Catalytic combustion gas sensors have been widely used for leakage detection of combustible gases. Therefore, the catalytic sensor with low preparation cost and high repeatability in a mass production has great importance. In this view, a new structure of high-performance catalytic sensor was proposed. Catalytic-type gas sensors based on screen-printing Platinum (Pt) heating electrode onto a porous alumina substrate was fabricated. This design enables porous alumina ceramics to act as the support of catalyst and substrate of heating electrode, simultaneously. The screen-printing technique obviously enhances the uniformity of the sensor devices in batch. To demonstrate the feasibility of this design, a prototype hydrogen sensor was prepared with a relatively high sensitivity around 30 mV/Vol% at 245°C and an excellent long-term stability. Additionally, sensing performances of hydrogen devices were also verified by finite element method (FEM) modeling. The simulation results suggested that the response time and response value were related to the thickness of substrate and the operating temperature of sensors. The facile and large-scale fabrication method of the sensor device in this work is expected to have potential utility for industrial detection and for personalized applications.

催化燃烧气体传感器已广泛用于可燃气体的泄漏检测。因此，在量产中制备成本低、重复性高的催化传感器具有重要意义。有鉴于此，提出了一种新型结构的高性能催化传感器。基于丝网印刷铂 (Pt) 加热电极到多孔氧化铝基板上的催化型气体传感器被制造出来。这种设计使多孔氧化铝陶瓷能够同时作为催化剂的载体和加热电极的基材。丝网印刷技术明显提高了批量传感器器件的均匀性。为了证明这种设计的可行性，制备了一个原型氢传感器，在 245°C 下具有大约 30 mV/Vol% 的相对较高的灵敏度和出色的长期稳定性。此外，还通过有限元方法 (FEM) 建模验证了氢设备的传感性能。仿真结果表明，响应时间和响应值与基板厚度和传感器工作温度有关。这项工作中传感器装置的简便和大规模制造方法有望在工业检测和个性化应用中具有潜在的实用性。