JP2007008033A - Mold assembly and manufactured method of foamed resin molding using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a mold assembly capable of preventing the staining of a foamed resin molding, and a manufacturing method of the foamed resin molding using it. <P>SOLUTION: In the mold assembly 1 wherein a support flange 18 is provided to the lower part of a cavity 6 to form an opening part 11B to the lower part of the cavity 6 and a female mold 2 is attached to the cavity 6 through the outer peripheral part of the inner plate 7 of the female mold 2 so as to provide a gap 32 between the female mold 2 and the cavity 6 in a state the female mold 2 is attached to the cavity 6 while piping for supplying processing water for processing the foamed resin molding S is provided to the gap 32, the inner plate 7 is attached to the support flange 18 so as to superpose the peripheral part of the inner plate 7 from below and a bulky part is provided so as to embed the recessed part 13 formed by opening peripheral wall surface 26 of the support flange 18, the upper surface 27 of the inner plate 7 and the outside surface 12b of the female mold 2. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a mold apparatus for manufacturing a foamed resin molded article, and a method for manufacturing a foamed resin molded article using the mold apparatus.

  Conventionally, as a mold apparatus for producing foamed resin molded products, a male mold is mounted on a female mold as a mold from the lateral direction, and a space formed between the molds is filled with foamable resin particles. In some cases, a foamed resin molded product is manufactured (see, for example, Patent Document 1). The mold apparatus includes a supply pipe for supplying steam for heating the expandable resin particles in the space and a supply pipe for supplying cold water for cooling the expandable resin particles in the space. The water that has finished heating and cooling the resin particles is drained from the drain hole.

  On the other hand, as the size of the foamed resin molded product is increased, there is a shift from horizontal molding to vertical molding, and as shown in FIG. 7, as an application of a conventional horizontal mold apparatus, A large mold apparatus 102 that combines a male mold 100 and a female mold 101 in the vertical direction has been proposed. In this mold apparatus 102, the female mold 101 is placed on the inner plate 103. The inner plate 103 is assembled to the cavity 104. Specifically, a frame-like support flange 106 projecting inward so as to leave an opening 105 into which the female die 101 is inserted is formed below the cavity 104 from below. It is assembled. A concave portion 107 into which the outer peripheral portion of the inner plate 103 is fitted is formed on the lower surface of the support flange 106 on the opening 105 side, and the outer peripheral portion of the inner plate 103 is fitted into the concave portion 107 in a state where the female die 101 is placed. Thus, the support flange 106 and the inner plate 103 are tightened with bolts 108 from the inner plate 103 side (outer side). In such a mold apparatus 102, the cavity 104 is inverted using a hoisting machine such as a hoist, and is assembled so that the bolt 108 is tightened from the inner plate 103 side as described above.

By the way, a large number of small holes (slits) 110 through which heated steam communicates are formed around the female mold 101, and after the foamable resin particles are heat-molded by the heated steam sprayed from the steam pipe 112 in the cavity 104, The foamed resin molded product is obtained by cooling the female mold 101 and the resin (expandable resin particles) with cooling water sprayed from the water-cooled piping 111 in the cavity 104. In such a mold apparatus 102, the male mold 100 and the female mold 101 having different shapes and sizes are used according to the shape and size of the foamed resin molded product to be manufactured.
Japanese Utility Model Publication No. 60-62927

  However, the support flange 106 to which the female die 101 is attached is rarely manufactured according to the shape and size of the female die 101, and is commonly used for the female die 101 (mold) having a different shape and size. For this reason, when the inner plate 103 is assembled to the cavity 104 and the female die 101 is assembled to the cavity 104, a recess 113 is formed between the inner end surface of the flange 106 of the cavity 104 and the outer peripheral portion of the female die 101. There is.

  In a mold apparatus of a type assembled in the horizontal direction, water (steam) supplied from a supply pipe or a water distribution pipe does not collect in the recess 113, but a female mold 101 and a male mold 100 as shown in FIG. In a mold apparatus that assembles in a vertical direction, water for heating and cooling may accumulate in the recess 113.

  By the way, when water accumulates in the recess 113 between the inner end face of the opening 105 of the flange 106 of the cavity 104 and the outer peripheral portion of the female die 101, rust is generated in the inner plate 103, the cavity 104, and the like with the use. Mixed in water. When heated steam is sprayed, water containing rust accumulated in the recess 113 may splash and enter from the slit 110 of the female die 101 to contaminate the foamed resin molded product.

  Therefore, the present invention provides a mold apparatus capable of preventing contamination of a foamed resin molded product and a method for producing a foamed resin molded product using the same.

  In the mold apparatus of the present invention, the female die is attached to the cavity via the outer peripheral portion of the female inner plate on the support flange that forms an opening in the lower portion of the cavity, and the female die is attached to the cavity. A mold apparatus is provided with a gap between a female mold and a cavity, and the gap is provided with piping for supplying processing water for processing a foamed resin molded product, wherein the inner plate has a peripheral portion It is attached to a support flange provided on the cavity side so as to be stacked from below, and a raised portion is provided so as to fill a recess formed by the opening peripheral wall surface of the support flange, the upper surface of the inner plate, and the outer surface of the female mold. It is a feature.

  In the above configuration, the concave portion formed by the opening peripheral wall surface of the support flange, the upper surface of the inner plate, and the outer surface of the female mold is raised and filled by the raised portion, so that the cavity has a volume of the recessed portion in which the processing water is accumulated. Less. Therefore, it is possible to effectively suppress the occurrence of rust due to the processing water in the mold apparatus, and when processing the foamed resin molded product using the processing water, the rust is mixed in the foamed resin molded product. It is possible to prevent the foamed resin molded product from being contaminated.

  In the mold apparatus of the present invention, it is preferable that the upper surface of the support flange and the upper surface of the raised portion are set to be on the same plane. According to this configuration, the cavity does not have a concave portion in which processing water is accumulated.

  In the mold apparatus of the present invention, the gap formed between the peripheral wall surface of the opening of the support flange and the vertical wall surface of the raised portion, and the gap generated between the vertical wall surface of the raised portion and the outer surface of the female mold are filled. It is characterized by being filled with. The difference in the linear expansion coefficient depending on the material of the support flange and the raised portion is absorbed by the gap, and the volume of the concave portion where water is accumulated by the filler can be reduced or eliminated.

  The method for producing a foamed resin molded article of the present invention uses any one of the above-described mold apparatuses to fill the gap between a female mold and a male mold combined with the female mold with foamable resin particles, It is characterized by supplying processed water to the mold and the male mold. According to this method, it is possible to prevent the foamed resin molded product from being contaminated by rust.

  According to the mold apparatus of the present invention and the method for producing a foamed resin molded product using the same, the concave portion is filled with the raised portion, thereby reducing or eliminating the volume of the concave portion in which water is accumulated in the cavity. Therefore, contamination of the foamed resin molded product due to rust can be prevented.

  Hereinafter, a mold apparatus according to an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a partially broken configuration diagram showing a schematic configuration of a mold apparatus according to an embodiment of the present invention in a state where a male mold side and a female mold side are separated, and FIG. 2 is an enlarged cross-sectional view of an upper structure of the mold apparatus 3 is a schematic plan view showing a schematic configuration of the mold apparatus, FIG. 4 is a front view of a drain hole portion, and FIG. 5 is a cross-sectional view taken along line AA in FIG.

  A mold apparatus 1 according to an embodiment of the present invention is for manufacturing a foamed resin molded product S (container) or the like, and combines the female mold 2 and the male mold 4 (core mold) in the vertical direction. Used to manufacture the molded product S.

  As shown in FIGS. 1 and 2, the mold apparatus 1 includes an upper structure 3 on the female mold 2 side and a lower structure 5 on the male mold 4 side. The upper structure 3 includes an outer cavity 6, the female mold 2 housed in the cavity 6, an inner plate 7 for attaching the female mold 2 to the cavity 6, a heating pipe 8 </ b> A, and a cooling pipe. 10A.

  The cavity 6 is formed in a rectangular parallelepiped shape having openings 11A and 11B above and below, and a large number of vertical and horizontal reinforcing ribs 15 are formed on the side wall (main body) 12A. The rectangular parallelepiped in this case is a shape in which the front-rear width b2 is shorter than the left-right width b1, as shown in FIG.

  A support flange 18 protruding inward is integrally formed at the lower end of the cavity 6. The support flange 18 is formed in a frame shape along the side wall 12 </ b> A of the cavity 6, whereby the opening 11 </ b> B is formed in the lower portion of the cavity 6.

  An engaged stepped portion 21 that is concave upward is formed at the inner end of the support flange 18 of the cavity 6. The engaged step portion 21 is formed over the entire inner peripheral portion of the support flange 18 and has an outer vertical wall surface 22, a bottom wall surface 24, and an inner vertical wall surface 26 as shown in FIG. The upper surface 28 of the support flange 18 is a horizontal plane. Furthermore, the lower surface 30 of the support flange 18 is also a horizontal plane.

  The inner plate 7 is formed in a rectangular flat frame shape, and the entire outer peripheral portion thereof is an engaging portion 40 that fits into the engaged stepped portion 21 from below. The engaging portion 40 has an outer vertical wall surface 23, a lower surface 25, and an upper surface 27. The upper surface 27 of the inner plate 7 is a horizontal plane, and the lower surface 25 of the inner plate 7 is also a horizontal plane. The thickness t2 of the inner plate 7 is smaller than the thickness t1 of the support flange 18. When the inner plate 7 is assembled to the support flange 18 so that the upper surface 27 of the engaging portion 40 is overlapped with the bottom wall surface 24 of the engaged stepped portion 21 from below, the lower surfaces 25 and 30 of both flanges 7 and 18 are assembled. Are flush with each other (same plane). Furthermore, the outer vertical wall surface 22 and the outer vertical wall surface 23 are opposed to the engaged step portion 21 and the engaging portion 40. Such engaged steps 21 and engaging portions 40 are fixed by inserting bolts 43 from below into bolt holes (not shown) formed in them.

  As shown in FIG. 3, drain holes 44 are formed in the support flange 18. In this embodiment, one point is formed on each longitudinal side of the support flange 18. Such drain holes 44 are preferably provided in as few places as possible.

  The female die 2 is formed in a rectangular parallelepiped corresponding to the shape of the cavity 6 with the lower side open. In a state where the female die 2 is attached to the cavity 6 via the inner plate 7, a predetermined attachment space (gap) 32 is formed between the side wall 12 </ b> A of the cavity 6 and the side wall 12 </ b> B of the female die 2. . In other words, the female mold 2 and the cavity 6 are set to have a size relationship that can form the mounting space 32. A supply port 36 of a feeder 35 is attached to the top wall 33 of the female mold 2. The feeder 35 is for supplying foamable resin particles to a molding space 57 described later provided between the female mold 2 and the male mold 4 in a state where the female mold 2 and the male mold 4 are combined. It is. Furthermore, the top wall 33 of the female die 2 is formed with an extrusion hole 33a into which the tip pushing portion 37a of the pushing pin 37 suspended from the eject plate 70 disposed above the cavity 6 is inserted. The extrusion pin 37 is for releasing the foamed resin molded product S molded in the molding space 57 from the female mold 2. Further, a number of small holes 38 (or slits) are formed in the top wall 33 and the side wall 12B of the female mold 2.

  In a state where the female die 2 is placed on the inner plate 7, the groove-like recess 13 is formed between the outer side surface 12 b of the side wall 12 B of the female die 2 and the inner vertical wall surface 26 of the engaged stepped portion 21 of the support flange 18. Is formed. The concave portion 13 is generated when the size of the female mold 2 to be used is smaller than the opening 11B of the cavity 6. In this case, as will be described later, water is accumulated in the recess 13 by heating steam, cooling water, or the like (processing water) when the foamed resin molded product S is molded. Therefore, in this embodiment, as a means for raising the concave portion 13, a plate-like raising member 14 (corresponding to the raised portion) is provided separately from the inner plate 7 and is fitted into the concave portion 13. Wearing. As long as the raising member 14 has a shape corresponding to the shape of the recess 13, the raising member 14 may be divided or may be a single piece. The height (thickness) of the raising member 14 substantially matches the height of the inner vertical wall surface 26 of the engaged stepped portion 21. The width of the raising member 14 is set slightly smaller than the width of the recess 13. The raising member 14 is detachably attached to the inner plate 7 with a bolt (not shown), and is further raised via a gap 31a between the inner end surface 14a of the raising member 14 and the outer surface of the side wall 12B of the female mold 2. Attached between the outer end surface 14b of the member 14 and the inner vertical wall surface 26 of the engaged stepped portion 21 through a gap 31b. These gaps 31a and 31b are filled with all or part of the region by packings 48 and 49. In the case of this embodiment, as will be described later, the front and rear width regions of the gaps 31a and 31b are all filled, while the left and right width regions have packings 48 and 49 only on the outer side (front and rear width side). Filled.

  Further, as shown in FIGS. 3 and 5, a plurality of drain holes 41 and 42 different from the drain holes 44 are formed at predetermined intervals in the longitudinal direction of the cavity 6. The drain holes 41 and 42 are formed in the inner plate 7 so as to include the gaps 31a and 31b in the width direction below the gaps 31a and 31b (so as to span the gaps 31a and 31b). The cavity 6 is made of steel, and the female die 2 and the inner plate 7 are made of aluminum.

  The heating pipe 8A and the cooling pipe 10A are arranged in the mounting space 32. The heating pipe 8A is arranged so as to surround the side wall 12B of the female mold 2, the cooling pipe 10A is arranged so as to surround the side wall 12B and the top wall 33, and the cooling pipe 10A has a number of branch pipes 50 in the middle thereof. . The heating pipe 8A is used to heat the female mold 2 from the outside, and the cooling pipe 10A is used to cool the female mold 2 from the outside.

The lower structure 5 includes a base 51, a mounting plate 52, a male mold 4, a heating pipe 8B, and a cooling pipe 10B. The heating pipe 8B is for heating the male mold 4 from the inside, and the cooling pipe 10B is for cooling the male mold 4 from the inside. A cooling water discharge hole is formed in the cooling pipe 10B. The male mold 4 is mounted and fixed on the mounting plate 52. The base 51 has a narrow portion 53 (support portion) formed on the upper portion thereof, and a support step portion 54 is formed on the upper portion of the narrow portion 53. The support step 54 has an inward support frame 56 on the upper portion of the vertical wall 55, and the support frame 56 is disposed below the upper surface 55 a of the vertical wall 55 by the thickness of the mounting plate 52, The placement plate 52 is placed and fixed on the support frame 56. The male mold 4 has a shape corresponding to the female mold 2, and is formed in a rectangular parallelepiped that is open from the side wall 12C and the top wall 34. In a state where the mounting plate 52 is mounted on the support frame 56, the upper surface 55a of the vertical wall 55 of the narrow width portion 53 and the upper surface 52a of the mounting plate 52 are flush with each other. In a state where the structure 5 is combined, the upper surface 52a of the mounting plate 52 and the upper surface 55a of the vertical wall 55, and the support flange 18 and the lower surfaces 30 and 31 of the inner plate 7 come into contact with each other in a plane.

  In such a mold apparatus 1, when the female mold 2 and the male mold 4 are combined in the up-down direction, a female between the inner surface of the side wall 12 </ b> B of the female mold 2 and the outer surface of the side wall 12 </ b> C of the male mold 4. A molding space 57 for molding the foamed resin molded product S is formed between the lower surface of the ceiling wall 33 of the mold 2 and the upper surface of the ceiling wall 34 of the male mold 4.

  In the above configuration, the lower mold 5 is assembled by mounting and fixing the male die 4 on the mounting plate 52 and mounting the mounting plate 52 on the support frame 56 of the support step portion 54. Here, the assembly procedure of the upper structure 3 assembled to the lower structure 5 will be described. That is, the female die 2 is placed and fixed on the inner plate 7, and the raising member 14 is fixed to a predetermined position of the inner plate 7 to form a female unit (reference numeral omitted), and the cavity 6 is connected to the female unit using a hoist or the like. The female unit is inserted from below the opening 11 </ b> B of the cavity 6. At this time, the female mold 2 and the cavity 6 are aligned so that the engaging portion 40 of the inner plate 7 is fitted to the engaged stepped portion 21 of the support flange 18 from below.

  After the female unit is mounted in the cavity 6 as described above, the inner plate 7 is fixed to the support flange 18 by inserting the bolts 43 into the bolt holes from below the upper structure 3 and tightening them. Then, since the height of the raising member 14 substantially matches the height of the inner vertical wall surface 26 of the engaged step portion 21, the upper surface 28 of the support flange 18 and the upper surface 14c of the raising member 14 are surfaces. The recess 13 is filled with the raising member 14 and the gaps 31a and 31b are generated. Here, an operation for filling the gaps 31a and 31b with the packings 48 and 49 is performed.

  Then, the heating pipe 8A and the cooling pipe 10A are lowered so as to surround the female mold 2 and fixed at a predetermined position to form the upper structure 3, and the upper structure 3 is fixed to a molding apparatus that moves up and down hydraulically.

  Next, a method for forming a foamed resin molded product using the mold apparatus 1 assembled as described above will be described. First, the female mold 2 and the lower structure 5 of the upper structure 3 are also assembled with the male mold in the direction, and the foamable resin particles are placed from the feeder 35 into the molding space 57 between the female mold 2 and the male mold 4. A fixed amount is supplied and filled.

  When the heating steam 60 as the processing water is discharged from the heating pipes 8A and 8B, the heat is transferred to the expandable resin particles through the female mold 2 and the male mold 4, and this is foamed and fused. Cooling water 61 as processing water is discharged from the cooling pipes 10 </ b> A and 10 </ b> B after heat molding for a predetermined time, and the foamed resin molded product is cooled through the female mold 2 and the male mold 4. At this time, the used heating steam 60 and cooling water 61 are smoothly guided from the concave portion 45 communicating with the drain hole 44 toward the drain hole 44 and discharged to the outside.

  A gap 31a, between the inner end surface 14a of the raising member 14 and the outer surface of the side wall 12B of the female mold 2, and between the outer end surface 14b of the raising member 14 and the inner vertical wall surface 26 of the engaged stepped portion 21, The reason for providing 31b is as follows. That is, the cavity 6 is made of steel, the female die 2 and the inner plate 7 are made of aluminum, and these materials have different coefficients of thermal expansion (linear expansion coefficients), so that the difference in the amount of thermal expansion is absorbed. It is.

  As described above, according to the embodiment of the present invention, since the concave portion 13 is filled with the raising member 14, the portion where the processing water necessary for the production of the foamed resin molded product S is accumulated can be extremely reduced or eliminated. The processed water is discharged from the drain hole 44 or the drain holes 41 and 42 to the outside. For this reason, even if the cavity 6 is formed of steel, it is possible to effectively suppress the generation of rust associated with its use. Then, by suppressing the generation of rust, for example, water containing rust accumulated in the recess 13 jumps by the heating steam 60 and enters the foamed resin molded product S from the small hole 38 of the side wall 12B as in the conventional case. Thus, it is possible to avoid a state in which the foamed resin molded product S is contaminated, and it is possible to provide the foamed resin molded product S having a high commercial value.

  The foamed resin molded product S formed in the molding space 57 between the female mold 2 and the male mold 4 is released from the mold apparatus 1 as follows. That is, after the foamed resin molded product S is heat-molded and cooled, the female mold 2 of the upper structure 3 is lifted together with the foamed resin molded product S using hydraulic pressure to separate the female mold 2 and the male mold 4 in the vertical direction. Thereafter, the lower structure 5 is moved to the side. As a result, an environment in which the lower structure 5 does not exist below the upper structure 3 is created, the eject plate 70 is lowered, and the foamed resin molded product S is released by the eject pin 37 and dropped. The foamed resin molded product S thus released from the female die 2 is conveyed toward a predetermined location.

  Subsequently, when the foamed resin molded product S is manufactured, the lower structure 5 is returned to the side so as to be positioned below the upper structure 3, and the upper structure 3 is lowered using hydraulic pressure in the same manner as described above, so that the female type The upper surface 52a of the mounting plate 52 and the upper surface 55a of the vertical wall 55 are brought into contact with the support flange 18 and the lower surfaces 30 and 25 of the inner plate 7 so that the two and the male mold 4 are combined. Thereafter, in the same manner as described above, the foaming resin particles are supplied from the feeder 35 to the molding space 57 between the male mold 4 and the female mold 2 by filling, and the heating steam 60 is discharged from the heating pipes 8A and 8B. Then, the foamed resin particles are foamed and fused, and the foamed resin molded product S is manufactured by discharging and cooling the cooling water 61 from the cooling pipes 10A and 10B after heat molding for a predetermined time. The procedure for releasing the foamed resin molded product S formed in the molding space 57 is as described above.

  The timing of attaching the raising member 14 on the inner plate 7 may be fixed in advance before the female die 2 (inner plate 7) is attached to the cavity 6, or the female die 2 (inner plate 7) may be attached to the cavity. After being attached to 6, it may be attached and fixed to the recess 13 from above.

  The present invention is not limited to the above embodiment. FIG. 6 shows another embodiment. In the above embodiment, the raising member 14 is provided separately from the inner plate 7 and is fixed to the inner plate 7. However, in the embodiment shown in FIG. 6, the raising member 14 is used for raising the recess 13. When the inner plate 7 is assembled to the support flange 18 using a raised portion 80 having a shape corresponding to the raised member 14 instead of the inner plate 7, the recess 13 (FIG. 1, FIG. 2) is not generated. Here, when the coefficient of thermal expansion differs depending on the material used, the outer end surface 80b of the raised portion 80 and the engaged stepped portion are formed between the inner end surface 80a of the raised portion 80 and the outer surface of the side wall 12B of the female mold 2. It is preferable to provide gaps 81 and 82 between the inner vertical wall surface 26 of 21 and fill these gaps 81 and 82 with a filler. Other configurations are the same as those of the embodiment shown in FIGS. 1 to 5 described above, and a description thereof will be omitted using common reference numerals.

The partially broken block diagram which shows schematic structure of the state which isolate | separated the male type | mold side and the female type | mold side of the metal mold | die apparatus which concerns on embodiment of this invention. Similarly the expanded sectional view of the superstructure of a metal mold apparatus. The schematic plan view which shows schematic structure of a metal mold | die apparatus similarly. The front view of a drain hole part similarly. FIG. 4 is a cross-sectional view taken along line AA in FIG. 3. The principal part expanded sectional view of the metal mold | die apparatus which shows another embodiment. The schematic sectional drawing which shows the whole structure of the conventional metal mold apparatus.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Mold apparatus, 2 ... Female type, 3 ... Upper structure, 4 ... Male type, 5 ... Lower structure, 6 ... Cavity, 7 ... Inner plate, 8 ... Heating piping, 10 ... Cooling piping, 11A, 11B DESCRIPTION OF SYMBOLS ... 12A ... Side wall of cavity, 12C ... Male side wall, 14 ... Male side wall, 14 ... Raising member, 14c ... Upper surface of raising member, 15 ... Reinforcement rib, 18 ... Support flange, 28 ... Support flange Upper surface, 21 ... engaged step, 31a, 31b ... gap, 32 ... mounting space, 38 ... small hole, 40 ... engagement step, 41, 42 ... drainage hole, 44 ... drainage hole, 51 ... base, 52: Mounting plate, S: Foamed resin molded product

Claims (4)

  A female die is attached to the cavity through the outer periphery of the female inner plate on the support flange that forms an opening at the bottom of the cavity, and the female die is attached to the cavity between the female die and the cavity. A mold apparatus is provided with a gap, and a pipe for supplying processing water for processing the foamed resin molded product is provided in the gap, and the inner plate is disposed on the cavity side so that its peripheral portion is stacked from below. A mold apparatus, which is attached to a provided support flange and is provided with a raised portion so as to fill a recess formed by an opening peripheral wall surface of the support flange, an upper surface of an inner plate, and an outer surface of a female mold.   2. The mold apparatus according to claim 1, wherein the upper surface of the support flange and the upper surface of the raised portion are set to be on the same plane.   The gap formed between the peripheral wall surface of the opening of the support flange and the vertical wall surface of the raised portion, and the gap formed between the vertical wall surface of the raised portion and the outer surface of the female mold are filled with a filler. The mold apparatus according to claim 1 or 2.   It is a manufacturing method which manufactures a foamed resin molded product using the metal mold apparatus in any one of Claims 1 thru | or 3, Comprising: In the clearance gap between a female type | mold and the male type | mold combined with this female type | mold. A method for producing a foamed resin molded article, comprising filling foamable resin particles and supplying processing water to a female mold and a male mold.

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