SEALING MATERIAL FOR HONEYCOMB STRUCTURE, HONEYCOMB STRUCTURE, AND METHOD FOR MANUFACTURING HONEYCOMB STRUCTURE

• US 20100247851A1
• Filed: 02/22/2010
• Published: 09/30/2010
• Est. Priority Date: 03/30/2009
• Status: Abandoned Application

• Current Assignee: Ibiden Co., Ltd.
• Original Assignee: Ibiden Co., Ltd.
• Inventors: MIYATA, Akikazu, KANAI, Masanori
• Application Number:
  US12/709,519
• Publication Number:
  US 20100247851A1
• Time in Patent Office: Days
• US Class Current: 428/116
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: C04B 14/022 Carbon
• CPC Class Codes: C04B 14/047 Zeolites
• CPC Class Codes: C04B 14/062 Microsilica, e.g. colloïdal silica preparing microsilica slurries or suspensions C04B18/148
• CPC Class Codes: C04B 14/064 Silica aerogel
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/20 Mica; Vermiculite mechanical splitting B28D
• CPC Class Codes: C04B 14/24 porous, e.g. foamed glass
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/324 Silicon carbide
• CPC Class Codes: C04B 14/327 Boron nitride
• CPC Class Codes: C04B 14/328 Silicon nitride
• CPC Class Codes: C04B 14/366 Phosphates, e.g. apatite
• CPC Class Codes: C04B 14/383 Whiskers
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 14/465 Ca-silicate, e.g. wollastonite
• CPC Class Codes: C04B 2103/46 Water-loss or fluid-loss reducers, hygroscopic or hydrophilic agents, water retention agents
• CPC Class Codes: C04B 2111/00793 as filters or diaphragms
• CPC Class Codes: C04B 2111/0081 as catalysts or catalyst carriers
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 2237/083 : Carbide interlayers, e.g. silicon carbide interlayers
• CPC Class Codes: C04B 2237/36 : Non-oxidic
• CPC Class Codes: C04B 2237/361 : Boron nitride
• CPC Class Codes: C04B 2237/365 : Silicon carbide
• CPC Class Codes: C04B 2237/366 : Aluminium nitride
• CPC Class Codes: C04B 2237/368 : Silicon nitride
• CPC Class Codes: C04B 2237/38 : Fiber or whisker reinforced
• CPC Class Codes: C04B 2237/62 : Forming laminates or joined articles comprising holes, channels or other types of openings
• CPC Class Codes: C04B 2237/708 : of one or more of the interlayers
• CPC Class Codes: C04B 24/383 : Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/001 : containing unburned clay polymer binder - clay mixtures used in well cementing C09K8/44
• CPC Class Codes: C04B 28/24 : containing alkyl, ammonium or metal silicates; containing silica sols reaction mixtures resulting in mineral polymers C04B28/006; polymeric reaction products of alkali metal silicates with isocyanates C08G18/3895
• CPC Class Codes: C04B 35/00 : Shaped ceramic products characterised by their composition porous ceramic products C04B38/00; ceramic articles characterised by particular shape, see the relevant classes, e.g. linings for casting ladles, tundishes, cups or the like B22D41/02; ceramic substrates for microelectronic semi-conductors H01L23/15; Ceramics compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides other than as macroscopic reinforcing agents C22C; shaping of ceramics B28B; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products chemical preparation of powders of inorganic compounds C01; infiltration of sintered ceramic preforms with molten metal C04B41/51
• CPC Class Codes: C04B 35/565 : based on silicon carbide
• CPC Class Codes: C04B 37/005 : consisting of glass or ceramic material
• CPC Class Codes: C04B 37/006 : consisting of metals or metal salts
• CPC Class Codes: C04B 38/0006 : Honeycomb structures from one or more corrugated sheets by winding or stacking C04B38/0083
• CPC Class Codes: C04B 38/0012 : characterised by the material used for sealing or plugging (some of) the channels of the honeycombs
• CPC Class Codes: C04B 38/0019 : characterised by the material used for joining separate subunits
• CPC Class Codes: C04B 38/0051 : characterised by the pore size, pore shape or kind of porosity
• CPC Class Codes: C04B 38/0074 : expressed as porosity percentage
• CPC Class Codes: C04B 38/04 : by dissolving-out added substances
• CPC Class Codes: C04B 41/009 : characterised by the material treated
• CPC Class Codes: C04B 41/5024 : Silicates C04B41/5022 takes precedence; silico-fluorides C04B41/5018
• CPC Class Codes: C04B 41/5037 : Clay, Kaolin
• CPC Class Codes: C04B 41/5048 : Phosphates
• CPC Class Codes: C04B 41/5059 : Silicon carbide
• CPC Class Codes: C04B 41/5089 : Silica sols, alkyl, ammonium or alkali metal silicate cements
• CPC Class Codes: C04B 41/85 : with inorganic materials
• CPC Class Codes: F01N 2330/48 : characterised by the number of flow passages, e.g. cell density
• CPC Class Codes: F01N 2370/04 : Zeolitic material
• CPC Class Codes: F01N 2370/24 : Zeolitic material
• CPC Class Codes: F01N 2450/28 : by using adhesive material, e.g. cement
• CPC Class Codes: F01N 3/0222 : the structure being monolithic, e.g. honeycombs
• CPC Class Codes: F01N 3/2828 : Ceramic multi-channel monoliths, e.g. honeycombs
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like

Abstract

A sealing material for a honeycomb structure includes inorganic fibers, inorganic particles, and an ion adsorbent. The inorganic fibers include a biosoluble inorganic compound. The ion adsorbent is in an amount of about 0.1% by weight or more.

Claims

1. A sealing material for a honeycomb structure, comprising:

inorganic fibers comprising a biosoluble inorganic compound;

inorganic particles; and

an ion adsorbent in an amount of about 0.1%by weight or more.

2. The sealing material according to claim 1,

wherein

the inorganic compound comprises at least one of alkali metal compounds and alkaline earth metal compounds.

3. The sealing material according to claim 1,

wherein

the ion adsorbent comprises at least one of silica adsorbents, alumina adsorbents, zeolite adsorbents, clay adsorbents, mesoporous adsorbents, polyvalent metal salts, and activated carbon.

4. The sealing material according to claim 3,

wherein

the ion adsorbent comprises a clay adsorbent.

5. The sealing material according to claim 4,

wherein

the clay adsorbent comprises at least one of bentonite, activated white clay, and montmorillonite.

6. The sealing material according to claim 4,

wherein

the clay adsorbent comprises at least one of kaolinite, acid clay, halloysite, sericite, and mica clay minerals.

7. The sealing material according to claim 3,

wherein

the ion adsorbent comprises at least one of a zeolite adsorbent and activated carbon.

8. The sealing material according to claim 7,

wherein

the zeolite adsorbent comprises at least one of alminosilicate zeolite, metallosilicate zeolite, and aluminophosphate zeolite.

9. The sealing material according to claim 3,

wherein

the ion adsorbent comprises a polyvalent metal salt.

10. The sealing material according to claim 9,

wherein

the polyvalent metal salt comprises at least one of aluminum phosphate, iron phosphate, magnesium phosphate, and aluminum fluoride.

11. The sealing material according to claim 3,

wherein

the ion adsorbent comprises a silica adsorbent, and

the silica adsorbent comprises at least one of silica gel, aero gel, colloidal silica, and porous silicate glass.

12. The sealing material according to claim 3,

wherein

the ion adsorbent comprises an almina adsorbent, and

the almina adsorbent comprises an activated alumina.

13. The sealing material according to claim 12,

wherein

the activated alumina comprises at least one of α

-alumina, γ

-alumina, δ

-alumina, and θ

-alumina.

14. The sealing material according to claim 3,

wherein

the ion adsorbent comprises a mesoporous adsorbent, and

the mesoporous adsorbent comprises at least one of mesoporous silica, mesoporous silica-alumina, mesoporous titania, and mesoporous zirconia.

15. The sealing material according to claim 1,

wherein

the amount of the ion adsorbent in the sealing material for the honeycomb structure is about 0.2% by weight or more.

16. The sealing material according to claim 1,

wherein

the amount of the ion adsorbent in the sealing material for the honeycomb structure is about 5.0% by weight or less.

17. The sealing material according to claim 1,

wherein

the ion adsorbent comprises at least one of a bentonite and a zeolite adsorbent, and

a content of the ion adsorbent in the sealing material for the honeycomb structure is from about 0.2% by weight to about 2.0% by weight.

18. The sealing material according to claim 1,

wherein

the ion adsorbent comprises an aluminum phosphate, and

a content of the ion adsorbent in the sealing material for the honeycomb structure is from about 0.1%by weight to about 2.0% by weight.

19. The sealing material according to claim 1,

wherein

a weight ratio of the ion adsorbent to the inorganic fibers (weight of inorganic fibers/weight of ion adsorbent) in the sealing material for the honeycomb structure is from about 100/1 to about 4/1.

20. The sealing material according to claim 1,

wherein

an average fiber length of the inorganic fibers is from about 0.1 μ

m to about 1000 μ

m.

21. The sealing material according to claim 1,

wherein

an amount of silica contained in the inorganic fibers is from about 60% by weight to about 85% by weight.

22. The sealing material according to claim 1,

wherein

an amount of Al₂O₃ contained in the inorganic fibers is about 2% by weight or less.

23. The sealing material according to claim 1,

wherein

an amount of the inorganic fibers contained in the sealing material for the honeycomb structure is from about 10% by weight to about 70% by weight.

24. The sealing material according to claim 1,

wherein

an average particle diameter of the inorganic particles is from about 0.01 μ

m to about 100 μ

m.

25. The sealing material according to claim 2,

wherein

the alkali metal compounds comprise at least one of sodium oxides, sodium salts, potassium oxides, and potassium salts, and

the alkaline earth metal compounds comprise at least one of magnesium oxides, magnesium salts, calcium oxides, calcium salts, barium oxides, and barium salts.

26. The sealing material according to claim 1, further comprising an oxide sol.

27. The sealing material according to claim 26,

wherein

the oxide sol comprises at least one of silica sol, alumina sol, and zirconia sol.

28. The sealing material according to claim 26,

wherein

an amount of the oxide sol contained in the sealing material for the honeycomb structure is from about 1% by weight to about 30% by weight as a solid content.

29. The sealing material according to claim 26,

wherein

an average particle diameter of the oxide included in the oxide sol is from about 5 nm to about 30 nm.

30. The sealing material according to claim 26,

wherein

the sealing material for the honeycomb structure is alkaline.

31. The sealing material according to claim 1,

wherein

the sealing material for the honeycomb structure is acidic.

32. The sealing material according to claim 1,

wherein

a pH value of the sealing material for the honeycomb structure is from about 4 to about 7.

33. A honeycomb structure comprising:

a ceramic block comprising a honeycomb fired body in which a plurality of through holes are longitudinally formed with a partition wall interposed therebetween; and

a peripheral sealing material layer formed on a peripheral surface of the ceramic block,

wherein

the peripheral sealing material layer is formed by solidifying a sealing material for the honeycomb structure, the sealing material for the honeycomb structure comprising;

inorganic fibers comprising a biosoluble inorganic compound;

inorganic particles; and

an ion adsorbent in an amount of about 0.1% by weight or more.

34. The honeycomb structure according to claim 33,

wherein

the inorganic compound in the sealing material for the honeycomb structure comprises at least one of alkali metal compounds and alkaline earth metal compounds.

35. The honeycomb structure according to claim 33,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises at least one of silica adsorbents, alumina adsorbents, zeolite adsorbents, clay adsorbents, mesoporous adsorbents, polyvalent metal salts, and activated carbon.

36. The honeycomb structure according to claim 35,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises a clay adsorbent.

37. The honeycomb structure according to claim 36,

wherein

the clay adsorbent comprises at least one of bentonite, activated white clay, and montmorillonite.

38. The honeycomb structure according to claim 36,

wherein

the clay adsorbent comprises at least one of kaolinite, acid clay, halloysite, sericite, and mica clay minerals.

39. The honeycomb structure according to claim 35,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises at least one of a zeolite adsorbent and activated carbon.

40. The honeycomb structure according to claim 39,

wherein

the zeolite adsorbent comprises at least one of alminosilicate zeolite, metallosilicate zeolite, and aluminophosphate zeolite.

41. The honeycomb structure according to claim 35,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises a polyvalent metal salt.

42. The honeycomb structure according to claim 41,

wherein

the polyvalent metal salt comprises at least one of aluminum phosphate, iron phosphate, magnesium phosphate, and aluminum fluoride.

43. The honeycomb structure according to claim 35,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises a silica adsorbent, and

the silica adsorbent comprises at least one of silica gel, aero gel, colloidal silica, and porous silicate glass.

44. The honeycomb structure according to claim 35,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises an almina adsorbent, and

the almina adsorbent comprises an activated alumina.

45. The honeycomb structure according to claim 44,

wherein

the activated alumina comprises at least one of α

-alumina, γ

-alumina, δ

-alumina, and θ

-alumina.

46. The honeycomb structure according to claim 35,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises a mesoporous adsorbent, and

the mesoporous adsorbent comprises at least one of mesoporous silica, mesoporous silica-alumina, mesoporous titania, and mesoporous zirconia.

47. The honeycomb structure according to claim 33,

wherein

the amount of the ion adsorbent in the sealing material for the honeycomb structure is about 0.2% by weight or more.

48. The honeycomb structure according to claim 33,

wherein

the amount of the ion adsorbent in the sealing material for the honeycomb structure is about 5.0% by weight or less.

49. The honeycomb structure according to claim 33,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises at least one of a bentonite and a zeolite adsorbent, and

a content of the ion adsorbent in the sealing material for the honeycomb structure is from about 0.2% by weight to about 2.0% by weight.

50. The honeycomb structure according to claim 33,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises an aluminum phosphate, and

a content of the ion adsorbent in the sealing material for the honeycomb structure is from about 0.1%by weight to about 2.0% by weight.

51. The honeycomb structure according to claim 33,

wherein

a weight ratio of the ion adsorbent to the inorganic fibers (weight of inorganic fibers/weight of ion adsorbent) in the sealing material for the honeycomb structure is from about 100/1 to about 4/1.

52. The honeycomb structure according to claim 33,

wherein

an average fiber length of the inorganic fibers in the sealing material for the honeycomb structure is from about 0.1 μ

m to about 1000 μ

m.

53. The honeycomb structure according to claim 33,

wherein

an amount of silica contained in the inorganic fibers in the sealing material for the honeycomb structure is from about 60% by weight to about 85% by weight.

54. The honeycomb structure according to claim 33,

wherein

an amount of Al₂O₃ contained in the inorganic fibers in the sealing material for the honeycomb structure is about 2% by weight or less.

55. The honeycomb structure according to claim 33,

wherein

an amount of the inorganic fibers contained in the sealing material for the honeycomb structure is from about 10% by weight to about 70% by weight.

56. The honeycomb structure according to claim 33,

wherein

an average particle diameter of the inorganic particles in the sealing material for the honeycomb structure is from about 0.01 μ

m to about 100 μ

m.

57. The honeycomb structure according to claim 34,

wherein

the alkali metal compounds in the sealing material for the honeycomb structure comprise at least one of sodium oxides, sodium salts, potassium oxides, and potassium salts, and

the alkaline earth metal compounds in the sealing material for the honeycomb structure comprise at least one of magnesium oxides, magnesium salts, calcium oxides, calcium salts, barium oxides, and barium salts.

58. The honeycomb structure according to claim 33,

wherein

the sealing material for the honeycomb structure further comprises an oxide sol.

59. The honeycomb structure according to claim 58,

wherein

the oxide sol comprises at least one of silica sol, alumina sol, and zirconia sol.

60. The honeycomb structure according to claim 58,

wherein

an amount of the oxide sol contained in the sealing material for the honeycomb structure is from about 1% by weight to about 30% by weight as a solid content.

61. The honeycomb structure according to claim 58,

wherein

an average particle diameter of the oxide included in the oxide sol is from about 5 nm to about 30 nm.

62. The honeycomb structure according to claim 58,

wherein

the sealing material for the honeycomb structure is alkaline.

63. The honeycomb structure according to claim 33,

wherein

the sealing material for the honeycomb structure is acidic.

64. The honeycomb structure according to claim 33,

wherein

a pH value of the sealing material for the honeycomb structure is from about 4 to about 7.

65. The honeycomb structure according to claim 33,

wherein the ceramic block comprises

a plurality of the honeycomb fired bodies, and

an adhesive layer formed between side surfaces of the plurality of the honeycomb fired bodies.

66. The honeycomb structure according to claim 65,

wherein

the adhesive layer is formed by solidifying an adhesive.

67. The honeycomb structure according to claim 66,

wherein

the adhesive comprises a sealing material for the honeycomb structure, the sealing material for the honeycomb structure comprising:

inorganic fibers comprising a biosoluble inorganic compound;

inorganic particles; and

an ion adsorbent in an amount of about 0.1% by weight or more.

68. The honeycomb structure according to claim 67,

wherein

the inorganic compound in the adhesive comprises at least one of alkali metal compounds and alkaline earth metal compounds.

69. The honeycomb structure according to claim 67,

wherein

the ion adsorbent in the adhesive comprises at least one of silica adsorbents, alumina adsorbents, zeolite adsorbents, clay adsorbents, mesoporous adsorbents, polyvalent metal salts, and activated carbon.

70. The honeycomb structure according to claim 69,

wherein

the ion adsorbent in the adhesive comprises a clay adsorbent.

71. The honeycomb structure according to claim 70,

wherein

the clay adsorbent comprises at least one of bentonite, activated white clay, and montmorillonite.

72. The honeycomb structure according to claim 70,

wherein

the clay adsorbent comprises at least one of kaolinite, acid clay, halloysite, sericite, and mica clay minerals.

73. The honeycomb structure according to claim 69,

wherein

the ion adsorbent in the adhesive comprises at least one of a zeolite adsorbent and activated carbon.

74. The honeycomb structure according to claim 73,

wherein

the zeolite adsorbent comprises at least one of alminosilicate zeolite, metallosilicate zeolite, and aluminophosphate zeolite.

75. The honeycomb structure according to claim 69,

wherein

the ion adsorbent in the adhesive comprises a polyvalent metal salt.

76. The honeycomb structure according to claim 75,

wherein

the polyvalent metal salt comprises at least one of aluminum phosphate, iron phosphate, magnesium phosphate, and aluminum fluoride.

77. The honeycomb structure according to claim 69,

wherein

the ion adsorbent in the adhesive comprises a silica adsorbent, and

the silica adsorbent comprises at least one of silica gel, aero gel, colloidal silica, and porous silicate glass.

78. The honeycomb structure according to claim 69,

wherein

the ion adsorbent in the adhesive comprises an almina adsorbent, and

the almina adsorbent comprises an activated alumina.

79. The honeycomb structure according to claim 78,

wherein

the activated alumina comprises at least one of α

-alumina, γ

-alumina, δ

-alumina, and θ

-alumina.

80. The honeycomb structure according to claim 69,

wherein

the ion adsorbent in the adhesive comprises a mesoporous adsorbent, and

the mesoporous adsorbent comprises at least one of mesoporous silica, mesoporous silica-alumina, mesoporous titania, and mesoporous zirconia.

81. The honeycomb structure according to claim 67,

wherein

the amount of the ion adsorbent in the adhesive is about 0.2% by weight or more.

82. The honeycomb structure according to claim 67,

wherein

the amount of the ion adsorbent in the adhesive is about 5.0% by weight or less.

83. The honeycomb structure according to claim 67,

wherein

the ion adsorbent in the adhesive comprises at least one of a bentonite and a zeolite adsorbent, and

a content of the ion adsorbent in the adhesive is from about 0.2% by weight to about 2.0% by weight.

84. The honeycomb structure according to claim 67,

wherein

the ion adsorbent in the adhesive comprises an aluminum phosphate, and

a content of the ion adsorbent in the adhesive is from about 0.1% by weight to about 2.0% by weight.

85. The honeycomb structure according to claim 67,

wherein

a weight ratio of the ion adsorbent to the inorganic fibers (weight of inorganic fibers/weight of ion adsorbent) in the adhesive is from about 100/1 to about 4/1.

86. The honeycomb structure according to claim 67,

wherein

an average fiber length of the inorganic fibers in the adhesive is from about 0.1 μ

m to about 1000 μ

m.

87. The honeycomb structure according to claim 67,

wherein

an amount of silica contained in the inorganic fibers in the adhesive is from about 60% by weight to about 85% by weight.

88. The honeycomb structure according to claim 67,

wherein

an amount of Al₂O₃ contained in the inorganic fibers in the adhesive is about 2% by weight or less.

89. The honeycomb structure according to claim 67,

wherein

an amount of the inorganic fibers contained in the adhesive is from about 10% by weight to about 70% by weight.

90. The honeycomb structure according to claim 67,

wherein

an average particle diameter of the inorganic particles in the adhesive is from about 0.01 μ

m to about 100 μ

m.

91. The honeycomb structure according to claim 68,

wherein

the alkali metal compounds in the adhesive comprise at least one of sodium oxides, sodium salts, potassium oxides, and potassium salts, and

the alkaline earth metal compounds in the adhesive comprise at least one of magnesium oxides, magnesium salts, calcium oxides, calcium salts, barium oxides, and barium salts.

92. The honeycomb structure according to claim 67,

wherein

the adhesive further comprises an oxide sol. 25

93. The honeycomb structure according to claim 92,

wherein

the oxide sol comprises at least one of silica sol, alumina sol, and zirconia sol.

94. The honeycomb structure according to claim 92,

wherein

an amount of the oxide sol contained in the adhesive is from about 1% by weight to about 30% by weight as a solid content .

95. The honeycomb structure according to claim 92,

wherein

an average particle diameter of the oxide included in the oxide sol is from about 5 nm to about 30 nm.

96. The honeycomb structure according to claim 92,

wherein

the adhesive is alkaline.

97. The honeycomb structure according to claim 67,

wherein

the adhesive is acidic.

98. The honeycomb structure according to claim 67,

wherein

a pH value of the adhesive is from about 4 to about 7.

99. The honeycomb structure according to claim 33,

wherein

the ceramic block comprises a single honeycomb fired body.

100. The honeycomb structure according to claim 33, further comprising a catalyst.

101. The honeycomb structure according to claim 33,

wherein

either one end portion of each of the through holes is plugged.

102. The honeycomb structure according to claim 33,

wherein

an end portion of each of the through holes is not plugged.

103. A method for manufacturing a honeycomb structure, comprising:

molding ceramic materials to construct a honeycomb molded body in which a plurality of through holes are longitudinally formed with a partition wall interposed therebetween;

constructing a ceramic block comprising a honeycomb fired body obtained after heat treatment of the honeycomb molded body; and

solidifying a peripheral sealing material paste layer formed on a peripheral surface of the ceramic block to form a peripheral sealing material layer,

said method further comprising

preparing a sealing material for the honeycomb structure by mixing at least inorganic fibers comprising a biosoluble inorganic compound, inorganic particles, and an ion adsorbent in an amount of about 0.1% by weight or more,

the peripheral sealing material paste layer being formed of the sealing material for the honeycomb structure.

104. The method according to claim 103, further comprising

bonding a plurality of the honeycomb fired bodies with an adhesive layer interposed therebetween to construct the ceramic block.

105. The method according to claim 103,

wherein

the inorganic compound in the sealing material for the honeycomb structure comprises at least one of alkali metal compounds and alkaline earth metal compounds.

106. The method according to claim 103,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises at least one of silica adsorbents, alumina adsorbents, zeolite adsorbents, clay adsorbents, mesoporous adsorbents, polyvalent metal salts, and activated carbon.

107. The method according to claim 106,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises a clay adsorbent.

108. The method according to claim 107,

wherein

the clay adsorbent comprises at least one of bentonite, activated white clay, and montmorillonite.

109. The method according to claim 107,

wherein

the clay adsorbent comprises at least one of kaolinite, acid clay, halloysite, sericite, and mica clay minerals.

110. The method according to claim 106,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises at least one of a zeolite adsorbent and activated carbon.

111. The method according to claim 110,

wherein

the zeolite adsorbent comprises at least one of alminosilicate zeolite, metallosilicate zeolite, and aluminophosphate zeolite.

112. The method according to claim 106,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises a polyvalent metal salt.

113. The method according to claim 112,

wherein

the polyvalent metal salt comprises at least one of aluminum phosphate, iron phosphate, magnesium phosphate, and aluminum fluoride.

114. The method according to claim 106,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises a silica adsorbent, and

the silica adsorbent comprises at least one of silica gel, aero gel, colloidal silica, and porous silicate glass.

115. The method according to claim 106,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises an almina adsorbent, and

the almina adsorbent comprises an activated alumina.

116. The method according to claim 115,

wherein

the activated alumina comprises at least one of α

-alumina, γ

-alumina, δ

-alumina, and θ

-alumina.

117. The method according to claim 106,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises a mesoporous adsorbent, and

the mesoporous adsorbent comprises at least one of mesoporous silica, mesoporous silica-alumina, mesoporous titania, and mesoporous zirconia.

118. The method according to claim 103,

wherein

the amount of the ion adsorbent in the sealing material for the honeycomb structure is about 0.2% by weight or more.

119. The method according to claim 103,

wherein

the amount of the ion adsorbent in the sealing material for the honeycomb structure is about 5.0% by weight or less.

120. The method according to claim 103,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises at least one of a bentonite and a zeolite adsorbent, and

a content of the ion adsorbent in the sealing material for the honeycomb structure is from about 0.2% by weight to about 2.0% by weight.

121. The method according to claim 103,

wherein

the ion adsorbent in the sealing material for the honeycomb structure comprises an aluminum phosphate, and

a content of the ion adsorbent in the sealing material for the honeycomb structure is from about 0.1% by weight to about 2.0% by weight.

122. The method according to claim 103,

wherein

a weight ratio of the ion adsorbent to the inorganic fibers (weight of inorganic fibers/weight of ion adsorbent) in the sealing material for the honeycomb structure is from about 100/1 to about 4/1.

123. The method according to claim 103,

wherein

an average fiber length of the inorganic fibers in the sealing material for the honeycomb structure is from about 0.1 μ

m to about 1000 μ

m.

124. The method according to claim 103,

wherein

an amount of silica contained in the inorganic fibers in the sealing material for the honeycomb structure is from about 60% by weight to about 85% by weight.

125. The method according to claim 103,

wherein

an amount of Al₂O₃ contained in the inorganic fibers in the sealing material for the honeycomb structure is about 2% by weight or less.

126. The method according to claim 103,

wherein

an amount of the inorganic fibers contained in the sealing material for the honeycomb structure is from about 10% by weight to about 70% by weight.

127. The method according to claim 103,

wherein

an average particle diameter of the inorganic particles in the sealing material for the honeycomb structure is from about 0.01 μ

m to about 100 μ

m.

128. The method according to claim 105,

wherein

the alkali metal compounds in the sealing material for the honeycomb structure comprise at least one of sodium oxides, sodium salts, potassium oxides, and potassium salts, and

the alkaline earth metal compounds in the sealing material for the honeycomb structure comprise at least one of magnesium oxides, magnesium salts, calcium oxides, calcium salts, barium oxides, and barium salts.

129. The method according to claim 103,

wherein

the sealing material for the honeycomb structure further comprises an oxide sol.

130. The method according to claim 129,

wherein

the oxide sol comprises at least one of silica sol, alumina sol, and zirconia sol.

131. The method according to claim 129,

wherein

an amount of the oxide sol contained in the sealing material for the honeycomb structure is from about 1% by weight to about 30% by weight as a solid content.

132. The method according to claim 129,

wherein

an average particle diameter of the oxide included in the oxide sol is from about 5 nm to about 30 nm.

133. The method according to claim 129,

wherein

the sealing material for the honeycomb structure is alkaline.

134. The method according to claim 103,

wherein

the sealing material for the honeycomb structure is acidic.

135. The method according to claim 103,

wherein

a pH value of the sealing material for the honeycomb structure is from about 4 to about 7.

136. The method according to claim 104, further comprising solidifying an adhesive to form the adhesive layer.

137. The method according to claim 136,

wherein

the adhesive comprises a sealing material for the honeycomb structure, the sealing material for the honeycomb structure comprising:

inorganic fibers comprising a biosoluble inorganic compound;

inorganic particles; and

an ion adsorbent in an amount of about 0.1% by weight or more.

138. The method according to claim 137,

wherein

the inorganic compound in the adhesive comprises at least one of alkali metal compounds and alkaline earth metal compounds.

139. The method according to claim 137,

wherein

the ion adsorbent in the adhesive comprises at least one of silica adsorbents, alumina adsorbents, zeolite adsorbents, clay adsorbents, mesoporous adsorbents, polyvalent metal salts, and activated carbon.

140. The method according to claim 139,

wherein

the ion adsorbent in the adhesive comprises a clay adsorbent.

141. The method according to claim 140,

wherein

the clay adsorbent comprises at least one of bentonite, activated white clay, and montmorillonite.

142. The method according to claim 140,

wherein

the clay adsorbent comprises at least one of kaolinite, acid clay, halloysite, sericite, and mica clay minerals.

143. The method according to claim 139,

wherein

the ion adsorbent in the adhesive comprises at least one of a zeolite adsorbent and activated carbon.

144. The method according to claim 143,

wherein

the zeolite adsorbent comprises at least one of alminosilicate zeolite, metallosilicate zeolite, and aluminophosphate zeolite.

145. The method according to claim 139,

wherein

the ion adsorbent in the adhesive comprises a polyvalent metal salt.

146. The method according to claim 145,

wherein

the polyvalent metal salt comprises at least one of aluminum phosphate, iron phosphate, magnesium phosphate, and aluminum fluoride.

147. The method according to claim 139,

wherein

the ion adsorbent in the adhesive comprises a silica adsorbent, and

the silica adsorbent comprises at least one of silica gel, aero gel, colloidal silica, and porous silicate glass.

148. The method according to claim 139,

wherein

the ion adsorbent in the adhesive comprises an almina adsorbent, and

the almina adsorbent comprises an activated alumina.

149. The method according to claim 148,

wherein

the activated alumina comprises at least one of α

-alumina, γ

-alumina, δ

-alumina, and θ

-alumina.

150. The method according to claim 139,

wherein

the ion adsorbent in the adhesive comprises a mesoporous adsorbent, and

the mesoporous adsorbent comprises at least one of mesoporous silica, mesoporous silica-alumina, mesoporous titania, and mesoporous zirconia.

151. The method according to claim 137,

wherein

the amount of the ion adsorbent in the adhesive is about 0.2% by weight or more.

152. The method according to claim 137,

wherein

the amount of the ion adsorbent in the adhesive is about 5.0% by weight or less.

153. The method according to claim 137,

wherein

the ion adsorbent in the adhesive comprises at least one of a bentonite and a zeolite adsorbent, and

a content of the ion adsorbent in the adhesive is from about 0.2% by weight to about 2.0% by weight.

154. The method according to claim 137,

wherein

the ion adsorbent in the adhesive comprises an aluminum phosphate, and

a content of the ion adsorbent in the adhesive is from about 0.1% by weight to about 2.0% by weight.

155. The method according to claim 137,

wherein

a weight ratio of the ion adsorbent to the inorganic fibers (weight of inorganic fibers/weight of ion adsorbent) in the adhesive is from about 100/1 to about 4/1.

156. The method according to claim 137,

wherein

an average fiber length of the inorganic fibers in the adhesive is from about 0.1 μ

m to about 1000 μ

m.

157. The method according to claim 137,

wherein

an amount of silica contained in the inorganic fibers in the adhesive is from about 60% by weight to about 85% by weight.

158. The method according to claim 137,

wherein

an amount of Al₂O₃ contained in the inorganic fibers in the adhesive is about 2% by weight or less.

159. The method according to claim 137,

wherein

an amount of the inorganic fibers contained in the adhesive is from about 10% by weight to about 70% by weight.

160. The method according to claim 137,

wherein

an average particle diameter of the inorganic particles in the adhesive is from about 0.01 μ

m to about 100 μ

m.

161. The method according to claim 138,

wherein

the alkali metal compounds in the adhesive comprise at least one of sodium oxides, sodium salts, potassium oxides, and potassium salts, and

the alkaline earth metal compounds in the adhesive comprise at least one of magnesium oxides, magnesium salts, calcium oxides, calcium salts, barium oxides, and barium salts.

162. The method according to claim 137,

wherein

the adhesive further comprises an oxide sol.

163. The method according to claim 162,

wherein

the oxide sol comprises at least one of silica sol, alumina sol, and zirconia sol.

164. The method according to claim 162,

wherein

an amount of the oxide sol contained in the adhesive is from about 1% by weight to about 30% by weight as a solid content .

165. The method according to claim 162,

wherein

an average particle diameter of the oxide included in the oxide sol is from about 5 nm to about 30 nm.

166. The method according to claim 162,

wherein

the adhesive is alkaline.

167. The method according to claim 137,

wherein

the adhesive is acidic.

168. The method according to claim 137,

wherein

a pH value of the adhesive is from about 4 to about 7.

169. The method according to claim 103,

wherein

the ceramic block comprises a single honeycomb fired body.

170. The method according to claim 103, further comprising supporting a catalyst on the honeycomb structure.

171. The method according to claim 103,

wherein

either one end portion of each of the through holes is plugged.

172. The method according to claim 103,

wherein

an end portion of each of the through holes is not plugged.

173. The method according to claim 104, further comprising,

applying an adhesive including the sealing material for the honeycomb structure on a predetermined side surface of each of the honeycomb fired bodies to form an adhesive paste layer,

placing other honeycomb fired bodies on the adhesive paste layer, and

solidifying the adhesive paste layer to form the adhesive layer.

174. The method according to claim 104, further comprising,

placing a plurality of honeycomb fired bodies in parallel with one another in columns and rows with a spacer interposed therebetween so as to form a parallel-arranged body of honeycomb fired bodies having a gap between the honeycomb fired bodies,

filling the gap with the sealing material for the honeycomb structure by using a filling apparatus to manufacture a laminated body of the honeycomb fired bodies, and

heating the laminated body of the honeycomb fired bodies to dry and solidify the sealing material for the honeycomb structure so that the adhesive layer is formed.

175. The method according to claim 104, further comprising,

placing multiple kinds of honeycomb fired bodies having mutually different cross-sectional shapes in parallel with one another in columns and rows with a spacer interposed therebetween so as to form a parallel-arranged body of honeycomb fired bodies having a gap between the honeycomb fired bodies,

disposing the parallel-arranged body of honeycomb fired bodies inside a filling apparatus having a tubiform so as to form a gap between the honeycomb fired body and the tubiform,

filling both the gap between the honeycomb fired bodies and the gap between the honeycomb fired body and the tubiform with the sealing material for the honeycomb structure, and

solidifying the sealing material for the honeycomb structure so that the adhesive layer between the honeycomb fired bodies and the peripheral sealing material layer are simultaneously formed.

176. The method according to claim 103, further comprising, cutting a periphery of the ceramic block.