Gas sensor and method of manufacturing the same

A method of manufacturing a gas sensor which includes:

• a sensor element having a plate shape, extending in a direction of an axial line and having an electrode pad on an outer surface of a rear end portion thereof;
• a metal terminal member extending in the direction of the axial line and electrically connected to the electrode pad;
• a tubular separator which holds the metal terminal member and surrounds the rear end portion of the sensor element;
• and
• a lead wire connected to a rear end portion of the metal terminal member and extending rearward of the separator, wherein
• the metal terminal member having a forward locking portion provided at forward end of the metal terminal member and a rear locking portion provided at a rear end of the metal terminal member,
• the separator being composed of a forward separator and a rear separator which are disposed on forward and rear sides in the direction of the axial line, respectively, and are connected to each other, the forward separator including a first locking portion having a rearward-facing surface, the rear separator including a second locking portion having a forward-facing surface,
• the method comprising the steps of:
• disposing the forward separator on the forward side of the metal terminal member and the rear separator on the rear side of the metal terminal member;
• and
• holding the metal terminal member between the forward separator and the rear separator such that the forward locking portion is in locking engagement with the rearward-facing surface and the rear locking portion is in locking engagement with the forward-facing surface.