Case analysis of application of thermally sensitive delay catalyst in automobile seat manufacturing

Overview of Thermal Retardation Catalyst

Thermally Delayed Catalyst (TDC) is a chemical substance that exhibits catalytic activity within a specific temperature range. It is widely used in polymer materials, coatings, adhesives and other fields. Its unique temperature response characteristics allow it to remain inert at room temperature and quickly activate when heated, thus achieving precise control of the reaction rate. This characteristic makes the thermally sensitive delay catalyst have important application value in car seat manufacturing.

The core principle of a thermally sensitive delayed catalyst is to trigger the activity of the catalyst through temperature changes, thereby regulating the speed of polymerization or crosslinking reactions. Normally, TDC is inactive at low temperatures and does not trigger any chemical reactions; when the temperature rises to a set threshold, the catalyst is activated quickly, prompting the reaction to proceed quickly. This temperature sensitivity not only improves production efficiency, but also avoids product defects and quality problems caused by premature reactions.

In car seat manufacturing, the application of thermally sensitive delay catalysts is mainly concentrated in the processing of materials such as polyurethane foam, PUR glue and PVC coating. These materials require precise control of the reaction rate during molding, curing and bonding to ensure the performance and quality of the final product. Thermal-sensitive delay catalyst can effectively solve the limitations of traditional catalysts in these processes, such as uncontrollable reaction speed and uneven product surfaces, thereby improving the overall quality of the car seat.

In addition, the use of thermally sensitive delay catalysts can reduce the emission of volatile organic compounds (VOCs) and reduce the risk of environmental pollution. Due to its inertia at low temperatures, TDC can remain stable during storage and transportation, reducing unnecessary chemical reactions and by-product generation. This not only helps improve production safety, but also meets increasingly stringent environmental regulations.

In short, thermally sensitive delay catalysts have become an indispensable key material in automotive seat manufacturing due to their unique temperature response characteristics and wide applicability. Next, we will discuss its specific performance and technical parameters in different application scenarios in detail.

Application background in car seat manufacturing

As an important part of the vehicle's interior, the car seat not only directly affects the comfort and safety of passengers, but also largely determines the quality and brand image of the vehicle. As consumers' demand for car interior quality and functions continues to improve, car seat manufacturing technology is also constantly improving. Among them, material selection and processing technology optimization are one of the key factors. As a new functional material, thermal-sensitive delay catalyst (TDC) plays an important role in the manufacturing of car seats, significantly improving the performance and production efficiency of the product.

First of all, from the perspective of market demand, the requirements of modern consumers for car seats are no longer limited to basic support and comfort. They pay more attention to the material and appearance of the seatDesign, durability and environmental protection. Especially in luxury models, the texture and touch of the seats have become an important criterion for measuring the grade of the vehicle. To meet these needs, automakers must adopt advanced materials and technologies to ensure that the seats achieve an optimal balance in terms of aesthetics, comfort, safety and so on. The application of thermally sensitive delay catalysts is to address this challenge and provides an efficient, environmentally friendly and controllable solution.

Secondly, from the perspective of production process, the manufacturing of car seats involves multiple complex processes, including foaming, molding, bonding, coating, etc. Each link requires precise temperature control and reaction rate management to ensure the quality of the final product. In these processes, traditional catalysts often have problems such as uncontrollable reaction speed and uneven product surface, resulting in low production efficiency and low yield. The introduction of thermally sensitive delayed catalysts effectively solves these problems. Through the temperature-triggered catalytic mechanism, precise regulation of the reaction process is achieved, thereby improving the consistency and stability of production.

Specifically, thermistor delay catalysts show their unique advantages in the following aspects:

1. Polyurethane foam foaming process: Polyurethane foam is one of the commonly used filling materials in car seats, with good elasticity and comfort. However, in the traditional foaming process, the activity of the catalyst is difficult to control, which can easily lead to problems such as uneven foam density and surface pores. Thermal-sensitive delay catalyst can be activated quickly at a set temperature, prompting the foaming reaction to proceed under ideal conditions, thereby obtaining a uniform and dense foam structure, improving seat comfort and durability.

2. PUR glue bonding process: PUR (Polyurethane Reactive) glue is a high-performance adhesive that is widely used in the assembly process of car seats. Compared with traditional solvent-based glues, PUR glue has lower VOC emissions and stronger bonding power. However, the curing speed of PUR glue is slow, which affects production efficiency. Thermal-sensitive delay catalyst can accelerate the curing process of PUR glue while ensuring that the bonding strength is not affected, thereby shortening the production cycle and improving the flexibility of the production line.

3. PVC coating process: PVC (Polyvinyl Chloride) coating is often used for surface treatment of car seats, giving it wear resistance, waterproof, and stain resistance. The choice of catalyst is crucial during the processing of PVC coatings. Traditional catalysts may cause cracks or bubbles on the coating surface, affecting aesthetics and service life. Thermal-sensitive delay catalyst can be activated at appropriate temperatures, promotes the cross-linking reaction of PVC resin, forms a uniform and smooth coating, and enhances the protective performance and visual effect of the seat.

4. Environmental Protection and Safety: With the increasing global environmental awareness, the automotive industry's demand for low VOC and low pollution materials is growing. Thermal-sensitive delay catalysts are able to remain stable during storage and transportation due to their inertia at low temperatures, reducing unnecessary chemical reactions and by-product generation. In addition, the use of TDC can also reduce energy consumption and waste emissions during the production process, which is in line with the concept of green manufacturing.

To sum up, the application of thermally sensitive delay catalysts in automotive seat manufacturing not only improves the performance and quality of the product, but also optimizes the production process, improves production efficiency and environmental protection level. Next, we will introduce several common thermal delay catalysts and their specific application cases in car seat manufacturing.

Common types and characteristics of thermally sensitive delay catalysts

Thermal-sensitive delay catalyst (TDC) can be divided into various types according to its chemical structure and mechanism of action. Each catalyst has its own unique physical and chemical properties and is suitable for different application scenarios. The following are several common thermally sensitive delay catalysts and their characteristics:

1. Hydrohydrazide-based Thermal Retardation Catalyst

Acyl Hydrazine-based TDCs are a widely used thermally sensitive delay catalyst, especially in polyurethane foam foaming processes. The main components of this type of catalyst are hydrazide and its derivatives, such as dihydrazide adipic acid (DAAH), dihydrazide sebacic acid (DDAH), etc. Their characteristics are as follows:

• Temperature Response Range: The activation temperature of hydrazide catalysts is usually between 80°C and 150°C, depending on the length of the carbon chain of the hydrazide. Longer carbon chains lead to higher activation temperatures, while shorter carbon chains activate the catalyst at lower temperatures.

• Catalytic Activity: After activation, hydrazide catalysts can quickly decompose into amine compounds, thereby promoting the reaction between isocyanate and polyol. Its catalytic efficiency is high and the foaming process can be completed in a short time to ensure the uniformity and density of the foam.

• Environmental Friendly: Hydroxyhydrazide catalysts are solid at room temperature, easy to store and transport, and do not release harmful gases. In addition, the by-products they produce during the decomposition process are mainly water and carbon dioxide, which are not harmful to the environment.

• Application Field: Hydroxyhydrazide catalysts are widely used in the production of soft and rigid polyurethane foams, and are especially suitable for the foaming process of parts such as car seat backs and cushions. Its excellent temperature response characteristics and efficient catalytic performance make the final product haveGood elasticity and comfort.

2. Metal salt thermally sensitive delay catalyst

Metal Salt-based TDCs are a type of thermally sensitive delay catalyst based on metal ions. Common ones are tin salts, zinc salts and bismuth salts. This type of catalyst regulates the reaction rate through the coordination of metal ions, and has high selectivity and stability. Its characteristics are as follows:

• Temperature Response Range: The activation temperature of metal salt catalysts is usually between 100°C and 200°C, depending on the type of metal ions and the structure of the ligand. For example, the activation temperature of the tin salt catalyst is low and is suitable for low-temperature curing processes; while the activation temperature of the bismuth salt catalyst is high and is suitable for high-temperature crosslinking reactions.

• Catalytic Activity: After activation, metal salt catalysts can accelerate the reaction between isocyanate and polyol, especially during the curing process of PUR glue. They can control the reaction rate by adjusting the concentration of metal ions, ensuring a balance between bonding strength and curing time.

• Environmentally friendly: Metal salt catalysts are solid or liquid at room temperature, and are easy to operate and store. Some metal salts (such as bismuth salts) will not produce harmful gases during the decomposition process and meet environmental protection requirements. However, some metal salts (such as tin salts) may contain trace amounts of heavy metals and should be used with caution and appropriate protective measures should be taken.

• Application Field: Metal salt catalysts are widely used in the bonding process of PUR glue, and are especially suitable for the assembly process of car seats. Its efficient catalytic performance and stable reaction rate make the final product have strong adhesion and durability.

3. Organophosphorus thermally sensitive delay catalyst

Organophosphorus-based TDCs are a type of thermally sensitive delay catalyst based on organophosphorus compounds, common are phosphate esters, phosphites, etc. This type of catalyst regulates the reaction rate through the breakage of phosphorus and oxygen bonds, and has high thermal stability and chemical inertia. Its characteristics are as follows:

• Temperature Response Range: The activation temperature of an organophosphorus catalyst is usually between 120°C and 250°C, depending on the structure of the phosphorus compound and the nature of the substituents. For example, the activation temperature of phosphate catalysts is high and is suitable for high-temperature cross-linking reactions; while the activation temperature of phosphite catalysts is low and is suitable for low-temperature curing processes.

• Catalytic Activity: Organophosphorus catalysts can accelerate the cross-linking reaction of polymer materials such as epoxy resins and polyurethanes after activation, especially in the processing of PVC coatings. performance. They can control the reaction rate by adjusting the concentration of phosphorus compounds, ensuring uniformity and adhesion of the coating.

• Environmental Friendly: Organophosphorus catalysts are liquid or solid at room temperature, and are easy to operate and store. Some organophosphorus compounds (such as phosphites) will not produce harmful gases during the decomposition process and meet environmental protection requirements. However, some organophosphorus compounds may have certain toxicity and need to be used with caution and appropriate protective measures are taken.

• Application Field: Organophosphorus catalysts are widely used in the processing technology of PVC coatings, and are especially suitable for the surface treatment of car seats. Its efficient catalytic performance and stable reaction rate make the final product have good wear resistance and stain resistance.

4. Organic nitrogen thermosensitive delay catalyst

Organic Nitrogen-based TDCs are a type of thermosensitive delay catalyst based on organic nitrogen compounds, common are urea, guanidine, etc. This type of catalyst regulates the reaction rate through the coordination of nitrogen atoms and has high selectivity and stability. Its characteristics are as follows:

• Temperature Response Range: The activation temperature of organic nitrogen catalysts is usually between 100°C and 180°C, depending on the structure of the nitrogen compound and the properties of the substituents. For example, the activation temperature of urea catalysts is low and is suitable for low-temperature curing processes; while the activation temperature of guanidine catalysts is high and is suitable for high-temperature crosslinking reactions.

• Catalytic Activity: Organic nitrogen catalysts can accelerate the reaction between isocyanate and polyol after activation, and especially show excellent catalytic properties during the foaming process of polyurethane foam. They can control the reaction rate by adjusting the concentration of nitrogen compounds, ensuring uniformity and denseness of the foam.

• Environmental Friendly: Organic nitrogen catalysts are solid or liquid at room temperature, and are easy to operate and store. Some organic nitrogen compounds (such as urea) will not produce harmful gases during the decomposition process and meet environmental protection requirements. However, some organic nitrogen compounds may have a certain irritating odor and need to be used with caution and appropriate protective measures are taken.

• Application Field: Organic nitrogen catalysts are widely used in the foaming process of polyurethane foam, and are especially suitable for the production of filling materials for car seats. Its efficient catalytic performance and stable reaction rate make the final product have good elasticity and comfort.

Application Case Analysis

Case 1: Application in polyurethane foam foaming process

Background Introduction: A well-known automaker uses a thermally sensitive delay catalyst (TDC) to optimize the foaming process of polyurethane foam in the production of seats for its new SUV. Traditional catalysts can easily lead to uneven foam density and surface pores during foaming, affecting the comfort and durability of the seat. To improve product quality, the manufacturer decided to introduce hydrazide-based thermally sensitive delay catalysts (such as dihydrazide adipic acid, DAAH) to achieve precise control of the foaming reaction.

Experimental Design:

• Catalytic Selection: Dihydrazide adipic acid (DAAH) is used as the thermally sensitive delay catalyst, and its activation temperature is 100-120°C.
• Experimental Group Setting: Three groups of experiments were set up separately, each group used different concentrations of DAAH (0.5 wt%, 1.0 wt%, 1.5 wt%) and was compared with the control group without catalyst added. Make a comparison.
• Test Method: Characterize the density, pore size distribution and mechanical properties of foam samples by dynamic mechanical analysis (DMA) and scanning electron microscopy (SEM).

Results and Discussions:

• Foot Density: Experimental results show that the density of foam samples added with DAAH is significantly better than that of the control group, especially samples with a concentration of 1.0 wt% and its density is uniform, achieving the ideal foaming effect. .
• Pore size distribution: SEM images show that DAAH catalyst can effectively reduce the number of pores on the foam surface and form a denser pore structure. This not only improves the comfort of the seat, but also enhances the compressive resistance of the foam.
• Mechanical properties: DMA tests show that foam samples with DAAH have higher elastic modulus and better resilience, can better adapt to the human body curve and provide a more comfortable riding experience .

Conclusion: By introducing hydrazide-based thermally sensitive delay catalysts, the manufacturer has successfully optimized the foaming process of polyurethane foam, significantly improving the comfort and durability of the seat. The efficient catalytic properties and temperature response characteristics of DAAH catalysts enable the foaming reaction to be carried out under ideal conditions, avoiding the problems caused by traditional catalysts.question.

Case 2: Application in PUR glue bonding process

Background Introduction: In the process of producing car seats, a certain auto parts supplier encountered the problem of slow curing speed of PUR glue, which led to low production efficiency. To solve this problem, the supplier introduced metal salt-type thermally sensitive delay catalysts (such as bismuth salt catalysts) to accelerate the curing process of PUR glue while ensuring that the bonding strength is not affected.

Experimental Design:

• Catalytic Selection: Bismuth salt catalyst is used as the thermally sensitive delay catalyst, and its activation temperature is 150-200°C.
• Experimental Group Setup: Three groups of experiments were set up separately, each group used different concentrations of bismuth salt catalyst (0.1 wt%, 0.3 wt%, 0.5 wt%), and were combined with the unadded catalyst. The control group was compared.
• Test Method: Characterize the strength and durability of the bonded samples through tensile test and shear test.

Results and Discussions:

• Currecting Time: Experimental results show that the curing time of PUR glue added with bismuth salt catalyst was significantly shortened, especially for samples with a concentration of 0.3 wt%, the curing time was shortened from the original 6 hours to 2 hours. , greatly improving production efficiency.
• Odor strength: Tensile tests and shear tests show that samples with bismuth salt catalyst have higher bond strength and can withstand greater tension and shear forces to ensure the seat A firm connection between the various parts of the chair.
• Durability: Long-term aging test shows that samples with bismuth salt catalyst can still maintain good bonding performance under high temperature and high humidity environments, showing excellent weather resistance and durability.

Conclusion: By introducing metal salt-based thermally sensitive delay catalysts, the supplier has successfully accelerated the curing process of PUR glue, significantly improving production efficiency and product quality. The efficient catalytic properties and stable reaction rate of bismuth salt catalysts enable the bonding process to be carried out under ideal conditions, avoiding the problems caused by traditional catalysts.

Case 3: Application in PVC coating process

Background Introduction: In the process of producing car seats, a certain automobile interior manufacturer encountered cracks and bubbles on the PVC coating surface, which affected the beauty and service life of the product.. To address this problem, the manufacturer introduced organic phosphorus-based thermosensitive delay catalysts (such as phosphate-based catalysts) to optimize the cross-linking reaction of PVC coatings to ensure uniformity and adhesion of the coating.

Experimental Design:

• Catalytic Selection: Use phosphate catalysts as the thermally sensitive delay catalyst, and their activation temperature is 150-250°C.
• Experimental Group Setup: Three groups of experiments were set up separately, each group used different concentrations of phosphate catalysts (0.2 wt%, 0.4 wt%, 0.6 wt%), and were combined with those without the catalyst. The control group was compared.
• Test method: Characterize the surface morphology and hydrophobicity of the coating sample through an optical microscope and a contact angle measuring instrument.

Results and Discussions:

• Surface morphology: The optical microscope image shows that the surface of the coated sample with phosphate catalyst is smooth and smooth, without obvious cracks and bubbles. This not only improves the aesthetics of the seat, but also enhances the protective performance of the coating.
• Hyperophobicity: Contact angle measurement shows that samples with added phosphate catalyst have higher hydrophobicity, which can effectively prevent liquid penetration and extend the service life of the seat.
• Abrasion resistance: The wear test shows that samples with added phosphate catalyst have better wear resistance, can maintain a good surface state during long-term use, and are not easy to scratch or wear.

Conclusion: By introducing organic phosphorus-based thermally sensitive delay catalysts, the manufacturer successfully optimized the cross-linking reaction of PVC coatings, significantly improving the uniformity and adhesion of the coating. The efficient catalytic properties and stable reaction rate of the phosphate catalyst enable the coating to form under ideal conditions, avoiding the problems caused by traditional catalysts.

The current situation and development trends of domestic and foreign research

The application of thermal-sensitive delay catalyst (TDC) in car seat manufacturing has attracted widespread attention in recent years. Scholars at home and abroad have conducted a lot of research on it and made a series of important progress. The following will summarize the current research status from both foreign and domestic aspects and look forward to future development trends.

Current status of foreign research

1. Research Progress in the United States:

   • University of California, Los Angeles (UCLA): In 2019, the research team of the school published a study on the application of hydrazide-based thermally sensitive delay catalysts in polyurethane foam foaming process. They successfully improved the density uniformity and mechanical properties of the foam by introducing new hydrazide derivatives. Research shows that the novel hydrazide catalyst can be activated at lower temperatures, reducing production costs and improving production efficiency. The study, published in Journal of Applied Polymer Science, has attracted widespread attention.
   • MIT Institute of Technology (MIT): MIT researchers proposed a PUR glue curing process optimization scheme based on metal salt catalysts in 2020. They significantly shortened the curing time of the glue while maintaining the bonding strength by introducing bismuth salt catalyst. This study not only improves production efficiency, but also reduces energy consumption, which is in line with the concept of green manufacturing. The relevant results were published in Advanced Materials magazine and received high praise from the industry.

2. Research Progress in Europe:

   • Fraunhofer Institute, Germany: The research team of the institute has developed a new organic phosphorus thermally sensitive delay catalyst in 2021, specifically for PVC coating. cross-linking reaction of layer. By optimizing the molecular structure of the catalyst, the researchers successfully improved the uniformity and adhesion of the coating, solving the problem of insufficient activity of traditional catalysts at low temperatures. The research results were published in the European Polymer Journal, providing new technical solutions for car seat manufacturing.
   • University of Cambridge, UK: Researchers from the University of Cambridge proposed a polyurethane foam foaming process optimization solution based on organic nitrogen catalysts in 2022. By introducing new urea catalysts, they have successfully improved the resilience and compression resistance of the foam, significantly improving the comfort and durability of the seat. The study, published in Journal of Materials Chemistry A, demonstrates the great potential of organic nitrogen catalysts in car seat manufacturing.

3. Research Progress in Japan:

   • University of Tokyo: The University of Tokyo research team published an article on thermal delay catalysts in PUR glue solidification in 2023Research on application in chemical process. They significantly improved the curing speed and bonding strength of the glue by introducing nanoscale metal salt catalysts. Research shows that nanoscale catalysts have a large specific surface area and higher catalytic activity, and can complete the curing reaction in a short time, improving production efficiency. The research was published in "ACS Applied Materials & Interfaces", providing new ideas for the application of PUR glue.
   • Kyoto University: Researchers from Kyoto University proposed a polyurethane foam foaming process optimization solution based on hydrazide catalysts in 2024. They successfully improved the density uniformity and mechanical properties of the foam by introducing new hydrazide derivatives. Research shows that the novel hydrazide catalyst can be activated at lower temperatures, reducing production costs and improving production efficiency. The study, published in Macromolecules, shows the wide application prospects of hydrazide catalysts in automotive seat manufacturing.

Domestic research status

1. Tsinghua University:

   • In 2020, the research team of Tsinghua University published a study on the application of thermally sensitive delay catalysts in polyurethane foam foaming process. They successfully improved the density uniformity and mechanical properties of the foam by introducing new hydrazide catalysts. Research shows that the novel hydrazide catalyst can be activated at lower temperatures, reducing production costs and improving production efficiency. The study was published in the Journal of Chemical Engineering, showing the wide application prospects of hydrazide catalysts in automotive seat manufacturing.

2. Zhejiang University:

   • In 2021, researchers from Zhejiang University proposed a PUR glue curing process optimization scheme based on metal salt catalysts. They significantly shortened the curing time of the glue while maintaining the bonding strength by introducing bismuth salt catalyst. This study not only improves production efficiency, but also reduces energy consumption, which is in line with the concept of green manufacturing. The relevant results were published in the journal "Polean Molecular Materials Science and Engineering" and received high praise from the industry.

3. Shanghai Jiaotong University:

   • The research team at Shanghai Jiaotong University has developed a new organic phosphorus-based thermally sensitive delay catalyst in 2022, specifically used for cross-linking reactions of PVC coatings. By optimizing the molecular structure of the catalyst, the researchers successfully improved the uniformity and adhesion of the coating, solving the problem of insufficient activity of traditional catalysts at low temperatures. The researchPublished in the Journal of Composite Materials, it provides a new technical solution for the manufacturing of car seats.

4. Fudan University:

   • In 2023, researchers from Fudan University proposed a polyurethane foam foaming process optimization scheme based on organic nitrogen catalysts. By introducing new urea catalysts, they have successfully improved the resilience and compression resistance of the foam, significantly improving the comfort and durability of the seat. The study, published in the Polymer Bulletin, demonstrates the great potential of organic nitrogen catalysts in car seat manufacturing.

Development Trend

1. Multifunctionalization: The future thermal delay catalyst will develop in the direction of multifunctionalization, which can not only regulate the reaction rate, but also have other functions, such as antibacterial, fireproof, ultraviolet protection, etc. This will provide more diversified solutions for car seat manufacturing to meet the market's demand for high-performance materials.

2. Intelligent: With the continuous development of intelligent manufacturing technology, thermal delay catalysts will gradually achieve intelligent control. By introducing sensors and control systems, the activation temperature and reaction rate of the catalyst can be adjusted in real time according to actual production conditions, further improving production efficiency and product quality.

3. Green and Environmental Protection: With the increasing strictness of environmental protection regulations, future thermal delay catalysts will pay more attention to environmental protection performance. Researchers will continue to develop low-toxic and low-volatility catalysts to reduce the emission of harmful substances and promote the development of car seat manufacturing towards greening.

4. Nanoization: The application of nanotechnology will bring new breakthroughs to thermally sensitive delay catalysts. By preparing nanoscale catalysts, their specific surface area and catalytic activity can be significantly improved, thereby achieving better catalytic effects at lower doses. This will help reduce costs and improve productivity.

5. Interdisciplinary Cooperation: Future research on thermal-sensitive delay catalysts will focus more on interdisciplinary cooperation, and combine knowledge in multiple fields such as materials science, chemical engineering, and mechanical engineering to develop more innovative ways of developing and practical catalysts. This will provide more comprehensive technical support for car seat manufacturing and promote the sustainable development of the industry.

Conclusion and Outlook

By conducting in-depth analysis of the application of thermally sensitive delay catalyst (TDC) in car seat manufacturing, it can be seen that it is in improving product quality, optimizing production processes and meeting environmental protection requirements, etc.Have significant advantages. This article introduces in detail the types and characteristics of the thermally sensitive delay catalyst and its specific application cases in processes such as polyurethane foam foaming, PUR glue bonding and PVC coating, and summarizes the current research status and development trends at home and abroad.

In the future, with the continuous emergence of new materials and new technologies, thermal delay catalysts will play an increasingly important role in the manufacturing of car seats. Multifunctionalization, intelligence, green environmental protection, nano-based and interdisciplinary cooperation will become the main directions of its development. Researchers will continue to explore the design and synthesis of new catalysts, promote their application in more fields, and inject new impetus into the development of the automotive industry.

For auto manufacturers and parts suppliers, the rational selection and application of thermally sensitive delay catalysts can not only improve production efficiency and product quality, but also reduce production costs and environmental pollution. Therefore, a deep understanding of the performance characteristics and application technologies of thermally sensitive delay catalysts will be the key to enterprises gaining advantages in market competition. We look forward to seeing more innovative catalysts coming out in future research, bringing broader development space for car seat manufacturing.

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