Patent 7544320 was granted and assigned to NGK Insulators on June, 2009 by the United States Patent and Trademark Office.
There is disclosed a method of manufacturing a porous ceramic structure, comprising the steps of: preparing a formed structure using a ceramic material containing a pore former and a binder; and drying and firing the formed structure, wherein the process of firing the formed structure comprises the steps of: holding a firing atmosphere temperature in a temperature range of −50 to +10° C. with respect to a combustion start temperature of the binder from the time when the temperature reaches the combustion start temperature of the binder contained in the porous ceramic structure to be fired to the time when the binder is burnt out. According to this method, ceramic structures having not only a low porosity but also a high porosity can be manufactured without generating any crack during the firing.