JP5388061B2 - Inductor - Google Patents

Description

  The present invention relates to an inductor.

  An inductor formed by winding a winding around a core (magnetic core) of a ferromagnetic material or a ferrimagnetic material is an electronic component that is used for purposes such as noise removal and voltage conversion.

  Some inductors are accommodated in a case in order to protect the core part and the windings, for example, as shown in Patent Document 1. Further, the core portion of the inductor may be formed by combining a plurality of divided cores due to magnetic characteristics and manufacturing reasons. As the shape of the split core, there are an EI core, an EE core, and the like in addition to the UI core disclosed in Patent Document 1.

  When the split core is used as the core portion of the inductor, an adhesive is applied to the split core, the core portion is assembled, and a winding is attached to the core portion. The core is fixed to the case directly by bolts or via a leaf spring.

JP 2009-43930 A

  When bonding the split cores using an adhesive, it is necessary to precisely position the split cores and adjust the thickness of the adhesive using a jig. For this reason, the number of man-hours required for the assembly of the inductor increases, and it is necessary to keep the jig attached to the core until the bonding of the split core is completed, while the case accommodates the core and the winding. This makes it difficult to manufacture inductors.

  The present invention solves the above problems. That is, an object of the present invention is to provide an inductor in which a core and a winding are accommodated in a case, which has a low manufacturing cost and a short manufacturing time.

  In order to achieve the above object, the inductor according to the present invention has a holding fitting that is attached to the core portion and holds the winding and the core portion in the case. When the holding fitting is attached to the core portion, four inductors are provided. A rectangular frame that covers one of the E-shaped surfaces of the split core so that one of the two opposite beams is close to the base of the split core and the other two opposite beams are close to the columns on both sides of the split core And at least a pair of holding the split cores so that the split cores are pressed against each other by extending in a vertical direction substantially perpendicular to the column alignment direction and the protruding direction. The first arm and a through-hole through which a bolt for fixing the holding metal fitting to the case is passed, and when the core portion is sandwiched between the pair of first arms, the other two beams are bent and a pair of Of the columns on both sides of the split core In contact with the upper surface of the wear part person so that the upper and lower direction of the pair of the split core positioning is performed.

  Preferably, a rib for increasing the rigidity of the two beams is provided at a substantially central portion of the other two beams of the base of the holding metal fitting.

  Preferably, the rib is a pair of second arms extending from the other two beams of the base of the holding metal fitting, and each of the pair of second arms is disposed on both sides of the split core when the core portion is sandwiched between the pair of first arms. The divided cores are positioned substantially in contact with the side surfaces of the adhesive portions of the columns in the arrangement direction of the columns of the divided cores.

  Preferably, the holding metal fitting has two pairs of first arms, and the two pairs of first arms are in contact with portions of the base portion of the split core located on the back sides of the columns on both sides of the split core.

  Preferably, the first arm is in contact with a substantially central portion in the vertical direction of the base portion of the split core.

  Preferably, the through hole of the holding metal is formed in a third arm extending from one of the two beams at the base of the holding metal, and the third arm is disposed so as to be sandwiched between the two first arms. Yes.

  Preferably, a notch is formed in a portion of the holding bracket between the first arm and the third arm of one of the two beams.

  In addition, the inductor further includes a levitating bracket that urges from the other side of the E-shape of the split core to hold the core portion with the holding bracket so that the core portion floats in the case. Also good.

  At this time, for example, the levitating metal fitting has a through hole through which a bolt for fixing the levitating metal fitting to the case is passed, and a common bolt is passed through the through hole of the levitating metal fitting and the through hole of the holding metal fitting. Thus, the levitating metal fitting and the holding metal fitting are fixed to the case.

  As described above, according to the present invention, the holding member for holding the core portion in the case has a function of positioning the divided cores. Therefore, it is not necessary to separately prepare a jig for positioning, and the core portion can be accommodated in the case before the bonding is completed. Since the number of man-hours for manufacturing the inductor is reduced and no jig is required, the manufacturing cost of the inductor is small, and the manufacturing time of the inductor is also short.

FIG. 1 is a perspective view of an inductor according to a first embodiment of the present invention. FIG. 2 is an exploded perspective view of the inductor according to the first embodiment of the present invention. FIG. 3 is an exploded perspective view of the inductor body of the inductor according to the first embodiment of the present invention. FIG. 4 is a top view of the core portion of the inductor according to the first embodiment of the present invention. FIG. 5 is a perspective view of the inductor holding metal fitting according to the first embodiment of the present invention. FIG. 6 is a cross-sectional view of the inductor according to the first embodiment of the present invention cut along a plane substantially perpendicular to the depth direction. FIG. 7 is a cross-sectional view of the inductor according to the first embodiment of the present invention cut along a plane substantially perpendicular to the width direction. FIG. 8 is an exploded perspective view of the inductor according to the second embodiment of the present invention. FIG. 9 is a cross-sectional view of an inductor according to the second embodiment of the present invention cut along a plane substantially perpendicular to the depth direction.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view of an inductor according to a first embodiment of the present invention. FIG. 2 is an exploded perspective view of the inductor according to the present embodiment. The inductor 1 of the present embodiment includes a case 100, an inductor main body 200 accommodated in the case 100, a holding metal fitting 300 for holding the inductor main body 200 in the case 100, and the holding metal fitting 300 fixed to the case 100. A bolt 410 and a sealing resin 420 filled in the case 100 after the inductor body 200 and the holding metal fitting 300 are attached to the case 100 are provided.

  The inductor body 200 will be described. FIG. 3 is an exploded perspective view of the inductor body 200. As shown in FIG. 3, the inductor body 200 includes a core portion 210, a bobbin 220, and a winding 230. The core portion 210 is formed by abutting the pair of E-shaped split cores 211 and 212 having three columns so that the columns face each other and bonding the end surfaces of the outer columns with an adhesive 213. . The split cores 211 and 212 are formed from a magnetic material having ferromagnetic or ferrimagnetism, for example, a powder core formed by compression molding a powdered magnetic material or a laminated silicon steel. Laminated core or the like. In the following description, the column extending direction is the width direction (the direction from the lower left to the upper right in FIG. 3), the column alignment direction is the depth direction (the direction from the upper left to the lower right in FIG. 3), and the width direction. A direction perpendicular to both of the depth directions is referred to as a height direction (vertical direction in the figure). Furthermore, when the inductor body 200 is accommodated in the case 100, the side where the opening 101 (FIG. 2) of the case 100 is located is the upper side in the vertical direction, and the opposite side, that is, the bottom surface 102 (FIG. 2) of the case 100 is located. The side is the lower side in the vertical direction.

  FIG. 4 is a top view of the core part 210. As shown in FIG. 4, among the three columns of the split cores 211 and 212, the central second columns 211b and 212b are shorter than the first columns 211a and 212a and the third columns 211c and 212c at both ends. For this reason, the adhesive 213 is applied to the end surfaces of the columns 211a, 211c, 212a, and 212c at both ends. In the state where the core part 210 is formed, an air gap G is formed between the second columns 211b and 212b.

  As shown in FIG. 3, the winding 230 is wound around the outer peripheral surface of the bobbin 220. The bobbin 220 is fitted and attached to the second columns 211b and 212b of the split cores 211 and 212.

  The holding metal fitting 300 according to the present embodiment also functions as a jig for bonding the split cores 211 and 212 with the adhesive 213. That is, as shown in FIG. 3, the adhesive 213 is applied to the end faces of the split cores 211 and 212, and the second column 211 b of the split cores 211 and 212 is placed in the hollow portion of the bobbin 220 to which the winding 230 is attached. 212b is inserted, and the split cores 211 and 212 are combined to assemble the inductor main body 200. Then, as shown in FIG. 2, the four arms 321 to 324 of the holding metal fitting 300 are formed, and the inductor main body 200 is configured from above. By fitting into the side surfaces 211e and 212e of the split cores 211 and 212 and pressing the side surfaces of the split cores 211 and 212 with the holding metal fitting 300, the split cores 211 and 212 are held so as not to shift their positions.

  Next, the holding metal fitting 300 will be described in detail below. FIG. 5 is a perspective view of the holding metal fitting 300. As shown in FIG. 5, the holding metal fitting 300 is formed by pressing a steel plate. The holding metal fitting 300 has a rectangular frame-shaped base portion 310 composed of the first beam 311 to the fourth beam 314. An area of the base 310 surrounded by the first beam 311 to the fourth beam 314 is an opening 315. The first beam 311 and the second beam 312 are parallel to each other, and similarly, the third beam 313 and the fourth beam 314 are parallel to each other. As shown in FIG. 2, in the holding metal fitting 300, the first beam 311 and the second beam 312 are disposed on the bases 211 d and 212 d of the split cores 211 and 212, respectively, and the third beam 313 is the split core 211. The fourth beam 314 is disposed on the third column 211c of the split core 211 and the third column 212c of the split core 212. The inductor body 200 is attached.

  The holding metal 300 includes four first arms 321 to 324, a pair of second arms 341 and 342, and a pair of third arms 331 and 332. These arms all extend from the four corner outer edges of the base 310 in one direction perpendicular to the base 310 (downward in the figure). When the holding metal fitting 300 is attached to the inductor body 200, each arm extends downward along the side surface of the inductor body 200 in the vertical direction.

  Furthermore, the first arms 321 and 322 of the holding metal fitting 300 extend from both ends of the edge portion 311a (lower left in the drawing) on the outer side in the width direction of the first beam 311. More specifically, the first arms 321 and 322 of the holding metal fitting 300 extend downward in the vertical direction along the side surface 211e located on the back side of the columns 211a to 211c of the split core 211. The first arms 323 and 324 of the holding metal fitting 300 extend from both ends of the outer edge 312a (upper right in the drawing) of the second beam 312. More specifically, the first arms 323 and 324 of the holding metal fitting 300 extend downward in the vertical direction along the side surface 212e located on the back side of the columns 212a to 212c of the split core 212.

  As described above, the first arms 321 and 323 of the holding metal fitting 300 are fitted to the inductor body 200 from above when the holding metal fitting 300 is fitted to the base body 211d of the split core 211, the first column 211a, One corner of the side surfaces 211e and 212e of the split cores 211 and 212 is pressed by its own elasticity so as to face each other through the first column 212a and the base 212d of the split core 212. Similarly, The first arms 322 and 324 also pass through the base 211d and the third column 211c of the split core 211 and the third column 212c and base 212d of the split core 212 when the holding metal fitting 300 is fitted to the inductor body 200 from above. Side surfaces 211e of the split cores 211 and 212 so that they face each other The other corners of the 12e and is pressing down by its own elasticity.

  As shown in FIG. 5, the first arms 321 to 324 of the holding metal fitting 300 have a dogleg shape so as to protrude toward the inner side in the width direction (the direction toward the core portion 210 when the holding metal fitting 300 is attached). Have bent portions 321a to 324a. Further, the interval d1 between the bent portions 321a and 323a and the interval d2 between the bent portions 322a and 324a are both slightly shorter than the dimension l1 of the core portion 210 in the direction from the divided core 211 to the divided core 212 (see FIG. 2). Therefore, when the holding metal fitting 300 is attached to the inductor body 200, the bent portions 321a to 324a of the first arms 321 to 324 are pushed outward in the width direction, and the repulsive force causes the split cores 211 and 212 to move inward in the width direction. The first column 211a and the third column 211c of the split core 211 are held in close contact with the first column 212a and the third column 212c of the split core 212, respectively.

  As described above, the holding metal fitting 300 has a function of holding the elastic arms of the first arms 321 to 324 so that they are not separated when the divided cores 211 and 212 are bonded without using the metal fitting alone (that is, without cooperating with the case 100). Have. Since the split cores 211 and 212 are held so as not to move by the holding metal fitting 300, the inductor body 200 can be accommodated in the case 100 before the adhesive is cured.

  The first arms 321 to 324 of the holding metal fitting 300 apply a compressive load in the width direction to the core part 210, and the compressive load is applied to the first columns 211a, 211a, 212a and the third columns 211c and 212c. When a compressive load in the width direction is applied to another position of the core part 210, a bending load may be applied to the base parts 211d and 212d of the split cores 211 and 212, and the split cores 211 and 212 may be damaged. Such a problem does not occur in the configuration of the embodiment.

  In addition, the first arms 321 to 324 of the holding metal fitting 300 are arranged at substantially the center in the vertical direction of the core part 210, and the first and third columns 211 a and 211 c of the split core 211 and the first and third columns 212 a of the split core 212. , 212c. Thereby, a substantially uniform load is applied to the bonding surfaces of the first columns 211 a and 212 a and the third columns 211 c and 212 c of the split cores 211 and 212. As a result, a uniform film thickness of the adhesive 213 is obtained, and variations in electrical characteristics of the core part 210 (and the inductor 1) are suppressed.

  In addition, when the holding metal fitting 300 is attached to the inductor body 200, the winding 230 is positioned at the position of the opening 315 of the holding metal fitting 300. It is necessary to secure a certain spatial distance between the winding 230 and the holding metal fitting 300 that is a conductor in order to prevent electric leakage. In a configuration in which the opening 315 is not formed in the base 310, the base 310 and the winding 230 The vertical interval needs to be long, and the vertical dimension of the inductor 1 is large. On the other hand, in the inductor 1 of the present embodiment, even if the bottom surface of the base portion 310 of the holding metal fitting 300 is brought close to the upper end of the winding 230, the majority of the base portion 310 occupies the opening 315. A sufficient spatial distance of the line 230 can be secured. As a result, the vertical dimension of the inductor 1 can be reduced.

  The third arms 331 and 332 of the holding metal fitting 300 extend in an L shape from a substantially central portion of the outer edge in the width direction of the first beam 311 and the second beam 312 of the base 310, respectively. Through holes 331a and 332a for passing the bolts 410 (FIGS. 1 and 2) are formed in the flat portions of the L-shaped third arms 331 and 332, respectively. As shown in FIG. 2, a pair of fixing protrusions 111 protruding inward in the width direction is formed on the inner side surface of the case 100. An internal thread 111 a is formed on the upper surface of the fixing protrusion 111. The through hole 331a or 332a of the holding metal fitting 300 is overlaid on the female screw 111a, and the bolt 410 is screwed into the female screw 111a, whereby the holding metal fitting 300 is fixed to the case 100, and the inductor body 200 held by the holding metal fitting 300 is It is held in the case 100. From this state, the inductor body 200 is fixed to the case 100 by injecting the sealing resin 420 (FIG. 1) into the case 100.

  Thus, the holding metal fitting 300 also has a function for holding the inductor body 200 in the case 100.

  As shown in FIG. 5, notches 351 and 352 are provided at portions between the first arms 321 and 322 and the third arm 331 at the outer edge in the width direction of the first beam 311 of the holding metal fitting 300. Is provided. Similarly, notches 353 and 354 are also provided in the portion between the first arms 323 and 324 and the third arm 332 at the outer edge in the width direction of the second beam 312 of the holding metal fitting 300. When the holding metal fitting 300 is attached to the inductor body 200 and the first arms 321 to 324 are pressed and deformed by the side surfaces 211e and 212e of the core part 210, the first beam 311 and the second beam 312 are directed upward in the vertical direction. A load is applied. At this time, due to the notches 351 to 354, the rigidity of the first beam 311 and the second beam 312 at the positions of the notches is smaller than the rigidity of the first beam 311 and the second beam 312 at the positions of the third arms 331 and 332. Therefore, the first beam 311 and the second beam 312 are twisted at the positions of the notches 351 to 354 with respect to the upward load, and the deformation amount of the third arms 331 and 332 due to this load is very small. .

  Further, when vibration in the width direction is applied to the inductor 1, the first metal beam 311 and the second beam 312 are twisted at the positions of the notches with low rigidity of the holding metal fitting 300, and vibration to the core unit 210 is generated. Transmission is reduced.

  Further, the holding metal fitting 300 also functions as a positioning jig for bonding the split cores 211 and 212. Hereinafter, the function of the holding metal fitting 300 as a positioning jig will be described.

  FIG. 6 is a cross-sectional view of the inductor 1 cut along a plane substantially perpendicular to the depth direction. In addition, the broken line part in FIG. 6 shows the shape of the third beam 313 and the fourth beam 314 of the holding metal fitting 300 in the natural state. As shown in FIG. 6, by attaching the holding metal fitting 300 to the inductor main body 200, the first arms 321 to 324 of the holding metal fitting 300 are deformed toward the outside in the width direction (direction away from the inductor main body 200). Then, the third beam 313 and the fourth beam 314 are deformed so that the central portion 313a of the third beam 313 and the central portion 314a of the fourth beam 314 move downward in the vertical direction. Then, the central portion 313a of the third beam 313 contacts the first columns 211a and 212a of the split cores 211 and 212, and the upper surfaces of the first columns 211a and 212a of the split cores 211 and 212 are aligned. Similarly, the central portion 314a of the fourth beam 314 contacts the third columns 211c and 212c of the split cores 211 and 212, and the upper surfaces of the third columns 211c and 212c of the split cores 211 and 212 are aligned. In this way, the third beam 313 and the fourth beam 314 of the holding metal fitting 300 are brought into contact with the upper surfaces of the split cores 211 and 212, and the vertical positioning of both is performed.

  As shown in FIG. 5, second arms 341 and 342 are formed at the center portions 313 a and 314 a of the third beam 313 and the fourth beam 314 of the holding metal fitting 300, respectively. The second arms 341 and 342 function as ribs for making the rigidity of the central portions 313a and 314a of the third beam 313 and the fourth beam 314 higher than both end portions 313b and 314b. Therefore, the third beam 313 and the fourth beam 314 are deformed exclusively at both end portions 313b and 314b. For this reason, when the third beam 313 and the fourth beam 314 are deformed, substantially the entire center portions 313 a and 314 a abut against the upper surfaces of the split cores 211 and 212. As described above, the third beam 313 and the fourth beam 314 come into contact with the split cores 211 and 212 with a relatively wide contact area, so that the split cores 211 and 212 are prevented from being damaged by a concentrated load.

  As shown in FIG. 6, a protrusion 102 a that protrudes upward in the vertical direction is formed on the bottom surface of the case 102. Further, the first columns 211 a and 212 a and the third columns 211 c and 212 c of the split cores 211 and 212 are pressed toward the bottom surface 102 of the case 100 by the third beam 313 and the fourth beam 314 of the holding metal fitting 300. ing. For this reason, the core part 210 and the protrusion part 102a are in direct contact, and heat generated in the core part 210 and the winding 230 when the inductor 1 is used is moved to the case 100 to efficiently cool the inductor body 200. Can be done.

  The holding metal fitting 300 has a function of roughly positioning the split cores 211 and 212 in the depth direction. This positioning function will be described below.

  FIG. 7 is a cross-sectional view of the inductor 1 cut along a plane substantially perpendicular to the width direction. As shown in FIG. 7, one second arm 341 of the holding metal fitting 300 faces the side surface on the outer side in the depth direction (left side in the drawing) of the first columns 211 a and 212 a of the split cores 211 and 212. Further, the other second arm 342 of the holding metal fitting 300 faces the side surface of the third columns 211c and 212c of the split cores 211 and 212 on the outer side (right side in the drawing).

  Here, the distance d3 between the second arms 341 and 342 of the holding metal fitting 300 is slightly larger than the depth direction dimension 12 of the split core 211 and the depth direction dimension 13 of the split core 212. For this reason, the split cores 211 and 212 are approximately positioned between the second arms 341 and 342.

  In the first embodiment of the present invention described above, the core portion 210 is pressed against the protruding portion 102 a of the bottom surface 102 of the case 100 by the holding metal fitting 300. However, the present invention is not limited to the above configuration. In the second embodiment of the present invention described below, the core portion 210 is lifted from the bottom surface 102 of the case 100.

  FIG. 8 is an exploded view of the inductor 1 ′ of the present embodiment. FIG. 9 is a cross-sectional view of the inductor 1 ′ according to the present embodiment cut along a plane substantially perpendicular to the depth direction. The inductor 1 ′ of the present embodiment further includes a levitating metal fitting 500 for levitating the core portion 210 from the bottom surface 102 of the case 100. Since the other points are the same as those of the first embodiment of the present invention, detailed description thereof is omitted.

  The levitation metal fitting 500 is formed by pressing a steel plate, like the holding metal fitting 300. The levitating metal fitting 500 has a square frame-shaped base 510 composed of the first beam 511 to the fourth beam 514. An area of the base 510 surrounded by the first beam 511 to the fourth beam 514 is an opening 515. The first beam 511 and the second beam 512 are parallel to each other, and similarly, the third beam 513 and the fourth beam 514 are parallel to each other. As shown in FIG. 8, in the floating metal fitting 500, the first beam 511 and the second beam 512 are disposed below the base portions 211 d and 212 d of the split cores 211 and 212, respectively, and the third beam 513 is the split core 211. The fourth beam 514 is disposed below the third column 211c of the split core 211 and the third column 212c of the split core 212. The inductor body 200 is attached.

  The levitation bracket 500 has upward arms 521 and 522. The arms 521 and 522 of the levitating metal fitting 500 extend upward from substantially the center of the outer edge in the width direction of the first beam 511 and the second beam 512 of the base 510, respectively. Through holes 521a and 522a for passing the bolts 410 are formed in the bent portions at the upper ends of the arms 521 and 522, respectively. The through hole 521a of the levitation metal fitting 500 and the through hole 331a of the holding metal fitting 300 are overlapped with the female screw 111a of the case 100, and the bolt 410 is screwed into the female screw 111a. By superimposing the hole 332a and screwing the bolt 410 into the female screw 112a, the floating metal fitting 500 and the holding metal fitting 300 are fixed to the case 100, and the inductor body 200 sandwiched and held between the floating metal fitting 500 and the holding metal fitting 300 is the case. Held within 100.

  As shown in FIG. 9, in this embodiment, the vertical dimension 14 of the arms 521 and 522 of the floating metal fitting 500 is the vertical dimension from the top surface to the bottom surface 102 of the fixing protrusions 111 and 112 of the case 100. It is sufficiently smaller than l5. For this reason, the core part 210 floats from the bottom surface 102 of the case 100.

  As described above, the inductor 1 ′ of the present embodiment can prevent the vibration generated from the core part 210 from directly propagating to the case 100 because the core part 210 does not contact the case 100. Further, according to the configuration of the present embodiment, an impact load is not applied to the core portion 210 via the case 100 due to vibration or the like, and damage to the core portion 210 due to the impact load is prevented.

1, 1 ′ Inductor 100 Case 200 Inductor body 210 Core parts 211, 212 Split cores 211a, 212a First column 211b, 212b Second column 211c, 212c Third column 230 Winding 300 Holding metal fittings 311-314 First to fourth Beams 321 to 324 First arm 331 and 332 Third arm 341 and 342 Second arm 500 Levitation bracket

Claims (8)

Windings,
A core around which the winding is wound;
A case in which the winding and the core part are accommodated,
A holding bracket for holding the windings and the core portion within the casing mounted on the core portion,
An inductor having
The core part is
A pair of split cores, has three columns each divided core projecting from the base portion and the base portion in a substantially E-shaped, face each other of the column that was Mukaiawasa are glued,
The holding bracket is
Comprising four beams, frame-shaped base portion other opposing two beams with one two opposite beams of the four beams covering a base of said split cores abutting on the sides of the column of the divided cores When,
The pair of split cores extend from the one opposing two beams in the vertical direction substantially perpendicular to the column alignment direction and the projecting direction, and abut the substantially central portion of the base of the split core in the vertical direction. a pair of first arms even without least sandwich,
An inductor comprising:   2. The inductor according to claim 1, wherein a rib for increasing rigidity of the two beams is provided at a substantially central portion of the other two beams of the base portion of the holding metal fitting. The ribs are a pair of second arms extending from the other two beams of the base of the holding fitting ,
Inductor according to claim 2 in which each of the previous SL pair of second arms and said Rukoto that Sessu Hoboto the side surface of the bonding portions on both sides of the column of the divided cores. The inductor according to any one of claims 1 to 3, wherein the holding metal fitting has a pair of the first arms on each of the two beams . The holding metal fitting has a pair of third arms extending from the one two beams at a position between the two first arms ,
The inductor according to claim 4 , wherein a through-hole through which a bolt for fixing the holding metal fitting to the case is passed is formed in the third arm. The holding metal fitting, said one of the two beams, inductor according to claim 5 in the portion between said first arm and said third arm, characterized in that it is formed notch. Inductor according to any one of claims 1 to 6, further comprising a floating bracket for holding the core portion between the cases and the core portion. The levitation metal fitting has a through hole through which a bolt for fixing the levitation metal fitting to the case is passed;
6. The method according to claim 5, wherein a common bolt is passed through the through-hole of the floating metal fitting and the through-hole of the holding metal fitting, and the floating metal fitting and the holding metal fitting are fixed to the case. 8. The inductor according to 7 .

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