# US 9,751,811 B1 · Graphite blending method for ceramic shrinkage control > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,751,811 B1 - Document ID: US9751811B1 - Status: Granted - Kind: B1 - Application number: 14/990,306 - Filed: 2016-01-07 - Granted: 2017-09-05 - Earliest claimed: 2012-11-28 - Assignees: Corning Incorporated - Applicants: Corning Incorporated - Inventors: Daniel Edward McCauley; Anthony Nicholas Rodbourn; Patrick David Tepesch - Web page: https://patentgrep.com/patent/US9751811B1 ## CPC - C04B 38/0006: {Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083)} - B28B 17/0072: {Product control or inspection} - B28C 7/0418: {control systems therefor} - C04B 35/478: based on aluminium titanates - C04B 38/06: by burning-out added substances {by burning natural expanding materials or by sublimating or melting out added substances} - C04B 2111/00129: {Extrudable mixtures} - C04B 2111/34: Non-shrinking or non-cracking materials - C04B 2235/425: Graphite - C04B 2235/6021: Extrusion moulding - C04B 2235/9615: Linear firing shrinkage - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - B28C: PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER (preparing material for foundry moulds B22C5/00) ## Abstract A method for green-to-fired shrinkage control in honeycomb ceramic article manufacture, including: measuring, prior to mixing, the particle size distribution properties of at least one fine particle size graphite pore former ingredient of a provided ceramic source batch mixture; calculating the expected shrinkage of the green body to the fired ceramic article based on the measured particle size distribution properties of the at least one fine particle graphite pore former; making the honeycomb ceramic article; measuring the shrinkage of the resulting fired honeycomb ceramic article; and adjusting the ceramic source batch mixture in a subsequent batch material schedule, as defined herein, wherein the adjusted ceramic source batch mixture provides finished honeycomb ceramic articles having controlled green-to-fired shrinkage. ## Claims ### Claim 1 A method for manufacturing ceramic articles, the method comprising: extruding green bodies of constant size, the extruding comprising: extruding a first green body from a first mixture comprised of a first blend of an inorganic component and a pore former component, the pore former component being comprised of a fine pore former ingredient from a first source and a coarse pore former ingredient from a second source, wherein the D10 of the coarse ingredient is greater than the D90 of the fine ingredient, and extruding a second green body from a second mixture comprised of a blend of the inorganic component, the fine pore former ingredient in a different amount compared to the first blend, and the coarse pore former ingredient in the same amount as in the first blend; and firing the first and second green bodies, wherein, upon firing, the first green body is formed into a first fired ceramic article having a first porosity and a first shape, and the second green body is formed into a second fired ceramic article having a second porosity which is substantially the same as the first porosity and a second shape which is different from the first shape. ### Claim 2 (depends on 1) The method of claim 1 wherein a diameter of the second fired ceramic article is different from the diameter of the first fired ceramic article. ### Claim 3 (depends on 1) The method of claim 1 wherein the fine pore former ingredient produces fine pores during the firing, and the resulting fine pores completely sinter away during firing. ### Claim 4 (depends on 1) The method of claim 1 wherein the fine pore former ingredient produces fine pores during the firing that affect shrinkage of the resulting fired ceramic body, and the resulting fine pores completely sinter away during firing. ### Claim 5 (depends on 1) The method of claim 1 wherein the fine pore former ingredient comprises graphite. ### Claim 6 (depends on 1) The method of claim 1 wherein the coarse pore former ingredient comprises graphite. ### Claim 7 (depends on 1) The method of claim 1 wherein the coarse pore former ingredient comprises graphite having a particle size distribution with a D10 of 9 to 13 microns. ### Claim 8 (depends on 1) The method of claim 1 wherein the fine pore former ingredient comprises graphite having a particle size distribution with a D90 of 8 microns or less. ### Claim 9 (depends on 1) The method of claim 1 wherein the fine pore former ingredient comprises graphite having a particle size distribution with a D90 of 8 microns or less, and the coarse pore former ingredient comprises graphite having a particle size distribution with a D10 of 9 to 13 microns. ### Claim 10 (depends on 1) The method of claim 1 wherein the first mixture comprises at least one of an aluminum oxide source, a silica source, a titanium oxide source, and a lanthanum oxide source.