JP6549514B2 - Tank manufacturing method - Google Patents

Description

  The present invention relates to a method of manufacturing a tank suitable for storing gas and the like.

  For example, in natural gas vehicles or fuel cell vehicles, tanks for storing fuel gas are used. In this type of tank, a fiber reinforced resin is coated on a liner according to the shape of the tank in order to achieve weight reduction and high strength.

  As a method of manufacturing such a tank, for example, Patent Document 1 proposes a method of manufacturing a tank described below. In this manufacturing method, first, a liner having a cylindrical body portion and dome-shaped side end portions formed on both sides of the body portion is prepared. Next, a filament is wound on the liner to form a first helical layer in which the continuous fiber impregnated with the resin is helically wound. Next, a sheet-like fiber reinforced resin is wound around the surface of the first helical layer to form a hoop layer. Further, a second helical layer is formed by helically winding a continuous fiber impregnated with a resin, in a portion where the first helical layer is exposed from the hoop layer and the hoop layer.

JP, 2010-265931, A

  However, when the hoop layer is formed from a sheet-like fiber reinforced resin, the hoop layer does not cover the dome-shaped side end of the tank (liner) in the manufacturing method shown in Patent Document 1; It can only be molded in a portion corresponding to the tank body.

  Therefore, in order to reinforce the dome-shaped side end of the tank, as shown in Patent Document 1, a thick helical layer (second helical layer) must be formed by the filament winding method, and the tank is manufactured. The time will be longer and the tank production cost will be higher.

  The present invention has been made in view of these points, and it is an object of the present invention to provide a method of manufacturing a tank, which can easily manufacture a tank having an increased strength at the side end.

  In view of the above problems, a method of manufacturing a tank according to the present invention includes: a liner having a cylindrical body portion; and dome-shaped side end portions formed on both sides of the body portion; It is a manufacturing method of a tank in which the covering layer which consists of fiber reinforced resin which covers each side end, and was formed, and is a plurality of 1st reinforcement fibers oriented to the 1st direction, and the 1st reinforcement fiber A sheet made of the fiber reinforced resin including a plurality of second reinforcing fibers oriented in a second direction intersecting the first direction, the first reinforcing fiber having a fiber length longer than the width of the liner Preparing a sheet in which the range in which the second reinforcing fibers are arranged in the sheet corresponds to the width of the body, and the second reinforcing fibers are arranged around the body. And the first reinforcing fiber is on the side Winding the sheet around the body so as to protrude from the part, and a periphery of a cylindrical portion which is on both sides of the sheet wound around the body of the liner and is not in contact with the body. Forming a plurality of small pieces obtained by dividing the cylindrical portion by providing a plurality of notches or notches along the longitudinal direction of the liner in the direction; and bending the plurality of small pieces divided. And a step of attaching the plurality of small pieces to the side end, with the plurality of small pieces following the side end of the liner.

  According to the present invention, the first reinforcing fiber is oriented along the longitudinal direction of the liner to the trunk of the liner by winding a sheet of fiber reinforced resin around the trunk of the liner, and the trunk The second reinforcing fiber can be oriented to wind the section.

  In addition, since only the first reinforcing fiber is oriented along the longitudinal direction of the liner in the cylindrical portions not in contact with the body portions on both sides of the sheet, a plurality of notched portions or circumferential portions of the cylindrical portions It is easy to provide a cut. Thereafter, the plurality of small pieces formed by the notch or the cut can be made to conform to the side end, and the plurality of small pieces can be attached to the side end of the liner. As a result, it is possible to easily manufacture a tank in which a coating layer made of a fiber reinforced resin is formed on a liner from one sheet.

  As a more preferable aspect, in the step of attaching the plurality of small pieces, the notch is provided such that small pieces having a shape corresponding to the surface shape of the side end are formed. According to this aspect, in the step of attaching the plurality of small pieces by forming the small pieces in a shape corresponding to the surface shape of the side end, the plurality of small pieces are made to follow the side ends. As compared with the case where the notches are provided, the overlapping margin between the small pieces can be reduced. As a result, the thickness of the portion where the plurality of small pieces are attached can be made more uniform.

  As a further preferable aspect, after the step of attaching the plurality of small pieces, a continuous fiber impregnated with a resin is wound on a portion to which the small pieces are attached so as to cross the first reinforcing fibers. Do. According to this aspect, it is possible to increase the circumferential strength of this portion by winding the continuous fiber around the portion to which the small piece portion is attached so as to cross the first reinforcing fiber.

  According to the present invention, the covering layer made of fiber reinforced resin, which covers the body of the liner and the side ends on both sides thereof, can be made of a sheet of fiber reinforced resin, A tank with increased strength can be easily manufactured.

It is a typical perspective view of a tank manufactured with a manufacturing method concerning an embodiment of the present invention. It is an AA line arrow directional cross-sectional view of FIG. (A) is a BB arrow directional cross-sectional view of FIG. 2, (b) is the figure which showed the state of the 2nd reinforcement fiber of the cross section shown to (a). It is a schematic perspective view for demonstrating the process of winding a sheet | seat to the fuselage | body part of a liner. FIG. 5 is a schematic perspective view showing a state in which a sheet is wound around a body portion of a liner according to the process shown in FIG. 4; It is a schematic perspective view for demonstrating the process of shape | molding a small piece part by providing a notch part from the state shown in FIG. It is a schematic perspective view for demonstrating the process of affixing a part of small piece part to a side edge part from the state shown in FIG. It is a schematic perspective view for demonstrating the process of shape | molding a small piece part by providing a cut part from the state shown in FIG. It is a schematic perspective view for demonstrating the process of affixing a part of small piece part to a side edge part from the state shown in FIG. It is a schematic perspective view for demonstrating the process of winding a continuous fiber around the side edge part of the tank shown in FIG.

Hereinafter, a method of manufacturing a tank according to an embodiment of the present invention will be described with reference to the drawings.
1. Tank 1 FIG. 1 is a schematic perspective view of the tank 1 manufactured by the manufacturing method according to the embodiment of the present invention, and FIG. 2 is a cross-sectional view taken along line AA of FIG. Fig.3 (a) is a BB arrow directional cross-sectional view of FIG. 2, FIG.3 (b) is a figure which showed the arrangement | positioning state of the 2nd reinforcement fiber 44 of sectional drawing shown to Fig.3 (a). It is. In FIG. 2 and FIG. 3A, the thickness is drawn thicker than the thickness of the covering layer 4 shown in FIG. 1 for the sake of explanation.

  As shown in FIGS. 1 and 2, the tank 1 according to the present embodiment is a tank that contains (fills) high-pressure hydrogen gas of, for example, about 70 MPa. The tank 1 is provided with a liner 2. The liner 2 has substantially the same shape as the tank 1, and includes a cylindrical body portion 21 and dome-shaped side end portions 22 formed on both sides of the body portion 21. A storage space S for storing high pressure hydrogen gas is formed inside the liner 2.

  The material of the liner 2 is polyester resin, polypropylene resin, nylon resin (for example, 6-nylon resin or 6,6-nylon resin), polyamide resin, polycarbonate resin, acrylic resin, or ABS resin, etc. Thermoplastic resins can be mentioned. Also, the other may be metal such as aluminum alloy, stainless steel and the like. By using such a material, it is possible to prevent permeation of the hydrogen gas stored in the storage space S.

  In the present embodiment, the caps 3 are attached to both sides of the liner 2 in such a manner that the side ends 22 of the liner 2 are folded back to the accommodation space S side. A tubular portion 31 is formed in each cap 3, and a through hole 32 is formed in the tubular portion 31.

  When the tank 1 is used, the through hole 32 formed in one of the mouthpieces 3 is sealed, and the supply of hydrogen gas to the containing space S and the discharging from the containing space S are performed from the other through hole 32. . The material of the die 3 is made of a metal such as an aluminum alloy, but may alternatively be the thermoplastic resin exemplified for the material of the liner 2.

  A cover layer 4 made of a fiber reinforced resin is formed on the surface of the liner 2 and the pair of the caps 3, 3 so as to cover them. Specifically, as shown in FIG. 2, the covering layer 4 is a sheet-like layer, and is formed on the body portion 21 of the liner 2, the side ends 22 and 22 on both sides thereof, and each side end 22. These surfaces are coated over the mounted caps 3,3. More specifically, the covering layer 4 includes a first reinforcing portion 41 covering the body portion 21 and a second reinforcing portion 42 covering the side end 22 and the mouthpiece 3 on both sides of the first reinforcing portion 41; It consists of

  The first reinforcing portion 41 that covers the body portion 21 is a portion in which a part of the covering layer 4 made of a fiber reinforced resin circulates (rolls) a plurality of times around the axial center CL. As described above, by providing one sheet-like covering layer 4 which is circulated a plurality of times in the body portion 21 of the liner 2, the tank 1 has a cross section orthogonal to the axial center CL (ie, the longitudinal direction of the body portion 21 (A cross section perpendicular to the above) can have more uniform pressure resistance.

  The covering layer 4 is a sheet-like layer in which reinforcing fibers are impregnated with a thermoplastic resin or a thermosetting resin. The reinforcing fibers may be staple fibers, long fibers, continuous fibers (continuous reinforcing fibers), or cloth fibers, but in the present embodiment, the reinforcing fibers of the covering layer 4 have an axial center CL of the trunk portion 21. (I.e., the longitudinal direction of the body portion 21), and the second reinforcement fibers 44 which orbit the body portion 21. As shown in FIG.

  As apparent from the manufacturing method to be described later, a part of the first reinforcing fibers 43 includes continuous reinforcing fibers disposed across the both ends of the tank 1. On the other hand, as shown in FIG. 3 (b), the second reinforcing fibers 44 are continuous reinforcing fibers wound along the circumferential direction of the body portion 21, and the plurality of second reinforcing fibers 44 are of the body portion 21. They are arranged in parallel across the width.

  More specifically, the second reinforcing fiber 44 continuously revolves around the axial center CL of the trunk 21 a plurality of times in a cross section orthogonal to the axial center CL of the trunk 21. That is, the winding direction of the second reinforcing fiber 44 matches the winding direction of the sheet 4A described later.

  As a result, the second reinforcing fiber 44 continuously circulates a plurality of times in the direction in which hoop stress acts on the body portion 11 by the internal pressure of the tank 1 in the body portion 11 of the tank 1. The strength of the body portion 11 can be increased.

  Here, as the first reinforcing fiber 43 and the second reinforcing fiber 44, fibers such as glass fiber, carbon fiber, aramid fiber, alumina fiber, boron fiber, steel fiber, PBO fiber, natural fiber, or high-strength polyethylene fiber are mentioned. be able to.

  When resin contained in the coating layer 4 is a thermoplastic resin, the thermoplastic resin illustrated by the material of the liner 2 mentioned above can be mentioned. When the resin contained in the covering layer 4 is a thermosetting resin, for example, an epoxy resin, a modified epoxy resin represented by a vinyl ester resin, a phenol resin, a melamine resin, a urea resin, an unsaturated polyester resin, an alkyd resin And polyurethane resins and thermosetting polyimide resins.

2. About the manufacturing method of the tank 1 Below, the manufacturing method of the tank 1 shown in FIG. 1 is demonstrated, referring FIGS. 4-7.
First, as shown in FIG. 4, a plurality of parallel first reinforcing fibers 43 are oriented in the width direction (first direction) of the sheet 4A, and a plurality of parallel second reinforcing fibers are intersected with them. A sheet 4A made of a fiber reinforced resin is prepared in which 44 is oriented in the longitudinal direction (second direction) of the sheet 4A. The sheet 4 </ b> A wound around the liner 2 becomes a part of the covering layer 4 made of a fiber reinforced resin composed of the first reinforcing portion 41 and the second reinforcing portion 42 after the tank 1 is manufactured. The width L1 of the sheet 4A is longer than the width (width length) L2 of the liner 2, and the tip of the small-piece portion 42B matches the end of the mouthpiece 3 when the small-piece portion 42B described later conforms to the side end 22. It is the length to do. The sheet 4A includes the first reinforcing fiber 43 and the second reinforcing fiber 44 described above, and the reinforcing fiber is impregnated with a resin.

  More specifically, the first reinforcing fibers 43 are disposed in the sheet 4A, and have a fiber length longer than the width (width length) L2 of the liner 2. The fiber length of the first reinforcing fiber 43 matches the width L1 of the sheet 4A. The second reinforcing fibers 44 extend in parallel in the longitudinal direction of the sheet 4A (in the direction of winding around the body portion 21) and appear at an equal pitch in the width direction of the body portion 21 when wound around the body portion 21. It is provided. Further, the range in which the plurality of second reinforcing fibers 44 are disposed in the sheet 4A is substantially the range corresponding to the width of the body portion 21 and is shifted to the middle in the width direction of the sheet 4A. In the present embodiment, an example in which the first reinforcing fiber 43 and the second reinforcing fiber 44 are orthogonal to each other is shown, but it is not necessary to be necessarily orthogonal to each other, and the other intersects with one at a predetermined angle. It may be something.

  Next, while rotating the liner 2 around the axial center CL, from the direction orthogonal to the axial center CL of the trunk portion 21 of the liner 2, a sheet of fiber reinforced resin is formed on the outer peripheral surface of the trunk portion 21 of the liner 2 The sheet 4A is wound several times.

  Specifically, the first reinforcing fibers 43 having a fiber length longer than the width (width length) L2 of the liner 2 are arranged along the longitudinal direction of the liner 2 so as to protrude from the side ends 22, The sheet 4A is wound around the body portion 21 so that the second reinforcing fiber 44 of the book is disposed in a range corresponding to the width of the body portion 21. The longitudinal direction of the liner 2 is a direction from one side end 22 to the other side end 22.

  Thereby, as shown in FIG. 5, the first reinforcing portion 41 is formed in the body portion 21, and the cylindrical portions 42A and 42A in which only the first reinforcing fiber 43 is oriented are formed on both sides of the first reinforcing portion 41. can do. That is, the cylindrical portion 42A is a portion located on both sides of the sheet 4A wound around the body portion 21 and not in contact with the body portion 21.

  When the resin impregnated in the sheet 4A is a thermoplastic resin, the sheet 4A is heated by the heater to a temperature higher than the softening point of the thermoplastic resin. In a state in which the thermoplastic resin of the heated sheet 4A is melted, the sheet 4A is wound around the liner 2 (the body portion 21) a plurality of times. The sheet 4A in the wound state may be cooled by standing to cool or forced cooling, and the temperature of the thermoplastic resin may be made lower than the softening point to solidify the thermoplastic resin, which is solidified after the process shown in FIG. You may

  On the other hand, when the resin impregnated in the sheet 4A is a thermosetting resin, the sheet 4A is wound around (the body 21 of the liner 2), and at this time, the sheet 4A is not heated and the thermosetting resin is not cured. .

  Next, a plurality of notches 46 are provided on each cylindrical portion 42A shown in FIG. 5 along the longitudinal direction of the liner 2 using a cutting tool (not shown) in the circumferential direction of the cylindrical portion 42A (see FIG. 6). Specifically, in the present embodiment, a plurality of notches 46 having the same shape are provided at equal intervals in the circumferential direction of the cylindrical portion 42A. Since only the first reinforcing fiber 43 is oriented in the longitudinal direction of the liner 2 in the tubular portion 42A, a plurality of notches along the longitudinal direction of the liner 2 in the circumferential direction of the tubular portion 42A It is easy to provide the part 46.

  In this manner, as shown in FIG. 6, by forming the plurality of notches 46 in the cylindrical portion 42A, a plurality of small pieces 42B, 42B,... Obtained by dividing the cylindrical portion 42A are formed. More specifically, in the present embodiment, the plurality of notch portions 46 are formed in the cylindrical portion 42A so that a plurality of small pieces 42B, 42B, ... having a shape corresponding to the surface shape of the side end 22 are formed. Provide

  Here, in the present embodiment, “the shape of the small piece 42B according to the surface shape of the side end 22” refers to the small piece 42B, when the small piece 42B is bent to conform to the side end 22, A shape in which the overlapping margin (overlapping width) of 42B is constant (width) along the longitudinal direction, or there is no overlapping margin of the small pieces 42B and 42B, and the edges of the small fragments 42B and 42B contact each other, It says the thing of the shape which can cover side end 22 uniformly.

  Next, as shown in FIG. 7, the plurality of small pieces 42 B, 42 B,... Are bent inward so as to be affixed to the respective side ends 22, and the plurality of small pieces 42 B, 42 B,. To imitate. Thereby, as shown in FIG. 1, the second reinforcing portion 42 can be formed in the tank 1. In this embodiment, with the plurality of small pieces 42B, 42B,... Following the side end portions 22, adjacent small pieces 42B, 42B are attached side by side without overlapping each other. The plurality of small pieces 42B may be in contact with the side end 22 and attached thereto, and may be bonded to the side end 22 with an adhesive or the like as needed.

  In the present embodiment, as described above, the small piece portion 42B having a shape corresponding to the surface shape of the side end portion 22 is formed. Thereby, when making a plurality of small pieces 42B, 42B,... Conform to the side end 22, the overlapping margin of the small pieces 42B, 42B is made to be a fixed width as compared with the case where the incision 47 described later is provided. Can be reduced, or the overlap can be eliminated. As a result, the thickness of the second reinforcing portion 42 can be made more uniform. Moreover, the level | step difference of the surface of the 2nd reinforcement part 42 by the overlap of the small piece part 42B can be suppressed.

  Here, when the resin impregnated in the sheet 4A is a thermoplastic resin, the sheet 4A is heated as necessary to soften the thermoplastic resin, and the plurality of small pieces 42B, 42B,... The side edge 22 of 2 is copied. Thereafter, the sheet 4A is cooled to solidify the thermoplastic resin.

  On the other hand, when the resin impregnated in the sheet 4A is a thermosetting resin, the sheet 4A is heated after the plurality of small pieces 42B, 42B,. This cures the thermosetting resin.

  As described above, in the present embodiment, the sheet 4A made of fiber reinforced resin can be wound from the body 21 to the side end 22 of the liner 2 to form the covering layer 4 made of fiber reinforced resin. . As a result, the tank 1 can be manufactured with the strength of the side end 12 enhanced at a low cost and in a short time by reinforcing the side end 22 of the liner 2 only by the filament winding method (FIG. 1). reference).

  Further, in the present embodiment, as shown in FIG. 4, one sheet 4 </ b> A is wound around the body portion 21 of the liner 2. Thereby, the first reinforcing portion 41 in which the first reinforcing fiber 43 is oriented in the longitudinal direction of the body portion 21 and in which the second reinforcing fiber 44 is oriented so as to go around the body portion 21 is simply formed. Can.

  On the other hand, since it is possible to bend and orient the first reinforcing fiber 43 along the longitudinal direction across the tank 1 on both sides of the second reinforcing portion 42, the strength of the side end 12 of the tank 1 is increased. Can.

  Here, in the embodiment described above, the notch 46 shown in FIG. 6 is provided to the cylindrical portion 42A shown in FIG. 5, but for example, as shown in FIG. The part 47 may be provided. Specifically, with respect to the cylindrical portion 42A shown in FIG. 5, a cutting portion 47 along the longitudinal direction of the liner 2 is used in a circumferential direction of the cylindrical portion 42A using a cutter (not shown) such as a cutter. More than one. Specifically, in the present embodiment, the notches 47 are provided at equal intervals in the circumferential direction of the cylindrical portion 42A.

  Since the cut portion 47 is a linear slit along the longitudinal direction of the liner 2 and only the first reinforcing fiber 43 is oriented in the cylindrical portion 42A, a plurality of slits 47 are formed in the circumferential direction of the cylindrical portion 42A. The notches 47 can be easily provided.

  In this manner, as shown in FIG. 8, by forming a plurality of cut portions 47, 47 in the cylindrical portion 42A, a plurality of small pieces 42C, 42C,. In the present embodiment, since the notches 47 are provided at equal intervals in the circumferential direction of the cylindrical portion 42A, a plurality of small-piece portions 42C of equal widths can be formed.

  Next, as shown in FIG. 9, a plurality of small pieces 42C, 42C,... Are bent so as to be attached to each side end 22, and a plurality of small pieces 42B, 42B,. At the same time, the second reinforcing portion 42 is formed. In a state in which the plurality of small pieces 42C, 42C,... Are copied to each side end 22, parts of the adjacent small pieces 42B, 42B overlap with each other at the same overlapping margin.

  In the present embodiment, since the small-piece portion 42C is formed by providing the cut portion 47 in the cylindrical portion 42A, the first reinforcing fiber 43 of the cylindrical portion 42A is not cut, and extends across the tank 1 The first reinforcing fibers 43 can be oriented.

  Further, as shown in FIG. 10, if necessary, to the tank 1 shown in FIG. 1, after the step of forming the second reinforcing portion 42 (the step of attaching the plurality of small pieces 42B), the first reinforcement The continuous fiber 5 impregnated with the resin may be wound around the second reinforcing portion 42 (the portion to which the small piece portion is attached) by hoop winding so as to cross the fiber 43. Specifically, the continuous fiber 5 is wound around the second reinforcing portion 42 so as to be orthogonal to the first reinforcing fiber 43 oriented in the second reinforcing portion 42. Thereby, the strength in the circumferential direction of the second reinforcing portion 42 can be enhanced by the continuous fibers 5 wound around the second reinforcing portion 42 so as to be orthogonal to the first reinforcing fibers 43 of the second reinforcing portion 42. In the present embodiment, an example is shown in which the first reinforcing fiber 43 of the second reinforcing portion 42 and the continuous fiber 5 are orthogonal to each other, but it is not necessary that the first reinforcing fiber 43 and the continuous fiber 5 are orthogonal to each other. You may cross it.

  When the resin impregnated in the continuous fiber 5 is a thermoplastic resin, the continuous fiber 5 is wound while heating the thermoplastic resin in a softened state. On the other hand, when the resin impregnated in the continuous fiber 5 is a thermosetting resin, after winding the continuous fiber 5, the (uncured) thermosetting resin is heated to cure it. In this manner, as shown in FIG. 10, the tank 1 can be manufactured in which the side end 12 of the tank 1 is further partially reinforced.

  In the present embodiment, as described above, since the small-piece portion 42B having a shape corresponding to the surface shape of the side end portion 22 is formed to suppress the step on the surface of the second reinforcing portion 42, the wound continuous fibers 5 and the second It is difficult to form a void due to a step or the like between the reinforcing portion 42 and the like, and a decrease in the strength of the tank 1 can be suppressed.

  As mentioned above, although the embodiment of the present invention has been described in detail, the specific configuration is not limited to this embodiment, and even if there is a design change without departing from the scope of the present invention, they are It is included in the invention.

  In the present embodiment, the body portion of the liner is cylindrical, but by covering the side end portion with the small piece portion, it is possible to form the first and second reinforcing portions from one sheet. The body portion of the liner may be cylindrical such that the cross section orthogonal to the longitudinal direction is polygonal or elliptical.

1: Tank 11, 11: side end, 2: liner, 21: body, 22: side end, 3: mouthpiece, 31: tubular, 32: through hole, 4: coating layer, 4A A: sheet, 41: first reinforcing portion, 42: second reinforcing portion, 42A: tubular portion, 42B, 42C: small piece portion, 43: first reinforcing fiber, 44: second reinforcing fiber, 46: notch portion, 47: notched part, 5: continuous fiber, CL: axial center, S: accommodation space

Claims (3)

A liner having a cylindrical body portion and dome-shaped side ends formed on both sides of the body portion;
A manufacturing method of a tank in which a covering layer made of a fiber reinforced resin for covering the body part and the side end parts is formed,
The fiber reinforced resin, comprising: a plurality of first reinforcing fibers oriented in a first direction; and a plurality of second reinforcing fibers oriented in a second direction intersecting the first direction of the first reinforcing fibers The first reinforcing fibers having a fiber length longer than the width of the liner are disposed in the sheet, and the range in which the second reinforcing fibers are disposed in the sheet is the width of the body portion. Preparing a sheet corresponding to the length;
Winding the sheet around the body such that the second reinforcing fibers are wound around the body, and the first reinforcing fibers protrude from the side end;
Notches or notches along the longitudinal direction of the liner on both sides of the sheet wound around the body of the liner and not in contact with the body. Forming a plurality of small pieces obtained by dividing the cylindrical portion by providing a plurality of pieces;
The method may further include the steps of: bending the plurality of divided small pieces; making the plurality of small pieces follow the side end of the liner; and bonding the plurality of small pieces to the side end. How to make a tank.   The tank according to claim 1, wherein the notch is provided such that small pieces having a shape corresponding to the surface shape of the side end are formed in the step of attaching the plurality of small pieces. Manufacturing method.   After the step of attaching the plurality of small pieces, a continuous fiber impregnated with a resin is wound around the portion to which the small pieces are attached so as to cross the first reinforcing fibers. The manufacturing method of the tank of Claim 1 or 2.

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