JP2006339040A - Composite electric cable - Google Patents
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本発明は、中心部と周囲に種類の異なる素材からなる金属線を配した複合電線であって、特にワイヤーハーネスに好適な電線に関するものである。 The present invention relates to a composite electric wire in which metal wires made of different kinds of materials are arranged at the center and the periphery, and particularly relates to an electric wire suitable for a wire harness.
電気機器や自動車等には多数の電装部品が使用されており、各電装部品は、多数本の電線、複数のコネクタ等からなるワイヤーハーネスを機器や車両内に複雑に配線することにより電気的に接続されている。このワイヤーハーネスに使用される電線は、銅の細線を撚り合わせたものが主流となっている。しかし近年、このワイヤーハーネスの電線用素材に関しては、見直しの動きが出てきた。 Many electrical components are used in electrical equipment, automobiles, etc., and each electrical component is electrically connected by wiring a wire harness consisting of multiple wires, multiple connectors, etc. in the equipment or vehicle. It is connected. Electric wires used in this wire harness are mainly made of twisted copper wires. However, in recent years, there has been a review of the wire harness material for this wire harness.
すなわち、自動車や各種電気機器には軽量化の必要性が高まっている。ワイヤーハーネスはかなりの重量を有するため、比重の大きい銅に替わりアルミニウムなどの軽い素材の採用が強く望まれている。また、家電製品や自動車等のリサイクルに関する法令が制定され、銅の分別回収が重要視されるようになってきた。特に、自動車については、廃自動車のいわゆる「ガラ」をプレス加工して電炉で使用する「全部再資源化」において銅分含有量を0.3%以下にする必要がある。これらのことから、ワイヤーハーネス用電線も銅線からアルミニウム線に移行しつつある。 That is, there is an increasing need for weight reduction in automobiles and various electric devices. Since the wire harness has a considerable weight, it is strongly desired to adopt a light material such as aluminum instead of copper having a large specific gravity. In addition, laws on the recycling of household electrical appliances and automobiles have been enacted, and importance has been placed on the separate collection of copper. In particular, for automobiles, it is necessary to reduce the copper content to 0.3% or less in the “all-recycling” process in which the so-called “gara” of scrap cars is pressed and used in an electric furnace. From these things, the electric wire for wire harnesses is also shifting from a copper wire to an aluminum wire.
アルミニウムは銅に次ぐ高い導電率を有し、伸線加工性にも優れ、かつ軽量であるという特質を有することから、従来より架空送電線や架空配電線の用途を中心に電線材料として使用されている。アルミニウム電線の場合、銅線と同じ導電性を確保するには断面積を約1.3倍に大きくする必要があることから、架空送電線等の用途では風雪害を受けやすい。その対策として電線の強度レベルを向上するために、アルミニウム撚線の断面中心部に鋼線を配した「鋼心アルミニウム撚線」が使用されており、種々の改良も試みられている(特許文献1)。 Aluminum has the second highest electrical conductivity after copper, is excellent in wire drawing workability, and is lightweight, so it has been used as a wire material mainly for applications in overhead power transmission lines and overhead distribution lines. ing. In the case of an aluminum electric wire, in order to ensure the same conductivity as that of a copper wire, it is necessary to increase the cross-sectional area by about 1.3 times. In order to improve the strength level of the electric wire as a countermeasure, a “steel core aluminum stranded wire” in which a steel wire is arranged at the center of the cross section of the aluminum stranded wire is used, and various improvements have been attempted (Patent Documents). 1).
一方、アルミニウム撚線は銅撚線と比べて「曲げ」に対する耐久性が低く、厳しい曲げ加工を受けた場合に断線に至る可能性が銅撚線よりも高い。このため、ワイヤーハーネス用途にアルミニウム撚線を適用することは必ずしも容易ではなく、例えば厳しい曲げを受ける部分に特殊な屈曲機構を設けるなどの提案がなされている(特許文献2)。また、アルミニウム撚線は銅撚線に比べ圧着部における断線が生じやすいという欠点も有している。 On the other hand, an aluminum stranded wire has lower durability against “bending” than a copper stranded wire, and is more likely to break when subjected to severe bending. For this reason, it is not always easy to apply an aluminum twisted wire for wire harness applications. For example, a special bending mechanism has been proposed in a portion subjected to severe bending (Patent Document 2). Moreover, the aluminum stranded wire also has a defect that disconnection at the crimping portion is more likely to occur than the copper stranded wire.
本発明はこのような現状に鑑み、ワイヤーハーネスにおいて銅撚線の代替に使用できる優れた可とう性と引張強さを兼ね備える電線であって、特にハーネスプラグとの接続において圧着部の耐断線性に優れ、かつ圧着部での通電発熱も低く抑えられる、銅を含まない電線を提供しようというものである。 In view of such a current situation, the present invention is an electric wire having excellent flexibility and tensile strength that can be used as a substitute for a copper stranded wire in a wire harness, and in particular, a disconnection resistance of a crimping portion in connection with a harness plug It is intended to provide an electric wire that does not contain copper and is excellent in electrical resistance and heat generation at the crimping part.
上記目的は、中心部に複数本のアルミニウム線をもち、その周囲に複数本の溶融アルミニウムめっき鉄線をもつ複合電線によって達成される。
中心部を構成する前記アルミニウム線としては例えば直径0.12〜1.5mmのものが適用でき、その周囲を構成する前記溶融アルミニウムめっき鉄線としては例えば直径0.1〜2.0mmの鉄線を心材として溶融アルミニウムめっきを施したものが適用できる。
The above object is achieved by a composite electric wire having a plurality of aluminum wires in the center and a plurality of hot-dip aluminized iron wires around it.
As the aluminum wire constituting the central portion, for example, a wire having a diameter of 0.12 to 1.5 mm can be applied, and as the molten aluminum plated iron wire constituting the periphery, for example, an iron wire having a diameter of 0.1 to 2.0 mm is used as a core material. A material subjected to hot dip aluminum plating can be applied.
また、中心部を構成する前記アルミニウム線の本数aと、その周囲を構成する溶融アルミニウムめっき鉄線の本数bとの間に下記(1)式が成立するものが好ましい対象となる。
0.2≦b/a≦0.5 ……(1)
Also, a preferable object is that the following equation (1) is established between the number a of the aluminum wires constituting the central portion and the number b of the hot-dip aluminum-plated iron wires constituting the periphery thereof.
0.2 ≦ b / a ≦ 0.5 (1)
前記溶融アルミニウムめっき鉄線1本あたりにおける溶融アルミニウムめっき付着量は30g/m2以上とすることが好ましい。ここで、前記「m2」は、溶融アルミニウムめっき鉄線のめっき前における単位表面積である。また、前記溶融アルミニウムめっき鉄線は、アルミニウムめっき層中のSi含有量が0〜15質量%であるものが適用できる。ここで、Si含有量の下限0%は、溶融めっきラインにおける通常の分析手法においてSi含有量が測定限界以下となる場合であり、例えば、いわゆる純アルミニウムめっきなどがこれに相当する。アルミニウムめっき層中にSiを含有させる場合、Si含有量が2〜15質量%のものが好適な対象として挙げられる。 The adhesion amount of the molten aluminum plating per one molten aluminum plated iron wire is preferably 30 g / m 2 or more. Here, the “m 2 ” is a unit surface area of the hot-dip aluminized iron wire before plating. Moreover, what the Si content in an aluminum plating layer is 0-15 mass% is applicable to the said molten aluminum plating iron wire. Here, the lower limit of Si content is 0% when the Si content is below the measurement limit in a normal analysis method in a hot dipping line, and for example, so-called pure aluminum plating corresponds to this. In the case where Si is contained in the aluminum plating layer, those having a Si content of 2 to 15% by mass are preferred.
本発明の複合電線は、アルミニウムを主体とする電線(以下「アルミニウム系電線」という)であるにも関わらず、屈曲曲げ部や端子圧着部での断線が生じにくい。このため特殊な屈曲機構などを設けることなくそのままワイヤーハーネスに使用することができる。また、引張強さが向上したことにより、ワイヤーハーネスの製造段階や、ワイヤーハーネスを自動車等に組み込む際の取扱い性に優れる。耐食性にも優れ、圧着端子部での通電発熱も低く抑えられる。したがって本発明は、アルミニウム系電線で構成されるワイヤーハーネスのコスト低減および信頼性向上をもたらすものであり、銅線を用いないワイヤーハーネスの普及を通じて、電気機器や自動車等のリサイクルおよび軽量化に寄与し得る。 Although the composite electric wire of the present invention is an electric wire mainly composed of aluminum (hereinafter referred to as “aluminum-based electric wire”), disconnection at a bent portion or a terminal crimping portion hardly occurs. For this reason, it can be used for a wire harness as it is without providing a special bending mechanism. In addition, since the tensile strength is improved, the wire harness manufacturing stage and the handleability when the wire harness is incorporated into an automobile or the like are excellent. It also has excellent corrosion resistance, and heat generation at the crimp terminal can be kept low. Therefore, the present invention brings about cost reduction and reliability improvement of wire harnesses composed of aluminum-based electric wires, and contributes to recycling and weight reduction of electrical equipment and automobiles through the widespread use of wire harnesses that do not use copper wires. Can do.
前述のように、従来、アルミニウム系電線の強度レベルを補うために鋼心アルミニウム撚線が実用化されている。しかし、鋼心アルミニウム撚線は、鋼線を使用しているので導電性の面では不利となる。また、通電を担う金属部材の最外層がアルミニウム線で構成されている点ではアルミニウム線のみからなる電線と変わりない。このため、鋼心アルミニウム撚線を屈曲曲げや圧着を施す用途で使用すると、最外層を構成するアルミニウム線が損傷を受けやすく、耐断線性の抜本的な改善には至らない。 As described above, steel core aluminum stranded wires have been put into practical use in order to supplement the strength level of aluminum-based electric wires. However, since the steel core aluminum stranded wire uses a steel wire, it is disadvantageous in terms of conductivity. Further, the outermost layer of the metal member responsible for energization is the same as an electric wire made of only an aluminum wire in that it is made of an aluminum wire. For this reason, when the steel core aluminum stranded wire is used for an application in which bending bending or crimping is performed, the aluminum wire constituting the outermost layer is easily damaged and does not lead to drastic improvement in breakage resistance.
発明者らは種々検討の結果、通電を担う金属部材の最外層を強度レベルの高い金属線で構成すれば、内部にアルミニウム線のような比較的耐久性の低い素材を配しても、屈曲曲げや圧着に対する耐断線性を大幅に向上できることを知見した。そのような強度レベルの高い金属線としては鉄線が挙げられる。しかしながら、単に鉄線で被覆した撚線とするだけではワイヤーハーネス用途において満足できるものは得られない。 As a result of various studies, if the outermost layer of the metal member responsible for energization is composed of a metal wire with a high strength level, the inventor will bend even if a relatively low durability material such as an aluminum wire is placed inside. It has been found that the breakage resistance against bending and crimping can be greatly improved. An example of such a high-strength metal wire is iron wire. However, what is satisfactory in a wire harness use cannot be obtained only by using a stranded wire covered with iron wire.
すなわち、金属部材の最外層を鉄線で構成すると、耐食性の面で充分な信頼性が確保できない。また、内部のアルミニウム線が最外層に露出しない程度に充分な量の鉄線で被覆すると、導電性が劣ってしまう。さらに、圧着端子との接触部分では高抵抗の鉄線を介しての電気的接続となるため、局部的な発熱も懸念される。したがって、アルミニウム系電線において最外層を高強度金属線で補強する手法を採用することは、必ずしも容易ではない。 That is, if the outermost layer of the metal member is made of iron wire, sufficient reliability cannot be ensured in terms of corrosion resistance. Further, if the inner aluminum wire is covered with a sufficient amount of iron wire so that it is not exposed to the outermost layer, the conductivity will be poor. Furthermore, since the contact portion with the crimp terminal is electrically connected via a high-resistance iron wire, local heat generation is also a concern. Accordingly, it is not always easy to employ a method of reinforcing the outermost layer with a high-strength metal wire in an aluminum-based electric wire.
そこで発明者らはさらに詳細な研究を進めた。その結果、最外層に配する高強度金属線として、溶融アルミニウムめっき鉄線を使用すると、上記のような問題が顕在化することなく耐断線性を顕著に高めることが可能になることを見出した。すなわち、本発明では、中心部に複数本のアルミニウム線をもち、その周囲に複数本の溶融アルミニウムめっき鉄線をもつ撚線構造を採用する。 Therefore, the inventors proceeded with further detailed research. As a result, it has been found that when a hot-dip aluminum plated iron wire is used as the high-strength metal wire disposed in the outermost layer, the disconnection resistance can be remarkably improved without the above-described problems becoming apparent. That is, in the present invention, a twisted wire structure having a plurality of aluminum wires at the center and a plurality of hot-dip aluminum-plated iron wires around the center is adopted.
中心部を構成するアルミニウム線としては、直径0.12〜1.5mmのものが採用でき、直径0.14〜0.8mmのものが自動車用ワイヤーハーネス用に一層好ましい。材質的には、既存のアルミニウム撚線に使用されるアルミニウム線と同等のものが採用できる。 As the aluminum wire constituting the center, one having a diameter of 0.12 to 1.5 mm can be adopted, and one having a diameter of 0.14 to 0.8 mm is more preferable for an automobile wire harness. In terms of material, an aluminum wire equivalent to an existing aluminum stranded wire can be adopted.
その周囲を構成する溶融アルミニウムめっき鉄線としては、直径0.09〜1.9mmの鉄線を心材として溶融アルミニウムめっきを施したものが採用できる。直径0.13〜0.7mmの心材にめっきしたものが自動車用ワイヤーハーネス用に一層好ましい。心材となる鉄線は、JIS G3532に示される普通鉄線が使用できるが、導電性の観点からできるだけ不純物を低減したものが好ましい。 As the hot-dip aluminum-plated iron wire constituting the periphery, a hot-dip aluminum plated wire having a diameter of 0.09 to 1.9 mm as a core material can be adopted. What plated the core material with a diameter of 0.13-0.7 mm is still more preferable for the wire harness for motor vehicles. The iron wire used as the core material can be a normal iron wire as shown in JIS G3532, but from the viewpoint of conductivity, it is preferable to reduce impurities as much as possible.
鉄線1本あたりの溶融アルミニウムめっきの付着量は、30g/m2以上を確保することが望ましい。これより少ないと圧着部分や、屈曲曲げを受けた部分で鉄の露出が生じる可能性が大きくなり、耐食性劣化および接触抵抗増大の問題が顕在化しやすい。また、電線断面における鉄の割合が大きくなり、導電性低下につながる。できればアルミニウムめっきの付着量は40g/m2以上とすることが好ましい。アルミニウムめっき付着量の上限については特に限定されないが、一般的には200g/m2以下の範囲で良好な結果が得られる。溶融アルミニウムめっき方法は、一般的な線材の連続めっき方法に従えばよい。 As for the adhesion amount of the molten aluminum plating per iron wire, it is desirable to ensure 30 g / m < 2 > or more. If the amount is less than this, there is a high possibility that iron is exposed at the crimped portion or the portion that has been bent and bent, and the problems of corrosion resistance deterioration and contact resistance increase are likely to become apparent. In addition, the ratio of iron in the cross section of the wire increases, leading to a decrease in conductivity. If possible, the adhesion amount of aluminum plating is preferably 40 g / m 2 or more. The upper limit of the aluminum plating adhesion amount is not particularly limited, but generally good results are obtained in the range of 200 g / m 2 or less. The hot dip aluminum plating method may follow a general continuous plating method for wire.
アルミニウム線と溶融アルミニウムめっき鉄線の比率は、本数比において下記(1)式を満たすようにすることが好ましい。
0.2≦b/a≦0.5 ……(1)
たたし、aはアルミニウム線の本数、bは溶融アルミニウムめっき鉄線の本数である。
It is preferable that the ratio of the aluminum wire and the galvanized iron wire satisfies the following formula (1) in the number ratio.
0.2 ≦ b / a ≦ 0.5 (1)
Where a is the number of aluminum wires, and b is the number of hot-dip aluminized iron wires.
以上のような線材を用いて本発明の複合電線を得るには、中心部を構成する複数本のアルミニウム線を一般的な撚線の製造方法に従って撚り合わせ、そのアルミニウム撚線の周囲に複数本の前記溶融アルミニウムめっき鉄線を更に撚り合わせればよい。 In order to obtain the composite electric wire of the present invention using the wires as described above, a plurality of aluminum wires constituting the central portion are twisted together according to a general method for producing a twisted wire, and a plurality of wires are disposed around the aluminum twisted wire. What is necessary is just to twist together the said hot-dip aluminum plating iron wire.
このようにして得られた複合電線は、従来の銅撚線に替えてワイヤーハーネスに使用することができる。 The composite electric wire thus obtained can be used for a wire harness in place of a conventional copper stranded wire.
以下の3種類の撚線を製造した。これらは、同じ種類の圧着端子が適用できる類似の形状・サイズを有している。
〔撚線A〕
本発明例の複合電線。
直径0.2mmのアルミニウム線10本を一般的な撚線製造方法に従って撚り合わせて「中心部撚線」とした。
一方、直径0.14mmの鉄線(JIS G3532の普通鉄線相当品)を心材として溶融アルミニウムめっきを施した溶融アルミニウムめっき鉄線を用意した。溶融アルミニウムめっき条件は、浴組成:2.5質量%Si、残部Alおよび不可避的不純物、浴温:680℃、浴に浸漬直前の鉄線が曝される雰囲気:50%H2−N2ガス、浴浸漬時間:1秒、めっき付着量制御:電磁ワイピング方式とし、連続めっきラインで行った。
このようにして得た溶融アルミニウムめっき鉄線7本を、前記中心部撚線の周囲に撚り合わせて、撚線Aとした。
The following three types of stranded wires were manufactured. These have similar shapes and sizes to which the same type of crimp terminals can be applied.
[Stranded wire A]
The composite electric wire of the example of the present invention.
Ten aluminum wires having a diameter of 0.2 mm were twisted in accordance with a general stranded wire manufacturing method to form a “central stranded wire”.
On the other hand, a hot-dip aluminum-plated iron wire was prepared by applying hot-dip aluminum plating with an iron wire having a diameter of 0.14 mm (equivalent to a normal iron wire of JIS G3532). The molten aluminum plating conditions are as follows: bath composition: 2.5 mass% Si, balance Al and inevitable impurities, bath temperature: 680 ° C., atmosphere exposed to the iron wire immediately before dipping in the bath: 50% H 2 —N 2 gas, Bath immersion time: 1 second, plating adhesion amount control: electromagnetic wiping method was performed on a continuous plating line.
Seven galvanized iron wires thus obtained were twisted around the central stranded wire to obtain a stranded wire A.
〔撚線B〕
比較例のアルミニウム撚線。
直径0.2mmのアルミニウム線17本を一般的な撚線製造方法に従って撚り合わせて、撚線Bとした。
[Stranded wire B]
Comparative aluminum stranded wire.
17 aluminum wires having a diameter of 0.2 mm were twisted in accordance with a general twisted wire manufacturing method to obtain a twisted wire B.
〔撚線C〕
比較例の銅撚線。現行のワイヤーハーネスに多用されているものと類似のもの。
直径0.15mmの銅線17本を一般的な撚線製造方法に従って撚り合わせて、撚線Cとした。
[Stranded wire C]
The copper twisted wire of a comparative example. It is similar to what is used frequently in current wire harnesses.
17 copper wires having a diameter of 0.15 mm were twisted together according to a general twisted wire manufacturing method to obtain a twisted wire C.
〔耐断線性試験〕
ワイヤーハーネスに一般的に使用される圧着端子を5種類用意した。各撚線をカットした短い試料電線の両端に、同じ種類の圧着端子を取り付けた。その際、両端子間の距離が10mmとなるようにした。その一方の端子を万力で固定したのち、他方の端子をペンチで掴み、端子間で電線が弛まない程度に軽い張力を付与した状態で、ペンチで掴んだ端子を電線長手方向を軸としてゆっくりとねじり、端子付近で撚線を構成する素線の少なくとも1本が断線するときのねじり角度(以下「断線ねじり角度」という)を測定した。このような試験を、撚線A〜Cについて同一種類の端子につき各10回、同一試験者により実施した。つまり、各撚線について端子5種類×10回分=計50個の試料を用意してねじり試験を実施したことになる。
(Disconnection resistance test)
Five types of crimp terminals generally used for wire harnesses were prepared. The same kind of crimp terminals were attached to both ends of a short sample electric wire obtained by cutting each stranded wire. At that time, the distance between both terminals was set to 10 mm. After fixing one of the terminals with a vise, grasp the other terminal with pliers and slowly apply the terminal grasped with the pliers to the longitudinal direction of the wire while applying a light tension so that the wire does not loosen between the terminals. The twist angle when at least one of the strands constituting the stranded wire near the terminal was disconnected (hereinafter referred to as “disconnection torsion angle”) was measured. Such a test was conducted by the same tester 10 times for each of the same type of terminals on the stranded wires A to C. That is, for each stranded wire, 5 types of terminals × 10 times = a total of 50 samples were prepared and the torsion test was performed.
その結果、同じ種類の端子ごとの比較において、いずれの場合も平均断線ねじり角度(°)は、撚線A≧撚線C>撚線Bとなった。すなわち、本発明の複合電線は、従来の銅撚線と同等以上の耐断線性を有することが確認された。 As a result, in the comparison for each terminal of the same type, the average breakage twist angle (°) in each case was stranded wire A ≧ stranded wire C> stranded wire B. That is, it was confirmed that the composite electric wire of the present invention has a breakage resistance equal to or higher than that of a conventional copper stranded wire.
〔通電試験〕
ワイヤーハーネスに一般的に使用される圧着端子を5種類用意した。本発明の撚線Aと、銅撚線である撚線Cについて、長さ300mmの試料電線を用意し、その両端に同じ種類の圧着端子を取り付けた。その際、一方の端子には、電線(撚線)と一緒に熱電対を圧着して取り付けた。この圧着端子に嵌合する端子を用意し、これらにリード線を取り付けた。そして、試料電線の両方の端子をそれぞれ前記リード線付きの端子と接合して電気回路を構成し、24Vの直流電源により負荷を介して当該試料電線に5Aの電流を流した。通電開始後、熱電対により計測される温度が一定になったときの温度を読み取り、端子部分での発熱の程度を評価した。このような試験を、撚線AおよびCについて同一種類の端子につき各10回実施した。つまり、各撚線について端子5種類×10回分=計50個の試料を用意して通電試験を実施したことになる。
[Energization test]
Five types of crimp terminals generally used for wire harnesses were prepared. About the twisted wire A of this invention and the twisted wire C which is a copper twisted wire, the sample electric wire of length 300mm was prepared, and the same kind crimp terminal was attached to the both ends. At that time, one terminal was attached by crimping a thermocouple together with the electric wire (twisted wire). Terminals fitted to the crimp terminals were prepared, and lead wires were attached thereto. Then, both terminals of the sample electric wire were joined to the terminals with the lead wires, respectively, to constitute an electric circuit, and a current of 5 A was passed through the sample electric wire via a load by a 24 V DC power source. After the start of energization, the temperature when the temperature measured by the thermocouple became constant was read, and the degree of heat generation at the terminal portion was evaluated. Such a test was performed 10 times for each of the same type of terminals on the stranded wires A and C. That is, for each stranded wire, 5 types of terminals × 10 times = total of 50 samples were prepared and the energization test was performed.
その結果、同じ種類の端子ごとの比較において、いずれの場合も平均発熱温度は、撚線A≧撚線Cであり、両者はほとんど差がないか、あるいは本発明のものが若干高かった。ただし、平均発熱温度が若干高かった本発明例の場合でも、その差はわずかであり、充分実用に供することができる発熱レベルであった。むしろ、前記耐断線性試験の結果を加味すると、過酷な使用条件においては、本発明の複合電線の方が断線が生じにくい点で、通電発熱の面でも信頼性が高いと考えられる。 As a result, in the comparison for each terminal of the same type, in each case, the average heat generation temperature was twisted wire A ≧ twisted wire C, and there was almost no difference between them, or that of the present invention was slightly higher. However, even in the case of the present invention example in which the average heat generation temperature was slightly high, the difference was slight, and the heat generation level was sufficient for practical use. Rather, considering the results of the disconnection resistance test, it is considered that the composite electric wire of the present invention is less likely to be disconnected under severe usage conditions, and is more reliable in terms of heat generation.
Claims (7)
0.2≦b/a≦0.5 ……(1) The composite electric wire according to claim 1 or 2, wherein the following expression (1) is established between the number a of the aluminum wires constituting the central portion and the number b of the molten aluminum-plated iron wires constituting the periphery thereof.
0.2 ≦ b / a ≦ 0.5 (1)
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