Classifications

• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
  • C01G23/00—Compounds of titanium
  • C01G23/003—Titanates
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/36—Selection of substances as active materials, active masses, active liquids
  • H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
  • H01M4/485—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of mixed oxides or hydroxides for inserting or intercalating light metals, e.g. LiTi2O4 or LiTi2OxFy
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
  • C01G23/00—Compounds of titanium
  • C01G23/003—Titanates
  • C01G23/005—Alkali titanates
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/052—Li-accumulators
  • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
  • H01M4/131—Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
  • H01M4/621—Binders
  • H01M4/622—Binders being polymers
  • H01M4/623—Binders being polymers fluorinated polymers
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
  • C01P2002/00—Crystal-structural characteristics
  • C01P2002/50—Solid solutions
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
  • C01P2006/00—Physical properties of inorganic compounds
  • C01P2006/40—Electric properties
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
  • H01M4/621—Binders
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/64—Carriers or collectors
  • H01M4/66—Selection of materials
  • H01M4/661—Metal or alloys, e.g. alloy coatings
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/10—Energy storage using batteries

Definitions

• hybrid vehicles use multiple propulsion systems to provide motive power.
• the most commonly referenced hybrid vehicles are gasoline-electric hybrid vehicles, which use gasoline (petrol) to power internal-combustion engines (ICEs), and electric batteries to power electric motors.
• Such hybrid vehicles recharge their batteries by capturing kinetic energy via regenerative braking.
• ICEs internal-combustion engines
• Gasoline -electric hybrid vehicles differ from all-electric vehicles, as the latter use batteries charged by an external source (such as from a power grid), or a range extending trailer.
• nearly all hybrid vehicles still require gasoline as their sole fuel source, although other types of fuel, such as diesel fuel, cthanol, or other plant- based oils, have also seen occasional use.
• Batteries and cells are important energy storage devices well known in the art. Electrical energy is produced in the battery by the chemical reaction that occurs between two dissimilar electrode plates that are immersed in an electrolyte solution.
• the largest demand placed on the battery occurs when it must supply current to operate a motive motor at acceleration, such as a situation when a battery is used to start a vehicle.
• the amperage requirements of the motive motor may be over several hundred amps.
• Most battery types that have a large volume (or level of current supply) require large packaging which results in large weight of the battery, and is therefore not cost effective. At the same time, such high currents are required for the very limited time, usually seconds. Therefore, so called "high-rate" batteries are required for certain applications.
• a typical lithium-ion cell consists of a positive electrode (a "cathode” or a “cathode matrix”), a negative electrode (an “anode” or an “anode matrix”) and an electrolyte (a solution or a solid-state product) containing dissociated salts separated by a micro-porous membrane (a "separator").
• the lithium ions transfer between the two electrodes through the electrolyte.
• lithium ions are extracted from the cathode matrix, go through the electrolyte and separator and intercalate into the anode matrix.
• electrons are released from the cathode, go through the external circuit and are accepted by anode compounds.
• the reverse process occurs during the discharging process.
• Metal oxides such as lithium metal oxides, have found utility in secondary batteries as cathode and anode intercalating materials.
• 2 has been found to be an attractive material for electrodes (Colbow et al., J. Power Sources, 26(3-4), pp. 397-402 (1989)).
• the formal valence of titanium is +4, which is the highest achievable oxidation state possible for titanium (Zachau-Christiansen et al., Solid Stale Ionics, 40-41 part 2, pp. 580-584 (1990)).
• This Li 4 TisOi 2 material has been found to intercalate lithium ions without strain or shrinkage to the lattice (Ohzuku et al., J Electrochem Soc, 142(5), pp. 1431 -1435 (1995)) making it ideal for hybrid electric vehicle (“HEV”) applications.
• the lithium insertion reaction (intercalation) at the anode is:
• This reaction occurs at approximately 1 .5V vs. metallic lithium.
• the titanium is reduced from the +4 state to the +3 state, with the mean oxidation state of 3.4 (60% Ti + and 40% Ti 4+ ) when fully intercalated.
• United States Patent No. 4,366,431 to Santini and United States Patent No. 5,126,649 to Osanai teach methods for detecting bubbles in the electrolyte and making adjustments to charging rate accordingly.
• United States Patent No. 6,437,542 to Liaw et al. and United States Patent No. 6,459,238 to Minamiura et al. teach methods for measuring and monitoring pressure within the cell and control charging based on the cells pressure profile.
• dopants are also well known in the art as a means to improve the thermal stability and overcharge protection in fully charged lithium metal oxides.
• Ohzuku et al. J. Electrochem Soc, 142(12), pp. 4033-4039
• doping lithium nickelates LiAI with Al 3+ and producing improved thermal stability and overcharge protection.
• United States Patent No. 6,794,085 to Gao et al. United States Patent No. 6,040,089 to Mancv et al.
• Battery gassing is a constant issue in the battery design and manufacturing process
• the disclosure of the present application provides a solution to such a problem, with at least one advantage thereof being to provide a highly safe electrode material for a lithium cell that excels in charge-discharge cycle durability while reducing or eliminating gassing during use.
• the disclosure of the present application provides various compositions, and methods for preparing the same, which may be useful, for example, to prepare one or more anodes of the present disclosure. Such anodes may be useful, for example, to prepare one or more batteries which themselves, for example, may be useful in connection with a vehicle as referenced herein.
• This disclosure of the present application relates to metal oxide compounds and methods of making the same.
• the present disclosure relates to doped metal oxide insertion compounds for use in lithium and lithium-ion batteries.
• the disclosure provides a composition of an anode of spinel-type structure with a dopant material that will replace some of the transition metal, and which may also replace some oxygen in the anode, and yet will maintain the overall potential of the electrode below -1.7V vs. lithium.
• the effect is the dopant metal would be reduced instead of the primary transition metal during cycling and reduces the gassing caused by the primary transition metal.
• the anode comprises a lithium-based compound having the formula wherein M comprises a dopant material, and wherein 0 ⁇ y ⁇ 1.
• the dopant material may comprise molybdenum (Mo), tungsten (W), zirconium (Zr), or hafnium (Hf).
• the anode comprises a lithium-based compound having the formula LL 4 Ti5.yMyO 12 . z Xz, wherein M comprises a dopant material, wherein X comprises a chalcogen, wherein O ⁇ y ⁇ 1, and wherein O ⁇ z ⁇ 2y.
• the chalcogen may comprise sulfur (S), selenium (Se) or tellurium (Te).
• the battery comprises an anode, a cathode, and an electrolyte, wherein the anode comprises a lithium-based compound.
• the lithium-based compound has the formula Li 4 Ti 5 .yM y Oi 2 , wherein M comprises a dopant material, and wherein O ⁇ y ⁇ 1.
• the lithium-based compound has the formula wherein M comprises a dopant material, wherein X comprises a chalcogen, wherein O ⁇ y ⁇ 1 , and wherein O ⁇ z ⁇ 2y.
• the method comprises the step of introducing amounts of a first material, a second material, and a third material to a vessel, wherein the first material comprises lithium, wherein the second material comprises titanium and oxygen, and wherein the third material comprises a dopant material and a chalcogen.
• a method further comprises the steps of grinding the first material, the second material, and the third material within the vessel, and heating the ground vessel contents for a period of time at an elevated temperature to create the lithium-based composition.
• the method comprises the steps of preparing a lithium-based composition of the disclosure of the present application, introducing the lithium-based composition, a conductive medium, a graphite source, and a binder to a receptacle, mixing the contents of the receptacle to form a mixture, and placing the mixture on a metallic substrate to form at least a portion of an anode.
• compositions, and methods for preparing the same which may be useful, for example, to prepare one or more anodes of the present disclosure.
• Such anodes may be useful, for example, to prepare one or more batteries which themselves, for example, may be useful in connection with a vehicle as referenced herein.
• the anode comprises a lithium-based compound having the formula Li 4 TiS- J -MyOi 2 , wherein M comprises a dopant material, and wherein 0 ⁇ y ⁇ 1.
• the dopant material may comprise molybdenum (Mo), tungsten (W), zirconium (Zr), or hafnium (Hf).
• y 0.1 , so that the lithium-based compound has the formula Li4Ti4.9M0. 1 O 12 .
• the dopant material comprises molybdenum, so that the lithium-based compound has the formula Li 4 Tis. y M ⁇ yO
• the lithium-based compound has the formula Li 4 Ti4.9Moo. 1 O 12 .
• the anode comprises a lithium-based compound having the formula Li 4 Ti5.yMyO1 2 .zXz, wherein M comprises a dopant material, wherein X comprises a chalcogen, wherein O ⁇ y ⁇ 1 , and wherein O ⁇ z ⁇ 2y.
• the chalcogen may comprise sulfur (S), selenium (Se) or tellurium (Te).
• the dopant material comprises molybdenum
• the chalcogen comprises sulfur
• z 0.2, so that the lithium-based compound has the formula Li 4 Ti 4 9M0 i ⁇
• said anode comprises at least a portion of a battery.
• Such a battery may comprise a lithium- ion cell or any other battery wherein such an anode is useful therein.
• the battery is rechargeable. Any or all of the various features and/or limitations disclosed herein regarding embodiments of an anode, or the various anodes themselves, may be useful in connection with any or all of the various batteries disclosed herein.
• the battery comprises a cathode, a separator plate positioned at least partially between the anode and the cathode, and an electrolyte, wherein during a charging and discharging battery cycle, at least a portion of the dopant material would be reduced prior to a reduction of titanium.
• the reduction of at least a portion of the dopant material prior to the reduction of titanium reduces gassing caused by the reduction of titanium.
• the overall potential is below approximately 1.7V versus lithium.
• the anode further comprises graphite, and may further comprise a binder effective to bind the lithium- based compound to the graphite.
• the binder comprises polyvinylidine fluoride (PVDF) and N-methyl pyrolinidone (NMP).
• PVDF polyvinylidine fluoride
• NMP N-methyl pyrolinidone
• the lithium-based compound bound to the graphite may positioned on a metallic substrate, such as copper foil.
• the battery comprises an anode, a cathode, and an electrolyte, wherein the anode comprises a lithium-based compound.
• the lithium-based compound has the formula Li4Ti5. y M y Oi 2 , wherein M comprises a dopant material selected from the group consisting of molybdenum, tungsten, zirconium, and hafnium, and wherein 0 ⁇ y ⁇ 1.
• M comprises Mo, so that the lithium-based compound of the anode of the battery has the formula
• the lithium-based compound of the anode of the battery has the formula Li 4 TJs. yMyOi 2 . z Xi, wherein M comprises a dopant material selected from the group consisting of molybdenum, tungsten, zirconium, and hafnium, wherein X comprises a chalcogen, wherein O ⁇ y ⁇ I , and wherein O ⁇ z ⁇ 2y.
• the chalcogen may comprise sulfur, selenium or tellurium.
• the lithium-based compound of the anode of the battery has the formula Li 4 Ti 5 .
• the dopant material comprises molybdenum
• the chalcogen comprises sulfur
• the battery comprises an anode, a cathode, and an electrolyte, wherein the anode comprises a spinel and at least one dopant selected from the group consisting of molybdenum, tungsten, zirconium, and hafnium.
• the spinel comprises at least one lithium metal oxide.
• the lithium metal oxide comprises
• any or all of the various features and/or limitations disclosed herein regarding embodiments of a battery or portion of a battery, or the various batteries or portions of the various batteries themselves, may be useful in connection with any or all of the various batteries disclosed herein.
• an exemplary embodiment of an anode referenced herein may be used within an exemplary embodiment of a battery disclosed herein, although the specific anode embodiment and the specific battery embodiment was not specifically referenced in connection with one another.
• exemplary compound of the present disclosure may have the formula Li 4 Tis. y M y O
• M comprises a dopant material selected from the group consisting of molybdenum, tungsten, zirconium, and hafnium
• 0 ⁇ y ⁇ 1 without such a compound having the sole use of being used in connection with the preparation of an anode of the present disclosure.
• Such compounds may have one or more other uses, and as such, any reference to a compound within the disclosure of the present application is not intended to be, and should not be treated as, having a sole utility in connection with anodes.
• a vehicle of the present disclosure may comprise a battery of the present disclosure, wherein the battery comprises an anode, a cathode, and an electrolyte, wherein the anode comprises a lithium-based compound having the formula wherein M comprises a dopant material selected from the group consisting of molybdenum, tungsten, zirconium, and hafnium, and wherein 0 ⁇ y ⁇ 1.
• an exemplary vehicle of the disclosure of the present application comprises a battery comprising an anode comprising a lithium-based compound having the formula wherein M comprises a dopant material selected from the group consisting of molybdenum, tungsten, zirconium, and hafnium, wherein X comprises a chalcogen selected from the group consisting of sulfur, selenium and tellurium, wherein O ⁇ y ⁇ 1 , and wherein O ⁇ z ⁇ 2y.
• At least one advantage of the disclosure of the present application is to provide materials that can also be used as dopants when mixed with anodic lithium metal oxide that will not reduce the overall cell potential.
• dopants, or combinations of dopants may be selected to replace some of the transition metal in a LiM y O z system as disclosed herein, but still keep the overall potential below 1.7V.
• the disclosure of the present application is not limited to any one specific dopant.
• the titanium can be replaced by molybdenum, tungsten, zirconium, or hafnium (Hf), and still maintain a potential below 1.7V.
• the formula for the active anode material would be LL)Ti 5 .
• the disclosure of the present application contains embodiments, in addition to replacing the primary transition metal, which replace some of the oxygen with another dopant material as well, such as with sulfur (S), selenium (Se) or tellurium (Te).
• S sulfur
• Se selenium
• Te tellurium
• a general objective remains the same in that gassing would be reduced and the overall potential of the electrode would remain below 1.7V.
• Molybdenum disulfide (M0S 2 ) for example, as an active material has a potential of ⁇ 1.6V vs. Li.
• Employing the sulfur in place of oxygen will help reduce the material voltage.
• An exemplary rechargeable lithium-ion battery whose anode comprises such an electrode material layer has significant advantages such that the magnitude of the volume expansion of the anode when lithium is inserted upon charging and the magnitude of the volume shrinkage of the anode when said lithium is released upon discharging are slight.
• the performance of such an anode is more difficult to deteriorate even when charge- and-discharge cycle is repeated over a long period of time, providing such a rechargeable lithium-ion battery with an improved charge-and-discharge cycle life.
• An exemplary lithium-based compound of the present disclosure may be prepared as follows.
• a method for preparing a lithium-based compound comprises the steps of introducing amounts of a first material, a second material, and a third material to a vessel, grinding those ingredients, and heating those ingredients for a period of time at an elevated temperature to create the lithium-based composition.
• the first material comprises lithium
• the second material comprises titanium and oxygen
• the third material comprises a dopant material and a chalcogen.
• a fourth material namely gas
• the gas would be introduced to the vessel by providing a flow of the gas to the vessel during the heating step.
• a gas may comprise air, oxygen gas, or any other suitable gas containing oxygen.
• the dopant material would comprise molybdenum, tungsten, zirconium, or hafnium, and the chalcogen would comprise sulfur, selenium and tellurium.
• the following ingredients may be used: lithium carbonate as the first material, titanium dioxide or anatase titanium dioxide as the second material, and/or molybdenum disulfide as the third material.
• the ingredients may be ground in a vessel using any number of known grinding methods, including the use of a mortar and pestle and/or a ball mill. Such grinding methods illustrated herein are not intended to limit the scope of the present disclosure as other suitable grinding methods may be used.
• the method would comprise grinding the ingredients in a first vessel, such as a mortar, and heating the ingredients in a second vessel, such as a platinum crucible.
• the heating step in at least one method of preparing an exemplary lithium-based compound, would last approximately 24 hours at an elevated temperature is approximately 900 0 C.
• an exemplary lithium-based compound After an exemplary lithium-based compound is prepared, it may be stored in a light-proof plastic container, for example, or it may be used to prepare an anode as referenced herein.
• the desired lithium-based composition comprises a compound of the formula Li4Ti5.yMyO12.zX2, wherein M comprises the dopant material, wherein X comprises the chalcogen, wherein 0 ⁇ y ⁇ 1, and wherein 0 ⁇ z ⁇ 2y.
• the dopant material may comprise consisting of molybdenum, tungsten, zirconium, or hafnium, and the chalcogen may comprise sulfur, selenium and tellurium.
• the dopant material comprises molybdenum
• the chalcogen comprises sulfur
• z 0.2.
• At least one method of preparing an exemplary lithium-based compound is as follows.
• O n ,S 0 2 are lithium carbonate (Li 2 CO 5 ) as the Li source, anatase titanium dioxide (TiO-) as the titanium and oxygen source, molybdenum disulfide (M0S 2 ) as the molybdenum (dopant material) and sulfur (chalcogen) source, and dry air as the rest of the oxygen.
• An exemplary anode of the present disclosure may be prepared as follows.
• a method for preparing at least a portion of an anode comprising the steps of preparing a lithium-based composition of the disclosure of the present application, introducing the lithium-based composition, a conductive medium, a graphite source, and a polymer/binder to a receptacle, mixing those items together, and placing the mixture on a metallic substrate to form at least a portion of an anode.
• Any or all of the various features, steps, and/or limitations disclosed herein regarding the preparation of a lithium-based composition of the present disclosure may be applicable to the preparation of a lithium-based composition useful to prepare an anode or a portion thereof.
• the conductive medium may comprise acetylene black ( ⁇ enka black).
• the polymer/binder may comprise polyvinylidine fluoride (PVDF) and N-methyl pyrolinidone (NMP), and/or the graphite source may comprise SGF6 graphite, also known as Superior Graphite.
• small aliquots of the polymer/binder may be added over time to the conductive medium, the graphite source, and the lithium-based compound. Mixing may be stopped when the mixture reaches a desired viscosity. In a least one embodiment, the mixing step is completed when the mixture reaches a viscosity between about 5100 cP and about 5300 cP as indicated by a viscometer operating at approximately 20 RPM.
• the mixture may be positioned on a metallic substrate, such as, for example, copper foil, and dried to prepare at least a portion of an anode.
• a metallic substrate such as, for example, copper foil
• the disclosure of the present application is not intended to be limited to any specific metallic substrate, as, for example, one or more other metallic substrates, such as an aluminum foil, may be suitable for the preparation of an exemplary anode, or part of an anode, of the present disclosure.
• the step of placing the mixture on a metallic substrate comprises feeding the mixture through a fixed-gap slot dye onto the metallic substrate, wherein the metallic substrate is rotated about a spool.
• the fixed-gap is fixed at 5 ⁇ m.
• an exemplary method of preparing at least a portion of an anode may further comprise the step of drying the at least a portion of an anode for a period of time at an elevated temperature under a vacuum.
• the period of time is approximately 15 hours, and wherein the elevated temperature is approximately 12O 0 C.
• B So 2 are prepared for a lithium-ion cell electrode.
• 2g of Denka black (acetylene black, a conductive medium) and 2g of SGF6 graphite (Superior Graphite) were combined.
• 33.73g of 13% PVDF solution in N-methyl pyrolinidone (NMP) (binder) was added to the mixture.
• NMP N-methyl pyrolinidone
• a roll of l O ⁇ m thick copper foil was mounted on a source spool and wound through a coating head made up of a driver roller and a fixed gap slot dye. The gap was fixed to 5 ⁇ m, and the mixture/slurry as prepared above was is fed through the dye and onto the copper foil.
• the NMP was removed by drying in a forced air convection oven in line on the coater.
• the coated copper foil was transferred to the dry room, and dried at 120 0 C for 15hr under a vacuum.
• the dried electrode stock was allowed to cool to room temperature under vacuum, and was then sealed in a laminated foil pouch to protect the coating until used.
• the disclosure may have presented a method and/or process as a particular sequence of steps.
• the method or process should not be limited to the particular sequence of steps described.
• other sequences of steps may be possible. Therefore, the particular order of the steps disclosed herein should not be construed as limitations of the present disclosure.
• disclosure directed to a method and/or process should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present disclosure.

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