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Journal of The Electrochemical Society, 147 (9) 3231-3236 (2000) 3231

S0013-4651(00)01-030-2 CCC: $7.00 © The Electrochemical Society, Inc.

A Novel Thermal Management System for Electric Vehicle Batteries


Using Phase-Change Material
S. Al Hallaj* and J. R. Selman**,z
Center for Electrochemical Science and Engineering, Department of Chemical and Environmental Engineering, Illinois Institute
of Technology, Chicago, Illinois 60616, USA

A novel thermal-management system that incorporates phase-change material (PCM) is proposed and investigated for electric vehi-
cle (EV) applications. A commercial finite-element (FE) software, PDEase2D™, was used to simulate the thermal behavior of EV
battery modules with a PCM thermal management system. Simulation results show that the temperature profile of the cells integrated
in the module design was substantially more uniform during discharge at different rates than without PCM. The PCM system is effec-
tive in thermally sensitive batteries such as Li-ion and most Li-polymer batteries with a significant reversible heat effect. The heat
generated during discharge and stored as latent heat is then largely utilized during charge, and a smaller part of it is transferred to
the surroundings. The stored heat will be rejected to the module when the battery is left to relax or when its temperature drops below
the melting point of the PCM. This is an important advantage for EV operation under cold conditions or in space applications where
the battery temperature drops significantly when an orbiting satellite moves from the light to the dark side of the earth.
© 2000 The Electrochemical Society. S0013-4651(00)01-030-2. All rights reserved.

Manuscript submitted January 10, 2000; revised manuscript received May 23, 2000.

Temperature excursions and nonuniformity of the temperature temperature distribution in the thickness direction is dominated by
are the main concern in any attempt to scale-up lithium-ion cells to the low thermal conductivity of the polymer electrolyte so that a uni-
the larger sizes desirable for high-power applications such as electric form temperature profile is obtained only at high rates. At low dis-
vehicle (EV) propulsion systems. Basically, battery design requires charge rates, the temperature profile is nonuniform, especially if
a trade-off between the risk of overheating individual cells of rela- forced convection cooling is used at the battery surface. The relative-
tively large sizes, and the cost of insulating or cooling a complex ly high temperature gradient under these conditions may cause ther-
array of small cells. However, this trade-off can be assumed to yield mal stresses in battery components and affect the battery performance
an optimum cell size that is significantly larger than the present com- negatively. Thermal management is not expected to be a problem for
mercial Li-ion cells (somewhat larger than AA size). Thus, a well- such a stack if an optimum number of cells is used in the stack, but
designed thermal management system is required to ensure good this may limit the energy capacity of the battery.
battery performance, safety, and high capacity. Pals and Newman7 studied the effect of temperature changes on
Baker et al.1 demonstrated the usefulness of Green’s functions to the cell performance of lithium-polymer electrolyte batteries during
analyze the steady-state temperature distribution in batteries and fuel galvanostatic discharge. In their study they utilized a general energy
cells. Lee et al.2 used a three-dimensional (3D) thermal model to balance for battery systems developed earlier by Bernardi et al.;9
simulate the temperature profile of a Ni/Fe EV battery. In their however, the dEeq/dT term was set to zero for lack of experimental
model, the composite electrode stack was considered as quasi- data. The energy balance was coupled with a one-dimensional model
homogenous medium with averaged properties. The numerical val- describing the cell performance at different current densities pre-
ues of the thermal properties and heat generation rates were estimat- sented by Doyle et al.10 Their results show a significant effect of the
ed from separate experimental data. Simulation results showed that temperature on the degree of utilization of these batteries. This was
the thermal behavior of a module is affected by several design para- explained by the exponential temperature dependence of the Li-ion
meters such as ampere-hour capacity, number of cells, packing and diffusion coefficient and the electrolyte ionic conductivity. Adiabat-
cooling orientations, and the space between cells. ic operation at different discharge rates was simulated to estimate the
Evans and White3 describe a two-dimensional thermal model for adiabatic short-circuit temperature, which is defined as the energy
a spiral-wound Li/SOCl2 battery. The model was solved using a capacity divided by the effective heat capacity of the battery. The
finite-element computer code. It assumes a thermally homogenous single-cell model results were used later by Pals and Newman8 to
but nonisotropic region made up of cathode, anode, electrolyte, and predict the temperature profile along a cell stack for EV application.
separator. Simulation results showed a much larger temperature gra- Data available in the literature for spirally wound Sony Li-ion
dient in the radial direction compared to that in the axial direction. A batteries were used by Chen and Evans11 to study the thermal behav-
similar conclusion was reported later by Chen and Evans.11 In their ior of a rectangular stack of prismatic scaled-up cells, with the same
work they estimated from component properties an effective thermal material of 20 3 20 cm cross-sectional area. To achieve a 40 kWh
conductivity for the Li-ion cell as a whole. Their calculations showed energy, a battery volume of 1.64 3 105 cm3 is required. The elec-
that the cell conductivity in the axial direction is twenty times higher trochemical behavior was simulated by means of a one-dimensional
than that in the radial direction. model for charge transfer and a three-dimensional model for the heat
Chen and Evans4-6 had earlier presented two- and three-dimen- transfer. Empirical equations (e.g., the Shepherd equation11) were
sional mathematical models to describe the thermal behavior of a rec- used to describe experimental charge-discharge curves for different
tangular stack of prismatic lithium-polymer electrolyte cells. In both rates. However, they did not take into account the fact that the Shep-
models the battery interior was treated as a homogenous but not nec- herd equation was developed for isothermal conditions. Heat gener-
essarily isotropic phase, having effective average properties. Heat ation rates used in the model were assumed to be independent of the
generation was assumed to be uniform within the cell stack. Their ob- cell temperature. They were calculated as a function of degree of dis-
jective was to determine the maximum size without the thermal-man- charge from the cell voltage under load and at open-circuit condi-
agement problems of a compact cell stack of 400 mm and 20 cm cell tions. A constant value of 10 mW/cm3 was estimated during dis-
thickness and width, respectively. Simulation results showed that the charge at moderate rates (e.g., C/2). During charge, a net cooling
** Electrochemical Society Student Member.
effect was found for the same rate. Temperature profiles of the bat-
** Electrochemical Society Active Member. tery thickness were simulated as functions of time for different dis-
*z E-mail: selman@charlie.cns.iit.edu charge rates and under simulated adiabatic conditions. Although

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3232 Journal of The Electrochemical Society, 147 (9) 3231-3236 (2000)
S0013-4651(00)01-030-2 CCC: $7.00 © The Electrochemical Society, Inc.

continuous cycling at high rates may cause the battery temperature


to rise significantly, Chen and Evans11 concluded that the tempera-
ture within the stack is unlikely to reach thermal runaway conditions
during normal operation.
Kanari et al.12,13 presented a two-dimensional model to simulate
the temperature profile of cylindrical Sony-type US18650 cell. The
model was used to simulate the cell temperature profile during
charge and discharge at 0.2C to 2C rates and compared with meas-
ured values of the center, top, and bottom sides of the cell. The cell
was regarded as a homogenous material which has effective values
of thermophysical properties. Heat was assumed to generate uni-
formly in the cell and was estimated from experimentally measured
values of cell overpotential and entropy coefficients (dEeq/dT). Sim-
ulation results showed fairly good agreement with measured values
during charge and discharge for all measured points. No significant Figure 1. A schematic of the proposed EV module with eight 100 Ah cells.
temperature difference (ca. 0.58C) was noticed between the temper-
ature measurements taken at different locations of the cell. Howev-
er, the open-circuit voltage measurements yielded scattered results. perature within the recommended range of operation of Li-ion cells.
This was due to the long time the measurements took (more than two Alternatively, mixtures of chlorobenzene and bromobenzene, which
months). They explained that “the state of charge of the cell may crystallize with very similar structure and have a low and narrow tem-
change due to the self-discharge, and the ampere-hour capacity of perature range of crystallization, are suitable for precise temperature
the cell may decrease due to the cell degradation.” Therefore, stair- control between 30 to 458C.17 Other candidates18 are stearic acid,
case voltage step coulometry (Vsvsc) was used instead of the open- which has a melting point of 708C, and various commercially avail-
circuit measurements. able esters of stearic acid with methyl, propyl, and butyl alcohols,
Rao and Newman14 discussed two different methods to estimate having melting points of 17-348C. Polyethylene glycol (PEG) is
the heat generation rates in insertion battery systems. A new calcu- another candidate, but it has thermal degradation problems.19
lation method was presented and compared to the general energy Battery Pack Design
balance method presented earlier by Bernardi et. al.9 The new meth- The design of a battery pack consisting of scaled-up Li-ion cells
od accounts for cell components in order to estimate the heat-gener- can be facilitated by models that incorporate information from elec-
ation rate for the whole cell. It utilizes the porous electrode model to trochemical calorimetric measurements. Details of such a model are
distinguish between heat generation in the cell due to ohmic, kinet- explained elsewhere.15 The battery pack consists of several modules,
ic, and entropic effects. Analysis of simulation results showed that and the module consists of a number of individual cells connected in
most of the heat generated in the porous electrodes is due to the series or parallel. The targeted module energy should be in the range
ohmic drop in the electrolyte phase contained in the pores of the of 1 to 4 kWh, to make it suitable for EV applications. As an exam-
electrodes. ple, in a module of four to eight scaled-up Li-ion cells, of cylindri-
In contrast, Al Hallaj et al.15 demonstrated that, for a Type 18650 cal or rectangular (prismatic) design, the cells may be connected in
cell under normal conditions of battery use, lumped properties and series and in parallel to achieve the required capacity and voltage.
overall heat-generation rates are adequate to model the temperature The cell module would be enclosed in a rectangular container of
excursion. For such an application, a minimum set of data is neces- shape and size similar to that of lead-acid batteries.
sary to develop a satisfactory model to predict the thermal behavior Figure 1 shows a schematic of a battery module with eight
of Li-ion batteries. A one-dimensional thermal mathematical model 100 Ah cells. Specifications for the cells and the module are sum-
was presented to simulate the temperature profile of cylindrical Li- marized in Table I. This module is similar to the prototype module
ion cells. The heat generation rates required as input in the comput- designed recently by Sony Corporation and is being used in the NIS-
er simulation were estimated from experimental measurements of SAN ALTRA-EV.24 A battery pack that consists of 12 modules con-
overvoltage and entropic heat effects using electrochemical calori- nected in series similar to the one described here, should have a full
metric techniques. energy of 30 kWh. This capacity enables an EV to achieve a driving
range of 120 miles. In this work, the thermal behavior for the mod-
Thermal Management Using PCM ule is simulated by assuming that the scaled-up prototype cells in the
Thermal management systems using active cooling (forced cir- module have the same chemistry as the Sony (US 18650) cell.
culation of air or liquid) have been proposed and simulated for lead- Therefore, the thermophysical properties and heat generation rates
acid batteries in electric vehicle applications.16 Simulation results per unit volume determined for the Sony (US 18650) cell15,20 are
showed that thermal management systems of this kind may improve used as input in the simulation.
battery performance by 30-40%. However, such active cooling sys- To achieve an effective thermal-management system, the voids
tems introduce another level of complexity into the design and oper- between cells in the module are assumed to be filled with PCM of a
ation of the battery system. type capable of preventing overheating problems. The PCM acts as
Thermal management for battery systems can be achieved with-
out excessive complexity by a passive cooling system that incorpo-
rates phase-change materials (PCM), as described in this work. The
PCM integrated into the cell and/or battery design will act as a heat Table I. Specifications of the proposed scaled-up cell and EV
sink for heat generated, for example, during discharge of a Li-ion module. The module contains eight cells which are connected
battery, which is a highly exothermic process. The heat stored will in series.
be evolved later when the battery temperature drops during battery
charge or under cold weather conditions. Specification
The ideal PCM candidate for Li-ion battery application will have Property Module Cell
a melting point between 30 and 608C, high latent heat per unit mass,
and a narrow melting temperature range. The material will be ther- Shape Rectangular Cylindrical
mally cyclable, safe, inert with respect to other battery components, Dimensions (mm) W290 3 L440 3 H186 H240 3 D80
nontoxic, cheap, and light. Paraffin waxes are good candidate materi- Voltage (V) 20 to 33 2.5 to 4.2
als, being cheap and not easily decomposed, with a low melting tem- Rated capacity (Ah) <100 100

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Journal of The Electrochemical Society, 147 (9) 3231-3236 (2000) 3233
S0013-4651(00)01-030-2 CCC: $7.00 © The Electrochemical Society, Inc.

a heat sink to absorb the heat generated during discharge and as a H2L
heat source during charge or at low operating temperature. A simu- T5 for H > (Cp Tl 1 L) ( liquid region) [6]
Cp
lation of the module performance with a PCM is presented here and
compared to the performance of conventional thermal management Here Ts and Tl (in K) are the start and end temperatures of the
systems using air and/or liquid circulation. PDEase2D™ (Macsyma phase-change region, respectively, Cp is the heat capacity (in J kg21
Corporation, Arlington, MA), a commercial two-dimensional (2D) K21), and L is the latent heat of phase change (in J kg21).
finite-element (FE) software, was used to simulate the thermal be- The finite element method (FEM) was used to simulate the tem-
havior of the battery pack. It was primarily used to account for the perature profile for the different battery packs described above. The
complications of cell shape and pack configuration. corresponding temperature relations in terms of enthalpy, shown in
Eq. 4 to 6, were used to calculate the temperature. The physical
Model Formulation and Method of Solution properties and temperature values are dependent on the phase in
Since phase change is involved, the energy equation must be question (liquid, solid, or mushy) and the level of energy and were
written separately for the solid and liquid phases. One difficulty of defined accordingly during simulation. The source heat term was
using such an approach is how to track the moving interface. For taken to be a function of time and C rate. For various C rates, a cor-
simplified shapes and designs, an analytic solution may be obtained, relation with time was developed based on the heat generation rates
as in the case of a thin slab having a 1D or 2D thermal profile and a for Sony cells reported earlier.20 The heat source term was nonzero
single melting temperature.21 In the case of complicated shapes and for the elements representing the Li-ion cells only and was consid-
a PCM having a melting range, the enthalpy form of the energy bal- ered zero elsewhere. The model accounts for the change in thermal
ance, in addition to the temperature form, may be advantageous to property values of the PCM by assigning different values for the
use. The enthalpy method applies a single energy equation in both solid, mushy, and liquid phases, respectively.
phases; hence, there is no need to consider liquid and solid phases
separately. This makes it easier to use numerical methods such as Results and Discussion
finite difference (FD) or finite element (FE). Another advantage of Sony-type (US 18650) cell.—Figures 2 and 3 show the radial and
the enthalpy method is that it can be applied easily in the case of axial, simulated temperature profiles of the Sony-type (US 18650)
phase change over a temperature range (e.g., glassy substances and cell, respectively, at C/1 discharge rate and at different depths of dis-
solid solutions) rather than a single melting temperature (i.e., pure charge (DOD). The model accounts for the experimental setup of the
crystalline substances and eutectics). cell during cell testing, where the cell top and bottom surfaces were
The enthalpy form of the energy equation is21 insulated using Teflon layers. Results are in good agreement with
experimental measurements for all discharge rates. Results for the
∂H (T )
= ?( k = T ) 1 s 5 r [1] C/1 discharge rate are in better agreement with experimental meas-
∂t urements than those presented earlier, where a one-dimensional (1D)
initial condition thermal model with radial variation was used.8 However, some devi-
ation from experimental measurements still exists. During fast dis-
T 5 To at t 5 0 [2] charge in a real cell, heat accumulates in the center of the cell, which
causes a nonuniformity in local heat generation across the cell. How-
boundary conditions ever, simulated temperature profiles did not show any significant dif-
ference, because of the assumption that the heat is generated uni-
n?(k=T) 5 h(T 2 Ta) at the module boundaries [3] formly across the cell.
Figure 4 shows the direction of the heat flow inside the cell. A
Here T is the temperature (K), k the thermal conductivity (W m21 significant variation is noted in the radial direction, and a less sig-
K21), s is the volumetric heat generation (W m23), r the density nificant variation in the axial direction. This is due to the layers of
(kg m23), H the enthalpy (J kg21), t time (s), To initial temperature, insulation placed on the top and bottom ends of the cell and the
Ta ambient temperature, and h is the effective heat-transfer coeffi- lower magnitude of the thermal conductivity in the radial direction
cient (W m22 K21) between the module and its surrounding. compared to the axial direction (i.e., ky/kr <20). The high axial con-
The enthalpy form is similar to the temperature form of the ener-
gy balance if the heat conduction equation is written separately for
the solid and liquid regions and coupled with an energy balance at
the solid-liquid interface. As a result, the enthalpy method can be
applied to the solution of phase-change problems in the case of a sin-
gle temperature as well as a temperature range. The physical prop-
erty values change significantly when the material changes phase,
and this should be taken into consideration in a numerical solution
of the problem. Some researchers23 pointed out that natural convec-
tion during melting of the PCM has a significant effect on the heat
transfer inside the battery pack. For simplification, we did not
account for it in the present model; however, in future work the
effect of natural convection should be included.
The PCMs used in battery applications are expected to be a mix-
ture of different materials with an extended temperature range of
phase change. The corresponding relationships for temperature as a
function of enthalpy are shown in Eq. 4 to 621
H
T5 for H < Cp Ts (solid region) [4]
Cp
H (Tl 2 Ts ) 1 LTs
T5
Cp (Tl 2 Ts ) 1 L
Figure 2. Simulated radial temperature profile for the Sony (Type US 18650)
for CpTs < H < (CpTl 1 L) (mushy region) [5] cell during discharge at C/1 rate with h5 6.4 W m22 K21.

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3234 Journal of The Electrochemical Society, 147 (9) 3231-3236 (2000)
S0013-4651(00)01-030-2 CCC: $7.00 © The Electrochemical Society, Inc.

Figure 5. Final temperature increase vs. discharge rate at the center of the
Figure 3. Simulated axial temperature profile for the Sony (Type US 18650) 100 Ah scaled-up cell under different cooling rates.
cell during discharge at C/1 rate with h 5 6.4 W m22 K21.

ductivity and insulated end conditions result in a uniform axial tem-


perature profile and a negligible axial heat flux. However, in the
radial direction, significant temperature nonuniformity is generated
by the low thermal conductivity and appreciable heat flux in the radi-
al direction.

The 100 Ah scaled-up cylindrical cell with natural and forced


cooling.—Figure 5 shows the temperature increase at the center of a
100 Ah scaled-up cylindrical cell as a function of the discharge rate
and under different cooling rates. Results showed that the tempera-
ture increase is highly dependent on the discharge rate and the heat-
transfer coefficient. At C/1 discharge rate and under near insulating
conditions (i.e., h 5 1 W m22 K21), the cell temperature rise at the
end of discharge was near 60 K while with a high cooling rate (i.e.,
h 5 100 W m22 K21) the temperature increase is less than 20 K.
At a low cooling rate (i.e., 1 < h < 10 W m22 K21), the cell per-
forms as a lumped system with a uniform temperature profile across
the cell due to the low Biot number (Bi 5 hl/k < 0.1). However, for
a high heat-transfer coefficient (h > 20 W m22 K21) Bi is higher than
0.1, and, as shown in Fig. 6 for h 5 100 W m22 K21, a significant
Figure 6. Radial temperature profile at different DOD for the 100 Ah scaled-
up cell at C/1 discharge rate and h 5 100 W m22 K21 heat-transfer
coefficient.

temperature difference is expected between the cell surface and cen-


ter at all DOD.

The EV module with PCM.—As an illustration, paraffin wax was


used as a PCM in the simulation of the proposed EV pack. Physical
properties of the n-type paraffin wax are listed in Table II. 23 Figure
7 shows the simulated temperature profile for cells 1 and 2 in the EV
module shown in Fig. 1, at different DOD values during C/1 dis-

Table II. Physical properties of the paraffin wax23 used in the


simulation (Fig. 7-9).

Wax
Melted Solid

Density, kg/m3 182211. 191011.


Heat capacity, J/kg-K 177011. 177011.
Thermal conductivity, W/m-K 11110.21 1110.29
Figure 4. Simulated profile of heat flow for the Sony (Type US 18650) cell Melting temperature, 8C 156
during discharge at C/1 rate with h 5 6.4 W m22 K21. Heat of fusion, kJ/kg 195

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Journal of The Electrochemical Society, 147 (9) 3231-3236 (2000) 3235
S0013-4651(00)01-030-2 CCC: $7.00 © The Electrochemical Society, Inc.

Figure 7. Temperature profile at different DOD across the center of cells 1 Figure 8. Radial temperature profile at different DOD for the 100 Ah scaled-
and 2 in the battery module with PCM at C/1 discharge rate and h 5 6.4 up cell at C/1 discharge rate with and without PCM at h 5 1 W m22 K21
W m22 K21 heat-transfer coefficient. heat-transfer coefficient.

charge with h 5 6.4 W m22 K21. The results shown are the temper- gated in this work. A finite-element software was used to simulate
ature profiles along a cross section through the center lines of both the temperature profile for a 100 Ah scaled-up cell of a Sony
cells. This end contains two out of a total of eight cells integrated in US18650 chemistry and design, and for an EV battery module dur-
the module. Results for the other three corners (cells) follow by sym- ing discharge at different rates and under different cooling condi-
metry, which implies h 5 0 across the dividing lines between the tions. Simulation results for the module using the PCM showed that
corners. The heat-transfer coefficient at the cell surface was assumed the temperature rise of the module was significantly lower than that
to be h 5 6.4 W m22 K for all discharge rates. The temperature rise for the same 100 Ah cell under the same cooling conditions. The
at the center of both cells at the end of discharge was near 53 K, temperature rise for the 100 Ah cell with medium to high heat-trans-
while a temperature rise of only 11 K was found for the PCM mate- fer coefficients is expected to be lower than that for cells in the mod-
rial. The temperature difference between cell surface and center was ule with a PCM thermal management system. However, at high cool-
less than 2 K for both cells at all DOD values. The lower tempera- ing rates (e.g., h 5 100 W m22 K21), the temperature variation be-
ture rise in the PCM is due to the latent heat of phase change; hence, tween the cell center and surface in 100 Ah cells is significant.
at To 1 11 K the PCM changes phase from solid to liquid, which is A major advantage of the PCM thermal management system is
accompanied by large heat absorption. Most of the heat rejected that the heat generated during discharge and stored as latent heat in
from the cell during discharge was stored as latent heat in the PCM the PCM is transferred to the cell module during relaxation and keeps
by changing its phase from solid to liquid. This stored heat is it at a temperature above the surrounding temperature for a long time
released after the end of discharge during the time when the cell is and will increase the overall energy efficiency of the battery system.
left to relax. This can be a significant advantage in EV applications under cold
Figure 8 shows the radial temperature profile at different DOD conditions, when the battery operates intermittently. The PCM will
for cell 2 in the module with and without PCM surrounding the cell
under near-insulating conditions (i.e., h 5 1 W m22 K21). Results
for different DODs showed a uniform temperature increase for the
cell with and without PCM due to the low Bi, as explained above.
However, the temperature increase with PCM was less than that
without PCM for all DODs.
As shown above, the temperature rise for cells 1 and 2 was 53 K
at the end of C/1 discharge rate with h 5 6.4 W m22 K. Figure 9
shows the temperature profile for the module at different times dur-
ing relaxation while the module is not operating. The temperature of
both cells was nearly 10 K higher than the initial (surrounding) tem-
perature after 24 h of relaxation. This is important in particular when
the battery is used in an EV under cold conditions. Smart et al.22
showed that the effective (or utilized) capacity of Li-ion batteries is
strongly dependent on the temperature, especially at low operating
temperatures. The effective capacity of the battery is increased sig-
nificantly if the cells remain at elevated temperatures throughout
operation. The heat stored in the PCM enables the cell temperature
to remain higher than the surrounding temperature during relaxation;
hence, the effective capacity during a subsequent charge or discharge
is higher.
Conclusions
A novel thermal management system for EV batteries that incor- Figure 9. Temperature profile during relaxation across the center of cells 1
porates a phase-change material (PCM) was presented and investi- and 2 in the battery module with PCM at h 5 6.4 W m22 K21.

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3236 Journal of The Electrochemical Society, 147 (9) 3231-3236 (2000)
S0013-4651(00)01-030-2 CCC: $7.00 © The Electrochemical Society, Inc.

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