WO2012158354A1 - Planches de fibres hydrofuges - Google Patents

Planches de fibres hydrofuges Download PDF

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Publication number
WO2012158354A1
WO2012158354A1 PCT/US2012/036220 US2012036220W WO2012158354A1 WO 2012158354 A1 WO2012158354 A1 WO 2012158354A1 US 2012036220 W US2012036220 W US 2012036220W WO 2012158354 A1 WO2012158354 A1 WO 2012158354A1
Authority
WO
WIPO (PCT)
Prior art keywords
reactive silicone
water
aqueous slurry
fiber
slurry
Prior art date
Application number
PCT/US2012/036220
Other languages
English (en)
Inventor
Qing Claire Yu
Original Assignee
Usg Interiors, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Usg Interiors, Llc filed Critical Usg Interiors, Llc
Priority to JP2014510360A priority Critical patent/JP2014520218A/ja
Priority to CA2836771A priority patent/CA2836771A1/fr
Priority to MX2013012867A priority patent/MX2013012867A/es
Priority to RU2013154971/03A priority patent/RU2013154971A/ru
Priority to BR112013028099A priority patent/BR112013028099A2/pt
Priority to EP12721098.7A priority patent/EP2710200A1/fr
Priority to KR1020137031312A priority patent/KR20140026533A/ko
Priority to AU2012256273A priority patent/AU2012256273A1/en
Priority to CN201280020870.4A priority patent/CN103534424A/zh
Publication of WO2012158354A1 publication Critical patent/WO2012158354A1/fr

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84Sound-absorbing elements
    • E04B1/86Sound-absorbing elements slab-shaped
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02Macromolecular compounds
    • C04B26/28Polysaccharides or derivatives thereof
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/16Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20Resistance against chemical, physical or biological attack
    • C04B2111/27Water resistance, i.e. waterproof or water-repellent materials
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Definitions

  • the field relates to an acoustic building material or fiber board as well as a method for its manufacture, and more particularly, to fiber board having increased water repellency and improved physical properties.
  • the fiber board includes a reactive silicone homogeneously dispersed within the board construction .
  • the acoustic building material or fiber board may be in the form of a ceiling tile, a ceiling panel, a wall panel or wall tile as are well known in the building trades.
  • the boards are prepared from a slurry of fibers, fillers, binders and other ingredients.
  • the boards are typically prepared using the slurry in a water felting process as is known in the art.
  • a dispersion of fiber, filler, binder and other ingredients flow onto a moving, porous support such as a Fourdrinier forming machine for dewatering.
  • the dispersion is dewatered first by gravity and then by vacuum suction.
  • the wet base mat is dried in heated convection drying ovens and the dried material is cut to the desired dimensions and optionally coated to produce the acoustic panels and tiles.
  • a wall covering is typically applied to the division wall using a water-based adhesive.
  • the base fibers are usually mineral fibers such as mineral wool or glass fibers. Also, c fiber may be used. Frequently, the organic fiber is cellulosic fiber in the form of recycled newsprint.
  • the fillers are commonly perlite, clay, calcium carbonate, or stucco (gypsum) .
  • the binder is typically starch, latex, or similar materials. These materials or ingredients are
  • the binder forms bonds with the other materials to provide a fibrous network that provides strength and rigidity to the core.
  • the core should have sufficient strength and rigidity to remain planar in its panel configuration during use.
  • the panel density is sufficient to provide the perception of solidarity
  • the wall density should be greater than about 16 pounds per ft 3 (pcf) .
  • the division wall should display water repellency sufficient to withstand liquid contact imposed in subsequent wall finishing and/or wall use applications.
  • constructions tend to be porous and hydrophilic, susceptible to moisture absorption and to the ingress of liquid applied to the wall surface. It is customary to adhesively apply a wall covering, such as fabric, to division wall surfaces to provide a desired aesthetic appearance.
  • the fabric or other wall covering is applied using a water-based adhesive.
  • the water absorbency or natural take-up of water by the panel has been found to hinder the achievement of the desired strong adhesive bond between the wall covering and the panel.
  • sizing agents are used with the panel to act as water repellants.
  • Typical sizing materials include paper sizing materials such as imidazolidone reactive sizing agents.
  • the prior agents are characterized by an undesirable level of volatile organic component or VOC during drying or curing.
  • the MSDS indications of these products respectively include a formaldehyde content of 0.3% and 0.113%.
  • imidazolidone based sizing agents contribute to the VOC and are believed to be responsible for a "blue haze" observed at the production plant exhaust system. It is desirable to reduce or eliminate the haze. In any case, imidazolidone agents may contribute to both process VOC and product
  • US Patent 5,964,934 teaches that the water retention of expanded perlite contained in the composition of acoustic tiles may be reduced by initially spray coating the perlite with a silicone and drying the treated perlite at an elevated temperature to cure the silicone.
  • the composition containing the treated perlite may be formed into an acoustic tile using a water felting process.
  • the water retention of the base mat containing the silicone treated perlite is reduced without affecting the physical properties of the resulting tile.
  • the reduction in water retention is indicated to enable increased manufacturing line speeds.
  • S Patent 5,539,028 discloses the incorporation of silicone fluid comprising polymethylhydorgensiloxane (PMHS) into the slurry used to form fiberboard for improving the water resistance without affecting the physical properties of the board.
  • the fiberboard may contain mineral fiber, non- fibrous inorganic filler, organic fiber and a binder such as starch .
  • reactive additives may be incorporated in acoustic building materials or fiber boards to improve water repellency.
  • the reactive additives also improve the physical properties of the material or board.
  • the reactive additives may be included in division wall ingredients at relatively low levels to provide water
  • the level of water repellency achieved is sufficient to provide improved adhesion for subsequently applied wall coverings using water based adhesive.
  • the additive is homogenously dispersed in the aqueous slurry used to form the core or base mat to provide the desired water repellency .
  • the reactive additives comprise reactive silicones or silicone fluids, and particularly those having a
  • polydimethylsiloxane backbone with substituted reactive side chains and/or ends.
  • hydrophilic side chains such as polyether side chains.
  • One preferred silicone includes alpha-iso-tridecly-omega-hydroxy polyglycolether side chains.
  • Another preferred silicone has a similar polyether side chain and further includes an amino-functional polydimethylsiloxane.
  • dispersion of the reactive silicone in the slurry composition provides a desired water repellency that is superior to that of the imidazolidone agents. Further, the reactive silicone has been found to reduce the cost of the water repellant ent in wall panel applications due to lower usage and increased effectiveness.
  • the reactive silicone also improves the mechanical properties of the panel. Particularly, improved strength characterized by increased modulus of rupture (MOR) and ball hardness is achieved. This is most unexpected since the prior art use of polymethylhydorgensiloxane (PMHS) silicone does not result in improved panel physical properties. In addition, no deleterious effect on other physical properties has been observed at the required silicone levels for water repellency.
  • MOR modulus of rupture
  • PMHS polymethylhydorgensiloxane
  • the reactive silicones provide the desired water repellency for the above adhesion purposes at concentrations also providing improved physical properties. Accordingly, the resulting division wall has increased water repellency and improved strength as indicated by increased modulus of rupture.
  • the reactive silicones tend to reduce, if not eliminate, the objectionable VOC emissions associated with processing.
  • preferred silicones are characterized by a water by-product upon curing so as to substantially
  • the fiber and filler components comprise the primary ingredients.
  • the following chart summarizes typical ceiling and wall compositions. It should be appreciated that the compositions may contain one or more of the illustrative types of fiber, filler, binder or reactive silicone as listed in the following table. The percentages herein are weight percent based on solids unless otherwise indicated by comment or context.
  • PDMS polyether 0.02 - 0.5 s 0.1 0.15
  • PDMS polyether/amino; 0.02 - 0.5 0.1 0.15
  • the fiber, filler and binder components are combined in aqueous slurry at a level of about 3% to 6% solids in a known manner.
  • the reactive silicone is added and homogenously blended into the slurry. Hydrophilic groups present in the silicone enhance the uniform distribution of the silicone and the thorough penetration and wetting of the fiber and filler slurry ingredients.
  • the division walls or wall panels of interest herein include base fibers that are usually mineral fibers such as mineral wool or glass fibers. Also, organic fiber such as cellulosic fiber derived from recycled newsprint may be used.
  • the fillers are commonly perlite, clay, calcium carbonate, or stucco.
  • the binder is typically starch, latex, or similar materials. These materials or ingredients are typically combined in aqueous slurry, and processed in a water felting process as described above.
  • the ted agents include the following commercially available products .
  • Imidazolidone A an imidazolidone reactive sizing.
  • the sizing is supplied as an emulsion that contains 45% solids and it was evaluated at an addition rate of about 0.75% based on the dry stock weight.
  • This sizing is supplied as an emulsion that contains 30% solids and it was evaluated at an addition rate of about
  • SILRES BS 1042 is a reactive PDMS supplied by Wacker Chemie AG as an emulsion containing 60% solids.
  • the silicone has an alpha-iso-tridecly-omega-hydroxy polyglycolether side chain and the curing by-product is water.
  • SILRES BS 1306 is a reactive PDMS also supplied by
  • Wacker Chemie AG as an emulsion containing 55% solids.
  • the silicone has an alpha-iso-tridecly-omega-hydroxy
  • the curing by-product is methanol.
  • Three wall panel Tappi boards were prepared using the following formulation: 35% mineral wool; 30% perlite; 18% recycled newsprint; 13% corn starch and 4% clay. The stock consistency was 4.5% solids, and 0.08% flocculent was added to the slurry. The boards were formed with a 0.5" thickness and a target density of 17 pounds/ft. 3 (pcf) . Different grades of wall panel may be simulated in accordance with product
  • the wet boards were dried in an air-circulating oven for 45 minutes at 600° F. fter, the drying was completed at 300° F for 3 hours.
  • the Tappi boards were cut into 3" x 10" and 4"x 4" samples and tested . Test Procedures
  • the MOR and ball hardness measurements were carried out on an APL Instron (Model 1130) .
  • the 3" x 10" samples were used for the MOR measurement.
  • a 2" diameter steel ball is pressed at a constant rate into the board to a depth of 1/8" and the maximum force is reported.
  • the 4" x 4" square samples were used for the water absorption test. The samples were first weighed individually, and then immersed in 70° F tap water and held at a depth of approximately 6-8 inches below the water surface for 1 hour. After 1 hour, the samples were taken from the water and re- weighed after excess surface water had been removed by tapping with a dry paper towel.
  • Absolute water absorption is expressed as the weight difference before and after immersion for each sample.
  • the percent water absorption is the percent of water of absorbed compared to the original dry weight of the test sample.
  • the overall test results show the effectiveness of the silicones as water repellants even at the low concentrations employed. Also, there is an increase in the MOR values as compared with the controls and the wax based products. The silicones did not adversely affect the physical properties of the boards.
  • the board composition included the following ingredients: 35% mineral wool; 30% perlite; 18% recycled newsprint; 13% corn starch and 4% clay. The stock consistency was 4.5% solids, and approximately 0.08% a flocculent was added. The boards were formed with a thickness of 0.5" and a target density of 23 pounds/ft. 3 (pcf) . This formulation was varied to provide Tappi board Sample 1 containing no water repellant, Tappi board Sample 2 containing 0.45% Imidazolidone A and Tappi board Sample 3 containing 0.12% SILRES BS 1042.
  • a 3.625" x 5.5" sample was cut from each board, placed in a sealed plastic container and stored in a refrigerator at about 40 F. prior to the VOC emission measurement.
  • the oven system consists of an electrically heated cabinet for receiving and drying small (e.g.4" x 6") panel samples with the capture of the oven air for analysis. To that end, the oven system also includes an air transport system for
  • THC total hydrocarbon content
  • THC total hydrocarbon content
  • Sample 2 Compared to the control Sample 1, Sample 2 (containing 0.34% Imidazolidone A) and Sample 3 (containing 0.12% SILRES BS 1042) showed increased VOC. However, the degree of VOC increase was much less for Sample 3 than for Sample 2.
  • Imidazolidone A since they are chemically similar and require like addition rates. As shown, the BS 1042 provides a reduced amount of VOC as compared with the Imidazolidone A.
  • trial production plant run confirmed the superior performance of reactive silicone over the production use of imidazolidone reactive Imidazolidone B.
  • slurry was processed on a production water felting line to compare BS 1042 and Imidazolidone B.
  • a slurry flow rate of 1300 gallons per minute (gpm) was used.
  • the BS 1042 (60% % solids) was added at a rate of 0.15 gpm and the reactive silicone is deemed to be added at a concentration of 1.5 wt% based on the total solids present in the slurry.
  • Imidazolidone B (30% solids) was added a rate of 0.40 gpm in place of the BS 1042.
  • target specifications of a thickness equal to 0.5" and a density of 23 pcf. (These specifications correspond with one form of commercial product and, as noted above, other commercial products may have different
  • the plant exhaust system was monitored during production for identification of the blue haze heretofore associated with the use of water repellent agents.
  • the blue haze was not detected in the plant exhaust consistent with the low THC observed above in connection with BS 1042.
  • the wall board incorporating the silicone additive.
  • the slurry processing results in foam accumulation even with the addition of defoamers.
  • silicone agent aids the defoamers allowing elimination and/or ion of the amount of defoamer additive required with use of other water repellant agents such as Imidazolidone B
  • %Combustibles equal to amount burned-off.
  • the BS 1042 yields a much higher MOR result as compared with Imidazolidone B.
  • the reactive side chains of the silicones are believed to be associated with the improved strength.
  • the hydrophilic side chains of the silicone may cause improved penetration and wetting of the base mat

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Civil Engineering (AREA)
  • Acoustics & Sound (AREA)
  • Wood Science & Technology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Electromagnetism (AREA)
  • Paper (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Building Environments (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Nonwoven Fabrics (AREA)
  • Finishing Walls (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Panels For Use In Building Construction (AREA)

Abstract

L'invention concerne un matériau de construction acoustique et un procédé de fabrication incorporant de la silicone réactive dispersée de façon homogène afin d'améliorer le caractère hydrofuge et les propriétés physiques.
PCT/US2012/036220 2011-05-14 2012-05-03 Planches de fibres hydrofuges WO2012158354A1 (fr)

Priority Applications (9)

Application Number Priority Date Filing Date Title
JP2014510360A JP2014520218A (ja) 2011-05-14 2012-05-03 撥水性ファイバーボード
CA2836771A CA2836771A1 (fr) 2011-05-14 2012-05-03 Planches de fibres hydrofuges
MX2013012867A MX2013012867A (es) 2011-05-14 2012-05-03 Tableros de fibra impermeables.
RU2013154971/03A RU2013154971A (ru) 2011-05-14 2012-05-03 Водоотталкивающие волокнистые плиты
BR112013028099A BR112013028099A2 (pt) 2011-05-14 2012-05-03 placas de fibra impermeáveis à água
EP12721098.7A EP2710200A1 (fr) 2011-05-14 2012-05-03 Planches de fibres hydrofuges
KR1020137031312A KR20140026533A (ko) 2011-05-14 2012-05-03 발수성 섬유판
AU2012256273A AU2012256273A1 (en) 2011-05-14 2012-05-03 Water repellent fiber boards
CN201280020870.4A CN103534424A (zh) 2011-05-14 2012-05-03 防水纤维板

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US13/107,885 2011-05-14
US13/107,885 US20120285643A1 (en) 2011-05-14 2011-05-14 Water repellent fiber boards

Publications (1)

Publication Number Publication Date
WO2012158354A1 true WO2012158354A1 (fr) 2012-11-22

Family

ID=46085212

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2012/036220 WO2012158354A1 (fr) 2011-05-14 2012-05-03 Planches de fibres hydrofuges

Country Status (12)

Country Link
US (1) US20120285643A1 (fr)
EP (1) EP2710200A1 (fr)
JP (1) JP2014520218A (fr)
KR (1) KR20140026533A (fr)
CN (1) CN103534424A (fr)
AR (1) AR086173A1 (fr)
AU (1) AU2012256273A1 (fr)
BR (1) BR112013028099A2 (fr)
CA (1) CA2836771A1 (fr)
MX (1) MX2013012867A (fr)
RU (1) RU2013154971A (fr)
WO (1) WO2012158354A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11111174B2 (en) 2017-09-13 2021-09-07 United States Gypsum Company Mineral fiber roof cover boards

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9950957B2 (en) * 2015-10-16 2018-04-24 United States Gypsum Company Light weight gypsum fiber panel suitable for use as roof cover board
MY186241A (en) * 2015-12-23 2021-06-30 Sioo Fargkultur Ab Coating compositions and treating method
US11597677B2 (en) * 2017-05-26 2023-03-07 Usg Interiors, Llc Wool surface treated with hydrophobic agent and acoustic panels made therefrom
DK3665132T3 (da) * 2017-08-07 2023-12-04 Owens Corning Intellectual Capital Llc Renoveringsloftmåtte

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4975122A (en) * 1989-08-10 1990-12-04 Siltech Inc. Water resistant cemetitious materials
US5539028A (en) 1994-03-23 1996-07-23 The Celotex Corporation Water-resistant fiberboard and method
US5964934A (en) 1997-12-18 1999-10-12 Usg Interiors, Inc. Acoustical tile containing treated perlite
US20100031852A1 (en) * 2008-08-05 2010-02-11 Sascha Herrwerth Hydrophobizing construction elements comprising mineral fibers

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2789679B1 (fr) * 1999-02-12 2001-03-30 Lafarge Platres Element de construction prefabrique a base de platre, presentant une resistance a l'eau

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4975122A (en) * 1989-08-10 1990-12-04 Siltech Inc. Water resistant cemetitious materials
US5539028A (en) 1994-03-23 1996-07-23 The Celotex Corporation Water-resistant fiberboard and method
US5964934A (en) 1997-12-18 1999-10-12 Usg Interiors, Inc. Acoustical tile containing treated perlite
US20100031852A1 (en) * 2008-08-05 2010-02-11 Sascha Herrwerth Hydrophobizing construction elements comprising mineral fibers

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11111174B2 (en) 2017-09-13 2021-09-07 United States Gypsum Company Mineral fiber roof cover boards

Also Published As

Publication number Publication date
AU2012256273A1 (en) 2013-12-12
CN103534424A (zh) 2014-01-22
MX2013012867A (es) 2013-12-02
RU2013154971A (ru) 2015-06-20
BR112013028099A2 (pt) 2017-04-25
AR086173A1 (es) 2013-11-27
KR20140026533A (ko) 2014-03-05
US20120285643A1 (en) 2012-11-15
EP2710200A1 (fr) 2014-03-26
JP2014520218A (ja) 2014-08-21
CA2836771A1 (fr) 2012-11-22

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