A gas sensor includes a sensing element having an electrode pad a metal terminal, and a separator that has insertion holes in which the metal terminal is held. The metal terminal includes a main body and an elastic portion that is integrally connected to the main body and is elastically connected to the electrode pad at a predetermined contact point. The main body includes a front-end-side restricting portion and a rear-end-side restricting portion that restrict the movement of the main body by contacting wall surfaces of the insertion hole when the main body moves in a direction intersecting the direction of an axial line. The contact point is located between the front-end-side restricting portion and the rear-end-side restricting portion in the direction of the axial line. The front-end-side restricting portion and the rear-end-side restricting portion are connected to each other so that a flat board portion is interposed therebetween.

A gas sensor includes a sensing element that includes an electrode pad, a metal terminal, and a separator. The metal terminal includes a lead-wire-connecting portion, a main body, a protruding piece that protrudes from a front-end side, and an elastic portion connected to an end of the protruding piece and to the electrode pad. An area S1 of a first opposed surface of a primary surface facing an insertion hole of the separator is larger than an area S2 of a second opposed surface of a secondary surface facing the insertion hole, and a part of the second opposed surface contacts an inner circumferential surface of the separator forming the insertion hole, and the first opposed surface is separated from the inner circumferential surface, where surfaces of the main body and the protruding piece that are located opposite the elastic portion are the primary surface and the secondary surface.

A metal terminal includes a front-side terminal member and a rear-side terminal member. The front-side terminal member includes a female connection portion, and the rear-side terminal member includes a male connection portion. The female connection portion has an insertion port in which the male connection portion is inserted. The insertion port is formed in a shape that prevents the insertion port and the male connection portion from coming into contact with each other when the male connection portion is inserted therein. The female connection portion includes a terminal contact portion which brings the male connection portion and the female connection portion into contact with each other by pressing the male connection portion toward the female connection portion inside the female connection portion.

A gas sensor for sensing a predetermined gas component contained in a measurement gas includes: a sensor element including a sensing part on one end portion thereof; a casing in which the sensor element is contained and secured; and a connector disposed in the casing, wherein the casing includes: an outer tube including a main portion in which a reference gas is included and a sealing portion as an end portion with a diameter smaller than the main portion so that another end portion of the sensor element protrudes to the main portion, a rubber seal member fitted into the sealing portion to seal the outer tube, and a spacer intervening between the seal member and the connector, and the spacer includes: a resin first spacer contacting with the seal member and having higher heat resistance than the seal member and a ceramic second spacer contacting with the connector.

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.

Apparatus and associated methods relate to a one-piece structure for a solid electrolyte chemical sensor (SECS) having a first surface defining a cavity (210, 305, 415) designed to receive a substrate (215, 350, 410) that retains a solid electrolyte (365, 440), an internal water impermeable coating (425) 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 (215, 350, 410) when the substrate (215, 350, 410) is received in the cavity (210, 305, 415), and a plurality of electrical contacts (335, 340, 345, 450a-450b) disposed on the second surface adapted to electrically couple with the electrodes (435a-435c) on the substrate (215, 350, 410) when the substrate (215, 350, 410) is received in the cavity (210, 305, 415) and electrical paths are provided between respective electrical contacts (335, 340, 345, 450a-450b) and electrodes (435a-435c).

A connector includes two insulators which hold contacts connected to lead wires and are arranged on two surfaces of a ceramic element, a spring component which includes two cantilever-shaped spring pieces and has a flexed portion at a middle portion of each spring piece, and a cylindrical sleeve. The two spring pieces are located over two outer surfaces of the two insulators, and are elastically deformed toward the two insulators by the sleeve hanging over the two spring pieces. The two insulators pushed by the flexed portions of the two elastically deformed spring pieces hold the ceramic element from two sides to push the contacts against the terminal electrodes.

A gas sensor has a sensor element, first element pads, second element pads, first contact-point members, and second contact-point members. The sensor element has first and second surfaces that are positioned on opposite sides in a first direction. The first element pads are disposed on the first surface. The second element pads are disposed on the second surface in a quantity greater than that of the first element pads. The first and second contact-point members are connected to the first and second element pads, respectively. The width (Wt) of at least one of the second contact-point members is less than the widths (Wa-Wd) of the rest of the first and second contact-point members.

A connector includes two insulators which hold contacts connected to lead wires and are arranged on two surfaces of a base end portion of a ceramic element, two spring components which have flat plate portions located on respective outer surfaces of the two insulators and spring portions supported by the flat plate portions, and a cylindrical sleeve. Each spring portion has an inclined surface which inclines in a movement direction in which the sleeve moves toward the spring components. Each spring portion is elastically deformed by the sleeve hanging over the spring portion. The two insulators hold the base end portion from two sides by being pushed by the flat plate portions in directions in which the two insulators are brought closer to each other. The contacts are pushed against the terminal electrodes.

A gas sensor includes: a sensor element; a ceramic housing holding a rear end portion of the sensor element and provided with metal terminals electrically connected to the sensor element; and an elastic insulating member that is fixed in the rear of the sensor element and into which a plurality of lead wires electrically connected to the metal terminals are inserted. The elastic insulating member has one or more common spaces formed in a surface of the elastic insulating member that faces the ceramic housing. Two or more of the lead wires are arranged in each common space.