Abstract:
An integrated data reader and electronic article surveillance (EAS) system, and methods of operation. Several configurations are also disclosed for alternate deactivation coil designs and mounting schemes.

Description:
RELATED APPLICATION DATA 
     This application claims priority to provisional application Ser. No. 60/651,058 filed Feb. 8, 2005, hereby incorporated by reference. 
    
    
     BACKGROUND 
     The field of the present invention relates to data reading systems and electronic article security (EAS) systems. In particular, various systems and methods are described herein for integrating an EAS system into a data reading system such as a barcode scanner. 
     In both retail checkout and inventory control environments, items are typically provided with readable tags or labels such as bar codes or RFID tags. Data reading devices such as barcode scanners and RFID readers are provided at the checkout station to read the codes or tags and obtain the data contained therein. The data may be used to identify the article, its price, and other characteristics or information related to checkout or inventory control. These data readers automate the information retrieval to facilitate and speed the checkout process. Thus data readers such as bar code scanners are pervasive at retail checkout. 
     Scanners generally come in three types: (a) handheld, such as the PowerScan™ scanner, (b) fixed and installed in the countertop such as the Magellan® scanner, or (c) a hybrid scanner such as the Duet® scanner usable in either a handheld or fixed mode. Each of these scanners is manufactured by PSC Inc. of Eugene, Oreg. In a typical operation, retail clerk uses either a handheld scanner to read the barcode symbols on the articles one at a time or passes the articles through the scan field of the fixed scanner one at a time. The clerk then places the articles into a shopping bag or other suitable container. 
     Though barcodes provide for rapid and accurate item identification at checkout, the bar codes do not provide for item security against theft. Electronic article surveillance (EAS) systems have employed either reusable EAS tags or disposable EAS tags to monitor articles to prevent shoplifting and unauthorized removal of articles from store. Reusable EAS tags are normally removed from the articles before the customer exits the store. Disposable EAS tags are generally attached to the packaging by adhesives or are disposed inside item packaging. These tags remain with the articles and must be deactivated before they are removed from the store by the customer. 
     There are several types of deactivation systems including magnetic, radio frequency (RF), and microwave. These systems have different structural designs and different operational characteristic. By way of example, magnetic deactivation devices use coils which are energized to generate a magnetic field of sufficient magnitude to render the EAS tag inactive. In another example, an RF system uses a wire loop antenna to generate an RF signal whereby an RF-based security tag receives the signal and deactivates in response thereto. 
     In any of the EAS systems, once deactivated, the tags are no longer responsive to the detection systems, the detection system typically being located at the store exits, so that an alarm is not triggered. 
     Some retail establishments having high volumes find it desirable to expedite and facilitate the checkout process including the scanning of the bar code data and the deactivation of the EAS tags. In the typical point of sale (POS) location such as the checkout counter of a retail checkout station, counter space is limited. In one RF-based system, an EAS deactivation wire loop is disposed around the horizontal scan window of a two-window “L” shaped scanner such as the Magellan® scanner. In such a system, barcode scanning and EAS tag deactivation presumably are accomplished over the same scan volume. Another system is disclosed in U.S. Pat. No. 6,783,072 which discloses, among other things, various embodiments of a magnetic-based EAS deactivation system integrated into a two-window “L” shaped scanner. 
     SUMMARY 
     Various embodiments disclosed herein are directed to integrated data reader and EAS systems, methods of operation, deactivation coil designs, and arrangements and mounting schemes. In a preferred configuration, a data reader such as a barcode scanner is equipped with one or more EAS deactivation modules disposed behind the scanner surface and arranged to generate a deactivation field of a desired orientation to deactivate EAS tags on items as they are passed through the scan field defined by the scanner window(s) of the data reader. 
     Additional aspects and advantages of this invention will be apparent from the following detailed description of preferred embodiments, which proceeds with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of a combined data reader and EAS system according to a first embodiment. 
         FIG. 2  is a top view of a combined data reader and EAS system according to a preferred embodiment, shown with the weigh platter removed. 
         FIG. 3  is a top view of the combined data reader and EAS system of  FIG. 2  with the top bonnet removed. 
         FIG. 4  is a top view of the combined data reader and EAS system of  FIG. 2  illustrating placement and details of the horizontal coil unit. 
         FIG. 5  is a perspective view of the horizontal coil unit from the combined data reader and EAS system of  FIGS. 2-4  removed from the system. 
         FIG. 6  is a perspective view of the vertical coil unit from the combined data reader and EAS system of  FIGS. 2-4  removed from the system. 
         FIG. 7  is a perspective view of the vertical coil unit of  FIG. 6  unwrapped with the internal coils exposed. 
         FIG. 8  is a perspective view of the vertical coil unit of  FIGS. 6-7  with the wrapped coils coated. 
         FIG. 9  is an isometric view of an alternate coil unit. 
         FIG. 10  is a front plan view of the coil unit of  FIG. 9 . 
         FIG. 11  is a cross-sectional view of the coil unit of  FIG. 10  taken along line  11 - 11 . 
         FIG. 12  is a detailed view of the windings of the coil unit of  FIG. 11 . 
         FIG. 13  is an isometric view of an alternate coil unit. 
         FIG. 14  is a front plan view of the coil unit of  FIG. 13 . 
         FIG. 15  is a cross-sectional view of the coil unit of  FIG. 14  taken along line  14 - 14 . 
         FIG. 16  is a detailed view of the windings of the coil unit of  FIG. 15 . 
         FIG. 17  is an isometric view of an alternate coil unit. 
         FIG. 18  is a front plan view of the coil unit of  FIG. 17 . 
         FIG. 19  is a cross-sectional view of the coil unit of  FIG. 18  taken along line  19 - 19 . 
         FIG. 20  is a detailed view of the windings of the coil unit of  FIG. 19 . 
         FIG. 21  is an isometric view of an alternate coil unit. 
         FIG. 22  is a front plan view of the coil unit of  FIG. 21 . 
         FIG. 23  is a cross-sectional view of the coil unit of  FIG. 22  taken along line  23 - 23 . 
         FIG. 24  is a detailed view of the windings of the coil unit of  FIG. 23 . 
         FIG. 25  is a top view of a combined data reader and EAS system according to an alternate embodiment, shown with the weigh platter removed. 
         FIG. 26  is a perspective view of the horizontal coil unit from the combined data reader and EAS system of  FIG. 25  removed from the system. 
         FIG. 27  is a detailed perspective view of a corner of the horizontal coil unit of  FIG. 26  unwrapped with the internal windings exposed. 
         FIG. 28  is a top perspective view of a combined data reader and EAS system according to another alternate embodiment with the weigh platter removed. 
         FIG. 29  is another perspective view of the combined data reader and EAS system of  FIG. 28  with the horizontal coil unit in its operating position. 
         FIG. 30  is a perspective view of the system of  FIGS. 28-29  with the horizontal coil unit shown pivoted to a second position. 
         FIG. 31  is a perspective view of a combined data reader and EAS system according to another alternate embodiment with a vertical deactivation unit disposed in an external position. 
         FIG. 32  is a perspective view of a combined data reader and EAS system according to another alternate embodiment with a vertical deactivation unit mounted to a rear surface of the removable weigh platter. 
         FIG. 33  is a perspective view of a combined data reader and EAS system according to another alternate embodiment with a horizontal deactivation unit mounted to an underside of the removable weigh platter. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Preferred embodiments of the present invention will now be described with reference to the drawings. To facilitate description, any reference numeral representing an element in one figure will represent the same element in any other figure. 
       FIG. 1  diagrammatically illustrates a system  5  comprised of an EAS controller  10  and a combined data reader and EAS deactivation system  15 . The combined data reader and EAS system  15  includes a lower housing section  20  and an upper housing section  40 . A horizontal EAS deactivation unit  50  is mounted within the lower housing section  20  and the upper or vertical EAS deactivation unit  52  is mounted within the upper housing section  40 . Each of the deactivation coil units  50 ,  52  is connected to the controller  10  which either may be integrated into the data reader housing or may comprise a separated component connected via a cable. 
       FIGS. 2-8  illustrate details of such a system  5  according to a first preferred embodiment. System  5  includes an external controller  10  connected via a cable  11  to a combined EAS and data reader system  15 . System  15  includes an outer housing or frame  12  with a lower housing section  20  containing a horizontal window  22  and an upper housing section  40  containing a vertical window  42 . 
     The system  15  is illustrated with a scale system disposed within the lower housing section for supporting a weigh platter. The weigh platter is not shown in  FIGS. 2-4  as it has been removed to allow internal components of the system  15  to be visible in the figures. The weigh platter may comprise a single plane, or may comprise multiple planes as described in U.S. Pat. No. 5,834,708 hereby incorporated by reference where the system comprises a scanner-scale having a two-plane or vertical plane scanner. Although the system  15  is illustrated as a two-plane scanner with a horizontal window  22  and a vertical window  42 , the system may alternatively comprise a single window, either a single horizontal window (such a horizontal scanner) or a single vertical window (such as a vertical scanner). 
     The scanner itself may be of any suitable configuration. As viewed in the figure, the scanner includes a facet wheel  23  disposed in the lower housing section. The illustrated embodiment for the scanner may comprise a Magellan 9500 dual plane scanner available from PSC Inc. of Eugene, Oreg. 
     In embodiments where the scanner  15  includes a weigh scale, the lower magnetic coil unit  50  must not only not interfere with the scanner optics being passed out from the lower scan section  24  but must also be disposed so as not to interfere with the scale system. In this embodiment, the scale system includes a spider  90  of a U-shaped construction, with the central portion  92  disposed over a load cell  91 , and a first lateral extension  94  disposed at a front or checker side of the weigh platter, and a second lateral extension  96  disposed at the rear of the weigh platter adjacent to the upper housing section  40 . The weigh platter is suspended on top of the U-shaped spider  90  via positioners such as height adjustment bolts  95   a ,  95   b ,  95   c ,  95   d.    
       FIG. 3  illustrates the system  15  with the bonnet of the upper housing section  40  removed exposing the upper coil  52 . The upper coil  52  is mounted to the frame of the unit  15  via upper coil mounts  46 , which support the upper coil unit  52  in a secure vertical orientation behind the vertical window  42 . Similar to the lower coil unit  50 , the upper coil unit  52  is configured so as to provide a large enough opening so as not to interfere with the scan pattern coming out of the upper scan section  44 . 
       FIG. 5  illustrates a preferred configuration for the horizontal coil unit  50 .  FIGS. 6-7  illustrate preferred configuration for the upper coil unit  52 . As viewed in the figures, each of the coil units  50 ,  52  is an air core magnetic coil assembly of a generally rectangular shape, the rectangular shape corresponding to the shape of the windows of the scanner. The coil units  50 ,  52  have been optimized to minimize the space required for the units and to minimize impact on scanner performance, that is to avoid interference with the scan pattern generation and the volume of the inner scan housings desired to generate the desired scan patterns. The shape is also designed to avoid interference with the scale systems previously described. 
     In a preferred configuration, the coil units  50 ,  52  are comprised of windings composed of a single wire of on the order of  50  turns as best shown in  FIG. 7 , which illustrates the vertical coil unit  52  with the internal coils exposed. The figure also illustrates the two ends of the single wire that forms the windings. In one configuration, the vertical coil unit  52  has  50  turns and the horizontal coil unit has 54 turns. 
     The controller  10  is connected to both the vertical coil unit  52  and the horizontal coil unit  50 . The vertical coil unit  52  surrounds the vertical scanner window  42  and likewise the horizontal coil unit  50  surrounds the horizontal scanner window  22 . In order to maximize space constraints for the scanner components and not interfere with scanner operation, the vertical coil unit  52  may be formed with a beveled profile to allow sufficient coil volume while not blocking the scan lines exiting through the vertical window  42  of the scanner. The horizontal coil unit  50  may also have a beveled profile so as to provide additional room for scan beams exiting the horizontal window  22 . 
     The geometry of the coil units may best be explained when referring to a cross-section. The inner side of the coil unit is beveled or angled, thus creating a cross-sectional shape rather than rectangular to better approximate a trapezoid or triangle. Thus the outermost inner edge of the coil unit is recessed radially outward so as to better accommodate exiting scan beams passing through the central portion of the coil unit. 
     In operation, each of the coil units provides for both detection (transmitting the magnetic field to excite the labels and then receiving a return signal from the label) and deactivation (sending a deactivation pulse to deactivate the label). In a preferred control method, the controller  10  may detect which coil is best suited for deactivation and then only energize the appropriate coil. For example, if the vertical coil unit  52  is the one that detects (or best detects with the strongest return signal), then the controller  10  would determine that the vertical coil unit  42  is best suited for deactivation and then only energizes vertical coil unit  52  to deactivate the EAS tag. 
     In a preferred construction, the coil units are formed by winding the bare wire the appropriate number of turns (see for example  FIG. 7 ) with the wound coils formed in the desired cross-sectional geometry. The coils may then be wrapped with a suitable insulated tape such as illustrated in  FIGS. 5 and 6 . In a preferred construction, the coil unit such as in  FIG. 7  would be dip coated such as with a liquid form of polyvinyl chloride (PVC) generally known as plastisol such as the coil illustrated in  FIG. 8 . 
       FIGS. 9-12  illustrate an alternate embodiment for a coil unit which may be particularly suitable for the vertical plane but may also be useable in the horizontal plane. As showed by the details of the cross-section of  FIGS. 11 and 12 , the coils  112  are arranged with a trapezoidal cross-section formed with a bevel  114  on one side thereof. The windings or turns of the copper wire are arranged such that there are five rows on the outward side of the coil and nine rows of wire turns on the inward side of the coil. The beveled side  114  permits exit of scan lines out the window (the scan lines would be passing from right to left as viewed in  FIGS. 11-12 ). In the particular winding configuration, the coil unit is formed with nine rows on the inside tapering down to five rows on the outside and with an eight-layer (four over four) width. 
       FIGS. 13-16  illustrate another alternative construction for a coil unit  120  useable in either a vertical or horizontal application. Coil unit  120  has approximately 56 complete turns and is shown in the detail of  FIG. 16  and has the windings or turns  122  arranged with a beveled side  124  formed of a similar trapezoidal shape as in the previous embodiment with one side somewhat rounded by the addition of five additional turns  126 . The coil unit  120  thus has nine rows on the upstream side and six rows on the downstream side and a seven-layer width (3/4 layers or three layers over four layers). 
     Although the non-rectangular, non-squared geometry of the coil units provides for certain benefits, rectangular units may provide sufficient geometric qualifications and tend to be more easily manufactured.  FIGS. 17-20  illustrate another embodiment for a horizontal coil unit  130  (which may also be used as a vertical coil unit). Coil unit  130  has 54 windings or turns  132  arranged in 13/14 layers (13 layers over 14 layers) as shown in the detailed cross-section of  FIG. 20 . The coil unit  130  thus presents a fairly elongated rectangular shape in cross-section as viewed in  FIG. 20  including about 54 complete turns arranged in four rows by 13/14 layers. 
       FIGS. 21-24  illustrate another embodiment for a coil unit  140  of a generally rectangular shape as viewed in  FIGS. 21-22 . As shown in the detailed cross-sections of  FIGS. 23-24 , the cross-sectional shape of the coil unit  140  is closer to square comprising nine rows by 5/6 layers for a total of approximately 50 turns  142 . 
       FIGS. 25-27  illustrate another combined EAS and data reading system  205 . The system  205  includes a data reader  215 , this embodiment shown as a dual plane L-shaped barcode scanner, and a controller  210  connected to the data reader  215  via cable  211 . The data reader  215  is illustrated in the figure as a scanner scale shown with its two-plane weigh platter  216  removed, a portion of the platter  216  being visible in the right side of the figure. The weigh platter  216  is supported by posts  295   a ,  295   b ,  295   c ,  295   d . The posts  295   a - c  extend to a bottom of the scanner housing  212  and are attached to a spider (not shown) which in turn is connected to and supported upon a load cell. 
     Disposed with the scanner  215  are a horizontal coil unit  250  surrounding the lower scan window  222  and an upper or vertical coil unit  252  disposed approximate the upper scan window  242 . 
       FIG. 26  illustrates details of the lower horizontal coil  250  with the windings wrapped.  FIG. 27  illustrates the actual coil windings before wrapping or coating as would typically be implemented during manufacture. 
     It is noted that the upper coil unit  252  is mounted external to the upper scan window  242  but would nonetheless be behind the vertical window  217  in the two-plane weigh platter  216  when the platter is disposed in position on the scanner  215 . 
       FIGS. 28-30  illustrate an alternative embodiment for a combined EAS deactivation system and data reader  315  particularly showing an alternate mounting scheme for the horizontal coil unit  350 . The data reader  315  is an L-shaped two-plane optical scanner such as the Magellan 9500 and illustrated with the two-plane weigh platter (known as the ALL-WEIGHS® platter) removed. The horizontal coil unit  350  is mounted either around or adjacent the horizontal window  322  of the lower scan section  320 . The horizontal coil unit  350  is mounted by a pair of hinge mounting brackets  360 ,  362  which are in turn mounted to the chassis or outer housing  312 . When in position, the coil unit  350  is nested within the U-shaped spider assembly  390  of the scale. The spider assembly  390  includes a central section  392  which is in turn mounted onto the load cell  391 . Scale arms  394 ,  396  extend outward from the central section  392  to form a U-shape. In combination, the scale arms  396  and central section  392  provide support for the weigh platter. 
     The hinge mounting bracket  360  includes a hinge section  361  and the hinge mounting bracket  362  includes a hinge section  363  which permits pivoting of the horizontal coil unit  350  from the horizontal position as in  FIGS. 28 and 29  upwardly and outwardly as illustrated in  FIG. 30 . Such a pivoting location allows for easy access for installation and/or repair of internal components. The pivoting coil unit  350  when in the pivoted condition also provides access to scale components such as the load cell cover door  397 , the scale calibration button access door  398  and the security locking tab  399  as well as the surrounding areas which are preferably readily accessible when the scale is tested for calibration, locked, and sealed by an authorized weighs and measures inspector or serviced and recalibrated by a service technician. It also may be useful to pivot the horizontal deactivation coil  350  out of position to allow cleaning of components. 
     With the horizontal deactivation coil  350  mounted on the hinge brackets, the coil  350  may be temporarily and easily repositioned out of the way of the load cell area without the removal of mounting hardware or brackets which would otherwise require removing screws or other fasteners. The hinge brackets  360 ,  362  provide a simple, repeatable repositioning mechanism that allows the horizontal coil unit  350  to be placed in the desired operating position, yet readily moved to allow the desirable access. This hinged repositioning movement of the horizontal deactivation coil unit  350  and does not require a service technician, requiring no tools or removal of any hardware. 
     It is noted that the second scale arm  394  visible in  FIG. 28  has been removed in  FIGS. 29 and 30  to allow components to be more readily visible in these figures. 
       FIG. 31  illustrates another combined EAS deactivation system and data reader  415  similar to previous embodiments but including an alternate mounting scheme for the vertical deactivation coil  452 . The vertical deactivation coil  452  is mounted external to the vertical window  442 , such as by brackets along the periphery thereof. The vertical coil unit  452  is mounted in position external to the upper bonnet  440 . The coil unit may either be mounted directly to the bonnet or to suitable brackets. Alternately, if the system  415  is equipped with a two-plane cover  417  or if it is a scanner scale with a two-plane weigh platter, the coil unit  452  may be mounted to the cover via a suitable attachment mechanism as described below in another embodiment. 
     By mounting the deactivation coil  452  outside of the optical cavity, it places the coil as close to the scanning area as possible and thus increasing the performance of the EAS deactivation. External mounting also allows the geometry of the coil to be large enough to avoid optical interference of the scan pattern being passed out through the window and through the central cavity of the coil unit  452 . 
       FIG. 32  illustrates another alternate combined EAS deactivation system and data reader  515 . In this system, the data reader is equipped with a two-plane  200  cover  517  similar to the ALL-WEIGHS® platter available from PSC Inc. of Eugene, Oreg. The cover  517  may merely be a cover over a scanner or may alternately comprise the weigh platter for a scanner-scale. The cover section  517  is positionable onto the main section  520 . The upper coil section  552  is mounted to a backside of the vertical section  518  of the two-plane cover  517  by a suitable mechanism. For example, the deactivation coil unit  552  may be mechanically fastened to the platter  517  via a bracket or bolts or it may be molded or otherwise formed into the platter structure itself. 
     By mounting the deactivation coil unit  552  into the vertical side of the removable platter  517  it becomes more fully integrated as part of the scanner. Having the coil unit  552  built into the platter places the coil in close proximity to the scanning area and thus increasing performance of EAS deactivation. The mounting method may insure more safety from electrical shock by enclosing the high voltage coil in the platter. By mounting the vertical deactivation coil unit  552  to the platter, more accurate and repeatable positioning of the coil after the platter has been removed and then returned to a normal operating position can be achieved. Mounting to the platter also simplifies the mounting mechanisms as compared to other mounting schemes. Where the platter  517  is merely a cover in a non-scale scanner, the platter is free from restriction of adding weigh and electrical wires to the platter assembly as would be encountered in a scanner scale. Thus, this mounting scheme may not be preferred for the scanner scale configuration, but would nonetheless be a feasible option. 
       FIG. 33  illustrates another combination EAS deactivation system and data reader  615 . The system includes a two-plane scanner  620  upon which is disposed a two-plane cover or weigh platter  617 . The horizontal coil unit  650  is mounted to an underside of the horizontal section of the two-plane platter  617 . Having the coil built into the removable platter places the coil in close proximity to the scanning area thus increasing EAS deactivation performance. This mounting is similar to the vertical coil mount of the previous embodiment and may also insure for more safety from electrical shock by enclosing the high voltage coil in the platter. The location also ensures accurate and repeatable repositioning of the horizontal deactivation coil unit  350  after it has been removed and then returned to normal operating position. Mounting the horizontal deactivation coil unit  650  to the platter  617  provides for a simplified assembly. When the coil unit  650  is mounted to a platter in a non-scale scanner, the platter  617  would be free of the restriction of adding weigh and electrical wires to the platter assembly. Further mounting the coil to the platter would take advantage of the any free space left by the absence of the scale in the non-scale scanner version. 
     Alternately the embodiments of the horizontal coil unit  650  mounted to the underside of the platter  617  may be combined with the vertical coil unit  552  being mounted to the back of the vertical section of the platter  518  of the previous embodiment. These mounting positions also provide for ready access to the coil units for service and repair. 
     The systems disclosed may alternately comprise not only EAS deactivation units, but also activation units or combined activation/deactivation units usable with activatable EAS tags. In addition, the EAS tag deactivators/activators described may include deactivation or activation of various types of EAS tags such as magnetoacoustic, magnetomechanical, magnetostrictive, RF (e.g. RFID), microwave, and harmonic type tags. Moreover, in each of the above embodiments, the deactivation units may comprise coil units with or without internal (magnetically active) core. For example, deactivation coils without internal core are described in U.S. Pat. No. 5,917,412 incorporated by reference. The deactivation units of the above embodiments may be controlled and operated by any suitable scheme as known by one skilled in the art, including but not limited to those schemes disclosed in U.S. Pat. Nos. 5,917,412; 6,281,796; 6,169,483; and 5,059,951 hereby incorporated by reference in their entirety. 
     In the various embodiments described above, the data reader unit has been generally described as a two window L-shaped bar code scanner, but other types of data readers may be combined with the EAS deactivation/activation system. The data reader may be for example a laser bar code scanner, an imaging reader, or other type of reader for reading optical codes, reading tags, or otherwise identifying items being passed through a scan/read zone. 
     Thus the present invention has been set forth in the form of its preferred embodiments. It is nevertheless intended that modifications to the disclosed scanning systems may be made by those skilled in the art without altering the essential inventive concepts set forth herein. 
     It will be obvious to those having skill in the art that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. The scope of the present invention should, therefore, be determined only by the following claims.