JP4614757B2 - Manufacturing method of bonded metal plate - Google Patents

Description

  The present invention relates to a method for manufacturing a bonded metal plate in which two metal plates are bonded to each other by an adhesive and welding.

  Spot welding is used for joining metal plates in large products such as automobile vehicles and railway vehicles. In spot welding, two stacked metal plates are sandwiched between a pair of electrode tips, and a current is passed in the thickness direction while sandwiching between the two metal plates to form a melted part called a weld nugget on both metal plates. The two metal plates are welded to each other in a dot shape.

  When this spot welding is performed, there is a joining method called weld bond joining in which a bonding portion of each metal plate is filled with an adhesive in advance (see, for example, Patent Document 1). According to this bonding method, since the bonding strength by the adhesive is added to the bonding strength by spot welding, the bonding strength is improved by the amount of solidified adhesive when the spot welding spot positions and number are the same. Can do.

In the bonded metal plate described in Patent Document 1, two metal plates continuously form one wall portion, and a flange portion substantially perpendicular to the wall portion is formed at the boundary portion of each metal plate. Then, in a state where the adhesive is filled between the flange portions, the flange portions are overlapped and spot welding is performed. When the joining metal plate has a bag-like structure, an adhesive is applied in advance to at least one of the upper metal plate and the lower metal plate before the flange portions are overlapped. In each metal plate, the wall portion and the flange portion are continuously formed via a curved bent portion. As described above, in a portion formed in a bag shape by two metal plates such as an outer panel and an inner panel of a vehicle, a flange portion is formed on each metal plate and spot welding is generally performed.
JP 2004-82136 A

By the way, if the adhesive can be solidified not only between the flange portions of each metal plate but also on the bent portion side, the bonding strength is dramatically improved. Here, the amount of the adhesive applied to the flange portion is increased, and the adhesive is made to protrude from each flange portion to each bent portion side during spot welding, thereby allowing the adhesive to be It is conceivable to fill it.
However, in the above-described manufacturing method of the bonded metal plate, since the adhesive is applied to the flange portion substantially uniformly in the horizontal direction, if the amount of the adhesive applied to the flange portion is increased, it is opposite to each bent portion. The adhesive also protrudes from the side and flows out to the outside of the bonded metal plate. The adhesive that has flowed to the outer surface of the bonded metal plate having a bag-like structure needs to be wiped off in a subsequent process, resulting in an increase in the number of work steps during manufacturing.

  The present invention has been made in view of the above circumstances, and the object of the present invention is to fill the bent portions of the respective metal plates with an adhesive without increasing the number of man-hours during manufacture. It is providing the manufacturing method of the joining metal plate which can improve the joining strength of a board.

In order to achieve the above object, according to the first aspect of the present invention, the upper wall portion that is formed continuously from the upper wall portion that extends substantially vertically and the upper flange portion that extends substantially horizontally is curved. A metal plate, and a lower metal plate formed continuously through a lower bent portion in which a lower wall portion extending substantially vertically and a lower flange portion extending substantially horizontally are curved, and A method of manufacturing a bonded metal plate in which an upper flange portion and a lower flange portion are joined, wherein an adhesive is interposed between the upper flange portion and the lower flange portion, and the upper flange portion and the lower flange portion are joined. After the positioning step of overlapping the side flange portions and the positioning step, the upper bent portion and the lower bent portion on the upper flange portion and the lower flange portion at the end opposite to the lower bent portion are used as spot welding tools. contact of the installed outflow prevention member The nipped between the upper flange portion by the electrode tip provided with the lower flange portion in the spot welding tool, have a, a bonding step of welding the said lower flange portion and the upper flange portion while said joining step Then, when the spot welding tool is moved to a position where the upper flange portion and the lower flange portion are clamped and welded by the front electrode tips, the outflow prevention member moves between the upper flange portion and the lower flange portion. It abuts on the end portion .

According to the first aspect of the present invention, when the upper flange portion and the lower flange portion overlapped in the positioning step are clamped in the joining step, they are interposed between the upper flange portion and the lower flange portion. Adhesive spreads between the flange portions. At this time, since the outflow prevention member abuts on the upper bent portion and the lower bent portion in the upper flange portion and the end on the opposite side to the lower bent portion, each flange portion from the opposite side to the bent portion. The outflow of the adhesive is regulated by the outflow prevention member.
In other words, if the amount of adhesive interposed between the flange portions in the positioning step is set larger than the amount spread between the flange portions, the side opposite to the bent portions in the flange portions at the time of clamping in the joining step The adhesive does not flow out from the flanges, but the adhesive flows out from the flange portions to the bent portions, and the adhesive is filled between the bent portions.
Accordingly, since the adhesive does not flow out to the outer surface of the bonded metal plate, it is not necessary to wipe off the adhesive in a subsequent process, and the number of work steps in manufacturing is not increased. In addition to the flange portions, the manufactured joining metal plate is bonded to the upper bent portion and the lower bent portion, and the upper metal plate and the lower metal plate are bonded to each other. Compared to the conventional one in which the metal plate and the lower metal plate are bonded, the bonding strength of the bonded metal plate can be dramatically improved.
According to the first aspect of the present invention, since the outflow prevention member installed in the spot welding tool is in contact with each flange portion when the clamping operation and the welding operation of each flange portion are performed, the outflow prevention is performed. The operation | work which contacts a member to each flange part does not generate | occur | produce, but the work man-hour at the time of manufacture can further be reduced.
In addition, since the positional relationship between each electrode tip and the outflow prevention member is fixed, as long as the outflow prevention member is properly attached to the spot welding tool, the outflow prevention member is properly applied to each flange portion in the joining process. It can be brought into contact with each other, and the function of preventing the adhesive from flowing out can be surely exhibited.

  According to a second aspect of the present invention, in the method for manufacturing a bonded metal plate according to the first aspect, the upper flange portion and the lower flange portion are clamped by a pair of upper and lower electrode tips in the bonding step. Spot welding is performed on the upper flange portion and the lower flange portion.

  According to the second aspect of the present invention, in addition to the action of the first aspect, the clamping work and the welding work of each flange portion can be performed at one time, and the number of work steps during the manufacturing can be reduced, and Productivity can be improved.

According to a third aspect of the present invention, in the method for manufacturing a bonded metal plate according to the first aspect, in the bonding step, a pair of upper and lower rolls rolling the upper surface of the upper flange portion and the lower surface of the lower flange portion. The upper flange portion and the lower flange portion are clamped using a roller.

According to the invention of claim 3 , in addition to the action of claim 1, since the upper flange portion and the lower flange portion are clamped by the pair of upper and lower rollers, each flange portion is accurately molded substantially horizontally. However, the adhesive can be filled evenly between the flange portions.

According to a fourth aspect of the present invention, in the method for manufacturing a bonded metal plate according to the third aspect , the shaft support portion of each roller serves as the outflow prevention member, and the shaft support portion of each roller in the bonding step. Is in sliding contact with the upper bent portion and the lower bent portion opposite to the upper bent portion of the upper flange portion and the lower flange portion.

According to the invention of claim 4 , in addition to the action of claim 3 , when the pressing operation of each flange portion by each roller is performed, the shaft support portion of each roller comes into contact with each flange portion. The operation | work which makes an outflow prevention member contact | abut to each flange part does not generate | occur | produce, but the work man-hour at the time of manufacture can further be reduced.
In addition, since the positional relationship between each roller and the shaft support portion is fixed, the outflow prevention member can be brought into contact with each flange portion accurately in the joining process, and the adhesive outflow prevention function can be reliably exhibited. Can do.

  Thus, according to the present invention, it is possible to improve the bonding strength of the bonded metal plate by filling the bent portions of the metal plates with the adhesive without increasing the number of work steps during manufacturing.

  1 to 3 show an embodiment of the present invention. FIG. 1 is a schematic perspective view of a side member of an automobile body, FIG. 2 is a schematic sectional view of a side member, and FIG. 3 is a spot welding gun. It is operation | movement explanatory drawing at the time of welding each flange part by.

  As shown in FIG. 1, the bonded metal plate 1 is used for a side member extending substantially front and rear in an automobile body, and the upper metal plate 10 whose cross section is formed in a substantially hat shape and the cross section is formed in a substantially reverse hat shape. The lower metal plate 20 is joined. The upper metal plate 10 and the lower metal plate 20 each made of iron are joined by spot welding in a state where the adhesive 30 is applied to the mating surfaces, and the upper metal plate 10 and the lower metal plate 20 The wall part 21 forms the vertical wall 31 continuously. The upper metal plate 10 has an upper flange portion 12 that extends substantially horizontally, the lower metal plate 20 has a lower flange portion 22 that extends substantially horizontally, and the lower surface of the upper flange portion 12 and the upper surface of the lower flange portion 22. Has a mating surface.

  As shown in FIG. 1, the upper metal plate 10 is formed such that an upper wall portion 11 that extends substantially vertically and an upper flange portion 12 that extends substantially horizontally are continuously formed via an upper bent portion 13 that is curved. . In addition, the lower metal plate 20 is formed such that a lower wall portion 21 extending substantially vertically and a lower flange portion 22 extending substantially horizontally are continuously formed via a lower bent portion 23 that is curved. As shown in FIG. 2, the upper bent portion 13 and the lower bent portion 23 are formed with substantially the same curvature, and are convexly formed inside the closed cross section formed by the respective metal plates 10 and 20. Thereby, the vertical wall 31 and each flange part 12 and 22 are connected smoothly. A solidified adhesive 30 is interposed between the flange portions 12 and 22.

  In this joined metal plate 1, the upper flange portion 12 of the upper metal plate 10 and the lower flange portion 22 of the lower metal plate 20 are joined by being sandwiched and welded with an adhesive 30 interposed therebetween. Is done. In the present embodiment, this clamping pressure is performed by sandwiching the flange portions 12 and 22 with a pair of upper and lower electrode tips 41 during spot welding, as indicated by black arrows in FIG. Spot welding is performed at intervals in the front-rear direction, and a plurality of nuggets 32 arranged in the front-rear direction are formed on the flange portions 12, 22 (see FIG. 1).

The manufacturing method of the metal joining plate 1 comprised as mentioned above is demonstrated.
First, the metal plate is bent to form the upper metal plate 10 in a substantially hat shape and the lower metal plate 20 in a substantially reverse hat shape. And the adhesive agent 30 is interposed between the upper side flange part 12 and the lower side flange part 22, and the upper side flange part 12 and the lower side flange part 22 are piled up (positioning process). In the present embodiment, the adhesive 30 is discharged from the nozzle connected to the adhesive delivery device toward the lower flange portion 22, and the adhesive 30 is applied to the opposing surface of the lower flange portion 22 in advance. The flange portions 12 and 22 are overlapped. As a result, the adhesive 30 is crushed and diffused between the upper flange portion 12 and the lower flange portion 22.

  After the positioning step, the upper flange portion 12 and the lower flange portion 22 and the lower flange portion 22 are in contact with the upper flange portion 12 and the lower flange portion 22 while the ends opposite to the upper bent portion 13 and the lower bent portion 23 are brought into contact with the outflow prevention member 42. The side flange portion 22 is clamped and the upper flange portion 12 and the lower flange portion 22 are welded (welding process). When the upper flange portion 12 and the lower flange portion 22 are clamped, the adhesive 30 interposed between the upper flange portion 12 and the lower flange portion 22 spreads between the flange portions 12 and 22.

  In the present embodiment, as described above, spot welding is performed on the upper flange portion 12 and the lower flange portion 22 while sandwiching the upper flange portion 12 and the lower flange portion 22 with the pair of upper and lower electrode tips 41 (FIG. 3). The outflow prevention member 42 is installed in the spot welding gun 40. When the spot welding gun 40 is moved to a position where the upper flange portion 12 and the lower flange portion 22 are clamped and welded by the electrode tips 41, the outflow prevention member 42 is moved. 42 abuts against the end portions of the upper flange portion 12 and the lower flange portion 22.

  The spot welding gun 40 as a spot welding tool is connected to a robot arm (not shown), and the position and orientation of each electrode tip 41 can be adjusted according to the part to be welded. As shown in FIG. 3, when the spot welding gun 40 is ready to weld the flange portions 12 and 22, the outflow prevention member 42 contacts the end portions of the flange portions 12 and 22.

  In this embodiment, the outflow prevention member 42 is a plate member having flexibility and extending substantially vertically. The upper and lower ends of the outflow prevention member 42 are fixed in a state of being elastically deformed so that the upper and lower central sides protrude toward the flange portions 12 and 22, and the upper and lower central sides are pressed against and contact the flange portions 12 and 22. That is, even if the positions of the flange portions 12 and 22 change before and after clamping by the electrode tips 41, the outflow prevention member 42 is deformed following this, and during the series of operations during welding, the outflow prevention member 42 and the flanges 12 and 22 are kept in contact with each other.

  In this way, the outflow prevention member 42 abuts against the upper bent portion 13 and the lower bent portion 23 of the upper flange portion 12 and the lower flange portion 22, so that the end portions of the flange portions 12 and 22 are in contact with each other. The outflow of the adhesive 30 from the side opposite to the bent portions 13 and 23 is restricted by the outflow prevention member 42.

  Accordingly, if the amount of the adhesive 30 interposed between the flange portions 12 and 22 in the positioning step is set to be larger than the amount spread between the flange portions 12 and 22, 12 and 22, the adhesive 30 does not flow out from the opposite side of the bent portions 13 and 23, and the bent portions 13 and 23 are bent from the flange portions 12 and 22 as indicated by the white arrows in FIG. The adhesive 30 flows out to the side, and the adhesive 30 is filled between the bent portions 13 and 23.

  Therefore, since the adhesive 30 does not flow out to the outer surface of the bonded metal plate 1, it is not necessary to wipe off the adhesive 30 in a subsequent process, and the number of work steps during manufacturing does not increase. In the manufactured bonded metal plate 1, the upper metal plate 10 and the lower metal plate 20 are bonded to each other at the upper bent portion 13 and the lower bent portion 23 in addition to the flange portions 12 and 22. The joining strength of the joining metal plate 1 can be dramatically improved as compared with the conventional one in which the upper metal plate 10 and the lower metal plate 20 are bonded only by the flange portions 12 and 22.

Moreover, according to the manufacturing method of the joining metal plate 1 of this embodiment, the clamping work and welding operation of each flange part 12 and 22 can be performed at once, the work man-hour at the time of manufacture is reduced, and a joining metal plate 1 productivity can be improved.
In addition, since the outflow prevention member 42 installed on the spot welding gun 40 is in contact with the flange portions 12 and 22 when the clamping operation and the welding operation of the flange portions 12 and 22 are performed, the outflow prevention member 42. There is no work for contacting the flanges 12 and 22 with each other, and this can also reduce the number of work steps during manufacturing.

  Further, since the positional relationship between each electrode tip 41 and the outflow prevention member 42 is fixed, as long as the outflow prevention member 42 is properly attached to the spot welding gun 40, the outflow prevention member 42 is attached to each flange in the joining process. The parts 12 and 22 can be brought into contact with each other accurately, and the function of preventing the adhesive 30 from flowing out can be reliably exhibited.

  Here, FIG. 4 shows experimental data obtained by measuring how the bonding strength changes depending on the application state of the adhesive 30. In the experiment, the adhesive 30 was bonded between the flange portions 12 and 22 in addition to spot welding as shown in FIG. 5 in which the flange portions 12 and 22 were joined only by spot welding (hereinafter referred to as sample 1). Solidified material (hereinafter referred to as sample 2), and solidified adhesive 30 between the flange portions 12 and 22 and the bent portions 13 and 23 in addition to spot welding as shown in FIG. Hereinafter, it was divided into Sample 3). Samples 1 to 3 had the same shape as the side members used in actual car bodies.

  As shown in FIG. 4, the bonding strengths of the flange portions 12 and 22 were higher in the order of sample 3, sample 2, and sample 1. In FIG. 4, the opening displacement of each flange portion 12, 22 is taken as the horizontal axis, and the load necessary for this opening displacement is taken as the vertical axis. Comparing sample 2 and sample 3, it has been experimentally proven that sample 3 must be loaded approximately 1.5 times or more at the same opening displacement. Thus, experimentally, when not only the flange portions 12 and 22 but also the upper bent portion 13 or the lower bent portion 23 are filled with the adhesive 30 and solidified, the bonding strength is greatly improved. It has been confirmed.

  In the above-described embodiment, the outflow prevention member 42 is installed on the spot welding gun 40. However, as shown in FIG. 6, the outflow prevention member 142 is independent of the spot welding tool. It may be in contact with the end of 22. In FIG. 6, the outflow prevention member 142 is engaged with the end portions of the flange portions 12 and 22, and the flange portions 12 and 22 are pinched by the outflow prevention member 142. The outflow prevention member 142 may be one that mechanically sandwiches the flange portions 12 and 22 or may sandwich the flange portions 12 and 22 using magnetic force or the like. In this case, before spot welding, the outflow prevention member 142 is fixed to the flange portions 12 and 22, and the flange portions 12 and 22 are clamped.

  Further, in the joining process, the upper flange portion 12 and the lower flange portion 22 may be clamped by using a pair of upper and lower rollers 240 that roll on the upper surface of the upper flange portion 12 and the lower surface of the lower flange portion 22. Good. FIG. 7 shows an embodiment in which the flanges 12 and 22 are clamped by the rollers 240.

  As shown in FIG. 7, the horizontal dimension of each roller 240 substantially matches the horizontal dimension of the upper flange portion 12 and the lower flange portion 22. A shaft member 241 that passes through each roller 240 is fixed to a shaft support 242 that extends vertically. The shaft support portion 242 is provided with an outflow prevention portion 242 a that is in sliding contact with the left and right end portions on the opposite side of the upper bent portion 13 and the lower bent portion 23 of the upper flange portion 12 and the lower flange portion 22. That is, the shaft support portion 242 of each roller 241 serves as an outflow prevention member. The outflow prevention portion 242a of the shaft support portion 242 is made of, for example, a resin member, and thereby the shaft support portion 242 and the rollers 240 are positioned to the left and right with respect to the flange portions 12 and 22, respectively.

  Further, as shown in FIG. 7, electrode tips 243 for welding are arranged on each roller 240 at a predetermined interval in the circumferential direction. The peripheral surface of each roller 240 is formed flat without protrusions and the like, and each electrode chip 243 embedded in the roller 240 is exposed to the peripheral surface. An insulator is disposed around each electrode tip 243 in each roller 240 so that current does not flow to the roller 240 side when each electrode tip 243 is energized, but current flows to each flange portion 12 and 22. The electrode tips 243 of the upper and lower rollers 240 are in contact with the upper and lower surfaces of the flange portions 12 and 22 at the same timing, and the flange portions 12 and 22 are sandwiched between the pair of upper and lower electrode tips 243. At this time, spot welding is performed by energizing each electrode tip 243 to form a nugget 32 as shown in FIG. Thereby, the clamping work and welding work of each flange part 12 and 22 are performed at once.

As described above, since the upper flange portion 12 and the lower flange portion 22 are clamped by the pair of upper and lower rollers 240, the adhesive 30 is applied to each flange portion while accurately molding the flange portions 12 and 22 substantially horizontally. 12 and 22 can be filled evenly. Further, since the shaft support portion 242 of each roller 240 is brought into contact with the flange portions 12 and 22 when the rollers 240 perform the pressing operation of the flange portions 12 and 22, the outflow prevention member is used as the flange portion 12. , 22 does not occur, and the number of work steps during manufacturing can be further reduced.
Further, since the positional relationship between each roller 240 and the shaft support portion 242 is fixed, the outflow prevention portion 242a can be brought into contact with each flange portion 12 and 22 accurately in the joining step, and the outflow prevention of the adhesive 30 can be achieved. The function can be surely exhibited.
Note that the pressing work may be performed with a roller on which no electrode is disposed, and the welding work may be performed separately with a spot welding gun.

  Moreover, in the said embodiment, although what applied the semi-fluid adhesive 30 to the lower flange part 22 was shown, you may make it apply | coat the adhesive 30 to the upper flange part 12. FIG. Further, instead of the semi-fluid adhesive 30, an adhesive having foamability may be interposed between the flange portions 12 and 22. In this case, if the adhesive is disposed between the flange portions 12 and 22 so that the adhesive expands toward the bent portions 13 and 23, it is effective for filling the adhesive between the bent portions 13 and 23. It is.

  Furthermore, in the said embodiment, although the joining metal plate 1 showed what was used for a motor vehicle body, it can also be used for a rail vehicle body, an aircraft, etc. Moreover, although what was used for the side member of a motor vehicle body was shown, it may be used for other parts, such as a cross member and a pillar. Here, even if the metal plate is divided vertically and horizontally or extending like a pillar, bonding is performed with one metal plate on the upper side and the other metal plate on the lower side, and the adhesive solidifies. After that, it can be assembled to other parts.

  Furthermore, in the above-described embodiment, a substantially hat-shaped metal plate and a substantially inverted hat-shaped metal plate are joined. However, the upper metal plate has an upper wall portion, an upper curved portion, and an upper flange portion. And if a lower metal plate has a lower wall part, a lower curved part, and a lower flange part, the shape of an upper metal plate and a lower metal plate will not be ask | required.

  Moreover, in the said embodiment, although what welded the upper flange part 12 and the lower flange part 22 by spot welding was shown, it may weld by seam welding or laser welding. That is, as long as the clamping of the flange portions 12 and 22 is performed together with welding, the same effects as those of the above-described embodiment can be obtained regardless of the welding method.

  Moreover, in the said embodiment, although the upper side metal plate 10 and the lower side metal plate 20 showed what consists of iron, they may consist of other metals, such as aluminum, for example. Further, the surface roughness of each of the bent portions 13 and 23 is made rougher than that of the respective flange portions 12 and 22 so that the adhesive 30 is easily stored between the respective bent portions 13 and 23, A plate member may be interposed between 22. Of course, a spot welding tool other than the spot welding gun 40 may be used, and other specific details such as a detailed structure can be appropriately changed.

It is a typical perspective view of the side member of the automobile body which shows one embodiment of the present invention. It is typical sectional drawing of a side member. It is operation | movement explanatory drawing at the time of welding each flange part with a spot welding gun. It is a graph which shows the relationship between the opening displacement of a flange part, and a load. It is typical sectional drawing of the side member which filled only the flange part with the adhesive agent. It is a typical sectional view of a side member showing a modification and showing a state in which each flange portion is clamped by an outflow prevention member. It is a typical sectional view of a side member showing a modification and showing a state in which each flange portion is clamped by a pair of upper and lower rollers. It is AA sectional drawing of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Joining metal plate 10 Upper metal plate 11 Upper wall part 12 Upper flange part 13 Upper bent part 20 Lower metal plate 21 Lower wall part 22 Lower flange part 23 Lower bent part 30 Adhesive 40 Spot welding gun 41 Electrode Chip 42 Outflow prevention member 142 Outflow prevention member 240 Roller 242 Shaft support 242a Outflow prevention portion

Claims (4)

An upper metal plate that is formed continuously through an upper bent portion in which an upper wall portion that extends substantially vertically and an upper flange portion that extends substantially horizontally are curved, and a lower wall portion that extends substantially vertically extend substantially horizontally. A lower metal plate continuously formed through a lower bent portion in which the lower flange portion is curved, and the bonded metal plate to which the upper flange portion and the lower flange portion are joined A manufacturing method of
A positioning step of overlapping the upper flange portion and the lower flange portion with an adhesive interposed between the upper flange portion and the lower flange portion;
After the positioning step, the upper bent portion and the lower bent portion of the upper flange portion and the lower flange portion are brought into contact with the outflow prevention member installed on the spot welding tool while contacting the end portion opposite to the lower bent portion. the nipped upper flange portion and the lower flange portion, have a, a bonding step of welding the said lower flange portion and the upper flange portion by the electrode tip provided in the spot welding tool,
When the spot welding tool is moved to a position where the upper flange portion and the lower flange portion are clamped and welded by the front electrode tips in the joining step, the outflow prevention member is moved to the upper flange portion and the lower side. A method for producing a bonded metal plate, comprising abutting against an end of a flange .   The spot welding is performed on the upper flange portion and the lower flange portion while sandwiching the upper flange portion and the lower flange portion with a pair of upper and lower electrode tips in the joining step. The manufacturing method of the joining metal plate of description.   In the joining step, the upper flange portion and the lower flange portion are clamped by using a pair of upper and lower rollers that roll on the upper surface of the upper flange portion and the lower surface of the lower flange portion. Item 2. A method for producing a bonded metal sheet according to Item 1. The shaft support portion of each roller constitutes the outflow prevention member,
In the joining step, the shaft support portion of each roller is in sliding contact with the upper bent portion and the lower bent portion on the opposite side of the upper flange portion and the lower flange portion. The manufacturing method of the joining metal plate of Claim 3 to do.

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