DE102022116063A1 - Multi-layer component for a ceiling, method for producing a multi-layer component and use of textile concrete strips - Google Patents

Abstract

The invention relates to a multi-layer component (1) for a ceiling, having at least three layers (2, 3, 4) arranged one above the other, a first layer (2) having a first shell (5) and a second layer (3) having a second shell (6) are formed, wherein at least one textile concrete strip (7, 8) with at least one textile reinforcement runs in an intermediate layer (4) formed between the first layer (2) and the second layer (3) and the course of the at least a textile concrete strip (7, 8) is shaped in such a way that a layer thickness (14) of the intermediate layer (4) can be adjusted and that at least one cavity (9) is formed in the intermediate layer (4).

Description

The invention relates to a multi-layer component for a (concrete) ceiling. In addition, a method for producing a multi-layer component and the use of extruded and formed textile concrete strips are specified. The invention can be used particularly advantageously to provide weight-reduced concrete ceilings. The invention can contribute to providing a ceiling element with or made from modular extrusion components.

Ceiling elements for concrete ceilings are often made from reinforced concrete in order to ensure sufficient load capacity. In a similar way, structural elements for concrete walls are often made from reinforced concrete. Steel typically has a density of approximately 7.85 kg/cm ³ [kilograms per cubic centimeter] and a tensile strength of approximately 500 MPa [megapascals]. This ensures the sufficient load-bearing capacity of appropriately manufactured elements and structures. However, a known disadvantage of corresponding elements and constructions is their usually high weight. In addition, corrosion of the steel reinforcement can occur over time.

In the latest applications, steel is currently being replaced by textiles such as carbon textiles or rods, which have an advantageously high tensile strength of up to 4000 MPa and a density of approximately 1.78 kg/cm ³ . The use of textiles instead of steel can therefore enable lighter and yet sufficiently stable textile-reinforced concrete elements. In addition, the carbon is inert and not sensitive to corrosion like conventional structural steel.

However, it has turned out that simply replacing the steel reinforcement with textile reinforcement is not sufficient to exploit the full potential of the material textile concrete and in particular the material carbon concrete.

Proceeding from this, it is an object of the invention to at least partially solve the problems described with reference to the prior art. In particular, a component and a manufacturing process should be specified, each of which contributes to the fact that concrete structures can be provided in the most material-friendly and/or weight-saving manner possible, but at the same time sufficiently stable. In addition, the components should advantageously be able to be provided quickly.

These tasks are solved with a multilayer component, a method and a use according to the features of the respective independent patent claims. Further advantageous embodiments of the invention are specified in the dependent claims. It should be noted that the features listed individually in the dependent patent claims can be combined with one another in any technologically sensible manner and define further embodiments of the invention. In addition, the features specified in the patent claims are specified and explained in more detail in the description, with further preferred embodiments of the invention being presented.

A multi-layer component for a (concrete) ceiling contributes to this, having at least three layers arranged one above the other, with a first layer being formed with a first shell and a second layer with a second shell, in one between the first layer and the second Layer formed intermediate layer at least one textile concrete strip with at least one textile reinforcement runs and the course of the at least one textile concrete strip is shaped so that a layer thickness of the intermediate layer can be adjusted and that at least one cavity is formed in the intermediate layer.

The multilayer component is suitable for providing a ceiling, in particular a concrete ceiling. For example, several components can be arranged next to each other and connected to each other to create a (concrete) ceiling. In addition, the multi-layer component can also be used for (concrete) walls or (concrete) floors or (concrete) floor slabs. For example, the component can also be used in walls, such as basement walls. However, the multi-layer component is preferably a multi-layer ceiling element. Alternatively or cumulatively, the multilayer component can be a modular, multilayer component. In particular, the individual layers can be provided or provided in a modular manner. In other words, this can be described in particular in such a way that the multilayer component can be formed in a modular manner. In particular, the first shell and/or the second shell and/or the at least one textile concrete strip can be provided in a modular manner.

The component has at least three layers arranged one above the other. As a rule, the first layer is arranged below the intermediate layer and below the second layer. In particular, the intermediate view is arranged lying in the vertical direction between the first layer and the second layer. In principle, more than three layers can also be present or formed. For example, a fourth or fifth layer can be formed. In this context, the fourth layer can, for example, also represent an intermediate layer in which at least one textile concrete strip with at least one textile reinforcement runs according to the solution presented here. The fifth layer can be formed with a third shell.

In the component, a first layer with a first shell and a second layer with a second shell are formed. The first shell may be formed in the form of a plate. The second shell may be formed in the form of a plate. A plate here is to be understood in particular as an element whose thickness or height is significantly smaller (at least twice smaller) than its length and/or width. The first shell and/or the second shell may (each) be formed with concrete. Preferably, the first shell and/or the second shell (each) can be formed at least partially (or completely) with textile concrete. Carbon concrete or concrete reinforced with carbon fibers can be used particularly advantageously as textile concrete. The first shell and/or the second shell may (each) be cast or extruded.

For example, at least the first shell or the second shell can be formed as textile concrete with at least one textile reinforcement. The textile reinforcement can be at least partially formed with fibers made of glass, aramid, basalt or carbon. The textile reinforcement is preferably at least partially formed with carbon or with carbon fibers. The textile reinforcement can be provided in the form of a prefabricated, in particular pre-impregnated, grid. The textile reinforcement can be provided, for example, as a flexible, pre-impregnated textile. A polymer material can advantageously be used as impregnation. Styrene-butadiene rubber (SBR), for example, can be used for flexible impregnation. A plurality of textile reinforcements, such as at least two or exactly two textile reinforcements, can be arranged in at least the first shell or the second shell. In at least the first shell or the second shell, for example, an upper textile reinforcement and a lower textile reinforcement can be arranged one above the other. This can advantageously contribute to better absorption of the tensile forces that occur on both the bottom and top of the shell.

At least one textile concrete strip with at least one textile reinforcement runs in an intermediate layer formed between the first layer and the second layer. The textile concrete strip can be formed, for example, as a carbon concrete strip or as concrete reinforced with carbon fibers. The textile reinforcement can be at least partially formed with fibers made of glass, aramid, basalt or carbon. The textile reinforcement is preferably at least partially formed with carbon or with carbon fibers. The textile reinforcement can be provided in the form of a prefabricated, in particular pre-impregnated, grid. The textile reinforcement can be provided, for example, as a flexible, pre-impregnated textile. Styrene-butadiene rubber (SBR), for example, can be used for flexible impregnation. Several textile reinforcements, such as at least two or exactly two textile reinforcements, can be arranged in at least one or more of the textile concrete strips. In at least one or more of the textile concrete strips, for example, an upper textile reinforcement and a lower textile reinforcement can be arranged one above the other. This can advantageously contribute to better absorption of the tensile forces that occur on both the bottom and top of the strip.

The course of the at least one textile concrete strip is shaped in such a way that a layer thickness of the intermediate layer can be adjusted and that at least one cavity is formed in the intermediate layer. The at least one textile concrete strip can (for this purpose) be curved or run through the intermediate layer with at least one arch. The at least one textile concrete strip can be curved about at least one axis extending parallel to the layers. The course refers in particular to the extent of the strip along its longitudinal direction. For example, it can be provided (alternatively or cumulatively) that at least one of the textile concrete strips has the shape of a particularly straight rod with, for example, an angular or W-profile-shaped cross section. Furthermore, the course of the textile concrete strip can, for example, describe the shape of a W-profile.

In particular, the at least one textile-reinforced concrete strip is a formed textile-reinforced concrete strip. Preferably, the at least one textile concrete strip is a textile concrete strip that has been shaped to adjust the course. In other words, this can be described in particular in such a way that the textile concrete strip was first shaped, such as extruded, and was reshaped to form its course. The cavity can be at least partially filled with an insulating material and/or form or contain a channel for cables or pipes. In principle, however, it is not intended that the cavity be filled with heavy fillers, such as concrete.

Advantageously, the component described here can enable the construction of ceiling structures that are significantly lighter compared to reinforced concrete ceilings. In particular, corresponding ceilings can have around 80% less weight compared to reinforced concrete. In an advantageous embodiment variant, the component described here can use the advantageous material properties of carbon concrete in combination with an extrusion process to enable a completely new construction method of ceiling structures with minimal use of materials.

According to an advantageous embodiment, it is proposed that the at least one textile concrete strip runs in a meandering or wavy manner in the intermediate layer. The textile concrete strip can form one or more wave crests and one or more wave troughs. Load application areas can be formed in the area of wave crests and/or wave troughs. In the area of the wave crests and/or wave troughs, the at least one textile concrete strip and the shells can be connected to one another, such as glued or screwed.

The course of the at least one textile concrete strip can, for example, have or describe at least one predefinable curvature and/or bend. The at least one textile concrete strip can be curved or curved about at least one axis extending parallel to the layers. By way of example, at least one maximum of the course can be connected to one of the shells and at least a minimum of the course can be connected to or contact one of the shells that is opposite. For example, according to an advantageous embodiment variant, the course of the at least one textile concrete strip can be (re)shaped in such a way that the (respective) textile concrete strip or its course describes at least one parabola or follows it.

According to a further advantageous embodiment variant, the course of the at least one textile concrete strip can, for example, be (re)shaped in such a way that the (respective) textile concrete strip or its course describes or follows a chain line. In particular, the course of the at least one textile-reinforced concrete strip can, for example, be (re)shaped in such a way that a load introduced into the textile-reinforced concrete strip can be or can be transmitted with the lowest possible moment. For this purpose, a course that essentially follows a chain line is particularly advantageous. A chain line (also cable curve, catenoid or chain curve; English: catenary or funicular curve) is a mathematical curve that describes the sag of a chain suspended at its ends under the influence of gravity. This is an elementary mathematical function, the hyperbolic cosine. The course of the at least one textile concrete strip can (thus) describe, for example, a hyperbolic cosine or follow it.

According to a further advantageous embodiment, it is proposed that the at least one textile-reinforced concrete strip comprises at least a first textile-reinforced concrete strip and a second textile-reinforced concrete strip, the first textile-reinforced concrete strip and the second textile-reinforced concrete strip running transversely to one another in the intermediate layer. In particular, the first textile concrete strip and the second textile concrete strip can run perpendicular to one another in the intermediate layer. In this context, it is particularly advantageous if at least several first textile concrete strips running parallel to one another at a predefinable first distance or several second textile concrete strips running parallel to one another at a predefinable second distance are arranged in the intermediate layer.

According to a further advantageous embodiment, it is proposed that the textile concrete strips each run in waves in the intermediate layer, with at least one wave trough of one of the textile concrete strips and a wave crest of another of the textile concrete strips overlapping one another. For example, several or all (internal, i.e. not ending at an edge region) wave troughs of one of the textile concrete strips can each be arranged to overlap with a wave crest of another of the textile concrete strips. The textile concrete strips can in particular be arranged and aligned in the manner of a wickerwork or a braided network.

According to a further advantageous embodiment, it is proposed that the textile concrete strips are each extruded together with their textile reinforcement. Extrusion can advantageously enable rapid production of the components on a plant scale.

1. a) Bereitstellen einer ersten Schale,
2. b) Bereitstellen mindestens eines Textilbetonstreifens, durch gemeinsames Extrudieren von Beton mit mindestens einer textilen Bewehrung,
3. c) Umformen des mindestens einen, extrudierten Textilbetonstreifens,
4. d) Anordnen des mindestens einen, umgeformten Textilbetonstreifens auf der ersten Schale,
5. e) Bereitstellen einer zweiten Schale und Anordnen der zweiten Schale auf dem mindestens einen Textilbetonstreifen.

According to a further aspect, a method for producing a multilayer component is specified, comprising at least the following steps:

1. a) providing a first shell,
2. b) providing at least one textile concrete strip by jointly extruding concrete with at least one textile reinforcement,
3. c) forming the at least one extruded textile concrete strip,
4. d) arranging the at least one formed textile concrete strip on the first shell,
5. e) Providing a second shell and arranging the second shell on the at least one textile concrete strip.

The specified order of steps a), b) and c) is exemplary and can, for example, be carried out at least once in the specified order to carry out the method. In addition, at least some of steps a), b), c), d) and e), in particular the provision according to steps a), b) and e) can be carried out at least partially in parallel or simultaneously.

The method can be carried out to produce a multilayer component described here. In series, the process for producing a large number of corresponding components can be carried out many times. The method can preferably be carried out at least partially automatically.

The forming according to step c) can be carried out in such a way that the at least one extruded textile concrete strip runs in a meandering or wavy shape. In step d), two different, each extruded and formed textile concrete strips can be arranged transversely to one another on the first shell. The various, each extruded and formed textile concrete strips can, for example, form a structure for the intermediate layer. The structure can advantageously be formed symmetrically. The structure may be formed in the manner of a wickerwork or represent a braided network.

The details, features and advantageous configurations discussed in connection with the component can also occur in the method presented here and vice versa. In this respect, full reference is made to the statements there regarding the more detailed characterization of the features.

According to a further aspect, the use of extruded and formed textile concrete strips with textile carbon reinforcement for the spaced connection of two shells of a multi-layer concrete component is specified.

The details, features and advantageous configurations discussed in connection with the component and/or the method can also occur in the use presented here and vice versa. In this respect, full reference is made to the statements there regarding the more detailed characterization of the features.

As a precaution, it should be noted that the number words used here (“first”, “second”, ...) primarily serve (only) to distinguish between several similar objects, sizes or processes, i.e. in particular no dependency and/or order of these objects, sizes or prescribe processes to each other. If a dependency and/or sequence is required, this is explicitly stated here or it will be obvious to the person skilled in the art when studying the specifically described embodiment. To the extent that a component can occur multiple times (“at least one”), the description of one of these components can apply equally to all or part of the majority of these components, but this is not mandatory.

• 1: eine Ausführungsvariante eines hier beschriebenen, mehrschichtigen Bauelements in teilweise geschnittener, perspektivischer Darstellung, und
• 2: eine weitere Ausführungsvariante eines hier beschriebenen, mehrschichtigen Bauelements in geschnitten dargestellter Seitenansicht.

The invention and the technical environment are explained in more detail below using the figures. It should be noted that the figures show particularly preferred embodiment variants of the invention, but this is not limited to this. The same components in the figures are given the same reference numbers. They show by way of example and schematically:

• 1 : an embodiment variant of a multi-layer component described here in a partially sectioned, perspective view, and
• 2 : Another embodiment variant of a multi-layer component described here in a sectioned side view.

1 shows schematically an example of a multi-layer component 1 described here for a concrete ceiling. The component 1 has at least three layers 2, 3, 4 arranged one above the other, a first layer 2 being formed with a first shell 5 and a second layer 3 having a second shell 6.

By way of example, the first layer 2 and the second layer 3 may be formed in the form of plates. In an exemplary embodiment, there can be two flat, parallel textile concrete panels on the outside. The thickness (height) of the first shell 2 can define a first layer thickness 15. The thickness (height) of the second shell 3 can define a second layer thickness 16. The plates or shells 2, 3 can, for example, have a thickness of (only) approximately 3 cm [centimeters] and thus define a corresponding dimension for the first layer thickness 15 and the second layer thickness 16.

For example, the first shell 5 and/or the second shell 6 can be formed as textile concrete with at least one textile reinforcement. For example, the first shell 5 and/or the second shell 6 can each contain two or more layers of textile reinforcement. The textile reinforcement can be made of carbon. As textile concrete for the first shell 5 and/or the second shell 6 can (thus) be used as an example and preferably carbon concrete.

At least one textile concrete strip 7, 8 with at least one textile reinforcement runs in an intermediate layer 4 formed between the first layer 2 and the second layer 3. The textile concrete strips 7, 8 are here, for example, shaped (extruded) in such a way that they have a strip width 17 of approximately 6 cm and a thickness or height of approximately 1 cm. The textile concrete strips 7, 8 here have, for example, two layers of textile reinforcement. The textile concrete strips 7, 8 can be glued or screwed to the support surfaces with the shells 5, 6, which are designed here as textile concrete panels.

The course of the at least one textile concrete strip 7, 8 is shaped so that a layer thickness 14 of the intermediate layer 4 can be adjusted and that at least one cavity 9 is formed in the intermediate layer 4. The layer thickness 14 of the intermediate layer 4 can, for example, be adjusted so that it has a (clear) height of approximately 24 cm. For example, materials for thermal or sound insulation and/or lines and pipes can be integrated into the at least one cavity 9.

In the exemplary embodiment according to 1 is shown by way of example that and possibly how the at least one textile concrete strip 7, 8 can run in a meandering or wave-shaped manner in the intermediate layer 4. For example, the at least one textile concrete strip 7, 8 can comprise at least a first textile concrete strip 7 and a second textile concrete strip 8. The first textile concrete strip 7 and the second textile concrete strip 8 can run transversely to one another in the intermediate layer 4, as can be seen in particular from the perspective view 1 is visible. Basically, the course shown in the figures as well as the arrangement and orientation of the textile concrete strips 7, 8 are exemplary. For example, the textile concrete strips 7, 8 (alternatively) could also be arranged or aligned rotated by 90 degrees.

For example, several first textile concrete strips 7 running parallel to one another at a predefinable first distance 10 and/or several second textile concrete strips 8 running parallel to one another at a predefinable second distance 11 can be arranged in the intermediate layer 4. The following are shown in the illustration only as examples 1 three first textile concrete strips 7 and three second textile concrete strips 8 shown. Of course, significantly more first textile-reinforced concrete strips 7 and second textile-reinforced concrete strips 8 are possible, particularly depending on the selected dimension of the component 1.

In the exemplary embodiment according to 1 is further shown by way of example that and possibly how the textile concrete strips 7, 8 can each run in waves in the intermediate layer 4. At least one wave trough 12 of one of the textile concrete strips 7 and a wave crest 13 of another of the textile concrete strips 8 can preferably overlap one another. Examples of this can also be seen in 1 can be seen, several or all (internal, ie not ending at an edge region) wave troughs 12 of one of the textile concrete strips 7, 8 can each be arranged to overlap with a wave crest 13 of another of the textile concrete strips 8, 7.

2 shows an example of a section through a multilayer component 1, as shown in 1 is shown. The cut would be according to component 1 1 run parallel to the element width 19 and transversely to the element length 18.

In 2 is shown as an example that the wave troughs 12 and wave crests 13 can also function as load introduction areas 20 here. A (vertical) load acting, for example, on the second layer 3 or the second shell 6 can be introduced into the structure of the intermediate layer 4 formed by the textile concrete strips 7, 8 via the wave crests 13. The load introduced into the structure of the intermediate layer 4 formed by the textile concrete strips 7, 8 can be introduced or diverted into the first layer 2 or the first shell 5 via the wave troughs 12. Preferably, the load introduction areas 20 can be at least partially adapted to the usual operating loads of the component 1. In particular, to form a respective load introduction area 20, a contact surface can be formed between the first shell 5 and a section of one of the textile concrete strips 7, 8 or between the second shell 5 and a section of one of the textile concrete strips 7, 8. The contact surface, in particular its dimensioning, can be adapted to the usual operating loads of the component 1.

Preferably, the textile concrete strips 7, 8 can each be extruded together with their textile reinforcement. This can help to make the manufacturing process for the component 1 much more efficient. Thus, a ceiling element using modular extrusion components can advantageously be provided by means of the component 1. The ceiling element can be a cavity ceiling element.

To produce a multilayer component 1, the following procedure can be followed, for example: A first shell 5 can be provided. It can provide at least one at least one textile concrete strip 7, 8, by jointly extruding concrete with at least one textile reinforcement. The at least one extruded textile concrete strip 7, 8 can be reshaped. The at least one formed textile concrete strip 7, 8 can be arranged on the first shell 5. A second shell 6 can be provided and the second shell 6 can be arranged on the at least one textile concrete strip 7, 8.

The method described can be carried out to produce a multilayer component 1, which is also described here. For example, the forming can take place in such a way that the at least one extruded textile concrete strip 7, 8 runs in a meandering or wavy shape. The forming can preferably be carried out in such a way that the respective textile concrete strip 7, 8 describes or has the shape of a parabola or catenary line.

Based on the representations in accordance with 1 and 2 An example of an advantageous use of extruded and formed textile concrete strips 7, 8 with textile carbon reinforcement for the spaced connection of two shells 5, 6 of a multi-layer concrete component 1 is also illustrated.

In an exemplary embodiment, the component 1 can contribute to providing a (modular) ceiling element. The component 1 can have two plates as shells 5, 6, which are made of textile concrete with two layers of textile reinforcement. Extruded, multi-layer, in particular two-layer reinforced textile concrete strips 7, 8 can be attached between the plates and were formed immediately after production.

The resulting formed textile concrete strips 7, 8 can be arranged symmetrically between the two plates or shells 5, 6. In the formed state, the textile concrete strips 7, 8 can define a predeterminable light height. The connection between the formed textile concrete strips 7, 8 and the plates or shells 5, 6 can be achieved, for example, using a two-component adhesive or a sleeve-screw connection.

All parts of the ceiling element or component 1, in particular at least the textile concrete strips 7, 8, can be produced with an extruder, which enables faster production, and assembled modularly at the desired location. In particular, the ceiling element or component 1 does not have to be manufactured as a whole. Due to the advantageously shaped textile concrete strips 7, 8, small material thicknesses, particularly in the intermediate layer 4, can advantageously be achieved. At the same time, a higher tensile strength can advantageously be achieved through the textile reinforcement, such as through the multi-layer textile reinforcement (for example: two layers). Thus, with the component 1 described here and the method described here, the cost of materials can be advantageously reduced and weight can therefore be saved.

An appropriately constructed ceiling can advantageously save approx. 80% weight compared to a conventional ceiling made of reinforced concrete.

Thus, a multilayer (modular) component 1 and a method for producing a multilayer (modular) component 1 are specified, which can at least partially solve the problems described with reference to the prior art. In particular, a component 1 and a manufacturing method can be specified here, which each contribute to ensuring that concrete structures can be provided in the most material-friendly and/or weight-saving manner possible, but at the same time sufficiently stable. In addition, the components 1 can advantageously be made available quickly.

Reference symbol list

1

Component

2

first layer

3

second layer

4

Interlayer

5

first bowl

6

second bowl

7

Textile concrete strips

8th

Textile concrete strips

9

cavity

10

first distance

11

second distance

12

Wave trough

13

Wellenberg

14

Layer thickness

15

Layer thickness

16

Layer thickness

17

Strip width

18

Element length

19

Element width

20

Load introduction area

Claims (10)

Multi-layer component (1) for a ceiling, comprising at least three layers (2, 3, 4) arranged one above the other, a first layer (2) having a first shell (5) and a second layer (3) having a second shell (6 ) are formed, wherein at least one textile concrete strip (7, 8) with at least one textile reinforcement runs in an intermediate layer (4) formed between the first layer (2) and the second layer (3), and the course of the at least one textile concrete strip (7 , 8) is shaped so that a layer thickness (14) of the intermediate layer (4) can be adjusted and that at least one cavity (9) is formed in the intermediate layer (4). Component (1). Claim 1 , wherein the at least one textile concrete strip (7, 8) runs in a meandering or wave-shaped manner in the intermediate layer (4). Component (1). Claim 1 or 2 , wherein the at least one textile concrete strip (7, 8) comprises at least a first textile concrete strip (7) and a second textile concrete strip (8), and wherein the first textile concrete strip (7) and the second textile concrete strip (8) are aligned transversely to one another in the intermediate layer (4) get lost. Component (1). Claim 3 , wherein at least several first textile concrete strips (7) running parallel to one another at a predefinable first distance (10) or several second textile concrete strips (8) running parallel to one another at a predefinable second distance (11) are arranged in the intermediate layer (4). Component (1) according to one of the preceding claims, wherein the textile concrete strips (7, 8) each run in a wave shape in the intermediate layer (4) and at least one wave trough (12) of one of the textile concrete strips (7) and a wave crest (13) of another one Textile concrete strips (8) overlap each other. Component (1) according to one of the preceding claims, wherein the textile concrete strips (7, 8) are each extruded together with their textile reinforcement. Method for producing a multilayer component (1), comprising at least the following steps: a) providing a first shell (5), b) providing at least one textile concrete strip (7, 8) by jointly extruding concrete with at least one textile reinforcement, c) forming the at least one extruded textile concrete strip (7, 8), d) arranging the at least one formed textile concrete strip (7, 8) on the first shell (5), e) providing a second shell (6) and arranging the second shell (6) on the at least one textile concrete strip (7, 8). Procedure according to Claim 7 , wherein the method for producing a multilayer component (1) according to one of Claims 1 until 6 is carried out. Procedure according to Claim 7 or 8th , wherein the forming according to step c) takes place in such a way that the at least one extruded textile concrete strip (7, 8) runs in a meandering or wavy shape. Use of extruded and formed textile concrete strips (7, 8) with textile carbon reinforcement for the spaced connection of two shells (5, 6) of a multi-layer concrete component (1).

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