Method of manufacturing a gas sensor

A method of manufacturing a gas sensor, said gas sensor comprising:

• a first processing space and a first gas passage for introducing a measuring gas containing oxygen, water vapor and a combustible gas component into said first processing space;
• a second processing space and a second gas passage for introducing a gas contained in said first processing space into said second processing space;
• an oxygen concentration detection element for measuring the oxygen concentration of gas contained in said first processing space;
• an oxygen pumping element comprising an oxygen-ion conductive solid electrolyte having electrodes formed on opposing surfaces thereof, said oxygen pumping element pumping oxygen out of or into said first processing space so as to adjust the oxygen concentration of the measurement gas introduced into said first processing space and measured by said oxygen concentration detection element to a predetermined level;
• an oxidation catalyst for accelerating combustion of a combustible gas component contained in the gas which has been introduced into said second processing space from said first processing space via the second gas passage;
• and
• a combustible gas component concentration detection element for providing information regarding the concentration of the combustible gas component of the measurement gas, comprising an oxygen-ion conductive solid electrolyte having electrodes formed on opposing surfaces thereof, one of said electrodes is exposed to said second processing space, said combustible gas component concentration detection element having an output current which varies according to the amount of oxygen consumed by combustion of the combustible gas component when a constant voltage is applied to the electrodes of the combustible gas component concentration detection element, to thereby provide information regarding the concentration of the combustible gas component of the measurement gas;
• said oxygen concentration detection element comprises an oxygen concentration cell element comprising an oxygen-ion conductive solid electrolyte having electrodes formed on opposing surfaces thereof, one of the electrodes of the oxygen concentration cell element is exposed to said first processing space and is defined as a first electrode;
• the electrode of said combustible gas component concentration detection element exposed to said second processing space is defined as a second electrode;
• said first and second electrodes comprising a porous electrode having oxygen molecule desorbent capability, said second electrode serving as an oxidation catalyst having oxidation-catalytic activity toward a combustible gas component contained in the measurement gas, and said first electrode having a lower oxidation-catalytic activity than said second electrode;
• and
• said oxygen pumping element comprises an oxygen-ion conductive solid electrolyte having electrodes formed on opposing surfaces thereof, one of the electrodes of the oxygen pumping element is exposed to said first processing space and is defined as a third electrode;
• the third electrode comprises:
• a porous main electrode layer comprising a Pt—Au alloy having an Au content of 1 wt % or less or Pt;
• and
• a porous surface electrode layer covering the main electrode layer, said surface electrode layer comprising a material selected from the group consisting of a metal containing Au or Ag as a main component, a Pt—Au alloy having an Au content of 5 wt % or more, an Au—Pd alloy, a Pt—Ag alloy and a Pt—Ni alloy,
• wherein the third electrode has a lower oxidation-catalytic activity toward the combustible gas component than the second electrode;
• said method comprising:
• a main electrode layer forming step which comprises forming a main electrode pattern containing an unfired main electrode layer of material powder for the main electrode layer of the third electrode on an unfired solid electrolyte compact of the oxygen-ion conductive solid electrolyte layer constituting said oxygen pumping element, and integrally firing the unfired main electrode layer with the unfired solid electrolyte compact at a first temperature to form on the oxygen-ion conductive solid electrolyte layer a main electrode layer;
• and
• a surface electrode layer forming step which comprises forming a layer of material powder for the surface electrode layer on the main electrode layer, and subjecting to secondary firing at a second temperature lower than the first temperature to thereby form the surface electrode layer.