Fabric for vehicle ceilings

Abstract

To provide a fabric for a vehicle ceiling material which is excellent in moldability and deodorant performance.SOLUTION: A fabric for a vehicle ceiling material is formed by applying a resin composition containing a deodorant and a binder resin to at least a part of a surface of a fibrous base material. Durability of the deodorant performance of the fabric for the vehicle ceiling material is grade 3 or better.SELECTED DRAWING: None

Description

[Technical Field]

[0001] This invention relates to a fabric for vehicle ceiling materials. [Background technology]

[0002] Because the interior spaces of vehicles such as cars and trains are enclosed spaces, odors tend to accumulate easily. Therefore, fabrics used as interior materials for vehicles, such as seat upholstery and ceiling materials, are required to have deodorizing properties against various odors, including everyday odors and cigarette smoke.

[0003] Patent Document 1 describes a deodorizing sheet in which a deodorizing agent is applied to a sheet material for use in bonding with a member to be bonded, wherein the deodorizing agent is applied to at least one surface of the sheet material so as to be distributed throughout the sheet material with predetermined intervals between them, and the space between adjacent deodorizing agents serves as an adhesive surface for bonding to the member to be bonded, thereby ensuring good moldability and adhesion. [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2003-687 [Overview of the project] [Problems that the invention aims to solve]

[0005] In order to fully exert the deodorizing effect, it is necessary to ensure sufficient contact between the deodorizer and the odor-causing substances. However, when using the deodorizing sheet described in Patent Document 1 as a ceiling material, the deodorizing sheet is adhered to the lower skin layer (the base material of the ceiling material) with an adhesive layer in between, on the side of the sheet material where the deodorizer is printed. Therefore, the deodorizer is located on the inside of the ceiling material and is not present on the outer surface (the surface visible during use (design surface)), leaving room for improvement in deodorizing performance.

[0006] This invention was made in view of the current situation, and its purpose is to provide a fabric for vehicle ceiling materials that has excellent moldability and deodorizing performance. [Means for solving the problem]

[0007] In an embodiment of the present invention, a fabric for vehicle ceiling material is provided with a resin composition containing a deodorant and a binder resin on at least a portion of the surface of a fibrous base material. The fabric for vehicle ceiling material has a deodorant durability of grade 3 or higher. [Effects of the Invention]

[0008] According to embodiments of the present invention, it is possible to provide a fabric for vehicle ceiling materials that has excellent moldability and deodorizing performance. [Modes for carrying out the invention]

[0009] The fabric for vehicle ceilings according to this embodiment is made by applying a resin composition containing a deodorant and a binder resin to the outer surface of a fibrous base material. The durability of the deodorizing performance of the fabric for vehicle ceilings is grade 3 or higher. By applying the resin composition containing the deodorant to the outer surface of the fibrous base material, the deodorant is more likely to come into contact with malodorous substances in the vehicle interior space, thereby enabling good deodorizing performance. Because the durability of the deodorizing performance of the fabric for vehicle ceilings is grade 3 or higher, the deodorizing performance can be maintained for a long period of time. Here, the outer surface of the fibrous base material refers to the surface that is visible during use (the design surface) of the front and back surfaces of the fibrous base material.

[0010] The fibrous base material described above is not particularly limited, and examples include woven fabrics, knitted fabrics, nonwoven fabrics, and other fibrous materials. In fibrous materials, the type of fiber is not particularly limited, and examples include natural fibers, regenerated fibers, semi-synthetic fibers, synthetic fibers, and other conventionally known fibers, and two or more of these may be combined. Among these, synthetic fibers are preferred from the viewpoint of strength, and polyester fibers are more preferred. The fibrous base material may be colored with dyes or pigments. The dyes and pigments used for coloring are not particularly limited.

[0011] The thickness of the fibrous base material is not particularly limited, but from the viewpoint of moldability, it is preferably 1.0 to 3.5 mm, and more preferably 1.5 to 2.5 mm. The mass per unit area of ​​the fibrous base material is also not particularly limited, but from the viewpoint of abrasion resistance, it is 80 to 350 g / m². 2 Preferably, and more preferably, 120-300 g / m² 2 That is the case.

[0012] The elongation of the fibrous base material is not particularly limited, but from the viewpoint of moldability, it is preferably 20% or more in the vertical direction and 20% or more in the horizontal direction, and more preferably 40% or more in the vertical direction and 40% or more in the horizontal direction.

[0013] Here, the elongation of the fibrous material is calculated as follows: Three test specimens measuring 50 mm in width and 300 mm in length are taken from both the longitudinal and transverse directions. Gauge marks are made at a distance of 100 mm from the center of each test specimen (50 mm parallel to the longitudinal side from the intersection of the diagonals toward each short side). Under conditions of room temperature 22 ± 2°C and relative humidity 65 ± 5% RH, both ends of the test specimen are clamped tightly with grips, and the specimen is mounted on a tensile testing machine (Autograph AG-1, manufactured by Shimadzu Corporation) with a grip width of 25.4 mm and a grip spacing of 150 mm, and the specimen is fractured at a grip movement speed of 200 mm / min. The distance between the gauge marks at the time of fracture is measured. The elongation is calculated using the following formula, and the average of the three points is taken as the elongation of the fibrous material. The distance between the gauge marks at the initial load is assumed to be 100 mm. Growth rate (%) = {(L1-L0) / L0} × 100 L0: Gauge line distance at initial load (mm) L1: Gauge line distance at fracture (mm)

[0014] The fabric for the vehicle ceiling of this embodiment is made by applying a resin composition containing a deodorant and a binder resin to at least a portion of the fibrous base material.

[0015] The binder resin included in the resin composition is not particularly limited and can include conventionally known thermoplastic resins and thermosetting resins, with thermosetting resins that crosslink upon heat being preferred. Examples of these resins include polyurethane resins, acrylic resins, polyamide resins, polyester resins, polyolefin resins, vinyl acetate resins, epoxy resins, and polyvinyl alcohol-based resins. These can be used individually or in combination of two or more. Among these, acrylic resins and polyurethane resins are preferred from the viewpoint of moldability and durability.

[0016] The elongation rate of the binder resin is not particularly limited, but is preferably 300% or more, and more preferably 500% or more. An elongation rate of 300% or more of the binder resin can suppress the occurrence of cracking in the resin composition during molding. It can also improve the durability of the deodorizing performance. The upper limit of the elongation rate of the binder resin is not particularly limited, but is preferably 1000% or less.

[0017] The tensile strength of the binder resin is not particularly limited, but is preferably 4 to 80 N, and more preferably 20 N or more. A tensile strength of 4 N or more in the binder resin suppresses the occurrence of cracking in the resin composition during molding. It also improves the durability of the deodorizing performance. A tensile strength of 80 N or less in the binder resin results in a ceiling material with a good tactile feel.

[0018] The deodorant contained in the resin composition is not particularly limited, and conventionally known deodorants can be used. Since the substances that can be deodorized vary depending on the type of deodorant, it is preferable to use a combination of a plurality of deodorants according to the purpose. For example, porous bodies, metal compounds, amines, ureas, amides, imides, hydrazides, azoles, and azines can be mentioned. Further, from the viewpoint of not reacting with the binder resin and being able to sufficiently exhibit deodorizing performance, those in which a metal compound is supported on a porous body or those in which an organic compound such as a hydroxyl group, amines, ureas, amides, imides, hydrazides, azoles, and azines is supported on a porous body are also preferably used.

[0019] Examples of the porous body include silica-based inorganic porous bodies such as silica gel, aerosol, and colloidal silica; alumina-based inorganic porous bodies such as activated alumina; zeolite-based inorganic porous bodies such as aluminosilicate zeolite, metallosilicate zeolite, and aluminophosphate zeolite; silicate compound-based inorganic porous bodies such as kaolinite, montmorillonite, and mica; mesoporous-based inorganic porous bodies such as mesoporous silica; inorganic porous bodies such as metal oxides and hydroxides including hydroxyapatite, layered zirconium phosphate, heteropolyacid salts, and porous manganese oxide; and clays such as activated clay, diatomaceous earth, bentonite, kibushi clay, and frog-eye clay. Among them, from the viewpoint of heat resistance, silica-based inorganic porous bodies are preferable.

[0020] Examples of the metal compound include oxides, hydroxides, chlorides, sulfates, acetates, citrates, and silicates of metals such as zinc, copper, aluminum, titanium, zirconium, lead, and iron. Specific examples include zinc oxide, copper oxide, aluminum oxide, titanium oxide, zirconium oxide, iron oxide, copper hydroxide, iron hydroxide, zinc chloride, copper chloride, and zinc silicate. Among them, metal oxides are preferable, and zinc oxide is more preferable.

[0021] The particle size of the deodorant is preferably 0.3 to 7 μm, more preferably 0.5 to 5 μm. When the particle size is 0.3 μm or more, the deodorant is difficult to be buried in the binder resin, and the deodorant performance can be exhibited. When the particle size is 7 μm or less, the deodorant is difficult to fall off, and the durability of the deodorant performance can be made good. Here, the particle size means "median diameter D50".

[0022] The content (solid content) of the deodorant in the resin composition is not particularly limited, but is preferably 20 to 60% by mass, more preferably 30 to 50% by mass. When the content of the deodorant is 20% by mass or more, the deodorant performance can be sufficiently exhibited. When the content of the deodorant is 60% by mass or less, the adhesion of the resin composition to the fibrous substrate can be made good. The durability of the deodorant performance can be made good.

[0023] The mixing ratio (solid content) of the deodorant and the binder resin in the resin composition is not particularly limited, but is preferably 1:0.80 to 1:2.5, more preferably 1:0.85 to 1:2.0. When the mixing ratio of the deodorant and the binder resin is 1:0.80 or more, the deodorant adheres to the fibrous substrate by the binder resin, and the durability of the deodorant performance can be made good. When the mixing ratio of the deodorant and the binder resin is 1:2.5 or less, it is possible to suppress the deodorant from being buried in the binder resin. The deodorant performance can be sufficiently exhibited.

[0024] In the resin composition, if necessary, within a range that does not impair its physical properties, conventionally known additives, for example, colorants (pigments, dyes), pigment dispersants, polymerization initiators, crosslinking agents, tackifiers, drying inhibitors, thickeners, flame retardants, conductivity imparting agents, antistatic agents, moisture permeability improvers, water repellents, oil repellents, water absorbents, moisture absorbents, defoamers, hydrolysis preventives, etc. can be used singly or in combination of two or more. Among them, from the viewpoint of design, it is preferable to contain a colorant.

[0025] The colorant content in the resin composition is not particularly limited, but is preferably 3% by mass or less, and more preferably 1% by mass or less. A colorant content of 3% by mass or less allows for a vehicle ceiling material with good friction fastness. The lower limit of the colorant content is not particularly limited, but is preferably 0.1% by mass or more.

[0026] The resin composition is applied to the surface of the fibrous substrate. Preferably, the outermost surface of the resin composition is smooth. A smooth outer surface of the resin composition helps to suppress the shedding of the resin composition due to abrasion. This improves the durability of the deodorizing performance. Furthermore, it improves the tactile feel of the resulting ceiling material. Here, "smooth outer surface" means that the shape of the resin composition is not affected by the uneven shape of the fibrous substrate, and the surface of the resin composition is flat.

[0027] The area ratio of the resin composition to the surface of the fibrous substrate is not particularly limited, but is preferably 18-60%, and more preferably 25-50%. A resin composition area ratio of 18% or more allows for sufficient deodorizing performance. A resin composition area ratio of 60% or less allows for good moldability.

[0028] Here, the area ratio of the resin composition to the surface surface of the fibrous substrate is the area per unit area (10 cm²) on the surface surface of the fibrous substrate. 2 This is the percentage of the area occupied by the resin, and is calculated as follows: The front surface of the fabric for the vehicle ceiling material is observed from above with a microscope (Hirox Co., Ltd., digital microscope KH-7700), and the area is measured using the area calculation software built into the microscope, and the area ratio occupied by the resin composition is calculated using the following formula. Area percentage of the resin composition (%) = Resin area / Unit area

[0029] The amount of resin composition adhering to the surface of the fibrous substrate (solid content) is not particularly limited, but is generally between 14 and 60 g / m². 2Preferably, it is 19-40 g / m² 2 The amount of resin composition that adheres is 14 g / m². 2 As a result, the deodorizing performance can be fully demonstrated. The amount of resin composition applied is 60 g / m². 2 The following conditions can be met to improve moldability.

[0030] Next, a method for manufacturing the vehicle ceiling fabric according to this embodiment will be described. The manufacturing method allows for the production of the vehicle ceiling fabric according to this embodiment by performing the following steps in order. That is, the manufacturing method is (1) A step of preparing a resin liquid for a resin composition by mixing a fibrous base material, a deodorant, and a binder resin, (2) A step of applying the resin liquid for the resin composition to at least a portion of the surface of the fibrous substrate, (3) The method includes a heat treatment step of drying the resin liquid for the resin composition.

[0031] (1) Preparation process Prepare the above-mentioned fibrous substrate and resin liquid for the resin composition. The fibrous substrate may be used as is, or, if necessary, a substrate that has undergone a smoothing treatment may be used. The smoothing treatment is performed to smooth the surface of the fibrous substrate. Specifically, this refers to a process of applying heat and pressure to the fibrous substrate. By performing the smoothing treatment, the surface of the fibrous substrate is smoothed, so that the outermost surface of the resin composition applied in a later process becomes smooth, and the shedding of the resin composition due to abrasion can be suppressed. The durability of the deodorizing performance can be improved. In addition, the tactile feel of the resulting ceiling material can be improved. The conditions for the heat and pressure treatment can be set appropriately depending on the fibrous substrate used, but for example, the fibrous substrate can be heated and pressed with a hot roll at a temperature of 80 to 130°C and a pressure of 0.2 to 4 MPa.

[0032] The resin liquid for the resin composition is obtained by mixing a deodorant and a binder resin. The viscosity of the resin liquid for the resin composition is preferably 5,000 to 20,000 mPa·s (BM type viscometer, rotor No. 4, 12 rpm), and more preferably 10,000 to 17,000 mPa·s. A viscosity of 5,000 mPa·s or higher allows the resin composition to be applied to the desired position, suppresses bleeding at the edges of patterns, and improves the aesthetic appearance. A viscosity of 20,000 mPa·s or lower suppresses the resin composition from adhering to the surface (not penetrating the fibrous substrate but remaining on the surface), improving wear resistance. The durability of the deodorant performance can be improved. The resulting ceiling material can have a good tactile feel. The deodorant is uniformly distributed in the resin composition, allowing it to fully exhibit its deodorant performance.

[0033] (2) Step of applying resin liquid for resin composition Various conventionally known methods can be used to apply the resin liquid for the resin composition onto a release substrate, and are not particularly limited. Examples include screen printing, rotary printing, and inkjet printing. Among these, rotary printing is preferred from the viewpoint of processability and cost.

[0034] (3) Heat treatment process After applying the resin liquid for the resin composition to a fibrous substrate, heat treatment is performed. The heat treatment is performed to evaporate the solvent in the resin liquid for the resin composition and dry the resin. In addition, when using a crosslinking agent that causes a crosslinking reaction by heat treatment, or when using a two-component curing type resin, the heat treatment is performed to promote the reaction and form a film with sufficient strength. The heat treatment only needs to be performed to the extent that no solvent remains, and the conditions are not particularly limited. The conditions should be set appropriately considering the boiling point of the solvent, production efficiency, and the material and form of the fabric used, but generally, it is preferable to set the treatment temperature to 130 to 150°C and the treatment time to 1 to 3 minutes. By setting the treatment temperature and treatment time above the lower limit, insufficient drying and crosslinking reaction can be prevented, and the deodorizing performance can be fully expressed. By setting the treatment temperature and treatment time below the upper limit, it is possible to prevent the texture and feel of the fabric from becoming rough and hard.

[0035] Next, if necessary, a smoothing treatment by heating and pressing may be performed after the heat treatment process. The smoothing treatment is performed to smooth the outermost surface of the applied resin composition. Specifically, it refers to a process of applying heating and pressing to the fibrous substrate to which the resin composition has been applied. By performing the smoothing treatment, the outermost surface of the resin composition is smoothed, which can suppress the shedding of the resin composition due to abrasion. This can improve the durability of the deodorizing performance. In addition, it can improve the tactile feel of the resulting ceiling material. The conditions for heating and pressing can be appropriately set depending on the fibrous substrate used, but for example, the fibrous substrate can be heated and pressed with a hot roll at a temperature of 80 to 130°C and a pressure of 0.2 to 4 MPa.

[0036] Thus, a fabric for vehicle ceiling material according to this embodiment is obtained. However, the method for manufacturing the fabric for vehicle ceiling material according to this embodiment is not limited to the method described above. [Examples]

[0037] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to the following examples.

[0038] Each evaluation item was assessed according to the following method.

[0039] [Elongation and tensile strength of binder resin] A binder resin solution was applied to flat release paper (EV130TPD, manufactured by Lintec Corporation) using an applicator to a thickness of 200 μm after drying. The solution was then air-dried for 24 hours, followed by heat treatment in a dryer at 80°C for 3 hours and then at 130°C for 30 minutes to produce a cured binder resin film. Three test specimens, each 50 mm wide and 100 mm long, were taken from the cured film. Under room temperature conditions of 22±2°C and relative humidity of 65±5%RH, both ends of the test specimens were clamped tightly with grips. A tensile testing machine (Autograph AG-1, manufactured by Shimadzu Corporation) was used, with a grip width of 50 mm and a grip spacing of 50 mm. The test specimens were fractured at a grip movement speed of 200 mm / min. The grip spacing at fracture was measured. The average of the maximum loads at the three points was defined as the fracture strength of the binder resin. Furthermore, the elongation rate was calculated using the following formula, and the average of the three points was taken as the elongation rate of the binder resin. The gripping distance at the initial load was set to 50 mm. Growth rate (%) = {(L1-L0) / L0} × 100 L0: Grip spacing at initial load (mm) L1: Grip spacing at fracture (mm)

[0040] [Moldability and design properties] Three test specimens measuring 50 mm in width and 100 mm in length were taken. Under room temperature conditions of 22 ± 2°C and relative humidity of 65 ± 5% RH, both ends of the test specimens were clamped tightly with grips, and a tensile test was performed using a tensile testing machine (Autograph AG-1 model, manufactured by Shimadzu Corporation) with a grip width of 50 mm and a grip spacing of 50 mm, at a grip movement speed of 200 mm / min. The surface condition of the test specimens was observed when the elongation rate reached 50%, and judged according to the following criteria. A grade of 3 or higher indicates excellent moldability and design properties. (Judgment criteria) Grade 5: No change in pattern shape (blurring at the edge of the pattern) or condition (cracks / peeling) in the resin composition-treated area. Grade 4: Slight changes in pattern shape and condition are observed in the resin composition-treated area, but these are not noticeable at all. Grade 3: Changes in pattern shape and condition are observed in the resin composition-treated area, but they are hardly noticeable. Grade 2: Changes in pattern shape or condition are observed in the resin composition-treated area, and these are of concern. Grade 1: Significant changes in the shape and condition of the resin composition applied to the part of the product.

[0041] [Touch] A sensory evaluation was conducted by 10 panelists, and the results were judged according to the following criteria. A score of 3 or higher is considered a passing grade. (Judgment criteria) Grade 5: The resin composition-treated part has a soft feel. Grade 4: No discomfort when touching the resin composition-applied area. Grade 3: The resin composition is slightly rough and hard, but not to a noticeable degree. Grade 2: The resin composition is coarse and rough, which is somewhat concerning. Grade 1: The resin composition is rough and hard, and has a gritty texture, which is a significant concern.

[0042] [Deodorizing performance] 42.25cm 2 A test specimen of the specified size was collected. The test specimen and 2 liters of nitrogen gas were injected into a sampling bag (Tedlar bag, single opening (Type A), manufactured by Omi Odor Air Service Co., Ltd.) and sealed. Then, the following substance was injected as an odor source, the bag was sealed, and left in a 25°C atmosphere. Three hours after the injection of the odor source, the residual concentration in the sampling bag was measured using a detector tube. <Odor components (initial concentration), detector tube> Ammonia (100 ppm), Kitagawa-type Tube No. 105SC (manufactured by Komei Rikagaku Kogyo Co., Ltd.) Trimethylamine (50 ppm), Kitagawa Tube No. 105SE (manufactured by Komei Rikagaku Kogyo Co., Ltd.) Hydrogen sulfide (50 ppm), Kitagawa-type Tube No. 4LL (manufactured by Komei Rikagaku Kogyo Co., Ltd.) The deodorization rate was calculated by the following formula. The deodorization rate is considered qualified when it is 80% or more for ammonia, 80% or more for trimethylamine, and 80% or more for hydrogen sulfide. Deodorization rate (%) = {(Initial concentration - Residual concentration) / Initial concentration} × 100

[0043] [Durability of deodorization performance] Two circular samples with a diameter of 120 mm were collected. The samples were tested according to JIS L1096 8.19.3C method (Taber method) (abrasion wheel CS - 10, load 2.5 N, number of abrasion cycles 50). From the abrasion measurement part of the samples after the test, samples were collected so that the total area was 42.25 cm 2 in size and used as test pieces after the durability test. The same test as the above deodorization performance was carried out, the residual concentration was measured, and the deodorization rate was calculated. The ratio of the deodorization rate before and after the durability test was calculated by the following formula and judged according to the following criteria. It is considered qualified when it is grade 3 or above. Ratio of deodorization rate before and after durability test = (Deodorization rate after durability test) / (Deodorization rate before durability test) (Judgment criteria) Grade 5: 1 Grade 4: 0.9 or more and less than 1 Grade 3: 0.8 or more and less than 0.9 Grade 2: 0.6 or more and less than 0.8 Grade 1: Less than 0.6

[0044] [Example 1] <Fibrous base material 1> As the fibrous base material 1, a beige non - woven fabric (polyester fiber, mass per unit area 167 g / m 2 , thickness 1.5 mm, elongation rate: warp 80%, weft 120%) was prepared.

[0045] <Formulation 1: Resin solution for resin composition> · Binder resin: 68 parts by mass (Samplex PUE - 800, urethane resin, manufactured by Murayama Chemical Laboratory Co., Ltd., solid content 40% by mass) · Deodorant: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3 - 5 μm, solid content 82% by mass) · Thickener: 1 part by mass (Boncoat VE, acrylic resin, DIC Corporation, solids content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 12.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 1. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0046] <Manufacturing of fabric for vehicle ceiling materials> On the surface of the fibrous substrate described above, the resin liquid for the resin composition prepared according to Formulation 1 described above was applied, with an adhesion amount of 36 g / m² after heat treatment. 2 The pattern was applied using a rotary screen printing machine with a mesh thickness of 150 μm and a pattern area of ​​32%. Next, it was heat-treated in a 120°C heat setter for 2 minutes and dried. Then, a calendering machine was used to perform a smoothing process at a roll temperature of 120°C, a roll pressure of 0.5 MPa, and a fabric speed of 7 m / min to obtain a fabric for vehicle ceiling material. The elongation of the binder resin was 750%, the breaking strength of the binder resin was 20 N, the content of the deodorant in the resin composition was 34.9% by mass, the mixing ratio (solids) of the deodorant to the binder resin in the resin composition was 1:1.8, the area ratio of the resin composition to the surface of the fibrous base material was 32%, and the outermost surface of the resin composition was smooth. The moldability and design properties of the obtained fabric for vehicle ceiling material were grade 5, and the tactile feel was grade 4. Furthermore, the deodorization rates were 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The ratio of deodorization rates before and after the durability test was grade 4 for all odor sources, demonstrating excellent deodorizing performance and durability.

[0047] [Example 2] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 2 below.

[0048] <Formulation 2: Resin liquid for resin composition> • Binder resin: 68 parts by mass (Sunplex PUE-744, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickener: 1 part by mass (Boncoat VE, acrylic resin, DIC Corporation, solids content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 12.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 2. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0049] The binder resin had an elongation of 250%, a breaking strength of 32N, a deodorant content of 34.9% by mass, a solid content ratio of deodorant to binder resin of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth, but molding caused a change in the state of the resin composition-applied area (slight cracking). The resulting fabric for vehicle ceiling material had a moldability and design quality of grade 3, and a tactile feel of grade 3. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The ratio of deodorization rates before and after the durability test was grade 3 for all odor sources, indicating excellent deodorizing performance and durability.

[0050] [Example 3] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 3 below.

[0051] <Formulation 3: Resin liquid for resin composition> • Binder resin: 54.4 parts by mass (Hydran HW920, urethane resin, manufactured by DIC Corporation, solid content 50% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickener: 1 part by mass (Boncoat VE, acrylic resin, DIC Corporation, solids content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 12.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 3. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0052] The binder resin had an elongation of 600%, a breaking strength of 2N, a deodorant content of 34.9% by mass, a solid content ratio of deodorant to binder resin of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth, but molding caused a change in the state of the resin composition-applied area (slight cracking). The resulting fabric for vehicle ceiling material had a moldability and design quality of grade 3, and a tactile feel of grade 4. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The ratio of deodorization rates before and after the durability test was grade 3 for all odor sources, indicating excellent deodorizing performance and durability.

[0053] [Example 4] Except for not performing a smoothing process using a calendering machine, a fabric for vehicle ceiling material was obtained in the same manner as in Example 1.

[0054] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 34.9% by mass, a solid content ratio of deodorant to binder resin in the resin composition of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was not smoothed because it had not undergone any smoothing treatment. The moldability and design of the resulting fabric for vehicle ceilings were grade 3, and the tactile feel was also grade 3. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The ratio of deodorization rates before and after the durability test was grade 3 for all odor sources, indicating excellent deodorizing performance and durability.

[0055] [Example 5] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 4 below.

[0056] <Formulation 4: Resin liquid for resin composition> • Binder resin: 68 parts by mass (Sunplex PUE-800, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickener: 1 part by mass (Boncoat VE, acrylic resin, DIC Corporation, solids content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass Pigment: 3 parts by mass (DEXCEL BLACK HR, black pigment, manufactured by DIC Corporation, solids content 20% by mass) ·Water: 9.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 4. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0057] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 34.4% by mass, a solid content ratio of deodorant to binder resin in the resin composition of 1:1.9, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. The resulting fabric for vehicle ceiling material had a moldability and design quality of grade 5, and a tactile feel of grade 4. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The ratio of deodorization rates before and after the durability test was grade 4 for all odor sources, demonstrating excellent deodorizing performance and durability.

[0058] [Example 6] A fabric for vehicle ceiling material was obtained in the same manner as in Example 4, except that the fibrous base material was changed to fibrous base material 2 described below.

[0059] <Fibrous base material 2> A fibrous base material 1 is smoothed using a calendering machine at a roll temperature of 120°C, a roll pressure of 0.5 MPa, and a fabric speed of 7 m / min. Fibrous base material 2 (beige nonwoven fabric (polyester fiber, mass per unit area 167 g / m²)) is then processed. 2 We prepared a material with a thickness of 1.45 mm and an elongation ratio of 80% vertically and 120% horizontally.

[0060] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 34.9% by mass in the resin composition, a mixing ratio (solids) of deodorant to binder resin of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smoother than that of Example 4 due to the smoothing treatment of the fibrous substrate, but slightly less smooth than that of Example 1. The moldability and design of the obtained fabric for vehicle ceiling material were grade 4, and the tactile feel was grade 3. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The deodorization rate before and after the durability test was grade 4 for all odor sources, indicating excellent deodorizing performance and durability.

[0061] [Example 7] Except for changing the fibrous base material to the fibrous base material 2 described above, a fabric for vehicle ceiling material was obtained in the same manner as in Example 1.

[0062] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 34.9% by mass, a mixing ratio (solids) of deodorant to binder resin of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was extremely smooth because the fibrous substrate was smoothed, and then smoothed again after applying the resin liquid for the resin composition. The resulting fabric for vehicle ceiling material had a moldability and design quality of grade 5, and a tactile feel of grade 5. Furthermore, the deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The deodorization rate before and after the durability test was grade 4 for all odor sources, demonstrating excellent deodorizing performance and durability.

[0063] [Example 8] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 5 below.

[0064] <Formulation 5: Resin liquid for resin composition> • Binder resin: 68 parts by mass (Sunplex PUE-800, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickening agent: 0.4 parts by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 13 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 5. The viscosity was adjusted with a thickener to 4000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0065] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 35.1% by mass, a solid content ratio of deodorant to binder resin of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. Due to the low viscosity of the resin liquid used for the resin composition, some pattern change (pattern bleeding) was observed in the area where the resin composition was applied, resulting in slightly inferior moldability. However, the tactile feel was good because the resin composition was embedded in the fibrous substrate. The moldability and design of the resulting fabric for vehicle ceilings were grade 3, and the tactile feel was grade 5. Furthermore, the deodorization rates were 88% for ammonia, 85% for trimethylamine, and 85% for hydrogen sulfide. The deodorization rates before and after the durability test were grade 4 for all odor sources, demonstrating excellent deodorizing performance and durability.

[0066] [Example 9] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 6 below.

[0067] <Prescription 6> • Binder resin: 68 parts by mass (Sunplex PUE-800, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickener: 0.6 parts by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 12.9 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 6. The viscosity was adjusted with a thickener to 5000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0068] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 35.0% by mass, a solid content ratio of deodorant to binder resin of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. Due to the low viscosity of the resin liquid used for the resin composition, some change in pattern shape (slight bleeding of the pattern) was observed in the area where the resin composition was applied, resulting in slightly inferior moldability. However, the tactile feel was good because the resin composition was slightly embedded in the fibrous substrate. The moldability and design of the obtained fabric for vehicle ceilings were grade 4, and the tactile feel was grade 5. Furthermore, the deodorization rates were 90% for ammonia, 87% for trimethylamine, and 85% for hydrogen sulfide. The deodorization rates before and after the durability test were grade 4 for all odor sources, demonstrating excellent deodorizing performance and durability.

[0069] [Example 10] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 7 below.

[0070] <Prescription 7> • Binder resin: 68 parts by mass (Sunplex PUE-800, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickener: 2 parts by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 11.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 7. The viscosity was adjusted with a thickener to 20,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0071] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 34.7% by mass in the resin composition, a mixing ratio (solids) of deodorant to binder resin of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. Due to the high viscosity of the resin liquid used for the resin composition, penetration into the fibrous substrate was poor, resulting in a slightly rough and hard texture, although the edges of the pattern were good. The moldability and design properties of the obtained fabric for vehicle ceiling material were grade 4, and the texture was also grade 4. Furthermore, the deodorization rates were 97% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The deodorization rates before and after the durability test were grade 4 for ammonia and grade 3 for trimethylamine and hydrogen sulfide, indicating excellent deodorizing performance and durability.

[0072] [Example 11] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 8 below.

[0073] <Prescription 8> • Binder resin: 68 parts by mass (Sunplex PUE-800, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickening agent: 2.5 parts by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 11.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 8. The viscosity was adjusted with a thickener to 28,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0074] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 34.6% by mass, a solid content ratio of deodorant to binder resin of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. Due to the high viscosity of the resin liquid used for the resin composition, penetration into the fibrous substrate was poor, resulting in a rough and hard texture, although the edges of the pattern were good. The moldability and design of the resulting fabric for vehicle ceilings were grade 3, and the texture was also grade 3. Furthermore, the deodorization rate was 97% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The deodorization rate before and after the durability test was grade 3 for all deodorizing sources, demonstrating excellent deodorizing performance and durability.

[0075] [Example 12] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 9 below.

[0076] <Prescription 9> • Binder resin: 23 parts by mass (Sunplex PUE-800, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickening agent: 3.5 parts by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 56.0 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 9. The viscosity was adjusted with a thickener to 28,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0077] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 59.0% by mass, a solid content ratio of deodorant to binder resin of 1:0.6, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth, but the smoothness was somewhat inferior due to the low ratio of binder resin to deodorant. The moldability and design of the resulting fabric for vehicle ceilings were grade 3, and the tactile feel was also grade 3. The deodorization rates were 95% for ammonia, 93% for trimethylamine, and 93% for hydrogen sulfide. The deodorization rates before and after the durability test were grade 3 for all deodorizing sources, indicating excellent deodorizing performance and durability.

[0078] [Example 13] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to the following formulation 10.

[0079] <Prescription 10> • Binder resin: 30 parts by mass (Sunplex PUE-800, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickening agent: 2.2 parts by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 49.3 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 10. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0080] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 53.8% by mass in the resin composition, a mixing ratio (solids) of deodorant to binder resin of 1:0.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. The moldability and design of the obtained fabric for vehicle ceiling material were grade 4, and the tactile feel was grade 3. The deodorization rate was 95% for ammonia, 93% for trimethylamine, and 93% for hydrogen sulfide. The deodorization rates before and after the durability test were grade 4 for ammonia, and grade 3 for trimethylamine and hydrogen sulfide, indicating excellent deodorizing performance and durability.

[0081] [Example 14] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 11 below.

[0082] <Prescription 11> • Binder resin: 68 parts by mass (Sunplex PUE-800, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 14 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickener: 1 part by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 16.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 11. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0083] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 29.5% by mass, a mixing ratio (solids) of deodorant to binder resin of 1:2.4, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. The resulting fabric for vehicle ceiling material had a moldability and design quality of grade 5, and a tactile feel of grade 4. The deodorization rate was 90% for ammonia, 88% for trimethylamine, and 88% for hydrogen sulfide. The deodorization rate before and after the durability test was grade 4 for all deodorizing sources, demonstrating excellent deodorizing performance and durability.

[0084] [Example 15] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 12 below.

[0085] <Prescription 12> • Binder resin: 68 parts by mass (Sunplex PUE-800, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 11 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickener: 1 part by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 16.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 12. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0086] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 24.7% by mass in the resin composition, a mixing ratio (solids) of deodorant to binder resin of 1:3.0, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. The moldability and design of the obtained fabric for vehicle ceiling material were grade 5, and the tactile feel was grade 4. The deodorization rate was 85% for ammonia, 80% for trimethylamine, and 80% for hydrogen sulfide. The deodorization ratio before and after the durability test was grade 4 for all deodorizing sources, indicating excellent deodorizing performance and durability. However, because the ratio of binder resin to deodorant was high, the deodorant settled in the binder resin, resulting in slightly inferior deodorizing performance before the durability test compared to Example 1.

[0087] [Example 16] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 13 below.

[0088] <Prescription 13> Binder resin: 10 parts by mass (Sunplex PUE-800, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) Binder resin: 58 parts by mass (Sunplex PUE-744, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickener: 1 part by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 12.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 13. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0089] The binder resin had an elongation of 300%, a breaking strength of 27N, a deodorant content of 34.9% by mass, a mixing ratio (solids) of deodorant to binder resin of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. The resulting fabric for vehicle ceiling material had a moldability and design quality of grade 4, and a tactile feel of grade 3. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The deodorization rate before and after the durability test was grade 3 for all deodorizing sources, demonstrating excellent deodorizing performance and durability.

[0090] [Example 17] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 14 below.

[0091] <Prescription 14> • Binder resin: 34 parts by mass (Sunplex PUE-800, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Binder resin: 34 parts by mass (Sunplex PUE-744, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickener: 1 part by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 12.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 14. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0092] The binder resin had an elongation of 500%, a breaking strength of 25N, a deodorant content of 34.9% by mass in the resin composition, a mixing ratio (solids) of deodorant to binder resin of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. The resulting fabric for vehicle ceiling material had a moldability and design quality of grade 4, and a tactile feel of grade 4. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The deodorization rates before and after the durability test were grade 4 for ammonia, and grade 3 for trimethylamine and hydrogen sulfide, indicating excellent deodorizing performance and durability.

[0093] [Example 18] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 15 below.

[0094] <Prescription 15> Binder resin: 10 parts by mass (Sunplex PUE-800, urethane resin, manufactured by Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) Binder resin: 46.4 parts by mass (Hydran HW-920, urethane resin, manufactured by DIC Corporation, solid content 50% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickener: 1 part by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 24.1 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 15. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0095] The binder resin had an elongation of 650%, a breaking strength of 4N, a deodorant content of 34.9% by mass in the resin composition, a mixing ratio (solids) of deodorant to binder resin of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. The moldability and design of the obtained fabric for vehicle ceiling material were grade 4, and the tactile feel was also grade 4. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The deodorization rates before and after the durability test were grade 4 for ammonia, and grade 3 for trimethylamine and hydrogen sulfide, indicating excellent deodorizing performance and durability.

[0096] [Example 19] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 16 below.

[0097] <Prescription 16> • Binder resin: 68 parts by mass (Hydran HW-333, urethane resin, DIC Corporation, solid content 40% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickener: 1 part by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 12.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 16. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0098] The binder resin had an elongation of 450%, a breaking strength of 80N, a deodorant content of 34.9% by mass in the resin composition, a mixing ratio (solids) of deodorant to binder resin of 1:1.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. The moldability and design of the resulting fabric for vehicle ceilings were grade 4, and the tactile feel was grade 3. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The deodorization rate before and after the durability test was grade 4 for all deodorizing sources, demonstrating excellent deodorizing performance and durability.

[0099] [Example 20] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 17 below.

[0100] <Prescription 17> • Binder resin: 50 parts by mass (Newplex W, urethane resin, manufactured by Hayashi Chemical Industry Co., Ltd., solid content 55% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickener: 1 part by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 30.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 17. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0101] The binder resin had an elongation of 700%, a breaking strength of 85N, a deodorant content of 34.7% by mass in the resin composition, a mixing ratio (solids) of deodorant to binder resin of 1:1.9, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. The moldability and design of the resulting fabric for vehicle ceilings were grade 5, and the tactile feel was grade 3. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The deodorization rate before and after the durability test was grade 4 for all deodorizing sources, demonstrating excellent deodorizing performance and durability.

[0102] [Example 21] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 18 below.

[0103] <Prescription 18> • Binder resin: 64 parts by mass (Sunplex PUE-800, urethane resin, Murayama Chemical Research Institute Co., Ltd., solids content 40% by mass) • Deodorizer: 14 parts by mass (Zinc and silver mixture supported on zeolite, particle size (D50) 2-3 μm, solid content 100% by mass) • Thickener: 1 part by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 30.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 18. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0104] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 33.7% by mass, a mixing ratio (solids) of deodorant to binder resin of 1:1.9, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. The moldability and design of the resulting fabric for vehicle ceilings were grade 5, and the tactile feel was grade 4. The deodorization rate was 90% for ammonia, 90% for trimethylamine, and 90% for hydrogen sulfide. The deodorization rate before and after the durability test was grade 4 for all deodorizing sources, demonstrating excellent deodorizing performance and durability.

[0105] [Example 22] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to Formulation 19 below.

[0106] <Prescription 19> • Binder resin: 68 parts by mass (RYUDYE-W BINDER DN-2014LH, acrylic resin, manufactured by DIC Corporation, solids content 35% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickening agent: 1.0 part by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 12.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 19. The viscosity was adjusted with a thickener to 15,000 Pa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0107] The binder resin had an elongation of 330%, a breaking strength of 4N, a deodorant content of 38.0% by mass in the resin composition, a mixing ratio (solids) of deodorant to binder resin of 1:1.6, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. The moldability and design of the resulting fabric for vehicle ceilings were grade 3, and the tactile feel was grade 4. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The deodorization rate before and after the durability test was grade 3 for all deodorizing sources, demonstrating excellent deodorizing performance and durability.

[0108] [Example 23] A fabric for vehicle ceiling material was obtained in the same manner as in Example 1, except that the resin liquid for the resin composition was changed to the following formulation 20.

[0109] <Prescription 20> • Binder resin: 68 parts by mass (Newcoat FH-4502, acrylic resin, Shin Nakamura Chemical Co., Ltd., solids content 50% by mass) • Deodorizer: 18 parts by mass (Composite of zinc oxide and silicon dioxide, particle size (D50) 3-5 μm, solid content 82% by mass) • Thickening agent: 1.0 part by mass (Boncoat VE, acrylic resin, manufactured by DIC Corporation, solid content 30% by mass) • 25% aqueous ammonia: 0.5 parts by mass ·Water: 12.5 parts by mass Preparation method: Each ingredient was mixed in a mixer according to Formula 20. The viscosity was adjusted with a thickener to 15,000 mPa·s (BM type viscometer, rotor: No. 4, 12 rpm, 25℃, manufactured by Toki Sangyo Co., Ltd.).

[0110] The binder resin had an elongation of 650%, a breaking strength of 10N, a deodorant content of 30.1% by mass, a mixing ratio (solids) of deodorant to binder resin of 1:2.3, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was smooth. The moldability and design of the resulting fabric for vehicle ceilings were grade 4, and the tactile feel was also grade 4. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The deodorization rate before and after the durability test was grade 4 for all deodorizing sources, demonstrating excellent deodorizing performance and durability.

[0111] [Comparative Example 1] Except for changing the resin liquid for the resin composition to Formulation 10, a fabric for vehicle ceiling material was obtained in the same manner as in Example 4.

[0112] The binder resin had an elongation of 750%, a breaking strength of 20N, a deodorant content of 53.8% by mass, a solid content ratio of deodorant to binder resin of 1:0.8, and an area ratio of the resin composition to the surface of the fibrous substrate of 32%. The outermost surface of the resin composition was not smooth because it had not undergone any smoothing treatment. The moldability and design of the resulting fabric for vehicle ceilings were grade 3, and the tactile feel was also grade 3. The deodorization rate was 95% for ammonia, 95% for trimethylamine, and 95% for hydrogen sulfide. The deodorization rate before and after the durability test was grade 2 for all odor sources, indicating excellent deodorizing performance but lacking durability in deodorizing performance.

[0113] [Table 1]

[0114] [Table 2]

[0115] [Table 3]

[0116] Table 4

[0117] Table 5

Claims

1. A fabric for vehicle ceiling material, wherein a resin composition containing a deodorant and a binder resin is applied to at least a portion of the visible surface of the fibrous base material during use, The binder resin has an elongation of 750 to 1000%, and the binder resin has a break elongation of 20 to 80 N. The mixing ratio (solid content) of the deodorant and the binder resin is 1:0.85 to 1:2.

0. The outermost surface of the resin composition is smooth, A fabric for vehicle ceilings, wherein the durability of the deodorizing performance of the fabric for vehicle ceilings is grade 3 or higher.

2. The fabric for vehicle ceiling material according to claim 1, wherein the resin composition contains a coloring agent.

3. A method for manufacturing a fabric for vehicle ceiling material, wherein a resin composition containing a deodorant and a binder resin is applied to at least a portion of the visible surface of the fibrous base material during use, A step of preparing a resin liquid for a resin composition by mixing a fibrous base material, a deodorant, and a binder resin having an elongation of 750 to 1000% and a breaking elongation of 20 to 80 N, such that the mixing ratio (solid content) of the deodorant and the binder resin is 1:0.85 to 1:2.

0. The process of applying a resin liquid for a resin composition to at least a portion of the surface of the fibrous base material that is visible during use, and A heat treatment step for drying the resin liquid for the resin composition, A smoothing step by heat pressing applied to the fibrous substrate, and / or a further smoothing step by heat pressing applied after the heat treatment step, A method for manufacturing fabric for vehicle ceiling materials.

4. The method for manufacturing a fabric for vehicle ceiling material according to claim 3, wherein the viscosity of the resin liquid for the resin composition is 5,000 to 20,000 mPa·s.

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