Fast firing method for high porosity ceramics

Abstract

A method for firing a green honeycomb ceramic body including heating the green honeycomb ceramic body from room temperature to a first temperature of less than or equal to about 350° C. with at least one heating rate of greater than or equal to about 80° C./hr. The green honeycomb ceramic body may be heated from the first temperature to a second temperature of greater than or equal to about 800° C. at a heating rate of greater than or equal to about 90° C./hr. The green honeycomb ceramic body may be heated from the second temperature to a third temperature of greater than or equal to about 1000° C. The green honeycomb ceramic body may include aluminum raw materials for forming an aluminum titanate ceramic body.

What is claimed is: 
     
         1 . A method for firing a green honeycomb ceramic body, the method comprising:
 heating the green honeycomb ceramic body from room temperature to a first temperature of less than or equal to about 350° C., wherein heating the green honeycomb ceramic body from room temperature to the first temperature comprises a heating rate of greater than or equal to about 80° C./hr;   heating the green honeycomb ceramic body from the first temperature to a second temperature of greater than or equal to about 800° C., wherein heating the green honeycomb ceramic body from the first temperature to the second temperature comprises a heating rate of greater than or equal to about 90° C./hr; and   heating the green honeycomb ceramic body from the second temperature to a third temperature of greater than or equal to about 1000° C.;   wherein the green honeycomb ceramic body has a diameter of from greater than or equal to about 4.0 inches to less than or equal to about 9.0 inches;   wherein the green honeycomb ceramic body comprises a carbon-based pore former in a concentration of from greater than or equal to about 10% to less than or equal to about 48% by weight;   wherein the green honeycomb ceramic body comprises aluminum raw materials for forming an aluminum titanate ceramic body; and   wherein heating the green honeycomb ceramic body from room temperature to the second temperature comprises heating the green honeycomb ceramic body at a single heating rate of greater than or equal to about 90° C./hr.   
     
     
         2 . The method of  claim 1 , wherein the single heating rate is less than or equal to about 300° C./hr. 
     
     
         3 . The method of  claim 1 , wherein heating the green honeycomb ceramic body from the second temperature to the third temperature comprises heating the green honeycomb ceramic body at a heating rate of less than or equal to about 150° C./hr. 
     
     
         4 . The method of  claim 1 , wherein heating the green honeycomb ceramic body from room temperature to the third temperature comprises heating the green honeycomb ceramic body at a single heating rate of less than or equal to about 150° C./hr. 
     
     
         5 . The method of  claim 1 , wherein the green honeycomb ceramic body has a diameter of from greater than or equal to about 5.5 inches to less than or equal to about 7.5 inches. 
     
     
         6 . The method of  claim 1 , wherein the green honeycomb ceramic body comprises a carbon-based pore former in a concentration of from greater than or equal to about 10% to less than or equal to about 40% by weight. 
     
     
         7 . The method of  claim 1 , wherein the raw materials for forming the green honeycomb ceramic body do not comprise magnesium-containing materials. 
     
     
         8 . The method of  claim 1 , wherein an atmosphere of a kiln comprises from about 6% to about 15% by volume of oxygen during the firing.