Abstract:
Described are a scan motor and a method of its manufacturing. The scan motor may include a static substrate; a dynamic substrate coupled to the static substrate via at least one flexible spring; a magnet coupled to a first side of the dynamic substrate; and a reflective element coupled to a second side of the dynamic substrate.

Description:
This application is a Continuation of U.S. patent application Ser. No. 11/047,240 filed on Jan. 31, 2005 now U.S. Pat. No. 7,207,489. 
    
    
     FIELD OF THE INVENTION 
     The invention is directed to laser scanners and, more particularly to a scan motor. 
     BACKGROUND OF THE INVENTION 
     There are numerous standards for encoding numeric and other information in visual form, such as the Universal Product Codes (UPC) and/or European Article Numbers (EAN). These numeric codes allow businesses to identify products and manufactures, maintain vast inventories, manage a wide variety of objects under a similar system and the like. The UPC and/or EAN of the product is printed, labeled, etched, or otherwise attached to the product as a dataform. 
     Dataforms are any indicia that encode numeric and other information in visual form. For example, dataforms can be barcodes, two dimensional codes, marks on the object, labels, signatures, signs etc. Barcodes are comprised of a series of light and dark rectangular areas of different widths. The light and dark areas can be arranged to represent the numbers of a UPC. Additionally, dataforms are not limited to products. They can be used to identify important objects, places, etc. Dataforms can also be other objects such as a trademarked image, a person&#39;s face, etc. 
     Scanners that can read and process the dataforms have become common and come in many forms and varieties. One embodiment of a scanning system resides, for example, in a hand-held gun shaped, laser scanning device. A user can point the head of the scanner at a target object and press a trigger to emit a light beam that is used to read, for example, a dataform, on the object. 
     In an embodiment, semiconductor lasers are used to create the light beam because they can be small in size, they are low in cost and they do not require a lot of power. One or more laser light beams can be directed by a lens or other optical components along a light path toward an object that includes a dataform. The light path comprises a pivoting scan mirror that sweeps the laser light back and forth across the object and/or dataform. The mirror can be part of a scan motor comprising a spring, and a permanent magnet. The magnet is positioned in the vicinity of a drive coil, which oscillates the scan motor. There are numerous other known methods of sweeping the laser light, such as moving the light source itself or illuminating a plurality of closely spaced light sources in sequence to create a sweeping scan line. The scanner can also create other scan patterns, such as, for example, an ellipse, a curved line, a two or three dimensional pattern, etc. 
     The scanner also comprises a sensor or photodetector for detecting light reflected or scattered from an object and/or dataform. The returning light is then analyzed to obtain data from the object or dataform. Two known scan systems for collecting light are retroreflective scan systems and non-retroflective scan systems. 
     In retroreflective scan systems, the same pivoting scan mirror that sweeps the laser light to form a scan line, also receives the light that returns to the scanner. The mirror&#39;s surface is made as large as possible to capture as much returning light as possible. The returning light is directed towards a sensor, such as for example, a photodiode, that emits electrical signals corresponding to the returning light. Data is obtained from a targeted dataform by interpreting the electrical signals. The sensor can be relatively small since the field of view of the scanner is dynamic and the instantaneous field of view of the scanner is relatively small. An exemplary retroflective scan system is described in U.S. Pat. No. 6,360,949, which is owned by the assignee of the instant invention and is incorporated by reference. 
     In non-retroreflective scan systems, the scan mirror that pivots to create a scan line is not used to receive light returning from a target dataform. Since the pivoting scan mirror does not have to receive returning light, it can be relatively small. Instead of using a large collection mirror and a small sensor to receive returning light, the scanner comprises a relatively large sensor that detects the returning laser light across its field of view. Since the field of view of the scanner is not dependant on the scan mirror, the sensor can be positioned below the source of the scan line. An exemplary non-retroreflective scan system is described in U.S. Pat. No. 6,592,040, which is owned by the assignee of the instant invention and is incorporated by reference. 
     Known non-retroreflective scan systems use scan motors created by an injection molding (IM) process, as described in U.S. Pat. No. 6,817,529, which is owned by the assignee of the instant invention and is incorporated by reference. In an exemplary embodiment, the scan motor comprises injection molded substrates and liquid injection molded (LIM) springs. The springs can be made of silicone, which provide shock protection. Additionally, the injection molded scan motor can be made at relatively low costs. Non-retroreflective scan systems are good candidates for IM scan motors because those systems use small mirrors, and small mirrors yield low inertia and low driving voltages. Since a retroreflective system uses a relatively large mirror, LIM scan motors have not been used since the drive voltages would be too high. Known retroreflective systems use scan motors that have springs made of mylar and/or metal. These materials do not have the cost and shock benefits of a material such as silicone. 
     Accordingly, there is a desire for a scan motor that can also be used in a retroreflective system that is durable, resistant to shocks and can be produced at low costs. Additionally, there is a desire for IM scan motors for non-retroreflective systems that use less power. 
     SUMMARY OF THE INVENTION 
     The invention as described and claimed herein satisfies this and other needs, which will be apparent from the teachings herein. 
     A scan motor used with, for example, a scan module. The scan motor comprising a spring module, a magnet and a reflective element. The spring module comprises a static substrate and a dynamic substrate that are coupled together by an injection molded flexible spring. In one exemplary embodiment, the substrates are made of thermo plastic and the spring is made of silicone. The spring is relatively small in size and can reduce the power required to drive the scan motor. Additionally, the scan motor can be made at low costs and has very good shock protection. 
     The dynamic substrate comprises an extending member comprising a first side and a second side. A magnet is coupled to the first side of the extending member and a reflective element, such as, for example, a mirror is coupled to the second side of the extending member. The reflective element is relatively large in size and extends beyond the static substrate and/or the dynamic substrate. In an embodiment of the invention, the scan motor comprises a pair of liquid injection molded (LIM) silicone springs and the extending member is positioned between the springs. 
     Another exemplary scan motor implemented in accordance with an embodiment of the invention comprises 
     In an embodiment of the invention, the scan motor can be a part of a scan module. An exemplary scan module further comprises a chassis, a laser module, a collection element and a drive coil. Exemplary scan modules can be a scan engine and/or a scan module of a handheld scanner, a terminal, etc. The exemplary scan modules can be retroreflective or non-retroreflective. 
     A method of scanning, implemented in accordance with the invention comprises driving a scan motor, for example by exciting a drive coil positioned opposite the magnet of the scan motor, directing a laser beam towards the reflective element and creating a scan line. A scanner user can aim the scan line over a dataform, for example, over a barcode, and read the information displayed in the dataform. 
     Other objects and features of the invention will become apparent from the following detailed description, considering in conjunction with the accompanying drawing figures. It is understood however, that the drawings are designed solely for the purpose of illustration and not as a definition of the limits of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       The drawing figures are not to scale, are merely illustrative, and like reference numerals depict like elements throughout the several views. 
         FIG. 1  illustrates a block diagram of an exemplary device implemented in accordance with an embodiment of the invention. 
         FIGS. 2 and 3  illustrate three-dimensional views of an exemplary scan engine implemented in accordance with an embodiment of the invention. 
         FIGS. 4 and 5  illustrate three-dimensional views of an exemplary spring assembly implemented in accordance with an embodiment of the invention. 
         FIGS. 6-8  illustrate three-dimensional views of an exemplary scan motor implemented in accordance with an embodiment of the invention. 
         FIG. 9  illustrates an exemplary data capture method implemented according to an embodiment of the invention. 
         FIG. 10  illustrates an alternate data capture method implemented according to an embodiment of the invention 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     There will now be shown and described in connection with the attached drawing figures several exemplary embodiments of methods and apparatus for providing a scan motor. 
     It is beneficial to have non-retroreflective and retroreflective scan systems comprising a scan motor with excellent shock protection and a minimum number of parts to reduce the cost of the scan motor. For example, some technical specification require shock protection from drops of 6 feet or more when the scan systems are incorporated into an end product, such as, for example, a scanner or a terminal. The injection molded spring module or assembly of the scan motor of the non-retroreflective scan system described in U.S. Pat. No. 6,817,529, which is owned by the assignee of the instant invention, provides excellent shock protection and can be made at low cost, but the spring assembly&#39;s size and power requirements do not make it a good alternative for some smaller sized retroreflective scan systems. 
     In an embodiment of the invention, a reduced sized injection molded spring assembly can be used in a scan motor for a non-retroreflective or a retroreflective scan system or module. The exemplary spring assembly comprises a static substrate and a dynamic substrate that can be coupled together by a flexible spring. An exemplary static substrate can be, for example, an injection molded thermoplastic material that can be secured to a chassis of a scan engine and remains static with respect to the scan engine. The dynamic substrate can also be, for example, an injection molded thermoplastic material. 
     In an embodiment of the invention, the substrates are coupled together by a flexible spring made of LIM material, such as, for example, silicone, using an over mold process. LIM material provides excellent shock protection because it can withstand substantial elongation before failure. This property allows any shock event, such as, for example, a drop form six feet, to significantly lower g-levels by stretching out the shock event in time. Since the amount of energy in a shock event is determined by the g-level and time of the event, i.e., the amount of energy in the shock event is equal to the area under a curve of g-level vs. time, a shock event for a LIM material is long in time and the g-level much lower. Other spring materials, such as, for example, mylar or metal springs, do not absorb shock as well as a LIM material since those materials do not have much elongation before failure. 
     In an alternate embodiment, the dynamic substrate and the spring can be molded as one piece using the same material. The working portion of the spring is made sufficiently small to improve efficiency and to meet volume requirements of small scan engines. The dynamic substrate also comprises an extending member that extends towards the static substrate. In an embodiment, the extending member has a wedge-like shape that grows wider as it extends towards the static substrate. 
     An exemplary scan motor comprises a spring assembly, a mirror and a magnet. The mirror is positioned next to the spring or springs rather than between a pair of springs. The extending member of the dynamic substrate receives a mirror on a first side and a magnet on a second side, and their angles relative to the spring can be manipulated by adjusting the size and/or the angle of inclination of the receiving sides of the wedge shaped extending member. Thus, the plane in which the mirror lies can be at any angle relative to the plane in which the spring or springs lie, and the plane in which the magnet lies can also be at any angle relative to the plane in which the spring or springs lie. The extending member of the dynamic substrate comprises a cradle on its first side to receive the large mirror, and the mirror comprises a receiving structure for coupling to the cradle. The magnet is bonded, for example, using an adhesive, to the second side of the extending member. 
     In known non-retroreflective scan systems, a relatively small mirror is coupled to an IM spring assembly between a pair of springs. Retroreflective systems use relatively large mirrors. Therefore, the mirror of the exemplary reduced sized IM spring assembly is positioned to the side of the springs, rather than between a pair of springs. This allows the spring assembly to receive a mirror that can be larger than the space between the springs. Additionally, positioning the mirror next to the springs creates a low moment of inertia, which helps to keep the operating power of the scan engine low. Power savings are also created by reducing the size of the spring assembly. The power saving from reducing the size of the spring assembly can also be applied to a non-retroreflective scan system that has been modified to receive a smaller spring assembly. 
     In an exemplary scan module, the scan motor is positioned in close proximity to a drive coil, such as, for example, a bi-directional drive coil as described in U.S. Pat. No. 6,824,060, which is owned by the assignee of the instant invention and is incorporated by reference. When powered, the drive coil causes the scan motor to oscillate back and forth. A laser beam impinging on the mirror is then moved back and forth to create a scan line that can be used to read dataforms, such as, for example, barcodes. 
     The scan motor is properly aligned within the scan module so that the laser beam reflects off the scan motor&#39;s mirror and creates a scan line in a desired direction. In an exemplary retroreflective scan module, the static substrate comprises a pivoting base, that is used to align the scan motor. The scan motor also comprises a chassis having a feature to receive the pivoting base. After the scan motor is aligned correctly, it is secured in place using an adhesive. The retroreflective scan module can be, in some embodiments, an independent scan engine that can be a module of a scanning device. 
     In an exemplary non-retroreflective scan system implemented in accordance with the invention, the extending member of the spring assembly can be modified to cradle a small mirror. The smaller mirror makes the scan motor even more efficient. 
     With reference to  FIG. 1 , there is shown an exemplary block diagram of a device  101  comprising a scan module  100 , a processing unit  105  and memory  120  coupled together by bus  125 . The modules of device  101  can be implemented as any combination of software, hardware, hardware emulating software, and reprogrammable hardware. The bus  125  is an exemplary bus showing the interoperability of the different modules of the invention. As a matter of design choice there may be more than one bus and in some embodiments certain modules may be directly coupled instead of coupled to a bus  125 . The device  101  can be, for example, a laser scanner, a mobile computer, a point of service, etc, and the scan module can be, for example, a retroreflective scan engine  100 . 
     Processing unit  105  can be implemented as, in exemplary embodiments, one or more Central Processing Units (CPU), Field-Programmable Gate Arrays (FPGA), etc. In an embodiment, the processing unit  105  may comprise a plurality of processing units or modules. Each module can comprise memory that can be preprogrammed to perform specific functions, such as, for example, signal processing, interface emulation, etc. In other embodiments, the processing unit  105  can comprise a general purpose CPU that is shared between the scan engine  100  and the device  101 . In alternate embodiments, one or more modules of processing unit  105  can be implemented as an FPGA that can be loaded with different processes, for example, from memory  120 , and perform a plurality of functions. Processing unit  105  can also comprise any combination of the processors described above. 
     Memory  120  can be implemented as volatile memory, non-volatile memory and rewriteable memory, such as, for example, Random Access Memory (RAM), Read Only Memory (ROM) and/or flash memory. The memory  120  stores methods and processes used to operate the device  101 , such as, data capture method  145 , signal processing method  150 , power management method  155  and interface method  160 . 
     In an exemplary embodiment of the invention, the device  101  can be a handheld scanner  101  comprising a trigger. When a scanning operation is initiated, for example the trigger is pressed, the scanner  101  begins data capture method  145 . An exemplary embodiment of data capture method  145  is described below with reference to  FIG. 9 . During the data capture method  145 , laser light is emitted by the scanner  101 , which interacts with a target dataform and returns to the scanner  101 . The returning laser light is analyzed, for example the received analog laser light is converted into a digital format, by the scanner  101  using signal processing method  150 . Power management method  155  manages the power used by the scanner  101  and interface method  160  allows the scan engine  100  to communicate with the scanner  101 . 
     The exemplary embodiment of  FIG. 1  illustrates data capture method  145 , signal processing method  150 , interface method  160  and power management method  155  as separate components, but those methods are not limited to this configuration. Each method described herein in whole or in part can be separate components or can interoperate and share operations. Additionally, although the methods are depicted in the memory  120 , in alternate embodiments the methods can be incorporated permanently or dynamically in the memory of processing unit  105 . 
     Memory  120  is illustrated as a single module in  FIG. 1 , but in some embodiments image scanner  100  can comprise more than one memory module. For example, the methods described above can be stored in separate memory modules. Additionally, some or all parts of memory  120  may be integrated as part of processing unit  105 . 
       FIGS. 2 and 3  illustrate a three-dimensional view of a scan engine  100 , implemented in accordance with an embodiment of the invention. The scan engine  100  can be used as the scan engine  100  of  FIG. 1 .  FIG. 2  illustrates a laser module or assembly  110  positioned in the upper left hand corner of the scan engine  101  chassis  112 . During a data capture method  145 , the laser assembly  110  emits a laser beam  210  that is reflected by a fold mirror  115 . The laser beam  210  goes through a hole in the collection mirror  130  and impinges on the scan mirror  170 . The scan mirror  170  is part of a scan motor  165 , which moves back and forth creating a scan line for reading dataforms. 
     After interacting with a dataform, some of the emitted laser light returns to the scan engine  100 . The returning light is received by the scan mirror  170  and is reflected towards the collection mirror  130 . The collection mirror  130 , which can have an off axis parabola shape, collects the returning light and concentrates it towards the sensor  140 . The sensor  140  can be implemented, in an exemplary embodiment, as a photodiode. The returning light is detected by the sensor  140  which produces a corresponding electrical signal. The electrical signal is analyzed and the target dataform is decoded. 
     The scan motor  165  comprises a spring module  175 , a scan mirror  170  and a magnet  180 .  FIGS. 4 and 5  illustrate an exemplary spring module  175 . The exemplary spring module  175  comprises a static substrate  177  and a dynamic substrate  176  coupled together by a flexible spring  179 . In one exemplary embodiment, the flexible spring  179  is made of a pair of silicone springs  179  that are over molded  410  to the dynamic substrate  176  and the static substrate  177 . The springs  179  are liquid injection molded to the substrates  176 ,  177 . In alternate embodiments, the flexible springs  179  can be made of thermoplastic using an injection molding process, or alternatively, the springs  179  and the dynamic substrate  176  can be made of an LIM material. 
     The exemplary static and dynamic substrates  176 ,  177  are made of a thermoplastic material. The static substrate  177  comprises a pivoting base  178  that is used to properly align and secure the scan motor  165  to the scan engine  100  chassis. The dynamic substrate  176  comprises an extending member  181  that receives the magnet  180  and the scan mirror  170 . 
     The extending member  181  has a first side  405  and a second side  505 . The first side  405  comprises a cradle for receiving the scan mirror  170 , and the second side  505  comprises a receiving structure for receiving the magnet  180 . The extending member  181  has a triangular or wedge-like shape. The extending member  181  starts at one end of the spring module  175  and gets larger as it extends from the dynamic substrate  176  towards the static substrate  177 . 
       FIGS. 6 through 8  illustrate the scan motor  165 . A magnet  180  is positioned in the receiving structure located on the second side  505  of the extending member  181 . The mirror  170  is coupled to the first side  405  of the extending member  181 . The mirror  170  comprises a receiving structure that receives the first side  405  of the extending member  181 . The magnet  180  and the mirror  170  can be secured to the extending member  181  using an adhesive. 
     In an alternate embodiment, the flexible springs  179  and the dynamic substrate  176  can be molded as one unit that is made of the same material. For example the combined unit can be made of silicone or thermoplastic. 
     Returning to  FIGS. 2 and 3 , the scan motor  165  is positioned in proximity to the drive coil  135 . The magnet  180  coupled to the scan motor  165  interacts with the magnetic field created by the drive coil  135  and oscillates the scan motor  165  when the drive coil  135  is excited. 
     Processing proceeds from step  905  to step  910 , where the scanner  101  initiates a laser  110 . The laser strikes a fold mirror  115  and is directed towards the scan mirror  170 . About or at the same time, in step  915 , the scanner  101  initiates the drive coil  135  by providing power to the drive coil  135 . The magnet  180  reacts to the magnetic field created by the drive coil  135  and begins to oscillate the scan motor  165 . As a result, the laser light impinging on the scan mirror  170  moves back and forth, creating a scan line.  FIG. 10  illustrates data capture method  1000 , which is an alternate embodiment of method  900 , where step  915  occurs before step  910 . Meaning, the drive coil  135  is initiated before the laser  110  is initiated. 
     Processing proceeds from step  905  to step  910 , where the scanner  101  initiates a laser  110 . The laser strikes a fold mirror  115  and is directed towards the scan mirror  170 . About or at the same time, in step  915 , the scanner  101  initiates the drive coil  135  by providing power to the drive coil  135 . The magnet  180  reacts to the magnetic field created by the drive coil  135  and begins to oscillate the scan motor  165 . As a result, the laser light impinging on the scan mirror  170  moves back and forth, creating a scan line. 
     The emitted laser light of the scan line interacts with the dataform and, in step  920 , the scanner  101  receives any light that returns to the scanner  101 . For example, the returning light is reflected by the scan mirror  170  towards a collection mirror  130 . The collection mirror directs the returning light towards a sensor. Since the scan mirror  170  is moving back and forth, the field of view of the scanner  101  also moves back and forth. 
     Following step  920 , in step  925 , the received light is analyzed and the target dataform is decoded. In step  930 , if the analysis is successful, processing proceeds to step  935 , where the decoded data is further processed. For example the data can be transmitted to another device. Following step  935 , processing of method  900  proceeds to step  950  where the method  900  ends. The scanner  101  may be in a standby mode, ready to process another dataform. 
     Returning to step  930 , if the scanner  101  does not successfully decode the target dataform, processing proceeds to step  940 . In some embodiments, the scanner  101  does nothing, and ends in step  950 , but in other embodiments the scanner  101  can emit an audible fail indicator to the scanner operator, transmit a fail signal to an attached device, etc. Still in other embodiments, the scanner  101  continues steps  910  through  925  until the dataform is successfully read or the operator removes power to the scan engine, for example, by releasing the trigger. 
     While the exemplary scan motor has been described as part of a retoreflective scan system, the scan motor of the invention can also be used in a reduced sized non-retroreflective scan system. The relatively large mirror can be replaced by a smaller mirror and the angle between the flat plane of the mirror and the spring can be properly adjusted, for example to 45 degrees, by adjusting the width of the wedge shaped extending member. Additionally, the structure of the static substrate can be modified so that the scan motor can be secured to a scan module coupled to a circuit board. An exemplary scan motor of the invention can help to increase the efficiency of the non-retroreflective scan system, since the exemplary scan motor uses less power. 
     While there have been shown and described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and detail of the disclosed invention may be made by those skilled in the art without departing from the spirit of the invention. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.