Patent ID: 8444737

Claim:
A method of firing a green structure to produce a ceramic structure, the method comprising: heating a firing environment during a first stage of firing of a green structure over a first timed temperature cycle having an average ramp rate sufficient to substantially complete burnout of organic material prior to initiation of clay dehydration proximate a core of the ceramic structure, wherein heating the firing environment during the first stage of firing comprises heating the firing environment from about 180° C. to about 425° C. at an average ramp rate of less than or equal to about 12° C./hr, and wherein heating the firing environment during the first stage comprises heating the firing environment up to a threshold temperature for at least a first predetermined minimum time period and holding the firing environment at the threshold temperature for a second predetermined time period, wherein the first and second predetermined time periods together range from about 24-46 hours; and heating the firing environment during a second stage of the firing over a second timed temperature cycle having an average ramp rate that is faster than the average ramp rate of the first timed temperature cycle, wherein heating the firing environment during the second stage of firing comprises heating the firing environment from about 425° C. to about 750° C.; and wherein the time from initiation of the first stage to completion of the second stage is less than or equal to about 62 hours.