JP2005243837A - Device and method for manufacturing solar battery module - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a device and method for manufacturing solar battery module, by which the problem can be solved wherein, when connecting tabs are soldered to electrodes provided on a solar battery element in point-like states, the generation efficiency of a solar battery module is lowered, because the connecting areas between the electrodes and connecting tabs become smaller and the connecting portions become resistors, when the solar battery module is operated to generate electricity. <P>SOLUTION: The device for manufacturing solar battery module has soldered the electrodes of the solar battery element so and the belt-like connecting tabs, formed by covering metal foil provided to lead out the electrical outputs or to connect two adjacent electrodes to each other by soldering with soldering layers, to each other by blowing hot air. A hot-air blowing body, constituted by arranging a plurality of hot air outlets in a line, is arranged above the solar battery element, so that the hot air hits almost the entire surfaces of the regions in which the electrodes and connecting tabs are soldered to each other. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  TECHNICAL FIELD The present invention relates to a solar cell module manufacturing apparatus and a solar cell module manufacturing method, and in particular, a manufacturing apparatus for manufacturing a solar cell module with improved power generation efficiency and improved solar cell module manufacturing yield. The present invention relates to a method for manufacturing a solar cell module.

  Solar cell elements are often manufactured using a single crystal silicon substrate or a polycrystalline silicon substrate. For this reason, a solar cell element is weak to a physical impact, and when a solar cell element is attached outdoors, it is necessary to protect this from rain. Further, since one solar cell element has a small electric output, it is necessary to use a plurality of solar cell elements that are electrically connected in series or in parallel.

  For this reason, the wiring material is cut to an appropriate length (hereinafter, the wiring material cut to an appropriate length is referred to as a connection tab), and a plurality of solar cell elements are usually connected in series and parallel using this. In general, a solar cell module is manufactured by encapsulating the connected solar cell elements with a filler between the translucent substrate and the back sheet.

  FIG. 6 shows a conventional solar cell module manufacturing apparatus in which a connection tab is connected to the solar cell element.

  In FIG. 6, 1 is a solar cell element, 2 is an electrode formed on the solar cell element, 3 is a connection tab, 4 is a pressing pin, and 5 is a hot air blowing nozzle.

  To attach the connection tab 3 to the electrode 2 formed on the solar cell element 1, first, the connection tab 3 is disposed on the electrode 2 formed on the solar cell element 1 to be attached. Next, the pressing pin 4 is lowered, and the connection tab 3 is pressed against the electrode 2 formed on the solar cell element 1. At the same time, hot air of about 400 to 500 ° C. is blown from the hot air blowing nozzle 5 for about 1 to 2 seconds onto the portion where the connection tab 3 is pressed against the electrode 2 formed on the solar cell element 1 by the pressing pin 4. The solder on the connection tab 3 and the solder on the electrode 2 formed on the solar cell element 1 are melted to connect both. After that, when the solder is solidified, the pressing pin 4 is pulled up.

  In such a method of attaching the connection tab 3 to the electrode 2 of the solar cell element 1, soldering is performed due to the difference in thermal expansion coefficient between the solar cell element 1 and the connection tab 3 because the heating is performed to around 200 ° C. during soldering. The back solar cell element may be warped, and the solar cell element may be cracked in the subsequent process, thereby reducing the yield.

As a countermeasure against warpage occurring after soldering between the solar cell element 1 and the connection tab 3, warpage is generated by soldering the connection tab to the electrode 2 of the solar cell element 1 intermittently and reducing the soldering area. Has been devised. (See Patent Document 1)
Prior art document information related to the invention of this application includes the following.
Japanese Patent Laid-Open No. 11-312820

  However, recent solar cell elements have been increased in area for cost reduction, and in order to improve the power generation efficiency, the electrodes have been made thinner, and the current generated by one solar potential element has increased. In addition, connection tabs that have a narrow width have come to be used along with the thinning of electrodes.

  For this reason, when the soldering area between the electrode on the solar cell element and the connection tab is reduced as described above, the connection area between the electrode of the solar cell element and the connection tab is reduced, and this portion is generated during power generation of the solar cell module. There was a problem that the power generation efficiency of the solar cell module was lowered due to resistance.

  Moreover, in order to increase the connection point of the electrode of a solar cell element and a connection tab, when increasing the above-mentioned pressing pin and a hot air blowing nozzle, a partial high temperature part is added to a solar cell element by the attachment height and angle of a hot air blowing nozzle. Therefore, thermal stress is applied to the solar cell element, and the bonding strength between the solar cell element and the electrode of the solar cell element may be reduced, or the solar cell element may be warped or cracked.

  The present invention has been made in view of the problems as described above, and the object thereof is to increase the connection area between the electrode and the connection tab when the connection tab is soldered to the electrode of the solar cell element, and An object of the present invention is to provide a solar cell module manufacturing apparatus that does not give a partial high temperature part to a battery element.

  Another object of the present invention is to increase the connection area between the electrode and the connection tab when the connection tab is soldered to the electrode of the solar cell element, and to provide a partial high temperature portion to the solar cell element. It is in providing the manufacturing method of a solar cell module which does not have.

  An apparatus for manufacturing a solar cell module according to the present invention includes an electrode of a solar cell element, and is disposed on the electrode to lead an electric output to the outside, or between two adjacent solar cell elements by soldering A device for manufacturing a solar cell module, which is provided for connection and is soldered by blowing hot air to a strip-shaped connection tab formed by coating a metal foil with a solder layer, and a plurality of hot air outlets are straightened. The hot air blowing body arranged is arranged above the solar cell element so that the hot air hits substantially the entire surface of the soldering area between the electrode and the connection tab.

  The method of manufacturing a solar cell module of the present invention includes an electrode of a solar cell element and an electrode disposed on the electrode for leading an electric output to the outside, or connecting two adjacent solar cell element electrodes by soldering A solar cell module manufacturing method for soldering a strip-shaped connection tab formed by covering a metal foil with a solder layer by spraying hot air to provide at least the following (1) to (4) Each step is included.

  (1) The connection tab is disposed on the electrode.

  (2) Press the connection tab onto the electrode with a pressing pin.

  (3) A hot air blowing body in which a plurality of hot air blowing holes are arranged in a straight line is disposed above the solar cell element so that hot air hits substantially the entire surface of the soldering area between the electrode and the connection tab. To do.

  (4) Hot air is blown out by delaying the timing of blowing hot air from the hot air blowing ports and the timing of stopping the blowing from the hot air blowing ports at both ends toward the hot air blowing port in the center.

  In another solar cell module manufacturing method of the present invention, the timing for blowing hot air from the plurality of hot air blowing ports and the timing for stopping the blowing are directed from the hot air blowing port at one end to the hot air blowing port at the other end. It is characterized by blowing hot air late.

  According to the manufacturing apparatus of the solar cell module of the present invention, the electrode of the solar cell element and the electrode disposed on the electrode for leading the electrical output to the outside or soldering between the electrodes of two adjacent solar cell elements A solar cell module manufacturing apparatus for soldering by blowing hot air to a strip-like connection tab formed by covering a metal foil with a solder layer provided for connection at a plurality of hot air outlets in a straight line The hot air blowing body arranged in a shape is arranged above the solar cell element so that the hot air is applied to substantially the entire surface of the soldering area between the electrode and the connection tab. The electrode formed above and the connection tab arranged on this electrode are soldered on the entire surface.

  As a result, even if the solar cell element is increased in area and the current generated by one solar potential element is increased due to the thinning of the electrode, the electrodes and connection tabs formed on the solar cell element are substantially omitted. Since the entire surface is soldered, the connection area between the electrode and the connection tab increases, and this portion does not become a resistance during power generation of the solar cell module, and the power generation efficiency of the solar cell module is not reduced.

  In addition, a thin connection tab can be used, which leads to a reduction in manufacturing cost of the solar cell module.

  Furthermore, since the plurality of hot air outlets arranged in a row as described above are provided in an integrated manner, it is not necessary to adjust the mounting height and angle of the hot air outlet nozzle as in the prior art. Due to insufficient angle adjustment, the solar cell element is partially heated, and thermal stress is applied to the solar cell element. The bonding strength between the solar cell element and the electrode formed on the solar cell element , And no warping or cracking occurs in the solar cell element.

  According to the method for manufacturing a solar cell module of the present invention according to claim 2, it is possible to reduce warpage due to the difference in thermal expansion coefficient between the solar cell element and the connection tab, and in the subsequent manufacturing process of the solar cell module. It is possible to prevent cracking.

  According to another method for manufacturing a solar cell module of the present invention as set forth in claim 3, no wrinkles or the like are generated on the connection tab after soldering, and a beautiful finish is obtained.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

  FIG. 1 is a view showing a state in which two solar cell elements according to the present invention are connected in series using a connection tab.

  In FIG. 1, 11a and 11b are solar cell elements, 12a and 12b are connection tabs, 13 is a light receiving surface side bus bar electrode of the solar cell element, and 14 is a finger electrode.

  The solar cell elements 11a and 11b are made of single crystal silicon or polycrystalline silicon having a thickness of about 0.3 to 0.4 mm and a size of about 150 mm square, for example. Inside the solar cell elements 11a and 11b, a PN junction is formed in which a P layer containing a large amount of P-type impurities such as boron and an N layer containing a large amount of N-type impurities such as phosphorus are in contact. The bus bar electrode 13 and the finger electrode 14 are formed by silver paste using a screen printing method or the like, and the surface of the bus bar electrode 13 is solder-coated over almost the entire surface in order to easily attach the protection tab and the connection tab. A large number of finger electrodes 14 having a width of about 0.1 to 0.2 mm are formed in parallel with the sides of the solar cell element to collect photogenerated carriers. In addition, the bus bar electrodes 13 collect about the collected carriers and have about 2 mm width for attaching the connection tabs, and about two bus bar electrodes 13 are formed so as to intersect the finger electrodes 14 vertically. Such bus bar electrodes 13 and finger electrodes 14 are similarly formed on the back surfaces (non-light-receiving surfaces) of the solar cell elements 11a and 11b.

  The connection tabs 12a and 12b are obtained by cutting a solder on a low resistance solar cell element connection wiring material such as a copper foil on the entire surface from one side 20 to 70 μm by plating or dipping to an appropriate length. Use. The width of the connection tabs 12a and 12b is set to be equal to or less than the width of the bus bar electrode 13 so that the connection tabs 12a and 12b themselves do not shade the light receiving surface of the solar cell element when soldering. The lengths of the connection tabs 12a and 12b overlap almost all of the bus bar electrodes 13, and further overlap with non-light-receiving surface bus bar electrodes (not shown) of adjacent solar cell elements at a predetermined interval between the solar cell elements. When a general 150 mm square polycrystalline silicon solar cell element is used, the connection tabs 12a and 12b have a width of about 1 to 3 mm and a length of about 160 to 210 mm. The reason why the connection tabs 12a and 12b overlap almost all of the light receiving surface side bus bar electrode 13 is to reduce the resistance component of the solar cell element.

  FIG. 2 shows an apparatus for manufacturing a solar cell module in which bus bar electrodes and connection tabs of a solar cell element according to the present invention are connected by soldering.

  In FIG. 2, 21 is a solar cell element, 22 is a bus bar electrode of the solar cell element, 23 is a connection tab, 24 is a blower formed by arranging a plurality of hot air outlets in a straight line, 25 is a hot air outlet, 26 Represents a heater, 27 represents a blower tube, 28 represents a pressing pin, and 25a, 25b, 25c, 25d, and 25e represent hot air outlets connected to each heater.

  The blower body 24 is provided with a plurality of heaters 26 and corresponding blower pipes 27 on the upper portion thereof, and provided with a plurality of hot air blowout ports 25 on the lower surface thereof. Compressed air is sent to the blower tube 27 from a compressor or the like, and this compressed air is heated by the heater 26 and blown out from the hot air outlet 25.

  Furthermore, the temperature of the hot air blown out from the hot air outlet 25 is measured by a temperature sensor such as a thermocouple provided in the vicinity of the hot air outlet 25, and the heat output of the heater is controlled so that the hot air becomes a predetermined temperature. Yes. Further, the compressed air sent to the blower tube 27 is controlled in blowing time by an electromagnetic valve, a timer, or the like.

  Further, the blowing body 24 is arranged so that hot air blown from the hot air blowing opening 25 hits the connection tab 23. One or a plurality of hot air outlets 25 are provided for one heater 26 (in FIG. 2, an example in which three hot air outlets are provided) is formed on the solar cell element. It is provided so that hot air strikes substantially the entire surface of the area where the bus bar electrode 22 and the connection tab 23 are soldered. When a plurality of hot air outlets 25 are attached to one heater 26, a plurality of hot air outlets 25 are connected inside the outlet 24. The pressing pin 28 is provided so that it can be moved up and down by a driving mechanism, and in particular, it is pressed down at a constant pressure using the pressure of a spring or the like.

  In such a solar cell module manufacturing apparatus, the method of connecting the connection tabs 23 to the bus bar electrodes 22 formed on the solar cell elements 21 by soldering is to first of the bus bar electrodes 22 formed on the solar cell elements 21. The connection tab 23 is arranged on the upper side, and the connection tab 23 is pressed with a pressing pin 28. Next, the heater 26 is energized to raise the temperature of the heater 26 and send compressed air to the blower pipe 27 to emit hot air from the hot air outlet 25 of the outlet 24. With this hot air, the solder of both the bus bar electrode 22 and the connection tab 23 of the solar cell element 21 is melted and connected. Thereafter, the blowing of hot air is stopped, and when the solder of the connecting portion cools and solidifies, the holding pin 28 is raised. At this time, in order to expedite the cooling of the solder, room temperature or cooled air or nitrogen gas may be blown onto the connecting portion.

  As described above, the blower body 24 having the plurality of hot air outlets 25 and the plurality of heaters 26 provided so that the hot air hits substantially the entire surface of the area where the bus bar electrode 22 and the connection tab 23 of the solar cell element 21 are soldered. By using the solar cell module manufacturing apparatus in which the solar cell element 21 is disposed, the bus bar electrode 22 formed on the solar cell element 21 and the connection tab 23 disposed on the electrode are soldered on the entire surface. Will be.

  As a result, the solar cell element 21 has a large area, and even if the current generated by the solar potential element 21 increases due to the thinning of the bus bar electrode formed on the solar cell element 21, the solar cell element Since the connection area of the bus bar electrode 22 and the connection tab 23 formed on 21 increases, this portion does not become a resistance during power generation of the solar cell module, and the power generation efficiency of the solar cell module is not reduced. .

  Further, since the hot air outlet 25 is provided integrally with the outlet 24 as described above, adjustment of the mounting height and angle of the hot air blowing nozzle as in the prior art is unnecessary, and adjustment of the mounting height and angle of the hot air blowing nozzle is unnecessary. Insufficiency will give a partial high temperature part to the solar cell element, and thermal stress will be applied to the solar cell element, and the bonding strength between the solar cell element and the electrode formed on this solar cell element will decrease. The solar cell element is no longer warped or cracked.

  Furthermore, in the method for manufacturing a solar cell module according to the present invention, the timing for starting the blowing of hot air from the hot air blowing port 25 of the blowing body 24 and / or the timing for stopping the blowing are not changed at the same time, but by various changes. It is possible to reduce the warpage of the solar cell element 21 that occurs after the connection tab 23 is attached. In particular, in a solar cell element having a large area of 150 mm square or more or a solar cell element having a thin silicon substrate, the warpage becomes large after the connection tab is attached, and the solar cell element may be cracked when pressed in a subsequent laminating process or the like. Therefore, the present invention is effective.

  For example, hot air blowing is first started from the hot air blowing ports 25 a and 25 e connected to the heaters 26 at both ends of the blowing body 24 at the timing to start blowing hot air from the hot air blowing port 25 of the blowing body 24. As a result, the solder at both ends of the bus bar electrode 22 and the connection tab 23 of the solar cell element 21 is dissolved, and then the blowing of hot air from the hot air blowing ports 25a and 25e is stopped, and both ends are soldered first. Thereafter, hot air blowing is started from hot air blowing ports 25b, 25c and 25d connected to the heater 26 in the center. Thereby, the solder of the center part of the electrode of the solar cell element 21 and the connection tab 23 is dissolved, and the center part is soldered. Thereafter, hot air blowing from the hot air blowing ports 25b, 25c, 25d is stopped.

  As a result, both end portions of the bus bar electrode 22 and the connection tab 23 of the solar cell element 21 are first soldered, and then the central portion is soldered, so that the warpage generated after the soldering can be reduced. It has become possible.

  Moreover, after soldering the both ends of the bus-bar electrode 22 of the solar cell element 21 and the connection tab 23 by the above-mentioned method first, hot-air blowing is simultaneously blown out from the hot-air blowing outlets 25b, 25c, and 25d connected to the heater 26 in the center. The solar air is started by stopping hot air blowing from the hot air blowing ports 25b, 25d on both sides of the hot air blowing ports 25b, 25c, 25d, and then stopping hot air blowing from the middle hot air blowing port 25c. It is possible to reduce the warpage of the battery element 21.

  Furthermore, hot air blowing is started from the hot air blowing port 25a of the blowing body 24, the solder at one end of the bus bar electrode 22 and the connection tab 23 of the solar cell element 21 is dissolved, and then hot air blowing from the hot air blowing port 25a. First, solder one end. After that, soldering the hot air outlet 25b on the side in the same manner, and then moving the hot air outlet from which the hot air is blown out sequentially from 25c to 25d, 25e also causes wrinkles or the like on the connection tab 23 after soldering. It has a beautiful finish and is effective.

  FIG. 3 shows another example of a solar cell module manufacturing apparatus for connecting a bus bar electrode and a connection tab of a solar cell element according to the present invention by soldering.

  In FIG. 3, reference numerals are the same as in FIG. 2, 21 is a solar cell element, 22 is a bus bar electrode of the solar cell element, 23 is a connection tab, 24 is a blowing body, 25 is a hot air outlet, 26 is a heater, and 27 is a blower tube. , 28 indicate pressing pins.

  In FIG. 3, the hot air outlet 25 is connected to the inside of the outlet 24.

  As shown in FIG. 3, the structure is simplified by combining the heater 26 and the blower tube 27 provided in the blower body 24, and the bus bar electrode 22 and the connection tab 23 of the solar cell element 21 as described above. It is not necessary to increase the connection area or to adjust the mounting height or angle of the hot air blowing nozzle, and the solar cell element 21 can be prevented from giving a partial high temperature portion.

  FIG. 4 shows an example of the connection state of the solar cell elements inside the solar cell module according to the present invention. FIG. 3 shows a structure in which four solar cell elements are connected in series, and two of them are connected in series.

  In FIG. 4, 30 is a solar cell element, 31 is a connection tab, 32 is a horizontal wiring, and 33 is an output wiring.

  The horizontal wiring 32 connects the connection of the solar cell elements 30 in the horizontal direction, and is provided to match the dimensions of the connected solar cell elements 30 to the dimensions of the solar cell module.

  The output wiring 33 is for leading the electrical output generated by the solar cell element 30 to the outside of the solar cell module.

  In many cases, both the lateral wiring 32 and the output wiring 33 are used by cutting the entire surface of a copper foil having a width of about 3 to 8 m into a predetermined length by solder coating.

  In the solar cell module, generally, as shown in FIG. 4, the solar cell elements 30 are connected by a predetermined number of connection tabs 31 by the above-described method, and further connected by a predetermined number of lateral wires 32.

  FIG. 5 is a diagram showing an example of the structure of the solar cell module according to the present invention.

  In FIG. 5, 41 is a translucent board | substrate, 42 is a light-receiving surface side filler, 43 is a solar cell element, 44 is a back surface side filler, 45 is a back surface sheet, 46 is a connection tab.

  Hereinafter, each member will be described.

  As the translucent substrate 41, a substrate made of glass or polycarbonate resin is used. As for the glass plate, white plate glass, tempered glass, double tempered glass, heat ray reflective glass and the like are used, but generally white plate tempered glass having a thickness of about 3 mm to 5 mm is used. On the other hand, when a substrate made of a synthetic resin such as polycarbonate resin is used, a substrate having a thickness of about 5 mm is often used.

  The light-receiving surface side filler 42 and the back surface side filler 44 are made of an ethylene-vinyl acetate copolymer (hereinafter abbreviated as EVA) or polyvinyl butyral (PVB), and have a thickness of about 0.4 to 1 mm by a T die and an extruder. The one formed into a sheet shape is used. These are heated and pressed under reduced pressure by a laminating apparatus, so that they are softened and fused to be integrated with other members.

  EVA and PVB may contain titanium oxide, pigments, and the like to be colored white, etc., but in the light-receiving surface side filler 22 in the method for manufacturing the solar cell module according to the present invention, the solar cell element 43 is colored. It is transparent because the amount of light incident on it decreases and power generation efficiency decreases.

  Moreover, EVA or PVB used for the back surface side filler 44 may be transparent, or may contain titanium oxide, a pigment, or the like and be colored white or the like according to the surrounding installation environment where the solar cell module is installed.

  As the back sheet 45, a weather-resistant fluorine-based resin sheet sandwiching an aluminum foil so as not to transmit moisture, a polyethylene terephthalate (PET) sheet deposited with alumina or silica, or the like is used.

  Next, a method for manufacturing a solar cell module will be described.

  In producing the solar cell module, the light receiving surface side filler 42 is placed on the translucent substrate 41, and the solar cell element 43 connected by the connection tab 46 or the like is further placed thereon. Further, a back side filler 44 and a back sheet 45 are sequentially laminated thereon. In such a state, it is set in a laminator and heated at 100 to 200 ° C. while being pressurized under reduced pressure, for example, for 15 minutes to 1 hour, so that they are integrated into a solar cell panel. When the frame is attached to the end of the panel, the solar cell module is completed.

  In addition, this invention is not limited to the said embodiment, Many corrections and changes can be added within the scope of the present invention. For example, the solar cell element is not limited to a crystalline solar cell such as a single crystal or polycrystalline silicon, and can be applied to a thin film solar cell.

It is the figure which showed the state which connected two solar cell elements which concern on this invention in series using the connection tab. The solar cell module manufacturing apparatus which connects the electrode and connection tab of the solar cell element which concerns on this invention by soldering is shown. The another example of the manufacturing apparatus of the solar cell module which connects the bus-bar electrode and connection tab of the solar cell element which concerns on this invention by soldering is shown. An example of the connection state of the solar cell element inside the solar cell module which concerns on this invention is shown. It is a figure which shows an example of the structure of the solar cell module which concerns on this invention. The manufacturing apparatus of the solar cell module which connects a connection tab to the solar cell element in a prior art is shown.

Explanation of symbols

1, 11a, 11b, 21, 30, 43; solar cell element 2; electrodes 3, 12a, 12b, 23, 31, 46 formed on the solar cell element; connection tabs 4, 28; pressing pin 5; Nozzle 13, 22; bus bar electrode 14; finger electrode 24; blower 25; hot air blowout port 26; heater 27; blower pipe 32; lateral wiring 33; output wiring 41; ; Back side filler 45; back sheet

Claims (3)

An electrode of the solar cell element and a metal foil disposed on the electrode and provided to lead out the electrical output to the outside or to connect the electrodes of two adjacent solar cell elements by soldering An apparatus for manufacturing a solar cell module for soldering a belt-like connection tab formed by coating a solder layer by blowing hot air, the hot air blowing body having a plurality of hot air blowing ports arranged in a straight line. An apparatus for manufacturing a solar cell module, wherein the solar cell module is disposed above a battery element so that hot air is applied to a substantially entire surface of a region where the electrode and the connection tab are soldered. Solder to the metal foil, which is provided on the electrode of the solar cell element and provided on the electrode to lead the electric output to the outside or to connect the electrodes of two adjacent solar cell elements by soldering A method for manufacturing a solar cell module, in which a strip-shaped connection tab formed by coating a layer is soldered by blowing hot air, and includes at least the following steps (1) to (4): Module manufacturing method.
(1) The connection tab is disposed on the electrode.
(2) Press the connection tab onto the electrode with a pressing pin.
(3) A hot air blowing body in which a plurality of hot air blowing holes are arranged in a straight line is disposed above the solar cell element so that hot air hits substantially the entire surface of the soldering area between the electrode and the connection tab. To do.
(4) Hot air is blown out by delaying the timing of blowing hot air from the plurality of hot air blowing ports and the timing of stopping the blowing from the hot air blowing ports at both ends toward the hot air blowing port in the center. The hot air is blown out by delaying the timing of blowing the hot air from the plurality of hot air blowing ports and the timing of stopping the blowing from the hot air blowing port at one end toward the hot air blowing port at the other end. Item 3. A method for manufacturing a solar cell module according to Item 2.

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