JP6592917B2 - Melamine decorative material and method for producing melamine decorative material - Google Patents

Description

  The present invention relates to a melamine decorative material and a method for producing a melamine decorative material.

  Melamine decorative material is a decorative material that uses melamine resin for the surface layer. From the characteristics of melamine resin, it has high surface hardness, abrasion resistance, heat resistance, hot water resistance, contamination resistance, boiling resistance, light resistance, etc. Excellent durability. On the other hand, since the melamine resin has a high refractive index, there is a problem that the cosmetic pattern cannot be clearly expressed and fingerprints are easily noticeable as compared with a cosmetic material made of a resin having a lower refractive index than the melamine resin.

  In order to solve such a problem, a cosmetic material in which a layer made of a material having a lower refractive index than that of the melamine resin is provided on the melamine resin layer has been proposed (for example, see Patent Document 1). . In this way, by providing a layer made of a material having a low refractive index on the melamine resin layer, the cosmetic pattern can be clearly expressed and the fingerprint can be made inconspicuous.

  However, when a layer made of a material having a low refractive index is provided on the melamine resin layer, the melamine resin is not exposed on the surface, so that the above-mentioned characteristics of the melamine resin cannot be obtained. It was.

JP 2009-233878 A

  An object of the present invention is to provide a melamine decorative material that is less noticeable and has excellent durability, and a method for manufacturing a melamine decorative material capable of easily manufacturing such a melamine decorative material. .

Such an object is achieved by the present inventions (1) to (3) below.
(1) having a surface layer composed of a material containing a melamine resin,
On the outer surface of the surface layer, irregularities having an arithmetic average roughness (Ra) represented by JIS B 0601 of 5 μm or more and 15 μm or less are formed,
A melamine cosmetic material having a surface area ratio (A) represented by the following formula (1) of 10 or more and 20 or less .
Surface area ratio (A) = SA / UA (1)
(SA indicates the surface area of an arbitrary region of the outer surface of the surface layer, and UA indicates the area of the arbitrary region of the outer surface of the surface layer when viewed in plan.)

(2) The melamine decorative material according to (1), wherein the average thickness is 0.4 mm or less.
(3) The method for producing a melamine decorative material according to (1) or (2) above,
Forming a melamine resin layer containing the melamine resin;
By pressing the melamine resin layer while heating it with a saddle-shaped material, the outer surface has an arithmetic mean roughness (Ra) represented by JIS B 0601 of 5 μm or more and 15 μm or less , and method for producing a melamine decorative material characterized by having the steps of forming the surface layer area ratio as Table (a) satisfies the 20 following relationship 10 or by the formula (1).

  ADVANTAGE OF THE INVENTION According to this invention, while the fingerprint etc. are not conspicuous, the melamine decorative material excellent in durability, and such a melamine decorative material can be provided.

  Moreover, the manufacturing method of the melamine decorative material which can manufacture such a melamine decorative material easily can be provided.

It is sectional drawing which shows suitable embodiment of the melamine decorative material of this invention. It is process drawing which showed an example of the manufacturing method of the melamine decorative material of this invention.

Hereinafter, the present invention will be described in detail based on preferred embodiments shown in the accompanying drawings.
《Melamine cosmetics》
First, a preferred embodiment of the melamine decorative material of the present invention will be described.

  The melamine decorative material of the present invention can give aesthetics and a high-class feeling by being attached to a building wall, interiors such as elevators and train cars, furniture such as desks and bookshelves.

FIG. 1 is a cross-sectional view showing a preferred embodiment of the melamine decorative material of the present invention.
As shown in FIG. 1, the melamine decorative material 100 is composed of a laminate in which a surface layer 11 and a base material layer 12 are laminated.

Hereinafter, each layer will be described in detail.
<1. Surface layer>
The surface layer 11 is a layer that contributes to design and aesthetics, and is obtained by impregnating a surface layer base material such as decorative paper with a melamine resin and drying it.

  The surface layer 11 has irregularities with an arithmetic mean roughness (Ra) represented by JIS B 0601 of 5 μm or more formed on the outer surface, and a surface area ratio (A ) Is 10 or more.

Surface area ratio (A) = SA / UA (1)
(SA indicates the surface area of an arbitrary region of the outer surface of the surface layer, and UA indicates the area of the arbitrary region of the outer surface of the surface layer when viewed in plan.)

  By the way, since the melamine resin has a relatively high refractive index of 1.6 to 1.7, reflected light on the surface of the decorative material increases. As a result, incident light to the interior of the decorative material is reduced, and reflected light from the decorative pattern (color information perceived by humans) is reduced, which causes a problem that the decorative pattern cannot be expressed clearly. In addition, the refractive index of the oil / fat component, which is a cause of fingerprints, is about 1.5, and the reflectance is low. In addition, due to the uneven shape of the attached oil / fat component, the fingerprints and the like are conspicuous.

  On the other hand, the melamine decorative material of the present invention is characterized in that it has an outer surface (design surface) that satisfies the above-described relationship. In other words, the outer surface of the melamine decorative material of the present invention has relatively steep irregularities that satisfy the above relationship. By having such characteristics, even when the outer surface is touched with a finger or the like, the contact area between the finger or the like and the outer surface can be reduced, and adhesion of dirt such as a fingerprint is suppressed. be able to. Furthermore, since the melamine resin is exposed on the outer surface of the melamine decorative material, the melamine decorative material has high surface hardness, abrasion resistance, heat resistance, hot water resistance, stain resistance, boiling resistance, light resistance, etc. The durability can be effectively exhibited.

  In the present invention, the arithmetic average roughness (Ra) represented by JIS B 0601 on the outer surface is 5 μm or more, more preferably 15 μm or less. Thereby, the effect of this invention can be made more remarkable.

  Moreover, in this invention, although the surface area ratio (A) represented by the said Formula (1) is 10 or more, it is more preferable that it is 10 or more and 20 or less. Thereby, the effect of this invention can be made more remarkable.

  The melamine resin is not particularly limited, and for example, a resin obtained by reacting melamine and formaldehyde in a neutral or weak alkali can be used.

  The reaction molar ratio of formaldehyde to melamine (the value of (molar amount of formaldehyde) / (molar amount of melamine), hereinafter may be simply referred to as “reaction molar ratio”) is not particularly limited. -4.0, preferably 1.0-2.0, more preferably 1.1-1.8, and those obtained by reaction can be suitably used. When the reaction molar ratio is less than the lower limit, unreacted components may increase, resulting in a decrease in storage stability and cost. Moreover, when the said upper limit is exceeded, the resin flexibility fall after hardening may become remarkable. In addition, as a melamine resin, what is contained individually by 1 type can also be used, and what mixed and contained 2 or more types of melamine resins from which a reaction molar ratio, a weight average molecular weight, etc. differ can also be used.

  Moreover, as a melamine resin, a commercially available thing, such as a melamine resin by Sumitomo Chemical Co., Ltd., can also be used.

  Although the weight average molecular weight of a melamine resin is not specifically limited, It is preferable that it is 200-500, and it is more preferable that it is 250-350. When the molecular weight is smaller than the lower limit, the amount of unreacted components increases, and the storage stability may decrease. Moreover, when larger than the said upper limit, the impregnation property to a base material may fall. The weight average molecular weight can be measured, for example, by GPC (gel permeation chromatography, standard substance: converted to polystyrene).

  The surface layer substrate is a sheet-like substrate on which a design surface is formed. The material of the surface layer substrate is not particularly limited, and for example, pulp, linter, synthetic fiber, glass fiber, or the like can be used. Further, if necessary, titanium oxide-containing decorative paper containing a pigment such as titanium oxide can be used.

Although the basic weight of a surface layer base material is not specifically limited, It is preferable that it is 40-150 g / m < ² >. When the basis weight is less than the lower limit, coating treatment is difficult due to problems of cutting and wrinkling in the resin impregnation step. On the other hand, when the basis weight exceeds the above upper limit, the impregnation amount of the resin carried by the surface layer base material becomes uneven, which reduces the flexibility of the melamine decorative material 100 and causes a decrease in productivity and cost. There is a case.

<2. Base material layer>
The base material layer 12 is a layer that supports the surface layer 11, and is bonded to the surface side opposite to the design surface of the surface layer 11.

  Examples of the base material layer 12 include various metal sheets (including metal foils and metal plates), various resin sheets (including resin plates), various cloths, various papers, various wooden boards, plaster boards, and the like, and composites thereof. And laminates.

  As a constituent material of various metal sheets, aluminum, iron, nickel, copper, magnesium, zinc etc. are mentioned, for example, Among these, it can use 1 type or in combination of 2 or more types.

  In addition, the metal sheet may be a sheet-like base material made of a material other than a metal material and the like plated with the metal material.

  The constituent materials of various resins include phenolic resin, epoxy resin, melamine resin, diallyl phthalate resin, urea resin, unsaturated polyester resin, alkyd resin, polyurethane, thermosetting polyimide, thermosetting resin, acrylic resin, polycarbonate, Examples thereof include thermoplastic resins such as polyethylene, polypropylene, polystyrene, polyvinyl acetate, polyolefin, and polyvinyl chloride, and one or more of these can be used in combination.

  Examples of the various papers include kraft paper, cotton linter paper, paper base materials mainly composed of linter and kraft pulp mixed paper, and the like. Further, these paper base materials may be used alone as the base material layer 12, resin impregnated paper obtained by impregnating these paper base materials with resin, titanium oxide-containing paper containing a pigment such as titanium oxide, or the like. May be used as the base material layer 12.

  As various kinds of cloth, a woven cloth or a non-woven cloth obtained by collecting a large number of fibers and processing them into a thin plate shape can be used.

  The fibers are not particularly limited, and examples thereof include inorganic fibers such as alumina fibers, silica fibers, and glass fibers, and chemically synthetic fibers such as cellulose fibers, polyolefin fibers, polyester fibers, and aramid fibers.

  Moreover, as various cloth, what made resin, a pigment, etc. contain in a woven fabric, a nonwoven fabric, etc. may be sufficient.

  Among the above-described materials, as the base material layer 12, it is particularly preferable to use a material made of cloth (glass cloth) made of glass fibers or a prepreg based on glass cloth. Thereby, heat resistance, nonflammability, rigidity, etc. can be provided to the melamine decorative material 100.

  Moreover, as glass which comprises a glass cloth, E glass, C glass, A glass, S glass, D glass, NE glass, T glass, H glass etc. are mentioned, for example. Among these, T glass is preferable. Thereby, the thermal expansion coefficient of a glass cloth can be made small.

The weight of the glass cloth is not particularly limited, but if it is necessary to satisfy the “combustible cracks / penetration after combustion” requirement of Article 2-9 of the Building Standards Act The basis weight is preferably 100 g / m ² or more. Moreover, although the upper limit of a weight does not require a restriction | limiting especially, the basic weight of 250 g / m < ² > or less is preferable from the surface of material cost and workability.

  The prepreg is not particularly limited, and for example, the prepreg may be obtained by impregnating the above-mentioned glass cloth with a resin composition containing a thermoplastic resin, a thermosetting resin, or the like.

  The content of the resin composition contained in the prepreg is not particularly limited as long as the interlayer adhesion strength with the surface layer 11 is sufficient for forming the melamine decorative material 100, but the resin composition is a thermoplastic resin. Is used, the prepreg preferably contains 1% by mass or more and 20% by mass or less, and more preferably 1% by mass or more and 10% by mass or less. Moreover, when using a thermosetting resin as a resin composition, it is preferable to contain 1 mass% or more and 20 mass% or less by solid content in a prepreg, and it is more preferable to contain 2 mass% or more and 10 mass% or less. preferable. Thereby, the interlayer adhesive strength of the surface layer 11 and the base material layer 12 can be improved.

  The thermoplastic resin is not particularly limited, and examples thereof include an acrylic resin, a urethane resin, an ethylene vinyl acetate resin, and a styrene butadiene rubber (SBR). Among these, it is preferable to use an acrylic resin and / or a urethane resin.

  The thermosetting resin is not particularly limited, and examples thereof include phenol resin, epoxy resin, oxetane resin, (meth) acrylate resin, unsaturated polyester resin, diallyl phthalate resin, urea resin, and maleimide resin. Among these, a phenol resin is preferable from the viewpoint of nonflammability, heat resistance, and adhesion. These resins can be used alone or in combination.

  The prepreg can be produced by a conventionally known method. For example, the prepreg can be obtained by impregnating a glass cloth similar to the glass cloth described above with a varnish obtained by dissolving the resin composition in a solvent and drying the glass cloth.

  The thickness of the base material layer 12 is preferably 100 μm or more. Thereby, sufficient heat resistance and nonflammability can be imparted to the melamine decorative material 100. Further, the upper limit of the thickness is not particularly limited, but the thickness and weight of the melamine decorative material 100 increase as the thickness increases, and the cost also increases. Therefore, the upper limit of the thickness is set within an allowable range in designing the final product. The thickness is preferably 350 μm or less.

  In addition, between the surface layer 11 and the base material layer 12, you may have an intermediate | middle layer which joins these. The material constituting the intermediate layer is not particularly limited, but it is preferable to use a thermoplastic resin. The thermoplastic resin may be in the form of particles, bulk, or a combination thereof, but is preferably included in the form of particles. In addition, particulate thermoplastic resin (thermoplastic resin particles) can be easily obtained by using a thermoplastic emulsion resin (resin varnish) in which the thermoplastic resin is dispersed in a solvent to form an emulsion and drying it. And it can be obtained reliably.

  The thermoplastic emulsion resin contains components present as thermoplastic resin particles, has adhesive properties with metals and various materials, and imparts flexibility to the melamine decorative material 100. As a result, the bending workability of the melamine decorative material 100 can be improved.

  The thermoplastic resin is not particularly limited, and examples thereof include acrylic resins, urethane resins, vinyl acetate copolymers, urethane acrylic composite resins, styrene butadiene rubber (SBR), and nitrile rubber (NBR). Among these, urethane acrylic composite particles are preferable. In the present specification, the urethane acrylic composite resin means one having a different phase structure of an acrylic resin and a urethane resin in a single particle. In the present specification, “heterophasic structure” means a structure in which a plurality of phases composed of different types of resins are present in one particle, and examples thereof include a core-shell structure, a localized structure, and a sea-island structure. It is done.

  The melamine decorative material 100 as described above can be bent with a minimum bending radius of 10 mmR or less at normal temperature (usually about 20 to 30 ° C.), but is not particularly limited. The minimum bend radius R is the minimum at which 100% non-defective product can be obtained without causing defects such as cracking even if the room temperature bending process is repeatedly performed in one direction along a mold having a curved portion with a radius R. Means the radius R of the mold.

  Moreover, it is preferable that the whole thickness of the melamine decorative material 100 is 0.4 mm or less. Thereby, the melamine decorative material 100 can perform a bending process more easily.

<Method for producing melamine cosmetic material>
Next, the manufacturing method of the melamine decorative material mentioned above is demonstrated.

FIG. 2 is a process diagram showing an example of a method for producing a melamine decorative material of the present invention.
First, as shown to Fig.2 (a), the melamine resin layer 11 'which impregnated the surface layer base material with the melamine resin is prepared. In addition, you may impregnate the solid content of a thermoplastic emulsion resin in the surface opposite to the design surface side of melamine resin layer 11 '.

  The method for impregnating the surface layer base material with the melamine resin is not particularly limited. For example, a resin varnish obtained by dissolving the resin in a solvent is used, for example, a known device such as a spray device, a shower device, a kiss coater, or a comma coater. The method etc. which heat-dry at about 80-130 degreeC after coating are mentioned.

  Next, a base material layer forming material 12 ′ for forming the base material layer is prepared and superposed so that the melamine resin layer 11 ′ and the base material layer forming material 12 ′ are in contact with each other (see FIG. 2B). .

On the other hand, a saddle material is prepared.
As a saddle type material, for example, a metal plate made of a metal such as aluminum, iron or SUS, a film made of a metal plate and a plastic such as polyethylene, polypropylene or PET, or a film made of a metal such as aluminum or iron And those composed of a resin plate having a melamine resin layer on the outermost surface and the film.

  Next, the melamine resin layer 11 ′ and the base material layer forming material 12 ′ are pressurized using a saddle type material while being heated. Accordingly, the outer surface has irregularities having an arithmetic average roughness (Ra) represented by JIS B 0601 of 5 μm or more, and the surface area ratio (A) represented by the above-described formula (1) is 10 or more. A surface layer 11 satisfying the relationship is formed, and a melamine decorative material 100 as shown in FIG. 1 is obtained.

  The conditions for heating and pressurizing (hot pressing) the melamine resin layer 11 ′ and the base material layer forming material 12 ′ are not particularly limited, but are preferably performed at a heating temperature of 130 to 150 ° C. and a pressure of 1 to 8 MPa. The time for thermocompression bonding is preferably 10 to 90 minutes.

As mentioned above, although preferred embodiment of the melamine decorative material of this invention was described, this invention is not limited to this.
For example, the base material layer 12 may not be present in the melamine decorative material of the present invention.

  EXAMPLES Hereinafter, although this invention is demonstrated in detail based on an Example and a comparative example, this invention is not limited to this.

1. Production of melamine cosmetic material (Example 1)
Using a titanium oxide-containing decorative paper (Dai Nippon Printing Co., Ltd.) having a basis weight of 80 g / m ² as the surface layer base material, an emulsion of urethane acrylic composite particles on the side opposite to the design surface of the titanium oxide-containing decorative paper (Manufactured by Chuo Rika Kogyo Co., Ltd., trade name “SU-100”, average particle size: 84 nm, dispersion medium: water) was applied to a solid content of 40 g / m ^2, and then the decorative paper On the design surface side, melamine resin varnish (reaction molar ratio 1.4, resin solid content 50% by mass) was applied at 50 g / m ^2, and then dried for 90 seconds with a 120 ° C. hot air dryer, A melamine resin layer having a resin ratio of 53% and a volatile content of 3% was obtained.

  The melamine resin varnish is prepared by adding raw material melamine and formalin to a reaction kettle at a predetermined blending ratio, adding a catalyst, raising the temperature to the boiling point, performing a reflux reaction, and confirming that melamine dissolution has been completed. When it reached, it was synthesized by adjusting the resin solids by dehydration and cooling.

  On the obtained melamine resin layer, a glass cloth having a thickness of 0.2 mm (trade name “WEA7628” manufactured by Nanya Plastic Co., Ltd.) was superimposed as a base material layer forming material.

  Next, the saddle-shaped material composed of SUS was stacked on the melamine resin layer side, and then subjected to heat and pressure molding at 140 ° C. and 2 MPa for 40 minutes to obtain a melamine decorative material having a thickness of 0.3 mm. The arithmetic average roughness Ra of the outer surface of the obtained melamine decorative material was 8.56 μm. Moreover, the surface area ratio (A) represented by the said Formula (1) of the outer surface of the obtained melamine decorative material was 11.87.

(Example 2, Comparative Examples 1-9)
A melamine decorative material having a thickness of 0.3 mm was obtained in the same manner as in Example 1 except that the type of the saddle material was changed so that the Ra and surface area ratio of the outer surface of the melamine decorative material became the values shown in Table 1. It was.

  Table 1 shows the arithmetic average roughness Ra and specific surface area (A) of the outer surface of the melamine decorative material obtained in each example and each comparative example.

2. Test method (1) Fingerprint resistance A fingerprint was adhered to the design surface of the melamine decorative material of each example and each comparative example, visually observed, and evaluated according to the following criteria.

○: The fingerprint is clearly not conspicuous compared with Comparative Example 1. ×: The fingerprint is conspicuous (equal or less than Comparative Example 1)

(2) Room temperature bendability (inner bending, outer bending)
The melamine decorative material of each example and each comparative example was bent against a specified R jig and evaluated according to the following criteria.

Inward bending:
○: Bent at 10 mmR, no defects such as cracks ×: Bent at 10 mmR, there are defects such as cracks External bending: Bends at 4 mmR, no defects such as cracks ×: Bends at 4 mmR, cracks, etc. Have the disadvantages

(3) Surface hardness (pencil hardness) test The melamine decorative material of each Example and each comparative example was evaluated by a pencil hardness test based on JIS K 5600.

○: Hardness is 5H or more ×: Hardness is 4H or less

(4) Heat resistance It processed by the method based on the heat resistance test of JISK 6902, and the presence or absence of abnormalities, such as a swelling, peeling, and a crack, was confirmed after the test.

○: None ×: Available

(5) Hot water resistance The treatment was carried out by a method based on the hot water resistance test of JIS K 6902. After the test, the presence or absence of swelling and whitening was confirmed.

○: None ×: Available

(6) Contamination resistance test It processed by the method based on the contamination resistance test of JISK6902, and the presence or absence of the contaminant material of the surface was confirmed after the test.

○: None ×: Available

(7) Light resistance test The color difference ΔE and grade measured by a method based on the light resistance test of JIS K 6902 were confirmed, and evaluation was performed according to the following criteria.

△ E
○: After standing for 168 hours ΔE is 3.0 or less ×: After standing for 168 hours ΔE is greater than 3.0 Grade ○: After standing for 168 hours, grade is 3 or more ×: After standing for 168 hours, grade is 2 or less

(8) Abrasion resistance test The abrasion amount and the abrasion value measured by a method based on the abrasion resistance test of JIS K 6902 were confirmed, and evaluation was performed according to the following criteria.

Wear amount ○: 0.1 g / 100 or less ×: Greater than 0.1 g / 100 Wear value ○: Vertical plane: 150 or more, horizontal plane: 300 or more ×: Vertical plane: smaller than 150, horizontal plane: smaller than 300

(9) Crack resistance test It processed by the method based on the crack resistance test of JISK6902, and after the test, the presence or absence and the grade of a crack were confirmed, and the following references | standards evaluated.

○: Grade 3 or higher ×: Grade 2 or lower

(10) Boiling resistance test The weight increase rate measured by the method based on the boiling resistance test of JIS K 6902 and the appearance after the test were evaluated according to the following criteria.

Weight increase rate ○: 16% or less ×: greater than 16% Appearance after test ○: No swelling or peeling ×: There is swelling or peeling

(11) Dimensional stability test (room temperature)
The vertical total change rate and the horizontal total change rate measured by a method based on the dimensional stability test of JIS K 6902 were evaluated according to the following criteria.

Vertical change rate ○: 1.1% or less ×: Greater than 1.1% Horizontal change rate ○: 1.4% or less ×: Greater than 1.4%

(12) Exothermic (non-combustible) test Business standard of the Japan Architectural Comprehensive Testing Center "Fireproof Performance Test / Evaluation Business Method" 4.10 In the non-combustible performance test / evaluation method, (2) ii) 4.10.2 The exothermic test / evaluation method was used.

The item of the above-mentioned business standard “Fireproofing Performance Test / Evaluation Business Method” describes the performance evaluation method related to the certification based on the provisions of Article 2, Item 9 (non-combustible material) of the Building Standard Law.
Evaluation was performed based on the following criteria.

Total calorific value ○: 8 MJ / m ² or less ×: Greater than 8 MJ / m ² Maximum heat generation rate ○: Maximum heat generation rate does not exceed 200 kW / m ² continuously for 10 seconds or more ×: Does not satisfy the above range Hole / crack ○: There is no crack reaching the through hole or the back surface. ×: There is a crack reaching the through hole or the back surface. The results are shown in Table 2.

  As can be seen from Table 2, the melamine decorative material of the present invention was hardly attached with a fingerprint or the like. In addition, the melamine decorative material of the present invention was not easily noticeable with fingerprints and was excellent in various durability. On the other hand, the melamine decorative material of the comparative example was excellent in various durability, but the fingerprints etc. were conspicuous.

DESCRIPTION OF SYMBOLS 100 Melamine cosmetic material 11 Surface layer 11 'Melamine resin layer 12 Base material layer 12' Base material layer forming material

Claims (3)

Having a surface layer made of a material containing melamine resin,
On the outer surface of the surface layer, irregularities having an arithmetic average roughness (Ra) represented by JIS B 0601 of 5 μm or more and 15 μm or less are formed,
A melamine cosmetic material having a surface area ratio (A) represented by the following formula (1) of 10 or more and 20 or less .
Surface area ratio (A) = SA / UA (1)
(SA indicates the surface area of an arbitrary region of the outer surface of the surface layer, and UA indicates the area of the arbitrary region of the outer surface of the surface layer when viewed in plan.)   The melamine decorative material according to claim 1, wherein the average thickness is 0.4 mm or less. A method for producing a melamine cosmetic material according to claim 1 or 2,
Forming a melamine resin layer containing the melamine resin;
By pressing the melamine resin layer while heating it with a saddle-shaped material, the outer surface has an arithmetic mean roughness (Ra) represented by JIS B 0601 of 5 μm or more and 15 μm or less , and method for producing a melamine decorative material characterized by having the steps of forming the surface layer area ratio as Table (a) satisfies the 20 following relationship 10 or by the formula (1).

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