JP4945582B2 - Manufacturing method of leather parts and leather surface treatment apparatus used in the manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing a leather part and a leather surface treatment apparatus used in the manufacturing method. More specifically, the present invention relates to a method for manufacturing a leather part that performs surface treatment on a semi-finished crust leather that has been tanned and dried, and a leather surface treatment apparatus that is used in the method.

Conventionally, leather parts used for automobile seats, handles, etc. are colored, embossed, etc. on crusted leather of the size of one cow, which is tanned and dried. It is manufactured by processing and then cutting to a predetermined size.
FIG. 5 shows steps of a method for manufacturing a leather part that covers the handle of a genuine leather handle according to the prior art.
First, as a preparation process, the crust leather 110 having the size of one cow is purchased, the crust leather 110 is dyed, and the surface is buffed.
Next, according to the following steps shown in FIG. 5, the crust leather 110 is subjected to a surface treatment and then checked for scratches and cut into a predetermined size to produce a leather part.
(1) Base coat process This is a process of applying a base coat to the crust leather 110 and drying it. The base coat is applied by a roll coater and dried to impart flexibility to the crust leather 110 and stabilize the fiber entanglement.
(2) Color coating step This is a step of coloring by spraying and drying. By applying a color coat with a clear paint, the crust leather 110 can be given natural beauty with transparency and durability can be improved.
(3) Embossing step This is a step of embossing the surface of the crust leather 110 by roll embossing.
(4) Topcoat step This is a step of forming a protective film on the surface of the crust leather 110 by applying a finish by spraying and drying. By forming the protective film, the wear resistance and weather resistance of the crust leather 110 are improved.
(5) Raw fabric inspection process This is a process for checking the presence or absence of scratches on the finished crust leather 110 (raw fabric) and marking the position of the scratches.
(6) This cutting process It is the process which cuts the raw material which has been finished-painted with a product type with a cutting machine in the position range which does not contain a flaw, and makes it the leather part 112.

  JP-A-6-179900 (Patent Document 1) describes a method of performing surface treatment after cutting crust leather into a predetermined size.

JP-A-6-179900

In the method described in Patent Document 1, it is noted that, in the prior art, finishing processing is performed in advance to unnecessary portions that are finally discarded, and the finishing chemicals and the like are wasted. It was proposed.
Certainly, the method described in Patent Document 1 is a method for solving a part of the problems of the prior art, but the disclosed embodiment is a general theory and is not concrete, It remains at the stage of presentation. Patent Document 1 does not describe a problem inherent to natural leather, which is caused by the fact that crust leather is obtained by processing animal skin.

From the inventor's point of view, the prior art includes the steps (1) to (6) described above for crust leather of the size of one cow, including the problems pointed out by Patent Document 1. There are various problems caused by this.
First, in the painting steps (1), (2), and (4), the adhesion of dust is a big problem. Since these processes process leather that is the size of one cow, painting and drying facilities are large, so it is difficult to introduce garbage countermeasures such as installing processing facilities in a clean room.
Next, in the embossing (3) embossing process, there is a problem that the embedding condition of the embossing becomes nonuniform. Since wrinkle processing is performed with a cow's worth of leather sandwiched between rolls, wrinkles deeply enter the thick leather back, and wrinkles are poor in the leather around the belly. For this reason, for example, in the case of a handle leather-wrapped product formed by stitching four leather cut products, it is necessary to use a combination of cut products with the same depth of embossing. If the depth of the wrinkles is different, a sense of incongruity will occur and it will not look good, resulting in a defective product.
And in the original fabric inspection process of (5), since leather of the size of one cow is inspected, since the area to inspect at a time is wide, it is difficult to overlook the inspection object range at a time. Therefore, it is easy to overlook the dust adhering in the coating steps of steps (1), (2), and (4). Moreover, since the inspection is performed after painting, it is not easy to detect the original scratches on the cow.
In the main cutting step (6), the product mold is cut after the original fabric inspection, but the yield is around 50%, and 50% of the original fabric is discarded. And since the expensive paint is used also in the part to discard, as patent document 1 points out, the expensive paint is wasted.
Moreover, since the surface treatment of leather has many processes, there also exists a problem that it takes time and effort.

  The present invention is proposed in order to solve the above-mentioned problems, and the problem to be solved by the present invention is to provide a method for manufacturing a leather part with reduced cost and time required for manufacturing the leather part. There is to do. And it is providing the surface treatment apparatus of the leather used for the manufacturing method.

In order to solve the above problems, the inventor of the present invention has made a method of manufacturing a leather part that can reduce the cost and time required for manufacturing a leather part as a result of intensive studies in consideration of the characteristics of natural leather. Invented. Then, the present inventors have invented a leather surface treatment apparatus that automates the surface treatment process of leather in the manufacturing method.
Therefore, the first invention of the present invention is a method for manufacturing a leather part,
Inspection of raw leather that has been tanned and made into a semi-finished product, parts that cannot be used as leather parts due to the presence of flaws in the cow's original scratches and tanning, and other parts other than the parts that cannot be used Skin cutting process for distinguishing between the above, a temporary cutting process for cutting a cut part larger than the leather part from the other part of the raw leather , and a stucco treatment on the cut part to repair the concave part on the surface A surface repairing process, a surface treatment process for applying a surface treatment including a coating process and an embossing process to the cut part, and a main cutting process for cutting the outer periphery of the cut part to make a leather part.

According to the first invention, since the raw leather is inspected before the surface treatment such as painting, it is easy to find a scratch on the raw leather. And after cutting into parts larger than leather parts from parts other than those that can not be used as leather parts, surface repair treatment and surface treatment consisting of painting and embossing are performed, so surface repair and surface treatment There is no waste of chemicals.
And since the surface treatment such as painting is performed on the cut parts, the surface treatment device can be miniaturized, so the equipment cost and the installation space of the device can be saved, and the surface treatment device can be saved. It is easy to introduce garbage countermeasures such as installing in a clean room.
In addition, since a predetermined surface treatment such as painting is performed on the cut part, the area of each leather to be subjected to the surface treatment is small, it is easy to perform the surface treatment uniformly, and the time required for the surface treatment is shortened. be able to.
Therefore, the manufacturing method of the leather component which reduced the expense and time which manufacture of the leather component can be provided.

Next, the second invention of the present invention is a method of manufacturing a leather part according to the first invention,
The surface treatment process includes an undercoating process, a coloring process, an embossing process, and a finish coating process.
According to the second aspect of the invention, in the steps of undercoating, coloring, and finish coating, since the area to be coated at a time is small because of the process for cutting parts, it is easy to uniformly coat the entire surface. Further, in the embossing process, the difference in the thickness of the leather in the cut part is small, so that the depth of the texture can be made constant by adjusting the pressure applied according to the thickness of the leather. Therefore, it is not necessary to make the depth of the texture uniform when sewing a plurality of cut parts. Therefore, in the surface treatment process, the man-hours and costs required to ensure the quality of the leather parts can be reduced.

Next, a third invention of the present invention is a method of manufacturing a leather part according to the first invention or the second invention, wherein the surface treatment means for the cut part and the surface treatment in the surface treatment step The means for conveying the cut part to the process is automated.
According to the third aspect of the invention, since the surface treatment means for the cut parts in the surface treatment process and the means for conveying the cut parts for the surface treatment process are automated, the cost and time required for manufacturing the leather parts are further reduced. be able to.

Next, a fourth invention of the present invention is a leather surface treatment apparatus used for a surface treatment step in the method for producing a leather part according to the first invention or the second invention,
The surface treatment means for the cut parts in the surface treatment process and the means for conveying the cut parts for the surface treatment process are automated.
By using the leather surface treatment apparatus according to the fourth aspect of the present invention, it is possible to further reduce the cost and time required for manufacturing the leather part.

According to each invention of the present invention described above, the following effects can be obtained.
First, according to the above-mentioned first invention, it is possible to provide a method for manufacturing a leather part with reduced cost and time required for manufacturing the leather part.
Next, according to the above-mentioned 2nd invention, the man-hour and cost required for ensuring the quality of leather parts can be reduced in a surface treatment process.
Next, according to the above-described third invention, the cost and time required for manufacturing leather parts can be further reduced by automating the surface treatment means for the cut parts in the surface treatment process and the conveying means for the cut parts for the surface treatment process. Can do.
Next, according to the fourth invention described above, it is necessary to manufacture leather parts by using a surface treatment device in which the surface treatment means for the cut parts in the surface treatment process and the means for conveying the cut parts to the surface treatment process are automated. Cost and time can be further reduced.

1 is a diagram illustrating a method for manufacturing a leather part in Example 1. FIG. It is a figure which shows the pre-process of the surface treatment in the manufacturing method of the leather-made components in Example 2. FIG. It is a figure which shows the surface treatment process in the manufacturing method of the leather-made components in Example 2. FIG. It is a figure which shows the structure of the automatic surface treatment apparatus used in Example 2. FIG. It is a figure which shows the manufacturing method of the components made from leather by a prior art.

  Hereinafter, the best mode for carrying out the present invention will be described according to examples.

A method for manufacturing the leather part 14 in Embodiment 1 of the present invention will be described with reference to FIG. In Example 1, a leather part 14 for an automobile leather handle is manufactured. First, as a preparation process, the crust leather 10 having the size of one cow is purchased, the crust leather 10 is dyed, and the buffing process for polishing the surface is performed. Up to this point, the method is the same as the conventional method. This crust leather 10 corresponds to the raw leather of the present invention.
Next, the leather part 14 is manufactured through the steps of the method for manufacturing the leather part 14 shown in FIG. The manufacturing process of the leather part 14 in Example 1 is a skin inspection process for inspecting the crust leather 10, and the crust leather 10 has a predetermined size slightly larger than that of the leather part from a part that does not include scratches outside the repair limit. A temporary cutting process for cutting the cutting part 12, a surface repairing process for repairing a concave portion on the surface by applying a stucco process to the cutting part 12, a surface treatment process for applying a predetermined surface treatment such as painting to the cutting part 12, It consists of a main cutting step of cutting the outer periphery into a leather part 14.
In Example 1, the surface treatment process includes a base coat process, a color coat process, an emboss process, and a top coat process. The base coat process corresponds to the undercoat process of the present invention, the color coat process corresponds to the coloring process of the present invention, and the top coat process corresponds to the finish coating process of the present invention. Hereinafter, details of processing contents in each step shown in FIG. 1 will be described.

(A) Skin Examination Process The skin examination process is a process for inspecting the crust leather 10 that has been dyed and buffed for the presence or absence of scratches. Since the crust leather 10 is produced by tanning cow skin, which is an animal, unlike industrial steel plates and fabrics, there may be scratches inherent to cattle or scratches that occur during the tanning process. Since the scratched portion cannot be used as the leather part 14, it is necessary to check whether there is a scratch before provisional cutting, and take measures so that the scratch is not included in the cut component 12.
Therefore, when a scratch outside the limit that cannot be repaired in the surface repair process described later is found in the skin inspection process, a mark is attached in a conspicuous color at the position of the scratch. In the skin inspection process, fine scratches within the limit that can be repaired in the surface repair process are allowed in order to secure the yield.
According to the first embodiment, since the scratch is inspected before the coating process such as the base coat process, it is easy to detect the scratch, and the part 12 where the scratch outside the limit is generated in the temporary cutting process is included in the cut part 12. It becomes easy to eliminate the defective product. Therefore, the yield rate is improved.

(B) Temporary cutting process The temporary cutting process is a process of cutting the crust leather 10 into a cut part 12 having a predetermined size slightly larger than the leather part 14. In Example 1, the crust leather 10 is temporarily cut with a mold having a size 1.03 times larger than that of the main mold when the leather part 14 is cut.
The cutting part 12 is cut larger than the leather part 14 for the following reason. First, since the cut component 12 is slightly stretched to apply pressure in an embossing process described later, trimming is necessary after the surface treatment. Further, since dripping of the coating due to the surface treatment occurs in the thickness direction of the cut part 12 at the terminal portion, trimming is also necessary after the surface treatment. Therefore, the cutting part 12 is cut larger than the leather part 14 in consideration of the trimming allowance.
At this time, the crust leather 10 is provisionally cut into a cut part 12 in a position range that does not include a scratch outside the limit found and marked in the skin inspection process. Since scratches outside the limit are detected and marked in the skin inspection process of the previous process, it is possible to prevent the scratches outside the limit from flowing to the subsequent process, so that the quality of the leather part 14 can be ensured and the yield is increased. The rate is improved.
Further, since the cut component 12 is a processing target in the subsequent processes, the equipment used in the subsequent processes can be made compact, and the cost of capital investment can be suppressed.

(C) Surface repairing process The surface repairing process is a process of repairing the surface of the cut part 12 by filling a fine scratch or a concave part of the surface of the cut part 12 with a chemical called “stucco”. Surface repair work by stucco is called stucco treatment.
In the past, stucco treatment was performed after buffing treatment and before surface treatment. However, since it was treated in the size of one cow in the past, it takes time, and the portion that does not eventually become leather parts 14 is also treated. As a result, processing time and chemical waste were generated.
However, in the first embodiment, since the stucco process is performed on the cut part 12, since the area to be processed is small, the cut part 12 can be pinched to perform the stucco process. Therefore, the processing efficiency is good and the waste of medicine does not occur.

(D) Base coat process The base coat process is a process in which the base material is coated on the cut part 12 by a mini roll coater and dried. By applying the base coat, the cut component 12 is made flexible and the entanglement of the fibers is stabilized, so that the cut component 12 becomes robust and wear resistance is improved.
And since it becomes the coating by the mini-roll coater to the cutting | judgement component 12, a compact installation can be used, introduction of dust adhesion countermeasure equipment becomes easy, and generation | occurrence | production of the malfunction by dust adhesion can be reduced. In addition, since the paint is applied to the cut part 12, the paint is used only for necessary portions, so that there is no waste of chemicals and the cost is reduced.

(E) Color coating process The color coating process is a process in which the cut parts 12 are colored and dried by mini spraying. By color coating with a clear paint, it is possible to give the cut part 12 a natural beauty with transparency and improve durability.
Conventionally, the crust leather 10 for one cow has been colored in the same color. For example, in order to prepare the leather parts 14 for the handle wrapping for four colors, the stock for the four colors is secured. There was a need. However, in the first embodiment, since it is only necessary to color the cut parts 12, it is only necessary to secure the stock with the quantity of the cut parts 12, and thus management of work in progress is easy.
In addition, since the cut parts 12 are colored by mini-spraying, a compact facility can be used, and the introduction of dust adhesion countermeasure facilities is facilitated, and the occurrence of defects due to dust adhesion can be reduced. In addition, since the paint is applied to the cut part 12, the paint is used only for necessary portions, so that there is no waste of chemicals and the cost is reduced.

(F) Embossing process The embossing process is a process of embossing the cut part 12 by pressure-type mini-embossing. The embossing is more uniform in the pressure type embossing than in the roll embossing, and the combination of the cut parts 12 becomes unnecessary.
In the past, embossing was performed on the crust leather 10 for one cow, and roll embossing was used because the equipment was huge in the pressure type. However, in Example 1, since the embossed part 12 is embossed, the equipment can be downsized and pressure embossing can be used.

(G) Topcoat process The topcoat process is a process of forming a protective film by applying a surface coating to the cut component 12 by mini spraying and drying it. By forming the protective film, the wear resistance and weather resistance of the cut part 12 are improved.
And since the surface coating by the mini spray on the cutting part 12 can be performed, a compact facility can be used, the introduction of the dust adhesion countermeasure facility can be facilitated, and the occurrence of defects due to the dust adhesion can be reduced. In addition, since the paint is applied to the cut part 12, the paint is used only for necessary portions, so that there is no waste of chemicals and the cost is reduced.

(H) This cutting process This cutting process is a process of trimming the outer peripheral part of the cutting part 12 with a clicker to make a leather part 14 of a predetermined size and opening a needle hole for hand-sewing. Only a few parts are cut off by trimming, and waste of paint hardly occurs.
In Example 1, since the leather part 14 is manufactured by provisional cutting and main cutting, the cutting process is two processes. However, conventionally, after cutting with a regular dimension from the raw fabric for one cow, the needle hole for hand-sewing was opened in a separate process, so the cutting was substantially composed of two processes. Therefore, in Example 1, the cutting process is not substantially increased.

According to the first embodiment, it is possible to provide a method for manufacturing a leather part in which the cost and time required for manufacturing the leather part are reduced. And the yield is improved. Further, in the surface treatment process, the man-hours and costs required to ensure the quality of the leather parts can be reduced.
In Example 1, the surface treatment process is the above four processes (D), (E), (F), and (G), but some processes are changed or omitted depending on the use of the leather part. And additional steps can be set.

Next, a method for manufacturing a leather part in Example 2 of the present invention will be described. The feature of the second embodiment is that it is implemented by an automatic surface treatment apparatus that automates the surface treatment means for painting or embossing the cut parts in the surface treatment process and the means for conveying the cut parts for each surface treatment process. The pre-process of the surface treatment is basically the same as that of the first embodiment, but some processes are added, so the pre-process of the surface treatment will be described with reference to FIG.
FIG. 2 shows a pre-process of surface treatment in the method for manufacturing a leather part of Example 2. First, as a preparation process, the crust leather 10 for one cow is purchased, and the crust leather 10 is dyed. Next, sealing is applied to the crust leather 10. Sealing is intended to control the penetration rate of the base coat and is a conventional technique. Next, a buffing process for polishing the surface is performed. Then, the surface of the leather is pressed and trimmed with an iron. This completes the preparation process.
Subsequently, a skin inspection process for inspecting the crust leather 10 in the same manner as in Example 1, a cut part 12 having a predetermined size slightly larger than the leather part from a part that does not include a scratch outside the repair limit of the crust leather 10 The cutting part 12 is in a state before being subjected to the surface treatment through a temporary cutting process for cutting, and a surface repairing process in which the cut part 12 is subjected to a stucco process to repair fine scratches and recesses on the surface. Since these steps are the same as those in the first embodiment, detailed description thereof is omitted.

  Next, surface treatment such as painting and embossing on the cut part 12 is automatically performed by the automatic surface treatment apparatus 20 (see FIG. 4). Specifically, when the cutting component 12 colored with the same color is placed on the pallet 30 (see FIG. 3) and placed in the automatic surface treatment apparatus 20, the cutting component 12 rides on the pallet 30 and performs each surface treatment step. Are automatically conveyed, and the surface treatment is automatically performed in each step of the surface treatment. The surface treatment is performed in a state where the cut part 12 is placed on the pallet 30. Then, after the surface treatment, the main cutting is performed in the same manner as in the first embodiment, and the outer periphery of the cutting part 12 is cut into the leather part 14.

FIG. 3 shows details of the surface treatment process in the second embodiment. The base coat corresponds to the undercoating process of the present invention, the color coat corresponds to the coloring process of the present invention, the embossing corresponds to the embossing process of the present invention, and the top coat corresponds to the finish coating process of the present invention.
In Example 2, the base coat, the color coat, and the top coat are all applied using a screen printer. The screen printer used in the painting process uses the same equipment, and only the paint used is different. Since the base coat cannot supply a sufficient amount of paint by one printing, it is carried out in two steps. The top coat is applied before and after embossing. If embossing is performed with the color coat applied to the surface of the cutting component 12, the cutting component 12 may stick to the embossing plate during the embossing operation and the position on the pallet 30 may shift. The top coat which does not stick to the plate is applied to the surface of the cut part 12, and then the embossing is performed. And after each coating process, it dries with a dryer.

  FIG. 4 shows the configuration of the automatic surface treatment apparatus 20 used in the second embodiment. The automatic surface treatment apparatus 20 has a configuration in which a conveyor 28 is disposed between five screen printing machines that apply paint and a grain machine 26 that performs graining. A dryer 27 is arranged after each screen printer. The five screen printing machines are the base coat printing machine 21, the base coat printing machine 22, the color coat printing machine 23, the top coat printing machine 24, and the top coat printing machine 25. As described above, the same equipment is used as the printing machine. Only the paint applied in each process is different. Hereinafter, for convenience of explanation, the five screen printers and the shibo machine 26 may be collectively referred to as each device.

The automatic surface treatment is performed according to the following procedure. First, the pallet 30 on which the cut parts 12 are placed in the carry-in / out space 32 of the automatic surface treatment apparatus 20 is placed on the conveyor 28 of the automatic surface treatment apparatus 20. The cutting component 12 may be arranged on the pallet 30 with the pallet 30 placed on the conveyor 28.
Then, the pallet 30 moves on the conveyor 28 and is sent to the screen printing machine or the grain machine 26, and the cutting part 12 is automatically painted and crimped on the pallet 30. Then, after the painting process by the screen printer, it is dried by the dryer 27 and sent to the next process. When all the surface treatment steps are completed, the cut part 12 is finally dried by the last dryer 27 longer than the others, and returned to the carry-in / out space 32 of the automatic surface treatment apparatus 20 in a state of being placed on the pallet 30. come.
And since the movement time and movement distance between each apparatus are set to be the same, and the cycle time of each apparatus is also set to the same, the movement is also performed at the same timing, and surface treatment such as painting by each apparatus. Are implemented at the same timing.

  Carrying in of the pallet 30 to each apparatus and carrying out of the pallet 30 from each apparatus are performed as follows. When the pallet 30 arrives at a predetermined position of each device, the pallet 30 is stopped by a stopper (not shown), and a pallet lifting device (not shown) feeds the pallet 30 to the painting or embossing position of each device. Then, the surface treatment in each device is automatically performed, and when the surface treatment is completed, the pallet lifting device takes out the pallet 30 from each device, and the pallet 30 is lowered to a predetermined position of each device. And the pallet 30 is conveyed by the conveyor 28 and moves to the next process.

  According to the second embodiment, after the pallet 30 on which the cutting component 12 before the surface treatment is placed is placed on the conveyor 28 of the automatic surface treatment apparatus 20 in the carry-in / out space 32, the surface treatment on the cutting component 12 is finished and the pallet is finished. All the steps of conveying the pallet 30 and performing the surface treatment are automatically performed until 30 returns to the carry-in / out space 32 of the automatic surface treatment apparatus 20. Therefore, it is not necessary to manually move the cutting part 12 to the next process, and it is not necessary for a person to operate each surface treatment apparatus. Therefore, the time and cost of the surface treatment of the cut part 12 can be reduced, leading to a reduction in time and cost related to the production of the leather part 14.

In each of the above embodiments, an example of a method for producing a leather part used for a leather-wrapped handle of an automobile from cow crust leather has been shown, but the present invention is also applicable to natural leather other than cow, such as sheep leather. can do. The use of leather parts is not limited to automobile leather handles, but can also be applied to handbags and wallets.
In addition, the method for manufacturing a leather part according to the present invention, and the leather surface treatment apparatus in which the surface treatment means and the conveying means used in the production method are automated can be implemented in various forms within the scope of the idea of the invention. Is.

10 Crust leather (raw leather)
12 Cutting parts 14 Leather parts 20 Automatic surface treatment device 21 Base coat printing machine 22 Base coat printing machine 23 Color coat printing machine 24 Top coat printing machine 25 Top coat printing machine 26 Shibo machine 27 Dryer 28 Conveyor 30 Pallet 32 Loading / unloading space

Claims (4)

A method of manufacturing a leather part,
Inspection of raw leather that has been tanned and made into a semi-finished product, parts that cannot be used as leather parts due to the presence of flaws in the cow's original scratches and tanning, and other parts other than the parts that cannot be used And the skin-cutting process to distinguish between
A provisional cutting step of cutting a cut part larger than the leather part from the other part of the raw leather;
A surface repairing process for repairing a concave portion on the surface by applying a stucco treatment to the cut parts;
A surface treatment step of performing a surface treatment comprising a coating treatment and an embossing treatment on the cut part;
A method for manufacturing a leather part comprising a main cutting step of cutting the outer periphery of the cut part into a leather part. A method for manufacturing a leather part according to claim 1,
The method for manufacturing a leather part, wherein the surface treatment step includes an undercoat step, a coloring step, an embossing step, and a finish coating step. A method for manufacturing a leather part according to claim 1 or 2,
A method for manufacturing a leather part, characterized in that a surface treatment means for the cut part in the surface treatment step and a conveying means for the cut part for the surface treatment step are automated. A leather surface treatment apparatus used for a surface treatment step in the method for producing a leather part according to claim 1 or 2,
A leather surface treatment apparatus, wherein a surface treatment means for the cut parts in a surface treatment step and a means for conveying the cut parts for the surface treatment step are automated.

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