Source: http://patents.com/us-10019020.html
Timestamp: 2019-01-16 09:53:47
Document Index: 652590617

Matched Legal Cases: ['Application No. 2016', 'Application No. 627392', 'Application No. 725880', 'art 1', 'art 6', 'art 6', 'Application No. 614053', 'Application No. 627386', 'Application No. 627392', 'Application No. 627399', 'application No. 201690595', 'Application No. 2011358554', 'Application No. 2013370583']

US Patent # 1,001,9020. Smart actuator for valve - Patents.com
United States Patent 10,019,020
Byler July 10, 2018
A system and method of monitoring and controlling the open and close states of a manifold diaphragm type valve includes using an actuator mechanism with feedback control. A pressure transducer and/or force gauge located on the contact end of the actuator mechanism monitors the pressure and/or force applied to the end of the actuator mechanism. A controller instructs the actuator mechanism to move forward or backward an appropriate distance based on the monitored pressure and/or force. Temperature and pressure changes in the system and material changes to the diaphragm are sensed immediately and positioning correction is applied to the actuator in real-time, thereby maintaining the same valve state while monitoring pressure separately. The linear actuator functions as a `smart` actuator, capable of fine tune adjustments without additional outside monitoring and providing a more accurate and reliable method of closing the valve in a dynamic environment.
Byler; Terry Lynn (Murrieta, CA)
Family ID: 53041938
15/139,144
US 20170023953 A1 Jan 26, 2017
14077122 Nov 11, 2013 9354640
Current CPC Class: A61M 1/14 (20130101); A61M 39/22 (20130101); G05D 16/202 (20130101); F16K 31/04 (20130101); F16K 37/0083 (20130101); A61M 2205/3331 (20130101); Y10T 137/7761 (20150401); A61M 2039/226 (20130101); A61M 2205/10 (20130101); A61M 2205/332 (20130101); A61M 2205/128 (20130101)
Current International Class: G05D 16/20 (20060101); A61M 39/22 (20060101); F16K 37/00 (20060101); A61M 1/14 (20060101); F16K 31/04 (20060101)
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The present application is a continuation application of U.S. patent application Ser. No. 14/077,112, entitled "Smart Actuator For Valve", and filed on Nov. 11, 2013. The above-mentioned application is herein incorporated by reference in its entirety.
1. A method for monitoring and maintaining a state of a valve in a dialysis machine, the method comprising: providing a valve actuator configured to open and close the valve having a diaphragm positioned adjacent a flow path in a fluid circuit, the valve actuator system comprising: a displacement member configured to be displaced linearly and having a contact end wherein the contact end is configured to push the diaphragm into the flow path to close the valve and not push the diaphragm into the flow path to open the valve; at least one pressure transducer positioned on the contact end; and a controller for receiving data from the pressure transducer and for controlling the displacement member; extending the displacement member to extend the contact end and push the diaphragm into the flow path of the fluid circuit to close the valve; sensing a pressure applied by the diaphragm against the pressure transducer; comparing the sensed pressure to a pre-determined pressure value; and retracting the displacement member to withdraw the diaphragm out of the flow path such that the sensed pressure is matched to the pre-determined pressure value.
2. The method of claim 1, wherein comparing the sensed pressure to the pre-determined pressure value comprises executing, by a processing unit, a plurality of programmatic instructions stored in a memory of the controller for comparing the sensed pressure to the pre-determined value stored in the memory.
3. The method of claim 1, wherein retracting the displacement member to withdraw the diaphragm out of the flow path comprises using the controller to activate a motor coupled with the displacement member, wherein the activation is based upon the comparison of the sensed pressure to the pre-determined pressure value.
4. The method of claim 3, wherein the motor is at least one of a DC motor and a stepper motor.
5. The method of claim 1, wherein the diaphragm is part of a disposable manifold positioned within the dialysis machine and the displacement member is fixedly attached to the dialysis machine.
6. The method of claim 1, wherein the pre-determined pressure value is at least 2 psi.
7. The method of claim 1, further comprising using an encoder to determine an amount of displacement of the displacement member.
8. A method for maintaining a valve in an open state, the method comprising: providing a valve actuator system configured to open the valve having a diaphragm positioned parallel to a flow path in a fluid circuit, the valve actuator system comprising: a displacement member configured to be linearly displaced perpendicular to the flow path and having a contact end wherein said contact end is configured to push said diaphragm into the flow path; a pressure transducer positioned on the contact end; and a controller for receiving data from the pressure transducer and for controlling the displacement member; retracting the displacement member to retract the contact end and pull the diaphragm out of the flow path of the fluid circuit to open the valve; sensing a pressure applied by the diaphragm against the pressure transducer; comparing the sensed pressure to a pre-determined threshold pressure value; and further retracting the displacement member to withdraw the diaphragm out of the flow path such that the sensed pressure is less than the pre-determined pressure threshold value.
9. The method of claim 8, wherein comparing the sensed pressure to the pre-determined pressure threshold value comprises executing, by a processing unit, a plurality of programmatic instructions stored in a memory of the controller for comparing the sensed pressure to the pre-determined pressure threshold value stored in the memory.
10. The method of claim 8, wherein further retracting the displacement member to withdraw the diaphragm out of the flow path such that the sensed pressure is less than the pre-determined pressure threshold value comprises using the controller to activate a motor coupled with the displacement member based upon the comparison of the sensed pressure to the pre-determined pressure threshold value.
11. The method of claim 10 wherein the motor is one of a DC motor and a stepper motor.
12. The method claim 8, wherein the diaphragm is part of a disposable manifold positioned within a dialysis machine and the displacement member is fixedly attached to the dialysis machine.
13. The method claim 8, wherein the controller retracts the displacement member to withdraw the diaphragm until the sensed pressure reaches zero, signifying that the pressure transducer has disengaged from the diaphragm, the diaphragm is in a relaxed configuration, and the valve is open.
14. A method for maintaining a valve in a closed state, the method comprising: providing a valve actuator system configured to close the valve having a diaphragm positioned parallel to a flow path in a fluid circuit, the valve actuator system comprising: a displacement member configured to be linearly displaced perpendicular to the flow path and having a contact end wherein the contact end is configured to push the diaphragm into the flow path; at least one pressure transducer positioned on the contact end; at least one force gauge positioned on the contact end; and a controller for receiving data from the pressure transducer and force gauge and for controlling the displacement member; extending the displacement member to extend the contact end and push the diaphragm into the flow path of the fluid circuit to close the valve; sensing a pressure applied by the diaphragm against the pressure transducer; sensing a force applied by the diaphragm against the force gauge; comparing the sensed pressure to a pre-determined pressure value; comparing the sensed force to a pre-determined force value; and extending the displacement member to push the diaphragm into the flow path to match the sensed pressure value to the pre-determined pressure and the sensed force to the pre-determined force value.
15. The method of claim 14 wherein comparing the sensed pressure to the pre-determined pressure value and comparing the sensed force to the pre-determined force value comprises executing, by a processing unit, a plurality of programmatic instructions stored in a memory of the controller for comparing the sensed pressure to the pre-determined pressure value stored in the memory and comparing the sensed force to the pre-determined force value stored in the memory.
16. The method of claim 14 wherein extending the displacement member to push the diaphragm into the flow path to match the sensed pressure value to the pre-determined pressure value and the sensed force to the pre-determined force value comprises using the controller to activate a motor coupled with the displacement member based upon the comparison of the sensed pressure to the pre-determined pressure value and the sensed force to the pre-determined force value.
17. The method of claim 16 wherein the motor is one of a DC motor and a stepper motor.
18. The method of claim 14, wherein the diaphragm is part of a disposable manifold positioned within a dialysis machine and the displacement member is fixedly attached to the dialysis machine.
19. The method of claim 18, wherein the pre-determined pressure value is at least 2 psi.
20. The method of claim 14, further comprising using an encoder to determine an amount of displacement of the displacement member.
Blood purification systems, which are used for conducting hemodialysis, hemodiafiltration or hemofiltration, involve the extracorporeal circulation of blood through an exchanger having a semi permeable membrane. Such systems further include a hydraulic system for circulating blood and a hydraulic system for circulating replacement fluid or dialysate comprising the certain blood electrolytes in concentrations close to those of the blood of a healthy subject. Flow in the fluid circuits is controlled by valves positioned in the fluid flow pathway. Examples of such fluid pathways include those disclosed in U.S. patent application Ser. No. 13/023,490, assigned to the applicant of the present invention, entitled "Portable Dialysis Machine" and filed on Feb. 8, 2011, which is incorporated herein by reference.
In various embodiments, any of the above valve actuator systems is used in a dialysis machine. In various embodiments, when used in a dialysis machine, the controller of the valve actuator system is programmed to maintain a sensed pressure of at least 2 psi. In various embodiments, when used in a dialysis machine, the controller of the valve actuator system is programmed to maintain a force of at least 5 pound-force (lb.sub.F).
The present specification discloses a system and a method of controlling actuator position for a diaphragm type valve of a fluid circuit based on feedback provided by a pressure transducer and/or force gauge located on the contact end of the actuator. In various embodiments, as a control signal and/or a voltage signal is applied to the linear actuator to cause the actuator to move to close the valve, a pressure transducer or force gauge senses the feedback pressure or opposing applied force from the surface of the diaphragm. The sensed pressure or force is relayed via firmware to a controller which then instructs the actuator to move forward or backward an appropriate distance to maintain a constant pressure or force. As such, temperature and pressure changes in the system and material changes to the diaphragm are sensed immediately and positioning correction is applied to the actuator in real-time, thereby maintaining the same valve state. In addition, changes due to the diaphragm as a result of exposure to sterilization methods can be accounted for during operation. The linear actuator functions as a `smart` actuator, capable of fine tune adjustments without additional outside monitoring and provides a more accurate and reliable method of closing the valve. In various embodiments, the actuator accommodates changes in force, pressure, temperature, flow, and/or viscosity of the fluid by continuously monitoring pressure and/or force at its contact end.
Referring to FIG. 1A, the actuator (pressure transducer 114 in this embodiment) is in its `home` position within the front plate 130 of a machine system. The pressure transducer 114 functions as a linear member contained within a conduit (in this embodiment, a front plate 130 of a machine system) through which it extends axially. Specifically, when the actuator is in its `home` position, the pressure transducer 114 of the actuator mechanism 110 rests embedded within the front plate 130 of a machine system, such as, in one embodiment, a portion of a dialysis system housing. In one embodiment, when the actuator is in the `home` position, the pressure transducer 114 rests within the front plate 130 such that the contact end 114' of the pressure transducer 114 is positioned just proximal to, with respect to the actuator mechanism 110, an outer surface 130' of the front plate 130. In other words, when the actuator is in the `home` position, the contact end 114' of the pressure transducer 114 is slightly recessed within the front plate 130. The pressure transducer 114 is linearly movable within the front plate 130 by activation of the motor 112 and linear movement of the actuator plunger 113 and pressure transducer holder 115. The pressure transducer 114 can be moved forward, with respect to the actuator mechanism 110, such that its contact end 114' extends beyond the outer surface 130' of the front plate 130. A fluid pathway 150 is positioned proximate, or adjacent to, the front plate 130. A diaphragm 118 is positioned in an outer wall 150' of the fluid pathway 150. In one embodiment, the outer wall 150' of the fluid pathway 150 is positioned proximate and adjacent to the outer surface 130' of the front plate 130 such that the diaphragm 118 is proximate to, and in linear alignment with, the pressure transducer 114 of the actuator mechanism 110. Since the actuator mechanism 110 is in the `home` state, the diaphragm 118 is flat and is not in contact with the pressure transducer 114, and the valve is in the open state. Within the fluid pathway 150, a gap 158 at the valve 161 is present between the diaphragm 118 and valve seat 155, allowing fluid to flow through.
In one embodiment, referring to FIG. 1A, the components of the actuator mechanism 110 are arranged in the following configuration. As mentioned above, in one embodiment, the pressure transducer 114 functions as the actuator. The pressure transducer 114, pressure transducer holder 115, and actuator plunger 113 are linearly movable as a unit via operation of the motor 112 and extend axially throughout the actuator mechanism 110. Using the diaphragm 118 of the outer wall 150' of the fluid pathway 150 as a reference point, the encoder 111 comprises the distal endpoint of the actuator mechanism 110. In one embodiment, a portion of the actuator plunger 113 extends distally from the distal end of the encoder 111. During operation, as the motor 112 moves the actuator plunger 113 toward the diaphragm 118, the portion of the plunger 113 extending from the distal end of the encoder 111 moves proximally through said encoder 111.
Referring to FIG. 1B, the actuator mechanism 110 is in an `extended` position with the pressure transducer 114 moved forward through the front plate 130 of the machine system such that the contact end 114' of the pressure transducer 114 extends distally, with respect to the actuator mechanism 110, beyond the outer surface 130' of the front plate 130. The diaphragm 118 has been pushed into the fluid pathway 150 through physical contact with the contact end 114' of the pressure transducer 114. In accordance with various embodiments of the present specification, based on feedback provided to the controller by the pressure transducer 114, the controller has instructed the motor 112 to move the actuator plunger 113 to extend the pressure transducer holder 115 and pressure transducer 114 such that the contact end 114' of the pressure transducer 114 has come into contact with, and pushed forward, the diaphragm 118. The diaphragm 118 is extended into the fluid pathway 150 and is in contact with the valve seat 155, effectively closing the valve 161 and shutting off fluid flow. The gap at valve seat 155, as seen as gap 158 in FIG. 1A, has been closed in FIG. 1B. Pressure 170 increases around the diaphragm 118 and valve seat 155 and pushes against the diaphragm 118.
Referring to FIG. 2A, the actuator (force gauge 220 in this embodiment) is in its `home` position within the front plate 230 of a machine system. The force gauge 220 functions as a linear member contained within a conduit (in this embodiment, a front plate 230 of a machine system) through which it extends axially. Specifically, when the actuator is in its `home` position, the force gauge 220 of the actuator mechanism 210 rests embedded within the front plate 230 of a machine system, such as, in one embodiment, a portion of a dialysis system housing. In one embodiment, when the actuator is in the `home` position, the force gauge 220 rests within the front plate 230 such that the contact end 220' of the force gauge 220 is positioned just proximal to, with respect to the actuator mechanism 210, an outer surface 230' of the front plate 230. In other words, when the actuator is in the `home` position, the contact end 220' of the force gauge 220 is slightly recessed within the front plate 230. The force gauge 220 is linearly movable within the front plate 230 by activation of the motor 212 and linear movement of the actuator plunger 213 and force gauge holder 225. The force gauge 220 can be moved forward, with respect to the actuator mechanism 210, such that its contact end 220' extends beyond the outer surface 230' of the front plate 230. A fluid pathway 250 is positioned proximate, or adjacent to, the front plate 230. A diaphragm 218 is positioned in an outer wall 250' of the fluid pathway 250. In one embodiment, the outer wall 250' of the fluid pathway 250 is positioned proximate and adjacent to the outer surface 230' of the front plate 230 such that the diaphragm 218 is proximate to, and in linear alignment with, the force gauge 220 of the actuator mechanism 210. Since the actuator mechanism 210 is in the `home` state, the diaphragm 218 is flat and is not in contact with the force gauge 220, and the valve is in the open state. Within the fluid pathway 250, a gap 258 at the valve 261 is present between the diaphragm 218 and valve seat 255, allowing fluid to flow through.
In one embodiment, referring to FIG. 2A, the components of the actuator mechanism 210 are arranged in the following configuration. As mentioned above, in one embodiment, the force gauge 220 functions as the actuator. The force gauge 220, force gauge holder 225, and actuator plunger 213 are linearly movable as a unit via operation of the motor 212 and extend axially throughout the actuator mechanism 210. Using the diaphragm 218 of the outer wall 250' of the fluid pathway 250 as a reference point, the encoder 211 comprises the distal endpoint of the actuator mechanism 210. In one embodiment, a portion of the actuator plunger 213 extends distally from the distal end of the encoder 211. During operation, as the motor 212 moves the actuator plunger 213 toward the diaphragm 218, the portion of the plunger 213 extending from the distal end of the encoder 211 moves proximally through said encoder 211. Next to the encoder 211 and at a position more proximal to the diaphragm 218 is the motor 212. The plunger 213 extends axially through the motor 212. Positioned proximal to the motor 212 is the actuator mechanism body 228. The distal end of the actuator mechanism body 228 is positioned adjacent to motor 212 and the proximal end of the actuator mechanism 228 is positioned adjacent to the front plate 230 of the machine system. A proximal portion of the actuator plunger 213 extends through the distal portion of the actuator mechanism body 228. Attached to the proximal end of the actuator plunger 213 and housed within the actuator mechanism body 228 is the force gauge holder 225. Through action of the motor 212 and extension/retraction of the actuator plunger 213, the force gauge holder 225 is linearly movable within the actuator mechanism body 228. Attached to a proximal end of the force gauge holder 225 is the force gauge 220. The force gauge 220 extends axially partially through the actuator mechanism body 228 and partially through the front plate 230. The force gauge 220 is linearly movable within the proximal portion of the actuator mechanism body 228 and the front plate 230 via operation of the motor 212 and movement of the actuator plunger 213 and force gauge holder 225.
Referring to FIG. 2B, the actuator mechanism 210 is in an `extended` position with the force gauge 220 moved forward through the front plate 230 of the machine system such that the contact end 220' of the force gauge 220 extends distally, with respect to the actuator mechanism 210, beyond the outer surface 230' of the front plate 230. The diaphragm 218 has been pushed into the fluid pathway 250 through physical contact with the contact end 220' of the force gauge 220. In accordance with various embodiments of the present specification, based on feedback provided to the controller by the force gauge, the controller has instructed the motor 212 to move the actuator plunger 213 to extend the force gauge holder 225 and force gauge 220 such that the contact end 220' of the force gauge 220 has come into contact with, and pushed forward, the diaphragm 218. The diaphragm 218 is extended into the fluid pathway 250 and is in contact with the valve seat 255, effectively closing the valve 261 and shutting off fluid flow. The gap at valve seat 255, as seen as gap 258 in FIG. 2A, has been closed in FIG. 2B. Pressure 270 increases around the diaphragm 218 and valve seat 255 and pushes against the diaphragm 218.
Referring to FIG. 3A, the actuator (pressure transducer 314 and force gauge 320 in this embodiment) is in its `home` position within the front plate 330 of a machine system. The pressure transducer 314 and force gauge 320 function together as a linear member contained within a conduit (in this embodiment, a front plate 330 of a machine system) through which they extend axially. In one embodiment, the pressure transducer 314 and force gauge 320 are configured to sit adjacent one another within the front plate 330. In another embodiment, the pressure transducer 314 and force gauge 320 are configured to sit coaxially, one within the other, within the front plate 330. Specifically, when the actuator is in its `home` position, the pressure transducer 314 and force gauge 320 of the actuator mechanism 310 rest embedded within the front plate 330 of a machine system, such as, in one embodiment, a portion of a dialysis system housing. In one embodiment, when the actuator is in the `home` position, the pressure transducer 314 and force gauge 320 rest within the front plate 330 such that the contact end 314' of the pressure transducer 314 and the contact end 320' of the force gauge 320 are positioned just proximal to, with respect to the actuator mechanism 310, an outer surface 330' of the front plate 330. In other words, when the actuator is in the `home` position, the contact end 314' of the pressure transducer 314 and the contact end 320' of the force gauge 320 are slightly recessed within the front plate 130. The contact ends 314', 320' are flush with one another. The pressure transducer 314 and force gauge 320 are linearly movable within the front plate 330 by activation of the motor 312 and linear movement of the actuator plunger 313 and pressure transducer/force gauge holder 325. The pressure transducer 314 and force gauge 320 can be moved forward, with respect to the actuator mechanism 310, such that their contact ends 314', 320' extend in unison beyond the outer surface 330' of the front plate 330. A fluid pathway 350 is positioned proximate, or adjacent to, the front plate 330. A diaphragm 318 is positioned in an outer wall 350' of the fluid pathway 350. In one embodiment, the outer wall 350' of the fluid pathway 350 is positioned proximate and adjacent to the outer surface 330' of the front plate 330 such that the diaphragm 318 is proximate to, and in linear alignment with, the pressure transducer 314 and force gauge 320 of the actuator mechanism 310. Since the actuator mechanism 310 is in the `home` state, the diaphragm 318 is flat and is not in contact with either the pressure transducer 314 or the force gauge 320, and the valve is in the open state. Within the fluid pathway 350, a gap 358 at the valve 361 is present between the diaphragm 318 and valve seat 355, allowing fluid to flow through.
In one embodiment, referring to FIG. 3A, the components of the actuator mechanism 310 are arranged in the following configuration. As mentioned above, in one embodiment, the pressure transducer 314 and force gauge 320 function together as the actuator. The pressure transducer 314 and force gauge 320, pressure transducer/force gauge holder 325, and actuator plunger 313 are linearly movable as a unit via operation of the motor 312 and extend axially throughout the actuator mechanism 310. Using the diaphragm 318 of the outer wall 350' of the fluid pathway 350 as a reference point, the encoder 311 comprises the distal endpoint of the actuator mechanism 310. In one embodiment, a portion of the actuator plunger 313 extends distally from the distal end of the encoder 311. During operation, as the motor 312 moves the actuator plunger 313 toward the diaphragm 318, the portion of the plunger 313 extending from the distal end of the encoder 311 moves proximally through said encoder 311.
Referring to FIG. 3B, the actuator mechanism 310 is in an `extended` position with the pressure transducer 314 and force gauge 320 moved forward through the front plate 330 of the machine system such that the contact end 314' of the pressure transducer 114 and the contact end of the force gauge 320' extend distally, with respect to the actuator mechanism 310, beyond the outer surface 330' of the front plate 330. The diaphragm 318 has been pushed into the fluid pathway 350 through physical contact with both the contact end 314' of the pressure transducer 314 and the contact end 320' of the force gauge 320. In accordance with various embodiments of the present specification, based on feedback provided to the controller by the pressure transducer 314 and force gauge 320, the controller has instructed the motor 312 to move the actuator plunger 313 to extend the pressure transducer/force gauge holder 325, pressure transducer 314, and force gauge 320, such that both the contact end 314' of the pressure transducer 314 and the contact end 320' of the force gauge 320 have come into contact with, and pushed forward, the diaphragm 318. The diaphragm 318 is extended into the fluid pathway 350 and is in contact with the valve seat 355, effectively closing the valve 361 and shutting off fluid flow. The gap at valve seat 355, as seen as gap 358 in FIG. 3A, has been closed in FIG. 3B. Pressure 370 increases around the diaphragm 318 and valve seat 355 and pushes against the diaphragm 318.
For example, in one embodiment, the actuator mechanism of the present specification can be used in a portable kidney dialysis system having a disposable manifold for fluidic circuits. One of ordinary skill in the art would appreciate that the actuator mechanism with feedback control system could be implemented with a disposable manifold by positioning the actuator external to the manifold at the desired valve location. This type of actuator is also separate and distinct from the disposable manifold and generally part of the non-disposable portion of the kidney dialysis system. Valve systems are preferably implemented in a disposable type of manifold using elastic membranes at flow control points which are selectively occluded, as required, by protrusions, pins, or other members extending from the machine. In various embodiments, fluid occlusion is enabled using an on/off DC motor, a stepper motor controlled by a controller, or a safe, low-energy magnetic valve. In one embodiment, the valve system is similar to that disclosed in U.S. patent application Ser. No. 13/023,490, assigned to the applicant of the present invention, filed on Feb. 8, 2011, and entitled "Portable Dialysis Machine", which is hereby incorporated by reference in its entirety. In another embodiment, the valve system is similar to that disclosed in U.S. patent application Ser. No. 13/726,457, assigned to the applicant of the present invention, filed on Dec. 24, 2012, and entitled "Portable Dialysis Machine with Improved Reservoir Heating System", which is hereby incorporated by reference in its entirety. In one embodiment, a valve actuator mechanism having a pressure transducer as disclosed in the present specification is used in a dialysis machine to maintain a sensed pressure of at least 2 psi, ensuring valve closure. In another embodiment, a valve actuator mechanism having a force gauge as disclosed in the present specification is used in a dialysis machine to maintain a sensed force of at least 5 pound-force (lb.sub.F), ensuring valve closure. In yet another embodiment, a valve actuator mechanism having both a pressure transducer and a force gauge as disclosed in the present specification is used in a dialysis machine to maintain a sensed pressure of at least 2 psi and a sensed force of at least 5 pound-force (lb.sub.F), ensuring valve closure.
In one embodiment, the diaphragms used as valves are similar to those described in the '490 application referenced above. In another embodiment, the diaphragms used as valves are similar to those disclosed in U.S. patent application Ser. No. 13/852,918, assigned to the applicant of the present invention, filed on Mar. 28, 2013, and entitled "Manifold Diaphragms", which is hereby incorporated by reference in its entirety.
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