JP2017506161A - Method and apparatus for forming profiled articles - Google Patents

Abstract

The present invention relates to an apparatus (40) for forming a profiled article (46) through which a blank of deformable material to be formed into the profiled article passes. A path (41), a pair of complementary opposing body forming die members (45, 45 ') adapted to travel along the forming path (41), and a body forming along the forming path (41) A drive (44, 44 ') that facilitates the progression of the die member (45, 45'), and the pair of body forming die members (45, 45 ') acts on the blank of deformable material and is independent. An apparatus (40) is provided that is adapted to form a desired profile into a blank. A positioning element (75) for positioning the blank may be provided. A method of forming the material is also provided. In addition, a predetermined length of deformable material for use with the device is provided. [Selection] Figure 4

Description

  The present invention relates to a method and apparatus for forming profiled articles, wherein the profiled article has a generally irregular body profile. In particular, the present invention relates to a method and apparatus in which at least one body forming die block is used to form at least a portion of a profiled article. The present invention is believed to provide an alternative to current stamping techniques.

  A known system for forming a deformable material, such as sheet metal, into a desired profile, particularly a desired uniform profile, includes a roll forming process. These processes require the sheet metal to pass through a series of roll sets, each of which further deforms the sheet beyond the profile achieved in the previous roll set. The disadvantages of roll forming include extra deformations resulting from non-uniform distortion paths as the strip passes through each roll set. This then leads to high residual stress, which results in product defects such as edge waves, flares, and twists. Another disadvantage of roll forming is that the distance between the first roll set and the last roll set is relatively large. As a result, the space required to accommodate the roll forming assembly becomes significant, especially when forming complex profiles.

  Also, known systems that use multiple roll sets suffer from significant difficulties associated with initial alignment. A further disadvantage of roll forming is that tooling design is related to the designer's experience. “Trial and error” plays a major role in tooling design and alignment, and for new complex profile tooling designs, which means that development time is difficult to predict. Additionally, a large amount of material can be wasted during the tooling design and alignment period, which contributes to the cost of tooling development.

  More recently, chain-die forming has been proposed as an alternative in the production of articles having a uniform profile. Chain die forming can be thought of as an extension of roll forming, which passes through a plurality of relatively short die blocks that progressively form the blank into a finally uniformly profiled article. It is necessary to gradually form the product through at least one pass. That is, as the blank moves through each die pair, its cross-sectional profile is changed until the final desired cross-sectional profile is achieved. The roll radius used in chain die forming is very large, so the longitudinal strain imparted to the material being formed is generally very small or negligible. As such, articles formed with a chain die can only have a small amount of residual stress resulting from the forming process.

  Forming an article having an irregular profile requires other considerations. Traditionally, such articles have been created by stamping. Stamping is known as pressing and generally includes various sheet metal forming manufacturing processes. For example, this can include punching, blanking, embossing, bending, flanging, and coining using a machine press or stamping press. Stamping can require a single stage operation where every stroke of the press creates the desired form on the sheet metal part, or alternatively, a series of stages can be required. is there. The process is usually performed on sheet metal, but can also be used on other materials such as polystyrene and the like.

  Articles created by stamping generally have earrings that need to be cut off after the stamping process, resulting in wasted material and additional processing time . Stamping is also discontinuous and requires a blank holder to hold the blank in place during processing.

  The present invention aims to provide an alternative to the forming technique described above with respect to the production of articles where the profile may be irregular.

  The subject matter claimed herein is not limited to embodiments that solve the disadvantages or that operate only in environments such as those described above. Rather, this background is merely provided to illustrate one exemplary technology area in which some embodiments described herein may be practiced.

  The present invention relates to a method and apparatus for forming a profiled article, wherein the profiled article has a generally irregular body profile. In particular, the present invention relates to a method and apparatus in which at least one body forming die block is used to form at least a portion of a profiled article.

One aspect of the present invention is an apparatus for forming a profiled article comprising:
A forming path through which a blank of deformable material that will be formed into a profiled article passes;
A pair of complementary opposing body forming die members adapted to travel along a forming path;
A drive that promotes the progression of the body forming die member along the forming path; and
Including
The pair of body forming die members provides a device that is adapted to act on a blank of deformable material and independently form the desired profile into the blank.

  The apparatus can include any number of pairs of body forming die members or a single pair of body forming die members. In one embodiment, the apparatus includes a plurality of pairs of body forming die members, each pair of body forming die members acting on a respective blank of deformable material and independently producing a desired profile, respectively. It is adapted to form into blanks. According to this embodiment, adjacent body forming die members of a plurality of pairs of body forming die members are generally hingedly connected to each other. Preferably, adjacent body forming die members are hingedly connected with a minimum clearance therebetween. This ensures, for example, a relatively strong structure and a simplified structure compared to chain die forming.

  In a preferred embodiment, the apparatus includes locating elements that are mounted between adjacent body forming die members, the locating elements prior to engagement of the blank with the body forming die member. It is adapted to position. In that regard, adjacent blanks can be interconnected by a web and positioning elements can be disposed in the lower section of the forming path between adjacent body forming die members, each in use, Can be positioned on one or both sides of the web. Preferably, the upper section of the forming path includes a gap between adjacent body forming die members, the gap cooperating with each positioning element in use to receive each positioning element.

  The positioning elements can be of any suitable form, provided that they serve to substantially limit the movement of the blank relative to the die member when the positioning elements are engaged with the blank. It is. For example, the positioning element can include a block, cylinder, hook, bolt, or pin. In a preferred embodiment, the positioning element includes a pin.

  In certain embodiments, each of the body forming die member pairs, or each pair of body forming die members, is a single pass along the forming path into a profiled article with a blank of deformable material. It is adapted to form. Depending on the complexity of the profile, more than one path may be required.

  In other embodiments, each of the body forming die member pairs, or each pair of body forming die members, is a single pass along the forming path with a blank of deformable material to the profiled intermediate. And the apparatus includes at least one additional pair of body forming die members, the at least one additional pair along the forming path or additional of the apparatus Adapted to act on the profiled intermediate independently and to form the profiled article in at least one additional path along a smooth forming path. If the forming path is one used in the initial forming process, an additional pair of body forming die members is inserted into the forming path, thereby replacing the initial pair of body forming die members. To do. In general, however, the device will include at least one additional forming path, along each pair of at least one additional pair of body forming die members along the at least one additional forming path. Progresses.

  In general, although not required, each pair of body forming die members or each pair of body forming die members is of a length substantially equivalent to the length of the blank of deformable material; Acts along the length of the blank. That is, the body forming die member effectively “stamps” the length of the blank according to the desired profile. In particular, the forming surface of the die member that the blank contacts can be configured with at least a portion of the desired profile.

  Preferably, the apparatus includes first and second mounts, the first and second mounts defining a forming path therebetween, wherein the first and second mounts are body forming die members A pair of first and second main body forming die members are mounted. The first and second mounts can include drive cogs, the drive cogs are engaged with the first and second body forming die members, and the drive cogs are driven by the drive. Driven.

  In certain embodiments, the first and second mounts define first and second endless paths, and the first body forming along the first and second endless paths. A first set of die members and a second set of second body forming die members proceed respectively.

  In other embodiments, the first and second mounts define a limited path along which a pair of body forming die members can be moved forward to form. Proceeds with movement and with reverse movement to reset.

  The form of the first and second mounts is not particularly limited. For example, at least one of the first and second mounts can include a large radial surface through the forming path. Each of the first and second mounts can include a large radius surface through the forming path. Each radius of the large radius surface can be substantially equal or different. The radius of curvature center can be on each opposite side of the forming path or can be on the same side of the forming path. One of the first and second mounts can include a large radius surface through the forming path, and the other of the first and second mounts includes a substantially flat surface through the forming path. It is possible.

  The blank for the deformable material can be of any suitable dimension dictated by the article to be formed. In general, the apparatus is primarily suitable for use with blanks having a length of about 100 mm to 3,000 mm, but it is envisioned that the present invention is not constrained by these dimensions.

According to another aspect of the invention, a method of forming a profiled article comprising:
Passing a blank of deformable material that is to be formed into a profiled article through a forming path, wherein the forming path is adapted to travel along the forming path Including a pair of opposing body forming die members, and
Progressively engaging a blank with a pair of complementary opposing body forming die members;
Including
A method is provided wherein a pair of body forming die members are adapted to act on a blank of deformable material and independently form a desired profile into the blank.

  As will be appreciated by the above discussion, the forming path may include a plurality of pairs of body forming die members, in which case the method preferably forms a plurality of blanks of deformable material. Passing through a path and engaging each blank with a respective pair of body forming die members and independently forming a desired profile into each blank. In this embodiment, the method preferably includes positioning the blank prior to engagement of the blank with the body forming die member, the positioning step being mounted between adjacent body forming die members. Realized by a positioning element. Again, the positioning element preferably includes a locating pin, although the above options and other options may be suitable.

  In certain embodiments, a pair of body forming die members form a blank of deformable material into a profiled article in a single pass along the forming path.

In other embodiments, a pair of body forming die members form a blank of deformable material into a profiled intermediate in a single pass along the forming path, the method comprising:
Passing the profiled intermediate through at least one additional forming path, such that at least one additional forming path travels along each at least one additional forming path. Including at least one additional pair of each of complementary opposing body forming die members adapted to
Progressively engaging the profiled intermediate with at least one additional pair of body forming die members;
Further including
At least one additional pair of body forming die members act and profile the independently profiled intermediate in at least one additional path along at least one additional forming path. The formed article is processed.

  Again, in certain embodiments, the pair of body forming die members is of a length substantially equivalent to the length of the blank of deformable material and acts along the length of the blank. . Similarly, blanks having a length of about 100 mm to 3,000 mm are suitable for use in the method, but the present invention is not bound by these dimensions.

  According to another aspect of the present invention, an apparatus as described above, specifically an apparatus comprising a positioning element mounted between adjacent body forming die members, wherein the positioning element comprises: A length of deformable material for use with the device is provided that is adapted to position the blank prior to engagement of the blank with the body forming die member. The predetermined length of material of this aspect of the invention includes a plurality of blanks of deformable material, and the continuous blanks of predetermined length of deformable material are interconnected by the web material The web and the continuous blank define a recess adapted to engage the positioning element of the device.

  In certain embodiments, the blank and web can be formed from the same material or different materials and can be connected or joined together by suitable means. However, preferably the blank and web are integral with each other.

  The predetermined length of deformable material may take the form of a sheet or strip, or may take any other form. In certain embodiments, the predetermined length of deformable material is in the form of a roll that can be fed into the forming path of the device.

  Preferably, the blank has a length of about 100 mm to 3,000 mm, but the present invention is not constrained by these dimensions.

  In a further aspect of the invention, there is provided a profiled article that is formed using the apparatus or method of the invention.

  The present invention consists of the features and combinations of parts fully described below and illustrated in the accompanying drawings, and without departing from the scope of the present invention or its advantages. It will be understood that various changes in detail may be made without sacrificing any of the above.

  In order to further clarify the various embodiments of the present invention, a more detailed description of the invention follows with reference to that particular embodiment, which is illustrated in the accompanying drawings . It should be appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the accompanying drawings.

FIG. 6 illustrates a method of an embodiment of the present invention in which multiple body forming die blocks are used to form an irregularly profiled article. FIG. 2 illustrates a blank used in the method illustrated in FIG. FIG. 2 illustrates a profiled article created by the method illustrated in FIG. FIG. 6 illustrates an apparatus according to an embodiment of the invention that includes a plurality of body forming die blocks. It is a figure which illustrates the pair of an irregular body forming die block. FIG. 6 illustrates an alternative arrangement for the apparatus and method of embodiments of the present invention. FIG. 3 illustrates an embodiment of the apparatus of the present invention showing locating pins for positioning a blank run. FIG. 6 illustrates an embodiment of the apparatus of the present invention showing locating pins for positioning a blank run. FIG. 3 is a diagram illustrating a drive arrangement for an apparatus according to an embodiment of the present invention. FIG. 3 is a diagram illustrating a drive arrangement for an apparatus according to an embodiment of the present invention. FIG. 3 is a diagram illustrating a drive arrangement for an apparatus according to an embodiment of the present invention. FIG. 6 illustrates a profile for a forming surface of a device according to an embodiment of the invention along which a body forming die block proceeds. FIG. 6 illustrates a profile for a forming surface of a device according to an embodiment of the invention along which a body forming die block proceeds. FIG. 6 illustrates a profile for a forming surface of a device according to an embodiment of the invention along which a body forming die block proceeds.

  The present invention relates to a method and apparatus for forming a profiled article, wherein the profiled article has a generally irregular body profile. In particular, the present invention relates to a method and apparatus in which at least one body forming die block is used to form at least a portion of a profiled article.

  In the following, this specification describes the invention according to preferred embodiments. It is to be understood that the following description of preferred embodiments of the present invention is provided to facilitate the discussion of the present invention and departs from the scope of the appended claims. It is assumed that there is no.

  Referring to FIG. 1, a simplified diagram of a method 10 for forming a final product 12 (shown in FIG. 3) from a blank 11 (as shown in FIG. 2) is illustrated. In the illustrated method 10, the blank 11 gradually achieves the final product 12 through “n” forming passes through the body forming die block pair 13. The proposed method 10 involves rolling blanks 11 between die block pairs 13 and thus differs from conventional stamping where the final product can be formed with a single stroke. This, like stamping, does not require a blank holder and does not result in the need to cut off the earring. Importantly, each die block pair 13 imparts the desired profile to the blank 11. Each die block pair 13 acts on the blank 11 and facilitates the production of the final product 12 having an irregular profile. For comparison with chain die forming, the proposed method 10 uses the entire body forming die block 13 instead of the individual die blocks found in chain die forming. Using the entire body forming die block 13 in the proposed method 10 advantageously means that the forming die has a higher strength than that used in chain die forming, and for the forming die It is considered to ensure that there is no gap between the dies. As such, it is assumed that the surface finish of the final product 12 will be improved. In addition, from the viewpoint of mechanical mounting, the structure of the apparatus discussed below is similar to chain die forming, and is more robust than chain die forming.

  Referring to FIG. 4, an apparatus 40 according to an embodiment of the present invention is illustrated. The device 40 includes a forming path 41 disposed between the first mount 42 and the second mount 43. Additional mounts may be provided, but this will not be described in detail here. The first and second mounts 42, 43 include drive gears 44, 44 ', which engage the cooperating first die member 45 and second die member 45', respectively. doing. According to this embodiment, the first and second mounts 42, 43 are endless paths (e.g., they can be large radius oval mounts) or large radius semi-elliptical It is possible to form a shaped mount. The blank of deformable material proceeds along the forming path 41 between the cooperating first and second die members 45, 45 'to form the final product 46.

  Each pair of cooperating first and second die members 45, 45 'acts on the respective blank and imparts the property of the pair of die members 45, 45' to the blank. In other words, each pair of die members 45, 45 ′ generally acts as a body die block, which is independent of any subsequent processing with additional die pairs, Acts on length. Accordingly, the pair of die members 45, 45 ′ does not act in the same manner as a die pair in chain die forming where a deformable material of a predetermined length is sequentially deformed into a desired cross-sectional profile. Rather, the pair of die members 45, 45 'works effectively in a manner similar to conventional stamping mechanisms. As shown, the profile of the pair of die members 45, 45 ′ acts on each blank independently, forming it into the desired profile of the final product 46, and the desired profile of the final product 46. The profile can be generally irregular or uniform.

  There is only a very small gap 47 between successive pairs of die members 45, 45 ′ that are hingedly connected by a joint 48. This ensures that the die members 45, 45 'are of relatively high strength compared to conventional chain die blocks used, for example, in generally uniform profile forming. The arrangement also prevents or ameliorates the problems related to the earring generally associated with the stamping process. It is also envisioned that the arrangement results in a better quality finish in the final product 46.

  Examples of die members 45, 45 ′ are provided in FIG. Referring to this figure, the first die member 45 includes a first profile 55 and the second die member 45 ′ includes a second profile 55 ′. The first and second profiles 55, 55 'are complementary and impart the desired profile to the final product as the blank or intermediate passes between the pair of die members 45, 45'.

  In an alternative embodiment of the device 60 as illustrated in FIG. 6, the pair of die members 45, 45 ′ pulls the blank 61 into the device 60, moves the blank 61 forward 62, and forms. Promote. When the process is complete, a final product 63 is created and the device 60 reverses, moving the die members 45, 45 ′ to the rear 64 and back to the starting position.

  A preferred embodiment of the device of the present invention is illustrated in FIGS. Referring to these figures, apparatus 70 is substantially as described above in that a blank 71 of deformable material is passed between a set of die members 45, 45 'to form a final product 73. It is as described. However, in this embodiment, the device 70 includes a locating pin 75 on one side or the opposite side of the die members 45, 45 ', which generally is a lower gap between the die members 45, 45'. And in cooperation with the upper gap 77 between the die members 45, 45 '. The positioning pin 75 engages with the recess 76 between the blanks 71, and in this embodiment, the blank 71 is joined by the web 78. This advantageously ensures that the blank 71 is correctly positioned between the respective die members 45, 45 ′ as it passes through the device 70. Thus, the die members 45, 45 ′ act independently on each blank 71 that passes through the device 70.

  FIGS. 9a to 9c show some exemplary ways in which the device 90 can operate. In FIG. 9a, the system is provided with a drive gear 91, which drives the two sets of die elements 45, 45 ′ in tune and draws the section through the forming part. . In FIG. 9b, a separate set of drive rolls 92 is provided to propel this section through the forming portion. FIG. 9c shows a similar configuration, in which a separate set of drive rolls 93 is used to push the section through the forming portion.

  Figures 10a to 10c show some of the possible configurations of the forming path in the forming part of the device. In FIG. 10a, each of the facing forming portions has a large radius, and the centers of the radii are each on the opposite side of the forming space. FIG. 10b shows a configuration in which one of the forming parts has a large radius and the other has an infinite radius or in other words is flat. FIG. 10c shows a configuration in which the centers of the radii are both on one side of the forming space and a large radius is used for each forming part to provide a path to join between the facing dies. Yes. It is also conceivable that the radius of the forming portion is not constant, for example, a configuration can be provided that provides a track that merges between opposing dies.

  Unless otherwise stated in context, or unless specifically stated to the contrary, the inventive integers described herein as singular integers, steps, or elements; A step or element specifically includes both the singular and plural form of the integer, step or element described.

  Throughout this specification, unless the context requires otherwise, a phrase such as `` comprise '' or `` comprises '' or `` comprising '' etc. Includes the stated step or element or integer, or a group of steps or elements or integers, but does not exclude any other step or element or integer or group of steps, elements or integers Is understood to imply that. Accordingly, in the context of this specification, the term “comprising” is used in an inclusive sense, and thus means “including primarily but not necessarily including”. Should be understood as

  The foregoing description has been given by way of example for purposes of illustration of the present invention, and all modifications and variations thereto as will be apparent to those skilled in the art are intended to be considered as described herein. It will be appreciated that it is considered to fall within the broad scope and scope of the invention.

Claims (32)

An apparatus for forming a profiled article,
A forming path through which a blank of deformable material to be formed into a profiled article;
A pair of complementary opposing body forming die members adapted to travel along the forming path;
Driving the body forming die member along the forming path,
An apparatus wherein a pair of body forming die members are adapted to act on a blank of deformable material and independently form a desired profile into the blank.   Includes multiple pairs of body forming die members, each pair of body forming die members acting on each blank of deformable material and independently adapted to form the desired profile into each blank 2. The device of claim 1, wherein:   The apparatus of claim 2, wherein adjacent body forming die members of a plurality of pairs of body forming die members are hingedly connected to each other.   4. The apparatus of claim 3, wherein the adjacent body forming die members are hingedly connected with a minimum clearance therebetween.   3. A positioning element mounted between adjacent body forming die members, wherein the positioning element is adapted to position the blank prior to engagement of the blank with the body forming die member. 5. The apparatus according to any one of 4 to 4.   6. The apparatus of claim 5, wherein the positioning element includes a positioning pin.   Adjacent blanks are interconnected by webs, and the positioning elements are disposed in the lower section of the forming path between adjacent body forming die members and, in use, each web's 7. A device according to claim 5 or 6, wherein the device is positioned on one or both sides.   The upper section of the forming path includes a gap between adjacent body forming die members, the gap cooperating with each positioning element in use to receive each positioning element. Equipment.   Each of the body forming die member pairs, or each pair of body forming die members, forms a blank of deformable material into a profiled article in a single pass along the forming path. 9. Apparatus according to any one of claims 1 to 8, which is adapted.   Each pair of body forming die members, or each pair of body forming die members, forms a blank of deformable material into a profiled intermediate in a single pass along the forming path. And the apparatus includes at least one additional pair of body forming die members, the at least one additional pair along the forming path or additional of the apparatus 10. Any one of claims 1 to 9 adapted to act independently on the profiled intermediate and form the profiled article in at least one additional pass along the forming path. A device according to claim 1.   The apparatus includes at least one additional forming path, and each pair of at least one additional pair of body forming die members travels along the at least one additional forming path. The apparatus according to 10.   Each pair of body forming die members, or each pair of body forming die members, is of a length substantially equivalent to the length of the blank of deformable material and acts along the length of the blank. 12. The device according to any one of claims 1 to 11.   First and second mounts, wherein the first and second mounts define the forming path therebetween, and a first and second body forming die members of a pair of body forming die members The device according to any one of claims 1 to 12, wherein the device is attached.   The first and second mounts include drive cogs, the drive cogs engaging the first and second body forming die members and driven by the drive. Equipment.   The first and second mounts define first and second endless paths, and along the first and second endless paths, a first set of first body forming die members; 15. An apparatus according to claim 13 or 14, wherein the second set of second body forming die members each proceeds.   The first and second mounts define a limited path, and along the limited path, a pair of body forming die members move forward and form a reverse and reverse 15. The device according to claim 13 or 14, wherein the device proceeds with the movement.   17. An apparatus according to any one of claims 13 to 16, wherein at least one of the first and second mounts includes a large radius surface through the forming path.   The apparatus of claim 17, wherein each of the first and second mounts includes a large radius surface through the forming path.   19. The apparatus of claim 18, wherein each radius of the large radius surface is substantially equal or different.   20. An apparatus according to claim 18 or 19, wherein a radius of curvature center is on each opposite side of the forming path or on the same side of the forming path.   One of the first and second mounts includes a large radius surface through the forming path and the other of the first and second mounts includes a substantially flat surface through the forming path; The apparatus of claim 17. A method of forming a profiled article,
Passing a blank of deformable material to be formed into a profiled article through a forming path, the forming path being adapted to travel along the forming path Including a pair of complementary opposing body forming die members; and
Gradually engaging a blank with a pair of complementary opposing body forming die members; and
A method wherein a pair of body forming die members are adapted to act on a blank of deformable material and independently form a desired profile into the blank.   The forming path includes a plurality of pairs of body forming die members, and the method includes passing a plurality of blanks of deformable material through the forming path, and each blank passing through each of the body forming die members. 23. The method of claim 22, comprising engaging the pair and independently forming a desired profile into each blank.   24. Positioning the blank prior to engagement between the blank and the body forming die member, wherein the positioning step is achieved by a positioning element mounted between adjacent body forming die members. The method described in 1.   25. The method of claim 24, wherein the positioning element includes a locating pin.   26. A pair of body forming die members form a blank of deformable material into a profiled article in a single pass along the forming path. the method of. A pair of body forming die members form a blank of deformable material into a profiled intermediate in a single pass along the forming path, the method comprising:
Passing the profiled intermediate through at least one additional forming path, wherein the at least one additional forming path travels along each at least one additional forming path. Including at least one additional pair of each of complementary opposing body forming die members adapted to
Gradually engaging the profiled intermediate with at least one additional pair of body forming die members; and
At least one additional pair of body forming die members act and profile the independently profiled intermediate in at least one additional path along at least one additional forming path. 26. A method according to any one of claims 22 to 25, wherein the formed article is formed.   28. The body forming die member pair is of a length substantially equivalent to a length of the deformable material blank and acts along the length of the blank. The method described in 1.   A deformable material of a predetermined length for use with the device according to any one of claims 5 to 8, comprising a plurality of blanks of deformable material, the deformable of a predetermined length A series of blanks of different materials are interconnected by a web of material, the web and the continuous blanks defining a recess adapted to engage a positioning element of the device; Length of deformable material.   30. The predetermined length of deformable material of claim 29, wherein the blank and the web are integral with each other.   31. A predetermined length of deformable material according to claim 29 or 30, wherein the predetermined length of deformable material is in the form of a roll that can be fed into the forming path of the device.   A profiled article that is formed in an apparatus according to any one of claims 1 to 21 or that is formed by a method according to any one of claims 22 to 28.

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