Patent ID: 8609206

Claim:
A process for producing a discrete metallization of a ceramic substrate surface, comprising the steps of: a) obtaining a substrate selected from the group consisting of oxygen-containing ceramics, and oxygen-non-containing ceramics; b) providing heat treatment when the substrate selected are oxygen-non-containing ceramics; c) forming a substantially continuous metal coating layer on the ceramic surface, using a process selected from the group consisting of physical vapor deposition, chemical vapor deposition, kinetic spraying, thermal spraying, electroless plating, electrolytic plating, thick film printing, ink jet printing, automated syringe dispensing, automated nozzle dispensing, slurry coating, slurry brushing, slurry spraying, laser cladding, and any combination of said processes; and d) converting the continuous metal coating layer into a multiplicity of discrete solidified droplets of the metal on the ceramic surface having a contact angle lower than ninety degrees by means of a heat treatment in a controlled gas atmosphere, wherein the heat treatment further comprises the steps of: heating up, in a gas atmosphere sufficiently inert not to cause substantial oxidation of the metal, the substrate with the substantially continuous metal layer to a temperature and for a time duration sufficient for the metal to transition into a liquid state and break up into a plurality of droplets on the ceramic substrate surface with a contact angle higher than ninety degrees; introducing a quantity of oxygen into the gas atmosphere in concentrations and for a time duration sufficient for the droplets of the liquid metal on the ceramic substrate to change shape so that the contact angle becomes lower than ninety degrees; and cooling down and solidifying the metal droplets on the ceramic substrate in a controlled gas atmosphere.