Classifications

• • D03D15/0083—
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D1/00—Woven fabrics designed to make specified articles
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
  • D03D13/008—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft characterised by weave density or surface weight
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
  • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/30—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the fibres or filaments
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/30—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the fibres or filaments
  • D03D15/37—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the fibres or filaments with specific cross-section or surface shape
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
  • D03D15/41—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads with specific twist
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
  • D03D15/573—Tensile strength
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4326—Condensation or reaction polymers
  • D04H1/435—Polyesters
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M10/00—Physical treatment of fibres, threads, yarns, fabrics, or fibrous goods made from such materials, e.g. ultrasonic, corona discharge, irradiation, electric currents, or magnetic fields; Physical treatment combined with treatment with chemical compounds or elements
  • D06M10/04—Physical treatment combined with treatment with chemical compounds or elements
  • D06M10/08—Organic compounds
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/30—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensation products not covered by indexing codes D10B2331/02 - D10B2331/14
  • D10B2331/301—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensation products not covered by indexing codes D10B2331/02 - D10B2331/14 polyarylene sulfides, e.g. polyphenylenesulfide
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/02—Moisture-responsive characteristics
  • D10B2401/022—Moisture-responsive characteristics hydrophylic
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2505/00—Industrial
  • D10B2505/04—Filters

Definitions

• the present invention relates to a high-performance polyphenylene sulfide (PPS) fiber structure and production method and use thereof.
• PPS polyphenylene sulfide
• Diaphragm cloth is the main core material of water electrolyzers.
• Water-electrolytic hydrogen generators and oxygen generators are widely applied in military, petrochemical, and iron and steel making fields.
• major manufacturers of alkaline water-electrolytic hydrogen generators in China still use asbestos cloth as diaphragm.
• asbestos diaphragms have some drawbacks in production practice. Though asbestos is non-hazardous in itself, a severe hazard is incurred by the asbestos fibers, which are fibers that are extremely fine and almost invisible to naked eyes. After those fine fibers are released, they will float in the air for a long time and may be inhaled into human body.
• diaphragm cloth has been used as the main core material of water electrolysis equipment for long.
• asbestos diaphragms are being replaced with diaphragm cloth made from PPS fibers.
• the obtained diaphragms may have non-uniform pore size and poor gas impermeability if the fineness of the fibers used to weave PPS diaphragm cloth is inappropriate and the ratio of the twist of single yarns to the twist of plied yarns is improper.
• a high temperature-resistant alkaline water electrolyzer diaphragm produced by sulfonating non-woven cloth made from ordinary PPS fibers with 90 to 98% H 2 SO 4 at 70 to 130° C. for 20 to 40 min. and then processing the non-woven cloth with 30% KOH is disclosed.
• the liquid absorption rate of the non-woven cloth is relatively high, a large quantity of valuable water resource and chemicals have to be consumed in the washing process after the non-woven cloth is processed with the strong acid, the washing time is long, the technological operations are complex, and pollution to the environment may occur.
• the process is not suitable for use in industrial production owing to its poor safety.
• a high temperature-resistant and alkali-resistant PPS diaphragm obtained by processing high-density woven fabric made from ordinary 2.2 T PPS fibers through plasma hydrophilic treatment process to endow hydrophilicity to the PPS diaphragm is disclosed.
• the gas impermeability of the obtained diaphragm in that invention is poor, owing to improper fineness of the fibers and improper ratio of the twist of single yarns to the twist of plied yarns.
• the PPS diaphragm cloth processed through the plasma hydrophilic treatment process can't truly meet the production demand owing to its poor hydrophilicity and poor durability.
• an asbestos-free environment-friendly and energy-saving diaphragm is disclosed.
• the diaphragm is a woven fabric woven from a raw material that consists of one, two or three of polyetheretherketone fibers, PPS fibers, and polypropylene fibers.
• the gas impermeability of the diaphragm cloth meets the requirements of the standard for asbestos diaphragms, the obtained diaphragm cloth has poor hydrophilicity and can't truly meet the application requirements, owing to the poor water absorptivity of the above-mentioned chemical fibers.
• An object of the present invention is to provide a high-performance PPS fiber structure with higher gas impermeability and better hydrophilicity.
• Another object of the present invention is to provide a method for producing a high-performance PPS fiber structure, which employs a simple process, can save energy, and has no pollution to the environment.
• embodiments of the present invention may have the following characteristics:
• the PPS fiber structure according to an embodiment of the present invention is a woven fabric formed of PPS fibers in 0.1 to 12 ⁇ m cross sectional diameter, wherein, the maximum pore size of the PPS fiber structure is 20 ⁇ m or smaller.
• the warp yarns and weft yarns that form the PPS fiber structure described in the item (1) are hydrophilic PPS staple yarns.
• the average pore size of the PPS fiber structure described in the above item (1) is 5 ⁇ m or smaller, and pores in 6 ⁇ m or smaller diameter account for 90% or a high percentage of all the pores in the fiber structure.
• the yarn count of the single yarns in the PPS fiber structure described in the above item (1) is 21 to 60 s.
• the twist factor of the yarns in the PPS fiber structure described in the above item (1) is 180 to 350.
• the twist of the warp yarns is greater than or equal to the twist of the weft yarns in the PPS fiber structure described in the above item (1).
• the ratio of the twist of the PPS yarns to the twist of PPS single yarns is 0.2 to 1.0.
• the gas impermeability of the PPS fiber structure described in the above item (1) is 400 mmH 2 O or above.
• the area resistance of the PPS fiber structure described in the above item (1) is 60 m ⁇ cm 2 or lower.
• Embodiments of the present invention may attain the following beneficial effects: in the present invention, since PPS fibers at 0.1 to 12 ⁇ m fineness are used and the ratio of the twist of single yarns to the twist of plied yarns is proper, the drawbacks of non-uniform pore size and low gas impermeability in the prior art may be overcome, and the obtained PPS woven fabric may have small and uniform pore size. Therefore, the PPS fiber structure provided in embodiments of the present invention not only has advantages of high gas impermeability and good hydrophilicity, but also has advantages of simple process, reduced energy consumption, and zero pollution to the environment.
• the PPS fiber structure provided in the present invention can be applied to diaphragms for electrolytic apparatuses, high-temperature liquid filter materials and insulating materials.
• the PPS fiber structure in the present invention is a woven fabric formed of PPS fibers in 0.1 to 12 ⁇ m cross sectional diameter, wherein, the maximum pore size of the PPS fiber structure is 20 ⁇ m or smaller.
• fabric with tabby has the highest number of interlacing points and the highest compactness. Therefore, woven fabric with tabby is preferred.
• the cross sectional diameter of the PPS fibers is smaller than 0.1 ⁇ m, the fibers will be difficult for carding in the carding procedure because the fibers are too thin. Consequently, cellfibre may be fractured, a phenomenon of undesirable resultant yarn and excessive neps may occur, and the quality of the yarns may be degraded.
• the obtained PPS cloth may have excessive flaws on the surface, which will influence the pore size and thickness of the fabric, leading to that the pore size and thickness of the fabric are non-uniform, and the gas impermeability of the fabric is further degraded; if the cross sectional diameter of the PPS fibers is greater than 12 ⁇ m, the cellfibre yarn will be too rigid and difficult to produce yarns because the fibers are too thick. Besides, the thick yarns will bring about difficulty in weaving, and the obtained fabric will have increased pore size and poor gas impermeability.
• the cross sectional diameter of the PPS fibers preferably is 6 to 10 ⁇ m, more preferably 6 to 8 ⁇ m.
• the warp yarns and weft yarns that form the PPS fiber structure are PPS staple yarns that have suffered from hydrophilic treatment. Both the warp yarns and weft yarns of the PPS fiber structure in the present invention use staple yarns. Compared with filament yarns, staple yarns have higher cohesive property between cellfibres, the voids between the cellfibres will not be increased owing to the structure of the yarns, and the pore size and gas impermeability of the fabric will not be affected.
• the staple yarns used in the present invention may be single yarns or plied yarns formed of single yarns, preferably are plied yarns. To ensure that the PPS fiber structure has excellent hydrophilicity, preferably PPS staple yarns treated through hydrophilic treatment are used.
• the hydrophilic treatment refers to increase hydrophilic groups, such as hydroxyl, carboxyl, carbonate, and sulfate groups, etc., on the surface of the PPS fibers by plasma treatment, sulfonation, or grafting.
• the grafting ratio of the PPS yarns treated through hydrophilic treatment is 0.1 to 3%, preferably is 0.5 to 3%.
• the maximum pore size of the PPS fiber structure in the present invention is 20 ⁇ m or smaller. If the maximum pore size of the PPS fiber structure is greater than 20 ⁇ m, the pore size of the PPS fiber structure will be too great, hydrogen or oxygen bubbles may penetrate through the voids in the fiber structure easily in the hydrogen generator when the PPS fiber structure is used. Consequently, the purity of single gas may be degraded. Therefore, the maximum pore size of the PPS fiber structure is 20 ⁇ m or smaller.
• the maximum pore size of the PPS fiber structure preferably is 15 ⁇ m or smaller; to make the pore size of the fiber structure more uniform and the distribution of pore sizes more concentrated, preferably the maximum pore size of the PPS fiber structure is 12 ⁇ m or smaller.
• the average pore size of the PPS fiber structure is 5 ⁇ m or smaller, and pores in 6 ⁇ m or smaller diameter account for 90% or a high percentage of all the pores in the fiber structure. If the average pore size of the PPS fiber structure is controlled within the above-mentioned range, high gas impermeability can be ensured, and it will be difficult for gas molecules and bubbles to penetrate through the voids, thereby mixing between the gas at the anode size and the gas at the cathode side can be prevented, and the purity and safety of the gas, will be good. If the average pore size of the PPS fiber structure is greater than 5 ⁇ m, the woven fabric can't attain an isolation effect when it is used in the hydrogen production equipment since the pore size of the woven fabric is too great.
• the purity of the obtained hydrogen or oxygen may be low and can't meet the application requirements of the customers.
• the weaving conditions are optimized to improve the uniformity of pore size, so that pores in 6 ⁇ m or smaller pore size account for 90% or above of all the pores, preferably 95% or above.
• the yarn count of single yarns in the PPS woven fabric is 21 to 60 s, and the twist factor ⁇ is 200 to 310. If the yarn count of the single yarns is within the above-mentioned range, the obtained PPS fabric will have small and uniform pore size and high gas impermeability; moreover, the obtained woven fabric can attain a good hydrophilic treatment effect in the post processing. If the yarn count of the single yarns is too low, the yarns will be too thick. Consequently, the pore size of the woven fabric will be great, the gas impermeability of the woven fabric will be low, and ultimately the purity of obtained hydrogen or oxygen will be poor; if the yarn count of the single yarns is too high, extremely thin yarns have to be used.
• the production process will be difficult.
• the twist factor of the single yarns is within the above-mentioned range, the obtained PPS yarn will have moderate fluffiness.
• the obtained woven fabric will have small and uniform pore size and high gas impermeability, and the woven fabric can attain a good hydrophilic treatment effect in the post processing. If the twist factor of the yarns is too low, the twist of the yarns will be too low.
• the strength of the yarns will be low, the yarns may be broken easily in the weaving process, and the strength of the obtained fabric will be degraded; on one hand, if the twist factor of the yarns is too high, the twist of the yarns will be too high, and the voids at the interlacing points in the fabric will be obvious, and the pore size will be increased; on the other hand, the voids among the fibers in the yarns will be deceased, and the pore size of the entire woven fabric will be non-uniform and the gas impermeability will be decreased.
• the twist factor of the yarns of the PPS woven fabric is 180 to 350. If the twist factor of the yarns is too low, the twisting angle of the single fibers will be small, the cohesion force among the fibers will be decreased, the strength of the yarns will be decreased, and the weaving operation will be difficult in the weaving process, since the strength of the yarns is too low; if the twist factor of the yarns is too high, the cohesion force among the fibers will be too high, the strength of the yarns will be decreased, and pigtails may occur easily in the weaving process, resulting in that the weaving process will difficult to go on.
• the tension on the warp yarns is greater than the tension for wefting insertion of the weft yarns.
• the twist of the warp yarns is greater than or equal to the twist of the weft yarns in the PPS fiber structure in the present invention. If the twist of the warp yarns is slightly greater, the strength of the warp yarns can be ensured, and the shedding rate can be improved, which are beneficial for the weaving operation. If the weft yarns are staple yarns with slightly lower twist, the yarns will be fluffy, and the defect of increased and non-uniform pore size incurred by the increased twist of the warp yarns can be compensated.
• the ratio of the twist of the PPS yarns to the twist of the PPS single yarns in the present invention is 0.2 to 1.0. If the ratio of the twist of the yarns to the twist of the single yarns is within the above-mentioned range, the woven fabric will have uniform pore size, and more hydrophilic groups can be grafted during the hydrophilic treatment on the woven fabric. Thus, the liquid content in the woven fabric will be increased, and the aqueous film formed on the surface layer of the woven fabric will be thicker and can effectively block bubble penetration. Therefore, the purity of the obtained gas will be increased. If the ratio of the twist of the PPS yarns to the twist of the single yarns is too low, the twist of the yarns will certainly be decreased, and the strength of the obtained PPS yarns will be low.
• the strength of the obtained PPS woven fabric will be decreased, and the woven fabric may be penetrated more easily; if the ratio of the twist of the PPS yarns to the twist of the single yarns is too high, the voids among the fibers in the yarns will be decreased, so the pore size of the entire woven fabric will be non-uniform, the decreased gas impermeability will lead to non-uniform pore size of the woven fabric, and thereby the hydrophilic groups grafted to the woven fabric will be less.
• the gas impermeability of the PPS fiber structure in the present invention is 400 mmH 2 O or above.
• the requirement for gas impermeability of diaphragm cloth for water electrolyzers can be met essentially; in addition, the diaphragm cloth has excellent gas impermeability, ion passing efficiency and processability. If the gas impermeability is lower than 400 mmH 2 O, the basic requirement for diaphragms can't be met, and the purity of the obtained gas will be affected.
• the area resistance of the PPS fiber structure in the present invention is 60 m ⁇ cm 2 or lower, preferably is 10 m ⁇ cm 2 or lower. If the area resistance of the PPS fiber structure is higher than 60 m ⁇ cm 2 , the resistance of the fabric will be great, the electric power consumption will be increased, and the production cost will be increased accordingly.
• the alkali absorption ratio of the PPS fiber structure in the present invention is 70 to 200%. If the alkali absorption ratio of the PPS fiber structure is too low, it will be difficult to form an aqueous film or the aqueous film will be too thin in alkaline liquor, and can't effectively block gas bubble penetration, and the purity of the obtained gas will be decreased; if the alkali absorption ratio of the PPS fiber structure is too high, the structure of the woven fabric will be certainly too loose, the voids in the woven fabric will be greater, and the performance of the diaphragm will be affected. In consideration of the hydrophilicity and structure of the PPS fiber structure, the alkali absorption ratio of the PPS fiber structure in the present invention preferably is 85 to 180%, more preferably is 100 to 160%.
• the high-performance PPS fiber structure in the present invention is applied to hydrogen generator, and its function is mainly for preventing penetration of gas molecules while allowing penetration of ions. Since different customers have different requirements for the purity of produced hydrogen and oxygen, the requirements for the pore size and gas impermeability of the fabric may be different, but such requirements are irrelevant to the type and texture of the fabric. The fabric can meet the requirements of the customers as long as interpenetration among gas molecules will not happen.
• the method for producing a high-performance PPS fiber structure in the present invention comprises the following steps:
• (1) cotton spinning process processing PPS fibers in 0.1 to 12 ⁇ m cross sectional diameter by opening and cleaning, carding, drawing and roving, drafting the roving to obtain PPS single yarns with yarn count equal to 20 to 60 s and twist factor ⁇ equal to 200 to 310, processing the PPS single yarns by winding, doubling, twisting and thermoforming into PPS yarns with ply number equal to 1 to 6;
• (2) weaving process processing the obtained PPS yarns by warp beaming, drafting, reeding, and weaving, to obtain PPS woven fabric with cover factor equal to 2400 to 2900; the cover factor of woven fabric is a parameter that represents the compactness of the fabric.
• cover factor of woven fabric with tabby is lower than 2400, the gas impermeability of the fabric will be low because of inadequate compactness of the fabric. Consequently, it will be difficult for the woven fabric to block gas penetration, and the purity of the obtained gas and the safety of the production process can't be ensured; if the cover factor of woven fabric with tabby is higher than 2900, the requirement for the loom will be high, and the weaving process will be difficult.
• the cover factor of the woven fabric preferably is 2600 to 2800; (3) post-finishing process: processing the obtained PPS woven fabric by scouring, water washing, drying, and thermoforming at 180 to 200° C.; the optimal experiment conditions for the above-mentioned scouring and thermoforming are as follows: a. Scouring agents used: YK30 12 g/L, YS66 3.0 g/L, and YK37 2.0 g/L b. Temperatures in scouring tanks: tank 1: 40 to 50° C., tank 2: 70 to 80° C., and tank 3: 95 to 105° C. c. Rate: 10 to 14 m/min. d. Thermoforming temperature: 180° C. to 210° C.
• hydrophilic treatment process processing the thermoformed fabric by plasma hydrophilic treatment and/or sulfonated hydrophilic treatment, to obtain a finished product finally.
• hydrophilic groups can be grafted to the surfaces of the PPS fibers, the wetting rate of the PPS woven fabric can be increased, and the liquid content in the PPS woven fabric can be increased.
• the grafting ratio of the obtained fabric after plasma hydrophilic treatment and/or sulfonated hydrophilic treatment may be different.
• the grafting ratio of the PPS woven fabric is 3.0 to 8.0%.
• the method for plasma hydrophilic treatment includes normal pressure plasma treatment and low pressure plasma treatment.
• Normal pressure plasma treatment methods include glow discharge, silent discharge, and corona discharge, wherein, the glow discharge includes direct current, high frequency current, and microwave radiation; the gasses processed by low pressure plasma treatment include oxygen, argon, and nitrogen, etc.
• the plasma hydrophilic treatment preferably is normal pressure plasma DC glow discharge, the conditions of which include: voltage: 5 to 15 V, current: 12 to 18 A, and the content of grated oxygen element accounts for 15 to 25% of the measured element content. After the plasma treatment, concavo-convex pits will be created on the surfaces of the PPS fibers.
• the capillary effect and water absorptivity of the PPS woven fabric can be improved.
• the hydrophilic groups grafted to the surface layer of the PPS fibers includes sulfate, carboxylate, carbonate, hydroxyl, and carbonyl, etc., these grafted hydrophilic groups can improve the water absorption rate of the PPS fibers and improve the purity of hydrogen and oxygen.
• thermoformed fabric is processed by plasma treatment and sulfonation processing
• the thermoformed fabric is processed by plasma treatment to physically etch the PPS yarns and form concavo-convex pits on the surface layer of the fibers to increase the specific surface area of the PPS fibers; then, the PPS fabric is processed by sulfonation processing after the plasma treatment, such that the number of grafted hydrophilic groups can be increased and the hydrophilic property of the PPS fabric will be better.
• the PPS yarns prepared in the step (1) is processed by at least one of plasma treatment, sulfonation processing, and graft copolymerization methods, to obtain hydrophilic PPS yarns.
• the yarn is processed merely by plasma treatment, the fabric may have poor durability, and the hydrophilicity of the fabric after scouring may be degraded.
• the hydrophilicity of the fabric may be decreased owing to the impact of chemicals and high temperature in post-treatment when the graft copolymerization process is used. Therefore, preferably the PPS yarns are sulfonation processing, or more preferably the PPS yarns are sulfonation processing after the plasma treatment.
• the sulfonation processing method is to treating the yarns in a sulfonation treatment liquid (85 to 98% chlorosulfonic acid or concentrated sulfuric acid) at 80 to 120° C. for 1 to 5 min., to graft hydrophilic groups (sulfate, etc.) to the surface layer of the PPS fibers.
• the plasma treatment method may be normal pressure plasma treatment or vacuum plasma treatment. Through plasma treatment, concavo-convex pits are formed on the surface of the PPS fibers, and thereby the capillary effect and water absorptivity of the PPS fibers are improved.
• hydrophilic groups including sulfate, carboxylate, carbonate, hydroxyl, and carbonyl, etc., are grafted to the surface layer of the PPS fibers, so that the water absorption rate of the PPS fibers can be improved, and the purity of hydrogen and oxygen can also be improved.
• the cover factor of the woven fabric is calculated with the following formula:
• N w Density of the fabric in warp direction (yarns/inch);
• D w Fineness of warp filament yarns in the fabric (dtex);
• N f Density of the fabric in weft direction (yarns/inch);
• the pore sizes of the fabric are measured with a capillary flow void measuring instrument (model: CFP-1100-AE, from PMI) in a wet-up/dry-down work mode according to the standard ASTMF316-03.
• the testing environment is 23° C. and 50% RH.
• a fabric sample is placed in a sample chamber, and is wetted with silwick silicone fluid with 19.1 dynes/cm surface tension.
• the bottom fixture in the sample chamber has a porous metal disc in 2.54 cm diameter and 3.175 mm thickness, and the top fixture in the sample chamber has pores in 3.175 mm diameter.
• the average pore size of the fabric can be read out directly. The average value of measurements in two times is taken as the final average pore size value.
• the gas impermeability is measured according to the Article 4.5.2 “Gas Impermeability Test” in the Chinese Building Material Industry Standard JCT 211-2009 “Diaphragm Asbestos Cloth”.
• the water absorption of diaphragm cloth before and after hydrophilic treatment is measured according to GB/T21655.1-2008.
• the water absorption rate is tested according to the Article 7.1.1 “falling-drop method” in JIS L1907-2010 “Water Absorption Testing Method for Fiber Products”.
• An apparatus for testing the area resistance of PPS diaphragm is set up according to the Electronics Industry Standard SJ/T 10171.5-91 “Measurement Methods for Performance of Separator of Alkaline Batteries—Determination of Area-Resistance of Separator” in PRC.
• the parameters of the apparatus are as follows:
• Low-temperature thermostat bath controller a The low-temperature thermostat bath controller is set to ⁇ 5 to 100° C. temperature range and ⁇ 0.05 temperature control deviation (the instrument is Model DC0506 from Shanghai Genggeng Instruments and Equipment Co., Ltd.); (b. Operating temperature: 60° C., the liquid medium is usually dimethyl silicon oil.
• Battery internal resistance tester a Model: AT526 (from Changzhou Applent Precision Instruments Co., Ltd.); b. Resistance test accuracy: 0.5%; voltage test accuracy: 0.01%; c. Test range: resistance: 0.0005 m ⁇ to 33 ⁇ ; voltage: 0.00001 to 120 V DC; d.
• a piece of woven fabric in 40 mm*40 mm size is obtained and the weight G 1 of the woven fabric is weighed; the woven fabric is immersed in 30% KOH solution for 4 h and then is taken out. The woven fabric is hung for half minute, so that the alkaline liquor in the woven fabric drops out; then, the weight G 2 is weighed, and the alkali absorption ratio is calculated.
• the alkali absorption ratio is calculated with the following formula:
• A alkali absorption ratio of the diaphragm, %
• G 1 the mass of the sample before the sample is immersed in the alkaline liquor, g;
• G 2 the mass of the sample after the sample is immersed in the alkaline liquor, g.
• Round PPS fibers in 10 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 40 s, twist equal to 81 T/10 cm, and twist factor equal to 311; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling—twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 4, warp twist and weft twist equal to 45 T/10 cm respectively, and twist factor equal to 346, wherein, the ratio of the twist of the PPS yarns to the twist of the single yarns is 0.56; the obtained PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 55.3 yarns/inch and density in weft direction equal to 48.0 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying and thermoforming at 180°
• a PPS fiber structure with cover factor equal to 2510, thickness equal to 0.64 mm, maximum pore size equal to 16 ⁇ m, average pore size equal to 3.0 ⁇ m (pores in 6 ⁇ m or smaller diameter account for 94% or above of all pores in the woven fabric), area resistance R equal to 2.2 m ⁇ cm 2 , and strength in warp direction and strength in weft direction equal to 900 N/3 cm and 602 N/3 cm respectively is obtained.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• the PPS yarns obtained in the Example 1 are treated with 98% concentrated sulfuric acid at 90° C. for 3 min. to obtain, hydrophilic PPS yarns with grafting ratio equal to 1.8%.
• the obtained hydrophilic PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 55.0 yarns/inch and density in weft direction equal to 48.7 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying, and thermoforming at 180° C.; and then the thermoformed PPS woven fabric is sulfonated.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 8 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 60 s, twist equal to 90 T/10 cm, and twist factor equal to 282; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling-twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 6, warp twist and weft twist equal to 44 T/10 cm respectively, and twist factor equal to 338, wherein, the ratio of the twist of the PPS yarns to the twist of the single yarns is 0.49; the obtained PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 66.3 yarns/inch and density in weft direction equal to 39.0 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying and thermoforming at 180°
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 8 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 40 s, twist equal to 57 T/10 cm, and twist factor equal to 219; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling-twisting—thermoforming procedures to obtain.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 9 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 20 s, twist equal to 48 T/10 cm and twist factor equal to 261; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling—twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 2, warp twist and weft twist equal to 40 T/10 cm respectively, and twist factor equal to 307, wherein, the ratio of the twist of the PPS yarns to the twist of the single yarns is 0.83; the obtained PPS yarns are processed with 98% concentrated sulfuric acid at 90° C.
• hydrophilic PPS yarns with grafting ratio equal to 1.3%.
• the obtained hydrophilic PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 68.3 yarns/inch and density in weft direction equal to 45.2 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying, and thermoforming at 180° C.; and then the thermoformed PPS woven fabric is sulfonated.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 10 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 40 s, twist equal to 81 T/10 cm and twist factor equal to 311; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling—twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 2, warp twist and weft twist equal to 71 T/10 cm respectively, and twist factor equal to 386, wherein, the ratio of the twist of the PPS yarns to the twist of the single yarns is 0.88; the obtained PPS yarns are processed by plasma treatment at normal pressure and then processed with 85% concentrated sulfuric acid at 95° C.
• hydrophilic PPS yarns with grafting ratio equal to 2.6%.
• the obtained hydrophilic PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 88.0 yarns/inch and density in weft direction equal to 64.0 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying, and thermoforming at 180° C.; and then the thermoformed PPS woven fabric is processed by plasma treatment and then processed by sulfonated hydrophilic processing.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 11 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 60 s, twist equal to 90 T/10 cm and twist factor equal to 282; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling—twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 2, warp twist and weft twist equal to 76 T/10 cm respectively, and twist factor equal to 337, wherein, the ratio of the twist of the PPS yarns to the twist of the single yarns is 0.84; the obtained PPS yarns are processed by steaming with polyester hydrophilic resin to obtain hydrophilic PPS yarns with grafting ratio equal to 0.6%.
• the obtained hydrophilic PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 113.0 yarns/inch and density in weft direction equal to 60.0 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying, and thermoforming at 180° C.; and then the thermoformed PPS woven fabric is processed by plasma treatment and then is sulfonated.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 4 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 60 s, twist equal to 90 T/10 cm, and twist factor equal to 282; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling—twisting-thermoforming procedures to obtain PPS yarns with ply number equal to 2, warp twist and weft twist equal to 76 T/10 cm respectively, and twist factor equal to 337, wherein, the ratio of the twist of the PPS yarns to the twist of the single yarns is 0.84; the obtained PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 113.0 yarns/inch and density in weft direction equal to 65.0 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying and thermoforming at
• a PPS fiber structure with cover factor equal to 2497, thickness equal to 0.30 mm, maximum pore size equal to 16 ⁇ m, average pore size equal to 4.2 ⁇ m (pores in 6 ⁇ m or smaller diameter account for 90% or above of all pores in the woven fabric), area resistance R equal to 1.4 m ⁇ cm 2 , and strength in warp direction and strength in weft direction equal to 625 N/3 cm and 378 N/3 cm respectively is obtained.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 7 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 60 s, twist equal to 90 T/10 cm, and twist factor equal to 282; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling—twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 4, warp twist and weft twist equal to 54 T/10 cm respectively, and twist factor equal to 339, wherein, the ratio of the twist of the PPS yarns to the twist of the single yarns is 0.60; the obtained PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 90.0 yarns/inch and density in weft direction equal to 60.0 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying and thermoforming at 180° C
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 11 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 20 s, twist equal to 56 T/10 cm and twist factor equal to 304; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling—twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 2, warp twist and weft twist equal to 24 T/10 cm respectively, and twist factor equal to 184, wherein, the ratio of the twist of the PPS yarns to the twist of the single yarns is 0.43; the obtained PPS yarns are processed by plasma treatment at normal pressure and then processed with 85% concentrated sulfuric acid at 95° C.
• hydrophilic PPS yarns with grafting ratio equal to 2.8%.
• the obtained hydrophilic PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 58.0 yarns/inch and density in weft direction equal to 54.0 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying, and thermoforming at 180° C.; and then the thermoformed PPS woven fabric is sulfonated.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 8 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 20 s, twist equal to 48 T/10 cm and twist factor equal to 261; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling—twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 2, warp twist equal to 40 T/10 cm and twist factor equal to 307, wherein, the ratio of the twist of the warp yarns to the twist of the single yarns is 0.83; and weft twist equal to 36 T/10 cm and twist factor equal to 277, wherein, the ratio of the twist of the weft yarns to the twist of the single yarns is 0.75.
• the obtained PPS yarns are processed with 98% concentrated sulfuric acid at 90° C. for 3 min. to obtain hydrophilic PPS yarns with grafting ratio equal to 1.5%.
• the obtained hydrophilic PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 68.3 yarns/inch and density in weft direction equal to 44.0 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying, and thermoforming at 180° C.; and then the thermoformed PPS woven fabric is sulfonated.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 8 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 40 s, twist equal to 81 T/10 cm and twist factor equal to 311; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling-twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 2, warp twist equal to 80 T/10 cm and twist factor equal to 435, wherein, the ratio of the twist of the warp yarns to the twist of the single yarns is 0.99; and weft twist equal to 60 T/10 cm and twist factor equal to 326, wherein, the ratio of the twist of the weft yarns to the twist of the single yarns is 0.74.
• the obtained PPS yarns are processed with 98% concentrated sulfuric acid at 90° C. for 3 min. to obtain hydrophilic PPS yarns with grafting ratio equal to 1.8%.
• the obtained hydrophilic PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 88.0 yarns/inch and density in weft direction equal to 62.0 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying, and thermoforming at 180° C.; and then the thermoformed PPS woven fabric is sulfonated.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 6 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 60 s, twist equal to 90 T/10 cm and twist factor equal to 282; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling-twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 3, warp twist equal to 54 T/10 cm and twist factor equal to 293, wherein, the ratio of the twist of the warp yarns to the twist of the single yarns is 0.60; and weft twist equal to 40 T/10 cm and twist factor equal to 217, wherein, the ratio of the twist of the weft yarns to the twist of the single yarns is 0.44.
• the obtained PPS yarns are woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 95.0 yarns/inch and density in weft direction equal to 68.0 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying, and thermoforming at 180° C.; and then the thermoformed. PPS woven fabric is sulfonated.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 10 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 20 s, twist equal to 48 T/10 cm and twist factor equal to 261; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling—twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 2, warp twist equal to 36 T/10 cm and twist factor equal to 277, wherein, the ratio of the twist of the warp yarns to the twist of the single yarns is 0.75; and weft twist equal to 40 T/10 cm and twist factor equal to 307, wherein, the ratio of the twist of the weft yarns to the twist of the single yarns is 0.83.
• the obtained PPS yarns are processed with 98% concentrated sulfuric acid at 90° C. for 3 min. to obtain hydrophilic PPS yarns with grafting ratio equal to 1.3%.
• the obtained hydrophilic PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 58.2 yarns/inch and density in weft direction equal to 50.3 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying, and thermoforming at 180° C.; and then the thermoformed PPS woven fabric is sulfonated.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• Round PPS fibers in 0.8 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 60 s, twist equal to 90 T/10 cm and twist factor equal to 282; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling—twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 6, twist equal to 45 T/10, and twist factor equal to 346, wherein, the ratio of the twist of the yarns to the twist of the single yarns is 0.50; the obtained PPS yarns are processed by plasma treatment to obtain hydrophilic PPS yarns with grafting ratio equal to 0.8%.
• the obtained hydrophilic PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 65.0 yarns/inch and density in weft direction equal to 51.5 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying, and thermoforming at 180° C.; and then the thermoformed PPS woven fabric is processed by plasma treatment.
• the properties of the PPS fiber structure obtained in the present invention are assessed and shown in Table 1.
• the PPS fiber structures obtained in the Examples 1 to 15 can be applied in diaphragms for electrolytic apparatuses, high-temperature liquid filter materials and insulating materials.
• Round PPS fibers in 13 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 20 s, twist equal to 56 T/10 cm, and twist factor equal to 304; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling—twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 2, warp twist and weft twist equal to 60 T/10 cm respectively, and twist factor equal to 461, wherein, the ratio of the twist of the PPS yarns to the twist of the single yarns is 1.07; the obtained PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 67.0 yarns/inch and density in weft direction equal to 46.0 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying and thermoforming at 180° C.
• the properties of the PPS fiber structure are assessed and shown in Table 1.
• Round PPS fibers in 14 ⁇ m cross sectional diameter are processed through scutching—carding—drawing—roving—fine yarns—winding—thermoforming procedures to obtain PPS single yarns with yarn count equal to 20 s, twist equal to 56 T/10 cm, and twist factor equal to 304; the obtained PPS single yarns are span through a cotton spinning process including winding—doubling-twisting—thermoforming procedures to obtain PPS yarns with ply number equal to 4, warp twist and weft twist equal to 40 T/10 cm respectively, and twist factor equal to 435, wherein, the ratio of the twist of the PPS yarns to the twist of the single yarns is 0.71; the obtained PPS yarns are used as warp yarns and weft yarns and woven on a loom to obtain grey cloth with tabby having density in warp direction equal to 45.0 yarns/inch and density in weft direction equal to 30.0 yarns/inch; the obtained grey cloth is processed by scouring, water washing, drying and thermoforming at 180° C
• the properties of the PPS fiber structure are assessed and shown in Table 1.

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• 2015
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