U.S. patent application number 10/445524 was filed with the patent office on 2003-11-20 for imaging module for optical reader comprising refractive diffuser.
This patent application is currently assigned to Welch Allyn Data Collection, Inc.. Invention is credited to Barber, Charles P., Coleman, Eric, Ehrhart, Michael, Havens, William H., Hennick, Robert J., Hunter, Vivian L., McCall, Melvin D..
Application Number | 20030213847 10/445524 |
Document ID | / |
Family ID | 25184108 |
Filed Date | 2003-11-20 |
United States Patent
Application |
20030213847 |
Kind Code |
A1 |
McCall, Melvin D. ; et
al. |
November 20, 2003 |
Imaging module for optical reader comprising refractive
diffuser
Abstract
The present invention is an imaging module including various
optical components and a circuit board, which, in one embodiment,
carries essentially an entirety of illumination and aiming LEDs of
the module. The module includes a combination of features which
result in the size of the module being reduced. The module may
comprise a refractive optic diffuser plate manufactured using a
textured surface mold.
Inventors: |
McCall, Melvin D.; (Homer,
NY) ; Hunter, Vivian L.; (Baldwinsville, NY) ;
Barber, Charles P.; (Fayetteville, NY) ; Havens,
William H.; (Skaneateles, NY) ; Coleman, Eric;
(Liverpool, NY) ; Ehrhart, Michael; (Liverpool,
NY) ; Hennick, Robert J.; (Auburn, NY) |
Correspondence
Address: |
Eric M. Smith
WALL MARJAMA & BILINSKI LLP
Suite 400
101 S. Salina St.
Syracuse
NY
13202
US
|
Assignee: |
Welch Allyn Data Collection,
Inc.
Skaneateles Falls
NY
|
Family ID: |
25184108 |
Appl. No.: |
10/445524 |
Filed: |
May 27, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10445524 |
May 27, 2003 |
|
|
|
09802579 |
Mar 8, 2001 |
|
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6601768 |
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Current U.S.
Class: |
235/462.42 |
Current CPC
Class: |
G06K 7/10742 20130101;
H05K 1/189 20130101; G06K 7/10881 20130101; G06K 7/10732
20130101 |
Class at
Publication: |
235/462.42 |
International
Class: |
G06K 007/10 |
Claims
What is claimed is:
1. A method for making an imaging module for an optical reader,
said module having a plurality of light emitting elements, said
method comprising the steps of: providing a mold; applying a
texture substantially throughout a surface of said mold; making an
optical plate using said mold, whereby said plate comprises a
textured diffuser surface substantially uniformly formed throughout
a surface of said plate; and disposing said optical plate forward
of at least one of said plurality of light emitting elements.
2. The method of claim 1, wherein said applying step includes the
step of applying a micro cylinder texture substantially throughout
a surface of said mold.
3. The method of claim 1, wherein said applying step includes the
step of a applying a texture to said mold such that during said
making step, a refractive optic diffuser surface is formed on said
plate.
4. The method of claim 1, wherein said applying step includes the
step of applying a texture to said mold such that during said
making step, a refractive optic diffuser surface is formed on said
plate, said diffuser surface comprising a plurality of
substantially cylindrical microlenses.
5. The method of claim 1, wherein said applying step includes the
step of applying a texture to said mold such that during said
making step, a refractive optic diffuser surface is formed on said
plate, said diffuser surface comprising a plurality of
substantially cylindrical microlenses formed in a randomized
pattern.
6. The method of claim 1, wherein said applying step includes the
step of applying a texture to said mold such that during said
making step, a refractive optic diffuser surface is formed on said
plate, said diffuser surface comprising a plurality of
substantially adjacent cylindrical microlenses of varying
sizes.
7. The method of claim 1, wherein said applying step includes the
step of applying a texture to said mold such that during said
making step, a refractive optic diffuser surface is formed on said
plate, said diffuser surface comprising a plurality of
substantially cylindrical microlenses and occasional cross
connections connecting valleys between an adjacent pair of
cylindrical microlenses.
8. The method of claim 1, wherein said applying step comprises an
acid resist process.
9. The method of claim 1, wherein said optical plate comprises
polycarbonate.
10. An illumination system for an optical reader having an imaging
axis, said illumination system comprising: a plurality of light
emitting diodes; and an optical plate positioned forward of said
plurality of light emitting diodes, said optical plate having a
diffuser surface formed on a light exit surface there of.
11. The illumination system of claim 10, wherein diffuser surface
is a substantially cylindrical mircolense diffuser surface.
12. The illumination system of claim 10, wherein said diffuser
surface comprises substantially cylindrical microlenses adapted to
diffuse light substantially via refractive optics.
13. The illumination system of claim 10, wherein said plurality of
spaced apart light sources comprise at least one vertically
oriented column of light emitting diodes, and wherein said diffuser
surface comprises substantially vertically oriented substantially
cylindrical microlenses for diffusing light substantially
horizontally with respect to said substantially cylindrical
microlenses.
14. The illumination system of claim 10, wherein said plurality of
spaced apart light sources comprise at least one horizontally
oriented row of spaced apart light sources and wherein said
diffuser surface comprises substantially horizontally oriented
substantially cylindrical microlenses for vertically diffusing
light transmitted through said optical plate.
15. The illumination system of claim 10, wherein said plurality of
light sources comprise a plurality of vertically arranged columns
of light sources, and wherein said diffuser surface comprises
vertically oriented substantially cylindrical microlenses for
diffusing light substantially horizontally with respect to said
substantially cylindrical microlenses.
16. The illumination system of claim 10, wherein said optical plate
includes at least one wedge for directing light from any of said
light emitting elements to a corner of a target area.
17. A method of making an optical diffuser plate comprising the
steps of: providing a mold, said mold having at least one textured
surface; providing a material that is moldable and transmissive of
light at predetermined wavelengths; and forming an optical diffuser
plate, wherein the step of forming the optical diffuser plate
includes injecting the material into the mold.
18. The method of claim 17, wherein the step of providing a mold
includes the step of forming said at least one textured surface by
etching.
19. The method of claim 17 wherein the at least one textured
surface includes a plurality of cylindrical lenses.
20. The method of claim 19 wherein the plurality of cylindrical
lenses includes a plurality of cylindrical microlenses.
21. The method of claim 19 wherein the plurality of cylindrical
lenses are randomly oriented with respect to one another.
22. The method of claim 17 wherein said textured surface includes a
plurality of substantially parallel valleys.
23. The method of claim 22 wherein said textured surface further
includes a plurality of cross-connections, each of said plurality
of cross-connections connecting adjacent valleys thereby forming a
plurality of microlenses.
24. An optical reader comprising: an image sensor; a light source
disposed proximate to said image sensor; and a diffuser plate
disposed to receive light from said light source; wherein said
diffuser plate includes a plurality of microlenses.
25. The optical reader of claim 24 wherein said diffuser optical
plate further includes a targeting optical element.
26. The optical reader of claim 25 wherein said targeting optical
element includes a plurality of cylindrical lenses.
27. The optical reader of claim 25 wherein said targeting optical
element is adapted to project a single horizontal aiming line.
28. The optical reader of claim 25 wherein said light source
includes a plurality of light sources.
29 The optical reader of claim 26 wherein said plurality of light
sources includes a plurality of light emitting diodes.
30. The optical reader of claim 28 wherein said targeting optical
element includes: a plurality of aiming pattern wedges; and a
plurality of cylindrical lenses, wherein each of said plurality of
cylindrical lenses is optical coupled to a respective aiming
pattern wedge of said plurality of aiming pattern wedges. each of
which is coupled to one of said plurality of light sources.
31. An optical reader comprising: a printed circuit board; and a
housing disposed about said printed circuit board, wherein said
printed circuit board includes: an electronic circuit for capturing
an image; an electronic circuit for storing said image; an
electronic circuit for decoding said image; and an electronic
circuit for providing illumination.
32. The optical reader of claim 31 wherein said electronic circuit
for capturing an image includes an image sensor chip.
33. The optical reader of claim 32 wherein said electronic circuit
for providing illumination includes a light source disposed
proximate to said image sensor chip.
34. The optical reader of claim 33 wherein said light source
includes a plurality of light emitting diodes, wherein at least two
light emitting diodes of said plurality of light emitting diodes
are disposed on opposite sides of said image sensor chip.
35. The optical reader of claim 34 wherein said plurality of light
emitting diodes are disposed in a substantially linear array.
36. The optical reader of claim 32 further including a diffusing
optical plate disposed proximate to said light source.
37. The optical reader of claim 36 further including a lens
assembly optically coupled to said image sensor chip.
38. The optical reader of claim 37 wherein said diffusing optical
plate includes a light entry surface and a light exit surface,
wherein said light exit surface includes a plurality of
substantially cylindrical microlenses.
39. The optical reader of claim 38 wherein said plurality of
substantially cylindrical microlenses includes a plurality of
substantially cylindrical microlenses oriented in a horizontal
direction.
40. The optical reader of claim 33 wherein said printed circuit
board includes a flexible printed circuit board.
41. The optical reader of claim 40 wherein said light source
includes at least one light pipe.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 09/802,579, filed Sep. 23, 2002, which claims
the benefit of U.S. Provisional Application Serial No. 60/387,842
filed Jun. 11, 2002, both of which are incorporated herein by
reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to optical reading devices in
general and in particular to an apparatus for packaging
illumination optical elements, receive optical elements, and signal
processing elements of an optical reader.
BACKGROUND OF THE INVENTION
[0003] Currently available optical readers include illumination
elements, electronic signal processing circuits, image capture
circuits and decoding circuits that are carried by more than one
circuit board. For example, shown in U.S. Pat. No. 5,780,834 is an
optical reader having numerous circuit boards, including an LED
board for carrying illumination LEDs, an "imaging board" carrying
an image sensor and circuitry for processing signals generated from
the image sensor, and a "mother board" carrying image capture and
decoding circuitry. U.S. Pat. No. 5,521,366 describes a modular
housing having a rear printed circuit board, a front printed
circuit board and a LED circuit board on which LEDs are
mounted.
[0004] Assembly of a prior art reader requires mounting of separate
circuit boards to separate internal structures of a reader, and
providing electrical connection between the multiple circuit
boards. In addition to being difficult to assemble, the multiple
circuit board design imposes size requirements on the optical
reader housing in which the electrical components are to be
integrated.
[0005] There is a need for an easier to manufacture and lower cost
packaging apparatus for packaging optical and electrical components
of an optical reader.
SUMMARY OF THE INVENTION
[0006] According to its major aspects and broadly stated the
present invention is a module for packaging optical illumination,
optical receive, and electrical signal processing components of an
optical reader.
[0007] The module includes a frame which carries a circuit board,
preferably a printed circuit board (PCB) and various optical
components. In one embodiment, the frame includes a back plate
having a retainer for receiving an optical lens barrel, and a
recess for receiving and aligning an image sensor which is carried
by the PCB. The frame may also include resilient fingers which
enable the frame to receive certain optical components of the
module in an adhesiveless snap-fitting arrangement
[0008] According to a preferred assembly method for assembling the
module, the PCB is first mounted onto the frame's back plate such
that the image sensor of the PCB is received and aligned by the
recess of the back plate. Next, illumination and aiming LEDs are
soldered to the PCB to mount the LEDs. As a space conserving
measure, the LEDs may be mounted so that a portion of rear surfaces
of the illumination LEDs oppose a portion of the top surface of the
image sensor when mounted.
[0009] After the LEDs are mounted to the PCB, additional components
are incorporated in the module. In a preferred embodiment, a lens
barrel is incorporated in the retainer, then an aperture plate
having domed apertures for shaping light rays emanating from the
aiming LEDs is placed over the LEDs. Finally, an optical plate for
diffusing light rays emanating from the illumination LEDs is
snap-fit into the frame. The optical plate may comprise discreet
diffuser elements or may comprise a substantially uniform diffuser
surface formed substantially over an entire surface thereof except
for areas of the plate in which aiming optic elements are
incorporated.
[0010] In addition to having diffusers for diffusing illumination
light, the optical plate may also include optical elements for
imaging light from the apertures onto a target defined by a
reader's field of view. In one embodiment of the invention, the
aiming LEDs and their associated optics project a solitary
horizontal aiming line onto a target in a field of view.
[0011] In another embodiment, the aiming LEDs and their associated
optics project a split horizontal line aiming pattern onto a target
in a field of view. The gap defined by the line segments of the
split horizontal aiming line aid a user in locating the center of
an optical reader's field of view.
[0012] In another embodiment of the imaging module, the imaging
module frame is deleted and the module retainer assembly is mounted
to and supported entirely by the printed circuit board prior to
being installed in a reader housing.
[0013] In another embodiment of the imaging module, the components
of the imaging module are mounted on a "flex strip" type printed
circuit board.
[0014] In another embodiment of the imaging module, light pipes are
mounted to the printed circuit board. The light pipes transmit
light from a source location proximate the circuit board to a
location remote from the source location. The light pipes may be
molded light pipes or may be provided by fiber optic cable.
[0015] In another embodiment of the imaging module, an image sensor
is face-mounted to a printed circuit board, and folding optics are
provided in the retainer assembly of the module for folding the
optical imaging path so that the imaging path extends substantially
parallel with the image sensor and circuit board. This type of
module is especially well suited for installation in "thin" reader
housings such as a reader housing for a personal data assistant or
"PDA" device.
[0016] The printed circuit board may be a full function printed
circuit board which carries a solid state image sensor and
essentially the entirety of electronic circuitry required for
supporting essentially all of the processing and control operations
to be performed by the optical device in which the module is to be
incorporated. Circuitry incorporated in the single PCB includes
signal processing circuitry for processing signals generated from
the image sensor, image capture circuitry for storing image data,
and decoding and/or recognizing circuitry for decoding and/or
recognizing indicia represented in image data that has been
stored.
[0017] In order to accommodate the full function circuit board, the
rear surface of the frame's back plate should be made to have a
central recess for aligning and receiving the image sensor, and
peripheral recesses for accommodating circuit elements such as
electrical components and/or wiring which may emanate from the
front surface of the full function printed circuit board.
[0018] These and other details, advantages and benefits of the
present invention will become apparent from the detailed
description of the preferred embodiment herein below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] For a fuller understanding of the nature and objects of the
invention, reference should be made to the following detailed
description of a preferred mode of practicing the invention, read
in connection with the accompanying drawings, in which:
[0020] FIG. 1A is a front perspective assembly diagram illustrating
assembly of an image capture module according to the invention;
[0021] FIG. 1B is a rear perspective assembly diagram illustrating
assembly of an image capture module according to the invention;
[0022] FIG. 1C is a front perspective view of an assembled image
capture module according to the invention;
[0023] FIG. 1D is a rear perspective view of an assembled image
capture module according to the invention;
[0024] FIG. 1E is a representation of an exemplary illumination and
aiming pattern projected by a module in accordance with the
invention;
[0025] FIG. 1F illustrates a restricted width split horizontal line
aiming pattern according to the invention;
[0026] FIG. 1G illustrates a split horizontal line aiming pattern
according to the invention;
[0027] FIG. 1H is an enlarged rear perspective view of an optical
plate according to the invention showing an inner surface of an
optical plate;
[0028] FIG. 1I is a top cross sectional view of the optical plate
of FIG. 1H taken at the elevation defined by line I-I of FIG.
1H;
[0029] FIG. 1J is an enlarged rear perspective view of an
alternative optical plate according the invention;
[0030] FIG. 1K is a top cross sectional view of the optical plate
of FIG. 1J taken at the elevation defined by line K-K of FIG.
1J;
[0031] FIG. 2a is an enlarged front view of an alternative optical
plate according to the invention;
[0032] FIG. 2b is a blown up view of the surface of the plate shown
in FIG. 2a;
[0033] FIG. 2c as an exploded side view of the plate section shown
in FIG. 2b.
[0034] FIG. 2d is an illumination diagram illustrating an
illumination pattern according to the invention;
[0035] FIGS. 2e and 2f are top views of molds which may be used in
the manufacture of optical plates according to the invention;
[0036] FIGS. 3a-3d are various views of a frameless imaging module
according to the invention;
[0037] FIGS. 4a-4d are various views of another frameless imaging
module according to the invention;
[0038] FIGS. 5a-5e are perspective views of various alternative
frameless imaging modules according to the invention;
[0039] FIGS. 6a-6d are various views. of an imaging module
according to the invention having light pipe illumination and a
flex strip printed circuit board;
[0040] FIGS. 7a-7d are various views of an imaging module according
to the invention having molded light pipe illumination;
[0041] FIGS. 7e-7h are various views of an imaging module according
to the invention having molded light pipe illumination and a face
mounted image sensor;
[0042] FIGS. 7i-7k are side views of various light pipe and
illumination assemblies according to the invention;
[0043] FIG. 8 is a block electrical diagram of the component of an
optical reader which may be mounted on a printed circuit board;
[0044] FIGS. 9a-9k are views of various housings of which the
module of the invention may be incorporated;
[0045] FIG. 10 is a side view of prior art optical reader
module.
DETAILED DESCRIPTION OF THE INVENTION
[0046] An embodiment of an imaging module 10 according to the
invention is shown in FIGS. 1A-1D. Imaging module 10-1 is
specifically designed for use in an indicia reader such as a bar
code reader, an optical character recognition (OCR) reader or in a
reader having both bar code and OCR reading capabilities. However,
it will be understood that features of module 10 may also find use
in other devices requiring image capture including personal data
assistants, "PDA's", video cameras, digital cameras, cellular
phones, and medical viewing instruments.
[0047] Module 10-1 includes a mounting frame 12 which is adapted to
receive both electrical components and optical components of an
imaging system. Specifically, mounting frame 12 receives a circuit
board, such as a printed circuit board (PCB) 14, illumination LEDs
16, aiming LEDs 18, aperture plate 24 and optical plate 26.
[0048] More specifically, the frame 12 includes a back plate 30 and
sidewalls including top sidewalls 31 and side sidewalls 31'. Back
plate 30 includes a recess 34 for receiving a solid-state image
sensor chip 32 and a plurality of pinholes 36 for receiving leads
38 of illumination and/or aiming light sources, provided by LEDs 16
and 18. Back plate 30 further includes a retainer 40 for receiving
a receive optics lens assembly 41, e.g. a lens barrel, which may be
installed in retainer 40 prior to or after any step in the assembly
process as described in greater detail below.
[0049] In assembling the module 10-1, PCB 14 is first mounted to
back plate 30 using screws 56 and frame 12 is oriented so that an
opening 13 is exposed. When PCB 14 is mounted to back plate 30 the
image sensor 32 carried by PCB 14 is received by center recess 34
which is shaped complimentary with the shape of image sensor 32 as
shown. After mounting PCB 14 to frame 12, an assembler mounts
illumination LEDs 16 and aiming LEDs 18 to PCB 14.
[0050] To mount LEDs 16 and 18 to PCB 14, the leads 38 of LEDs 16
and 18 are pushed through aligned pin holes 36 and 54 of back plate
30 and PCB 14, then the LEDs 16 and 18 are soldered to PCB 14.
Preferably, all of the LEDs 16 and 18 are positioned in their
respective pinholes before soldering. In soldering LEDs 16 and 18,
the rear surface 15 of PCB 14 should be oriented for easy access by
an assembler. To the end that LEDs 16 and 18 remain in a desired
orientation which is substantially normal to PCB 14 during
soldering, a standardly known fixture (not shown) shaped to receive
LEDs 16 and 18 can be temporarily applied over LEDs 16 and 18
through the soldering process.
[0051] An important feature of the imaging module is that leads 38
of the illumination LEDs 16 are installed in a nearly abutting
relation to sides 32s of image sensor 32 such that a portion of
rear surfaces 19 of LEDs 16 oppose a portion of a front surface 32f
of image sensor 32 when the LEDs 16 are completely installed. This
arrangement reduces the size of the imaging module 12, enabling
installation in smaller sized optical readers.
[0052] After LEDs 16 and 18 are mounted onto PCB 14 in the manner
described above, the aperture plate 24 is mounted into the frame
12, the plate having domes 42 which fit over the aiming LEDs 18.
The domes are preferably opaque to substantially block all light
emanating from aiming LEDs 18, except light exiting the domes
through slit apertures 43. Slit apertures 43 should be formed so
that a desired shaped aiming pattern of illumination is projected
onto a target, T. Preferably, aperture slits 43 are shaped
rectangularly so that a horizontal line pattern is projected onto a
target.
[0053] Aperture plate 24 further includes a number of cutaway
sections 46 providing clearance to allow the aperture plate to be
fitted over the illumination LEDs 16. The domes 42 and cutaway
sections 46 are formed so they do not contact LEDs 16. In the
embodiment shown, each LED is held in a desired orientation while
being soldered, so that the flat surfaces of LED bases 17 are
biased against the flat surface of back plate 30 during the
assembly process. In a further aspect, aperture plate 24 includes a
shroud 58 for preventing light transmitted by the LEDs 16 and 18
from interfering with the receive optical systems of the
module.
[0054] After aperture plate 24 is placed over LEDs 16 and 18 and
moved toward back plate 30, an optical plate 26 is snap-fitted into
the opening 13 of the frame 12. Optical plate 26 includes diffusers
27 for diffusing light emanating from the illumination LEDs. In
addition to having diffusers 27 formed on a front surface thereof
optical plate 26 may further have wedges 28 formed on an inner
surface thereof. Wedges 28 direct light from LEDs 16 toward corners
of a target T so as to improve the uniformity of a target's
illumination.
[0055] Resilient fingers 48 having hook ends 49 are formed in the
top sidewalls 31 or side sidewalls 31' of frame 12 to enable
snap-fitting of the optical plate 26 onto frame 12. In the
embodiment shown, the optical plate 26 is snap-fitted onto the
frame 12 by pulling back the resilient fingers 48, pushing the
optical 26 toward the back plate 30, then releasing the fingers 48
to lock plate 26 in position inside module 10-1. The plate and
fingers may be formed.
[0056] The aperture plate 24 includes spacers 52 which operate to
bias aperture plate 24 toward back plate 30 when optical plate 26
is snap fitted onto frame 12. The spacers 52 further transfer the
force imparted by fingers 48 on optical plate 26 to the aperture
plate 24, securing both the aperture plate 24 and optical plate 26
inside frame 12 without the use of adhesives or outside mechanical
securing means, such as screws or pins. In the embodiment of FIG.
1C optical plate 26 includes a separate diffuser 27 for each
illumination LED 16. In the alternative embodiment of FIG. 2A a
single diffuser 27' is formed substantially throughout the surface
of plate 26'.
[0057] For substantially uniform illumination of a target area T in
an overall pattern 72 corresponding to the field of view of image
sensor 32 (in which corners are illuminated to a brightness of at
least about 50% of the target areas maximum brightness), light
emanating from each LED in a four LED illumination system should be
diffused to provide a substantially rectangular illumination
pattern 72R as is shown in FIG. 2d.
[0058] Shown in FIG. 2e is a surface of a mold 76-1 for use in
manufacturing the multiple diffuser optical plate of FIG. 1c, mold
76-1 may have installed therein separately manufactured diffractive
mold element 77. Mold element 77 installed in mold 76-1 may be of
the type manufactured using holographic techniques as are available
from Physical Optics Corp. of Torrance, Calif. and Fresnel Optics
of Rochester, N.Y. Other manufactures of diffuser optical elements
include DOC of Charlotte, N.C., MEMS of Huntsville, Ala. and RPC of
Rochester, N.Y.
[0059] Shown in FIG. 2f is a surface of a mold 76-2 for use in
manufacturing the single diffuser optical plate of FIG. 2a. Mold
76-2 includes a texture formed directly thereon. The texture may be
applied by way of an acid resist process. Mold texturing companies;
such as Mold Tech, Inc. of Painsville, Ohio specialize in applying
textures to molds by way of an acid resist process as in the
texture shown in FIG. 2b. A suitable material for use in the
manufacture of plate 26 or plate 26' is polycarbonate.
[0060] The textured surface mold 76-2 of FIG. 2f is generally less
expensive and more durable than the mold having installed diffuser
mold elements of FIG. 2e. Mold element 77 is costly to manufacture,
and requires frequent replacement. Textured molds as shown in FIG.
2f are typically used in applications such as manufacturing
fingerprint-resistant surfaces. As far as is known, light
transmissive plates made using insertless textured surface molds as
shown in FIG. 2f have been incorporated in products having light
sources primarily for the purpose of obscuring the view of a light
source, and have not been used to produce controlled target area
illumination of an image capture system.
[0061] Exploded views of the diffuser surface of optical plate 26'
of FIG. 2a are shown in FIGS. 2b and 2c. Plate 26' comprises a
plurality of substantially adjacent and substantially cylindrical
microlenses 27L. Referring to further aspects of microlenses 27L,
microlenses 27L are preferably formed in randomized pattern on
plate 26' characterized in that microlenses 27L comprise at least
two different sizes without a particular ordering of similar-sized
microlenses and without precise parallel relative orientation
between the lenses. Randomization of the pattern reduces the
formation of "hot spots," concentrated areas of constant higher
radiance illumination, on a target area T. In another aspect of
plate 26' plate 26' preferably comprises occasional
cross-connections 27C defined in the valleys 27v delimiting the
various cylindrical microlenses 27L. In the embodiment of FIG. 2b
cross-connections 27C connect pairs of adjacent valleys 27v
delimiting a microlens 27L. Cross-connection 27c provide diffusion
of light in a direction generally transverse to the direction of
light diffusion provided by microlenses 27L.
[0062] Referring to FIG. 2d, the diffused light pattern generated
by a single light source as diffused by diffuser optical plate 26'
is designated as pattern 72R of overall pattern 72. Vertically
oriented cylindrical microlenses 27L tend to diffuse light in a
horizontal direction while the lensing provided by
cross-connections 27e tend to diffuse light from a light source in
a vertical direction. It can be seen that diffusion patterns can be
controlled by appropriate shaping of microlenses 27L. Reducing the
incidence of cross-connections 27c would reduce the diffusion of
light in the vertical direction. With a reduced incidence of
cross-connections an illumination pattern corresponding to a single
light source delimited by dashed line 72R-1 may be generated.
Increasing the incidence of cross-connections 27c would increase
the diffusion of light in the vertical direction. An increased
incidence of cross-connections 27c might generate the illumination
pattern for a single light source delimited by dashed lines 72R-2.
A diffuser comprising a series of spherical refractive optic
microlenses would be expected to generate a substantially uniform
circular illumination pattern. Diffusing light in a vertical
direction to increase the height of an illumination pattern is
particularly useful in the case that a target illumination diffuser
is incorporated in an imaging module having a single row of
horizontally oriented light sources and incorporates a 2D image
sensor. Referring ahead to FIGS. 5d and 5e, modules 10-7 and 10-8
comprise diffuser plate inserts 27" having horizontally oriented
cylindrical microlenses 27L. Microlenses 27L diffuse light
vertically with respect to the horizontal axes h of modules 10-7
and 10-8 thereby increasing the vertical (height) dimension of the
illumination pattern projected by modules 10-7 and 10-8.
Microlenses 27L of plate 27" may not be formed in a randomized
pattern and may not comprise cross-connections 27C. Nevertheless,
cylindrical microlenses 27L of plate 27" operate to diffuse light
in a direction generally perpendicular to microlenses 27L in a
manner similar to microlenses 27L of plate 26'. Plate 27" could be
replaced with a plate similar to plate 26' having randomized
pattern of microlenses and being modified to include cylindrical
microlenses oriented horizontally rather than vertically.
[0063] Diffuser plate 26' formed with use of substantially
uniformly textured mold 76-2, diffuses light substantially via
refractive optics. By contrast, diffuser plate 26 made using a mold
e.g. mold 76-1 having holographic formed inserts diffuses light
substantially via diffractive optics. Providing diffuser plate 26'
diffusing light substantially via refractive optics as opposed to
substantially via diffractive optics is advantageous at least for
the reason that molds used to make refractive optic diffusers are
easier to make and less expensive, while being substantially more
durable than molds used to make diffractive optic diffusers. As is
known by skilled artisans, diffractive optical characteristics
predominate when optical elements transmitting light are in a range
of sizes proximate the wavelength of light being transmitted.
Imaging modules described herein include light sources that emit
light in the range of from about 0.4 to about 1.0 microns. For
refractive diffusing of light in this wavelength range the optical
elements of a diffuser should have dimension substantially larger
than the upper limit of this range, e.g. at least about 10 microns.
For example, as best seen in cross sectional view of FIG. 2c,
cylindrical microlenses 27L of optical plate 26' may have an
apex-to-apex separation that ranges from about 0.018 inches to
about 0.028 inches.
[0064] Referring now to aspects of targeting optics of the
invention, optical plate 26 may also include cylindrical lenses 25
or other optical elements for imaging light from slit aperture 43
onto a target area T. Representations of illumination and aiming
illumination patterns which may be projected by the illumination
system of module 10-1 are shown in FIGS. 1e-1g. In FIG. 1e, area 72
represents the region of a target area T illuminated by
illumination LEDs 16 while area 74 represents the region of the
target area highlighted by aiming LEDs 18 and their associated
optics. In the embodiment of FIG. 1e aiming LEDs 18 and their
associated optics project a solitary horizontal aiming line 74 onto
a target area T.
[0065] In generating the straight line aiming pattern of FIG. 1e
may be generated cylindrical lenses 25 are formed on the outer
surface of optical plate 26 as is shown in FIGS. 11 and 1K.
Horizontally oriented cylindrical lenses 26 are formed so that when
plate 26 is applied over LEDs 18 lenses 25 are aligned
coextensively and forwardly relative to slit apertures 43 in order
to image light from slit apertures 43 onto a target T, defined by a
module=s field of view. Cylindrical lenses 25 may have a thickness
of about 3 mm and a radius of curvature of about 2.5 mm,
convex.
[0066] The split horizontal line aiming pattern 74s shown in FIG.
1F may be formed by providing, as shown in FIG. 11, aiming pattern
wedges 29 on the inner surface of optical plate 26 opposite aiming
pattern cylindrical lenses 25. Aiming pattern wedges 29 operate to
direct light from aperture slits 43 outwardly toward the sides of a
target area T so that a gap 74g between two horizontal line
segments 741s is defined in the center of a module's field of view.
The split line aiming pattern 74s allows a user to easily align the
center of the module's field of view with a center of a region of
interest.
[0067] It may be desirable to restrict the width of split
horizontal line aiming pattern 74s so that line 74s does not extend
substantially beyond a reader's target area T as defined by a
reader's field of view. In order to restrict the width of split
horizontal line aiming pattern 74s, vertically oriented cylindrical
lenses may be superimposed on aiming pattern wedges 29 as is
illustrated in FIG. 1J to form combined wedge and vertically
oriented cylindrical lens elements 29'. Aligning combined wedge and
lens elements 29' with slit aperture 43 provides an aiming pattern
having the features shown in FIG. 1G, wherein split horizontal line
aiming pattern 74s is contained substantially within a target area
T defined by a reader's field of view.
[0068] Cylindrical lenses 25 of plate 26 operate to collimate light
from aperture slits 43. Accordingly, in the embodiment shown having
cylindrical lenses 25, the sharpness of aiming pattern 74 and 74s
will not vary substantially as the distance of module 10 to a
target is varied.
[0069] However, in one variation of the invention, aiming
illumination optics are provided so that the sharpness of aiming
lines 74 and 74s varies depending on the module to target distance.
More specifically, aiming illumination optics may be provided so
that aiming lines 74 and 74s are substantially most sharp at the
best focus position of module 10-1 and less sharp when a reader
equipped with module 10-1 is moved away from the best focus
position.
[0070] To the end that essentially the entirety of the required
electronic circuitry of an optical reader can be packaged into a
single printed circuit board, the back surface of the frame's back
plate 30 should be configured to accommodate electrical components
that will extend from the front surface 15 of PCB 14. Accordingly,
it is seen that the rear surface of back plate 30 includes a
central recess 34 for aligning and receiving solid state image
sensor 32 and peripheral recesses 35 for accommodating electrical
circuitry such as components and/or conductors which may protrude
from the front surface of PCB 14.
[0071] In the embodiment of FIGS. 3a-3d imaging module 10-2
includes a printed circuit board 14 having both an image sensor 32
and illumination LEDs 16 mounted thereon. A pair of LEDs are
mounted on either side of image sensor chip 32 to form a pattern of
LEDs comprising four substantially linearly arranged LEDs. Mounting
of LEDs in a horizontally oriented linear pattern reduces the
height dimension requirements of module 10-2 relative to that of
module 10-1. Mounting of LEDs in a horizontally oriented linear
pattern allows the height of module to be reduced to a height
closer to the height o image sensor 32. Referring to further
aspects of module 10-2, module 10-2 includes a containment and
retainer assembly 80 mounted to and extending from PCB 14.
Containment section 81 contains image sensor chip 32 while retainer
section 82 retains lens assembly 41. Retainer 82 also prevents
light rays not corresponding to the image at a target, notably rays
emanating directly from LEDs 16 from reaching image sensor 32.
[0072] In the embodiment of FIGS. 4a-4d imaging module 10-3
includes a printed circuit board 14 having mounted thereon an image
sensor chip 32, illumination LEDs 16, and aiming LEDs 18. Three
LEDs are mounted on either side of module 10-3 to form a
horizontally oriented substantially liner pattern of LEDs
comprising six LEDs. Inner LEDs 18 are aiming LEDs while outer LEDs
16 are illumination LEDs. Illumination LEDs 16 may can be canted
(mounted at angles) as best seen in FIG. 4d so that a center of a
target area is more uniformly illuminated absent additional
illumination optics.
[0073] Further variations of imaging modules are shown in FIGS.
5a-5e. In module 10-4 of FIG. 5a the configuration of containment
and retainer assembly 80 is modified so that assembly 80 is box
shaped and of substantially uniform height, width and depth.
Box-shaped containment and retainer assembly 80, particularly when
sized to a height substantially equally to that of circuit board 14
provides certain packaging advantages. For example, if module 10-4
is mounted in an instrument housing so that assembly 80 abuts on a
planar surface of an instrument housing, box shaped assembly 80
aids in the stabilization of module 10-4. Module 10-5 shown in FIG.
5b comprises a configuration essentially identical to module 10-4
except that the leaded LEDs are replaced with surface mounted LEDs
16s and 18s. It is understood that the leaded LEDs described herein
can normally be replaced with surface mounted LEDs as seen in FIG.
5b.
[0074] Modules 10-2, 10-3, 10-4, and 10-5 may be used in
combination with illumination optics mounted to a separate member
of an instrument housing. Alternatively, illumination optics can be
incorporated into the module as illustrated by modules 10-6, 10-7
and 10B8 of FIGS. 5c, 5d, and 5e. Module 10-6 of FIG. 5c includes
form fit diffusers 83 which are adapted to be friction-fit over
illumination LEDs 16. In the embodiments shown in FIGS. 5d module
10-7 includes optical flange 84 extending outwardly from assembly
80. Each flange 84 may include slit aperture 43 for shaping light
from aiming LEDs 18 and a diffuser optical plate 27: for diffusing
light from illumination LEDs 16. Diffusers 27" may be molded into
flanges 84. Flanges 84 may be formed integral with retainer
assembly 80 using a mold adapted for manufacture of a one piece
containment, retainer and flange assembly. Flanges 84 may also be
mounted to PCB 14 or to a member of the instrument housing in which
the module is installed. Module 10-8 shown in FIG. 5e is similar to
module 10-7 except that leaded LEDs are replaced with face mounted
LEDs 16s and 18s. In addition, flanges 84 of module 10-8 are spaced
apart at a closer distance to PCB 14 than flanges 84 of module
10-7.
[0075] Diffuser optical plates 27" include horizontally oriented
substantially cylindrical microlenses 27L formed on a light exit
surface of diffusers 27". As explained previously in connection
with FIGS. 2a, 2b, and 2c, substantially cylindrical microlenses
27-L operate to diffuse light vertically with respect to lenses
27L, to increase the height dimension of the overall illumination
pattern generated using a linearly arranged set of light
sources.
[0076] Another imaging module is shown in FIGS. 6a-6d. In module
10-9, a flexible printed circuit board 14' carries an image sensor
chip 32 and light pipes 86-1 for transmitting light from a source
location 85-1 to a light pipe distal end 87 remote from the source
location. Light pipes 86-1 are shown as being provided by a fiber
optic cable. However, light pipes 86-1 may also be molded light
pipes. Fiber optic cables are available from several manufacturers
including Schott Corp. of Wayzata, Minn. and Bivaropto, Inc. of
Irvine, Calif. Light pipes 86-1 can be any length and can be
mounted at substantially any location of flexible circuit board
14'. It will be appreciated that the configuration of module 10-9
allows installation of module 10-9 into a wide variety of
instrument housings and equipment. Flexible circuit board 14' which
may be a type available from Minco, Inc. of Minneapolis, Minn., may
be bended into a virtually limitless number of forms to allow
installation of module 10-9 into instrument housings of a wide
variety of shapes and sizes. Furthermore, light pipes 86-1 provide
illumination of a target area T without requiring that space
consuming LEDs to be mounted in a certain arrangement about an
imaging axis. An important advantage of incorporating light pipes
86-1 into an imaging module 10-9 is that the radiance of
illumination emitted by an individual light pipe can be increase
without increasing the space consumed by the distal end 87 of the
individual light pipe. The radiance of light emitted at a distal
end 87 of a light pipe can be increased by directing light from
more than one source into a source end 85-1 of the light pipe. A
source end of a light pipe can be split into two or more light
entry units, each of which is disposed in proximity with a light
source such as an LED. Also, a light pipe can be made to have a
diameter enabling it to receive light from more than one light
source.
[0077] Now referring to FIGS. 7a-7e an imaging module 10-12 is
described having molded light pipes 86-2. In module 10-12, PCB 14
is arranged parallel to imaging axis, a.sub.i, and image sensor
chip 32 is mounted perpendicularly on PCB 14. Image sensor chip 32
may be perpendicularly mounted on PCB 14 by using a rigid flex PCB.
Referring to further aspects of module 10-12, LEDs 16s and 18s so
that light from LEDs 16s and 18s is directed through distal ends
87-2 of light pipes in a direction generally parallel to imaging
axis, a.sub.i, toward a target T. Molded light pipes are available
from such manufacturers as Bivaropto, Inc. of Irvine Calif. and
Dialight Corp. of Manasquan, N.J. Diffusers can be molded onto the
distal ends of illumination light pipes 86-2i as is indicated by
diffuser 89-2d shown in FIG. 7j.
[0078] Arranging PCB 14 parallel to imaging axis, a.sub.i, and
installing molded light pipe 86-2 on PCB 14 to direct light in a
direction parallel to PCB 14 reduces the height dimension of module
10-12 and allows the module to be installed in a Athin@ instrument
housing having a small height dimension. The height dimension of an
imaging module 10-12 having light pipe illumination can be reduced
further by back mounting of image sensor chip 32 on PCB 14, as is
illustrated by module 10- 13 shown in FIGS. 7e-7h. In the
embodiment of FIGS. 7e-7h image sensor chip 32 is back mounted on
PCB 14 together with a containment and retainer assembly 80 that is
equipped with folding optics sufficient to fold imaging axis,
a.sub.i, substantially 90 degrees. Folding optics can be provided,
for example, by formation of plated reflective material on or by
affixing a mirror to wall 90 as indicated by dashed-in mirror 91.
Because module 10-13 can be designed to have a height dimension
smaller than the width of image sensor 32, module 10-13 is
especially well-suited for installation in Athin@ reader housings.
For example, module 10-13 is well suited for installation into the
housings of a personal data assistant APDA@ such as a cellular
phone as shown in FIG. 9I, or a hand-held computer as shown in FIG.
9J.
[0079] As in the case of a fiber optic cable light pipe, the
radiance of illumination emitted by any one molded light pipe 86-2
can be increased by widening source end 85-2 of pipe 86-2 and
disposing source end 85-2 to collect light from more than one light
source, as is indicated by light pipe 86-2i. Illumination light
pipe 86-2i of module 10-12 shown in FIG. 7d collects light from
three face mounted LEDs 16s whereas aiming light pipes 86-2a
collects light from a single LED 18s.
[0080] Variations of molded light pipe and LED assemblies are
described in greater detail with reference to FIGS. 7i, 7j, and 7k.
In the embodiment of FIG. 7i light pipe and light source assembly
89-1 includes a single surface mount LED package 92-1 mounted to
PCB 14. LED 92-1 includes a single LED die. Further with reference
to the embodiment of FIG. 7i light pipe 86-2 is manufactured and
mounted so that primary light refractive surface 86-2-sr of light
pipe 86-2 forms a constant substantially 45 degree angle with PCB
14.
[0081] In the embodiment of FIG. 7j light pipe and light source
assembly 89-2 includes a multiple lead frame surface mount package
92-2. LED 92-2 has three LED dies LD mounted therein and a single
Bragg reflector R. Disposing multiple LED dies LD in a LED package
having a single Bragg reflector R reduces the size of the surface
mount LED package. Further with reference to the embodiment of FIG.
7j the light entry surface of light pipe are separated into three
sections se.sub.1, se.sub.2, and se.sub.3, each corresponding to
one of the LED dies LD. Each light entry surface se.sub.1,
se.sub.2, and se.sub.3 forms a different angle with PCB 14 so as to
optimize the efficiency of light transmission through light pipe
for each of the LED dies LD. A diffuser optical plate 89-2d can be
molded onto distal end of light pipe 86-2. Diffuser optical plate
89-2d diffuses light from light pipe 86-2 and further reduces
fresnel losses.
[0082] In the embodiment of FIG. 7k light pipe and light source
assembly 89-3 includes a LED having three LED dies LD, each formed
by mounting. a light emitting die on PCB 14 directly, and disposing
epoxy e over the assembly of PCB mounted dies. Direct mounting of
LED dies LD onto PCB 14 reduces the size of LED package 92-3.
Further referring to the embodiment of FIG. 7k the primary light
reflective surface sr of assembly 89-3 is divided into three
sections sr.sub.1, sr.sub.2, and sr.sub.3 each corresponding to a
different one of the LED dies LD. Each section sr.sub.1, sr.sub.2,
and sr.sub.3 of light reflective curved surface sr forms a
different angle with PCB 14 so as to optimize the efficiency of
light transmission through light pipe 86-2 for each of the LED dies
LD. For reducing Fresnel losses in system 89-3, the index of
refraction, N.sub.e, of epoxy e can be selected to substantially
match the index of refraction, N.sub.p, of molded light pipe
86-2.
[0083] Assembly 89-3 of FIG. 7k and assembly 89-2 of FIG. 7j
illustrate two different systems for optimizing the efficiency in
light transmission through a light pipe in a light pipe and source
assembly having multiple dies. LEDs 92-2 and LED 92-3 are single
light sources which comprise multiple dies. It will be understood
that either of these systems can be employed in a light pipe and
light source assembly having multiple light sources, wherein the
multiple sources comprise standard surface mount LEDs having one
Bragg reflector per die or standard single die leaded LEDs. Light
rays LR depicted in FIGS. 7i, 7j, and 7k are shown as originating
from ideal light sources LD. It is understood that actual light
sources exhibit substantially greater variety in the origin and
angles of the incident rays. It will be understood further that any
of the LEDs, e.g. LED 16, LED 18, LED 16s, and LED 18s described
herein can be provided by an LED package having multiple LED dies
incorporated therein. Infineon Corp. of Munchen, Germany
specializes in designing and manufacturing LEDs comprising multiple
LED dies. .
[0084] An important feature of the invention is that essentially
all the illumination elements of a reader in which module 10 is to
be incorporated are included on a single circuit board shown as
being provided by PCB 14. This is in contrast to the design of the
prior art reader shown in FIG. 10 in which illumination elements
and image sensing elements are spread out over several circuit
boards. In the prior art device shown in FIG. 10, an aiming
illumination source 53 is mounted to a first circuit board 54,
illumination LEDs 55 are mounted to a second circuit board 56,
while image sensor 32 is mounted to first circuit board 54. The
device of FIG. 10 further includes a third circuit board 60
carrying signal processing and decoding electrical hardware
components. The assembly of a module of this prior art design is
difficult and requires material components not required by the
design of the present invention including circuit boards 54, 56 and
electrical connectors between the circuit boards such as connectors
57A & 57B. Providing a single circuit board that carries an
image sensor, illumination LEDs, and aiming LEDs significantly
simplifies assembly, reduces material consumption and thereby
reduces the overall cost of producing the module.
[0085] Another important aspect of the invention, in one
embodiment, is that essentially all electronic circuitry supporting
the data processing operations required of module 10 are located on
single, full function PCB 14, including circuitry for processing
signals generated from image sensor 32, circuitry for capturing
image data into a memory device, circuitry for decoding and/or
recognizing indicia represented in captured image data. Circuitry
for supporting serial transfers of data to peripheral devices may
also be carried by PCB 14.
[0086] The all in one PCB arrangement of the present invention is
in contrast to the traditional design in the prior art wherein
circuitry for processing signals from an image sensor, circuitry
for capturing and decoding image data and circuitry supporting
serial interfacing with external devices are spread out over more
than one circuit board.
[0087] In the design of the prior art reader shown in FIG. 10, a
first vertically oriented circuit board 56 is provided for carrying
circuitry for processing signals generated by an image sensor 32
and a second horizontally oriented circuit board 60, known as a
Amother board@ is provided for carrying circuitry for storing image
data and for decoding symbologies. The one PCB design of the
present invention provides numerous advantages over the two PCB
designs of the prior art. The multiple circuit board arrangement of
the prior art requires a complex assembly procedure wherein the
first circuit board 56 is mounted to a first internal structure of
the reader in which it is incorporated, the second circuit board is
mounted to a second internal structure of the reader, and then the
two circuit boards are electrically connected. The separate
horizontal and vertical orientations of the two circuit boards 56
and 60 are inefficient in terms of space consumption and impose
restrictions on the configurations of housing in which the reader
optical and electrical components may be incorporated. The one full
function PCB design of the present invention does not exhibit these
disadvantages.
[0088] A block diagram illustrating one type of optical reading
device in which the invention may be incorporated is described with
reference to FIG. 8.
[0089] Optical reader 110 includes an illumination assembly 120 for
illuminating a target object T, such as a ID or 2D bar code symbol,
and an imaging assembly 130 for receiving an image of object T and
generating an electrical output signal indicative of the data
optically encoded therein. Illumination assembly 120 may, for
example, include an illumination source assembly 122, such as one
or more LEDs, together with an illuminating optics assembly 124,
such as one or more lenses, reflectors or other optical elements
such as diffusers and wedges 27 and 28, for directing light from
light source 122 in the direction of target object T. The
illumination assembly in the embodiment of FIGS. 1A-1D is provided
entirely by LEDs 16. Illumination assembly 120 may be eliminated if
ambient light levels are certain to be high enough to allow high
quality images of object T to be taken. Illumination assembly 120
may comprise white LEDs, red LEDs, a combination of these, or other
types of light sources. Imaging assembly 130 may include an image
sensor 132, such as a ID or 2D CCD, CMOS, NMOS, PMOS, CID OR CMD
solid state image sensor, together with an imaging optics assembly
134 for receiving and focusing an image of object T onto image
sensor 132. The array-based imaging assembly shown in FIG. 1F may
be replaced by a laser array based imaging assembly comprising at
least one laser source, a scanning mechanism, emit and receive
optics, at least one photodetector and accompanying signal
processing circuitry. Technologies for fabrication of LEDs and
white LEDs in particular are described in an article entitled "LEDS
light of the Future" in the online magazine MIT Enterprise
Technology Review, www.technology
review.com/magazine/sep.00/savage.asp
[0090] Optical reader 110 of FIG. 9 also includes programmable
control unit 140 which preferably comprises an integrated circuit
microprocessor 142 and an application specific integrated circuit
(ASIC 144). The function of ASIC 144 could also be provided by
field programmable gate array (FPGA). Processor 142 and ASIC 144
are both programmable control devices which are able to receive,
output and process data in accordance with a stored program stored
in memory unit 145 which may comprise such memory elements as a
read/write random access memory or RAM 146 and an erasable read
only memory or EROM 147. RAM 146 typically includes at least one
volatile memory device but may include one or more long-term
non-volatile memory devices. Processor 142 and ASIC 144 are also
both connected to a common bus 148 through which program data and
working data, including address data, may be received and
transmitted in either direction to any circuitry that is also
connected thereto. Processor 142 and ASIC 144 differ from one
another, however, in how they are made and how they are used.
[0091] More particularly, processor 142 is preferably a general
purpose, off-the-shelf VLSI integrated circuit microprocessor which
has overall control of the circuitry of FIG. 8, but which devotes
most of its time to decoding image data stored in RAM 146 in
accordance with program data stored in EROM 147. Processor 144, on
the other hand, is preferably a special purpose VLSI integrated
circuit, such as a programmable logic or gate array, which is
programmed to devote its time to functions other than decoding
image data, and thereby relieve processor 142 from the burden of
performing these functions.
[0092] The actual division of labor between processors 142 and 144
will naturally depend on the type of off-the-shelf microprocessors
that are available, the type of image sensor which is used, the
rate at which image data is output by imaging assembly 130, etc.
There is nothing in principle, however, that requires that any
particular division of labor be made between processors 142 and
144, or even that such a division be made at all. This is because
special purpose processor 144 may be eliminated entirely if general
purpose processor 142 is fast enough and powerful enough to perform
all of the functions contemplated by the present invention. It
will, therefore, be understood that neither the number of
processors used, nor the division of labor there between, is of any
fundamental significance for purposes of the present invention.
[0093] With processor architectures of the type shown in FIG. 8, a
typical division of labor between processors 142 and 144 will be as
follows. Processor 142 is preferably devoted primarily to such
tasks as decoding image data, once such data has been stored in RAM
146, recognizing characters represented in stored image data
according to an optical character recognition (OCR) scheme,
handling menuing options and reprogramming functions, processing
commands and data received from control/data input unit 139 which
may comprise such elements as trigger 174 and keyboard 184 and
providing overall system level coordination. Processor 144 is
preferably devoted primarily to controlling the image acquisition
process, the A/D conversion process and the storage of image data,
including the ability to access memories 146 and 147 via a DMA
channel. Processor 144 may also perform many timing and
communication operations. Processor 144 may, for example, control
the illumination of LEDs 122, the timing of image sensor 132 and an
analog-to-digital (A/D) converter 136, the transmission and
reception of data to and from a processor external to reader 110,
through an RS-232, a network such as an Ethernet, or a serial bus
such as USB, (or other) compatible I/O interface 137 and the
outputting of user perceptible data via an output device 138, such
as a beeper, a good read LED and/or a display monitor which may be
provided by a liquid crystal display such as display 182. Control
of output, display and I/O functions may also be shared between
processors 142 and 144, as suggested by bus driver I/O and
output/display devices 137.quadrature. and 138.quadrature. or may
be duplicated, as suggested by microprocessor serial I/O ports 142A
and 142B and I/O and display devices 137" and 138.quadrature.. As
explained earlier, the specifics of this division of labor is of no
significance to the present invention.
[0094] In accordance with a feature of one embodiment of the
invention described with reference to FIGS. 1A-7H, essentially all
of the electrical signal processing components described with
reference to FIG. 8 may be carried by a single circuit board, PCB
14 or PCB 14', as is indicated by dashed-in border 14, of FIG. 8.
In order to incorporate essentially all of the electrical signal
processing components of FIG. 8 onto a single PCB 14, it is
normally necessary to integrate several electrical components into
a reduced number of electrical components. For example, using known
integrated circuit fabrication techniques, components 142, 144,
146, and 147 and interfaces 137, 137', and 137" can be incorporated
in a single integrated circuit chip of reduced size. Further, as
explained in an article by Eric R. Fossum entitled Digital Camera
System on a Chip, IEEE Computer Society (IEEE Micro), Volume 18,
Number 3, May/June 1998, image sensor 132, signal processing
components 135, 136, and components 142, 144, 146, 147, 137, 137',
and 137" may be incorporated in a single integrated circuit of
reduced size.
[0095] FIGS. 9A-J show examples of types of housings in which the
modules of the present invention may be incorporated. FIGS. 9A and
9B show a ID optical reader 110-1, while FIGS. 9C-9H show 2D
optical readers 110-2, 110-3, and 110-4. Housing 112 of each of the
optical readers 110-1 - 110-4 is adapted to be graspable by a human
hand and has incorporated therein at least one trigger switch 174
for activating image capture and decoding and/or image capture and
character recognition operations. Readers 110- 1, 110-2, and 110-3
include hardwired communication links 178 for communication with
external devices such as other data collection devices or a host
processor, while reader 110-4 includes an antenna 180 for providing
wireless communication with an external device such as another data
collection device or a host processor.
[0096] In addition to the above elements, readers 110-3 and 110-4
each include a display 182 for displaying information to a user and
a keyboard 184 for enabling a user to input commands and data into
the reader.
[0097] Any one of the readers described with reference to FIGS.
9A-9H may be mounted in a stationary position as is illustrated in
FIG. 9K showing a generic optical reader 110 docked in a scan stand
190. Scan stand 190 adapts portable optical reader 110 for
presentation mode scanning. In a presentation mode, reader 110 is
held in a stationary position and an indicia bearing article is
moved across the field of view of reader 110.
[0098] While this invention has been described in detail with
reference to a preferred embodiment, it should be appreciated that
the present invention is not limited to that precise embodiment.
Rather, in view of the present disclosure which describes the best
mode for practicing the invention, many modifications and
variations would present themselves to those skilled in the art
without departing from the scope and spirit of this invention, as
defined in the following claims.
* * * * *
References