An exhaust sensor includes a sensing element with a ceramic sensing element substrate and a sensing element terminal which is electrically conductive and which is supported by the ceramic sensing element substrate such that the sensing element is configured to sense constituents of exhaust gases when exposed thereto. The exhaust sensor also includes a mating terminal which is electrically conductive and which is in electrical communication with the sensing element terminal. The mating terminal has a base material and a clad material bonded to the base material such that the clad material contacts the sensing element terminal and such that the clad material is located between the sensing element terminal and the base material, thereby providing the electrical communication. The clad material is an alloy which is less than or equal to 20% iron, greater than or equal to 40% nickel, and greater than or equal to 13% chromium.

A gas sensor includes: a sensor element; a plurality of element pads formed on a rear end portion of the sensor element; and a plurality of contact members holding the rear end portion of the sensor element and electrically connected respectively to the plurality of element pads. At least one contact member of the plurality of contact members has an end portion having a smaller width Wt than the other contact members.

Apparatus and associated methods relate to a one-piece structure for a solid electrolyte chemical sensor (SECS) having a first surface defining a cavity designed to receive a substrate that retains a solid electrolyte, an internal water impermeable coating on at least a portion of the first surface, a second surface that is substantially coplanar with an adjacent peripheral edge of a top surface of the substrate when the substrate is received in the cavity, and a plurality of electrical contacts disposed on the second surface adapted to electrically couple with the electrodes on the substrate when the substrate is received in the cavity and electrical paths are provided between respective electrical contacts and electrodes. In an illustrative example, the internal water impermeable coating may include a metallic material, such as gold. In various embodiments, the one-piece structure may advantageously prevent water loss from both the sensor substrate and the SECS.

A gas sensor (200) including a sensor element (10) having electrode pads (11a-12b); a separator (166); and a plurality of metal terminals (21a, 21b, 22a, 22b) each having a body portion (21a1) and a front end portion (21a2), and being insulated from each other by the separator. The separator has an element storage portion (168) penetrating in the axial-line direction or recessed toward a rear side from a front facing surface of the separator, the element storage portion has a first storage space (168a) at a front side thereof and a second storage space (168b) at a rear side thereof, the second storage space has a rotation restriction wall (168w) configured such that a relative rotation allowable angle 2θ between the sensor element and the separator is smaller than in the first storage space, and the rear end side of the sensor element is stored in the second storage space.

A method of forming a glass electrochemical sensor is described. In some embodiments, the method may include forming a plurality of electrical through glass vias (TGVs) in an electrode substrate; filling each of the plurality of electrical TGVs with an electrode material; forming a plurality of contact TGVs in the electrode substrate; filling each of the plurality of contact TGVs with a conductive material; patterning the conductive material to connect the electrical TGVs with the contact TGVs; forming a cavity in a first glass layer; and bonding a first side of the first glass layer to the electrode substrate.

In order to suppress a deterioration in the measurement precision while also reducing the manufacturing cost of a gas sensor element, an aspect of the present invention is directed to a gas sensor element including: a stack formed by stacking a plurality of oxygen ion-conductive solid electrolyte layers, and including an internal space configured to receive a measurement target gas from the outside, a first face adjacent to the internal space, and a second face adjacent to an external space; a first pump electrode provided on the first face; a second pump electrode provided on the second face; a first lead formed on the first face so as to extend from the first pump electrode; and a second lead formed on the second face so as to extend from the second pump electrode and configured to be electrically connected to the first lead. At least one of the first and second leads has a shape with a maximum current density of 3.5 A/mm.sup.2 or less.

Disclosed is a manufacturing method of a gas sensor. The gas sensor has a plate-shaped sensor element with at least one pair of electrode pads, a separator disposed around the sensor element, and at least one pair of opposed metal terminals held in an insertion hole of the separator and electrically connected at contact regions thereof to the respective electrode pads. The manufacturing method includes mounting the metal terminals in the insertion hole of the separator with use of a mounting jig. The mounting jig has a flat portion interposed between the contact regions of the metal terminals during the mounting of the metal terminals in the separator so as to prevent contact and entanglement of the opposed metal terminals.

A gas sensor includes a sensor element, an elastic insulating member, a plurality of lead wires, a plurality of metal terminals, and a ceramic housing. The plurality of lead wires are inserted in the elastic insulating member. The plurality of metal terminals each have a first end electrically connected to the sensor element, and a second end electrically connected to a corresponding one of the plurality of lead wires. The ceramic housing includes a plurality of insertion portions each including a through hole in which a corresponding one of the plurality of metal terminals is inserted, and at least one of the plurality of insertion portions has a different height from other insertion portions.

The present disclosure relates to an ion-selective electrode for an electrochemical sensor for determining a measurand representing a concentration of an analyte in a measuring medium, including a probe body made of a first material and a sensor element including a base body made of a second material different from the first material and an ion-selective layer arranged on the base body. The probe body is connected to the base body by way of a liquid-tight joint, where the joint is formed by a receptacle, serving as a first joining partner, and a joining section protruding into the receptacle, serving as a second joining partner.

A sensor element for detecting a specific gas concentration in a measurement-object gas, the sensor element includes; an elongate element body that includes a solid electrolyte layer and has a shape including at least one side surface extending in a longitudinal direction; a dense layer that is disposed on the side surface; and an intermediate layer disposed at least between the dense layer and the element body, wherein, when thermal expansion coefficients of the solid electrolyte layer, the dense layer, and the intermediate layer in a temperature range of from 20° C. to 1360° C. are denoted by thermal expansion coefficients Ea, Eb, and Ec, respectively, a ratio Ea/Eb is more than 1.0 and 5.0 or less, and Ea>Ec>Eb is satisfied.