JP2006145077A - Surface material for electric carpet and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a surface material for an electric carpet and its manufacturing method, having an antifouling surface, capable of easily removing stains when it is stained, having superior load bearing, not affected by unevenness or the like by a constituent material of a surface material itself, and being provided at low costs. <P>SOLUTION: This surface material for the electric carpet is composed of a polypropylene film 1, a first polyolefin resin layer 3, a glass nonwoven fablic layer 4, a second polyolefin resin layer 5, and a felt layer 6 successively stacked, the film 1 is provided with a decorative layer 2 on its rear face, and an adhesion face with the film 1, of the first polyolefin resin layer 3 is oxidized. The first polyolefin resin layer 3 is extruded and laminated on the decorative layer 2 of the film while oxidizing the surface of the adhesion face with the film 1, of the resin layer 3, simultaneously, the glass nonwoven fabric layer is stuck, and the felt layer 6 is stuck to the glass nonwoven fabric layer 4 while extruding and laminating the second polyolefin resin layer 5. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a surface material for hot carpet and a method for producing the same, and in particular, the surface is not easily soiled, and when the surface is soiled, the removal is easy and the load resistance is excellent. Further, the present invention relates to the above-mentioned surface material in which the influence of unevenness or the like due to the constituent material of the surface material itself does not appear on the surface, and excellent in production efficiency, and a manufacturing method thereof.

Conventionally, as a surface material for a hot carpet, one having a surface made of a fiber material is generally used from the viewpoint of excellent heat retention and design.
However, in particular in kitchens and dining areas, and in families with small children, dirt frequently adheres by spilling food, beverages, seasonings, etc. Has been proposed (see, for example, JP-A-8-84653, JP-A-2003-294257, etc.).

As a surface material for hot carpets as described above, a surface material made of vinyl chloride resin has been proposed because it is excellent in moldability and design impartability. However, it is useful when burning at low temperatures in the event of a fire. In view of the possibility of generating poisonous gases and the recent viewpoint of global environmental conservation, there is an increasing market demand for alternatives from vinyl chloride resin to other materials.
In the above Japanese Patent Application Laid-Open No. 2003-294257, a polyolefin resin is used as a surface material for a hot carpet.

  This previous proposal consists of a surface protective layer made of a polyolefin resin having a design layer formed on the back surface, a core layer in which a glass nonwoven fabric layer or a glass net for reinforcement is sandwiched between polyolefin resin layers, and for heat insulation. Since the polyolefin resin is inferior in adhesiveness, a nonwoven fabric layer is interposed between the two layers in order to firmly bond the surface protective layer and the core material layer.

Thus, in the previously proposed one, since the nonwoven fabric layer is interposed between the surface protective layer and the core material layer, the process becomes complicated and the production efficiency is lowered.
Moreover, in order to improve load resistance, in addition to the above-mentioned nonwoven fabric layer or in place of the above-mentioned nonwoven fabric layer, a net made of polyester or the like may be used. May appear as irregularities.
In order to solve this problem, the polyolefin resin layer in the core layer is thickened so that the nonwoven fabric and net are completely buried. However, it is not possible to laminate the polyolefin resin thickly in one process. This requires a number of stacking steps, which is a factor that further reduces production efficiency.
JP-A-8-84653 JP 2003-294257 A

  In consideration of the above-mentioned points, the present invention is less likely to become dirty on the surface, and if the surface becomes dirty, the removal is easy and not only has excellent load resistance, but also depends on the constituent material of the surface material itself. The present invention relates to a surface material for a hot carpet in which the influence of unevenness or the like does not appear on the surface and is excellent in production efficiency, and a manufacturing method thereof.

As a result of studies to solve the above problems, the present inventors have
(1) In order to firmly bond the polyolefin resin layer constituting the uppermost layer of the core material layer and the surface protective layer without the need of so-called adhesion aids such as nonwoven fabrics, What is necessary is just to give adhesiveness to the adhesive surface with the surface protective layer, and for this purpose, the surface of the polyolefin resin layer may be subjected to surface oxidation treatment during extrusion lamination,
(2) Also, in order to improve load resistance, a glass nonwoven fabric layer is used as a reinforcing material provided in the core material layer, and the glass nonwoven fabric layer is completely buried with a polyolefin resin layer sandwiched between the upper and lower surfaces. What should I do,
(3) By adopting the configuration as described in (2) above, the unevenness caused by the glass nonwoven fabric for reinforcement as well as the unevenness caused by the internal heater of the hot carpet can be almost completely eliminated.
I found.

The present invention can be made based on the above findings,
[1] In order from the top, a polypropylene film, a first polyolefin resin layer, a glass nonwoven fabric layer, a second polyolefin resin layer, and a felt layer are laminated,
A decorative layer is formed on the adhesive surface (that is, the back surface) of the polypropylene film with the first polyolefin resin layer,
An adhesive surface of the first polyolefin resin layer with the polypropylene film is subjected to surface oxidation treatment, and [2] the polypropylene film having a decoration layer formed on the back surface thereof. On the decorative layer, the first polyolefin-based resin layer is subjected to extrusion lamination while subjecting the adhesive surface of the resin layer to the polypropylene film to surface oxidation treatment, and at the same time, a glass nonwoven fabric layer is adhered,
The method for producing a hot carpet surface material as set forth in [1], wherein a felt layer is adhered to the glass nonwoven fabric layer while extruding and laminating the second polyolefin resin layer;
Is the gist.
The decorative layer may be formed of an ink having adhesiveness to the first polyolefin resin layer, and the glass nonwoven fabric layer is formed in the first and second polyolefin resin layers. It is preferable that it is completely buried.

In the surface material for hot carpet of the present invention, the polypropylene film located at the uppermost layer serves as a surface protective layer, and is a decorative layer on the back surface (that is, the adhesive surface with the first polyolefin resin layer). Is formed.
As this polypropylene film, a normal polypropylene film which is usually used as a protective layer for this kind of surface material can be used.
For the thickness of the film, a normal thickness that is usually used as a protective layer for this type of surface material is sufficient, and in the present invention, the effect as the surface protective layer is well expressed, and from the viewpoint of handleability and the like. 50 to 300 μm can be preferably used.

The decorative layer provided on the back surface of the polypropylene film is formed by, for example, roll coating, doctor knife coating, rotary screening, gravure printing, flexographic printing, or other appropriate means after corona discharge treatment is performed on the back surface of the polypropylene film. .
The ink used at this time may be any ink normally used for polypropylene films, but may be an ink having adhesiveness to the first polyolefin resin layer described below.

This adhesive ink is, for example, an ethylene-vinyl acetate-based, butadiene-based, or epoxy-based anchor coating agent blended with a colorant, or a polyester polyol resin or polyester polyurethane described in JP-A-2001-271015. An ink containing a resin can be preferably used.
This polyester polyurethane resin is a resin obtained by chain-extending a polyester having hydroxyl groups at both ends obtained by dehydration condensation of a dicarboxylic acid and a diol using diisocyanate. The polyester polyurethane resin is obtained by converting the above polyester into a diisocyanate. It is a resin obtained by further chain-extending a prepolymer having isocyanate groups at both ends obtained by chain extension using diamine with diamine.
The above ink having adhesiveness contains at least one of chlorinated polypropylene, aniline black, vinyl chloride-vinyl acetate-vinyl alcohol copolymer, vinyl chloride-vinyl acetate-hydroxyalkyl acrylate copolymer. May be.

Further, instead of the ink having the adhesive property as described above, a decorative layer is formed by the above-mentioned means using a normal ink, and an anchor coat agent is further used on the decorative layer, and the same as the decorative layer. For example, an anchor coat layer may be formed by means.
In addition, the anchor coat agent can use the resin component similar to the ink which has adhesiveness.

By forming the decorative layer and the anchor coat layer in this manner, it becomes possible to impart better adhesion to the back surface of the surface protective layer, that is, the adhesive surface with the first polyolefin resin layer. .
Furthermore, in order to improve adhesiveness, you may perform a corona discharge treatment etc. on the back surface of the surface protective layer in which the decoration layer and the anchor coat layer were formed.

Next, a first polyolefin-based resin layer is formed on the back surface of the surface protective layer made of a polypropylene film having a decoration layer or an anchor coat layer formed on the back surface as follows.
That is, the first polyolefin resin layer is laminated on the back surface of the surface protective layer by a method such as extrusion lamination. Since the surface of the first polyolefin resin layer is heated to a temperature higher than the melting temperature of the resin, the surface is oxidized at this high temperature. The optimum temperature is selected from the range of about 290 to 330 ° C. depending on the polyolefin resin used.
In this surface oxidation treatment at high temperature, depending on the polyolefin-based resin used, the adhesive strength may be insufficient. In such a case, corona discharge treatment, ozone treatment, A plasma treatment or the like can be added to improve the adhesive strength.
In the present invention, by performing the surface oxidation treatment as described above, the adhesion between the surface protective layer and the first polyolefin resin layer is improved, and between the surface protective layer and the first polyolefin resin layer, There is no need to interpose an adhesive auxiliary material such as a nonwoven fabric.

By this surface oxidation treatment, in the present invention, the adhesion between the polypropylene film and the first polyolefin resin layer can be improved.
Of course, if the decorative layer formed on the back surface of the polypropylene film is made of the ink having the adhesive property as described above, a better adhesive property can be secured by the synergistic action with the decorative layer.

  The first polyolefin resin layer includes a low density polyethylene (LDPE), a linear low density polyethylene (LLDPE), a medium density polyethylene (MDPE), a high density polyethylene (HDPE), and an ethylene-vinyl acetate copolymer. (EVA), ethylene-methyl methacrylate copolymer (EMMA), ethylene-ethyl acrylate copolymer (EEA), ethylene-methyl acrylate copolymer (EMA), ethylene-acrylic acid copolymer (EAA), ethylene- A resin having a melting point of 100 ° C. or higher such as a methacrylic acid copolymer (EMAA), an ionomer, or a polyethylene resin, or a polypropylene resin is used. These polyolefin resins may be used alone or as appropriate. Two or more kinds may be used in combination.

A glass nonwoven fabric layer is laminated on the back surface (lower side) of the first polyolefin resin layer. The lamination of the glass nonwoven fabric is preferably performed at the time of bonding the surface protective layer and the first polyolefin resin layer or immediately after bonding.
As this glass nonwoven fabric, what is conventionally used as materials, such as a flooring and a carpet, can be used.
If the thickness (weight per unit area) of the glass nonwoven fabric is too thin, not only the load resistance necessary for the hot carpet surface material in the present invention can be imparted, but also on the lower side of the hot carpet surface material of the present invention. Unevenness due to the built-in heater of the hot carpet to be arranged cannot be eliminated, and conversely, if it is too thick, this load resistance and unevenness elimination effect will be saturated, and workability such as folding and winding will be extreme Or about ²⁰ to 200 g / m ² is suitable.

A second polyolefin resin layer is laminated on the back surface (lower side) of the glass nonwoven fabric layer.
As the second polyolefin resin layer, a polyolefin resin similar to the first polyolefin resin layer described above is used.

  In the present invention, the glass nonwoven fabric layer is completely buried in the first and second polyolefin resin layers to prevent the appearance of irregularities due to the internal heater of the hot carpet or the delamination of the glass nonwoven fabric layer. can do.

In the present invention, the first polyolefin resin layer also has a role as a layer for tactilely or visually hiding the glass nonwoven fabric layer laminated on the back surface (lower side) of the resin layer. The second polyolefin resin layer has a synergistic effect with the glass nonwoven fabric layer and the first polyolefin resin layer in order to give sufficient load resistance to the surface material of the present invention. It also has a role as a layer for eliminating irregularities caused by a hot carpet built-in heater disposed on the back surface (lower side), and furthermore, both of these polyolefin-based resin layers are impregnated into the glass nonwoven fabric layer. It also has the effect of preventing delamination of layers.
In order to obtain these functions satisfactorily, the thicknesses of the first and second polyolefin resin layers are both preferably about 50 to 500 μm.

The glass nonwoven fabric layer is completely buried and laminated with the first and second polyolefin resin layers, and the lamination position is the thickness of the first polyolefin resin layer: the thickness of the second polyolefin resin layer. A position satisfying the formula of thickness = 1: 1 to 5 is preferable, and a position of 1: 1 to 3 is more preferable.
When the first polyolefin resin layer becomes thicker, the warpage of the product surface material toward the surface side becomes stronger, which is not only a problem in product quality, but also the first polyolefin resin layer becomes thicker from the surface protective layer. As the distance increases, the rigidity of the product becomes higher than necessary, and the product becomes plate-like and cannot be wound or bent, resulting in extremely poor handling.
Further, the degree of impregnation of the first and second polyolefin resins into the glass nonwoven fabric layer requires that the glass nonwoven fabric layer is completely buried in these resin layers. If there is an unimpregnated portion of the layer, there is a possibility that delamination of the glass nonwoven fabric layer may occur due to a load caused by a dynamic load during use as a product.

The felt layer laminated on the back surface (lower side) of the second polyolefin-based resin layer functions as a heat insulating layer in the same manner as the previous proposal. If the basis weight is too small, a desired heat insulating effect is obtained. If it is too large, not only is this heat insulation effect saturated, but workability such as bending and winding is extremely reduced, so it is suitable to be about 100 to 500 g / m ^2. Yes.
In addition, this felt layer may be composed of any fiber, and even if melt fiber that acts as an adhesive such as fiber is blended, it is not blended. The blending ratio of the molten fiber may be about 0 to 30% by weight.

The surface material for a hot carpet of the present invention having the above-described configuration can be obtained by the following production method of the present invention.
First, a polypropylene film serving as a protective layer for the surface material for hot carpet of the present invention is prepared.
On the back surface of the film, a decorative layer is formed by the various methods described above.
Furthermore, in order to improve the adhesion between the film and the first polyolefin resin layer described below, a corona discharge treatment or the like may be performed on the back surface of the film on which the decorative layer is formed.

Next, the first polyolefin resin layer is extruded and laminated on the decorative layer of the film while subjecting the adhesive surface to the film to surface oxidation treatment by various methods as described above.
That is, the first polyolefin resin is heated and melted, extruded onto the decorative layer of the polypropylene film, and laminated on the film. At the time of this lamination, a surface oxidation treatment is performed on the adhesive surface of the first polyolefin resin layer with the polypropylene film.

Simultaneously with this extrusion, surface oxidation treatment, and lamination, a glass nonwoven fabric layer is bonded onto the first polyolefin resin layer.
At the time of this sticking, at least a part of the glass nonwoven fabric layer is buried in at least a part of the first polyolefin resin layer.
That is, while the surface oxidation treatment is performed, the glass nonwoven fabric layer is placed on the first polyolefin resin layer at the same time as being extruded and laminated onto the decorative layer of the polypropylene film, and at least of the glass nonwoven fabric layer. It presses and affixes so that a part may be embedded in at least one part of this 1st polyolefin resin layer.
The press pressure is not particularly limited, and depends on the viscosity of the first polyolefin resin in a molten state, the amount of embedded glass nonwoven fabric layer (embedding depth) in the first polyolefin resin layer, and the like. And set to the optimum pressure.

Subsequently, while extruding and laminating the second polyolefin resin layer on the glass nonwoven fabric layer, at least a part of the glass nonwoven fabric layer is embedded in at least a part of the second polyolefin resin layer. To.
That is, the second polyolefin resin is heated and melted, extruded onto the glass nonwoven fabric layer, and laminated on the glass nonwoven fabric layer. Simultaneously with the lamination, pressing is performed so that at least a part of the glass nonwoven fabric layer is buried in at least a part of the second polyolefin resin layer in a molten state.
This press pressure is not particularly limited, and depends on the viscosity of the second polyolefin resin in the molten state, the amount of embedded glass nonwoven fabric layer (embedding depth) in the second polyolefin resin layer, and the like. And set to the optimum pressure.

Finally, a felt layer may be stuck on the second polyolefin resin layer.
The felt layer is adhered when the second polyolefin resin layer is in a molten state (for example, when the second polyolefin resin layer is extruded and laminated at that time), or when the molten fiber acting as an adhesive is melted. If it is performed at a temperature, it is possible to achieve adhesion with good strength without using an adhesive.

  In the surface material for hot carpet of the present invention, the surface of the first polyolefin-based resin layer laminated on the lower side of the polypropylene film as the surface protective layer is subjected to surface oxidation treatment on the adhesive surface with the film. Thus, it is possible to laminate the film and the first polyolefin resin layer with good adhesive strength without the need to interpose an adhesive auxiliary material such as a nonwoven fabric, and as a result, the adhesion auxiliary material and the like There is no such thing as saying that the fiber texture and the like appear on the surface.

  In addition, if the decorative layer formed on the back surface of the film (that is, the adhesive surface with the first polyolefin resin layer) is formed with an ink having adhesiveness to the first polyolefin resin layer, This adhesiveness can be further improved.

Furthermore, the glass nonwoven fabric layer laminated on the lower side of the first polyolefin-based resin layer can be excellent in load resistance.
And since this glass nonwoven fabric layer is completely embedded in the 1st, 2nd polyolefin resin layer laminated | stacked on the upper and lower surfaces, the hot carpet arrange | positioned under the surface material for hot carpets of this invention It is possible to eliminate the unevenness caused by the built-in heater and the effect of the fiber mesh of the glass nonwoven fabric layer itself from appearing on the surface.

  In addition, the surface oxidation treatment of the first polyolefin-based resin layer can be performed simultaneously with the extrusion lamination of the resin layer, and the embedding of the glass nonwoven fabric layer in the first and second polyolefin-based resin layers is as follows. Since it can be performed at the time of the extrusion lamination of the first and second polyolefin resin layers and the glass nonwoven fabric layer adhered to them, the production process is extremely simplified and simplified, and the production cost is greatly reduced. be able to.

[Example 1]
A surface material for a hot carpet having the configuration shown in FIG. 1 was produced in the following manner.
The decorative layer 2 was formed on the back surface of the polypropylene film 1 having a thickness of 200 μm by printing with adhesive ink (trade name “RAMIC FIT” manufactured by Dainichi Seika Co., Ltd.).

Next, the decorative layer 2 was subjected to corona discharge treatment, and the first polyethylene heated and melted at 320 ° C. or higher was extruded and laminated to a thickness of 100 μm. At the same time, the first polyethylene layer 3 was The glass nonwoven fabric 4 having a basis weight of 50 g / m ² was press-bonded so that the upper layer portion 41 of the glass nonwoven fabric 4 was buried in the lower layer portion 31 of the first polyethylene layer 3.

  Subsequently, the second polyethylene heated and melted at 190 to 250 ° C. is extruded and laminated on the back surface of the glass nonwoven fabric 4 so as to have a thickness of 250 μm. 2 was pressed and attached so as to be buried in the upper layer portion 51 of the polyethylene layer 5.

Further, simultaneously with the extrusion lamination of the second polyethylene layer 5, a felt layer 6 having a basis weight of 300 g / m ² is adhered to the back surface of the second polyethylene layer 5, and according to the present invention having the configuration shown in FIG. A surface material for hot carpet was produced.

[Example 2]
A surface material for a hot carpet having the configuration shown in FIG. 1 was produced in the following manner.
The decorative layer 2 was formed on the back surface of the polypropylene film 1 having a thickness used in Example 1 by gravure printing using ordinary ink, and then gravure printing was performed using an ethylene-vinyl acetate resin-based anchor coating agent. .

Next, a corona discharge treatment is applied to the anchor coat layer 2 ', and a first polyethylene heated and melted at 300 to 320 ° C is extruded and laminated so as to have a thickness of 100 µm. The glass nonwoven fabric 4 having a weight per unit area of 50 g / m ² was press-bonded to the layer 3 so that the upper layer portion 41 of the glass nonwoven fabric 4 was buried in the lower layer portion 31 of the first polyethylene layer 3.

  Subsequently, the second polyethylene is extruded and laminated on the back surface of the glass nonwoven fabric layer 4 in the same manner as in Example 1, while the lower layer portion 42 of the glass nonwoven fabric 4 is the upper layer portion of the second polyethylene layer 5. The surface layer for hot carpet according to the present invention having the configuration shown in FIG. 1 was manufactured by pressing and adhering to 51 so that the felt layer 6 was adhered to the back surface of the second polyethylene layer 5.

[Comparative Example 1]
A surface material for a hot carpet having the configuration shown in FIG. 2 was produced in the following manner.
A surface material for a comparative hot carpet having the structure shown in FIG. 2 was produced in the same manner as in Example 1 except that the glass nonwoven fabric layer was not laminated, and therefore the glass nonwoven fabric layer was not buried in the first and second polyethylene layers.

[Comparative Example 2]
A surface material for a hot carpet having the configuration shown in FIG. 2 was produced in the following manner.
A surface material for a comparative hot carpet having the structure shown in FIG. 2 was produced in the same manner as in Example 2 except that the glass nonwoven fabric layer was not laminated, and therefore the glass nonwoven fabric layer was not buried in the first and second polyethylene layers.

  The surface materials for hot carpets obtained in Examples 1 and 2 and Comparative Examples 1 and 2 were evaluated for durability, adhesion, and printing diversity according to the following procedures and standards, and the results are shown in Table 1. In Table 1, the importance is 1 is the most important, 2 is the second most important, 3 is the least important, and the meanings of ◎, ○, △, × are as follows: ◎ is optimal, ○ is suitable, Δ is somewhat problematic, and × is unsuitable.

(1) Durability (adhesiveness): A caster chair that assumes the dynamic load of the chair by combining the surface material for hot carpet obtained in Examples and Comparative Examples with the specified heater wire and back felt. A repeated dynamic load test was conducted with a testing machine to evaluate the appearance change.
A: Appearance is not abnormal, delamination does not occur, and the bonded heater wire does not rise to the surface and maintains a good state.
○: Appearance problems and delamination do not occur, but there are many floating on the surface of the bonded heater wires.
Δ: Appearance is the same as in the case of ○, but the broken heater wire is partially visible.
-: The surface protective layer is peeled off, causing a problem in appearance, and the bonded heater wire is also broken and cannot be a product.
(2) Adhesiveness: A peel test was conducted in a thermostatic bath at 20 to 120 ° C. assuming practical use, and the relationship between temperature and peel strength was evaluated.
A: No change in adhesive strength at each temperature.
○: Adhesive strength decreases in a high temperature range of 100 ° C. or higher, but is within the specification standard range without any problem in product.
(Triangle | delta): The adhesive strength falls extremely in the high temperature range of 100 degreeC or more, and delamination arises.
-: Adhesive strength below the specification standard range around 60 ° C, which cannot be a product.
(3) Diversity of printing: The design expression was evaluated while taking into account the limitations of printing.
(Double-circle): The thing which can express most design without being restricted by printing processing.
○: Although there are some restrictions on the printing process, it is possible to express the desired design roughly.
(Triangle | delta): Since it can receive only the limited design expression since it receives the restriction | limiting of a printing process, What can express a desired design within this limited range.
・ ： Unable to express desired design due to restrictions on printing. .

The surface material for a hot carpet of the present invention can easily remove spilled dirt such as food, beverages, seasonings and the like particularly in a kitchen or dining room by laying on the upper surface of a hot carpet that is an electric device.
Moreover, it can be used for other members for electric equipment that require heat resistance and flexibility, members for vehicles such as automobiles, and members for construction.

It is sectional drawing for demonstrating the surface material for hot carpets of this invention manufactured in the Example. It is sectional drawing for demonstrating the comparative surface material for hot carpets manufactured by the comparative example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Polypropylene film 2 Decoration layer 2 'Anchor coat layer 3 1st polyolefin resin layer 4 Glass nonwoven fabric layer 5 2nd polyolefin resin layer 6 Felt layer

Claims (3)

In order from the top, a polypropylene film, a first polyolefin resin layer, a glass nonwoven fabric layer, a second polyolefin resin layer, and a felt layer are laminated,
A decorative layer is formed on the adhesive surface of the polypropylene film with the first polyolefin resin layer,
A surface material for a hot carpet, wherein a surface of the first polyolefin resin layer bonded to the polypropylene film is subjected to surface oxidation treatment.   The hot carpet surface material according to claim 1, wherein the decorative layer is formed of an ink having adhesiveness to the first polyolefin resin layer. On the decorative layer of the polypropylene film having a decorative layer formed on the back surface, the first polyolefin resin layer is extruded and laminated while subjecting the adhesive surface of the resin layer to the polypropylene film to surface oxidation treatment. A non-woven fabric layer,
The method for producing a surface material for a hot carpet according to claim 1 or 2, wherein a felt layer is stuck on the glass nonwoven fabric layer while extruding and laminating a second polyolefin resin layer.

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