Imaging module for supporting printed circuit boards in a predetermined angular relationship in an imaging reader

Abstract

Imaging module for reading a target by image capture, the module comprising: a first printed circuit board (PCB); an imaging system including an imager mounted on the first PCB for capturing an image of the target over a field of view; a second PCB; an interface connector mounted on the second PCB; and a rack having first rack walls in direct contact with the first PCB in the surface area to support the imaging device and to automatically position the first PCB to lie in a generally upright, first predetermined plane, and second rack walls in direct contact with the second PCB in the surface area to support the interface connector and to automatically position the second PCB to lie in a generally oblique, second predetermined plane inclined at an angle of inclination with respect to the first predetermined plane, the first and second rack walls being formed as a one-piece support that maintains the angle of inclination between the PCBs.

Description

BACKGROUND OF THE INVENTION

[0001] The present disclosure relates generally to an imaging module mountable in an imaging reader for reading targets, such as bar code symbols, to be electro-optically read by image capture in a field of view, and, more particularly, to support a plurality of circuit boards having electro-optical reading and / or interfacing components mounted thereon to lie in predetermined planes in a predetermined angular relationship on the module, and more particularly, to a method of assembling the module and mounting the assembled module as a unitary assembly in the reader.

[0002] Solid-state imaging readers have long been used in both handheld and hands-free applications in many industries, including retail, manufacturing, warehousing, distribution, shipping, transportation, logistics, and more. They electro-optically read and decode targets, such as one- or two-dimensional barcode symbols. A common imaging reader generally includes an imaging module, also known as a scan engine, mounted within the reader and has a chassis on which an engine printed circuit board (PCB) is mounted. A solid-state imager for capturing an image of a target along an imaging axis across a field of view is mounted on the engine PCB.For optical reasons, it is desirable for the imager to be positioned with its imaging axis generally horizontally directed directly at the target and to lie in a generally upright or perpendicular plane to maximize imaging performance, as lying in any other plane could defocus the acquired image. Typically, a pilot light source directing one or more visible pilot lights along respective axes toward the target for visual targeting is also mounted on the engine PCB, and an illuminator light source directing one or more illuminator lights along respective illumination axes toward the target to illuminate the target, particularly in poorly lit environments, is mounted either on the engine PCB or elsewhere on the gantry.For optical reasons, it is also desirable that the pilot light source and / or the illumination light source be aligned generally horizontally with their respective aiming and / or illumination axes directly at the target and lie in a generally upright or perpendicular plane, thereby maximizing the amount of pilot and / or illumination light directed at the target and avoiding excessive light correction with the aiming lenses and / or illumination lenses. If the imaging device, pilot light source, and / or illumination light source are all mounted on the surface of the same engine PCB such that their imaging, aiming, and / or illumination axes are generally at right angles to the engine PCB, then the engine PCB is typically supported on the gantry to lie in the generally upright or perpendicular plane.

[0003] It is known to configure the handheld imaging reader with a generally firearm-shaped configuration, with a handle extending, for ergonomic reasons, along a handle axis that is typically inclined at an angle of approximately fifteen to about twenty-two degrees relative to the vertical. Rather than occupying and wasting the available space inside the handle, another PCB, also known as a handle, control, or decoder PCB, is mounted within the handle and extends along its handle axis. The handle PCB advantageously supports other electro-optical reading components, such as a controller or processor for controlling the imager, the targeting light source, and the illumination light source, and for processing the acquired image.The handle PCB also supports an electrical interface connector at a lower end of the handle PCB, adjacent to a bottom of the handle, for connection to electrical power / data cables, and an indicator light source at an upper end of the handle PCB, adjacent to a top of the handle, for visually indicating when a successful target read has been performed. The handle PCB is mounted at an angle relative to the engine PCB using separate mounting clamps or frames that are individually secured to the frame.

[0004] Although generally sufficient for their intended purpose, the mounting clamps used to hold the engine PCB and handle PCB at the tilt angle are relatively cumbersome to mount on the rack, complicate and delay module assembly, and represent a non-negligible cost, not only in terms of manufacturing and inventory management of additional components, but also in terms of assembly and installation. The mounting clamps could break under certain circumstances, such as if the reader is dropped and subjected to high recoil, resulting in unwanted movement between the PCBs. In the worst case, the required predetermined angular relationship between the engine PCB and handle PCB might not be maintained, and as a result, reading performance could degrade.

[0005] Accordingly, it would be desirable to avoid the use of mounting clamps to make the reader more resistant to shocks and to simplify, speed up and reduce the cost of assembling the module. BRIEF DESCRIPTION OF THE DRAWING

[0006] The accompanying drawings, in which like reference characters refer to identical or similarly functioning elements throughout the several views, together with the detailed description below, are incorporated herein and constitute a part of the specification, and further serve to illustrate embodiments of concepts incorporating the claimed invention and to explain various principles and advantages of the embodiments. Fig. 1 shows a side view of one embodiment of an electro-optical handheld reader that reads targets by image capture and that includes an imaging module according to this disclosure. Fig. Figure 2 shows a schematic representation of electro-optical imaging components and pilot light systems on the imaging module plate within the reader of the Fig. 1. Fig. Figure 3 shows an enlarged front view of an imager, a pair of pilot light sources, and a pair of illumination light sources mounted on an engine PCB and to be supported by the imaging module. Fig. 4 shows a front view of a frame on which the engine PCB of the Fig. 3 and a handle PCB were mounted. Fig. Figure 5 shows an enlarged sectional view of the line 5 - 5 of the Fig. 4. Fig. Figure 6 shows an enlarged sectional view of the line 6 - 6 of the Fig. 4. Fig. Figure 7 shows a rear perspective view of an embodiment of the insulated frame of the Fig. 4. Fig. Figure 8 shows a rear perspective view of the frame of the Fig. 7 after the engine PCB was criticized. Fig. Figure 9 shows a rear perspective view of the frame of the Fig. 7 after the handle PCB was mounted on it. Fig. Figure 10 shows an exploded perspective view of a portion of the imaging module during its assembly in the reader of the Fig. 1. Fig. Figure 11 shows a cutaway cross-sectional view of the imaging module in the reader of the Fig. 1. Fig. Figure 12 shows a broken upper sectional view showing the device in the reader of the Fig. 1 mounted imaging module. Fig. Figure 13 shows a perspective front view of an embodiment of an insulated window mounted against the frame of the Fig. 7 is to be positioned. Fig. 14 shows a rear perspective view of another embodiment of the insulated window. Fig. Figure 15 shows a top cross-sectional view of imaging components and illumination light systems of the imaging module. Fig. Figure 16 shows a side cross-sectional view of imaging components and illumination light systems of the imaging module. Fig. Figure 17 shows a cutaway, perspective top view of the imaging module on which a hood is mounted to surround the window. Fig. 18 shows a view analogous to Fig. 17, viewed from below. Fig. Figure 19 shows a cutaway, perspective front view of a variant of the imaging module in which the illumination light sources are mounted on a separate PCB. Fig. 20 shows a perspective view of another embodiment of the insulated frame. Fig. Figure 21 shows a side sectional view of the frame mounted in the reader of the Fig. 20 and represents a light guide. Fig. Figure 22 is an enlarged, cutaway, perspective view of the imaging module showing the pilot lights and illumination lights exiting the window, as well as the light reflected into the window of the reader of the Fig. 1 incoming field of view of the imaging device.

[0007] Those skilled in the art will understand that portions of the drawings are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions and positions of some elements in the drawings may be exaggerated relative to other elements to help improve understanding of embodiments of the present invention.

[0008] The imaging module, the imaging reader, and the method components are represented by conventional symbols in the drawings where appropriate, showing only those specific details that are pertinent to understanding the embodiments of the present invention so that the disclosure is not obscured by details that would be readily apparent to one of ordinary skill in the art having the benefit of the presented description. DETAILED DESCRIPTION OF THE INVENTION

[0009] According to one feature of this disclosure, an imaging module is operable to read a target, e.g., a barcode symbol, by image capture. The module includes a first, or engine, printed circuit board (PCB) and an imaging system having an imaging device, e.g., a charge-coupled device (CCD) array or a complementary metal-oxide-semiconductor (CMOS) array of cells or sensors, mounted on the first PCB to capture an image of the target over a field of view. The module also includes a second, or handle, PCB and an interface port mounted on the second PCB.The module further includes a rack having first rack walls in direct contact with the first PCB in the surface area to support the imaging device and to automatically position the first PCB to lie in a generally upright, first predetermined plane, and second rack walls in direct contact with the second PCB in the surface area to support the interface connector and to automatically position the second PCB to lie in a generally oblique, second predetermined plane inclined at an angle of inclination, preferably an acute angle of about fifteen degrees, with respect to the first predetermined plane. The first and second rack walls are formed from a one-piece support that maintains the angle of inclination or predetermined angular relationship between the PCBs.The module is mounted as a unitary assembly inside a housing of an imaging reader, which is preferably configured as a portable, field-ready, firearm-shaped handheld housing having an elongated handle in which the second PCB is received in the longitudinal direction of the handle.

[0010] Preferably, the module includes a pilot light system having one or more pilot light sources mounted on the first PCB. The rack has internal compartments, each containing the imaging device and each of the pilot light sources. Advantageously, the module includes an illuminating light system having one or more illuminating light sources mounted on the first PCB. The rack has internal compartments, each containing the imaging device and each of the illuminating light sources. In a variant of the construction, each illuminating light source is mounted on a third PCB that is in direct contact with third rack walls of the rack, and that is supported and positioned in a generally upright, third predetermined plane that is either coplanar or generally parallel to the first predetermined plane.

[0011] The first PCB may have a pair of first cutouts, and the rack may have a first pair of guide pins received in the first cutouts for positioning the first PCB to lie in the first predetermined plane, and a first pair of PCB fasteners for securing the first PCB to remain firmly in the first predetermined plane. Additionally, the second PCB may have a pair of second cutouts, and the rack may have a second pair of guide pins received in the second cutouts for positioning the second PCB to lie in the second predetermined plane, and a second pair of PCB fasteners for securing the second PCB to remain firmly in the second predetermined plane.The rack may include a pair of eyelets extending in opposite directions away from each other, and a pair of housing fasteners extending through openings in the eyelets for fixedly mounting the rack in the imaging reader. A light-transmitting window may be positioned in direct contact with the rack, and a hood may surround the window. The rack advantageously includes a plurality of hooks extending through openings in the hood for mounting the hood and window to the rack.

[0012] According to another feature of this disclosure, a method of assembling an imaging reader for reading a target by image capture is performed by assembling an imaging module by mounting an imaging device on a first printed circuit board (PCB); by mounting an interface connector on a second PCB; by supporting the imaging device, and by automatically positioning the first PCB so that it is in direct surface contact with first rack walls of a rack in a generally upright, first predetermined plane; by supporting the interface connector, and by automatically positioning the second PCB so that it is in direct surface contact with second rack walls of the rack in a generally oblique, second predetermined plane inclined at an angle of inclination with respect to the first predetermined plane;and by forming the first and second rack walls as a one-piece support that maintains the tilt angle or predetermined angular relationship between the PCBs. The assembled imaging module is then mounted into the reader as a unitary assembly.

[0013] The one-piece frame support eliminates the need for mounting clamps and makes the reader more resistant to the effects of vibration. The first and second frame walls automatically position the first and second PCBs so that they lie in their predetermined planes with the required predetermined angular relationship, thereby simplifying and accelerating module assembly and reducing its cost.

[0014] Turning now to the drawing, reference numeral 30 in Fig. 1 generally illustrates an exemplary ergonomic imaging handheld reader for electro-optically reading targets, such as barcode symbols or similar markings, by image capture across an oblique field of view (FOV) 20. The reader 30 is advantageously configured as a firearm-shaped housing having an upper barrel or body 32 and a lower elongated handle 28 that is tilted rearwardly along a handle axis away from the body 32 at an acute or oblique angle of inclination, for example, an angle anywhere between twenty-two and fifteen degrees (fifteen degrees is shown) with respect to the vertical. The body 32 and handle 28 may be constructed of a lightweight, durable, shock-absorbing, crush-resistant material, such as a synthetic plastic material.The plastic housing may be injection molded, but it may also be vacuum formed or blow molded to form a thin, hollow shell defining an interior space of sufficient volume to contain a scan engine or imaging module 40, as described in detail below in connection with the . Fig. 2 to 20. In the body 32 and the interior of the housing there is a translucent window 26 (see Fig. 2) and seals it from the outside environment. The imaging reader 30 is held in the operator's hand by the handle 28 and used in a handheld mode in which a forward-facing trigger 34 is manually pressed to initiate imaging of targets to be read within a range of working distances relative to the reader 30.

[0015] As shown schematically in Fig. 2, the imaging module 40 includes an imaging system comprising a solid-state imager 10, in turn mounted on a generally planar engine printed circuit board (PCB) 38 supported on a chassis 70 of the module 40 as described below, and an imaging lens assembly 12 mounted in a tubular holder 14 having a circular aperture 16. The imager 10 is a two-dimensional charge-coupled device (CCD) array or a complementary metal-oxide-semiconductor (CMOS) array of cells or sensors having either a global or a rolling shutter. To keep costs low, a CMOS imager may advantageously be used with a rolling shutter.The imager 10 and the imaging lens 12 are preferably aligned along a central axis or optical imaging axis 18 that is generally centrally located in the upper body 32 of the housing and that is generally at right angles to the engine PCB 38.

[0016] In operation, the imaging system detects light returning from the target located at a range of working distances from the window 26, passing through an upper central zone 54 of the window 26 along the imaging axis 18 centered in the imaging field of view 20 of the imaging lens assembly 12. The imaging device 10 is advantageously positioned closer to a rear wall of the upper body 32 to increase the imaging field of view 20 in the near range of working distances near the reader 30. The imaging lens assembly 12 preferably includes one or more fixed focus lenses, preferably a Cooke triplet, having an imaging plane at which the target is best focused and imaged onto the imaging device 10. The field of view 20 is generally rectangular and extends along a horizontal X-axis and a vertical Y-axis, both generally perpendicular to the imaging axis 18.The sensors generate electrical signals corresponding to a two-dimensional array of pixel information for an image of the target. The electrical signals are processed by a controller or programmed processor 22 into data indicative of the read target. The controller 22 is connected to a memory 36 for data retrieval and storage. The controller 22 and memory 36 may be mounted on the engine PCB 38 or, advantageously, on a generally planar handle PCB 68, which is also supported on the frame 70 of the module 40, as described below.

[0017] The imaging system is capable of acquiring a complete image of the target under various lighting conditions. An illumination system, as described below, can also be mounted on module 40 to provide illumination light to illuminate the target. The exposure time is controlled by controller 22. The array resolution can have various values, although a VGA resolution of 640 x 480 pixels can be used to minimize costs.

[0018] A targeting system including one or more pilot light assemblies is supported on the module 40 and is remote from the imaging system. The targeting system is operable to project a target marker 60 (see Fig. 2) at the target. The aiming light assemblies are spatially separated from each other along the horizontal X-axis on opposite sides of the imaging sensor 10. Each aiming light assembly includes a aiming light source or emitter, e.g., a light-emitting diode (LED) 42, mounted on the engine PCB 38; a generally linear aiming aperture 46 extending along the horizontal X-axis in front of the respective LED 42; and an aiming lens 44, preferably an annular lens, mounted remote from its respective LED 42 and preferably integrated with the window 26 as described below. Each aiming LED 42, aiming lens 44, and aiming aperture 46 is centered and lies along a respective aiming axis 48. The aiming axes 48 lie generally in a common plane and are generally parallel to each other. As shown in Fig. 3, the aiming LED 42 and the sensor 10 are mounted along a common horizontal X-axis, but this need not be the case, as the aiming LEDs 42 can be mounted either above or below the imaging device 10. Advantageously, the imaging axis 18 lies in the same plane and is generally parallel to the aiming axis 48.

[0019] The aiming light assemblies are operable to direct the aiming light emitted by each aiming LED 42 through the respective aperture 46 and the respective aiming lens 44 along the respective aiming axis 48 across an oblique aiming field 52 centered on the respective aiming axis 48 at the target. On the target, these aiming fields 52 define a pair of aiming light lines 50, each of which has a predetermined brightness. The aiming light lines 50 are collinear along the horizontal X-axis. The aiming light lines 50 have inner linear end regions 50A that extend beyond the imaging axis 18 and that overlap on the target to form a bright, linear aiming mark 60 having a brightness greater than the predetermined brightness due to the superposition of the inner linear end regions 50A to visually indicate a central region of the field of view 20 over the range of working distances.Thus, the operator can position the aiming marker 60 on the target, and the target will be substantially centered within the imaging field of view 20. The pilot light lines 50 also have outer linear end portions 50B that extend along the horizontal X-axis to and visually indicate approximate boundary zones or end limits of the field of view 20 across the range of working distances. Thus, the operator is guided to position the outer linear end portions 50B on the target so that the target is substantially entirely contained within the imaging field of view 20.

[0020] How best to Fig. 13 through 14, the aiming lenses 44 are formed with the window 26 in a one-piece construction on opposite sides of and facing away from the central zone 54 through which the image of the target is captured. The window 26 and the aiming lenses 44 may be made of glass and / or molded plastic materials. Thus, the window 26 may be made of glass, and each aiming lens 44 may be made of the same glass. Alternatively, the window 26 may be made of plastic, and each aiming lens 44 may be made of the same plastic. In other variations, the window 26 may be made of glass, and each aiming lens 44 may be made of plastic coated or molded onto the glass in a process known as overmolding or remodeling, or vice versa, such that the window 26 may be made of plastic, and each aiming lens 44 may be made of glass molded into the plastic.Although the aiming lenses 44 are shown on the outer surface of the window 26, they can also be formed on the inner surface of the window 26. The aiming lenses 44 are therefore integral with the window 26, thereby reducing the overall number of components that must be individually manufactured, installed, and aligned.

[0021] As in the Fig. 3 to 4, 6 and 15 to 16, the reader 30 may also include an illumination light system, e.g., one or more illumination light sources or illumination light emitters, such as light emitting diodes (LEDs) 62 mounted on the engine PCB 38. As best shown in Fig. 3, the pilot light sources 32, the illumination light sources 62 and the image device 10 are all mounted on the surface of the same engine PCB 38. In a variant of the construction, the illumination light sources 62 could be mounted as shown in Fig. 19, be mounted on a separate PCB 24, which is preferably coplanar or generally parallel to the engine PCB 38. Each illumination LED 62 is operable to illuminate the target by projecting illumination light toward, reflecting, and scattering it at an illumination angle centered on an illumination axis 64. Each illumination LED 62 is advantageously equipped with an optical component, such as a compound parabolic reflector (CPR) 66, to uniformly and efficiently illuminate the target with an illumination light pattern.Each CPR 66 is preferably integrated into the window 26 and is configured to receive and optically modify the illumination light emitted by each illumination LED 62 to produce a generally uniform and efficient illumination pattern, preferably of a generally rectangular shape, substantially congruent with and substantially overlapping the field of view 20, which in turn is preferably rectangular in shape along both the X-axis and the Y-axis, illustrated in FIG. Fig. 3. Each CPR 66 includes a first pair of parabolic segments mounted on opposite sides of the illumination axis 64 for reflecting the illumination light emitted at a first illumination angle along the X-axis, and a second pair of parabolic segments, also mounted on opposite sides of the illumination axis 64, for reflecting the illumination light emitted at a second illumination angle along the Y-axis. Each CPR 66 is advantageously a solid component, e.g., a molded plastic, whose inner surface reflects the illumination light by total internal reflection and directs it away from each illumination LED 62. Each CPR 66 could also be a hollow component.

[0022] How best in Fig. 14, the CPRs 66 are formed with the window 26 in a one-piece construction on opposite sides of and below the upper central zone 54 through which the image of the target is captured. The window 26 and the CPRs 66 may be made of glass and / or molded plastic materials. Therefore, the window 26 may be made of glass, and each CPR 66 may be made of the same glass. Alternatively, the window 26 may be made of plastic, and each CPR 66 may be made of the same plastic. In other variations, the window 26 may be made of glass, and each CPR 66 may be made of plastic that is coated or molded onto the glass in a process known as overmolding or remodeling, or vice versa, such that the window 26 may be made of plastic, and each CPR 66 may be made of glass molded into the plastic.Although the CPRs 66 are shown on the inner surface of the window 26, they can also be formed on the outer surface of the window 26. The CPRs 66 are therefore integral with the window 26, thereby reducing the overall number of components that must be individually manufactured, installed, and aligned.

[0023] According to this revelation, as in Fig. 4, the frame 70 has frame walls that border a plurality of open, interior compartments 72, 74, and 76. The imaging device 10 and the imaging lens assembly 12 are contained in the compartment 72. The pilot light sources 42 and the pilot light shutters 46 are each contained in a pair of the compartments 74. The illumination light sources 62 are each contained in a pair of the compartments 76. The imaging device 10, the pilot light sources 42, and the illumination light sources 62 are all mounted on the same engine PCB 38, which is also sometimes described herein as the first PCB, which is as shown in the Fig. 5 to 7, is supported in direct surface contact with generally planar first frame walls 82 of frame 70 to lie in a generally upright, first predetermined plane 84. For optical reasons, it is desirable that the imaging device 10 be oriented to lie along the first predetermined plane 84, which is generally perpendicular to the imaging axis 18, to maximize imaging performance, since lying in any other plane could defocus the acquired image.For optical reasons, it is also desirable that the pilot light sources 42 and / or the illumination light sources 62 also be aligned to lie along the first predetermined plane 84, which is generally perpendicular to the imaging axis 18, in order to maximize the amount of light delivered to the target and to avoid excessive light corrections with the aiming lenses 44 and / or any illumination lenses.

[0024] As in Fig. 3, the engine PCB 38 has a pair of first side cutouts 86 and a first pair of openings 92. As shown in Fig. 8, the frame 70 includes a first pair of guide pins 88 received in the first cutouts 86 to accurately register and position the engine PCB 38 to lie in the first predetermined plane 84, and a first pair of PCB fasteners 90 extending through the openings 92 to firmly secure the engine PCB 38 to remain in the first predetermined plane 84 by seating the PCB fasteners 90 in threaded holes 98 (see Fig. 7) are screwed.

[0025] An electrical interface connector 130 for connection to electrical power / data cables is mounted at a lower end of the handle PCB 68 adjacent a bottom of the handle 28. As mentioned above, the controller 22 may also be mounted on the handle PCB 68, which is also known as a control or decode PCB, and is sometimes described herein as a second PCB. As shown in the Fig. 5 through 7, the handle PCB 68 is supported in direct surface contact with generally planar second rack walls 94 of the rack 70 to lie within a generally oblique, second predetermined plane 96 inclined at an angle of inclination relative to the first predetermined plane 84. For ergonomic reasons, to best utilize the available space within the handle 28, the handle PCB 68 extends along the handle axis, which, as described above, is typically inclined with respect to the vertical at the angle of inclination of approximately fifteen to about twenty-two degrees. A pair of cylindrical hubs 100 extend rearwardly from a lower region of the rack 70 and terminate in a pair of lower end surfaces inclined at the angle of inclination. A T-shaped post 102 extends rearwardly from an upper region of the rack 70 and terminates in an upper end surface inclined at the angle of inclination.The upper and lower end surfaces lie along the second predetermined plane 96 and represent the second frame walls 94.

[0026] As in Fig. 9, the handle PCB 68 has a pair of second side cutouts 104, and the frame 70 has a second pair of guide pins 106 received in the second cutouts 104 to accurately register and position the handle PCB 68 to lie in the second predetermined plane 96, and it has a second pair of PCB fasteners 108 extending through openings in the handle PCB 68 to firmly secure the engine PCB 38 to remain in the second predetermined plane 96 by seating the PCB fasteners 108 in threaded holes 110 (see Fig. 7) are screwed into the cylindrical hubs 100.

[0027] Thus assembled, the frame 70 is a one-piece support that maintains the tilt angle between the PCBs 38, 68. The module 40 is insertable and mounted as a unitary assembly within the reader 30. As shown in Fig. 10, the frame 70 also has side projections 112 extending in opposite directions away from each other and a pair of housing mounts 114 extending through openings 116 (see Fig. 4) extend into the lugs 112 to firmly mount the frame 70 to threaded holes 126 within the imaging reader 30. Fig. 11 to 12 are sectional views of the module 40 after assembly in the housing. Fig. 11 represents the tilt angle maintained between the PCBs 38, 36 during operation.

[0028] As also in the Fig. 11 through 12, the light-transmitting window 26 is positioned in direct, sealed contact with the rack 70. The rack walls of all of the interior compartments 72, 74, and 76 extend forward, away from the engine PCB 38, in a direction generally perpendicular to the engine PCB 38 and terminate in outer wall surfaces. The window 26 directly engages the outer wall surfaces of the rack 70 and covers each compartment 72, 74, and 76. The rack walls extend sufficiently forward to create physical barriers between the compartments 72, 74, and 76 to optically separate them from one another, and the covering window 26 therefore seals off the environment, optically isolates, and prevents any stray pilot light and / or stray illumination light from entering the interior compartment 72 containing the imaging device 10.

[0029] How best to Fig. 11 to 12, the window 26 seals the interior of the housing 32 from the environment, such as dirt, moisture, dust, and similar contaminants. A rubber gasket or seal 56 helps seal the window 26 in its position at the front of the reader 30. As best shown in the Fig. As shown in Figures 13 through 14, a plurality of guide pins 58 are formed integrally with the window 26 to assist in mounting the window 26 in its sealed position and to prevent rotation of the window 26. One such pin 58 is provided on one side of the window 26, and a pair of such pins 58 are provided on the opposite side of the window 26. The guide pins 58 assist in precisely positioning the window 26 with respect to the aiming, imaging, and illumination systems. In particular, the optical elements on the window 26 are precisely positioned with respect to the aiming lenses 44, the aiming apertures 46, the aiming LEDs 42, the CPRs 66, and the illumination LEDs 62. Fig. Figure 22 shows both the pilot lights and the illumination lights exiting the precisely positioned window 26, as well as the field of view of the imaging device 10 entering the precisely positioned window 26.

[0030] The window 26 is either releasably held against or firmly and permanently mounted, for example, by an adhesive or other fastening, to the chassis 70. With the window 26 so firmly mounted, the module 40 is completely sealed and can be moved around a manufacturing facility, or even shipped to another facility, without concern for contamination from environmental contaminants. Advantageously, the window 26 is generally planar and positioned to be generally parallel to the PCB 38. The window 26 may also be curved or formed into another shape, in which case the outer chassis surfaces are configured with a complementary contour so that a tight seal is established when the window 26 mates with the chassis 70.Although the window 26 is shown connecting to the frame 70 at external frame surfaces, it is also understood that the frame 70 may also be recessed into a recess in which the window 26 is mounted. A recessed window will be more resistant to scratches and contamination.

[0031] As in the Fig. 17 through 18, a bezel or hood 120 surrounds the window 26. The chassis includes an upper hook 116 and a pair of lower hooks 118 extending through complementary openings in the hood 120 for mounting the hood 120 and window 26 on the chassis 70. Thus, the hood 120, window 26, and chassis 70 with the PCBs 38, 68 and their supported electro-optical components are all mounted together in the reader 30.

[0032] An indicator light source 78 (see Fig. 9 and Fig. 11) may also be supported on the handle PCB 68 and rearwardly aligned with the frame 70. The indicator light source 78 emits a visual indicator light to a light scattering section 80 of the body 32 whenever the target has been successfully read. The window 26 not only prevents any scattered pilot light and / or scattered illumination light from leaking into the light scattering section 80 and falsely indicating that a target has been successfully read, but also prevents visual indicator light from leaking into the internal compartments, and primarily into the compartment 72 containing the imager 10.

[0033] The illumination light sources 62 do not need to be mounted on the engine PCB 38, but could, as in Fig. 19, be mounted on the separate PCB 24, which is also sometimes referred to herein as the third or lighting PCB. In a variant of the frame construction, the frame 70 of the Fig. 19 third rack walls in direct contact with the illumination PCB 24 to support the illumination light sources 62 and to automatically position the illumination PCB 24 to lie in a generally upright, third predetermined plane, which is preferably coplanar or generally parallel to the engine PCB 38. The illumination PCB 24 is advantageously registered in position by a pair of guide pins 122 and is firmly secured in position by snaps 124 with a snapping action. Mountings other than snaps could also be used.

[0034] As also in Fig. 19, a pair of battery level indicator LEDs 132, 134 for emitting light, preferably in different colors, is mounted on the engine PCB 38. As shown in Fig. As shown in Figure 20, a depression 142 is formed in the frame in front of the indicator LEDs 132, 134. A light-conducting light guide 136 is mounted in the depression 142 and has an internal reflector 138 that reflects and diffuses the indicator light from the indicator LEDs 132, 134 upward toward an indicator window 140 or slot where the operator can see a green light when the battery level is high, a red light when the battery level is low, or another color, such as yellow, when the battery level is at a medium level. For wireless, powered, mobile operation, the battery is mounted in the handle 28.

[0035] While precise embodiments have been described in the foregoing specification, one of ordinary skill in the art will appreciate that various modifications and changes may be made without departing from the scope of the invention as set forth in the following claims. Accordingly, the specification and drawings are to be regarded as illustrative rather than restrictive, and all such modifications are intended to be included within the scope of the present teachings.

[0036] The benefits, advantages, solutions to problems, and any element(s) that cause or enhance the occurrence of benefits, advantages, or solutions are not to be construed as critical, necessary, or essential features or elements of any or all of the claims. The invention is defined solely by the appended claims, which incorporate any amendments made during the prosecution of this application, and all equivalents of the granted claims.

[0037] Furthermore, in this document, relational terms such as first and second, upper and lower, and the like may be used solely to distinguish one object or act from another object or act, without necessarily requiring or implying any actual such relationship or ordering between such objects or acts. The terms "comprises," "comprising," "having," "with," "includes," "containing," "contains," "containing," or any variation thereof are intended to cover a non-exclusive connotation such that a process, procedure, article, or assembly which comprises, has, includes, or contains a list of elements not only includes those elements, but may include other elements not expressly listed or inherent in such process, procedure, article, or assembly.An element preceded by "comprises... a," "having... a," "includes... a," or "containing... a" includes, without further limitation, the existence of other identical elements in the process, method, article, or assembly comprising, having, including, or containing the element. The terms "a" and "an," in the absence of an explicit statement to the contrary, are defined herein as one or more. The terms "substantially," "substantially," "approximately," "about," or any other version thereof are defined as an approximation as understood by one of ordinary skill in the art, and in one non-limiting embodiment, the term is defined as within 10%, in another embodiment, within 5%, in another embodiment, within 1%, and in another embodiment, within 0.5%.The term "coupled," as used herein, is defined as connected, although not necessarily directly and not necessarily mechanically. A device or structure "configured" in a particular manner is configured in at least that manner, but may also be configured in unlisted ways.

[0038] It should be understood that some embodiments may be comprised of one or more generic or specialized processors (or "processor devices") such as microprocessors, digital signal processors, custom processors, and field programmable gate arrays (FPGAs), and unique stored program instructions (including both software and firmware) controlling the one or more processors, together with certain non-processor circuitry, to implement some, most, or all of the functions of the method and / or apparatus described herein. Alternatively, some or all of the functions may be implemented by a state machine that does not have stored program instructions or in one or more application-specific integrated circuits (ASIs).It can be implemented as an application-specific integrated circuit (ASIC), in which each function or some combination of certain functions is implemented as custom logic. Of course, a combination of the two approaches can also be used.

[0039] Furthermore, an embodiment may be implemented as a computer-readable storage medium having computer-readable code stored thereon for programming a computer (e.g., comprising a processor) to perform a method as described and claimed herein. Examples of such computer-readable storage media include, but are not limited to, a hard disk, a CD-ROM, an optical storage device, a magnetic storage device, a ROM (Read Only Memory), a PROM (Programmable Read Only Memory), an EPROM (Erasable Programmable Read Only Memory), an EEPROM (Electrically Erasable Programmable Read Only Memory), and a flash memory.Furthermore, it is believed that one of ordinary skill in the art, despite potentially significant effort and many design options, motivated by, for example, available time, current technology, and economic considerations, will readily be able to create such software instructions and programs and integrated circuits with little experimentation when guided by the concepts and principles disclosed herein.

[0040] The Summary of the Disclosure is provided to enable the reader to quickly determine the nature of the technical disclosure. It is presented with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Additionally, it can be seen from the foregoing Detailed Description that various features in various embodiments are grouped together to streamline the disclosure. This arrangement of the disclosure should not be interpreted as reflecting an intent that the claimed embodiments require more features than are expressly recited in the respective claim. Instead, as the following claims reflect, inventive subject matter consists in fewer than all of the features of a single disclosed embodiment.Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as separately claimed subject matter.

Claims

[1] Imaging module for reading a target by image acquisition, the module comprising: a first printed circuit board (PCB); an imaging system including an imager mounted on the first PCB for capturing an image of the target over a field of view; a second PCB; an interface connector mounted on the second PCB; and a rack having first rack walls in direct contact with the first PCB in the surface area to support the imaging device and to automatically position the first PCB to lie in a generally upright, first predetermined plane, and second rack walls in direct contact with the second PCB in the surface area to support the interface connector and to automatically position the second PCB to lie in a generally oblique, second predetermined plane inclined at an angle of inclination with respect to the first predetermined plane, the first and second rack walls being formed as a one-piece support that maintains the angle of inclination between the PCBs. [2] The module according to claim 1, and a pilot light system including at least one pilot light source mounted on the first PCB, and an illumination light system including at least one illumination light source mounted on the first PCB, wherein the frame has internal compartments in which the image device, the at least one pilot light source and the at least one illumination light source are respectively contained. [3] The module of claim 1, and a third PCB; and an illuminating light system including at least one illuminating light source mounted on the third PCB, and wherein the rack has third rack walls in direct contact with the third PCB in the surface area to support the at least one illuminating light source and to automatically position the third PCB to lie in a generally upright, third predetermined plane. [4] The module of claim 1, wherein the first PCB has a pair of first cutouts, the rack has a first pair of guide pins received in the first cutouts for positioning the first PCB to lie in the first predetermined plane, and a first pair of PCB fasteners for securing the first PCB to remain firmly in the first predetermined plane, and wherein the second PCB has a pair of second cutouts, the rack has a second pair of guide pins received in the second cutouts for positioning the second PCB to lie in the second predetermined plane, and a second pair of PCB fasteners for securing the second PCB to remain firmly in the second predetermined plane. [5] The module of claim 1, wherein the rack includes a pair of lugs extending in opposite directions away from each other and a pair of housing fasteners extending through openings in the lugs for fixedly mounting the rack in an imaging reader. [6] The module of claim 1, and a light-transmitting window positioned in direct contact with the frame and a hood for surrounding the window, and wherein the frame has a plurality of hooks extending through openings in the hood for mounting the hood and window on the frame. [7] A module according to claim 1, and a recess in the frame, and a light guide mounted in the recess for guiding indicator lights away from the module. [8] An imaging reader for reading a target by image capture, the reader comprising: a housing with an interior; and an imaging module mounted within the interior of the housing as a unitary assembly, the module including a first printed circuit board (PCB); an imaging system including an imager mounted on the first PCB for capturing an image of the target over a field of view, a second PCB, an interface connector mounted on the second PCB, and a rack having first rack walls in direct contact with the first PCB in the surface area to support the imaging device and to automatically position the first PCB to lie in a generally upright, first predetermined plane, and second rack walls in direct contact with the second PCB in the surface area to support the interface connector and to automatically position the second PCB to lie in a generally oblique, second predetermined plane inclined at an angle of inclination with respect to the first predetermined plane, the first and second rack walls being formed as a one-piece support that maintains the angle of inclination between the PCBs. [9] Reader according to claim 8, and a pilot light system including at least one pilot light source mounted on the first PCB, and wherein the frame has internal compartments in which the image device and the at least one pilot light source are respectively contained. [10] Reader according to claim 8, and an illumination light system including at least one illumination light source mounted on the first PCB, and wherein the frame has inner compartments in which the image device and the at least one illumination light source are respectively contained. [11] Reader according to claim 8, and a third PCB; and an illuminating light system including at least one illuminating light source mounted on the third PCB, and wherein the rack has third rack walls in direct contact with the third PCB to support the at least one illuminating light source and to position the third PCB to lie in a generally upright, third predetermined plane [12] The reader of claim 8, wherein the first PCB has a pair of first cutouts, the rack has a first pair of guide pins received in the first cutouts for positioning the first PCB to lie in the first predetermined plane, and a first pair of PCB fasteners for securing the first PCB to remain firmly in the first predetermined plane; and wherein the second PCB has a pair of second cutouts, the rack has a second pair of guide pins received in the second cutouts for positioning the second PCB to lie in the second predetermined plane, and a second pair of PCB fasteners for securing the second PCB to remain firmly in the second predetermined plane. [13] A reader according to claim 8, wherein the chassis includes a pair of lugs extending in opposite directions away from each other and a pair of housing fasteners extending through openings in the lugs for fixedly mounting the chassis in the housing. [14] A reader according to claim 8, and a light-transmitting window positioned in direct contact with the frame and a hood for surrounding the window, and wherein the frame has a plurality of hooks extending through openings in the hood for mounting the hood and window on the frame. [15] The reader of claim 8, wherein the housing includes a handle extending at the inclination angle along a handle axis, and wherein the second PCB extends at the inclination angle along a handle axis in the handle.

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