System and method for producing a continuous fabric strip for use in manufacturing paint roller covers
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B65H-023/198
B65H-019/18
B65H-019/14
B65H-054/28
출원번호
US-0426541
(2003-04-30)
발명자
/ 주소
Jelinek, Dale C.
Skildum, Marcus L.
Heitzler, Theodore S.
출원인 / 주소
Monterey, Inc.
대리인 / 주소
Reinhart Boerner Van Deuren s.c.
인용정보
피인용 횟수 :
17인용 특허 :
14
초록▼
A system and method for producing a spool having a continuous fabric strip is disclosed which produces an extended length fabric strip made from a plurality of seamed standard lengths of the fabric, the extended length fabric strip being substantially spirally wound upon a hollow core with consecuti
A system and method for producing a spool having a continuous fabric strip is disclosed which produces an extended length fabric strip made from a plurality of seamed standard lengths of the fabric, the extended length fabric strip being substantially spirally wound upon a hollow core with consecutive windings of the extended length fabric strip being located close adjacent each other, and with consecutive rows of the extended length fabric strip overlaying each other on the hollow core. In a first embodiment, the standard length fabric strips are joined together at their respective contiguous ends using a small strip of heat-activated seaming tape. In a second embodiment, the standard length fabric strips are stitched together at their respective contiguous ends using thread. The winding operation simultaneously controls both the lateral position at which the extended length fabric strip is wound onto the core and the rotation of the core to achieve the tight and highly compact winding operation, with the speed of the winding operation being controlled according to the amount of the extended length fabric strip which is available at any given time. The extended length fabric strip is suitable for use in the manufacture of paint roller covers.
대표청구항▼
1. A method for producing an extended length knitted pile fabric strip from a plurality of fabric strips, comprising:sewing a plurality of fabric strips together at their respective ends to produce an extended length fabric strip;removably supporting a take-up core member for rotation at a controlle
1. A method for producing an extended length knitted pile fabric strip from a plurality of fabric strips, comprising:sewing a plurality of fabric strips together at their respective ends to produce an extended length fabric strip;removably supporting a take-up core member for rotation at a controlled rate to thereby control rotational displacement of said take-up core member;supplying said extended length fabric strip to be wound onto said take-up core member;controlling the lateral position at which said extended length fabric strip is presented to said take-up core member to be wound thereupon and varying said lateral position with respect to said take-up core member; andwinding said extended length fabric strip onto said take-up core member to produce a spool of fabric strip while simultaneously controlling both the rotational displacement of said take-up core member and the lateral position in which said extended length fabric strip is presented to said take-up core member to thereby substantially spirally wind said extended length fabric strip onto said take-up core member with consecutive windings of said extended length fabric strip being located close adjacent each other, and with consecutive rows of said extended length fabric strip overlaying each other on said take-up core member.2. A method as defined in claim 1, wherein each of said fabric strips are between thirty and fifty yards long.3. A method as defined in claim 1, wherein said extended length fabric strip comprises between three and ten of said fabric strips.4. A method as defined in claim 1, wherein said fabric strips each having ends and opposite pile and backing sides, and wherein said sewing step comprises:bringing contiguous ends of two fabric strips being joined together so that they substantially abut each other,;lowering a needle assembly including a clamping foot over the abutting ends of the two fabric strips being joined together to secure each of the two fabric strips in place; andstitching said fabric strips together at said contiguous ends.5. A method as defined in claim 4, wherein said bringing step includes bringing said contiguous ends of said two fabric strips together with said pile sides facing downwardly to expose said backing sides thereof.6. A method as defined in claim 4, wherein said bringing step includes bringing said contiguous ends of said two fabric strips together with said backing sides facing downwardly to expose said pile sides thereof.7. A method as defined in claim 4, wherein said bringing step includes bringing said contiguous ends of said two fabric strips together so that said ends overlap each other.8. A method as defined in claim 1, wherein said take-up core member is made of cardboard or thermoplastic material.9. A method as defined in claim 1, wherein said controlling step comprises:guiding said extended length fabric strip in a manner which restricts its lateral movement as it is being wound onto said take-up core member, said extended length fabric strip being moved laterally with respect to said take-up core member as said take-up core member is rotated to thereby substantially spirally wind said extended length fabric strip onto said take-up core member with consecutive windings of said extended length fabric strip being located close adjacent each other.10. A method as defined in claim 1, additionally comprising:removing particulate from said extended length fabric strip before being wound onto said take-up core member.11. A method as defined in claim 1, additionally comprising:determining the relative relationship between the lateral position at which said extended length fabric strip is presented to said take-up core member of said extended length fabric strip and the rotational displacement of said take-up core member based upon the width and thickness of said fabric strips, the outer diameter of said take-up core member, and the position on said take-up core member at which said winding step begins.12. A method as defined in claim 1, additionally comprising:varying the rate of rotational displacement of said take-up core member based at least in part upon the amount of said extended length fabric strip which has been made by joining said plurality of fabric strips together.13. A method as defined in claim 12, wherein said varying step comprises:accumulating the portion of said extended length fabric strip which has been made by joining said plurality of fabric strips together in an accumulator and detecting whether said accumulator has more or less than a particular amount of said extended length fabric strip contained therein, said extended length fabric strip being removed from said accumulator to be wound onto said take-up core member; androtating said take-up core member at a higher rate of rotational displacement if said accumulator has more than said particular amount of said extended length fabric strip contained therein and rotating said take-up core member at a lower rate of rotational displacement if said accumulator has less than said particular amount of said extended length fabric strip contained therein.14. An extended length knitted pile fabric strip roll produced in accordance with the method of claim 1.15. A method for producing an extended length knitted pile fabric strip from a plurality of knitted pile fabric strips, comprising:sewing a plurality of knitted pile fabric strips together at their respective ends to produce an extended length knitted pile fabric strip;removably supporting a hollow cylindrical take-up core member for rotation at a controlled rate to thereby control rotational displacement of said take-up core member;accumulating the portion of said extended length fabric strip which has been made by joining said plurality of fabric strips together in an accumulator and detecting whether said accumulator has more or less than a particular amount of said extended length fabric strip contained therein;supplying said extended length knitted pile fabric strip from said accumulator to be wound onto said take-up core member;controlling and guiding said extended length fabric strip in a manner which restricts its lateral movement and controls its lateral position as it is presented to said take-up core member to be wound onto said take-up core member, said extended length fabric strip being moved laterally with respect to said take-up core member as said take-up core member is rotated to thereby substantially spirally wind said extended length fabric strip onto said take-up core member with consecutive windings of said extended length fabric strip being located close adjacent each other;winding said extended length knitted pile fabric strip onto said take-up core member to produce a spool of knitted pile fabric strip while simultaneously controlling both the rotational displacement of said take-up core member and the lateral position in which said extended length knitted pile fabric strip is presented to said take-up core member to thereby substantially spirally wind said extended length knitted pile fabric strip onto said take-up core member with consecutive windings of said extended length knitted pile fabric strip being located close adjacent each other, and with consecutive rows of said extended length knitted pile fabric strip overlaying each other on said take-up core member; androtating said take-up core member at a higher rate of rotational displacement if said accumulator has more than said particular amount of said extended length fabric strip contained therein and rotating said take-up core member at a lower rate of rotational displacement if said accumulator has less than said particular amount of said extended length fabric strip contained therein.16. An extended length knitted pile fabric strip roll produced in accordance with the method of claim 15.17. A method for producing an extended length fabric strip from a plurality of fabric strips, comprising:sewing a plurality of fabric strips together at their respective ends to produce an extended length fabric strip;supplying said extended length fabric strip to be wound onto a take-up core member; andwinding said extended length fabric strip onto said take-up core member to produce a spool of fabric strip while simultaneously controlling both the rotational displacement of said take-up core member and the lateral position in which said extended length fabric strip is presented to said take-up core whereby said extended length fabric strip is substantially spirally wound on said take-up core member with consecutive windings of said extended length fabric strip being located close adjacent each other, and with consecutive rows of said extended length fabric strip overlaying each other on said take-up core member.18. A method as defined in claim 17, additionally comprising:removing particulate from said extended length fabric strip before being wound onto said take-up core member.19. An extended length knitted pile fabric strip roll produced in accordance with the method of claim 17.20. A system for producing an extended length fabric strip from a plurality of fabric strips, comprising:a seamer station for sewing a plurality of fabric strips together at their respective ends to produce an extended length fabric strip;a winder support which removably supports a take-up core member for rotation at a controlled rate to thereby control rotational displacement of said take-up core member;a guide member which is used to supply said extended length fabric strip to be wound onto said take-up core member;a lateral position controller to vary the lateral position of said guide member from which said extended length fabric strip is presented to said take-up core member to be wound thereupon; anda motorized winder to rotate said take-up core member to thereby wind said extended length fabric strip onto said take-up core member to produce a spool of fabric strip, the amount of rotational displacement of said take-up core member and the lateral position of said guide member being simultaneously controlled to thereby substantially spirally wind said extended length fabric strip onto said take-up core member with consecutive windings of said extended length fabric strip being located close adjacent each other, and with consecutive rows of said extended length fabric strip overlaying each other on said take-up core member.21. A system as defined in claim 20, wherein said seamer station comprises:a sewing machine capable of stitching the contiguous ends of two fabric strips together with thread, thereby joining said two fabric strips together.22. A system as defined in claim 20, wherein said winder support comprises:a first support member for supporting a first end of said take-up core member; anda second support member for supporting a second end of said take-up core member, said second support member being retractable to allow said take-up core member to be removed from said winder support and to allow a new take-up core member to be installed on said winder support.23. A system as defined in claim 20, wherein said guide member comprises:a carriage member defining a path through which said extended length fabric strip may pass as it is being wound onto said take-up core member, said carriage member being located sufficiently close to said take-up core member that lateral movement of said carriage member will vary the location on said take-up core member at which said extended length fabric strip is wound;and wherein said lateral position controller comprises:a carriage track upon which said carriage member is mounted for axial movement in a direction parallel to said take-up core member; anda drive mechanism for moving said carriage member laterally on said track to thereby adjust the location on said take-up core member at which said extended length fabric strip is wound.24. A system as defined in claim 20, wherein said guide member comprises:a detector for determining the presence or absence of said extended length fabric strip in said guide member, said detector facilitating the stoppage of rotation of said take-up core member when the entire extended length fabric strip has passed therethrough and been wound onto said take-up core member.25. A system as defined in claim 20, wherein said lateral position controller comprises:a first highly precise drive system for varying the position of said guide member;and wherein said motorized winder comprises:a second highly precise drive system for rotating said take-up core member.26. A system as defined in claim 25, additionally comprising:a control system for operating said first and second highly precise drive systems, said control system automatically determining the interrelationship between said first and second highly precise drive systems based upon the width and thickness of said fabric strips, the outer diameter of said take-up core member, and the position on said take-up core member at which said winding step begins.27. A system as defined in claim 20, additionally comprising:a plurality of parallel, spaced-apart rollers through which said extended length fabric strip must pass to reach said guide member, said extended length fabric strip passing over each of said plurality of rollers, said plurality of rollers acting to pre-tension said extended length fabric strip prior to it reaching said guide member, said extended length fabric strip being moveable laterally on each of said plurality of rollers as it passes thereupon, such lateral movement being caused by lateral movement of said guide carriage as it is moved by said lateral position controller.28. A system as defined in claim 20, additionally comprising:an accumulator for accommodating the portion of said extended length fabric strip which has been made joined at said seamer station, said extended length fabric strip being removed from said accumulator to be wound onto said take-up core member.29. A system as defined in claim 28, wherein said accumulator comprises:at least one detector for determining whether said accumulator has more or less than a particular amount of said extended length fabric strip contained therein.30. A system as defined in claim 28, wherein said accumulator comprises:a slide having an upper end and a lower end;a motorized drive for drawing said extended length fabric strip into said accumulator when said motorized drive is operating, said motorized drive being located at the top end of said slide and providing said extended length fabric strip to said slide at the top end of said slide, the portion of said extended length fabric strip drawn into said accumulator moving down said slide through the force of gravity; andan accumulator bin located at said bottom end of said slide, said portion of said extended length fabric strip drawn into said accumulator moving down said slide into said accumulator bin, said extended length fabric strip moving out of said accumulator bin as it is wound on said take-up core member.31. A system as defined in claim 30, additionally comprising:a first detector mounted in said slide near the bottom thereof for detecting accumulated portions of said extended length fabric strip in said slide at the location of said first detector; anda second detector mounted in said slide at an location intermediate said top and bottom ends thereof for detecting accumulated portions of said extended length fabric strip in said slide at the location of said second detector.32. A system as defined in claim 31, additionally comprising:a rotation speed controller for varying the rate at which said extended length fabric strip is wound onto said take-up core member, said rotation speed controller operating at a high speed when both said first and second detectors detect accumulated portions of said extended length fabric strip at their respective locations, at a medium speed when said first detector detects accumulated portions of said extended length fabric strip at its respective location but said second detector does not detect accumulated portions of said extended length fabric strip at its respective location, and at a low speed when neither of said first and second detectors detects accumulated portions of said extended length fabric strip at their respective locations.33. A system as defined in claim 31, wherein each of said first and second detectors comprise:a light source mounted at a first side of said slide and a light detector being located at an opposite side of said slide, said light source being oriented to direct light onto said light detector and said light detector being oriented to detect light directed onto it from said light source.34. A system as defined in claim 30, wherein said motorized drive comprises:a first roller operated by a motor; anda second roller located close adjacent said first roller, said extended length fabric strip located between said first and second rollers and being drawn into said accumulator whenever said first roller is driven to rotate by said motor.35. A system as defined in claim 20, additionally comprising:a vacuum system which is used to remove particulate from said extended length fabric strip before being wound onto said take-up core member.36. A system for producing an extended length fabric strip from a plurality of fabric strips, comprising:a seamer station for sewing a plurality of fabric strips together at their respective ends to produce an extended length fabric strip;a winder support which removably supports a take-up core member for rotation at a controlled rate to thereby control rotational displacement of said take-up core member;an accumulator for accommodating the portion of said extended length fabric strip which has been made joined at said seamer station, said extended length fabric strip being removed from said accumulator to be wound onto said take-up core member;a guide member which is used to supply said extended length fabric strip to be wound onto said take-up core member;a lateral position controller to vary the lateral position of said guide member from which said extended length fabric strip is presented to said take-up core member to be wound thereupon, said lateral position controller being operable to precisely vary the position of said guide member;a motorized winder to rotate said take-up core member to thereby wind said extended length fabric strip onto said take-up core member to produce a spool of fabric strip, said motorized winder being operable to precisely rotate said take-up core member, the amount of rotational displacement of said take-up core member and the lateral position of said guide member being simultaneously controlled to thereby substantially spirally wind said extended length fabric strip onto said take-up core member with consecutive windings of said extended length fabric strip being located close adjacent each other, and with consecutive rows of said extended length fabric strip overlaying each other on said take-up core member; anda control system for operating said lateral position controller and said motorized winder, said control system automatically determining the interrelationship between said lateral position controller and said motorized winder.37. A system for producing an extended length fabric strip from a plurality of fabric strips, comprising:a seamer station for stitching a plurality of fabric strips together at their respective ends to produce an extended length fabric strip; anda winding station at which said extended length fabric strip is wound onto a take-up core member to produce a spool of fabric strip, said winding station being operable to simultaneously control the amount of rotational displacement of said take-up core member and the lateral position of said extended length fabric strip whereby said extended length fabric strip is substantially spirally wound on said take-up core member with consecutive windings of said extended length fabric strip being located close adjacent each other, and with consecutive rows of said extended length fabric strip overlaying each other on said take-up core member.38. A method for winding an extended length fabric strip onto a take-up core member comprising:providing said extended length fabric strip formed from a plurality of fabric strips that have been sewn together;removably supporting said take-up core member for rotation at a controlled rate to thereby control rotational displacement of said take-up core member;controlling the lateral position at which said extended length fabric strip is presented to said take-up core member to be wound thereupon and varying said lateral position with respect to said take-up core member; andwinding said extended length fabric strip onto said take-up core member to produce a spool of fabric strip while simultaneously controlling both the rotational displacement of said take-up core member and the lateral position in which said extended length fabric strip is presented to said take-up core member to thereby substantially spirally wind said extended length fabric strip onto said take-up core member with consecutive windings of said extended length fabric strip being located close adjacent each other, and with consecutive rows of said extended length fabric strip overlaying each other on said take-up core member.39. A method as defined in claim 38, wherein said controlling step comprises:guiding said extended length fabric strip in a manner which restricts its lateral movement as it is being wound onto said take-up core member, said extended length fabric strip being moved laterally with respect to said take-up core member as said take-up core member is rotated to thereby substantially spirally wind said extended length fabric strip onto said take-up core member with consecutive windings of said extended length fabric strip being located close adjacent each other.40. A method as defined in claim 38, additionally comprising:determining the relative relationship between the lateral position at which said extended length fabric strip is presented to said take-up core member of said extended length fabric strip and the rotational displacement of said take-up core member based upon the width and thickness of said fabric strips, the outer diameter of said take-up core member, and the position on said take-up core member at which said winding step begins.41. A method as defined in claim 38, wherein said determining step comprises:using a computer-controlled operating system to operate and control the lateral position at which said extended length fabric strip is presented to said take-up core member of said extended length fabric strip and the rotational displacement of said take-up core member to thereby substantially spirally wind said extended length fabric strip onto said take-up core member with consecutive windings of said extended length fabric strip being located close adjacent each other, and with consecutive rows of said extended length fabric strip overlaying each other on said take-up core member.42. A method as defined in claim 38, additionally comprising:varying the rate of rotational displacement of said take-up core member based at least in part upon the amount of said extended length fabric strip which has been made by joining said plurality of fabric strips together.43. A method as defined in claim 42, wherein said varying step comprises:accumulating the portion of said extended length fabric strip which has been made by joining said plurality of fabric strips together in an accumulator and detecting whether said accumulator has more or less than a particular amount of said extended length fabric strip contained therein, said extended length fabric strip being removed from said accumulator to be wound onto said take-up core member; androtating said take-up core member at a higher rate of rotational displacement if said accumulator has more than said particular amount of said extended length fabric strip contained therein and rotating said take-up core member at a lower rate of rotational displacement if said accumulator has less than said particular amount of said extended length fabric strip contained therein.44. An extended length knitted pile fabric strip roll produced in accordance with the method of claim 43.45. A method as defined in claim 38, additionally comprising:removing particulate from said extended length fabric strip before being wound onto said take-up core member.46. An extended length knitted pile fabric strip roll produced in accordance with the method of claim 38.47. A method for winding an extended length fabric strip onto a take-up core member comprising:supplying said extended length knitted pile fabric strip to be wound onto said take-up core member, said extended length knitted pile fabric strip being constructed from a plurality of fabric strips that have been sewn together;removably supporting a cylindrical take-up core member for rotation at a controlled rate to thereby control rotational displacement of said take-up core member;controlling and guiding said extended length fabric strip in a manner which restricts its lateral movement and controls its lateral position as it is presented to said take-up core member to be wound onto said take-up core member, said extended length fabric strip being moved laterally with respect to said take-up core member as said take-up core member is rotated to thereby substantially spirally wind said extended length fabric strip onto said take-up core member with consecutive windings of said extended length fabric strip being located close adjacent each other;winding said extended length knitted pile fabric strip onto said take-up core member to produce a spool of knitted pile fabric strip while simultaneously controlling both the rotational displacement of said take-up core member and the lateral position in which said extended length knitted pile fabric strip is presented to said take-up core member to thereby substantially spirally wind said extended length knitted pile fabric strip onto said take-up core member with consecutive windings of said extended length knitted pile fabric strip being located close adjacent each other, and with consecutive rows of said extended length knitted pile fabric strip overlaying each other on said take-up core member; androtating said take-up core member at a higher rate of rotational displacement if said accumulator has more than said particular amount of said extended length fabric strip contained therein and rotating said take-up core member at a lower rate of rotational displacement if said accumulator has less than said particular amount of said extended length fabric strip contained therein.48. A system for winding an extended length fabric strip onto a take-up core, said system comprising:a guide member which is used to supply said extended length fabric strip to be wound onto said take-up core member, said extended length knitted pile fabric strip being constructed from a plurality of fabric strips that have been sewn together;a lateral position controller to vary the lateral position of said guide member from which said extended length fabric strip is presented to said take-up core member to be wound thereupon; anda motorized winder to rotate said take-up core member to thereby wind said extended length fabric strip onto said take-up core member to produce a spool of fabric strip, the amount of rotational displacement of said take-up core member and the lateral position of said guide member being simultaneously controlled to thereby substantially spirally wind said extended length fabric strip onto said take-up core member with consecutive windings of said extended length fabric strip being located close adjacent each other, and with consecutive rows of said extended length fabric strip overlaying each other on said take-up core member.49. A system as defined in claim 48, wherein said winder support comprises:a first support member for supporting a first end of said take-up core member; anda second support member for supporting a second end of said take-up core member, said second support member being retractable to allow said take-up core member to be removed from said winder support and to allow a new take-up core member to be installed on said winder support.50. A system as defined in claim 48, wherein said guide member comprises:a carriage member defining a path through which said extended length fabric strip may pass as it is being wound onto said take-up core member, said carriage member being located sufficiently close to said take-up core member that lateral movement of said carriage member will vary the location on said take-up core member at which said extended length fabric strip is wound;and wherein said lateral position controller comprises:a carriage track upon which said carriage member is mounted for axial movement in a direction parallel to said take-up core member; anda drive mechanism for moving said carriage member laterally on said track to thereby adjust the location on said take-up core member at which said extended length fabric strip is wound.51. A system as defined in claim 48, wherein said guide member comprises:a detector for determining the presence or absence of said extended length fabric strip in said guide member, said detector facilitating the stoppage of rotation of said take-up core member when the entire extended length fabric strip has passed therethrough and been wound onto said take-up core member.52. A system as defined in claim 48, wherein said lateral position controller comprises:a first highly precise drive system for varying the position of said guide member;and wherein said motorized winder comprises:a second highly precise drive system for rotating said take-up core member.53. A system as defined in claim 52, additionally comprising:a control system for operating said first and second highly precise drive systems, said control system automatically determining the interrelationship between said first and second highly precise drive systems based upon the width and thickness of said fabric strips, the outer diameter of said take-up core member, and the position on said take-up core member at which said winding step begins.54. A system as defined in claim 48, additionally comprising:a plurality of parallel, spaced-apart rollers through which said extended length fabric strip must pass to reach said guide member, said extended length fabric strip passing over each of said plurality of rollers, said plurality of rollers acting to pre-tension said extended length fabric strip prior to it reaching said guide member, said extended length fabric strip being moveable laterally on each of said plurality of rollers as it passes thereupon, such lateral movement being caused by lateral movement of said guide carriage as it is moved by said lateral position controller.55. A system as defined in claim 48, additionally comprising:an accumulator for storing a portion of said extended length fabric strip which has been made by joining a plurality of fabric strips together at their respective ends, said extended length fabric strip being removed from said accumulator to be wound on to said take-up core member.56. A system as defined in claim 55, wherein said accumulator comprises:at least one detector for determining whether said accumulator has more or less than a particular amount of said extended length fabric strip contained therein.57. A system as defined in claim 56, additionally comprising:a first detector mounted at a first location in said accumulator for detecting a first amount of said extended length fabric strip stored in said accumulator at the location of said first detector; anda second detector mounted at a second location in said accumulator for detecting a second, larger amount of accumulated portions of said extended length fabric strip stored in said accumulator at the location of said second detector.58. A system as defined in claim 57, additionally comprising:a rotation speed controller for varying the rate at which said extended length fabric strip is wound onto said take-up core member, said rotation speed controller operating at a high speed when both said first and second detectors detect accumulated portions of said extended length fabric strip at their respective locations, at a medium speed when said first detector detects accumulated portions of said extended length fabric strip at its respective location but said second detector does not detect accumulated portions of said extended length fabric strip at its respective location, and at a low speed when neither of said first and second detectors detects accumulated portions of said extended length fabric strip at their respective locations.59. A method as defined in claim 48, additionally comprising: removing particulate from said extended length fabric strip before being wound onto said take-up core member.
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이 특허에 인용된 특허 (14)
Wyser Johann (Ligerz CHX), Apparatus and method for adhering successive webs by means of adhesive applied to a predetermined side thereof.
Musch Gordon F. (West Salem OH) Gerardo Serafin J. (Mansfield OH) Humphrey Dennis D. (Wooster OH) Bochnak Bruce E. (Wooster OH) Barker Richard L. (Apple Creek OH) Roberts William J. (West Salem OH) Y, Method and apparatus for making paint roller cover.
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