One piece optical assembly for low cost optical scanner

Abstract

An optical scan module, for example for an optical scanner, includes an integrally molded plastics material member which defines not only the laser focusing lens, but also the laser focusing aperture and the collection mirror. In addition, the molded member may act to house and to locate both a semiconductor laser and a photodetector, thereby ensuring easy and accurate placement of those elements within the scanning assembly. The optical assembly may be in modular form, mounted onto a common printed circuit board with a beam scanner.

Description

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The field of the invention relates to electro-optical readers or scanning systems, such as bar code symbol readers, and more particularly to a scanning module for use in applications requiring particularly compact scanners.

[0004] 2. Description of the Related Art

[0005] Electro-optical readers, such as bar code symbol readers, are now very common. Typically, a bar code symbol comprises one or more rows of light and dark regions, typically in the form of rectangles. The widths of the dark regions, i.e., the bars, and/or the widths of the light regions, i.e., the spaces, between the bars indicate encoded information to be read.

[0006] A bar code symbol reader illuminates the symbol and senses light reflected from the coded regions to detect the widths and spacings of the coded regions and derive the encoded information. Bar code reading type data input systems improve the efficiency and accuracy of data input for a wide variety of applications. The ease of data input in such systems facilitates more frequent and detailed data input, for example to provide efficient inventories, tracking of work in progress, etc. To achieve these advantages, however, users or employees must be willing to consistently use the readers. The readers therefore must be easy and convenient to operate.

[0007] A variety of scanning systems are known. One particularly advantageous type of reader is an optical scanner which scans a beam of light, such as a laser beam, across the symbols. Laser scanner systems and components of the type exemplified by U.S. Pat. Nos. 4,387,297 and 4,760,248—which are owned by the assignee of the instant invention and are incorporated by reference herein—have generally been designed to read indicia having parts of different light reflectivity, i.e., bar code symbols, particularly of the Universal Product Code (UPC) type, at a certain working range or reading distance from a hand-held or stationary scanner.

[0008] A variety of mirror and motor configurations can be used to move the beam in a desired scanning pattern. For example, U.S. Pat. No. 4,251,798 discloses a rotating polygon having a planar mirror at each side, each mirror tracing a scan line across the symbol. U.S. Pat. Nos. 4,387,297 and 4,409,470 both employ a planar mirror which is repetitively and reciprocally driven in alternate circumferential directions about a drive shaft on which the mirror is mounted. U.S. Pat. No. 4,816,660 discloses a multi-mirror construction composed of a generally concave mirror portion and a generally planar mirror portion. The multi-mirror construction is repetitively reciprocally driven in alternative circumferential directions about a drive shaft on which the multi-mirror construction is mounted. All of the above-mentioned U.S. Patents are incorporated herein by reference.

[0009] In electro-optical scanners of the type discussed above, the “scan engine” including the laser source, the optics the mirror structure, the drive to oscillate the mirror structure, the photodetector, and the associated signal processing and decoding circuitry all add size and weight to the scanner. In applications involving protracted use, a large heavy hand-held scanner can produce user fatigue. When use of the scanner produces fatigue or is in some other way inconvenient, the user is reluctant to operate the scanner. Any reluctance to consistently use the scanner defeats the data gathering purposes for which such bar code systems are intended. Also, a need exists for compact scanners to fit into small compact devices, such as notebooks.

[0010] Thus, an ongoing objective of bar code reader development is to miniaturize the reader as much as possible, and a need still exists to further reduce the size and weight of the scan engine and to provide a particularly convenient to use scanner. The mass of the moving components should be as low as possible to minimize the power required to produce the scanning movement.

[0011] It is also desirable to modularize the scan engine so that a particular module can be used in a variety of different scanners. A need exists, however, to develop a particularly compact, lightweight module which contains all the necessary scanner components.

SUMMARY OF THE INVENTION

[0012] Objects of the Invention

[0013] It is an object of the present invention to reduce the size and weight of components used to produce scanning motion of the light bean, and to collect the reflected light.

[0014] A related object is to develop an electro-optical scanning system which is both smaller and lighter in weight.

[0015] It is yet a further object to produce a module which may be manufactured conveniently, and at low cost. A related object is to provide a module which may be assembled easily.

FEATURES OF THE INVENTION

[0016] According to the present invention there is provided an optical scan module comprising:

[0017] (a) a light source for emitting a light beam;

[0018] (b) a scanning assembly for receiving said light beam and for generating therefrom a scanning beam directed to an indicia to be read;

[0019] (c) a photodetector; and

[0020] (d) a one-piece optical element including:

[0021] (i) a beam-shaping lens for receiving and shaping said light beam prior to transmission to said scanning assembly; and

[0022] (ii) a mirror-defining portion for locating a mirror surface, said mirror surface being arranged to receive reflected light from said indicia and to direct it to said photodetector.

[0023] Preferably, the one-piece or integral optical element may be molded from an optically transparent plastics material which is selectively coated to provide the collection mirror reflective surface. The molded member may also define mounting and/or location portions for the light source/laser and/or the photodetector. The photodetector mounting portion may also be coated, preferably with the same material that is used to coat the collection mirror, so as to provide not only optical but also electromagnetic shielding for the photodetector.

[0024] The molded member may include downwardly-extending “snaps”, allowing the member, along with the mounted laser and photodetector, easily to be secured to an underlying PCB.

[0025] Also on the same PCB may be mounted a beam scanning arrangement providing either linear or two-dimensional scanning.

[0026] According to the invention there is further provided an optical scan module comprising a mounting base defining a reference plane and having mounted thereon;

[0027] a) a light source for emitting a light beam;

[0028] b) a scanning assembly for receiving said light beam and for generating therefrom a scanning beam directed to an indicia to be read in which said module is arranged such that the scanning beam defines a scanning plane which is non-orthogonal to the reference plane.

[0029] Accordingly the module can be placed on a mother board without the need of spacers to achieve a desired angle.

[0030] In another form the invention provides an optical scan module comprising a base defining a reference plane, a beam reflecting element and a beam reflecting element drive, in which the beam reflecting element is mounted relative to the base to be driven to oscillate in a plane angled to a plane orthogonal to the reference plane.

[0031] According to the invention there is further provided a small-size optical scan module comprising a substantially rectangular module base, and mounted thereon a light source for emitting a light beam, a scanning assembly for receiving said light beam and for generating therefrom a scanning beam directed to an indicia to be read, a detector, and a one piece optical element including a beam shaping lens for receiving and shaping said light beam prior to transmission to said scanning assembly and a mirror defining portion for locating a mirror surface, said mirror surface being arranged to received retro-reflected light and to direct it to said detector.

[0032] The invention further provides an optical scan module comprising a light source for emitting a light beam, a first scanning assembly for receiving said light beam and for generating therefrom a scanning beam in a first scanning plane; a second scanning assembly for receiving said scanning beam from said first scanning assembly and for generating a scanning beam also scanning in a second plane non-parallel to the first scanning plane; and a detector for detecting a returning beam in which the light source, the scanning assembly and the detector are provided on a single module base. Accordingly two dimensional scanning is achieved allowing customised scan patterns.

[0033] According to the invention there is further provided a scanning element for an optical scanner, the scanning element including a reflector for reflecting a scanning beam and a drive for driving the reflector in a scanning motion in which the reflector is mounted on a torsionally deformable element and is driven in a scanning motion thereon, and in which the torsionally deformable element is elongate, deformable about its elongate axis, and non-planar in cross sectional shape perpendicular to its elongate axis, said cross sectional shape being selected to provide substantially uniform torsional deformation along the elongate axis.

[0034] The invention also provides an optical reader comprising a reader housing, and a reading beam generator, a reading beam detector and a reading beam window mounted in the housing, the housing comprising a base, a handle and a head portion, including the reading window, mounted at one end of the handle, the handle being attached at its other end to the base, in which the reader is free-standing on the base. An improved ergonomic including hands-free/free-standing and hand-held use is thus achieved.

[0035] The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings. Further features of the invention are set out in the appended independent claims, and further preferred features are set out in the dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] FIG. 1 is a partially sectioned view of an optical assembly according to the preferred embodiment of the invention;

[0037] FIG. 2 a shows a side view of a gun-type scanner suitable for use with the optical assembly of FIG. 1;

[0038] FIG. 2 b is a front view of the scanner of FIG. 2a;

[0039] FIG. 2 c is a plan view of the scanner of FIG. 2a;

[0040] FIG. 2 d is an exemplary hand-held optical scanner, suitable for use with the optical assembly of FIG. 1;

[0041] FIG. 2 e is an exemplary hand-held combined computer terminal and optical scanner, again suitable for use with the optical assembly of FIG. 1;

[0042] FIG. 3 shows an optical assembly from which a scanning beam exists at a non-90° angle;

[0043] FIG. 4 is a flow chart showing operation of the scanner of FIGS. 2a-2c;

[0044] FIG. 5 a shows a think flexible band drive of known type;

[0045] FIG. 5 b shows an improved think flexible band;

[0046] FIG. 6 is an exploded view showing mounting of the thin flexible band of FIG. 5b;

[0047] FIG. 7 shows the components set out in FIG. 6 in assembled form;

[0048] FIG. 8 shows an optical assembly in a housing in cut-away from;

[0049] FIG. 9 shows a 2D scan motion scanner assembly;

[0050] FIG. 10 is a schematic plan view corresponding to FIG. 9;

[0051] FIG. 11 shows an alternative scan assembly configuration;

[0052] FIG. 12 is an end view corresponding to FIG. 11;

[0053] FIG. 13 a illustrates the scanning plane in a conventional assembly;

[0054] FIG. 13 b illustrates the scanning plane in an assembly of the type shown in FIG. 11; and

[0055] FIG. 14 shows an alternative scan module housing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0056] FIG. 1 shows a low-cost optical assembly, according to the preferred embodiment, for creating a scanning laser beam.

[0057] The optical assembly comprises two essentially separate portions, the “static optics” 10 and the scanner motor drive 12, both mounted to a common printed circuit board (PCB) 14. Before the structure of the assembly is described in detail, it may be helpful to provide a brief overview of the operation of the device. The light beam 16 from a semi-conductor laser 18 passes through a molded plastics lens 20 and is turned through 90° by total internal reflection from a prism 22. After exiting the prism, the beam passes through an aperture 24 in a collector mirror 26, and impinges onto an oscillating scanning mirror 28. This produces a scanning outgoing light beam 30, which is directed toward an indicia (not shown) to be read.

[0058] Reflected light 32 from the indicia is first received by the scanning mirror 28, which directs it onto a concave surface 34 of the collector mirror 36. This focuses the light via an aperture 36 and a filter 38 onto a photodetector 40. The photodetector output signal is then passed on to suitable electronics within the PCB 14 by an electrical coupling 42.

[0059] The scanning mirror 28 is mounted at 44 for oscillation about an axis, this being achieved by virtue of the interaction between a permanent magnet 46 and a driven electromagnetic coil 48. A suitable driving signal is applied to the coil, via the PCB 14 and coil electrical contact 50.

[0060] The scanner motor drive 12 shown in FIG. 1 is exemplary, and may be replaced with any type of mechanism for effecting a scanning motion of the beam in one or two dimensions. For example, the scanner motor drive could comprise any of the configurations disclosed in U.S. Pat. Nos. 5,581,067 and 5,367,151, all of which are incorporated by reference. In this way, the static optics assembly 10 may be used as a component in a variety of scanner designs.

[0061] The optical assembly shown in FIG. 1 may be incorporated within any type of fixed or portable optical scanner, for example the scan-type scanner of FIGS. 2a-2c the hand-held scanner shown in FIG. 2d or the hand-held computer terminal/scanner shown in FIG. 2e.

[0062] Referring to FIGS. 2a to 2c a hand-held, gun-type scanner of ergonomic design is shown. The scanner includes a scanner body designated generated 100 including a handle portion 102 and a head portion 104. The handle portion 102 is configured to be held upright in the user's palm and has a forward portion including a trigger 106 positioned preferably to be operable by the user's forefinger. The head portion 104 is provided at the top of the handle portion 102 and includes a front face including a scanning window 108 and a bulbous rear portion extending rearwardly from the handle 102 to rest on or above the user's hand in use.

[0063] The scanner 100 is pivotably fixed to a base portion 110 about a pivot axis 112 provided at the lower end of the handle 102. The base includes a flat bottom face 114 and extends outwardly from the handle portion both forward and rear and to the sides such that the assembly as a whole can be placed freestanding stably on a supporting surface. The scanner 100 is arranged to pivot on the base 110 in the forward/backward direction. The base 100 provides an interface between the scanner 100 and a host (not shown) by a cable 116. The cable 116 can simply carry power or can also include a data path either for control information to be passed to the scanner or for data read to be downloaded to the host from the scanner 100.

[0064] The base 110 includes on its underside 114 a pressure switch of any suitable known type (not shown) release of which indicates to a processor in the scanner that the scanner is being operated in hand-held mode. Accordingly the scanner switches to triggered mode indicating that reading will only take place when trigger 106 is activated.

[0065] The control system is illustrated in more detail in the flow chart of FIG. 4. It will be seen that a continuous loop is maintained by a suitable controller establishing whether or not the pressure switch is activated (step 150). If the pressure switch is deactivated then triggered (hand-held) mode is entered (step 152); further discussion of relevant features may be found in U.S. Pat No. 5,151,581, incorporated herein by reference.

[0066] In the alternative mode, where the pressure switch is activated, continuous scanning (hand free) mode 154 is entered. In this mode a presentation scan pattern is always activated allowing all items to pass in front of the scanner to be scanned. This can be used for example at a retail sales point such as a check-out stand. Accordingly the arrangement allows dual mode operation.

[0067] The scanner is preferably an omni-direction scanner but the gun-type configuration provides the benefits of a conventional one-dimensional scanner. In addition the adjustable angle provided by the incorporation of a pivot axis 112 allows the scanner as a whole to be positioned at any desired pivot angle for ease of reading and also allows the base to be angled to a comfortable position when in hand-held mode.

[0068] The main body 100 and base 110 are preferably modular such that one or other components can be changed at minimum expense to arrive at, for example, a cordless embodiment. Optionally a mode button 118 is additionally provided on the upper face of the head 104 (see FIG. 2c) allowing the user to select a scanning pattern of any desired type for example based on the bar code symbols or other indicia to be read, or the scanning conditions. In addition indicator lights such as LED's are provided at 120 which can indicate, for example, the mode of operation of the scanner, whether it is in hands-free or hand-held mode, and so forth.

[0069] Referring now to FIG. 2d, reference numeral 210 generally identifies a hand-held scanner in an alternative embodiment. The scanner may alternatively be gun-shaped, or any suitable configuration may be used. The scanner is manually-operable for example by a trigger (not shown). As known from the above-identified patents and applications incorporated by reference herein, a light source component,typically but not necessarily a laser, is mounted inside the scanner shown at block 210. The light source emits a light beam along a transmission path which extends outwardly through a window 218 that faces indicia, e.g. bar code symbols, to be read. Also mounted within the block 210 is a photodetector component, e.g. a photodiode, having a field of view, and operative for collecting reflected light returning through the window 214 along a path from the symbol.

[0070] The optical assembly of FIG. 1 is mounted within or as part of the block 210.

[0071] In whichever scanner type the arrangement is provided, operation is generally the same. The photodetector generates an electrical analog signal indicative of the variable intensity of the reflected light. This analog signal is converted into a digital signal by an analog-to-digital converter circuit. This digital signal is decoded by a decode module 222. The decode module 222 decodes the digital signal into data descriptive of the symbol. An external host device 224, usually a computer, serves mainly as a data storage in which the data generated by the decode module 222 is stored for subsequent processing.

[0072] The block 210 and decoder 222 are mounted on a PCB 214.

[0073] In operation, each time a user wishes to have a symbol read, the user aims the scanner at the symbol and pulls the trigger or otherwise initiates reading of the symbol. The trigger is an electrical switch that actuates the drive means. The symbol is repetitively scanned a plurality of times per second, e.g. more than 100 times per second. As soon as the symbol has been successfully decoded and read, the scanning action is automatically terminated, thereby enabling the scanner to be directed to the next symbol to be read in its respective turn.

[0074] In addition, the head need not be a portable hand-held type as fixedly mounted heads are also contemplated in this invention. Furthermore, the heads may have manually operated triggers, or may be continuously operated by direct connection to an electrical source.

[0075] The oscillations need only last a second or so, since the multiple oscillations, rather than time, increase the probability of getting a successful decode for a symbol, even a poorly printed one. The resonating reflector has a predetermined, predictable, known, generally uniform, angular speed for increased system reliability.

[0076] Turning now to FIG. 2e, there is shown an alternative hand-held optical scanner including additional features, this time taking the form of a scanning terminal 326. The terminal comprises a hand-held case 328 having a data display screen 30 and a data input keypad 332. The optical assembly of FIG. 1, within the case 328, produces a scanning light beam which extends outwardly through a window 334 which faces the indicia to be read. Light reflected from the indicia passes back through the window 334 and impinges on the photodetector component, for example a photodiode, which creates a returning light output signal. The information content within that signal may be stored in an on-board memory (not shown) or may be downloaded to a remote computer via a data port 336. Alternatively, the information may be transmitted via a radio frequency signal produced by an on-board radio transmitter/receiver 338.

[0077] In one embodiment the motor drive used to obtain scanning action is preferably a “taut band element” drive. This type of drive is fully described in, inter alia, U.S. Pat. Nos. 5,614,706 and 5,665,954 which are commonly assigned herewith and incorporated herein by reference. In essence, the arrangement includes an optical element such as a lightweight mirror mounted on a thin flexible strip (the “taut band”) mounted across an electromagnetic coil. A permanent magnet is attached to the optical element which interacts with a varying magnetic field created when an AC signal is applied to the coil to cause repetitive torsional motion in the flexible strip. As a result the optical element oscillates providing scanning motion.

[0078] FIG. 5 a shows a taut band element drive of known type in more detail. In particular coil 70, flexible strip 72, mirror 74 and permanent magnet 76 can be seen. The flexible strip 72 can be held against the coil 70 for example by a holding annulus 78. An AC voltage applied to the coil is represented schematically at 80 and causes torsional oscillation represented schematically by arrow 82. It will be apparent that this arrangement can replace the arrangement shown generally in FIG. 1 as mirror 28 and drive arrangement 44, 46, 48 in a manner apparent to the skilled reader.

[0079] In a further embodiment shown in FIG. 5b the flexible strip 72 is replaced by an elongate element 84 which is V-shaped in cross-section perpendicular to its elongate axis on which is mounted the mirror 74 and permanent magnet element 76. The V-shaped element 84 extends across a coil or is otherwise appropriately mounted in the same manner as previous thin flexible element 72 and the permanent magnet 76 interacts with the AC magnetic field resulting in torsional deflection represented by arrow 86. The V-shaped cross section of the band increases its stiffness and in particular ensures that the torsional deflection is uniform or substantially uniform over the length of the band, the mirror 74 being mounted on the apex of the “V”. It will be appreciated that alternative configurations for the band cross section can be contemplated such as X shaped, I or H shaped, W shaped as long as the requirements of torsional deflection and uniformity of that torsional deflection along the length of the band are maintained.

[0080] FIG. 6 shows in exploded form a practical mode of mounting the V-shaped element 84 of FIG. 5b. Coil 70 is mounted on an E-configuration core 71a including a central arm 71b which is received in the central recess of the coil 70 and outer arms 71c and 71d which extend either side of the coil and above it. A mounting plate 75a is received on the outer arm 71c, 71d of the E-core and extends above and across the coil 70. The mounting plate 75a includes a central aperture 75b defining the space across which the V-shaped element 84 extends. The V-shaped element 84 includes limbs 84a extending either side of its longitudinal axis symmetrically at either end and the centre and is mounted on the mounting plate 75a across the aperture 75b in any suitable manner, for example by securing the end limbs 84a to the upper face of the mounting place 75a. Cooperatingly configured V-shaped connecting elements 85 are secured to the V-shaped element 84 and generally aligned with the limbs 84a and the mirror 74 is mounted on the connecting elements 85 at the apex of the V-shaped element. Depending from the mirror 74 is a yoke 73 also substantially of V-shaped but straddling the V-shaped element 84, having its outer ends 73a, 73b attached to the rear of the mirror 74. The yoke 73 has a central portion which extends away from the mirror 74 and has lateral tabs 73a, 73d. The lateral tabs 73a and 73d are in register with the central limbs 84a, 84b of the V-shaped element and are attached thereto. The permanent magnet 76 is attached to the underside of the central portion of the yoke 73 for example to the underside of the tabs 73a and 73d. Accordingly the yoke 73 straddles the V-shaped element 84 such that the permanent magnet projects over or through the aperture 75b in the mounting plate 75a allowing optimum magnetic coupling with the coil 70. When an AC current is applied to the coil 70 the permanent magnet 76 oscillates which in turn gives rise to torsional flexing of the-V-shaped element 84 and oscillation of the mirror 74. The assembled arrangement is shown in FIG. 7.

[0081] An assembled module incorporating the arrangement of FIG. 7 is shown in FIG. 8 in which it will be seen that a substantially cuboidal housing is incorporated. The direction of angular motion of the mirror is depicted by arrow A.

[0082] Alternatively the type of motor drive used to oscillate the scan mirror can be a “mylar motor” for example of the unbalanced type as discussed below in relation to FIGS. 11-12 according to which the mirror is mounted to a mylar leaf spring which flexes back and forth as the permanent magnet is driven by the AC coil imparting oscillating motion. Yet a further alternative is a micro machine mirror as discussed in the introduction in relation to U.S. Pat. Nos. 4,387,297 and 4,409,470 according to which the mirror is driven back and forth directly by a suitable drive motor, preferably of very small dimension. Yet a further alternative is to use a mirror of known rotating polygon type as discussed in the introduction in relation ot U.S. Pat. No. 4,251,798 according to which the mirror comprises a solid body having a plurality of face angled to one another. As the body rotates the beam is scanned by successive rotating faces of the polygon body. In one embodiment the mylar motor can be used in an arrangement for one dimensional scanning whilst a V-shaped taut band element (described above) can be used for two dimensional scanning also as discussed in more detail below.

[0083] Turning now to the static optics assembly 10 shown in FIG. 1, it will be noted that the laser focusing lens 20, the laser aperture 24 and the collection mirror 26 are all defined by a single molded plastics material member, shown in cross-hatching and indicated generally by the reference numeral 52. The molded member 52 further acts to house and to locate the laser 18, the filter 38 and the photodetector 40.

[0084] The preferred laser 18 is a semiconductor laser, and preferably an SMD (“surface mounted device”) photodiode. This eliminates the need for photodiode standoffs and hand-soldering or sockets, as are used on prior art scanners. Typically, the laser will be a standard packaged edge-emitting laser. For minimum cost, the laser focusing is not adjustable, and the laser is simply installed with its mounting flange in contact with a shoulder molded as part of the molded member. This will position the laser accurately enough with respect to the molded focusing lens 20 to provide adequate performance within an inexpensive scanner. The fact that the focusing lens is molded as part of the same component as the shoulder 54 minimises tolerance build-ups that could otherwise cause improper focusing.

[0085] The laser is held in place within the molded member 52 by means of UV-curing cement. Since the plastics material of the molded member is transparent to UV light, the cement may be cured by shining UV light through the member into the cavity within which the laser is positioned. Cement may be applied to the laser 18, or to the molded member 52, with the laser then being pushed into the cavity until it abuts the positioning shoulder 54. The assembly may then be exposed to ultraviolet light for a few seconds, so curing the cement. If desired for higher performance, this method of retaining the laser also allows for a focusing adjustment to be made. In this case, the laser is gradually slid into the cavity while the output beam is being monitored. When correct focus is achieved, the assembly is exposed to UV light, thus curing the cement and locking the assembly into place.

[0086] In the unadjusted assembly, it may be possible to eliminate the cement by spring-loading the laser up against the positioning shoulder 54, for example by means of a rubber or foam washer 56 between the PCB 14 and the bottom of the laser 18.

[0087] As shown in the drawing, the laser 18 has dowardly-extending electrical leads 58 which are simply installed directly into the PCB 14. This eliminates hand-soldering, but soldering could be used if desired.

[0088] The fact that the leads extend downwardly into the circuit board means that in a conventional laser, the beam will be directly upwardly perpendicular to the board. The prism 22, previously described, is molded into the top of the molded member 52 to direct the vertical laser beam through the aperture 24 in the collector mirror 26 towards the scanning mirror 28. The prism 22 uses total internal reflection to reflect the laser beam, so it is not necessary to coat the upper surface with a reflective coating.

[0089] To provide for further focusing of the laser beam, should it be desired, it would also be possible to shape the exit surface 60 of the prism.

[0090] It is desirable that, somewhere along its path, the laser beam should pass through a beam stop. The aperture 24 in the collector mirror 26 may serve this purpose. Alternatively, the lens 20 or the reflecting or exit surface of the prism 22 could provide the beam stop.

[0091] In fact it is preferred to keep the aperture 24 as small as possible which improves the collection capability of the collector mirror 26. For example the aperture 24 may be in the region of 0.5 mm in diameter. This provides an additional advantage as the resulting diffraction pattern gives rise to a light distribution following a Bessel function which is particularly well adapted for scanning indicia.

[0092] The molded member 52 needs to be secured to the circuit board 14, and to that end snaps 62, 64 are provided. These automatically latch onto the circuit board when the component is installed. Alternatively, posts on the lower side of the molded member may protrude through the board to be heat-staked onto the bottom of the board. Ultrasonic staking could also be used.

[0093] The collector mirror 26 is coated with a reflective coating so that light impinging upon it will be reflected downwardly toward the photodetector 40. This coating may also cover that part 62 of the molded member that serves as a housing for the photodiode. This will render the optics assembly opaque in that area to prevent any light from reaching the photodiode except via the aperture 36 and the filter 38.

[0094] This reflective coating may also serve another function. Typically, the coating will be a thin film of metal such as gold, aluminium or chrome. These films are electrically conductive. Accordingly, the film also acts as an electromagnetic interference shield for the photodiode 40. The use of a surface coating to protect the photodiode enables the usual EMI shield to be dispensed with, thereby eliminating both the cost of a separate shield and the labor to have it installed within the assembly.

[0095] The coating is electrically grounded by extending a projection 66 of the molded member into a small socket 68 in the PCB. Alternatively, the projection 66 could be press-fitted into a plated through-hole in the board.

[0096] The housing portion 62 of the molded member 52 not only acts to hold the optical filter 38 in place on top of the photodiode 40, but also entirely surrounds the photodiode, thereby preventing stray light from reaching it. The aperture 36 in the housing may be small to limit the field of view of the detector, maximising ambient light immunity. The aperture needs to be accurately located with respect to the collector mirror 26, to allow the use of a minimum-sized field of view. Accurate relative positions of the aperture and the collector mirror are easily achieved since they are molded as a single part.

[0097] An alternative arrangement is shown in FIG. 3. In certain circumstances it is desired to provide an arrangement in which the beam 30 leaves the optical assembly at an angle other than 90° to the vertical (relative to the PCB 14). For example there may be instances in which the mounting requirements mean that the PCB 14 is mounted at a non-orthogonal position. In previous arrangements it has been necessary to overcome this problem by introducing additional spacers when mounting the PCB 14 such that the beam 30 leaves at the desired angle. This problem is solved in the arrangement according to FIG. 3 by adjusting the angle by which the beam exits the optical assembly to compensate for the mounting angle and remove the need to mount the PCB including a spacer. In the arrangement shown this is achieved by altering the angle of the scanning mirror assembly 28, which is of particular benefit as no adjustment of the laser mounting would be required. It will be appreciated that the remaining optics may also require adjustment to further compensate which adjustments can be easily achieved by the person skilled in the art.

[0098] The angle involved is dependent on the particular consumer requirements but may be in the region of 45-90° to the PC board, more preferably in the range of 60-70° and most preferably 65° to the PCB.

[0099] FIGS. 11 and 12 show an alternative optical assembly and motor drive embodiment to FIG. 3 according to an embodiment of the invention. The arrangement is mounted on a single base board 500 and includes a laser assembly 502 of suitable type for example of the type discussed above. A beam from the laser assembly 502 passes through an aperture 504 in a collector mirror 506 and is reflected by a scanning mirror 508. The returning beam is retroreflected onto the collector mirror 506 and directed to a detector of suitable known type 510. Turning now to the drive assembly for the scanning mirror 508 in more detail the mirror is mounted in conjunction with a permanent magnet 512 which interacts with a magnetic field provided by an AC current driven coil 514 to oscillate the mirror. The mirror is mounted relative to the base 500 via an attachment element 501 which is connected to the mirror by two mylar springs 518, 520. Although the mirror is mounted parallel to the base the attachment element 516 is mounted at 25° to the horizontal base and the mylar springs which extend perpendicular to the attachment strip 516 are hence at 25° to the vertical. Accordingly a scanning plane is defined at 25° to the vertical as discussed in more detail below. It will be appreciated, of course, that any appropriate angle can be selected. The scan angle is then defined by the amplitude of motion of the mirror and is preferably selected to be 50°. The mirror is of the unbalanced type, that is, no counterweights are provided against the mirror mass.

[0100] It will be seen that the mirror 508 is angled relative to the vertical to direct the scanning beam out of the upper face of the assembly. As with FIG. 1 although the mirror 508 is represented in FIG. 11 as being also angled out of a plane orthogonal with a plane of the paper, this is merely a drawing representation to render the figure, clearer. It will be seen that the attachment element 516 includes limbs 522 and 524 extending either side of the mylar springs 518, 520. These limbs are positioned within shaped recesses in side blocks 526, 528 allowing a certain amount of clearance for the limbs which provides adequate space for the desired scanning angle to be achieved whilst providing stops to limit the amount of oscillation of the mirror should a shock be imparted to the unit for example by dropping it.

[0101] Accordingly a beam emitted by the laser assembly 502 incident on the mirror 508 is swept through an angle of 50° by the scanning mirror, however the plane of sweep of the beam (the scan plane) is not at 90° to the base 500 but is at an angle constrained by the direction in which the magnet is driven to oscillate i.e. the axis of flexing of the mylar springs. This can be best be understood with reference to FIGS. 13a and 13b. In FIG. 13a the laser beam 30 enters in the Y direction. The mirror and drive assembly are not shown but in FIG. 13a the normal mirror configuration is assumed that is the mirror is angled at 45° to the X Z plane and is mounted to oscillate about the X direction. As a result a scan plane 530 is established in the Y Z plane. However in FIG. 13b the mirror and mirror drive are mounted as discussed in relation to FIGS. 11 and 12. It will be seen, therefore, that the scan line is obtained in a plane 532 at 25° to the Y Z plane. Again, any desired scan plane angle or scanning angle can be selected.

[0102] Accordingly a non-90° output angle of the beam as discussed in relation to FIG. 3 is achieved in a different manner.

[0103] FIG. 9 shows a second preferred embodiment in which two-dimensional scanning motion is achieved by using two mirrors each oscillating in an orthogonal claim. Multi-pattern scanners can be achieved by using two reflector X-Y motion as described in U.S. Pat. Nos. 5,581,070, 5,637,856 and 5,614,706 all of which are incorporated herein by reference. Preferably the two reflectors are driven by a thin flexible element-type drive of the type shown in FIG. 5a or FIG. 7. In particular the optical module 10 emits a beam 30 through aperture 24 in collector 34 which is oscillated in a first direction for example the X direction by a first oscillating mirror 28a mounted on a first V-shaped element 84 and is then oscillated in a second direction for example the Y direction by a second mirror 28b mounted on a V-shaped band 84. As a result any desired scanning pattern can be achieved at the target as represented schematically by pattern 11. All of the elements are preferably provided in a single module as can be seen from the base lay out depicted in FIG. 10. In particular laser 18 emits an outgoing beam 30 through an aperture 34 in collector mirror 26. The beam is oscillated in the X direction by mirror 28a and in the Y direction by mirror 28b giving rise to a scanning pattern shown schematically at 11. The returning beam 32 returns along the reflection path and is directed onto the detector 40 by the collector mirror 26. It will of course be appreciated that the arrangement is preferably used in conjunction with the optical assembly shown in FIG. 1 and the exact positioning and orientation of the parts will be apparent to the skilled reader.

[0104] FIG. 14 shows an alternative scan engine form-factor and ergonomic housing variation for incorporation of the scanner described herein or any other suitably dimensioned scanner. In particular the scanner is incorporated into a pen-type housing 600 having a scanning window 602. The pen-type housing 600 is preferably elongate having broad front and rear faces 604, 606 and narrow side faces. The scanning window is preferably provided at the upper end of broad face 604, at the opposite end to the pen “nib” 612 . Scanning can be triggered by one or more triggers 608, 610 provided for example on the side or front face of the pen housing 600. The pen nib 612 can either be a conventional pen or an electronic pen. Because of the broad faces the arrangement easily houses a scanner module of the type described herein. In addition the positioning of the window 602 allows ergonomic scanning and the positioning of a plurality of triggers allows left or right handed users to use the scanner with ease. It will be seen that the broad rear face 606 of the housing 600 contacts the user's palm in reading mode for comfort and ease of use whilst in the writing mode the narrow side face contacts the user's palm, so that the arrangement can be used normally as a pen.

[0105] It will be understood that each of the features described above, or two or more together, may find a useful application in other types of scanners and bar code readers differing from the types described above.

[0106] While the invention has been illustrated and described as embodied in a scan module for an electro-optical scanner, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit and scope of the present invention. In particular it will be recognised that features described in relation to one embodiment can be incorporated into other embodiments as appropriate in a manner that will be apparent to the skilled reader.

[0107] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.

Claims

1. An optical scan module comprising: (a) a light source for emitting a light beam; (b) a scanning assembly for receiving said light beam and for generating therefrom a scanning beam directed to an indicia to be read; (c) a photodetector; and (d) a one-piece optical element including: (i) a beam-shaping lens for receiving and shaping said light beam prior to transmission to said scanning assembly; and (ii) a mirror-defining portion for locating a mirror surface, said mirror surface being arranged to receive reflected light from said indicia and to direct it to said photodetector.

2. An optical scan module according to claim 1 wherein said mirror surface comprises a coating on said one-piece optical element.

3. An optical scan module according to claim 1 wherein said one-piece optical element defines a beam stop for said light beam.

4. An optical scan module according to claim 3 wherein said beam stop is defined by an aperture in said mirror-defining portion.

5. An optical scan module according to claim 3 wherein said beam stop is defined by said beam-shaping lens.

6. An optical scan module according to claim 1 wherein said one-piece optical element includes an integral beam-folding prism.

7. An optical scan module according to claim 6 wherein said beam-folding prism is arranged to fold said beam by total internal reflection.

8. An optical scan module according to claim 6 wherein said beam-folding prism defines a beam stop for said light beam.

9. An optical scan module according to claim 1 wherein said one-piece optical element includes a light-source-locating portion.

10. An optical scan module according to claim 9 wherein said light source locating portion comprises a shoulder on the one-piece optical element which abuts said light source.

11. An optical scan module according to claim 1 wherein said one-piece optical element includes a light-source-housing portion.

12. An optical scan module according to claim 1 wherein said one-piece optical element includes a photodetector-locating portion.

13. An optical scan module according to claim 1 wherein said one-piece optical element includes a photodetector housing portion.

14. An optical scan module according to claim 13 wherein said photodetector housing portion comprises a locating cavity within the integral optical element.

15. An optical scan module according to claim 14 wherein said photodetector housing portion is coated with an electromagnetic shielding material.

16. An optical scan module according to claim 13 wherein the electromagnetic shielding material further provides optical shielding.

17. An optical scan module according to claim 2 wherein the one-piece optical element includes a photodetector housing portion, said photodetector housing portion also being coated with said coating to provide electromagnetic shielding for said photodetector.

18. An optical scan module according to claim 13 wherein said photodetector housing portion defines an aperture to limit the photodetector's field of view.

19. An optical scan module according to claim 1 wherein said one-piece optical element includes mounting portions for mounting said optical scan module to a printed circuit board.

20. An optical scan module according to claim 19 wherein said housing portions comprise flexible snaps.

21. An optical scan module according to claim 1 wherein said one-piece optical element is molded of a plastics material.

22. An optical scan module according to claim 1 wherein said mirror surface is arranged to receive said reflected light via said scanning assembly.

23. An optical scan module according to claim 1 wherein said optical scan module comprises a mounting base defining a reference plane and the scan module is arranged such that a light beam is emitted from the scan module at a non-orthogonal angle to the reference plane.

24. An optical scan module according to claim 23 in which the mirror defining portion is positioned to provide emission of a light beam at said non-orthogonal angle.

25. An optical scan module comprising a mounting base defining a reference plane and having mounted thereon; a) a light source for emitting a light beam; b) a scanning assembly for receiving said light beam and for generating therefrom a scanning beam directed to an indicia to be read in which said module is arranged such that the scanning beam defines a scanning plane which is non-orthogonal to the reference plane.

26. An optical scan module as claimed in claim 25 in which the scanning assembly is mounted at an angle such that the scanning plane is non-orthogonal to said reference plane.

27. An optical scan module as claimed in claim 25 in which the scanning plane is at an angle to the reference plane in the range of 45-90°, more preferably 60-70° and most preferably 65°.

28. An optical scan module according to claim 4 wherein said aperture is of relatively small dimension compared to said mirror-defining portion.

29. An optical scan module according to claim 28 in which said aperture is of suitable dimension to cause diffraction of the beam.

30. An optical scan module as claimed in claim 28 in which the aperture diameter is approximately 0.5 mm.

31. An optical scan module comprising a base defining a reference plane, a beam reflecting element and a beam reflecting element drive, in which the beam reflecting element is mounted relative to the base to be driven to oscillate in a plane angled to a plane orthogonal to the reference plane.

32. A module as claimed in claim 31 in which the reflecting element is mounted on a resilient deformable element disposed on the base to deform about an axis non-parallel to the reference plane.

33. A module as claimed in claim 32 in which the reflecting element is mounted on a flexible leaf spring having a flexing axis non-parallel to the reference plane.

34. A small-size optical scan module comprising a substantially rectangular module base, and mounted thereon a light source for emitting a light beam, a scanning assembly for receiving said light beam and for generating therefrom a scanning beam directed to an indicia to be read, a detector, and a one piece optical element including a beam shaping lens for receiving and shaping said light beam prior to transmission to said scanning assembly and a mirror defining portion for locating a mirror surface, said mirror surface being arranged to received retro-reflected light and to direct it to said detector.

35. A module as claimed in claim 34 in which the scanning assembly includes a reflecting element moveably mounted relative to the base and means for moving the reflecting element, in which the reflecting element is mounted via a resilient coupling.

36. A module as claimed in claim 35 in which the resilient coupling comprises a leaf spring.

37. A module as claimed in claim 35 in which the resilient coupling comprises a torsionally deformable elongate element.

38. A module as claimed in claim 35 in which the reflecting element is moveable to oscillate at high speed.

39. An optical scan module comprising a light source for emitting a light beam, a first scanning assembly for receiving said light beam and for generating therefrom a scanning beam in a first scanning plane; a second scanning assembly for receiving said scanning beam from said first scanning assembly and for generating a scanning beam also scanning in a second plane non-parallel to the first scanning plane; and a detector for detecting a returning beam in which the light source, the scanning assembly and the detector are provided on a single module base.

40. A module as claimed in claim 39 further including a one piece optical element including a beam-shaping lens for receiving and shaping said light beam prior to transmission to said scanning assembly; and a mirror defining portion for locating a mirror surface said mirror surface being arranged to receive retro-reflected light and to direct it to said detector.

41. A module as claimed in claim 39 in which each reflector element is mounted on a torsionally deformable element and driven to oscillate on said element.

42. A scanning element for an optical scanner, the scanning element including a reflector for reflecting a scanning beam and a drive for driving the reflector in a scanning motion in which the reflector is mounted on a torsionally deformable element and is driven in a scanning motion thereon, and in which the torsionally deformable element is elongate, deformable about its elongate axis, and non-planar in cross sectional shape perpendicular to its elongate axis, said cross sectional shape being selected to provide substantially uniform torsional deformation along the elongate axis.

43. An element as claimed in claim 42 in which the torsionally deformable element has, as its cross sectional shape one of the group of shapes: V shaped, X shaped, I shaped, H shaped, W shaped.

44. An element as claimed in claim 43 in which the torsionally deformable element is V-shaped in cross sectional shape.

45. An element as claimed in claim 44 in which the mirror is mounted at the apex of the V-shaped torsionally deformable element.

46. An optical reader comprising a reader housing, and a reading beam generator, a reading beam detector and a reading beam window mounted in the housing, the housing comprising a base, a handle and a head portion, including the reading window, mounted at one end of the handle, the handle being attached at its other end to the base, in which the reader is free-standing on the base.

47. A reader as claimed in claim 46 in which the handle is pivotably mounted on the base.

48. A reader as claimed in claim 46 in which the base includes a mode detector to detect whether the reader is in free-standing mode or hand-held mode.

49. A reader as claimed in claim 48 in which the mode detector comprises a pressure switch on the underside of the base.

50. A reader as claimed in claim 48 in which operation of the reader is varied according to the mode detected.

51. A reader as claimed in claim 50 in which, if hand-held mode is detected a reading beam is generated only when an actuator is actuated.

52. A reader as claimed in claim 50 in which if free-standing/hands-free mode is detected a reading beam is generated continuously allowing hands-free operation.

53. A reader as claimed in claim 46 comprising a flying spot optical scanner.

54. A reader as claimed in claim 46 comprising a field of view scanner.

55. An optical scan module as claimed in claim 1 further comprising a pen-type module housing having a rectangular cross section perpendicular to its long axis defining opposing broad elongate faces and opposing narrow elongate faces, having as one end a pen end and further including a scanning window provided on a broad elongate face substantially at the other end.