JP7461107B2 - Surface mounting material, method of manufacturing surface mounting material - Google Patents

Description

The present invention relates to a surface material suitable for use on, for example, the interior and exterior wall surfaces and floor surfaces of buildings, and a method for manufacturing the surface material.

As a covering material suitable for the inner and outer wall surfaces and floor surfaces of a building, there is, for example, one having a configuration disclosed in Patent Document 1. The structure disclosed in Patent Document 1 includes a synthetic resin, a natural stone, a colored aggregate, a decorative material part containing an endothermic substance, and a base material part. The synthetic resin component contains 20% by mass or more of a component selected from vinyl chloride, vinylidene chloride, polychloroprene, and chlorinated polyethylene, and the solid content of the synthetic resin accounts for the percentage (x%) of the mass of the decorative material part. ) is more than 4% and less than 13%. Further, the proportion (y%) of the endothermic substance in the mass of the decorative material portion is 60% or less. Furthermore, x and y are within a range that satisfies y≧7x−56.

Japanese Patent No. 2542992

However, in the configuration disclosed in Patent Document 1, since the base material portion has low self-extinguishing properties, there is a problem that the fire resistance performance as a covering material for buildings etc. is low.
The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a cladding material that can improve fire resistance performance and a method for manufacturing the cladding material.

In order to solve the above problems, one aspect of the present invention is a facing material including a base substrate, a pattern layer laminated on the base substrate, and a top coat layer laminated on the pattern layer. In addition, the base material has self-extinguishing properties, which requires that the flammability distance be 25 [mm] or less when the base material is evaluated according to the flame resistance evaluation method (A method) specified in JIS K6911. have
Moreover, in order to solve the above-mentioned problem, one aspect of the present invention is a method for manufacturing a facing material including a base substrate, a pattern layer, and a top coat layer, in which the pattern layer is formed by an inkjet printing method.

According to one aspect of the present invention, it is possible to provide a cladding material that can improve fire resistance and a method for manufacturing the cladding material.

FIG. 2 is a cross-sectional view showing the configuration of the covering material in the first embodiment of the present invention. FIG. 11 is a cross-sectional view showing a configuration of a modified example of the present invention.

Embodiments of the present technology will be described below with reference to the drawings. In the description of the drawings, the same or similar parts are given the same or similar symbols, and overlapping explanations are omitted. Each drawing is schematic and may differ from the actual drawing. The embodiments shown below illustrate devices and methods for embodying the technical idea of the present technology, and the technical idea of the present technology is specific to the devices and methods illustrated in the embodiments below. It's not something you do. The technical idea of the present technology can be modified in various ways within the technical scope described in the claims. Further, the directions "left and right" and "up and down" in the following description are simply defined for convenience of explanation, and do not limit the technical idea of the present invention. Therefore, for example, if you rotate the page 90 degrees, "left and right" and "top and bottom" will be read interchangeably, and if you rotate the page 180 degrees, "left" becomes "right" and "right" becomes "left." Of course it will become.

(First embodiment)
The configuration of the covering material 10 will be described below with reference to FIG.
The facing material 10 includes a base material 1, a pattern layer 2, and a top coat layer 4, as shown in FIG.

(Base material)
The base material 1 is formed using a material that has self-extinguishing properties. Thereby, the base substrate 1 has self-extinguishing properties.
The self-extinguishing property requires that the combustion distance be 25 [mm] or less when the base substrate 1 is evaluated according to the flame resistance evaluation method (A method) specified in JIS K6911.
Examples of self-extinguishing materials include self-extinguishing resin films such as polycarbonate and vinyl chloride, and resin films such as polypropylene and polyethylene terephthalate to which known flame retardants and endothermic substances are added. It is possible to use In addition to aggregates and fillers selected from natural stone, crushed natural stone, colored aggregates, cold water sand, and crushed ceramic granules, heat-absorbing substances such as aluminum hydroxide are used as aggregates or fillers, and synthetic resins It is also possible to use a sheet-like material in which the components are used as a binder.

In the first embodiment, as an example, a case will be described in which the base material 1 is configured to contain synthetic resins, aggregate, and an endothermic substance.
An endothermic substance is a substance that absorbs heat when thermally decomposed. As the endothermic substance, for example, metal hydroxide, aluminum fluoride, dicalcium phosphate, calcium oxalate, borax, sodium bicarbonate, cobalt chloride ammonia complex, etc. can be used, and at least one metal water Preferably, it contains an oxide.
As the metal hydroxide, aluminum hydroxide, magnesium hydroxide, calcium hydroxide, cobalt hydroxide, barium hydroxide, strontium hydroxide, etc. can be used.

In the first embodiment, as an example, a case where the metal hydroxide contained in the endothermic substance is at least one of aluminum hydroxide, magnesium hydroxide, and calcium hydroxide will be described. That is, in the first embodiment, as an example, a case where the endothermic substance contains at least one of aluminum hydroxide, magnesium hydroxide, and calcium hydroxide as the metal hydroxide will be described.
Aluminum hydroxide includes natural minerals, boehmite, gibbsite, and diasporic acid.
In the first embodiment, as an example, a case will be described in which the base substrate 1 is configured to include at least one of aluminum hydroxide, magnesium hydroxide, and calcium hydroxide.

Considering the texture, processability, and handling of the base substrate 1, the content of the synthetic resin component as a binder is preferably within a range of 20% by mass to 30% by mass. The contents of the aggregate, filler, and heat-absorbing substance are preferably within a range of 70% by mass to 80% by mass. In particular, it is necessary to add the heat-absorbing substance in an amount that allows the base substrate 1 to exhibit self-extinguishing properties.
In the first embodiment, as an example, a case will be described in which the configuration of the base substrate 1 is configured so that the content of synthetic resins is in the range of 20% by mass or more and 30% by mass or less, and the content of aggregate and heat-absorbing substance is in the range of 70% by mass or more and 80% by mass or less.

(Pattern layer)
The pattern layer 2 is laminated on the base substrate 1. Specifically, in Fig. 1, the pattern layer 2 is laminated on the surface of the base substrate 1 and is formed so as to cover the entire surface of the base substrate 1. Depending on the pattern to be formed, there may be some parts of the base substrate 1 that are exposed.
The design layer 2 can be formed by using a known printing method such as gravure printing, offset printing, screen printing, inkjet printing, etc., depending on the type of base substrate 1 to be printed. In particular, when the surface of the base substrate 1 has an uneven shape, it is preferable to use the inkjet printing method, which is a non-contact printing method.

Known materials can be used as the ink for forming the pattern layer 2. In particular, when using an inkjet printing method, various conventionally known inks such as water-based, solvent-based, and UV-based inks can be used, and can be appropriately selected depending on the type of base substrate 1 to be printed. Here, the ink components include pigments or dyes as colorants, and conventionally known pigments (inorganic pigments, organic pigments, black pigments, etc.) and dyes can be used to match the color of the ink used.

As inorganic pigments, for example, titanium oxide, zinc white, zinc sulfide, white lead, calcium carbonate, precipitated barium sulfate, white carbon, alumina white, kaolin clay, talc, bentonite, black iron oxide, etc. can be used. be. Further, for example, it is possible to use cadmium red, red iron oxide, molybdenum red, molybdate orange, chrome vermilion, yellow lead, cadmium yellow, yellow iron oxide, titanium yellow, chromium oxide, and the like. Further, for example, viridian, titanium cobalt green, cobalt green, cobalt chrome green, Victoria green, etc. can be used. In addition, it is possible to use, for example, ultramarine blue, navy blue, cobalt blue, cerulean blue, cobalt silica blue, cobalt zinc silica blue, manganese violet, cobalt violet, and the like.

As the organic pigment, for example, azo pigments, phthalocyanine pigments, anthraquinone pigments, quinacridone pigments, isoindolinone pigments, quinophthalone pigments, dye lake pigments, fluorescent pigments, etc. can be used.
As the black pigment, carbon black produced by the furnace method or the channel method can be used. In addition to carbon black, other black pigments that can be used in the present invention include, for example, aniline black, lumogen black, azomethine azo black, etc. In addition, it is also possible to use a plurality of chromatic pigments such as cyan pigments, magenta pigments, yellow pigments, brown pigments, orange pigments, etc. to form a black pigment.

The dye is not particularly limited, and oil dyes, disperse dyes, direct dyes, acid dyes, basic dyes, and the like can be used. As the hue, yellow, magenta, cyan, black, blue, green, and red are preferably used, and yellow, magenta, cyan, and black dyes are particularly preferably used. Oil-soluble dyes include dyes that exhibit oil-solubility by forming salts between water-soluble dyes and long-chain bases. Also, C. I. Disperse Yellow, C. I. Dispersed Red, C. I. It is also possible to use disperse dyes such as dispersed blue. In particular, when it is desired to provide long-term weather resistance, it is desirable to use an ink containing an inorganic pigment.

The design layer 2 preferably contains at least an organic resin cured product and an inorganic pigment, and the maximum thickness of the organic resin cured product in the design layer 2 is preferably within the range of 3 μm to 30 μm.
In the first embodiment, as an example, a case will be described in which the maximum thickness of the cured organic resin in the design layer 2 is within a range of 3 μm or more and 30 μm or less.
This is because, when the maximum thickness of the cured organic resin in the design layer 2 is less than 3 μm, the color development is poor and the design is poor when an inorganic pigment is used as the ink for forming the design layer 2. Also, when the maximum thickness of the cured organic resin in the design layer 2 exceeds 30 μm, the ink for forming the design layer 2 is applied in excess, which lengthens the printing time.

(Topcoat Layer)
The top coat layer 4 is laminated on the design layer 2 and faces the surface of the base substrate 1 with the design layer 2 sandwiched therebetween.
The topcoat layer 4 is a layer provided as necessary to impart design properties such as gloss, and surface physical properties such as scratch resistance and weather resistance. The topcoat layer 4 can be cured using known methods such as one-liquid, two-liquid, and active energy ray irradiation. The resin material used for the topcoat layer 4 can be known materials such as urethane-based, acrylic-based, and polyester-based materials.

(Method of manufacturing the surface material 10)
Hereinafter, a manufacturing method for manufacturing the covering material 10 of the first embodiment (a manufacturing method for the covering material 10) will be described with reference to FIG.
First, ink for forming the design layer 2 is applied to the surface of the base substrate 1 by inkjet printing, thereby forming the design layer 2. That is, the design layer 2 is formed by inkjet printing.
Here, the ink applied by the inkjet printing method is a cationic curable UV inkjet ink, that is, the design layer 2 is formed using the cationic curable UV inkjet ink.

Moreover, the structure of the cationic curable UV inkjet ink is such that it contains an inorganic pigment as a main pigment component.
After forming the pattern layer 2, the pattern layer 2 is cured by irradiating it with ultraviolet rays.
Next, a top coat layer 4 is laminated on the surface of the cured pattern layer 2 opposite to the surface facing the base substrate 1. In this way, the facing material 10 is manufactured.
Note that the first embodiment described above is an example of the present invention, and the present invention is not limited to the first embodiment described above, and even forms other than this embodiment can be applied to the present invention. Various changes can be made according to the design, etc., as long as they do not deviate from the technical concept.

(Effects of the first embodiment)
With the covering material 10 of the first embodiment, it is possible to achieve the effects described below.
(1) The base material 1 includes a base material 1, a pattern layer 2 laminated on the base material 1, and a top coat layer 4 laminated on the pattern layer 2, and the base material 1 has self-extinguishing properties.
As a result, it becomes possible to impart self-extinguishing properties to the cladding material 10, and it becomes possible to provide a cladding material 10 that can improve fire resistance. In addition to this, by providing the pattern layer 2, it becomes possible to express various stones, etc., and it becomes possible to improve the design. Furthermore, the configuration of the pattern layer 2 makes it possible to improve fire resistance and provide a facing material 10 that imitates precious stone.

(2) The base substrate 1 contains synthetic resins, aggregate, and a heat absorbing material. In addition, the content of the synthetic resins is within a range of 20% by mass to 30% by mass, and the content of the aggregate and the heat absorbing material is within a range of 70% by mass to 80% by mass.
As a result, by defining the composition of the components contained in the base substrate 1, the configuration of the base substrate 1 can achieve both flexibility and self-extinguishing properties.
(3) The endothermic material includes at least one metal hydroxide.
As a result, the self-extinguishing properties of the base material 1 can be improved.

(4) The pattern layer 2 contains a cured organic resin and an inorganic pigment. In addition, the maximum thickness of the cured organic resin material is within the range of 3 [μm] or more and 30 [μm] or less.
As a result, by containing the inorganic pigment in the pattern layer 2, it becomes possible to form a pattern and also to form a pattern layer 2 with excellent weather resistance.
In addition to this, it is possible to suppress deterioration in design and prolongation of the time for forming the pattern layer 2.
Furthermore, the method for manufacturing the covering material of the first embodiment can produce the effects described below.
(5) The pattern layer 2 is formed by an inkjet printing method.
As a result, by forming the pattern layer 2 by the inkjet printing method, it is possible to reliably print a desired pattern regardless of the material, surface shape, etc. of the base material 1. Furthermore, it is possible to provide a method for manufacturing a facing material that can improve the fire resistance of the facing material 10.

(6) The design layer 2 is formed using a cationic curable UV inkjet ink.
As a result, by forming the pattern layer 2 using a cationic curing UV inkjet ink, it is possible to reduce curing problems caused by oxygen inhibition, and it is possible to form a pattern layer 2 with excellent adhesion to the base substrate 1.
(7) The cationic curable UV inkjet ink forming the design layer 2 contains an inorganic pigment as the main pigment component.
As a result, by using only inorganic pigments as the pigment components in the cationic curable UV inkjet ink, it is possible to form a pattern layer 2 having excellent weather resistance. This makes it possible to provide a covering material 10 having excellent weather resistance.

(Modified example)
(1) In the first embodiment, the mounting material 10 has a structure including the base material 1, the pattern layer 2, and the top coat layer 4, but is not limited to this. That is, in addition to the base material 1, the pattern layer 2, and the top coat layer 4, the facing material 10 may also have a functional layer 6, as shown in FIG. 2, for example.
The functional layer 6 is formed on the surface (back surface) opposite to the surface to be printed (the upper surface in FIG. 2) of the base material 1, for example, by an adhesive layer or the like with the surface protected with a release sheet or the like. .
Furthermore, for example, a woven fabric, a nonwoven fabric, or the like may be laminated on the back surface of the base material 1.
Further, for example, a primer layer may be formed between the base material 1 and the pattern layer 2 to improve ink adhesion.

With reference to the first embodiment, the following describes the covering materials of Examples 1 to 6 and Comparative Examples 1 to 4.

(Example 1)
・Base substrate The base substrate was formed into a sheet shape containing 30% by mass of a synthetic resin component (acrylic resin emulsion) as a binder, 60% by mass of colored fine aggregate, and 10% by mass of aluminum hydroxide. .
- Pattern layer The pattern layer was formed by printing a granite-like design using an inkjet printing method using cationic curable UV inkjet ink.
Only inorganic pigments were used as colorants in the cationically curable UV inkjet inks.
The maximum thickness of the cured organic resin material in the pattern layer was 10.3 [μm].
-Top coat layer The top coat layer was formed using an acrylic resin material.
- Surface material After storing the base sheet on which the pattern layer was laminated at room temperature for 24 hours or more in order to advance the reaction, a top coat layer was laminated on the pattern layer to produce the surface material of Example 1. did.

Example 2
Base Substrate The base substrate was formed into a sheet containing 30% by mass of a synthetic resin component (acrylic resin emulsion) as a binder, 60% by mass of colored fine aggregate, and 10% by mass of aluminum hydroxide.
-Pattern Layer The pattern layer was formed by printing a dark charcoal gray design by the inkjet printing method using a cationic curing UV inkjet ink.
The cationically curable UV inkjet inks used only inorganic pigments as colorants.
The maximum thickness of the cured organic resin in the design layer was 27.9 μm.
Topcoat Layer The topcoat layer was formed using an acrylic resin material.
- Surface material The base sheet with the pattern layer laminated thereon was stored in a room temperature environment for more than 24 hours to allow the reaction to proceed, and then a top coat layer was laminated onto the pattern layer to produce the surface material of Example 2.

Example 3
Base Substrate The base substrate was formed into a sheet containing 30% by mass of a synthetic resin component (acrylic resin emulsion) as a binder, 60% by mass of colored fine aggregate, and 10% by mass of magnesium hydroxide.
-Pattern layer The pattern layer was formed by printing a granite-like design using a cationic curing UV inkjet ink by inkjet printing method.
The cationically curable UV inkjet inks used only inorganic pigments as colorants.
The maximum thickness of the cured organic resin in the design layer was 11.6 μm.
Topcoat Layer The topcoat layer was formed using an acrylic resin material.
- Surface material The base sheet with the pattern layer laminated thereon was stored in a room temperature environment for more than 24 hours to allow the reaction to proceed, and then a top coat layer was laminated onto the pattern layer to produce the surface material of Example 3.

Example 4
Base Substrate The base substrate was formed into a sheet containing 30% by mass of a synthetic resin component (acrylic resin emulsion) as a binder, 60% by mass of colored fine aggregate, and 10% by mass of aluminum hydroxide.
-Pattern layer The pattern layer was formed by printing a granite-like design using the inkjet printing method with radical polymerization type UV inkjet ink.
For the radical polymerization type UV inkjet ink, only inorganic pigments were used as colorants.
The maximum thickness of the cured organic resin in the design layer was 9.4 μm.
Topcoat Layer The topcoat layer was formed using an acrylic resin material.
Surface Material The base sheet with the pattern layer laminated thereon was not stored at room temperature due to the characteristics of the curing reaction of the radical polymerization type UV inkjet ink, and a top coat layer was laminated onto the pattern layer to produce the surface material of Example 4.

Example 5
Base Substrate The base substrate was formed using a vinyl chloride film having a thickness of 150 μm.
-Pattern layer The pattern layer was formed by printing a granite-like design using a cationic curing UV inkjet ink by inkjet printing method.
For the cationic curable UV inkjet inks, only inorganic pigments were used as colorants.
The maximum thickness of the cured organic resin in the design layer was 8.8 μm.
Topcoat Layer The topcoat layer was formed using an acrylic resin material.
- Surface material The base sheet with the pattern layer laminated thereon was stored in a room temperature environment for more than 24 hours to allow the reaction to proceed, and then a top coat layer was laminated onto the pattern layer to produce the surface material of Example 5.

Example 6
Base Substrate The base substrate was formed into a sheet containing 30% by mass of a synthetic resin component (acrylic resin emulsion) as a binder, 60% by mass of colored fine aggregate, and 10% by mass of aluminum hydroxide.
-Pattern layer The pattern layer was formed by printing a granite-like design using a cationic curing UV inkjet ink by inkjet printing method.
For the cationic curable UV inkjet inks, only inorganic pigments were used as colorants.
The maximum thickness of the cured organic resin in the design layer was 4.9 μm.
Topcoat Layer The topcoat layer was formed using an acrylic resin material.
- Surface material The base sheet with the pattern layer laminated thereon was stored in a room temperature environment for more than 24 hours to allow the reaction to proceed, and then a top coat layer was laminated onto the pattern layer to produce the surface material of Example 6.

(Comparative Example 1)
Base Material The base material was formed in the same manner as in Example 1, except that the base material contained 30 mass % of a synthetic resin component (acrylic resin emulsion) as a binder and 70 mass % of colored fine aggregate.
Design Layer and Topcoat Layer The design layer and the topcoat layer were formed in the same manner as in Example 1.
- Surface material The base sheet with the pattern layer laminated thereon was stored in a room temperature environment for more than 24 hours to allow the reaction to proceed, and then a topcoat layer was laminated onto the pattern layer to produce the surface material of Comparative Example 1.

(Comparative Example 2)
Base Substrate The base substrate was formed using a biaxially stretched polyethylene terephthalate film having a thickness of 125 μm.
Design Layer and Topcoat Layer The design layer and the topcoat layer were formed in the same manner as in Example 1.
- Surface material The base sheet with the pattern layer laminated thereon was stored in a room temperature environment for more than 24 hours to allow the reaction to proceed, and then a top coat layer was laminated onto the pattern layer to produce the surface material of Comparative Example 2.

(Comparative example 3)
-Base substrate The base substrate was formed in the same manner as in Comparative Example 1.
- Pattern layer The pattern layer was formed by printing a granite-like design using an inkjet printing method using water-based dye inkjet ink.
Water-based dye inkjet inks used only dyes as colorants.
The pattern layer was formed by soaking dye inkjet ink into the base material.
-Top coat layer The top coat layer was formed in the same manner as in Example 1.
- Surface material After the base sheet on which the pattern layer was laminated was sufficiently dried, a top coat layer was laminated on the pattern layer to produce a surface material of Comparative Example 3.

(Comparative Example 4)
Base Substrate The base substrate was formed into a sheet containing 30% by mass of a synthetic resin component (acrylic resin emulsion) as a binder, 60% by mass of colored fine aggregate, and 10% by mass of aluminum hydroxide.
-Pattern layer The pattern layer was formed by printing a granite-like design using a cationic curing UV inkjet ink by inkjet printing method.
For the cationic curable UV inkjet inks, only inorganic pigments were used as colorants.
The maximum thickness of the cured organic resin in the design layer was 11.7 μm.
- Surface mounting material The base sheet with the pattern layer laminated thereon was stored in a room temperature environment for more than 24 hours to allow the reaction to proceed, and then, unlike Examples 1 to 6 and Comparative Examples 1 to 3, the surface mounting material of Comparative Example 4 was produced without forming a topcoat layer.

(Performance evaluation, evaluation results)
The self-extinguishing property, design property, ink adhesion, solvent resistance, and weather resistance were evaluated for each of the mounting materials of Examples 1 to 6 and the mounting materials of Comparative Examples 1 to 4. The evaluation methods used were as follows.

<Self-extinguishing property>
Evaluation was performed using the flame resistance evaluation method (Method A) specified in JIS K6911.
In the flame resistance evaluation method, if the combustion distance is 25 [mm] or less, the self-extinguishing property is "passed: ○", and if the combustion distance is within the range of more than 25 [mm] and 100 [mm] or less The self-extinguishing property was rated as “fail: ×”.
<Design>
The printed design was evaluated by visually evaluating the retention of the design (difficulty of the design falling off) when the surface of the covering material was rubbed.

<Ink adhesion>
The adhesion of the printed coating film was evaluated by conducting an adhesion test using adhesive tape on the pattern layer before forming the top coat layer.
<Solvent resistance>
Solvent resistance was evaluated by rubbing the pattern layer before forming the top coat layer with ethanol diluted 50% with pure water.

<Weather resistance>
Weather resistance was evaluated by conducting a metal weather test.
(Evaluation criteria)
○: No defects occurred during the production or processing of the covering material for each item.
△: For each item, there may be a problem in producing or processing the mounting material depending on the conditions, but there is no problem in using it.
×: Defects occur in each item.
In addition, any surface material rated as "x" was deemed to have failed as a whole surface material.

As shown in Table 1, the surface materials of Examples 1 to 6 showed excellent performance in all evaluation tests, and showed satisfactory results as surface materials. On the other hand, the surface materials of Comparative Examples 1 to 4 had failing elements in at least one evaluation test, and showed unsuitable results as surface materials.

1... Base material, 2... Pattern layer, 4... Top coat layer, 6... Functional layer, 10... Surface material

Claims (5)

a base material,
a pattern layer laminated on the base material and formed with ink;
a top coat layer laminated on the pattern layer,
The base material contains synthetic resins, aggregate, and an endothermic substance,
The laminate of the base substrate, the pattern layer, and the top coat layer has a combustion distance of 25 mm or less when evaluated in accordance with the flame resistance evaluation method (Method A) specified in JIS K6911. It has self-extinguishing properties that require
The pattern layer contains a cured organic resin and an inorganic pigment,
The maximum thickness of the cured organic resin in the pattern layer is within the range of 10.3 μm or more and 27.9 μm or less,
The content of the synthetic resin is within the range of 20% by mass or more and 30% by mass or less,
The aggregate is colored fine aggregate,
The content of the aggregate and the endothermic substance is within a range of 70% by mass or more and 80% by mass or less,
The content of the aggregate is 60% by mass or more ,
A mounting material characterized in that the content of the endothermic substance is 10% by mass or more . The surface material according to claim 1, characterized in that the endothermic substance contains at least one metal hydroxide. A method for manufacturing a cladding material for manufacturing the cladding material according to claim 1 or 2, comprising:
A method for manufacturing a mounting material, characterized in that the pattern layer is formed by an inkjet printing method. 4. The method for manufacturing a facing material according to claim 3, wherein the pattern layer is formed using a cationically curable UV inkjet ink. 5. The method for producing a surface material according to claim 4, wherein the cationically curable UV inkjet ink contains an inorganic pigment as a main pigment component.

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