JP2011086801A - Reactor, and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor excelling in quality, a manufacturing efficiency property and a yield property because a bobbin for a coil is integrally formed of an insulation resin body simultaneously with a gap layer without subjecting magnetic cores to press work or the like in its manufacturing process, and to provide a method of manufacturing the same. <P>SOLUTION: The reactor includes: a reactor core comprising two magnetic cores 1, 1 each having a U-shaped form in plan view, square magnetic cores 2, 2, and gap layers 4 interposed between the magnetic cores 1, 2; and insulation resin bodies 3, 4 formed in outer peripheries of the magnetic cores 1, 2 and the gap layers 4, and integrally molded from an insulation resin material having adhesiveness. A portion of the insulation resin body 3 is used as a coil bobbin 3' for forming a coil 5 in its circumference. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a reactor mounted on an electric vehicle, a hybrid vehicle, and the like, and a manufacturing method thereof.

  A reactor of a power conversion circuit is generally housed in a housing (case) in a posture in which a coil is formed at two longitudinal portions of a reactor ring that is substantially horizontally long in plan view. This reactor core is composed of a laminated core of a plurality of magnetic steel sheets or divided cores consisting of dust cores. Between each divided core, for example, a non-magnetic material gap plate or insulating paper is interposed, and the gap The plate and the core are bonded and fixed with an adhesive to form a reactor core.

  A heat radiating plate (heat sink) is provided on the lower surface (bottom surface) of the housing, and a cooler for recirculating cooling water and air is provided below the heat sink. In general, a structure is used in which the air is discharged from the reactor core to the outside through the heat sink and the cooler. Here, a molded sealing resin body is formed between the housing and the reactor core accommodated in the housing, and heat from the coil or the reactor core is transmitted to the heat radiating plate through the sealing resin body. Be heated.

  In a conventional reactor, a resin bobbin, insulating paper, or the like is interposed between the coil and the reactor core to prevent both contacts and to ensure heat dissipation. In the form in which the bobbin is interposed and the form in which the insulating paper is interposed, the process of separately manufacturing them and the process of installing them on a U-shaped core, for example, are included in the manufacturing process. It is necessary to prepare an injection molding die, and there has been a problem that the material cost and the manufacturing cost increase in order to produce these.

  In addition, it is necessary to insert the insulating paper into the outer periphery of the core. However, it is difficult to position the paper as compared with the bobbin, and it is difficult to obtain the dimensional accuracy.

  In the structure in which the insulating paper (insulating sheet) is inserted into the gap between the cores, by further performing thermocompression bonding with the insulating paper interposed between the cores, The cores on both sides are joined. Therefore, for example, when the core is made of a dust core, the strength is relatively low, and there is a risk that the core may crack due to the pressure during the thermocompression bonding.

  In addition, the insulating paper itself has a strength of about 10 MPa at most. For example, when a vehicle equipped with a reactor is in a severe use environment, there is a concern about the destruction of the base material of the insulating paper. Due to the breakdown, the gap length of the reactor is changed, which can lead to deterioration of magnetic characteristics. In order to cope with this problem, when an insulating paper is interposed between the gaps, if an insulating paper as thin as possible is interposed, another problem arises that it becomes difficult to satisfy the desired gap length. Come.

  From the above, when applying bobbins and insulating paper (sheets) to gaps, it takes time and money to produce them and install them on the core, leading to a reduction in manufacturing efficiency, and interposing in gaps. Insulating the cores with only insulating paper, and securing the desired gap length (directly connected to the magnetic path length), it is necessary to eliminate the strength problem of the insulating paper base material. It is necessary to solve the problem of deterioration of magnetic characteristics due to change in length. In addition, although the reactor which adhere | attaches divided cores through a spacer and forms the resin bobbin around a core is disclosed by patent document 1, in this reactor, a spacer and a core material are adhere | attached. Since both are integrated, there is a concern about problems such as breakage of the core material due to the pressure applied at the time of bonding.

JP 2008-78219 A

  The present invention has been made in view of the above-described problems, and is a problem when a coil is formed using an insulating paper interposed in a gap between cores constituting a reactor or using a separately formed bobbin. There is a certain increase in material cost and manufacturing cost, difficulty in installation in gaps such as insulating paper, the strength problem of the insulating material itself and the problem of gap length change caused by its deterioration or damage, the core material and the insulating material An object of the present invention is to provide a reactor that can effectively eliminate all of the problems such as the problem of breakage of the core material due to the pressure applied during the integration, and a manufacturing method thereof.

  In order to achieve the above object, a reactor according to the present invention includes a reactor core including at least two U-shaped magnetic cores in a plan view and a gap layer interposed between the magnetic cores, and the magnetic core. And an insulating resin body integrally formed from an insulating resin material having adhesiveness, and a coil bobbin in which a coil is formed around a part of the insulating resin body It is what has become.

  Here, the reactor of the present invention has a configuration in which two U-shaped cores having magnetism are joined via a gap layer, or one or two or more plan views are square between two U-shaped cores (also called I-type cores). There is a form in which a square shape or a rectangular shape in a plan view is similarly joined through a gap layer. Further, the reactor of the present invention has a structure (caseless) without a housing (or case), the reactor core is accommodated in a housing made of aluminum or an aluminum alloy thereof, and an insulating resin body is contained in the reactor core and the housing. It encompasses all forms of what is formed.

  Here, the magnetic core may be formed from a laminate formed by laminating silicon steel plates, and is a compact formed by pressing a soft magnetic metal powder or a magnetic powder coated with a soft magnetic metal powder with a resin binder. You may form from a magnetic core. As the soft magnetic metal powder, iron, iron-silicon alloy, iron-nitrogen alloy, iron-nickel alloy, iron-carbon alloy, iron-boron alloy, iron-cobalt alloy, iron- Phosphorus alloys, iron-nickel-cobalt alloys, iron-aluminum-silicon alloys, and the like can be used. As the soft magnetic metal oxide powder, ferrites such as manganese, nickel, and magnesium can be used.

  In the reactor of the present invention, an insulating resin body is integrally formed on both the gap layer and the periphery of the magnetic core. With this integrally formed insulating resin body, a desired magnetic path length can be secured and the magnetic core Reinforcement and rust prevention are all achieved.

  In addition, this insulating resin body is formed from an adhesive resin, and the resin material is not particularly limited. For example, an adhesive epoxy resin, a silicone resin (including modified silicone), Any one of a polyester-based resin, a polyolefin-based resin, or a mixed material thereof can be applied. Moreover, the material which mixed these resin which has adhesiveness, and the material which does not have adhesiveness, for example, polyphenylene sulfide (PPS), liquid crystal polymer (LCP), polybutylene terephthalate (PBT), etc. may be sufficient. Furthermore, a material containing an inorganic filler such as glass fiber may be applied to these resin materials to take measures to further increase the strength of the gap layer.

  By forming the gap layer with the insulating resin body made of an adhesive resin material in this way, the adhesion between the insulating resin body and the magnetic core is improved, and the magnetic core is formed at the time of forming the reactor as in the case of the reactor of the conventional structure. There is no need to press the gap layer forming member. Therefore, problems such as damage to the magnetic core, which has been a problem during the press working, and a decrease in yield due to the damage can be effectively solved.

  Furthermore, an integrally formed insulating resin body is also formed on the outer periphery of the magnetic core, and a part of this is also an insulating coil bobbin, so that the bobbin is molded separately as in the case of a conventional reactor. This leads to solving all the problems such as processing labor, assembly labor, and material cost increase when installing around the magnetic core.

  In another embodiment of the reactor according to the present invention, there is provided a reactor core including at least two U-shaped magnetic cores in plan view and a gap layer interposed between the magnetic cores, and the magnetic An insulating resin body integrally formed with the outer periphery of the core and the gap layer, and a part of the insulating resin body is a coil bobbin around which a coil is formed, and the gap layer of the magnetic core Protrusions are formed on the side surfaces facing each other, insulating paper having concave grooves engaged with the projections is attached to the side surfaces, and the insulating resin body is formed between the opposing insulating papers.

  In the reactor of this embodiment, the gap layer is composed of insulating paper and an insulating resin body, and as a specific configuration therefor, a protrusion is formed on the side surface facing the gap layer of the magnetic core, An insulating paper having a concave groove that engages with the protrusion is mounted on the side surface, and for example, an insulating resin body is formed between the opposing insulating papers.

  In this configuration, the entire gap layer is formed while pressing the insulating paper against the magnetic core side with the resin pressure of the resin injected into the gap layer, so that excessive pressure is applied to the magnetic core during the manufacturing process. Can be prevented. Furthermore, since the magnetic core and the insulating paper are brought into close contact with each other in an engagement structure in which one protrusion and the other concave groove engage with each other, it is possible to ensure the close contact posture of both. In particular, due to the coil heat generation during the reactor drive, even when each member repeats deformation such as expansion and contraction, the close contact posture between the magnetic core and the insulating paper is ensured by this engagement structure. This will also ensure the magnetic properties of the reactor.

  Still another embodiment of the reactor according to the present invention includes a reactor core including at least two U-shaped magnetic cores in plan view and a gap layer interposed between the magnetic cores, An insulating resin body integrally formed with an outer periphery of the magnetic core and the gap layer, and a part of the insulating resin body is a coil bobbin in which a coil is formed around the magnetic core, and the opposing magnetic core Insulating paper having adhesiveness is attached to each of the side surfaces facing the gap layer, and the insulating resin body is formed between the facing insulating papers.

  The reactor of this embodiment is such that an insulating insulating paper is attached to the side surface facing the gap layer of the magnetic core, and therefore, even when there is no engagement structure as described above, both the contact postures are maintained. Can be secured.

  The “insulating paper having adhesiveness” means, for example, insulating paper made of an appropriate material having no adhesiveness, in addition to insulating paper made of adhesive epoxy resin, silicone resin, or the like. It includes both insulating paper having a laminated structure provided with an adhesive layer made of epoxy resin or the like on the side.

  The reactor manufacturing method according to the present invention provides a U-shaped magnetic core in at least two plan views, and secures the thickness of the gap layer to be formed between the two magnetic cores in the mold. A first step of maintaining the posture of the magnetic core in a posture; an injection is provided at a position corresponding to the gap layer between the accommodated magnetic cores in the molding die, and the magnetic A second step of integrally molding an insulating resin body by injection molding a resin having adhesiveness to the outer periphery of the core and the gap layer.

  The injection resin provided in the mold for molding the insulating resin body is located at the gap layer forming portion between the magnetic cores placed in the mold, so that the injection resin directly into the gap layer. For example, the resin is filled from the central part of the gap layer so as to pressurize the magnetic cores on both sides, and the injected resin is also provided around the magnetic core. An insulating resin body is molded around the layer and the magnetic core.

  If this manufacturing method is applied, as in the conventional manufacturing method, the gap layer forming member is interposed between the magnetic cores, and then the step of pressing the magnetic cores is completely abolished. The risk of damaging the magnetic core in the process is completely eliminated.

  In another embodiment of the method for manufacturing a reactor according to the present invention, at least two planar views are provided with a U-shaped magnetic core, and a gap to be formed between the two magnetic cores in the mold. A first step of securing a layer thickness and maintaining a posture in which an insulating paper having adhesiveness is fixed to a side surface facing the gap layer of the magnetic core, between the contained magnetic cores in the mold Injection is provided at a position corresponding to the gap layer, and through the injection, a second step of integrally molding an insulating resin body by injection molding a resin into the outer periphery of the magnetic core and the gap layer It will be.

  Furthermore, in another embodiment of the method for manufacturing a reactor according to the present invention, at least two planar views have U-shaped magnetic cores, and a gap to be formed between the two magnetic cores in the mold. A first step of maintaining a posture in which the thickness of the layer is secured and an insulating paper having a concave groove engaging with the protrusion provided on the side surface facing the gap layer of the magnetic core is fitted and fixed. An injection is provided in the molding die at a position corresponding to the gap layer between the accommodated magnetic cores, and resin is injection-molded to the outer periphery of the magnetic core and the gap layer through the injection for insulation. The second step of integrally molding the resin body.

  In any of the manufacturing methods of these embodiments, an insulating paper having adhesive properties as described above is interposed in the gap layer, or a groove formed in the insulating paper is engaged with a protrusion formed in the magnetic core. The present invention relates to a reactor manufacturing method in which an insulating resin body is formed around a gap layer and a magnetic core with the insulating paper interposed therebetween.

  Resin is injected from the injection at a position corresponding to the gap layer, and the insulating paper disposed on the side surface of the magnetic core is pressed against the magnetic core side by the injection pressure of the resin, so that both the insulating paper and the magnetic core are Reliable adhesion is guaranteed.

  Even with these manufacturing methods, it is possible to completely eliminate the step of interposing the gap layer forming member between the magnetic cores and then pressing the magnetic cores together, effectively reducing the risk of damage to the magnetic cores. Can be resolved.

  As can be understood from the above description, according to the reactor of the present invention and the manufacturing method thereof, the magnetic cores are not pressed together during the manufacturing process, and the coil bobbin is insulated simultaneously with the gap layer. Since the resin body is integrally formed, the reactor is excellent in quality and excellent in manufacturing efficiency and yield. In addition, the adhesiveness between the gap layer forming member and the magnetic core (adhesiveness) can be obtained in any form in which insulating paper is interposed in the gap layer and in which insulating paper is not interposed in the gap layer. An excellent reactor.

It is the cross-sectional view which showed one Embodiment of the reactor of this invention. It is the cross-sectional view which showed other embodiment of the reactor of this invention. (A) is the cross-sectional view which showed other embodiment of the reactor of this invention, (b) is the schematic diagram explaining the state before engagement with a magnetic core and insulating paper. It is the longitudinal cross-sectional view explaining the manufacturing method of the reactor of this invention. FIG. 5 is a longitudinal sectional view illustrating the method for manufacturing the reactor of the present invention following FIG. 4.

  Embodiments of the present invention will be described below with reference to the drawings. In the illustrated example, two planar views show a reactor in which one (two in total) planar magnetic cores are arranged between core ends of a U-shaped magnetic core. For example, two or more (four or more in total) square magnetic cores in plan view are arranged between the ends of two U-shaped magnetic cores and two U-shaped magnetic cores. Of course, it may be a reactor that has been used. Furthermore, a form in which a heat sink is arranged below the illustrated reactor, and a form in which a cooler that circulates the cooling medium is arranged below the reactor may be used, and these may be in a case made of aluminum or an alloy thereof. The form accommodated may be sufficient.

1 to 3 are cross-sectional views each showing an embodiment of the reactor of the present invention.
First, the reactor 10 shown in FIG. 1 includes a magnetic core 2, 2 having a rectangular shape in plan view between end portions of two U-shaped magnetic cores 1, 1 in plan view, and a gap between the magnetic cores 1, 2. The insulating resin bodies 4 and 3 are integrally formed around the layer and the magnetic cores 1 and 2.

  The insulating resin body 3 ′ in a part of the outer periphery of the magnetic cores 1 and 2 and in the region where the coil 5 is formed forms a bobbin. That is, in this reactor 10, a coating for increasing the strength of the entire reactor covering the outer periphery of the bobbin 3 ′, the gap layer 4, and the magnetic cores 1, 2 for insulation between the coil 5 and the magnetic cores 1, 2. All of the insulating resin bodies 3) are integrally molded by injection molding or the like using the resin of the same material.

  Here, both the U-shaped magnetic core 1 and the rectangular magnetic core 2 may be formed of a laminate formed by laminating electromagnetic steel plates, and the soft magnetic metal powder or the soft magnetic metal oxide powder is a resin binder. You may form from the powder magnetic core formed by pressure-molding the covered magnetic powder. As the soft magnetic metal powder, iron, iron-silicon alloy, iron-nitrogen alloy, iron-nickel alloy, iron-carbon alloy, iron-boron alloy, iron-cobalt alloy, iron- Phosphorus alloys, iron-nickel-cobalt alloys, iron-aluminum-silicon alloys, and the like can be used.

  The resin material of the insulating resin bodies 3, 3 ', 4 is any one of adhesive epoxy resin, silicone resin, polyester resin, polyolefin resin, etc., or a mixed material thereof, and these adhesive properties. And a material that does not have adhesive properties, such as polyphenylene sulfide (PPS), liquid crystal polymer (LCP), polybutylene terephthalate (PBT), etc., and these resin materials, such as glass fiber A material containing an inorganic filler can be applied.

  Since the resin used has adhesiveness, it is possible to ensure mutual adhesion when the magnetic cores 1 and 2 and the gap layer 4 are thermally deformed when the reactor is driven. The property can be ensured.

  Next, the reactor 10A shown in FIG. 2 includes insulating papers 6 and 6 bonded and fixed to the side surfaces of the magnetic cores 1 and 2, and an insulating resin body 4 ′ formed between the insulating papers 6 and 6. A gap layer 4A is formed.

  In order to ensure strong adhesion between the insulating paper 6 and the side surfaces of the magnetic cores 1 and 2, the insulating paper 6 is preferably formed from an epoxy resin, a silicone resin, or the like. Moreover, the insulating paper which exhibits the laminated structure of the layer which consists of non-adhesive resin, and the contact bonding layer formed from the epoxy resin etc. may be sufficient.

  In addition, the reactor 10B shown in FIG. 3 applies insulating paper as a constituent member of the gap layer as in FIG. 2, but the insulating paper 6A constituting the gap layer 4B has a concave groove 6Aa ( On the other hand, a protrusion 11 that engages with the groove 6Aa is formed on the side surface of the magnetic core 1 that faces the gap layer, and these are fitted together to form an engagement structure. Is pressed by the inner insulating resin body 4 ′ of the gap layer 4B, which is a reactor having excellent adhesion between the insulating paper 6A and the magnetic core 1. A similar protrusion 21 is also formed on the side surface of the magnetic core 2 that is rectangular in plan view, and the concave groove 6Aa of the insulating paper 6A is engaged therewith.

Next, based on FIG.4, 5, the manufacturing method of the reactor 10B shown in FIG. 3 is outlined.
First, the U-shaped magnetic core 1 and the rectangular magnetic core 2 are placed in a posture in which a gap for forming a gap layer is ensured in a cavity of a mold composed of a fixed mold K1 and a movable mold K2.

  Here, by positioning the magnetic cores 1 and 2 with a plurality of dimples K1a provided on the side and bottom surfaces of the fixed mold K1, as shown in FIG. 3, the insulating resin body 3 around the magnetic cores 1 and 2 is provided. The cavity C1 for molding the resin and the cavity C2 for molding the insulating resin body 4 ′ constituting the gap layer 4B can be accurately defined, and the insulating resin bodies 3, 3 ′, 4 ′ A desired thickness can be ensured.

  The movable mold K2 is provided with an injection main pipe K2a for injecting resin, and a plurality of branch pipes K2a ′ branched therefrom. The position where the injection branch pipe K2a ′ faces the cavity is formed. It is adjusted to correspond to the cavity C2.

  The mold is closed, and as shown in FIG. 5, the resin J is injected into the mold through the main pipe K2a (X1 direction) and the branch pipe K2a '(X2 direction) (injection molding).

  The injected resin J is provided in the cavity C1 and closes the cavity C2. In this process, the insulating paper 6A and 6A engaged with the magnetic cores 1 and 2 are pressed from the inside of the cavity C2. (X3 direction). That is, the gap layer constituting member and the magnetic core are joined by pressing with the injected resin, and the press work between the magnetic core and the gap layer constituting member is eliminated as in the conventional manufacturing method. Can do.

  By the pressing force of the resin J acting on the insulating paper 6A, the adhesiveness between the insulating paper 6A and the magnetic cores 1 and 2 is achieved, and the resin J is cured in this posture to form an insulating resin body 4 ′. A reactor having excellent adhesion between the insulating paper and the magnetic core can be manufactured.

  In addition, when manufacturing the reactor 10 shown in FIG. 1, it is as above-mentioned that it is good to use the epoxy resin, silicone resin, etc. which have adhesiveness as resin J inject | poured. Further, as an example of the manufacturing method, manufacturing conditions such as the temperature of the injection resin being 300 ° C., the injection pressure being 70 MPa, and the temperature of the mold (mold) being 130 ° C. can be mentioned.

  Although not shown, the side surfaces of the magnetic cores 1 and 2 facing the gap layer are subjected to a surface treatment including an —OH group, such as a silane coupling material, so that the magnetic core and the insulating paper Further improvement in adhesion between the two may be achieved.

  1 to 3 and the reactor manufacturing method shown in FIGS. 4 and 5, there is no need to press the magnetic cores in the manufacturing process, and the coil bobbin. Is integrally formed with the insulating resin body simultaneously with the gap layer, it is possible to manufacture a reactor having excellent quality with good manufacturing efficiency and yield.

  In addition, the adhesiveness between the gap layer forming member and the magnetic core (adhesiveness) can be obtained in any form in which insulating paper is interposed in the gap layer and in which insulating paper is not interposed in the gap layer. It will be an excellent reactor.

  The embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and there are design changes and the like without departing from the gist of the present invention. They are also included in the present invention.

  DESCRIPTION OF SYMBOLS 1 ... U-shaped magnetic core, 11 ... Protrusion, 2 ... Rectangular magnetic core, 3 ... Insulating resin body, 3 '... Bobbin (insulating resin body), 4, 4A, 4B, 4' ... Gap layer (insulating resin body) 5) Coil, 6A 6 ... Insulating paper, 6Aa ... Recessed groove 10, 10A, 10B ... Reactor, K1 ... Fixed type, K2 ... Movable type, K2a ... Main pipe for injection, K2a '... Branch pipe for injection, C1: Cavity for forming the outer coating of the magnetic core, C2: Cavity for the gap layer, J: Resin

Claims (7)

A reactor core comprising at least two U-shaped magnetic cores in a plan view and a gap layer interposed between the magnetic cores;
An insulating resin body integrally formed from an insulating resin material having adhesiveness formed on the outer periphery of the magnetic core and the gap layer;
A reactor in which a part of the insulating resin body is a coil bobbin around which a coil is formed. A reactor core comprising at least two U-shaped magnetic cores in a plan view and a gap layer interposed between the magnetic cores;
An insulating resin body integrally formed with the outer periphery of the magnetic core and the gap layer, and a part of the insulating resin body is a coil bobbin in which a coil is formed,
A protrusion is formed on a side surface facing the gap layer of the magnetic core, an insulating paper having a concave groove engaging with the protrusion is attached to the side surface, and the insulating resin body is formed between the opposing insulating papers. , Reactor. A reactor core comprising at least two U-shaped magnetic cores in a plan view and a gap layer interposed between the magnetic cores;
An insulating resin body integrally formed with the outer periphery of the magnetic core and the gap layer, and a part of the insulating resin body is a coil bobbin in which a coil is formed,
A reactor in which insulating paper having adhesiveness is attached to each of the side surfaces of the opposing magnetic core facing the gap layer, and the insulating resin body is formed between the opposing insulating papers.   One or more planar magnetic cores are interposed between the two U-shaped magnetic cores, and the gap layer is interposed between the U-shaped magnetic core and the rectangular magnetic core. The reactor in any one of Claims 1-3. A U-shaped magnetic core is prepared in at least two plan views, and the magnetic core is held in a posture in which a thickness of a gap layer to be formed between the two magnetic cores is secured in the mold. 1 step,
An injection is provided in the molding die at a position corresponding to the gap layer between the accommodated magnetic cores, and an adhesive resin is injected to the outer periphery of the magnetic core and the gap layer through the injection. A reactor manufacturing method comprising a second step of molding and integrally molding an insulating resin body. Prepare at least two U-shaped magnetic cores in plan view, ensure the thickness of the gap layer to be formed between the two magnetic cores in the mold, and face the gap layer of the magnetic core A first step of maintaining a posture in which insulating paper having adhesiveness is fixed to the side surface
An injection is provided in the molding die at a position corresponding to the gap layer between the accommodated magnetic cores, and resin is injection-molded to the outer periphery of the magnetic core and the gap layer through the injection for insulation. A method for manufacturing a reactor, comprising a second step of integrally molding a resin body. Prepare at least two U-shaped magnetic cores in plan view, ensure the thickness of the gap layer to be formed between the two magnetic cores in the mold, and face the gap layer of the magnetic core A first step of maintaining a posture in which an insulating paper having a concave groove to be engaged with the protrusion provided on the side surface is fitted and fixed;
An injection is provided in the molding die at a position corresponding to the gap layer between the accommodated magnetic cores, and resin is injection-molded to the outer periphery of the magnetic core and the gap layer through the injection for insulation. A method for manufacturing a reactor, comprising a second step of integrally molding a resin body.

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