Patent ID: 8669131

Claim:
A method for forming a gas sensor structure, comprising forming the gas sensor structure without exceeding a temperature of about 400° C. using the following steps: forming a gas sensitive material formulation for deposition on a surface by combining the following components: a gas sensitive particulate material that exhibits a shift in one or more electrical parameters upon exposure to at least one target gas, a binder material having a burn-out temperature of less than or equal to about 400° C., and a solvent effective for dissolving the binder, the solvent having an evaporation temperature that is less than the burn-out temperature of the binder material, where the gas sensitive particulate material, binder, and solvent are combined at a temperature below the burn-out temperature of the binder and at a temperature below the boiling point of the solvent; depositing the gas sensitive material formulation on the surface; exposing the deposited gas sensitive material formulation to a first temperature above the boiling point of the solvent to substantially evaporate the solvent from the deposited gas sensitive material formulation; and exposing the deposited gas sensitive material formulation to a second temperature less than or equal to about 400° C. to substantially burn-out the binder and form the gas sensor structure from the remaining gas sensitive material.