Abstract:
A method for producing leather generally including the steps of: (a) providing wet blue, full grain skins, (b) applying a degreasing and emulsifying agent to the skins, (d) neutralizing the skins to provide the skins with a pH level of in the range of about 5.7-6.2, (e) applying a waterproofing agent to the skins, (f) introducing the skins to a dye bath, (g) fixing the dyestuff and waterproofing agents in the skins without metal salt while reducing the pH level to about −3.2, (g) applying a water repellant and oil repellant agent to the skins in a fluorchemical process, (h) fixing the skins a second time without metal salt while moving the pH level to the range of 3.0-3.5, (i) introducing the skins to a bath containing an antimicrobial treatment and an antistatic treatment, (j) washing and drying the skins, and (k) staking and otherwise finishing the skins.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     The present invention relates to methods for the production of leather, and more particularly to a process for producing leather from wet blue pig skins.  
         [0002]     A wide variety of methods are used commercially for producing leather from skins or hides. In general, leather production involves three broad phases. First, the skins or hides are prepared for tanning. This generally involves curing the skins so that they do not begin to decompose before tanning. At the tannery, the skins are typically soaked in water to remove all water-soluble materials, such as salt, blood, and dirt, and to replace moisture lost in the curing process. Typically, the next step is to remove hair from the skins. Often, this is done by soaking the skins in a lime solution and then mechanically removing the hair, along with extraneous flesh and tissue, by machine. The next general step is “deliming,” which removes the lime introduced during the dehairing step. The deliming process involves soaking the skins in a mild acid solution. Bating may also occur at this time. Bating is a process in which the skins are treated with enzymes that make the skins soft and flexible and provide them with a smoother grain.  
         [0003]     The bated skins are then tanned using any of a variety of conventional tanning methods. For example, the skins may be tanned in a mineral tanning process. In mineral tanning, the skins are soaked in a mineral tanning agent, typically the salt compound of chromium. To prepare the bated skins for chrome tanning, the skins are pickled in a conventional salt and acid brine. Once pickled, the skins are tumbled in a chromium-sulfate solution containing liquors that enhance the skins&#39; ability to absorb the tanning agent. Alternatively, the skins may be tanned in a vegetable tanning process. Vegetable tanning generally involves soaking the skins in a tannin solution containing liquors that improve and speed the absorption of tannin. Tannin is typically extracted from wood or bark, such as the chestnut wood or oak bark. The skins are soaked in successively stronger solutions until they have absorbed the appropriate amount of tannin for the particular application.  
         [0004]     The tanned skins, which in the case of chrome tanned skins are sometimes referred to as “wet blue leather,” are then subjected to a variety of treatments that provide the skins with the desired characteristics. For example, the skins can be lubricated using a blend of oils and greases, and dyed to the desired color through drum dyeing, spraying, brush dyeing or staining processes. In some applications, the skins are retanned to introduce additives that provide the skins with desirable characteristics. For example, waterproofing agents are typically introduced during a retanning process. Waterproofing is a particularly important characteristic in many applications, including footwear applications. The waterproofness of leather is typically measured in Maeser flexes, which is essentially the number of flexes that leather can undergo before it loses the waterproof characteristic. The waterproofness standard set by the U.S. military is 15,000 Maeser flexes. Further, heat resistant and flame resistant agents are often introduced prior to and/or during the retanning process. Finally, the skins are staked and finished. Staking is a mechanical softening process in which the skins are repeatedly beat by fingers. Finishing typically involves the application of a finishing compound, such as oil blend, to the surface of the leather. The above described processes are typical steps involved in the production, but are not exhaustive. Alternative and additional processes are commonplace in the leather production industry.  
         [0005]     Although there are a variety of well-known techniques for obtaining leather with one or more desired characteristics, such as softness, suppleness, waterproofness, flame resistance, and heat resistance, it is difficult to produce leather that has the appropriate combination of these characteristics. In fact, these characteristics are achieved only by carefully controlling a complex series of variables in the production process. For example, the precise additive formulation, the quantity of additives, the mixture ratio of additives to water in the various steps, the temperature of the solutions in which the skins are treated, the running time in a given liquor bath and the pH level of the solutions in which the skins are treated are all crucial to the production process. In many cases, the procedures for providing the leather with one desirable characteristic adversely affect other desirable characteristics. Accordingly, leather processing often involves a careful and delicate balance of processing techniques and additive choices.  
         [0006]     In conventional processes, the skins are capped to remove or inactivate emulsifying agents. Capping typically involves the introduction of a metal salt that interacts with the emulsifying agent rendering it inactive. Although capping can improve the overall performance of the finished leather, it can have a number of disadvantages. For example, capping can cause the leather to shrink, thereby reducing the yield. Also, capping can have a negative impact on the ability of the leather to readily and uniformly accept coloring and dyes. In fact, capping can make it nearly impossible to obtain certain colors. As a result, capping can make it difficult or impossible to obtain uniform and even coloring of leather. This is particularly true with bright colors, which have a tendency to more clearly show any discontinuity in color. Accordingly, leather produced in a process involving a conventional capping step is typically not colored or dyed using bright colors. Rather, these leathers are typically colored using dark colors that inherently show less discrepancy in coloring.  
         [0007]     As perhaps the result of these complexities, there remains an unmet need for leather that is soft and supple while at the same time being durable, highly oil resistant, water resistant and uniformly accepting of dyestuffs.  
       SUMMARY OF THE INVENTION  
       [0008]     The aforementioned problems are overcome by the present invention wherein a leather production process is provided which produces leather that is soft and supple, yet durable, highly oil resistant, water resistant, while at the same time being suitable for use with bright colors. The production process generally includes the steps of: (a) providing wet blue, full grain skins, (b) applying a degreasing and emulsifying agent to the skins, (d) neutralizing the skins to provide the skins with a pH level of in the range of about 5.7-6.2, (e) applying a waterproofing agent to the skins, (f) introducing the skins to a dye bath, (g) fixing the dyestuff and waterproofing agents in the skins without chrome or other metal salts while reducing the pH level to about −3.2, (g) applying a water repellant and oil repellant agent to the skins in a fluorchemical process, (h) fixing the skins a second time without chrome or other metal salts while moving the pH level to the range of 3.0-3.5, (i) introducing the skins to a bath containing an antimicrobial treatment and an antistatic treatment, (j) washing and drying the skins, and (k) staking and otherwise finishing the skins. If desired, the skins can also be subjected to additional treatments, such as flame resistant/flame proof treatments.  
         [0009]     In one embodiment, the skins are washed and drained after the neutralizing step, but not between the waterproofing and coloring steps. The first fixing step may occur immediately following the coloring step to fix both the waterproofing agents and the dyestuffs.  
         [0010]     In another embodiment, the skins are washed and drained between the first fixing step and the fluorchemical step, but not between the fluorchemical process and the antimicrobial and antistatic treatments.  
         [0011]     The present invention produces soft and supple leather that is durable, highly water resistant and oil resistant and that readily and uniformly receiving of dyestuffs. The process therefore provides leather capable of consistently and uniformly receiving color. Because the leather is highly oil resistant and water resistant, the leather is highly stain resistant. As a result of these characteristics, the process is particularly well-suited for use in producing high performance leather in bright colors.  
         [0012]     These and other objects, advantages, and features of the invention will be readily understood and appreciated by reference to the detailed description of the preferred embodiment and the drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  is a flow chart showing the general steps of the present invention;  
         [0014]      FIG. 2  is a flow chart showing the general steps of the degreasing and neutralizing phases;  
         [0015]      FIG. 3  is a flow chart showing the general steps of the waterproofing phase;  
         [0016]      FIG. 4  is a flow chart showing the general steps of the coloring phase;  
         [0017]      FIG. 5  is a flow chart showing the general steps of the fixing phase;  
         [0018]      FIG. 6  is a flow chart showing the general steps of the fluorchemical phase; and  
         [0019]      FIG. 7  is a flow chart showing the general steps of the antimicrobial and anti static treatment phases. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0020]     An embodiment of the present invention is described in connection with the flowchart of  FIG. 1 . As shown in  FIG. 1 , the present method  10  generally includes the steps of (a) degreasing and soaking the skins  20 , (b) neutralizing the skins  30 , (c) waterproofing the skins  35 , (d) coloring the skins  40 , (d) fixing the skins  60 , (f) fluorchemical treatment of the skins  70 , (g) fixing the skins  72 , (h) antimicrobial and antistatic treatment of the skins  74  and (g) staking and finishing the skins  80 . Together, these steps provide leather having a unique and highly advantageous combination of features and characteristics, including the ability to be uniformly and consistently colored while at the same time being highly oil resistant and stain resistant. The method is particularly well-suited for use in treating wet blue pig skins, but can be used in whole or in part to treat other skins as well. In some applications, the process may require routine modification to provide optimal results depending, for example, on the type and specific characteristics of the skins to be treated and on the specifically desired characteristics of the finished leather. The manner and degree of any such modifications will be readily apparent to those skilled in the art.  
         [0021]     The following description sets forth an embodiment of the present invention that is optimized to provide finished leather with a particular set of desired characteristics. Those skilled in the field will readily appreciate that the specified times and quantities are approximate and that some variation in a specified time or in a specified quantity will typically yield acceptable results in the finished leather, and adjustments can be used to intentionally adjust the characteristics of the finished leather. The amount of acceptable variation in a particular time or quantity will vary depending primarily on the amount of acceptable variance in the finished leather. For example, variations in the range of approximately ±20% in the quantity of a particular additive are likely to be acceptable for each of the additives, except for the acidic and caustic materials used to adjust the pH level of the float (i.e. formic acid, sodium formate, sodium bicarbonate and aqua ammonia). However, even with the acidic and caustic materials, variation in the quantity of a particular additive may be compensated for by adjustment in the strength (e.g. percent of composition) of the additive or in time that the mill is run with the additive in the float provided that the specified pH levels are obtained. It should further be noted that, in the following paragraphs, the percentages of various additives are specified in parentheses following the specified weight or volume quantities. These percentages refer to the weight of the additive with respect to the total weight of the wet blue skins being processed.  
         [0022]     In the illustrated embodiment, the process begins by loading the wet blue skins into a conventional mill. In this embodiment, approximately 1000 lbs. of skins are loaded into the mill. Typically, the wet blue skins have a pH of 3.5 or lower. As a first step, the skins may be washed. Initially, approximately 1,000 gallons of water are added to the mill. The water may be at a temperature of approximately 140° Fahrenheit (F.), but the temperature may vary, for example, between 105-150° F. The skins are washed and then the water is drained. After washing, the water is drained from the mill.  
         [0023]     After the initial washing step, the skins undergo the degreasing and neutralizing phase  20 ,  30  (See  FIG. 2 ). In this embodiment, the two phases are carried out somewhat together. This phase begins by adding  102  approximately 240 gallons of water to the mill to create the float. The water is preferably at a temperature of approximately 100° F., but the temperature may vary, for example, between 80-110° F. Following this, a degreasing agent is added to the mill. In this embodiment, approximately 3 lbs. (or 0.3%) of Borron SE-G (available from TFL USA/Canada Ltd.) is added  104  to the mill through the door. Borron SE-G is a nonionic, degreasing and emulsifying agent, which degreases the skins and prepares them to receive further treatments. Obviously, the Borron SE-G can be replaced by other degreasing/emulsifying agents, as desired. Additionally, approximately 20 lbs. (or 2.0%) of Sodium Acetate are added  106  to the mill. The mill is run  108  for approximately 30 minutes, but the running time may vary, for example, between 20-60 minutes.  
         [0024]     Following these steps, the skins are neutralized  30  (See  FIG. 2 ). In the illustrated embodiment, the neutralization process includes two stages. In the first stage, approximately 12.5 lbs. of sodium acetate (or 1.25%) are added  110  to the mill and approximately 12.5 lbs. of sodium bicarbonate (or 1.25%) are added  112  to the mill. The mill is then run  114  for approximately 30 minutes. The mill running time may vary, for example, between 20-60 minutes. This initial step is likely to provide the skins with a pH value of approximately 4.8 or higher.  
         [0025]     In the second stage of the neutralization process, approximately 12.5 lbs. of sodium bicarbonate (or 1.25%) are added  116  to the mill. The mill is then run  118  for approximately 2 hours, which will raise the pH level of the skins to a range of approximately 5.7-6.2. The mill running time may vary, for example, between 90-180 minutes.  
         [0026]     The neutralized skins are next subjected to the waterproofing phase  35  (See  FIG. 3 ). To prepare for the waterproofing phase, approximately 1,000 gallons of water at approximately 100° F. are added to the mill, and the skins are washed and drained  120 . The temperature of the water may vary, for example, between 70-100° F. After the skins have been washed, approximately 60 gallons of water is added  122  to the mill to create the float. The water may be at a temperature of approximately 100° F., but vary, for example, in a range of 70-105° F. Then, approximately 80 lbs. (or 8%) of Xeroderm P-AF (available from ______ of ______) and approximately 60 lbs. (6%) of Leukotan NS3 (available from ______ of ______) are mixed  124 . Xeroderm P-AF and Leukotan are waterproofing agents that have proven to be well-suited for use in this application. These chemicals may be replaced by other waterproofing agents in alternative applications. Afterwards, approximately 45 gallons of water are combined  126  with the waterproofing agents, and the mix is added  128  to the mill. This water may be at a temperature of approximately 90° F., but its temperature may vary. The mill is then run  130  for approximately 90 minutes. The running time of the mill may vary, for example, between 60 to 120 minutes. After the mill has run, the skins should be at a pH level of approximately 6.5.  
         [0027]     The skins next undergo the coloring and dyeing phase  40  (See  FIG. 4 ). The coloring phase  40  begins by combining  132  approximately 20.0 lbs. (2%) of aqua ammonia (approximately 29% concentration) and approximately 11.111 gallons of water. The water is at a temperature of approximately 100° F., but may vary between 70-105° F. The mixture is added  136  to the mill and the mill is run  136  for approximately 10 minutes. This will bring the skins to a pH level of approximately 7. The dyestuffs are next mixed together with water and the desired penetrators. More specifically, approximately 10.0 lbs. (1%) of Penetrator #7312 available from ______ of ______, approximately 24.832 lbs. (2.48%) of Sellafast Brown H available from ______ of ______, approximately 21.957 lbs. (2.196%) Sellaset Yellow H available from _____ of ______, approximately 4.187 lbs. (0.419%) Sellaset Blue H available from ______ of ______, approximately 5.0 lbs. (0.5%) Invaderm LU available from ______ of ______ and approximately 45 gallons of water at approximately 100° F. are mixed  138  together. The mixture is heated  140  to approximately 200° F. and then cooled  142  to approximately 100° F. The mixture is then added  144  to the float, and the mill is run for approximately 60 minutes. The runtime of the mill vary, for example, from 60 to 180 minutes). Although the described process includes the use of dissolved dyestuff and penetrators, the dyestuff and penetrators may alternatively be added dry, if desired. The Penetrator #7312 and Invaderm LU are commercially available penetrators. If desired, these penetrators may be replaced or supplemented by other conventional penetrating agents. The coloring phase has been described in connection with a collection of three dyestuffs selected to provide the leather with a specific color. These dyestuffs may be replaced by other dyestuff as appropriate to obtain essentially any desired color.  
         [0028]     The skins next pass into the fixation phase  60 . To aid in fixing  170  the waterproofing agents and dyestuff in the skins, formic acid is added to the mill in two sequential installments. First, approximately 6.0 lbs. (0.6%) of formic acid (90% concentration) is mixed  148  with approximately 11.111 gallons of water at approximately 100° F. The mixture is added  150  to the mill. The mill is run  152  for approximately 20 minutes. The runtime of the mill may vary, for example, between 15 to 45 minutes). Then, a second installment of approximately 6.0 lbs. (0.6%) of formic acid (90% concentration) and 11.111 gallons of water at approximately 100° F. are mixed  154  and added  156  to the mill. The mill is then run for approximately 20 minutes. The runtime of the mill may vary, for example, between 15 to 45 minutes). This should bring the skins to a pH level below approximately 3.5.  
         [0029]     A water repellant and oil repellant agent is next added to the skins in a fluorchemical process  70 . To prepare for this process, the skins are washed  160  in approximately 2000 gallons of water at approximately 135° F., and the mill is drained  172 . The temperature of the water may vary, for example, between 115 to 150° F. The fluorchemical process begins by adding  162  approximately 111.11 gallons of water at approximately 135° F. to the mill to establish the float. Next, approximately 2.5 lbs. (0.25%) of formic acid (90% concentration) is mixed  164  with approximately 11.111 gallons of water at approximately 100° F. The mixture is added  166  to the mill. The mill is run  168  for approximately 15 minutes. The runtime of the mill may vary, for example, between 10 to 30 minutes). These steps should bring the skins to a pH level in the range of 3.2 to 3.6. After, approximately 30.0 lbs. (3%) of PM 4700 is mixed  170  with approximately 11.111 gallons of water at approximately 120° F. The mixture is added  172  to the mill, and the mill is run  174  for approximately 30 minutes. The runtime of the mill may vary, for example, between 20 to 60 minutes). The PM 4700 is a conventional leather protectant that renders the skins oil resistant and water resistant, and is available from 3M under the trade name “Scotch Guard®.” This protectant can be replaced or supplemented by other conventional protectants, if desired. The skins are next treated to fix the protectant in the skins. Approximately 10.0 lbs. (1%) of formic acid (90% concentration) is mixed  176  with approximately 11.111 gallons of water at approximately 100° F. The mixture is added  178  to the mill. The mill is run  180  for approximately 30 minutes. The runtime of the mill may vary, for example, between 20 to 60 minutes). These steps should bring the skins to a pH level in the range of 3.0 to 3.5.  
         [0030]     If desired, the skins can be subjected to a variety of additional treatments. These various treatments are option. In one embodiment, the skins are treated with antimicrobial and antistatic treatments (See  FIG. 7 ). More specifically, approximately 3.2 lbs. (0.32%) of Amical WP is dry fed  182  into the mill, and the mill is run  184  for approximately 10 minutes. Amical WP is a conventional antimicrobial treatment that is available from ______ of ______. This additive may be replaced or supplemented with other antimicrobial agents. The runtime of the mill may vary, for example, between 10 to 20 minutes. In addition, approximately 10.0 lbs. (1%) of Antistat 7493 is mixed  186  with a minimal amount of water at approximately 100° F. Antistat 7493 is a conventional antistatic agent that is available from ______ of ______. This agent may be replaced or supplemented with other antistatic agents. The mixture is added  188  to the mill, and the mill is run for approximately 5 minutes. The runtime of the mill may vary, for example, between 5 to 15 minutes. The particular order of application of these two treatments is not particularly important, and they may be applied in reverse order if desired.  
         [0031]     If desired, additional treatments may be applied to the skins. For example, a flame resistant or flame proof treatment may be applied. The flame resistant or flame proof treatment may be applied to the skins in a dry or dissolved state, as desired. Further, additional antimicrobial treatments may be applied. Additional antimicrobial treatments may also be applied in a dry or dissolved state.  
         [0032]     Next, the skins are subjected to a final washing. Approximately 1000 gallons of water at 100° F. are added to the mill while the mill is running. The washing door of the mill may be left open, permitting the water to slosh from the mill. The mill is run until nearly all of the water has sloshed from the mill. Then, the skins or leathers are dumped from the mill.  
         [0033]     The leathers are preferably dried using conventional vacuum dryers or other similar machinery. The dried leathers can be staked and finished  80  as desired. Staking is a mechanical softening process that typically involves beating the leather repeatedly with small fingers. The leathers can also be sanded and milled, as appropriate. The leathers can undergo additional finishing, as desired. For example, oil can be applied to the leather to add to waterproofness and change the look and feel of the leather.  
         [0034]     The above description is that of a preferred embodiment of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.