Styrene Butadiene Rubber

Synthetic Butadiene Rubber, commonly known as SBR, is a type of Synthetic Rubber produced from the polymerization of butadiene, a hydrocarbon compound. Butadiene is typically derived from petroleum or natural gas. SBR is one of the most widely used types of Synthetic Rubber due to its versatile properties and relatively low cost of production.

OVERVIEW OF STYRENE BUTADIENE RUBBER

SBR, or Styrene Butadiene Rubber, is one of the most widely used synthetic rubbers. It is renowned for its abrasion resistance, excellent aging characteristics, and versatility. SBR is commonly utilized in tire manufacturing, automotive parts, conveyor belts, footwear, rubber mats & floorings, hoses & tubing, adhesives & sealants, electrical insulation, construction material, consumer goods etc. These diverse applications highlight SBR’s importance across multiple industries due to its adaptable and resilient nature.

Properties

Styrene Butadiene Rubber (SBR) possesses several properties that make it a versatile and widely used synthetic rubber. Some key properties include:

  • Abrasion Resistance: SBR is highly resistant to wear and tear, making it suitable for applications that require durability.
  • Good Aging Characteristics: It maintains its properties over time, especially when exposed to heat, oxygen, and ozone.
  • Flexibility: SBR remains flexible even at low temperatures, which is beneficial for various dynamic applications.
  • Tensile Strength: It has good tensile strength, contributing to its resilience and ability to withstand significant stress and deformation.
  • Hardness: SBR can be formulated to have a range of hardness levels, allowing it to be used in both soft and hard rubber products.
  • Water Resistance: It has moderate resistance to water, making it suitable for applications where exposure to moisture is expected.
  • Chemical Resistance: SBR exhibits good resistance to many chemicals, although it is not suitable for use with oils, fuels, and hydrocarbons.
  • Impact Resistance: It has good impact resistance, making it suitable for applications subject to mechanical shocks and impacts.
  • Temperature Range: SBR can function effectively in a temperature range of -40°C to +100°C, although its properties may degrade at the higher end of this range.
  • Electrical Insulation: SBR has decent electrical insulating properties, making it useful in certain electrical applications.

These properties make SBR a preferred material in industries such as automotive, construction, footwear, and manufacturing, where durability, flexibility, and resistance to aging and wear are essential.

Manufacturing Process

The manufacturing process of Styrene Butadiene Rubber (SBR) involves the polymerization of styrene and butadiene. There are two main methods for producing SBR: emulsion polymerization and solution polymerization.

Emulsion Polymerization

Preparation of Emulsion:
  • Monomers: Styrene and butadiene are emulsified in water with the help of surfactants (emulsifying agents).
  • Initiator: A free-radical initiator, such as potassium persulfate, is added to initiate the polymerization process.
  • Modifiers: Chain transfer agents like mercaptans may be added to control the molecular weight of the polymer.
Polymerization:
  • The reaction takes place in a reactor under controlled temperature and pressure conditions.
  • The polymerization can be either batch or continuous.
  • The temperature is typically maintained between 5°C and 50°C.
Coagulation:
  • After polymerization, the latex (a colloidal dispersion of the polymer) is coagulated using acids or salts.
  • The coagulated rubber is then separated from the liquid phase.
Washing and Dehydration:
  • The rubber is washed to remove any residual emulsifiers and other impurities.
  • Excess water is removed through mechanical means such as centrifugation or filtration.
Drying:
  • The washed rubber is dried using hot air or steam to obtain the final dry rubber product.

Solution Polymerization

Preparation of Solution:
  • Monomers: Styrene and butadiene are dissolved in an organic solvent.
  • Initiator: An organometallic compound, such as butyllithium, is used as an initiator for anionic polymerization.
Polymerization:
  • The polymerization occurs in a reactor under controlled temperature and pressure conditions, typically between -50°C and 100°C.
  • The reaction proceeds via anionic polymerization, which allows for better control over the molecular weight and distribution of the polymer.
Precipitation and Recovery:
  • The polymer is precipitated out of the solution using a non-solvent such as methanol.
  • The precipitated rubber is then separated from the solvent and any unreacted monomers.
Washing and Drying:
  • The rubber is washed to remove residual solvents and other impurities.
  • It is then dried using hot air or steam.

Final Processing

  • Compounding: The dried SBR may be mixed with various additives such as fillers, plasticizers, antioxidants, and curing agents to achieve the desired properties.
  • Mastication: The rubber is masticated (mechanically worked) to improve its processability.
  • Forming and Shaping: The compounded rubber is then processed into the desired shapes and forms, such as sheets, pellets, or moulded products.
  • Vulcanization: The rubber is vulcanized (cross-linked) through heating with sulphur or other curing agents to enhance its mechanical properties and stability.

Applications

Styrene Butadiene Rubber (SBR) has a wide range of applications due to its versatile properties. Some of the key applications include:

  • Tire Manufacturing:
    • Passenger and Light Truck Tires: Used in tread and sidewalls for its abrasion resistance and durability.
    • Heavy-Duty Tires: Employed in the production of truck, bus, and off-road vehicle tires.
    • Retread Tires: Utilized in the retreading process to extend the life of worn tires.
  • Automotive Parts:
    • Hoses: Used in radiator and heater hoses for its flexibility and heat resistance.
    • Seals and Gaskets: Employed in various seals and gaskets due to its good sealing properties.
    • Belts: Used in fan belts and other drive belts for its wear resistance.
  • Footwear:
    • Shoe Soles: Used in the production of durable and flexible shoe soles.
    • Athletic Footwear: Employed in sports shoes for its cushioning and wear resistance.
  • Industrial Products:
    • Conveyor Belts: Used in manufacturing conveyor belts for its strength and abrasion resistance.
    • Rubber Mats: Employed in industrial and commercial flooring for its durability.
    • Rollers: Used in printing and textile rollers for its resilience.
  • Construction Materials:
    • Roofing Membranes: Used in roofing applications for its weather resistance.
    • Sealants and Adhesives: Employed in construction sealants and adhesives for its bonding properties.
  • Consumer Goods:
    • Toys: Used in the production of durable and safe toys.
    • Household Items: Employed in various household products such as spatulas and grips.
  • Electrical Insulation:
    • Cables and Wires: Used as insulation for electrical cables and wires for its dielectric properties.
  • Medical Applications:
    • Medical Devices: Employed in non-latex medical devices and components.
  • Sports Equipment:
    • Balls: Used in the production of sports balls for its bounce and durability.
    • Padding: Employed in protective padding and grips for sports equipment.
  • Packaging:
    • Rubber Bands: Used in packaging for its elasticity and strength.
    • Bottle Stoppers: Employed in bottle stoppers for its sealing properties.
  • Textile Industry:
    • Elastic Threads: Used in elastic threads and bands for its stretchability.
  • Miscellaneous:
    • Crayons and Candles: Employed in the production of crayons and candles for its smoothness and flexibility.
    • Paints and Coatings: Used as a binder in certain paints and coatings for its film-forming properties.

Blends

Blends of Styrene Butadiene Rubber (SBR) are often used to enhance the properties of the rubber or to combine the advantages of different types of rubber. Here are some common blends involving SBR:

1. SBR/NR (Natural Rubber) Blends

  • Properties: Combining SBR with natural rubber improves elasticity, resilience, and overall performance. These blends often provide a balance between the strength of natural rubber and the aging resistance of SBR.
  • Applications: Used in tires, automotive parts, and industrial products.

2. SBR/BR (Butadiene Rubber) Blends

  • Properties: Blending SBR with butadiene rubber enhances abrasion resistance and impact strength. The combination improves the resilience and toughness of the rubber.
  • Applications: Commonly used in tires, conveyor belts, and various industrial applications.

3. SBR/EPDM (Ethylene Propylene Diene Monomer) Blends

  • Properties: The blend of SBR with EPDM improves resistance to heat, ozone, and weathering. It enhances the flexibility and durability of the rubber.
  • Applications: Used in automotive seals, gaskets, and outdoor applications where weather resistance is crucial.

4. SBR/NBR (Nitrile Butadiene Rubber) Blends

  • Properties: Combining SBR with NBR enhances oil resistance and mechanical strength. This blend also maintains good flexibility and resilience.
  • Applications: Commonly used in fuel and oil seals, hoses, and gaskets.

5. SBR/CR (Chloroprene Rubber) Blends

  • Properties: Blending SBR with chloroprene rubber (Neoprene) improves chemical resistance and weather resistance. It also offers better aging properties.
  • Applications: Used in industrial applications, automotive parts, and applications requiring resistance to chemicals and weathering.

6. SBR/TPR (Thermoplastic Rubber) Blends

  • Properties: Combining SBR with TPR can enhance processability and flexibility. This blend also allows for easy recycling of the rubber.
  • Applications: Used in consumer goods, footwear, and various industrial products.

7. SBR/PU (Polyurethane) Blends

  • Properties: Blending SBR with polyurethane improves abrasion resistance and elasticity. It also enhances the mechanical properties of the rubber.
  • Applications: Used in high-performance applications like wheels, rollers, and various industrial components.

8. SBR/NR/BR (Natural Rubber/Butadiene Rubber) Blends

  • Properties: This tri-blend combines the strengths of natural rubber, butadiene rubber, and SBR to enhance overall performance, including elasticity, strength, and abrasion resistance.
  • Applications: Used in high-performance tires and heavy-duty applications.

9. SBR/EPDM/NR (Ethylene Propylene Diene Monomer/Natural Rubber) Blends

  • Properties: This blend improves the weather resistance of SBR while retaining the elasticity of natural rubber.
  • Applications: Used in automotive weather seals, roofing membranes, and outdoor applications.

These blends are tailored to meet specific performance requirements and can be customized depending on the desired properties for different applications.
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STYRENE-BUTADIENE RUBBER 1500

SBR 1500 refers to grade of Styrene Butadiene Rubber (SBR). SBR 1500 is produced through the copolymerization of styrene and butadiene monomers.

Characteristics

  • Styrene Content: Typically around 23.50%
  • Butadiene Content: Typically around 76.50%

Key Characteristics of SBR 1500:

  1. High Abrasion Resistance:
    • Provides excellent resistance to wear and tear, making it ideal for applications like tires and conveyor belts where durability is crucial.
  2. Good Flexibility:
    • Maintains flexibility at low temperatures, ensuring it performs well in environments that experience temperature fluctuations.
  3. High Tensile Strength:
    • Exhibits strong resistance to stretching and breaking under tension, contributing to its durability and reliability in demanding applications.
  4. Excellent Elasticity:
    • Capable of returning to its original shape after deformation, which enhances its performance in applications requiring resilience and bounce.
  5. Moderate Aging Resistance:
    • Shows reasonable resistance to aging, including exposure to oxygen and ozone, although additional stabilizers may be needed for extended longevity.
  6. Adjustable Hardness:
    • Hardness can be tailored during the compounding process to meet specific requirements for different applications.
  7. Wide Temperature Range:
    • Performs effectively within a temperature range of approximately -40°C to +100°C, though its properties may degrade at the higher end of this range.
  8. Good Impact Resistance:
    • Offers strong resistance to impacts and mechanical shocks, making it suitable for applications subject to sudden force or impact.
  9. Moderate Water Resistance:
    • Provides adequate resistance to water, making it suitable for applications where exposure to moisture is expected.
  10. Decent Processing Characteristics:
    • Exhibits good processability, facilitating ease of manufacturing and shaping into various products.
  11. Limited Chemical Resistance:
    • Has moderate resistance to certain chemicals but is generally unsuitable for environments involving oils, fuels, or hydrocarbons.
  12. Reasonable Electrical Insulation:
    • Provides adequate electrical insulation properties, making it suitable for certain electrical and electronic applications.

Applications

SBR 1500, like other SBR grades, finds applications in various industries due to its versatile properties. Common applications may include:

  1. Tyre Manufacturing: SBR is used in tyre treads and sidewalls due to its durability and abrasion resistance.
  2. Footwear: SBR is employed in shoe soles and components due to its resilience and flexibility.
  3. Industrial Rubber Products: Conveyor belts, hoses, gaskets, seals, and other industrial rubber products often utilize SBR due to its excellent mechanical properties.
  4. Automotive Parts: SBR finds applications in automotive components such as bushings, mounts, and seals.
  5. Construction Materials: SBR is used in construction materials like roofing membranes and adhesives.
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STYRENE-BUTADIENE RUBBER 1502

SBR 1502 is a specific grade of Styrene Butadiene Rubber (SBR) with particular properties suited for various applications.

Characteristics

  1. Composition:
    • Styrene Content: Approximately 23-25% by weight.
    • Butadiene Content: Around 75-77% by weight.
    • Polymerization: Produced via emulsion polymerization.
  2. Physical Properties:
    • Mooney Viscosity: Typically between 40-60 Mooney units, indicating its processability and ease of mixing.
    • Tensile Strength: Provides good tensile strength, suitable for various demanding applications.
    • Elongation at Break: High elongation, offering flexibility and the ability to stretch without breaking.
    • Hardness: Generally has a Shore A hardness around 50-70, which can be adjusted based on formulation needs.
  3. Durability:
    • Wear Resistance: Good resistance to abrasion, making it suitable for high-wear applications.
    • Heat Resistance: Moderate, capable of withstanding typical operating temperatures but not as high as some specialty rubbers.
    • Chemical Resistance: Moderate, effective against water and mild chemicals but less resistant to oils and solvents.

Key Characteristics

  1. Balanced Performance: Combines wear resistance, flexibility, and cost-effectiveness, making it suitable for a range of applications.
  2. Cost-Efficiency: Provides a good balance between performance and affordability, making it a cost-effective choice for many applications.
  3. Versatility: Adaptable to various formulations and processing techniques, allowing for customization to meet specific performance requirements.

Applications

  1. Automobile Tires:
    • Tire Treads: Used for its abrasion resistance and durability, crucial for tread longevity and traction.
    • Sidewalls: Provides flexibility and strength to absorb impacts and enhance overall tire performance.
  2. Footwear:
    • Shoe Soles: Used in both casual and athletic footwear for its comfort, wear resistance, and durability.
    • Work Boots: Provides impact resistance and durability for safety footwear used in demanding environments.
  3. Industrial Belts and Hoses:
    • Conveyor Belts: Employed in conveyor systems for its durability and resistance to wear, suitable for transporting heavy or abrasive materials.
    • Hoses: Provides flexibility and resistance to abrasion for various applications involving fluid or gas transfer.
  4. Gaskets and Seals:
    • Automotive Gaskets: Used in engine gaskets and seals to ensure a reliable seal against fluids and gases.
    • Industrial Seals: Employed in machinery to prevent leaks, offering moderate resistance to heat and chemicals.
  5. Automotive Parts:
    • Suspension Bushings: Absorbs shocks and vibrations in vehicle suspension systems, improving ride comfort and handling.
    • Engine Mounts: Helps reduce engine vibrations and noise, contributing to smoother operation and less stress on components.
  6. Additional Applications:
    • Rubber Mats: Used in industrial and commercial flooring for its durability and impact resistance.
    • Rubber Rollers: Utilized in manufacturing processes where resistance to abrasion and mechanical stress is needed.

SBR 1502 is valued for its balance of performance characteristics, making it a versatile choice across various industrial and consumer applications.
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STYRENE-BUTADIENE RUBBER 1705

SBR 1705 is variant of Styrene Butadiene Rubber (SBR). Similar to other SBR grades, SBR 1705 is produced through the copolymerization of styrene and butadiene monomers.

Characteristics

  1. Composition:
    • Styrene Content: Typically around 23-25% by weight.
    • Butadiene Content: Approximately 75-77% by weight.
    • Polymerization Method: Emulsion polymerization, which affects the rubber’s properties and performance.
  2. Physical Properties:
    • Mooney Viscosity: Generally ranges from 45-60 Mooney units, indicating its processability and ease of mixing.
    • Tensile Strength: Provides moderate to high tensile strength, which is important for structural applications.
    • Elongation at Break: High, offering good flexibility and the ability to stretch before breaking.
    • Hardness: Typically has a Shore A hardness of 50-70, which can be adjusted based on specific formulation needs.
  3. Durability:
    • Wear Resistance: Good, making it suitable for applications that experience moderate wear and tear.
    • Heat Resistance: Moderate, capable of withstanding typical operating temperatures but not suited for extreme heat.
    • Chemical Resistance: Moderate, effective against water and mild chemicals but less resistant to oils and solvents.

Key Characteristics

  1. Balanced Mechanical Properties: Offers a good balance of tensile strength, elongation, and wear resistance, making it versatile for various applications.
  2. Cost-Effectiveness: Provides a cost-efficient option while delivering reliable performance in numerous applications.
  3. Processability: Good processability due to its Mooney viscosity, making it easy to mix and mold during manufacturing.

Applications

  1. Automobile Tires:
    • Tire Treads: Used for its durability and wear resistance in tire treads, which helps extend tire life and improve performance.
    • Tire Sidewalls: Provides flexibility and strength, enhancing the durability and impact resistance of tire sidewalls.
  2. Footwear:
    • Shoe Soles: Employed in both casual and performance footwear for its comfort, wear resistance, and flexibility.
    • Work Boots: Suitable for safety and industrial footwear where durability and impact resistance are crucial.
  3. Industrial Belts and Hoses:
    • Conveyor Belts: Used in conveyor systems for its wear resistance and ability to handle heavy or abrasive materials.
    • Hoses: Provides flexibility and durability for various hoses used in industrial applications.
  4. Gaskets and Seals:
    • Automotive Gaskets: Used in engine gaskets and seals for its reliability and ability to withstand engine conditions.
    • Industrial Seals: Employed in machinery to prevent leaks, with moderate resistance to heat and chemicals.
  5. Automotive Parts:
    • Suspension Bushings: Absorbs shocks and vibrations in vehicle suspension systems, enhancing ride comfort and handling.
    • Engine Mounts: Helps reduce engine vibrations and noise, contributing to smoother vehicle operation.
  6. Additional Applications:
    • Rubber Mats and Flooring: Used in industrial and commercial flooring for its durability and resistance to impact.
    • Rubber Rollers: Suitable for manufacturing processes that require resistance to wear and mechanical stress.

SBR 1705’s combination of balanced mechanical properties and cost-effectiveness makes it a versatile choice for a wide range of applications across different industries.
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STYRENE-BUTADIENE RUBBER 1712

SBR 1712 is a specific grade of Styrene Butadiene Rubber (SBR), a Synthetic Rubber derived from the copolymerization of Styrene and Butadiene. SBR 1712 has distinct properties and applications compared to other grades within the SBR.

Characteristics

  1. Composition:
    • Styrene Content: Approximately 23-27% by weight.
    • Butadiene Content: Around 73-77% by weight.
    • Polymerization Method: Emulsion polymerization.
  2. Physical Properties:
    • Mooney Viscosity: Typically in the range of 50-70 Mooney units, indicating good processability and ease of mixing.
    • Tensile Strength: Generally high, providing good mechanical strength for various applications.
    • Elongation at Break: High elongation, offering flexibility and the ability to stretch without breaking.
    • Hardness: Usually has a Shore A hardness of 55-75, adjustable based on specific needs.
  3. Durability:
    • Wear Resistance: Excellent, making it suitable for high-wear applications.
    • Heat Resistance: Superior compared to some other SBR grades, suitable for elevated temperature conditions.
    • Chemical Resistance: Moderate, with reasonable resistance to water and mild chemicals but less effective against oils and solvents.

Key Characteristics

  1. Enhanced Wear Resistance: Ideal for applications that experience significant wear and tear, such as tire treads and industrial belts.
  2. High Heat Resistance: Performs well in higher temperature environments, making it suitable for applications involving heat.
  3. Flexibility: Maintains flexibility and elongation, which is crucial for applications requiring dynamic movement and shock absorption.
  4. Versatility: Can be formulated and processed for various applications, providing customization options for specific performance needs.

Applications

  1. Automobile Tires:
    • Tire Treads: Utilized for its excellent wear resistance, enhancing tire durability and performance on various road surfaces.
    • Tire Sidewalls: Provides flexibility and strength, contributing to overall tire resilience and impact absorption.
  2. Footwear:
    • Shoe Soles: Used in both casual and performance footwear for its balance of durability and flexibility.
    • Work Boots: Ideal for safety footwear where high wear resistance and comfort are important.
  3. Industrial Belts and Hoses:
    • Conveyor Belts: Employed in heavy-duty conveyor systems where high wear resistance is required for transporting abrasive materials.
    • Hoses: Suitable for hoses needing flexibility and durability, used in various industrial applications.
  4. Gaskets and Seals:
    • Automotive Gaskets: Used in engine gaskets and seals for its durability and ability to withstand engine conditions.
    • Industrial Seals: Employed in machinery where heat and wear resistance are essential for preventing leaks.
  5. Automotive Parts:
    • Suspension Bushings: Absorbs shocks and vibrations, improving vehicle ride quality and handling.
    • Engine Mounts: Reduces engine vibrations and noise, enhancing overall vehicle performance.
  6. Additional Applications:
    • Rubber Mats and Flooring: Used in industrial and commercial settings for durability and impact resistance.
    • Rubber Rollers: Suitable for manufacturing processes requiring resistance to wear and mechanical stress.

SBR 1712 is valued for its superior wear and heat resistance, making it suitable for demanding applications across various industries.
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STYRENE-BUTADIENE RUBBER 1723

SBR 1723 is a synthetic rubber produced via emulsion polymerization of styrene and butadiene. It is designed to offer a balance of performance characteristics, including wear resistance, flexibility, and cost-effectiveness, making it suitable for demanding applications.

Characteristics

  1. Composition:
    • Styrene Content: Approximately 23-27% by weight.
    • Butadiene Content: Around 73-77% by weight.
    • Polymerization Method: Emulsion polymerization, which influences the rubber’s properties.
  2. Physical Properties:
    • Mooney Viscosity: Typically in the range of 50-70 Mooney units, indicating its processability and ease of handling during mixing.
    • Tensile Strength: Generally high, providing strong mechanical performance.
    • Elongation at Break: High, offering flexibility and the ability to stretch without breaking.
    • Hardness: Usually around Shore A 55-75, allowing for adjustment based on application needs.
  3. Durability:
    • Wear Resistance: Excellent, making it suitable for high-wear applications.
    • Heat Resistance: Good, capable of withstanding moderate to high temperatures.
    • Chemical Resistance: Moderate, effective against water and mild chemicals but less resistant to oils and solvents.

Key Characteristics

  1. Enhanced Wear Resistance: Provides superior durability and abrasion resistance, making it ideal for applications subject to significant wear.
  2. Good Heat Resistance: Performs well in higher temperature environments, suitable for applications involving elevated temperatures.
  3. Flexibility: Maintains good elongation and flexibility, which is important for dynamic applications requiring shock absorption and movement.
  4. Versatility: Adaptable to various formulations and processing techniques, allowing customization for specific performance needs.

Applications

  1. Automobile Tires:
    • Tire Treads: Used for its excellent wear resistance, which extends tire life and enhances performance on various surfaces.
    • Tire Sidewalls: Provides flexibility and strength, improving the durability and impact resistance of tire sidewalls.
  2. Footwear:
    • Shoe Soles: Employed in both casual and athletic footwear for its durability, comfort, and resistance to wear.
    • Work Boots: Suitable for safety and industrial footwear where high durability and impact resistance are required.
  3. Industrial Belts and Hoses:
    • Conveyor Belts: Used in heavy-duty conveyor systems for its wear resistance and ability to handle abrasive materials.
    • Hoses: Provides flexibility and resistance to abrasion for various industrial fluid and gas transfer applications.
  4. Gaskets and Seals:
    • Automotive Gaskets: Used in engine gaskets and seals to ensure reliable sealing under engine conditions.
    • Industrial Seals: Employed in machinery to prevent leaks, with moderate resistance to heat and chemicals.
  5. Automotive Parts:
    • Suspension Bushings: Absorbs shocks and vibrations in vehicle suspension systems, enhancing ride comfort and handling.
    • Engine Mounts: Helps reduce engine vibrations and noise, contributing to smoother operation.
  6. Additional Applications:
    • Rubber Mats and Flooring: Used in industrial and commercial settings for durability and resistance to impact.
    • Rubber Rollers: Suitable for manufacturing processes requiring resistance to wear and mechanical stress.

SBR 1723’s blend of enhanced wear and heat resistance, flexibility, and cost-effectiveness makes it a versatile choice for a variety of applications across different industries.
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