the first plate groups are interleaved with the second plate groups the substantially planar surfaces of the respective first and second plates of the first plate groups substantially contact the substantially planar surfaces of the respective first and second plates of the second plate group.

In another embodiment, the heat exchanger includes: a plurality of first plate groups including a top plate, a bottom plate and a first flow path formed between the first plate and the second plate of the first plate group to trap a first working liquid therein each of the first plate and the second plate includes a first surface, a substantially planar second surface and at least one working fluid port formed therein, and wherein the first plate and the second plate of the respective first plate groups are arranged so that the first surfaces face each other and the first working fluid ports of the first plate groups are substantially lined up to form a first external manifold, the first external manifold being in fluid communication with the first flow path for collecting the first A working fluid is located therein; and a plurality of second plate groups including a top plate, a bottom plate, and a second flow path formed between the first plate and the second plate of the second plate groups to trap a second working liquid therein, wherein each of the first plate and the first plate second plate of the second plate groups include a first surface, a substantially planar second surface and at least a second working fluid port formed therein, and wherein the first plate and the second plate of the respective second plate groups are arranged so that the first surfaces face each other and the second surfaces Working fluid ports of the second plate groups are substantially lined up so that they form a second external manifold, wherein the second external manifold in fluid communication with the second flow path for collecting the second work and the first plate groups are nested with the second plate groups such that the substantially planar surfaces of the respective first and second plates of the first plate groups substantially contact the substantially planar surfaces of the respective first and second plates of the second plate group.

In another embodiment, a heat exchanger includes: a plurality of first plate groups including a top plate, a bottom plate, and a first flow path formed between the first plate and the second plate of the first plate group to trap a first working liquid therein the first flow path includes a turbulator, and wherein each of the first plate and the second plate of the first plate groups includes a first surface, a substantially planar second surface and at least one working fluid port formed therein, and wherein the first plate and the second plate are the respective first Plate groups are arranged so that the first surfaces face each other and the first working fluid ports of the first plate groups are lined up so that they form a first external manifold, wherein the first external manifold in liquidkei tskommunikation with the first flow path for collecting the first working fluid is located therein; and a plurality of second plate groups including an upper plate, a lower plate and a second flow path formed between the first plate and the second plate of the second plate groups to trap a second working liquid therein, the second flow path including a turbulator, and wherein each of the first plate and the second plate of the second plate groups includes a first surface, a substantially planar second surface and at least a second working fluid port formed therein, and wherein the first plate and the second plate of the respective second plate groups are arranged such that the first surfaces are opposed to each other and the second working fluid ports of the second plate groups are substantially lined up to form a second external manifold, the second external manifold being in fluid communication it is the second flow path for collecting the second working fluid therein, and the first plate groups are nested with the second plate groups, so that the substantially planar surfaces of the respective first and second plates of the first plate groups, the substantially planar surfaces of the respective first and second plate essentially touch the second plate group.

BRIEF DESCRIPTION OF THE DRAWINGS

Professionals will use the above as well as other benefits of. in the following detailed descriptions of the preferred embodiment in conjunction with the accompanying drawings, in which:

1 Fig. 12 illustrates a side-view heat exchanger in which, according to the present invention, a plurality of first plate groups are interleaved with a plurality of second plate groups;

2 a cross-sectional side view of the in 1 illustrated heat exchanger, which is along line 2-2 in 1 runs;

3 Fig. 5 illustrates the side view of a heat exchanger in which, according to the present invention, a plurality of first plate groups are interleaved with a plurality of second plate groups, and shown here with alternative plate groups;

4 the exploded top view of one of the plate groups of the 3 the illustrated heat exchanger, wherein each of the plate groups has an upper and a lower plate;

5 Figure 11 illustrates the plan view of an alternative bottom plate of the first plate groups, including a plurality of spherical projections formed thereon;

6 Figure 11 illustrates the plan view of an alternative lower plate of the first plate groups, including a combination of separate, inwardly bent, elongate ribs and separate, V-shaped ribs that together form a substantially arrow-shaped pattern;

7 Figure 12 illustrates the plan view of an alternative bottom plate of the first plate groups, including a plurality of alternating subdivisions that form a plurality of separate, parallel baffles;

8th Fig. 10 illustrates the plan view of an alternative lower plate of the first plate groups, including a plurality of fins formed thereon;

9 a side-view heat exchanger in which, according to the present invention, a plurality of first plate groups are interleaved with a plurality of second plate groups, and which is shown here with an alternative inlet and outlet configuration.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description and attached drawings describe and illustrate an embodiment of the invention. Description and drawings are intended to enable those skilled in the art to make and use the invention and are not intended to limit the scope of the invention in any way.

1 - 3 show a heat exchanger 10 according to the present invention. In the illustrated heat exchanger 10 it is a heat exchanger for cold water production. It is understood, however, that the heat exchanger 10 can represent any type of heat exchanger for the particular application desired, such as for automotive, commercial, residential, marine, aviation and RV applications. The heat exchanger 10 contains a large number of first disk groups 12 that come with a variety of second disk groups 14 nested, arranged between a pair of end plates 16 . 18 in layered form.

For illustration purposes, the disk groups are 12 . 14 and end plates 16 . 18 However, it is also understood that the plate groups 12 . 14 and end plates 16 . 18 can be designed according to your wishes in a different shape and size. It is further understood that the disk groups 12 . 14 and end plates 16 . 18 from a suitable one. Material of any kind can be made, such as metal. The width and length of the heat exchanger shown 10 depends on the shape and size of the disk groups 12 . 14 and the end plates 16 . 18 from, and the height of the heat exchanger 10 depends on the amount and number of layered plate groups 12 . 14 from. The number of layered plate groups 12 . 14 is based on the desired cooling, heat and flow capacity of the heat exchanger 10 established. The illustrated heat exchanger 10 shows nine (9) first disk groups 12 and (9) second plate groups 14 , It is understood, however, that as desired additional or fewer disk groups 12 . 14 can be used as shown here. Other plates may be used as desired, such as barrier, corner, spacer or transfer plates.

Each of the disk groups 12 has a top plate 20 and a lower plate 22 , and every disk group 14 has a top plate 24 and a lower plate 26 , In certain embodiments, the plates are 20 . 22 the first disk groups 12 essentially identical as well as the plates 24 . 26 the second disk groups 14 also essentially identical. In other embodiments, the plates are 20 . 22 the first disk groups 12 essentially identical to the plates 24 . 26 the second disk groups 14 , Identical plates 20 . 22 . 24 . 26 Simplify manufacturing processes and minimize tooling costs during plate production 20 . 22 . 24 . 26 , It is understood, however, that at least one of the plates 20 . 22 . 24 . 26 may be substantially different, if desired.

The top plate 20 and the bottom plate 22 the first disk group 12 are distanced from each other to a flow path 28 to define a first working fluid (not shown) therein. Similar are the top plate 24 and the bottom plate 26 the second disk groups 14 away from each other to a flow path 30 to define a second working fluid (not shown) therein. The working fluids may be of any type, such as fluids used in automotive applications, cooling fluid (eg, R12, R134a, etc.), coolant (eg, ethylene glycol), engine oil, transmission fluid, power steering fluid, and the like. In a non-limiting example, the first working fluid is a cooling fluid and the second working fluid is an engine or battery coolant. In certain embodiments, the flow paths are 28 . 30 substantially U-shaped and arranged in a counterflow configuration to each other to maximize the flow distribution of the working fluids as well as the heat transfer. It is understood, however, that the flow paths 28 . 30 may have another suitable shape or size as desired. For example, height, length and width of the flow paths 28 . 30 be modified to suit the properties of the liquid as well as the distribution and the pressure drop of the respective working fluids.

As in 4 shown has each of the plates 20 . 22 , the first record group 12 over a first surface 32 , a substantially planar second surface 34 and a pair of first working fluid ports formed therein 36 . 38 , The first surface 32 the plates 20 . 22 can one edge part 40 included, which is formed around the outer edge, and a divider 42 that between the fluid ports 36 . 38 is formed and laterally into the middle part of the plates 20 . 22 extends. The plates 20 . 22 lie one above the other, with the first surfaces 32 face each other so that the outer edge of the plates 20 . 22 and their divisors 42 border each other. The plates 20 . 22 may be attached in a substantially liquid-tight manner at any suitable location and by any means. For example, the upper plates 20 to the respective lower plates 22 along the outward sidebars 44 . 46 the respective plates 20 . 22 be soldered as in 1 - 2 shown, or along edge portion 40 next to the sidebars 44 . 46 , as in 3 shown. The pictured edge parts 40 and the dividers 42 define the flow path 28 continue and direct the flow F of the first working fluid through the first plate groups 12 ,

To each of the plates 24 . 26 belongs to a surface 52 , a substantially planar second surface 54 and a pair of first working fluid connections 56 . 58 , The first surface 52 the plates 24 . 26 can be an edge part 60 which is formed around its outer edge thereof, as well as a divider 62 that between the fluid ports 56 . 58 is formed and laterally into the middle part of the plates 24 . 26 extends. The plates 24 . 26 lie one above the other, with the first surfaces 52 face each other so that the outer edge of the plates 24 . 26 and their divisors 62 border each other. The plates 24 . 26 may be attached in a substantially liquid-tight manner at any suitable location and by any means. For example, the upper plates 24 to the respective lower plates 26 along the outward sidebars 64 . 66 the respective plates 24 . 26 be soldered as in 1 - 2 shown, or along edge portion 60 next to the sidebars 64 . 66 , as in 3 shown. The pictured edge parts 60 and the dividers 62 define the flow path 30 and steer the flow F of the first working fluid through the second plate groups 14 ,

Each of the flow paths 28 . 30 can have at least one turbulator 70 included, as in 5 - 8th shown. It is understood that others, from the turbulator 70 deviating turbulators can be used. The turbulator 70 causes turbulence in the working fluids and defines a variety of non-linear flow paths within the flow paths 28 . 30 to the total length of the flow paths 28 . 30 and to maximize the heat transfer between the working fluids. In some embodiments, the turbulator is 70 from a plurality of in or on at least one of the first surfaces 32 the plates 20 . 22 and the first surfaces 52 the plates 24 . 26 irregularities. Without being limited thereto, the appropriate configurations of such surface irregularities include those in U.S. Patent Nos. 4,605,731 and 5,605,954 5 shown variety of spherical projections and the in 6 shown combination of separate, inwardly bent, elongated ribs and separate, V-shaped ribs, which together form a substantially arrow-shaped pattern. In other embodiments, the turbulator is 70 around a separate turbulator, between at least one of the plates 20 . 22 the first disk group 12 and the plates 24 . 26 the second disk groups 14 is appropriate. Without being limited thereto, the suitable configurations of such a separate turbulator include those in U.S. Pat 7 shown alternating subdivisions, which form a plurality of separate, parallel baffles, as well as in 8th pictured lamellae.

To the heat exchanger 10 to assemble the first plate groups 12 alternating with the second plate groups 14 stacked. The disk groups 12 . 14 are arranged so that they are closely nested by the disk groups 12 . 14 as in 4 be positioned substantially 180 degrees opposite each other. In the nested position, the substantially planar second surfaces are adjacent 34 the first disk groups 12 to the substantially planar second surfaces 54 the second disk groups 14 at. This will create a double wall between the flow paths 28 . 30 formed during the substantial contact between the planar surfaces 34 . 54 the respective disk groups 12 . 14 maximizes the efficiency of heat transfer through conduction.

In addition, in the nested position, the first working fluid ports become 36 . 38 the first disk groups 12 essentially brought into a line and soldered together to an external influence collection pipe 72 and an external effluent header 74 to build. It is understood that the size and shape of the first working fluid connections 36 . 38 can be modified to change the size and shape of the flow paths 28 . 30 to match, thus the mounting of and the contact between the plate groups 12 . 14 is ensured. The first working fluid influence tube 72 allows the first working fluid, in the flow path 28 inflow, and the first working fluid outflow pipe 74 allows the first working fluid, from the flow path 28 emanate. In some embodiments, at least one baffle is 75 in at least one of the first working fluid flow tubes 72 and the first working fluid outflow pipe 74 attached to a multi-circuit in the heat exchangers 10 to form, so that the flow distribution of the first working fluid and the heat transfer between the working fluids is maximized. For example, the baffles 75 to be used as desired, a 2-, 4- or 6-loop circuit inside the heat exchanger 10 to configure.

An influence line 76 is in fluid communication with the first working fluid influent tube 72 to the heat exchanger 10 coupled to allow the working fluid in the heat exchanger 10 to flow. An outflow line 78 is in fluid communication with the first working fluid outflow pipe 74 to the heat exchanger 10 coupled to allow the working fluid from the heat exchanger 10 emanate. As shown in the pictures, the wires end 76 . 78 in the respective openings of the end plates 16 and form a liquid-tight connection. It is understood that the wires 76 . 78 in any way with one of the end plates 16 . 18 can be connected, such as by soldering, welding, clamping, use of a seal and the like.

Likewise, the second working fluid connections 56 . 58 the second disk groups 14 essentially brought into line and soldered together to an external influence tube 82 and an external spout 84 to build. It is understood that the size and shape of the first working fluid connections 56 . 58 can be modified to change the size and shape of the flow paths 28 . 30 to match, thus the mounting of and the contact between the plate groups 12 . 14 is ensured. The second working fluid flow tube 82 allows the second working fluid, in the flow path 30 inflow, and the second working fluid outflow pipe 84 allows the second working fluid, from the flow path 30 emanate. In some embodiments, at least one baffle is 85 in at least one of the second working fluid flow tubes 82 and the second working fluid outflow tube 84 attached to a multi-circuit in the heat exchanger 10 to form, so that the flow distribution of the first working fluid and the heat transfer between the working fluids is maximized. For example, the baffles 85 to be used as desired, a 2-, 4- or 6-loop circuit inside the heat exchanger 10 to configure.

An influence line 86 will be in fluid communication with the second working fluid inlet tube 82 to the heat exchanger 10 coupled to allow the second working fluid in the heat exchanger 10 to flow. An outflow line 88 is in fluid communication with the second working fluid outflow tube 84 to the heat exchanger 10 coupled to allow the second working fluid from the heat exchanger 10 emanate. As shown in the pictures, the wires end 86 . 88 in the respective openings of the end plates 16 and form a liquid-tight connection. It is understood that the wires 86 . 88 in any way with one of the end plates 16 . 18 can be connected, such as by soldering, welding, clamping, use of a seal and the like. It goes without saying that the lines 76 . 78 . 86 . 88 can be made of any suitable material, such. As metal or plastic. As shown in the illustrations, the cables run 76 . 78 . 86 . 88 laterally outward from one side of the heat exchanger 10 , It is understood, however, that, as in 9 shown, each of the lines 76 . 78 . 86 . 88 and additional lines from any side of the heat exchanger 10 can run in any direction and in any desired configuration to the packaging size of the heat exchanger 10 to minimize working fluid supply and return connections as well as the installation of thermal expansion valve blocks directly on or in close proximity to the heat exchanger 10 to enable.

During commissioning, the first working fluid flows into the heat exchanger 10 through the influence line 76 and into the influent header 72 for the first working fluid. The first working fluid then flows into between the plates 20 . 22 formed flow paths 28 , When the first working fluid through the flow paths 28 runs, the first working fluid flows around the turbulator 70 in the plates 20 . 22 , which causes a turbulence of the first working fluid. Thereafter, the first working fluid flows from the flow paths 28 through the discharge manifold 74 and in the outflow line 78 from the heat exchanger 10 ,

At the same time, the second working fluid flows into the heat exchanger 10 through the influence line 86 and into the influent header 82 for the second working fluid. The second working fluid then flows into between the plates 24 . 26 formed flow paths 30 , When the second working fluid through the flow paths 30 runs, the second working fluid flows around the turbulator 70 in the plates 24 . 26 , which causes a turbulence of the second working fluid. Typically, heat is transferred from the second working fluid to the first working fluid. It is understood, however, that in some applications of the heat exchanger 10 for example, when used in cold climates, heat may be transferred from the first working fluid to the second working fluid if desired. Thereafter, the second working fluid flows from the flow paths 30 through the discharge manifold 84 and in the outflow line 88 from the heat exchanger 10 ,

This minimizes the heat exchanger 10 the present invention, the leakage and contamination of the working fluids by the flow paths 28 . 30 the respective working fluids are separated by adjacent double walls and by external headers 72 . 74 for the first working fluid separately from the external manifolds 82 . 84 be provided for the second working fluid.

Based on the foregoing description, one of ordinary skill in the art can readily appreciate the essential characteristics of the present invention as well as make various changes and modifications to the invention to adapt it to various uses and conditions without departing from the spirit or scope thereof.

Claims (20)

A heat exchanger consisting of: a plurality of first plate groups, including a top plate, a bottom plate, and a first flow path formed between the first plate and the second plate of the first plate groups to trap a first working liquid therein, wherein each of the first plate and the second A plate of the first plate groups having a first surface and a substantially planar second surface, and wherein the first plate and the second plate of the respective first plate groups are arranged so that the first surfaces face each other; and a plurality of second plate groups, including a top plate, a bottom plate, and a second flow path formed between the first plate and the second plate of the second plate groups, for collecting a second working liquid, wherein the first plate and the second plate are the second Plate groups have a first surface and a substantially planar second surface, and wherein the first plate and the second plate of the respective second plate groups with the opposing first surfaces are arranged so that the first plate groups are interleaved with the second plate groups, so that in Substantially planar surfaces of the respective first and second plate of the first plate groups substantially contact the substantially planar surfaces of the respective first and second plate of the second plate group substantially. The heat exchanger of claim 1, wherein the first plate and the second plate of the respective first plate groups are substantially identical. The heat exchanger of claim 1, wherein the first plate and the second plate of the respective second plate groups are substantially identical. The heat exchanger of claim 1, wherein the first plate and the second plate of the respective first plate groups and each of the first and second plates of the second plate groups are substantially identical. Heat exchanger according to claim 1, wherein at least one of the flow paths is substantially U-shaped. A heat exchanger according to claim 1, wherein the size of at least one of the flow paths is determined by the flow characteristics of the first working fluid or the second working fluid. Heat exchanger according to claim 1, wherein at least one of the flow paths contains at least one turbulator. A heat exchanger according to claim 1, wherein the first plate groups are soldered together with the second plate groups. A heat exchanger comprising: a plurality of first plate groups including a top plate, a bottom plate, and a first flow path formed between the first plate and the second plate of the first plate group to trap a first working liquid therein, the first one Plate as well as the second plate a first surface, one in the And the first plate and the second plate of the respective first plate groups are arranged so that the first surfaces oppose each other, and the first working fluid ports of the first plate groups are substantially lined up to one another forming a first external header, the first external header being in fluid communication with the first flow path for collecting the first working fluid; and a plurality of second plate groups, including a top plate, a bottom plate, and a second flow path formed between the first plate and the second plate of the second plate groups to trap a second working liquid therein, wherein each of the first plate and the first plate second plate of the second plate groups include a second surface, a substantially planar second surface and at least a second working fluid port formed therein, and wherein the first plate and the second plate of the respective second plate groups are arranged so that the first surfaces face each other and the second surfaces Working fluid ports of the second plate groups are lined up so that they form a second external manifold, wherein the second external manifold in fluid communication with the second flow path for collecting the second working fluid be and the first plate groups are nested with the second plate groups such that the substantially planar surfaces of the first and second plates of the first plate groups substantially contact the planar surfaces of the respective first and second plates of the second plate group. A heat exchanger according to claim 9, wherein the first and second plates of the respective first plate groups are substantially identical. A heat exchanger according to claim 9, wherein the first and second plates of the respective second plate groups are substantially identical. The heat exchanger of claim 9, wherein the first and second plates of the respective first plate groups and the first and second plates of the second plate groups are substantially identical. Heat exchanger according to claim 9, wherein at least one of the flow paths is substantially U-shaped. A heat exchanger according to claim 9, wherein the size of at least one of the flow paths is determined by the flow characteristics of the first working fluid or the second working fluid. A heat exchanger according to claim 9, wherein at least one of the flow paths includes at least one turbulator. A heat exchanger according to claim 9, wherein the first plate groups are soldered together with the second plate groups. A heat exchanger consisting of: a plurality of first plate groups including an upper plate, a lower plate, and a first flow path formed between the first plate and the second plate of the first plate group to trap a first working liquid therein, the first flow path including at least one turbulator; wherein each of the first plate and the second plate of the first plate groups includes a first surface, a substantially planar second surface and at least one working fluid port formed therein, and wherein the first plate and the second plate of the respective first plate groups are arranged so that the first surfaces facing each other and the first working fluid ports of the first plate groups are substantially lined up to form a first external manifold, the first external manifold being in fluid communication with the first one Flow path for collecting the first working fluid is located therein; and a plurality of second plate groups including a top plate, a bottom plate, and a second flow path formed between the first plate and the second plate of the second plate groups to trap a second working liquid therein, the second flow path including at least one turbulator; wherein each of the first plate and the second plate of the second plate groups includes a first surface, a substantially planar second surface and at least a second working fluid port formed therein, and wherein the first plate and the second plate of the respective second plate groups are arranged such that the first surfaces are opposed to each other and the second working fluid ports of the second plate groups are substantially lined up to form a second external manifold, the second external manifold being in fluid communication With the second flow path for collecting the second working fluid, and the first plate groups are nested with the second plate groups, so that the substantially planar surfaces of the respective first and second plate of the first plate groups, the substantially planar surfaces of the respective first and second plate essentially touch the second plate group. A heat exchanger according to claim 17, comprising at least one turbulator consisting of a plurality of irregularities formed on the first surfaces on at least one of the plates in at least one of the plate groups. A heat exchanger according to claim 17, including at least one separate turbulator mounted between the plates in at least one of the plate groups. The heat exchanger of claim 17, wherein at least one of the first or second external headers of at least one of the first and second plate groups includes at least one baffle mounted therein.

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