JP6082621B2 - Electric wire with terminal and manufacturing method of electric wire with terminal - Google Patents

Description

  The present invention mainly relates to an electric wire with a terminal constituted by a covered electric wire and a terminal.

  The wire harness is routed in the body of an automobile, and is used for supplying power to various electric devices included in the automobile, communicating control signals between the electric devices, and the like. The wire harness includes a plurality of bundled covered electric wires and terminals connected to the covered electric wires.

  When a terminal is used in a wet area, it is necessary to prevent water from the gap between the terminals and water from the boundary between the covered electric wire and the crimp terminal in order to prevent the conductor portion from corroding. In particular, in the case where different metals are used for the terminal and the conductor, it is necessary to reliably prevent flooding in order not to cause electrolytic corrosion. Patent Documents 1 and 2 disclose this type of technology.

  In Patent Document 1, when the conductor portion of the covered electric wire is crimped to the terminal, the conductor portion is exposed at a plurality of locations. Patent Document 1 discloses a technique for waterproofing by covering the exposed portions of the plurality of electric wires together with a mold resin. Patent Document 2 discloses a technique for waterproofing by applying a resin so as to cover only an exposed portion of a conductor portion.

JP 2001-162647 A JP 2010-108828 A

  Here, the techniques disclosed in Patent Documents 1 and 2 require the cost of the resin itself, the cost of the equipment for applying the resin, the cost of the operation of applying the resin, and the like, resulting in high costs. However, a gap is easily generated between the electric wire connecting portion and the covered electric wire, and it has been difficult in the prior art to prevent water from flowing through the covered electric wire without using a resin or the like.

  Thus, in the electric wire with a terminal, it is difficult to waterproof between the electric wire connecting portion and the covered electric wire at low cost, and there is still room for improvement.

  The present invention has been made in view of the above circumstances, and its main object is to provide a terminal-attached electric wire that waterproofs between an electric wire connection portion and a covered electric wire at low cost without using a mold resin or the like. It is in.

Means and effects for solving the problems

  The problems to be solved by the present invention are as described above. Next, means for solving the problems and the effects thereof will be described.

According to the 1st viewpoint of this invention, the electric wire with a terminal of the following structures is provided. That is, this electric wire with a terminal includes a covered electric wire, an electric wire connecting portion, and a terminal connecting portion. The said covered electric wire has a conductor part and a coating | coated part. The electric wire connecting portion has a hollow portion formed by welding end portions of plate members, the conductor portion is electrically connected to the inside of the hollow portion, and the inside of the hollow portion. The covering portions are connected by welding. The said terminal connection part is connected with the said electric wire connection part by being comprised from the same board | plate material as the said electric wire connection part, and is connected to another terminal. As for the said electric wire connection part, one end becomes the insertion port of the said covered electric wire, the other end is sealed, and the said electric wire connection part is welded to the said coating | coated part without passing through another member. The insertion port is waterproof.

Thereby, since a covered electric wire can be stuck to an electric wire connection part, flooding to the inside of an electric wire connection part can be prevented more certainly. Further, by forming the hollow member by welding, the gap can be eliminated and the waterproofness can be enhanced. Moreover, waterproofing can be further improved by sealing the other end. Moreover, the insertion opening of the covered electric wire has a waterproof property by welding the covering portion. From the above, it is possible to prevent water from entering the inside of the electric wire connecting portion.

  The electric wire with terminal preferably has the following configuration. That is, the outline of the cross section when the covered electric wire is cut by a plane perpendicular to the longitudinal direction is substantially circular. The outline of the cross section when the wire connecting portion is cut by a plane perpendicular to the longitudinal direction is substantially circular.

  Thereby, since the cross section of both members is the same shape and circular, welding can be performed uniformly. Accordingly, it is possible to improve the waterproofness by enhancing the adhesion.

  In the electric wire with terminal, the conductor is preferably aluminum or copper.

  Thereby, the effect of this application can be exhibited about a general covered electric wire. In addition, when the material of a conductor part and an electric wire connection part differs, since electric corrosion generate | occur | produces, since high waterproofness is needed, the effect of this application can be utilized more effectively.

According to the 2nd viewpoint of this invention, the manufacturing method of the following electric wires with a terminal is provided. That is, this method is a method of manufacturing an electric wire with a terminal by inserting and connecting a covered electric wire having a conductor portion and a covering portion to the terminal, and includes an inserting step and a connecting step. In the insertion step, the covered electric wire is inserted into a hollow portion of the electric wire connecting portion. In the connecting step, the conductor portion is electrically connected to the electric wire connecting portion, and the insertion port is waterproofed by connecting the electric wire connecting portion to the covering portion without any other member by welding.

Thereby, since a covered electric wire can be stuck to an electric wire connection part by welding, the electric wire with a terminal which can prevent inundation to the inside of an electric wire connection part can be manufactured. Further, by forming the hollow member by welding, the gap can be eliminated and the waterproofness can be enhanced. Moreover, waterproofing can be further improved by sealing the other end. Moreover, the insertion opening of the covered electric wire has a waterproof property by welding the covering portion. From the above, it is possible to prevent water from entering the inside of the electric wire connecting portion.

  In the manufacturing method of the electric wire with terminal, in the connecting step, it is preferable that the covering portion is welded to the electric wire connecting portion by laser or resistance heating from the outside of the electric wire connecting portion.

  Thereby, welding with a coating | coated part and an electric wire connection part can be performed appropriately according to various conditions. Moreover, since the electric wire connection part is a metal, since conductivity is high normally, even if it heats from the outer side of the said electric wire connection part, it can weld appropriately.

  In the manufacturing method of the electric wire with terminal, in the connecting step, the conductor portion is connected to the electric wire connecting portion using any one of crimping, ultrasonic welding, resistance welding, soldering, and laser welding. Is preferred.

  Thereby, electrical connection with a conductor part and an electric wire connection part can be performed appropriately according to various conditions.

The external appearance perspective view and decomposition | disassembly perspective view which show the structure of the electric wire with a terminal which concerns on one Embodiment of this invention. Side surface sectional drawing explaining the process of inserting a covered electric wire in a crimp terminal. Side surface sectional drawing explaining the process of performing a crimping and connecting a crimp terminal and a covered electric wire. Side surface sectional drawing explaining the process of welding a coating | coated part to an electric wire connection part using a resistance heating apparatus. Side surface sectional drawing explaining the process of welding a coating | coated part to an electric wire connection part using a laser processing apparatus. The cross-sectional perspective view and side surface sectional drawing of the crimp terminal which concern on a modification.

  Next, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is an external perspective view and an exploded perspective view showing a configuration of an electric wire with a terminal.

  As shown in FIG. 1, the electric wire with terminal 1 includes a crimp terminal (terminal) 10 and a covered electric wire 50.

  The covered electric wire 50 includes a conductor part 51 and a covering part 52. The conductor 51 is a bundle of a plurality of aluminum strands. Note that the conductor portion 51 may be made of a material other than aluminum (for example, copper) as long as it is a conductor. The covering portion 52 is made of an insulating material such as resin, and is arranged so as to cover the periphery of the conductor portion 51.

  The crimp terminal 10 is a female terminal made of brass or the like whose surface is plated with tin (Sn). In addition, if the crimp terminal 10 is a conductor, you may be comprised from raw materials (for example, aluminum) other than copper. The crimp terminal 10 can be electrically connected to the conductor portion 51 of the covered electric wire 50 and can also be electrically connected to a male terminal (not shown). Other electric wires and electric devices are connected to the male terminal, and thereby electric power or electric signals can be supplied to the electric devices.

  In the following description, as shown in FIG. 1B, the side connected to the male terminal (other terminal, counterpart terminal) is referred to as the tip side, and the side opposite to the insertion direction of the covered electric wire 50 is defined as the base side. It is called the end side.

  Hereinafter, the crimp terminal 10 will be described in detail. The crimp terminal 10 is formed by punching, bending, welding, or the like on a metal plate (plate material). As shown in FIG. 1, the crimp terminal 10 includes a box part (terminal connection part) 20, an electric wire connection part 30, and a transition part 40.

  The box part 20 is a part formed by bending a metal plate into a hollow rectangular parallelepiped shape. As shown in FIG. 2, an elastic contact piece 21 is formed in the box portion 20 by bending a bottom surface portion 22 that is one surface of the box portion 20 inward.

  The elastic contact piece 21 is formed on the distal end side of the box portion 20. The elastic contact piece 21 is configured to be elastically deformable in a direction away from and approaching the bottom surface portion 22. By inserting a male terminal (not shown) into the box portion 20, the elastic contact piece 21 pushed by the male terminal is deformed so as to approach the bottom surface portion 22. And if a male terminal is inserted to the back, a deformation | transformation of the elastic contact piece 21 will return. Thereby, the box part 20 and the male terminal are electrically and mechanically connected.

  The wire connection part 30 is connected to the base end side of the box part 20 via the transition part 40. The electric wire connection part 30 is cylindrical (hollow shape), and the edge part of the base end side of the electric wire connection part 30 is open | released so that the covered electric wire 50 can be inserted (opening part 31). Moreover, the other end (end part on the front end side) of the electric wire connection part 30 is sealed for waterproofing (sealing part 32).

  In the step of forming the wire connection portion 30, first, the metal plate is bent into a circular shape, and the ends are welded with a fiber laser or the like (welding point A in FIG. 1) to form a cylindrical portion. After that, after crushing one end (end portion on the front end side) of this cylindrical portion, the sealing portion 32 is formed by welding so as to close the portion (welding portion B). Here, it can be expressed that the welding location A is formed in parallel with the insertion direction of the covered electric wire 50 (the axial direction of the cylindrical portion). Moreover, the welding location B can be expressed as being formed perpendicular to the insertion direction of the covered electric wire.

  The method for forming the wire connection portion 30 is not limited to the above. For example, the metal plate is first bent to create a cylindrical portion (no welding is performed at this stage), and further one end (end portion on the tip side) May be crushed and then welded together. In this case, since the number of man-hours can be reduced, the cost can be reduced. Moreover, the welding method is also arbitrary, and welding may be performed with the end faces of the metal plates in contact with each other, or welding may be performed with the end portions of the metal plates overlapped. Furthermore, the welding location may not be on the upper surface side (upper side in FIG. 1), but may be on the bottom surface side (lower side in FIG. 1).

  The electric wire connection part 30 is completed by performing the above process. By performing welding on the welding location A as described above, water from the surface of the wire connection portion 30 can be prevented. Moreover, the welding part B is welded as described above to form the sealing portion 32, thereby preventing water from entering between the wire connection portion 30 and the box portion 20. In addition, the method of preventing the flooding from the open part 31 (the flooding from the path | route which passes along the covered electric wire 50) is mentioned later.

  Next, with reference to FIG.2 and FIG.3, the method to manufacture the electric wire 1 with a terminal is demonstrated. FIG. 2 is a side cross-sectional view illustrating a process of inserting the covered electric wire 50 into the crimp terminal 10. FIG. 3 is a side cross-sectional view for explaining the process of connecting the crimp terminal 10 and the covered electric wire 50 by crimping.

  First, the crimp terminal 10 is formed by processing a metal plate as described above. Next, the operator inserts the covered electric wire 50 into the electric wire connecting portion 30 (see FIG. 2A). FIG. 2B shows a state after the covered electric wire 50 is inserted.

  Next, the operator operates the crimping tool composed of the first crimping die 71 and the second crimping die 72 to crimp the wire connecting part 30 so as to sandwich the crimping tool (FIG. 3A). reference). Since the first crimping die 71 has a step, not only the conductor portion 51 but also the covering portion 52 can be strongly crimped. FIG. 3B shows a state after the covered electric wire 50 is crimped.

  Thereby, the crimping | compression-bonding of the conductor part 51 and the electric wire connection part 30 can electrically connect the covered electric wire 50 and the electric wire connection part 30 (crimp terminal 10). Moreover, the crimping | bonding of the coating | coated part 52 and the electric wire connection part 30 can prevent the water immersion (water immersion from the open part 31) from the path | route which carries the covered electric wire 50. FIG.

  Here, in order to compress the covering portion 52 for waterproofing, it is necessary to prevent a gap from being formed between the covering portion 52 and the wire connecting portion 30. Therefore, accuracy is required for the positions where the first crimping die 71 and the second crimping die 72 are crimped and the shapes of the wire connecting portion 30 and the covering portion 52.

  In consideration of these points, in this embodiment, not only the covering portion 52 is compressed, but also the waterproof covering performance is exerted by welding the covering portion 52 after crimping to the wire connecting portion 30. Hereinafter, the process of performing welding will be described.

  First, with reference to FIG. 4, a method of performing welding using the resistance heating device 73 will be described. FIG. 4 is a side cross-sectional view for explaining a process of connecting the covering portion 52 to the electric wire connecting portion 30 using the resistance heating device 73. FIG. 4B is a cross-sectional view taken along the line AA in FIG.

  The resistance heating device 73 is a device that performs heating using Joule heat generated by flowing an electric current. Although the shape of the resistance heating device 73 is arbitrary, it is preferable that the covering portion 52 can be heated uniformly in the circumferential direction. In the example shown in FIG. 4, the resistance heating device 73 is configured in a sheet shape so as to have flexibility, and the wire connection part 30 can be uniformly heated by being wound around the wire connection part 30.

  Instead of this configuration, for example, a resistance heating device 73 that can heat only a part of the peripheral surface of the wire connection portion 30 at a time is used, and the resistance heating device 73 or the wire connection portion 30 is rotated to connect the wire. The structure which heats the part 30 uniformly may be sufficient.

  Thus, the temperature of the surface of the electric wire connection part 30 rises by heating the electric wire connection part 30 first. And if time passes, the temperature inside the electric wire connection part 30 will rise by heat transfer. Thereby, the coating | coated part 52 is heated. And when the temperature inside the electric wire connection part 30 becomes more than melting | fusing point of the coating | coated part 52, the coating | coated part 52 will fuse | melt.

  Thus, in this embodiment, since the electric wire connection part 30 is comprised with the metal, it is excellent in thermal conductivity. Therefore, even if it is a case where it heats from the outer side of the electric wire connection part 30, the coating | coated part 52 can be fuse | melted.

  Next, pressure is applied so as to press the wire connecting portion 30 against the covering portion 52 in a state where the covering portion 52 is melted. Thereby, welding occurs and the resin of the covering portion 52 is connected to the wire connecting portion 30 at the molecular level.

  As shown in FIG. 4B, since both the wire connecting portion 30 and the covering portion 52 have the same shape and a circular cross section, the covering portion 52 is uniformly heated while the covering portion 52 is uniformly heated. be able to.

  Moreover, the method of applying a pressure to the electric wire connection part 30 is arbitrary, For example, the above-mentioned crimping tool or an apparatus similar to it can be used. Moreover, the timing which applies a pressure to the electric wire connection part 30 is arbitrary, may be simultaneous with a heating, and may be after heating and the coating | coated part 52 fuse | melted. Further, it is possible to melt the covering portion 52 before performing the pressure bonding shown in FIG. 3 and perform the pressure bonding of the conductor portion 51 and the welding of the covering portion 52 at a time.

  By performing the welding as described above, no gap is generated between the wire connecting portion 30 and the covering portion 52. Therefore, it is possible to reliably prevent water from entering the route that passes through the covered electric wire 50.

  Moreover, in this embodiment, the conductor part 51 is comprised with aluminum and the crimp terminal 10 is comprised with copper. As described above, when different metals are used for the electric wire connection portion 30 and the conductor portion 51, high waterproof performance is required in order not to cause electrolytic corrosion. In this regard, in the present embodiment, as described above, the welded portions A and B prevent water from entering from the surface of the crimp terminal 10, and also prevent the water from entering the route passing through the covered electric wire 50 by compressing the covering 52. doing. Thus, the structure of this embodiment which waterproofs can reduce cost significantly compared with the structure which block | closes the clearance gap between the electric wire connection part 30 and the box part 20 with a mold resin etc. FIG.

  Next, with reference to FIG. 5, a method for performing welding using the laser processing apparatus 74 will be described. FIG. 5 is a side cross-sectional view for explaining a process of connecting the covering portion 52 to the electric wire connecting portion 30 using the laser processing device 74.

  Although it is the structure which heats the electric wire connection part 30 using Joule heat in the above, it is the structure which heats the electric wire connection part 30 with the laser processing apparatus 74 in this example.

  The laser processing device 74 is configured to emit a laser, and the irradiated portion can be heated by being irradiated with the laser. Since the laser processing device 74 is expensive, it is preferable to irradiate the laser while rotating the wire connection portion 30 or the laser processing device 74 without irradiating the laser around the wire connection portion 30 at once.

  Thereby, the circumference | surroundings of the electric wire connection part 30 can be heated uniformly, and the internal coating | coated part 52 can be fuse | melted uniformly. Then, the coating | coated part 52 can be welded to the electric wire connection part 30 by applying a pressure to the electric wire connection part 30 similarly to the above.

  Next, a modification of the above embodiment will be described with reference to FIG. FIG. 6 is a sectional perspective view and a side sectional view of a crimp terminal according to a modification.

  In the above, no groove or protrusion is formed on the inner wall surface 33 of the electric wire connection portion 30. In this regard, the inner wall surface 33 of the electric wire connection portion 30 of the modified example is formed with a conduction pressing portion 33a including a plurality of rectangular grooves at a position where the conductor portion 51 is crimped. Further, a waterproof compression portion 33b made of an arcuate protrusion is formed on the inner wall surface 33 of the wire connection portion 30 at a position where the covering portion 52 is crimped.

  The conduction pressing portion 33 a is formed to ensure conduction between the electric wire connection portion 30 and the conductor portion 51. That is, when the conductor part 51 is comprised with aluminum, since aluminum has the influence of an oxide film larger than copper, it is possible that electrical conductivity worsens. In this respect, by strongly pressing the conductor portion 51 with the edge of the rectangular groove of the pressing portion 33a for conduction, the oxide film can be broken to ensure conduction. The conduction pressing portion 33a is not limited to a rectangular groove, and may be a groove or a protrusion having another shape.

  The waterproof compression part 33b is formed in order to prevent the water from the opening part 31 more reliably. As described above, in order to improve the waterproof performance, it is preferable to compress the covering portion 52 locally. Therefore, by strongly compressing the covering portion 52 with the arc-shaped protrusions of the waterproof compression portion 33b, the waterproof portion 52 is waterproofed. Performance can be improved. The waterproof compression portion 33b is not limited to the arc-shaped protrusion, and may be a protrusion or groove having another shape.

  As described above, in the modified example, in addition to the improvement of the waterproof property by welding, the waterproof property is improved by the compression of the local covering portion 52, so that it is possible to more reliably prevent water from entering the inside of the wire connecting portion 30. .

  As described above, the terminal-attached electric wire 1 includes the covered electric wire 50, the electric wire connection portion 30, and the box portion 20. The covered electric wire 50 includes a conductor part 51 and a covering part 52. The electric wire connection part 30 has a hollow part, and the conductor part 51 is electrically connected to the inside of the hollow part, and the covering part 52 is connected to the inside of the hollow part by welding. The box part 20 is connected with the electric wire connection part 30, and is connected to another terminal (male terminal).

  Thereby, since the covered electric wire 50 can be stuck to the electric wire connection part 30, the water immersion to the inside of the electric wire connection part 30 can be prevented more reliably.

  Moreover, in the said electric wire 1 with a terminal, it is preferable to set it as the following structures. That is, the wire connection portion 30 is formed with a hollow portion by welding the end portions of the plate members. One end of the electric wire connecting portion 30 is an insertion port for the covered electric wire 50 and the other end is sealed.

  Thereby, by forming a hollow member by welding, a gap can be eliminated and waterproofness can be enhanced. Moreover, waterproofing can be further improved by sealing the other end. Moreover, the insertion port of the covered electric wire 50 has waterproofness by welding the covering portion 52. As described above, it is possible to prevent water from entering the inside of the electric wire connection portion 30.

  In manufacturing the above-described terminal-attached electric wire 1, in the step of welding the covering portion 52 to the electric wire connecting portion 30, the covering portion 52 is attached to the electric wire connecting portion 30 by laser or resistance heating from the outside of the electric wire connecting portion 30. Weld.

  Thereby, welding with the coating | coated part 52 and the electric wire connection part 30 can be performed appropriately according to various conditions. Moreover, since the electric wire connection part 30 is a metal, since heat conductivity is high normally, even if it heats from the outer side of the said electric wire connection part 30, it can weld appropriately.

  The preferred embodiments and modifications of the present invention have been described above, but the above configuration can be modified as follows, for example.

  The welding method and welding location of the crimp terminal 10 may be other than the examples given above. Moreover, the crimp terminal 10 is not restricted to the structure formed from one metal plate. For example, the box part 20 and the electric wire connection part 30 are shape | molded separately, and can also be connected by a suitable connection method (for example, welding).

  The method of connecting the electric wire connection part 30 and the conductor part 51 is not restricted to crimping. For example, ultrasonic welding, resistance welding, soldering, laser welding, or the like can be used. Further, the inner diameter of the wire connecting portion 30 and the outer diameter of the covering portion 52 are made substantially the same, and the wire connecting portion 30 and the covering portion 52 are not pressed after the conductor portion 51 is pressed. The structure which welds may be sufficient.

  The electric wire connecting part 30 is sealed on one side by the sealing part 32, but may have a shape in which both are open.

  Although the example which heats the electric wire connection part 30 with the resistance heating apparatus 73 and the laser processing apparatus 74 was demonstrated above, the electric wire connection part 30 can also be heated using another apparatus. Specific examples include a method of sandwiching the electric wire connection portion 30 with a heating plate, a method of heating using hot air, a method of heating by frictional heat using ultrasonic waves, and the like.

  The crimp terminal 10 can be used as a terminal for connecting single wires (or a single wire and an electric device). Also, a plurality of crimp terminals 10 can be arranged side by side to be a part of the joint connector.

  In the above, the crimp terminal 10 of the female terminal has been described as an example, but the crimp terminal 10 of the present application can also be applied to a male terminal.

  Although the electric wire 1 with a terminal is assumed to be applied to, for example, a wire harness installed in an automobile, it can be used as a part of connectors at various places where waterproofness is required.

1 Electric wire with terminal 10 Crimp terminal (terminal)
20 Box part (terminal connection part)
DESCRIPTION OF SYMBOLS 21 Elastic contact piece 30 Electric wire connection part 31 Opening part 32 Sealing part 33 Inner wall surface 33a Conducting press part 33b Waterproofing compression part 50 Covered electric wire 51 Conductor part 52 Cover part 71 1st crimping type 72 2nd crimping type 73 Resistance heating Equipment 74 Laser processing equipment

Claims (6)

A covered electric wire having a conductor portion and a covering portion;
It has a hollow portion by welding the end portions of the plate material, the conductor portion is electrically connected to the inside of the hollow portion, and the covering portion is welded to the inside of the hollow portion A wire connection portion to be connected;
It is connected with the electric wire connecting part by being composed of the same plate material as the electric wire connecting part, and a terminal connecting part connected to other terminals,
With
As for the said electric wire connection part, one end becomes the insertion port of the said covered electric wire, the other end is sealed, and the said electric wire connection part is welded to the said coating | coated part without passing through another member. An electric wire with a terminal, wherein the insertion opening is waterproof . It is an electric wire with a terminal according to claim 1,
The cross-sectional outline when the covered electric wire is cut by a plane perpendicular to the longitudinal direction is substantially circular,
An electric wire with a terminal, wherein a contour of a cross section when the wire connecting portion is cut by a plane perpendicular to the longitudinal direction is substantially circular. It is an electric wire with a terminal according to claim 1 or 2 ,
The said conductor part is aluminum or copper, The electric wire with a terminal characterized by the above-mentioned. In the method of manufacturing an electric wire with a terminal by inserting and connecting a covered electric wire having a conductor portion and a covering portion to a terminal,
The terminal is
An electric wire connecting portion having a hollow portion by welding the end portions of the plate material ;
It is connected with the electric wire connecting part by being composed of the same plate material as the electric wire connecting part, and a terminal connecting part connected to other terminals,
With
One end of the wire connection part is an insertion port for the covered wire, and the other end is sealed,
An insertion step of inserting the covered electric wire into the hollow portion of the electric wire connecting portion;
A step of electrically connecting the conductor portion to the wire connection portion and waterproofing the insertion port by connecting the wire connection portion to the covering portion without passing through another member by welding,
The manufacturing method of the electric wire with a terminal characterized by the above-mentioned. It is a manufacturing method of the electric wire with a terminal according to claim 4 ,
In the connecting step, the covering portion is welded to the wire connecting portion by laser or resistance heating from the outside of the wire connecting portion. It is a manufacturing method of the electric wire with a terminal according to claim 4 or 5 ,
In the connecting step, the conductor portion is connected to the wire connecting portion using any one of crimping, ultrasonic welding, resistance welding, soldering, and laser welding.

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