Patent ID: 8226784

Claim:
A method of manufacturing a gas sensor element comprising the steps of: (a) forming a preceding lamination sheet which is substantially treated and used as a single ceramics green sheet by laminating and bonding at least two blank ceramics green sheets together out of a plurality of ceramics green sheets, wherein said at least two blank ceramics green sheets have not been printed thereon, wherein said two blank ceramic sheets contact one another along their entire widths and lengths, respectively, and wherein the surfaces of said two blank ceramic sheets that contact one another have the same area; (b) printing a predetermined pattern on said preceding lamination sheet and at least one non-preceding lamination sheet which is a ceramics green sheet not used for forming said preceding lamination sheet out of said plurality of ceramics green sheets; (c) laminating and bonding said preceding lamination sheet and said non-preceding lamination sheet, on which said predetermined pattern is printed in said step (b), in a predetermined order, wherein each of said steps (a) and (c) comprises the steps of: (d) applying a bonding paste on said ceramics green sheets so as to bond each of said ceramics green sheets; and (e) drying said bonding paste applied in said step (d), wherein said bonding paste is dried so that a weight of a solvent is decreased in said bonding paste by greater or equal to 80% to less or equal to 90% in said step (e), wherein in step (c), laminating and bonding said preceding lamination sheet and said non-proceding lamination sheet is performed after step (e), wherein said predetermined pattern printed on said preceding lamination sheet is a heater pattern, and wherein said preceding lamination sheet defines an outermost surface of the gas sensor element.