Patent ID: 7335331

Claim:
A method of making ceramic plates, the method comprising the steps of: mixing a slurry comprising a filler material, a carbon source and water; casting the slurry to make a wet preform; drying the wet preform to make a substantially dry preform; providing a silicon loaf having a solid form and adequate height, width and length for supporting one or more substantially dry preforms; placing the substantially dry preform on top of the silicon loaf inside of an infiltration furnace; and heating the substantially dry preform and loaf to melt silicon within the loaf and infiltrate the substantially dry perform; wherein the step of providing the silicon loaf comprises the steps of: mixing a loaf batch comprising a major proportion of silicon, a minor proportion of one or more bonding agents and water; placing the loaf batch into a mold; and drying the loaf batch to form a loaf.