Optical sensor and manufacturing method

Abstract

To provide an optical sensor that ensures the accuracy of adjusting the optical axes and the fixing strength of modules.SOLUTION: An optical sensor 10 comprises: a projection light source module 22 that generates a projection beam PB; a projection lens module 26 that guides the projection beam PB from the projection light source module 22 toward the outside along a projection optical axis POA; and a UV / heat curable projection adhesive 28 that is interposed between projection adhesion surfaces 222, 262 of the projection light source module 22 and the projection lens module 26 opposite to a projection direction PD along the projection optical axis POA. The projection adhesion surfaces 222, 262 form therebetween a projection main gap 280 that is filled with the projection adhesive 28, and a projection sub-gap 281 that is widened in the projection direction PD compared to the projection main gap 280 and opened toward the outer periphery around the projection optical axis POA, the gap 281 in which the projection adhesive 28 continuing from the projection main gap 280 spreads over both surfaces 222, 262.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present disclosure relates to optical sensors and methods for manufacturing the same. [Background technology]

[0002] Optical sensors that detect the outside world by projecting a light beam toward the outside world and receiving a beam reflected from the outside world have been widely known. In a technology disclosed in Patent Document 1 as an optical sensor of this type, the optical axis of a lens module that guides the light beam from the light source module toward the outside world is adjusted relative to the light source module that generates the light beam. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-3938 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the device disclosed in Patent Document 1, the lens module is fixed to the light source module by screws, making it difficult to adjust the position in three or more axes. Therefore, it is conceivable to use an ultraviolet and heat curing adhesive to fix the lens module to the light source module.

[0005] However, when using an ultraviolet-thermal curing adhesive, the size of the gap between the light source module and the lens module where the uncured adhesive is filled varies for each filling location depending on the relative orientation of the modules. As a result, if the amount of adhesive is insufficient for the gap size, the fixing strength between the modules decreases. Therefore, if the amount of adhesive is excessive for the gap size, ultraviolet light will be irradiated onto the adhesive that has spilled out of the gap, preventing the ultraviolet light from reaching the adhesive filling the gap, which could result in misalignment of the optical axis.

[0006] In view of the above, an object of the present disclosure is to provide an optical sensor and a manufacturing method thereof that ensures the accuracy of optical axis adjustment and fixing strength between modules. [Means for solving the problem]

[0007] The technical means of the present disclosure for solving the problems will be described below. Note that the claims and the reference characters in parentheses in this section indicate the correspondence with the specific means described in the embodiments described later in detail, and do not limit the technical scope of the present disclosure.

[0008] A first aspect of the present disclosure is An optical sensor (10) that detects the outside world by projecting a projected beam (PB) toward the outside world and receiving a reflected beam (RB) that is reflected from the outside world in response to the projected beam, a floodlight source module (22, 3022, 4022) that generates a floodlight beam; a projection lens module (26, 2026, 4026) that guides a projection beam from the projection light source module to the outside world along a projection optical axis (POA); a light-projection adhesive (28) of ultraviolet and heat curing type interposed between the light-projection adhesive surfaces (222, 262, 2262, 3222, 4222, 4262) of the light-projection light source module and the light-projection lens module that face each other in a light-projection direction (PD) along the light-projection optical axis, Each light-emitting adhesive surface is On the inner circumference around the light projection axis Light-emitting adhesive is interposed across each light-emitting adhesive surface The light-projecting main gap (280) and the light-projecting adhesive material that continues from the light-projecting main gap are used as a gap that is wider than the light-projecting main gap in the light-projecting direction and is open to the outer periphery around the light-projecting optical axis. Each light-emitting adhesive straddling the face It is arranged so that A light-emitting sub-gap (281) is formed between them. death, Each light-projecting adhesive surface has a light-projecting inclined surface portion (222b, 262b) that is inclined in a shape such that it gradually separates from the opposing light-projecting adhesive surface toward the outer periphery around the light-projecting optical axis to form a light-projecting sub-gap, The light-projecting inclined surface portion of one of the light-projecting adhesive surfaces extends to a position on the inner periphery side of the light-projecting inclined surface portion of the other light-projecting adhesive surface. .

[0009] A second aspect of the present disclosure is A method for manufacturing the optical sensor of the first aspect, comprising the steps of: Placing a light-projecting adhesive in the light-projecting main gap and the light-projecting sub-gap; irradiating the light-projecting sub-gap with ultraviolet light from the outer periphery around the light-projecting optical axis to temporarily harden a part of the light-projecting adhesive; and thermally curing the remaining portion of the light-projecting adhesive after the temporary curing.

[0010] According to the first and second aspects, a light-projecting adhesive material of ultraviolet and heat curing type is interposed between the light-projecting adhesive surfaces of the light-projecting light source module and the light-projecting lens module that face each other in the light-projecting direction along the light-projecting optical axis. On the inner circumference around the light projection axis Light-emitting adhesive is installed across both sides. The main gap is wider than the main gap in the light projection direction and is open to the outer periphery around the light projection optical axis. The light projection adhesive material continues from the main gap and spans both sides of the gap. It is arranged so that A light-emitting sub-gap is formed between them.

[0011] As a result, even if the uncured light-projecting adhesive escapes from the light-projecting main gap depending on the relative orientation of the modules, in the light-projecting sub-gap, which is wider than the light-projecting main gap, it can be exposed from the open portion toward the outer periphery in an arrangement spanning the light-projecting adhesive surfaces of each module. Therefore, by irradiating ultraviolet light from the outer periphery in this arrangement, a portion of the light-projecting adhesive can be pre-cured in the light-projecting sub-gap, and after this pre-curing, the remaining portion of the light-projecting adhesive can be thermally cured in the light-projecting main gap while suppressing misalignment of the light-projecting optical axis. Therefore, it is possible to ensure the accuracy of optical axis adjustment and fixing strength between modules.

[0012] A third aspect of the present disclosure is The projected beam (PB) is projected towards the outside world, and the reflected beam (RB) is received from the outside world. detection An optical sensor (10) a light receiving and detecting module (45, 3045, 4045) that detects the outside world by receiving the reflected beam; a light receiving lens module (42, 2042, 4042) that guides a reflected beam from the outside to the light receiving detection module along a light receiving optical axis (ROA); a light-receiving adhesive (48) of ultraviolet and heat curing type interposed between the light-receiving adhesive surfaces (422, 452, 2422, 3452, 4422, 4452) of the light-receiving detection module and the light-receiving lens module that face each other in a light-receiving direction (RD) along the light-receiving optical axis; Each light-receiving adhesive surface is On the inner side around the light receiving axis Light-receiving adhesive is interposed across each light-receiving adhesive surface The light receiving main gap (480) and the light receiving adhesive material that continues from the light receiving main gap are gaps that are wider than the light receiving main gap in the light receiving direction and open to the outer periphery around the light receiving optical axis. Each light receiving adhesive straddling the face It is arranged so that A light receiving sub-gap (481) is formed between them. death, Each light-receiving adhesive surface has a light-receiving inclined surface portion (422b, 452b) that is inclined in a shape such that it gradually separates from the opposing light-receiving adhesive surface toward the outer periphery around the light-receiving optical axis to form a light-receiving sub-gap; The light-receiving inclined surface portion of one of the light-receiving adhesive surfaces extends to a position on the inner periphery side of the light-receiving inclined surface portion of the other light-receiving adhesive surface. .

[0013] A fourth aspect of the present disclosure is A manufacturing method for manufacturing the optical sensor of the third aspect, comprising: disposing a light-receiving adhesive in the light-receiving main gap and the light-receiving sub-gap; irradiating the light-receiving sub-gap with ultraviolet light from the outer periphery around the light-receiving optical axis to temporarily harden a part of the light-receiving adhesive; and thermally curing the remaining portion of the light-receiving adhesive after the temporary curing.

[0014] According to the third and fourth aspects, a photosensitive adhesive material of ultraviolet and heat curing type is interposed between the photosensitive adhesive surfaces of the photosensitive detection module and the photosensitive lens module that face each other in the light receiving direction along the light receiving optical axis. On the inner side around the light receiving axis Light-receiving adhesive is installed across both sides. The light-receiving main gap and the gap that is wider than the light-receiving main gap in the light-receiving direction and is open to the outer periphery around the light-receiving optical axis are separated by a light-receiving adhesive that continues from the light-receiving main gap and spans both sides. It is arranged so that A light receiving sub-gap is formed between them.

[0015] As a result, even if the uncured light-receiving adhesive escapes from the light-receiving main gap depending on the relative positions of the modules, it can be exposed from the open portion toward the outer periphery in the light-receiving sub-gap, which is wider than the light-receiving main gap, when arranged across the light-receiving adhesive surfaces of each module. Therefore, by irradiating ultraviolet light from the outer periphery in this arrangement, a portion of the light-receiving adhesive can be pre-cured in the light-receiving sub-gap. After this pre-curing, the remaining portion of the light-receiving adhesive can be thermally cured in the light-receiving main gap while suppressing misalignment of the light-receiving optical axis. Therefore, it is possible to ensure the optical axis adjustment precision and fixing strength between the modules. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a cross-sectional view showing the overall configuration of an optical sensor according to a first embodiment. [Figure 2] FIG. 2 is a schematic diagram showing a light projection unit according to the first embodiment. [Figure 3] FIG. 2 is a schematic diagram showing a light receiving unit according to the first embodiment. [Figure 4] FIG. 2 is a partial cross-sectional view showing the configuration of a light projecting unit and a light receiving unit according to the first embodiment. [Figure 5] FIG. 2 is a perspective view showing the appearance of the light projection unit according to the first embodiment. [Figure 6] FIG. 2 is a cross-sectional view showing a detailed configuration of the light projection unit according to the first embodiment. [Figure 7] 5 is a flowchart showing a method for manufacturing the light projection unit according to the first embodiment. [Figure 8] 5A to 5C are cross-sectional views illustrating a method for manufacturing the light projection unit according to the first embodiment. [Figure 9] 5A to 5C are cross-sectional views illustrating a method for manufacturing the light projection unit according to the first embodiment. [Figure 10] FIG. 2 is a perspective view showing the appearance of the light receiving unit according to the first embodiment. [Figure 11] FIG. 2 is a cross-sectional view showing a detailed configuration of the light receiving unit according to the first embodiment. [Figure 12]4 is a flowchart showing a method for manufacturing the light receiving unit according to the first embodiment. [Figure 13] FIG. 10 is a cross-sectional view showing a detailed configuration of a light projection unit according to a second embodiment. [Figure 14] FIG. 10 is a cross-sectional view showing a detailed configuration of a light receiving unit according to a second embodiment. [Figure 15] FIG. 10 is a cross-sectional view showing a detailed configuration of a light projection unit according to a third embodiment. [Figure 16] FIG. 10 is a cross-sectional view showing a detailed configuration of a light receiving unit according to a third embodiment. [Figure 17] FIG. 10 is a cross-sectional view showing a detailed configuration of a light projection unit according to a fourth embodiment. [Figure 18] FIG. 10 is a cross-sectional view showing a detailed configuration of a light receiving unit according to a fourth embodiment. [Figure 19] FIG. 10 is a cross-sectional view showing a detailed configuration of a light projection unit according to a modified example of the first embodiment. [Figure 20] FIG. 10 is a cross-sectional view showing a detailed configuration of a light receiving unit according to a modified example of the first embodiment. [Figure 21] FIG. 10 is a cross-sectional view showing a detailed configuration of a light projection unit according to a modified example of the first embodiment. [Figure 22] FIG. 10 is a cross-sectional view showing a detailed configuration of a light receiving unit according to a modified example of the first embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0017] Hereinafter, multiple embodiments of the present disclosure will be described with reference to the drawings. Note that corresponding components in each embodiment are designated by the same reference numerals, and redundant description may be omitted. Furthermore, when only a portion of the configuration is described in each embodiment, the configuration of another previously described embodiment may be applied to the remaining portions of the configuration. Furthermore, in addition to the combinations of configurations explicitly stated in the description of each embodiment, configurations of multiple embodiments may be partially combined together even if not explicitly stated, provided that there is no particular problem with the combination.

[0018] (First embodiment) As shown in FIG. 1 , an optical sensor 10 according to a first embodiment of the present disclosure is a LiDAR (Light Detection and Ranging / Laser Imaging Detection and Ranging) device that is installed on a moving body and optically detects the external environment. The moving body on which the optical sensor 10 is installed is a vehicle, such as an automobile, that can be driven manually, automatically, or remotely. In the following description, unless otherwise specified, the directions indicated as front, rear, up, down, left, and right are defined with respect to the vehicle on a horizontal plane. In the following description, the horizontal direction and the vertical direction refer to the directions parallel to and perpendicular to the horizontal plane, respectively, of the vehicle on the horizontal plane. In the following description, the direction of gravity refers to the downward direction of the vertical direction of the vehicle on the horizontal plane.

[0019] The optical sensor 10 is disposed in at least one location on the vehicle, such as the front, left and right side portions, rear portion, or upper roof. The optical sensor 10 projects a projected beam PB toward a detection area DA in the outside world that corresponds to the location on the vehicle where the optical sensor 10 is disposed. The optical sensor 10 detects, as a reflected beam RB, the return light that is returned when the projected beam PB is reflected by a target in the detection area DA in the outside world. The projected beam PB that becomes the reflected beam RB in this way is selected to be light in the near-infrared range that is difficult for humans to see.

[0020] The optical sensor 10 detects a target object present in a detection area DA in the external world by receiving a reflected beam RB reflected from the projected beam PB. The detection of such an external target may be one or more types of detection including at least distance, such as the distance from the optical sensor 10 to the target, the direction in which the target is located, and the reflection intensity of the reflected beam RB from the target. A typical target object to be detected by the optical sensor 10 applied to a vehicle may be at least one of moving objects such as pedestrians, cyclists, non-human animals, and other vehicles. A typical target object to be detected by the optical sensor 10 applied to a vehicle may be at least one of stationary objects such as guardrails, road signs, roadside structures, and fallen objects on the road.

[0021] A three-dimensional coordinate system is defined for the optical sensor 10 by three mutually orthogonal axes: an X-axis, a Y-axis, and a Z-axis. In particular, in the three-dimensional coordinate system of this embodiment, the Y-axis direction is defined along the vertical direction of the vehicle, and the X-axis direction and the Z-axis direction are defined along different horizontal directions of the vehicle. As a result, for a vehicle on a horizontal plane, the XY plane and the YZ plane of the three-dimensional coordinate system are aligned with a vertical plane perpendicular to the horizontal plane, and the XZ plane is aligned with the horizontal plane. Note that in FIG. 1 , the left side of the dashed-dotted line along the Y-axis direction (the side of the cover panel 12 described below) actually illustrates a cross section perpendicular to the right side of the dashed-dotted line (the side of the units 21 and 41 described below).

[0022] The optical sensor 10 includes a sensor base 11, a light-emitting unit 21, a scanning unit 31, a light-receiving unit 41, and a control unit 51. The light-blocking sensor base 11 is formed in a box shape from, for example, metal or resin. The sensor base 11 is a housing or casing that houses the light-emitting unit 21, the scanning unit 31, and the light-receiving unit 41 inside. The sensor base 11 has an opening that is closed by a cover panel 12. The light-transmitting cover panel 12 is formed in a plate shape from, for example, resin or glass.

[0023] The light projection unit 21 includes a light projection light source module 22 and a light projection lens module 26 (see also FIGS. 4 and 5 described later). As shown in FIG. 2, the light projection light source module 22 is constructed by mounting a plurality of laser diodes 24 in an array on a substrate. In particular, the laser diodes 24 in this embodiment are arranged in a single row along the Y-axis direction. Each laser diode 24 generates pulsed laser light that becomes part of the respective projection beam PB in accordance with a control signal from the control unit 51. Each laser diode 24 may be an edge emitter laser or a vertical cavity surface emitting laser (VCSEL).

[0024] The light projecting light source module 22 has a light projecting window 25 formed on one side of the substrate, the light projecting window 25 being defined as a quasi-rectangular outline whose long sides are along the Y-axis direction and whose short sides are along the X-axis direction. The light projecting window 25 is configured as a collection of laser oscillation apertures of the laser diodes 24. The laser light projected from the laser oscillation apertures of the laser diodes 24 is projected from the light projecting window 25 as a light projecting beam PB that is shaped into a line whose long sides are along the vertical direction in the detection area DA shown in FIG.

[0025] The projection lens module 26 is constructed in a structure in which at least one projection lens 260 is held by a lens barrel 261. The light-transmitting projection lens 260 is formed mainly from a base material such as resin or glass into a lens shape according to the optical function to be exerted. The projection lens 260 exerts at least one optical function, such as focusing, collimating, and shaping, on the projection beam PB from the projection light source module 22. The projection lens 260 is positioned within a light-blocking lens barrel 261 (see also Figures 4 and 5 described below) made of, for example, metal or resin.

[0026] The projector lens module 26 configured as described above is aligned with the projector light source module 22 so as to form a projector optical axis POA. The projector beam PB projected from the projector light source module 22 is guided along the projector optical axis POA to the outside of the vehicle by the optical action of the projector lens module 26.

[0027] The scanning unit 31 includes a scanning mirror 32 and a scanning motor 35. The scanning mirror 32 is formed in a plate shape with a reflective film deposited on a reflective surface 33, which is one side of a substrate. The scanning mirror 32 is supported by the sensor base 11 so as to be rotatable about a rotation centerline along the Y-axis direction. The scanning mirror 32 oscillates within a limited driving range defined by a mechanical or electrical stopper. The scanning motor 35 is, for example, a voice coil motor, a brushed DC motor, or a stepping motor. The output shaft of the scanning motor 35 is coupled to the scanning mirror 32 directly or indirectly via a drive mechanism such as a reducer. The scanning motor 35 is held by the sensor base 11 so as to be able to rotate the scanning mirror 32 together with the output shaft. The scanning motor 35 rotates (i.e., oscillates) the scanning mirror 32 within a limited driving range in accordance with a control signal from the control unit 51.

[0028] The scanning mirror 32 reflects the projected beam PB incident from the light projecting unit 21 by the reflecting surface 33 and irradiates the detection area DA through the cover panel 12, thereby scanning the area DA in accordance with the rotation angle of the scanning motor 35. At this time, scanning of the detection area DA by the projected beam PB is substantially limited to scanning in the horizontal direction in this embodiment, in accordance with the rotational drive of the scanning mirror 32.

[0029] The scanning mirror 32 reflects the reflected beam RB, which is incident from a target in the detection area DA through the cover panel 12, toward the light-receiving unit 41 by the reflecting surface 33 in accordance with the rotation angle of the scanning motor 35. At this time, the speeds of the projected beam PB and the reflected beam RB are sufficiently greater than the rotational speed of the scanning mirror 32. As a result, the reflected beam RB is reflected by the scanning mirror 32, whose rotation angle with respect to the projected beam PB can be assumed to be substantially the same, and is guided toward the light-receiving unit 41 in the opposite direction to the projected beam PB.

[0030] The light receiving unit 41 is configured to include a light receiving lens module 42 and a light receiving and detecting module 45 (see also Figures 4 and 10 described below). The light receiving lens module 42 is constructed so that at least one light receiving lens 420 is held by a lens barrel 421. The light transmissive light receiving lens 420 is formed mainly from a base material such as resin or glass into a lens shape according to the optical function it will exhibit. The light receiving lens 420 exhibits an optical function such as forming an image of the reflected beam RB from the scanning mirror 32 onto the light receiving and detecting module 45. The light receiving lens 420 is positioned within a light-blocking lens barrel 421 (see also Figures 4 and 10 described below) made of, for example, metal or resin.

[0031] The light-receiving lens module 42 configured as described above is aligned with the light-receiving detection module 45 so as to form a light-receiving optical axis ROA. Here, the light-receiving optical axis ROA of the light-receiving lens module 42 is shifted in the Y-axis direction with respect to the light-projecting optical axis POA of the light-projecting lens module 26. As a result, the reflected beam RB reflected from the reflecting surface 33 of the scanning mirror 32 while being shifted in the Y-axis direction is guided along the light-receiving optical axis ROA by the optical action of the light-receiving lens module 42, and is thereby imaged on the light-receiving detection module 45.

[0032] As shown in FIG. 3, the light receiving and detecting module 45 is constructed by mounting a plurality of light receiving pixels 46 in an array on a substrate. The light receiving pixels 46 are arranged at least along the Y-axis direction. The light receiving and detecting module 45 has a light receiving surface 45a formed on one side of the substrate, the light receiving surface 45a having a rectangular outline with its long sides along the Y-axis direction and its short sides along the X-axis direction. The light receiving surface 45a is configured as a collection of incident surfaces of the light receiving pixels 46. Here, each light receiving pixel 46 further includes a plurality of light receiving elements 460, such as single photon avalanche diodes. Each light receiving pixel 46 receives the reflected beam RB incident on the light receiving surface 45a from the light receiving lens module 42 as a linear beam with its long sides along the Y-axis direction and its short sides along the X-axis direction, as shown in FIG. 1.

[0033] The light receiving and detecting module 45 has an output circuit 47. The output circuit 47 performs sampling processing for each control period in accordance with a control signal from the control unit 51 in a detection frame for each scanning line that is synchronized with the projection period of the light projecting beam PB from the light projecting light source module 22 and that corresponds to the rotation angle of the scanning mirror 32. At this time, the output circuit 47 generates a detection signal by combining response outputs from the light receiving elements 460 of each light receiving pixel 46 for each control period. The detection signals generated in this manner are output from the output circuit 47 to the control unit 51 for each scanning line.

[0034] The control unit 51 controls target detection in the external detection area DA. The control unit 51 is mainly constructed using at least one computer including a processor and a memory. The control unit 51 is connected to the light projecting light source module 22, the scanning motor 35, and the light receiving and detecting module 45. The control unit 51 controls the light projecting light source module 22 to generate a light projecting beam PB for each light projecting period. At the same time, the control unit 51 controls the scanning motor 35 to control scanning and reflection by the scanning mirror 32 synchronized with the light projecting period of the light projecting light source module 22. Furthermore, the control unit 51 processes the detection signal output from the light receiving and detecting module 45 in accordance with the light projecting period of the light projecting light source module 22 and the scanning and reflection by the scanning mirror 32, thereby generating detection data of targets in the detection area DA.

[0035] Next, the detailed configuration of the light projection unit 21 will be described.

[0036] 4 to 6, in the light projection unit 21, the light projection light source module 22 and the light projection lens module 26 are arranged to face each other in the Z-axis direction as a light projection direction PD along a light projection optical axis POA that guides the light projection beam PB. In the light projection light source module 22, a light projection holder 221 that holds a substrate 220 on which multiple laser diodes 24 (see FIG. 2) are mounted forms a light projection adhesive surface 222 with an end face that faces the light projection lens module 26 in the light projection direction PD. In the light projection lens module 26, a lens barrel 261 forms a light projection adhesive surface 262 with an end face that faces the light projection light source module 22 in the light projection direction PD.

[0037] A light-projecting adhesive 28 is interposed continuously around the entire circumference of the light-projecting optical axis POA between the light-projecting adhesive surface 222 of the light-projecting light source module 22 and the light-projecting adhesive surface 262 of the light-projecting lens module 26. The light-projecting adhesive 28 is an ultraviolet-heat-combined adhesive, such as an epoxy resin, that can be cured by both ultraviolet irradiation and heat. The light-projecting adhesive surfaces 222, 262 of the light-projecting light source module 22 and the light-projecting lens module 26 form therebetween a pair of a light-projecting main gap 280 and a light-projecting sub-gap 281, as shown in FIG. 6, as two types of gaps in which the light-projecting adhesive 28 is disposed.

[0038] The light-projection main gap 280 is defined in the shape of a ring that extends continuously all around the light-projection optical axis POA between the light-projection adhesive surfaces 222, 262. The portions of the light-projection adhesive surfaces 222, 262 that define the light-projection main gap 280 form flat surface portions 222a, 262a that are substantially perpendicular to the geometric central axes of the modules 22, 26 (hereinafter simply referred to as the geometric central axes of the modules 22, 26), which would coincide with the light-projection optical axis POA in an ideal design.

[0039] The light-projecting sub-gap 281 is defined in an annular shape that extends continuously around the entire circumference on the outer side of the light-projecting main gap 280 around the light-projecting optical axis POA between the light-projecting adhesive surfaces 222, 262. The light-projecting sub-gap 281 is wider in the light-projection direction PD than the light-projecting main gap 280, which is on the inner side around the light-projecting optical axis POA. The light-projecting sub-gap 281 is open by opening around the entire circumference on the outermost side, which is opposite the light-projecting main gap 280 around the light-projecting optical axis POA.

[0040] The portion of each light-projecting adhesive surface 222, 262 that defines the light-projecting sub-gap 281 forms an inclined surface portion 222b, 262b that is inclined at an acute angle with respect to the geometric central axis of each module 22, 26. As a result, it can be said that the inclined surface portion 222b, 262b that defines the light-projecting sub-gap 281 is also inclined at an acute angle with respect to the flat surface portion 222a or 262a that is connected to the inner peripheral side around the light-projecting optical axis POA, among the flat surface portions 222a, 262a that define the light-projecting main gap 280.

[0041] In the first embodiment, the inclined surface portions 222b, 262b of both the light-projecting bonding surfaces 222, 262 are inclined in a tapered shape that gradually separates from the opposing light-projecting bonding surface 262 or 222 as they move toward the outer periphery around the light-projection optical axis POA, thereby forming the light-projection sub-gap 281. In particular, it is preferable that both the inclined surface portions 222b, 262b are given a taper angle Pθ of approximately 45 degrees so that they are inclined along the bisector PL of the angle between the light-projection direction PD and the perpendicular direction POD. With this configuration, the width of the light-projection sub-gap 281 in the light-projection direction PD is set to gradually increase from the common width with the light-projection main gap 280 as they move toward the outer periphery around the light-projection optical axis POA.

[0042] As described above, the light-projection main gap 280 is filled in the light-projection direction PD with the light-projection adhesive 28 that straddles the flat surface portions 222a, 262a of both light-projection adhesive surfaces 222, 262. At the same time, the light-projection sub-gap 281 is filled with the light-projection adhesive 28 that continues from the light-projection main gap 280 on the inner periphery side toward the outer periphery around the light-projection optical axis POA and that straddles the inclined surface portions 222b, 262b of both light-projection adhesive surfaces 222, 262 in the light-projection direction PD.

[0043] Next, a method for manufacturing the light-projecting unit 21, which is one of the methods for manufacturing the optical sensor 10, will be described in accordance with the manufacturing flow shown in Fig. 7. Note that in the manufacturing flow of Fig. 9, "S" denotes a "manufacturing process" for manufacturing the light-projecting unit 21.

[0044] In the arrangement step of S101, first, light-projection adhesive 28 in an uncured state, for example, a gel state, is applied to at least one of flat surface portions 222a, 262a that constitute light-projection adhesive surfaces 222, 262 of each module 22, 26, which is set on the lower side in the direction of gravity. In the arrangement step of S101, the positions of the individual optical axes of each module 22, 26 are adjusted relative to each other by, for example, six-axis adjustment using a position adjustment jig of the manufacturing equipment to determine the light-projection optical axis POA, and then the relative attitudes of those modules 22, 26 are set.

[0045] 8 , in the arrangement step of S101, by these application processes and attitude setting processes, the uncured light-projection adhesive 28 is filled and arranged in the light-projection main gap 280 between the modules 22, 26, and is also extruded from the light-projection main gap 280 and arranged to fill and arrange in the light-projection sub-gap 281. Therefore, it is preferable to manage the amount of application of the light-projection adhesive 28 to an amount that allows the light-projection adhesive 28 to be filled and arranged across both gaps 280, 281. In particular, with an attitude in which one of the light-projection adhesive surfaces 222, 262, which is set on the upper side in the direction of gravity, has the inclined surface portion 222b or 262b of the other light-projection adhesive surface 222, 262, which is set on the lower side in the direction of gravity, gradually moving away from the other inclined surface portion 222b or 262b toward the outer periphery around the light-projection optical axis POA, the light-projection adhesive 28 is sandwiched between the upper and lower adhesive surfaces 222, 262 in the direction of gravity.

[0046] In the manufacturing flow shown in FIG. 7 , the temporary curing step S102 following S101 irradiates the light-projection sub-gap 281 between the modules 22, 26 whose relative orientations have been set with ultraviolet light from the outer periphery around the light-projection optical axis POA. The ultraviolet light, irradiated with a wavelength of, for example, 300 to 450 nm as shown in FIG. 9 , is absorbed by the light-projection adhesive 28 filling the light-projection sub-gap 281, causing the adhesive 28 to temporarily cure as a photopolymerization reaction progresses. For this purpose, ultraviolet light irradiation may be performed simultaneously over the entire area around the light-projection optical axis POA by ultraviolet irradiation devices surrounding the entire area. Alternatively, ultraviolet light irradiation may be performed sequentially for each drive destination location by driving the ultraviolet irradiation devices over the entire area around the light-projection optical axis POA.

[0047] It is preferable to control the irradiation conditions other than the wavelength so that the portion of the light-projection adhesive 28 to be pre-cured in the pre-curing step of S102 is at least the outermost portion around the light-projection optical axis POA of the light-projection adhesive 28 in the light-projection sub-gap 281. Furthermore, when the entire light-projection adhesive 28 in the light-projection sub-gap 281 is pre-cured in the pre-curing step of S102, the irradiation conditions other than the wavelength may be controlled so that the outer periphery around the light-projection optical axis POA, which is part of the light-projection adhesive 28 that fills the light-projection main gap 280, is also pre-cured. In this way, in the pre-curing step of S102, a portion of the light-projection adhesive 28 between the modules 22, 26 is brought into a pre-cured state.

[0048] 7, the thermal curing step in S103 following S102 involves thermally curing the remaining uncured portion of the temporarily cured light-projection adhesive 28 between the modules 22, 26 whose relative orientations have been set. The heating at this time involves placing the modules 22, 26 sandwiching the temporarily cured light-projection adhesive 28 whose relative orientations have been set into a heating chamber, and controlling the heating conditions, so that at least the uncured portion of the adhesive 28 remaining in the light-projection main gap 280 is completely cured by the progress of a thermal polymerization reaction. This completes the production of the light-projecting unit 21.

[0049] Next, the detailed configuration of the light receiving unit 41 will be described.

[0050] 4, 10, and 11, in the light receiving unit 41, the light receiving detection module 45 and the light receiving lens module 42 are disposed opposite each other in the Z-axis direction, which is the light receiving direction RD along the light receiving optical axis ROA that guides the reflected beam RB. In the light receiving detection module 45, a light receiving holder 451 that holds a substrate 450 on which a plurality of light receiving pixels 46 (see FIG. 3) are arranged forms a light receiving adhesive surface 452 with an end face that faces the light receiving direction RD and is opposite the light receiving lens module 42. In the light receiving lens module 42, the lens barrel 421 forms a light receiving adhesive surface 422 with an end face that faces the light receiving direction RD and is opposite the light receiving detection module 45.

[0051] A light-receiving adhesive 48 is interposed continuously around the entire circumference of the light-receiving optical axis ROA between the light-receiving adhesive surface 452 of the light-receiving detection module 45 and the light-receiving adhesive surface 422 of the light-receiving lens module 42. The light-receiving adhesive 48 is an ultraviolet / heat-compatible adhesive that is substantially the same as the light-emitter adhesive 28. The light-receiving adhesive surfaces 452, 422 of the light-receiving detection module 45 and the light-receiving lens module 42 form two types of gaps in which the light-receiving adhesive 48 is disposed, namely, a pair of a light-receiving main gap 480 and a light-receiving sub-gap 481 as shown in FIG.

[0052] The light-receiving main gap 480 is defined in an annular shape extending continuously all around the light-receiving optical axis ROA between the light-receiving adhesive surfaces 452, 422. The portions of the light-receiving adhesive surfaces 452, 422 that define the light-receiving main gap 480 form flat surface portions 452a, 422a that are substantially perpendicular to the geometric central axes of the modules 45, 42 (hereinafter simply referred to as the geometric central axes of the modules 45, 42), which in an ideal design would coincide with the light-receiving optical axis ROA.

[0053] The light-receiving sub-gap 481 is defined in an annular shape that extends continuously around the entire circumference on the outer side of the light-receiving main gap 480 around the light-receiving optical axis ROA between the light-receiving adhesive surfaces 452, 422. The light-receiving sub-gap 481 is wider in the light-receiving direction RD than the light-receiving main gap 480, which is on the inner side around the light-receiving optical axis ROA. The light-receiving sub-gap 481 is open by opening around the entire circumference on the outermost side, which is opposite the light-receiving main gap 480 around the light-receiving optical axis ROA.

[0054] The portion of each light-receiving adhesive surface 452, 422 that defines the light-receiving sub-gap 481 forms an inclined surface portion 452b, 422b that is inclined at an acute angle with respect to the geometric central axis of each module 45, 42. As a result, it can be said that the inclined surface portion 452b, 422b that defines the light-receiving sub-gap 481 is also inclined at an acute angle with respect to the flat surface portion 452a or 422a that is connected to the inner peripheral side around the light-receiving optical axis ROA, among the flat surface portions 452a, 422a that define the light-receiving main gap 480.

[0055] In the first embodiment, the inclined surface portions 452b, 422b of both the light-receiving adhesive surfaces 452, 422 are inclined in a tapered shape such that they gradually separate from the opposing light-receiving adhesive surface 422 or 452 as they move toward the outer periphery around the light-receiving optical axis ROA, thereby forming the light-receiving sub-gap 481. In particular, it is preferable that both the inclined surface portions 452b, 422b are given a taper angle Rθ of approximately 45 degrees so as to be inclined along the bisector RL of the angle formed by the light-receiving direction RD and the perpendicular direction ROD. With this configuration, the width of the light-receiving sub-gap 481 in the light-receiving direction RD is set to gradually increase from the common width with the light-receiving main gap 480 as it moves toward the outer periphery around the light-receiving optical axis ROA.

[0056] As a result, the light-receiving main gap 480 is filled in the light-receiving direction RD with the light-receiving adhesive 48 that straddles the flat surface portions 452 a, 422 a of both light-receiving adhesive surfaces 452, 422. At the same time, the light-receiving sub-gap 481 is filled with the light-receiving adhesive 48 that continues from the inner light-receiving main gap 480 toward the outer periphery around the light-receiving optical axis ROA and that straddles the inclined surface portions 452 b, 422 b of both light-receiving adhesive surfaces 452, 422 in the light-receiving direction RD.

[0057] Next, a method for manufacturing the light receiving unit 41, which is one of the methods for manufacturing the optical sensor 10, will be described in accordance with the manufacturing flow shown in Fig. 12. In the manufacturing flow of Fig. 12, "S" denotes a "manufacturing process" for manufacturing the light receiving unit 41.

[0058] In the arrangement step of S201, first, the light-receiving adhesive 48 is applied in accordance with S101 to at least one of the flat surface portions 452a, 422a constituting the light-receiving adhesive surfaces 452, 422 of each module 45, 42, which is set on the lower side in the direction of gravity. Next, in the arrangement step of S201, the positions of the individual optical axes of each module 45, 42 are adjusted relative to each other in accordance with S101 to determine the light-receiving optical axis ROA, and then the relative attitudes of those modules 45, 42 are set.

[0059] By these application and orientation setting processes, in the arrangement step S201, the uncured light-receiving adhesive 48 is filled and disposed in the light-receiving main gap 480 between the modules 45, 42, and is also extruded from the light-receiving main gap 480 and disposed in the light-receiving sub-gap 481. Therefore, it is preferable to manage the amount of application of the light-receiving adhesive 48 so that the light-receiving adhesive 48 can be disposed and filled across both gaps 480, 481. In particular, the inclined surface portion 452b or 422b of the light-receiving adhesive surfaces 452, 422, which is set on the upper side in the direction of gravity, is gradually spaced away from the other inclined surface portion 452b or 422b, which is set on the lower side in the direction of gravity, toward the outer periphery around the light-receiving optical axis ROA, and the light-receiving adhesive 48 is sandwiched between the upper and lower adhesive surfaces 452, 422 in the direction of gravity.

[0060] In the provisional curing step S202 following S201, ultraviolet light is irradiated from the outer periphery around the light-receiving optical axis ROA onto the light-receiving sub-gap 481 between the modules 45, 42 whose relative orientations have been set. At this time, under irradiation conditions conforming to S102, the ultraviolet light is absorbed by the light-receiving adhesive 48 filling the light-receiving sub-gap 481, and as a result, the adhesive 48 is provisionally cured as a photopolymerization reaction progresses. In this provisional curing step S202, a portion of the light-receiving adhesive 48 between the modules 45, 42 is provisionally cured.

[0061] In the thermal curing step S203 following S202, the remaining uncured portion of the light-receiving adhesive 48 between the modules 45, 42 whose relative orientations have been set after the provisional curing is thermally cured by heating. The heating at this time is controlled in accordance with S103, so that at least the uncured portion of the light-receiving adhesive 48 remaining in the light-receiving main gap 480 is completely cured by the progress of a thermal polymerization reaction. This completes the manufacture of the light-receiving unit 41.

[0062] (Action and effect) The effects of the first embodiment described above will be explained below.

[0063] According to the first embodiment, an ultraviolet-heat-curing light-projection adhesive 28 is interposed between the light-projection bonding surfaces 222, 262 of the light-projection light source module 22 and the light-projection lens module 26 that face each other in the light-projection direction PD along the light-projection optical axis POA. Thus, between the light-projection bonding surfaces 222, 262, a light-projection main gap 280 that is filled with the light-projection adhesive 28 and a light-projection sub-gap 281 that is wider than the light-projection main gap 280 in the light-projection direction PD and opens to the outer circumferential side around the light-projection optical axis POA, and in which the light-projection adhesive 28 that continues from the light-projection main gap 280 spans both surfaces 222, 262, are formed.

[0064] As a result, even if the uncured light-projection adhesive 28 escapes from the light-projection main gap 280 depending on the relative orientations of the modules 22, 26, in the light-projection sub-gap 281, which is wider than the light-projection main gap 280, the light-projection adhesive 28 can be exposed from an open portion toward the outer periphery in an arrangement state spanning the light-projection adhesive surfaces 222, 262 of the modules 22, 26. Therefore, by irradiating ultraviolet light from the outer periphery in this arrangement state, a portion of the light-projection adhesive 28 can be provisionally cured in the light-projection sub-gap 281. After the provisional curing, the remaining portion of the light-projection adhesive 28 can be thermally cured in the light-projection main gap 280 while suppressing misalignment of the light-projection optical axis POA. Therefore, it is possible to ensure the optical axis adjustment precision and fixing strength between the modules 22, 26.

[0065] According to the first embodiment, the light-projection inclined surface portions 222b, 262b of both light-projection adhesive surfaces 222, 262 are inclined into a shape that gradually separates from the opposing light-projection adhesive surface 262 or 222 toward the outer periphery around the light-projection optical axis POA, forming the light-projection sub-gap 281. This makes it possible to suppress stress concentration that occurs particularly at the interface with each light-projection adhesive surface 222, 262 in the light-projection adhesive 28 that has hardened to a state that fills the light-projection sub-gap 281 by spanning the light-projection adhesive surfaces 222, 262. Moreover, the light-projection inclined surface portions 222b, 262b that are inclined along the bisector PL of the angle between the light-projection direction PD and the orthogonal direction POD can enhance the suppression of stress concentration in the hardened light-projection adhesive 28. Furthermore, during manufacturing, the light-projection adhesive surface 222 or 262 in which the light-projection inclined surface portion 222b or 262b that gradually moves away toward the outer periphery around the light-projection optical axis POA is set lower in the direction of gravity than one of the light-projection adhesive surfaces 262, 222 that is set upper in the direction of gravity can be prevented from separating from the light-projection adhesive 28 sandwiched between the one and the light-projection adhesive surface 222 or 262 after it hardens. For these reasons, in the first embodiment, it is possible to maintain high fixing strength.

[0066] According to the first embodiment, an ultraviolet-thermal curing type light-receiving adhesive 48 is interposed between the light-receiving adhesive surfaces 452, 422 of the light-receiving detection module 45 and the light-receiving lens module 42, which face each other in the light-receiving direction RD along the light-receiving optical axis ROA. Thus, between the light-receiving adhesive surfaces 452, 422, a light-receiving main gap 480 filled with the light-receiving adhesive 48 and a light-receiving sub-gap 481 formed by the light-receiving adhesive 48 continuing from the light-receiving main gap 480 and spanning both surfaces 452, 422 as a gap 481 wider than the light-receiving main gap 480 in the light-receiving direction RD and open to the outer periphery around the light-receiving optical axis ROA are formed.

[0067] As a result, even if the uncured light-receiving adhesive 48 escapes from the light-receiving main gap 480 depending on the relative orientation of the modules 45, 42, in the light-receiving sub-gap 481, which is wider than the light-receiving main gap 480, the light-receiving adhesive 48 can be exposed from an open portion toward the outer periphery in an arrangement state spanning the light-receiving adhesive surfaces 452, 422 of each module 45, 42. Therefore, by irradiating ultraviolet light from the outer periphery in this arrangement state, a portion of the light-receiving adhesive 48 can be pre-cured in the light-receiving sub-gap 481. After the pre-curing, the remaining portion of the light-receiving adhesive 48 can be thermally cured in the light-receiving main gap 480 while suppressing misalignment of the light-receiving optical axis ROA. Therefore, it is possible to ensure the optical axis adjustment precision and fixing strength between the modules 45, 42.

[0068] According to the first embodiment, the light-receiving inclined surface portions 452b, 422b of both light-receiving adhesive surfaces 452, 422 are inclined so as to gradually separate from the opposing light-receiving adhesive surface 422 or 452 toward the outer periphery around the light-receiving optical axis ROA, thereby forming a light-receiving sub-gap 481. This makes it possible to suppress stress concentration, particularly at the interface with each adhesive surface 452, 422, in the light-receiving adhesive 48 that has hardened to a state in which it spans between the light-receiving adhesive surfaces 452, 422 and fills the light-receiving sub-gap 481. Moreover, the light-receiving inclined surface portions 452b, 422b that are inclined along the bisector RL of the angle between the light-receiving direction RD and the perpendicular direction ROD, can enhance the suppression of stress concentration in the hardened light-receiving adhesive 48. Furthermore, during manufacturing, the light-receiving adhesive surface 452 or 422 in which the light-receiving inclined surface portion 452b or 422b that gradually moves away from the light-receiving adhesive surface 422 or 452 toward the outer periphery around the light-receiving optical axis ROA is set lower in the direction of gravity than the light-receiving adhesive surface 422 or 452 that is set upper in the direction of gravity can be prevented from separating from the light-receiving adhesive 48 sandwiched between the light-receiving adhesive surface 452 or 422 after it hardens. This makes it possible to maintain high fixing strength.

[0069] Second Embodiment The second embodiment is a modification of the first embodiment.

[0070] 13 , in the light-projection lens module 2026 of the second embodiment, a portion of the light-projection adhesive surface 2262 that defines the light-projection sub-gap 281 forms a flat surface portion 2262b that is substantially perpendicular to the geometric central axis and is on the same plane as the flat surface portion 262a. The light-projection sub-gap 281 that is wider in the light-projection direction PD than the light-projection main gap 280 is formed between this flat surface portion 2262b and the inclined surface portion 222b. Therefore, in the arrangement step S101, the light-projection adhesive 28 is sandwiched between the adhesive surfaces 2262, 222 in an attitude in which the inclined surface portion 222b of the other light-projection adhesive surface 222, which is set lower in the gravity direction, is gradually spaced apart from one light-projection adhesive surface 2262, which is set upper in the gravity direction, toward the outer periphery around the light-projection optical axis POA.

[0071] 14 , in the light-receiving lens module 2042 of the second embodiment, a portion of the light-receiving adhesive surface 2422 that defines the light-receiving sub-gap 481 has a flat surface portion 2422b that is substantially perpendicular to the geometric center axis and is formed on the same plane as the flat surface portion 422a. The light-receiving sub-gap 481 is formed between the flat surface portion 2422b and the inclined surface portion 452b, and is wider in the light-receiving direction RD than the light-receiving main gap 480. Therefore, in the arrangement step S201, the light-receiving adhesive 48 is sandwiched between the adhesive surfaces 2422, 452 in an orientation in which the inclined surface portion 452b of the other light-receiving adhesive surface 452, which is set lower in the direction of gravity, is gradually spaced apart from one light-receiving adhesive surface 2422, which is set upper in the direction of gravity, toward the outer periphery around the light-receiving optical axis ROA.

[0072] (Third embodiment) The third embodiment is a modification of the first embodiment.

[0073] 15 , in the light projecting light source module 3022 of the third embodiment, a portion of the light projecting adhesive surface 3222 that defines the light projecting sub-gap 281 forms a flat surface portion 3222b that is substantially perpendicular to the geometric central axis and is on the same plane as the flat surface portion 222a. The light projecting sub-gap 281 that is wider in the light projecting direction PD than the light projecting main gap 280 is formed between the flat surface portion 3222b and the inclined surface portion 262b. Therefore, in the arrangement step S101, the light projecting adhesive 28 is sandwiched between the adhesive surfaces 3222, 262 in an attitude in which the inclined surface portion 262b of the other light projecting adhesive surface 262 that is set on the lower side in the direction of gravity is gradually spaced away from one light projecting adhesive surface 3222 that is set on the upper side in the direction of gravity, which is the opposite direction to that in FIG. 15 , toward the outer periphery around the light projecting optical axis POA.

[0074] 16 , in the light receiving detection module 3045 of the third embodiment, a portion of the light receiving adhesive surface 3452 that defines the light receiving sub-gap 481 has a flat surface portion 3452b that is substantially perpendicular to the geometric center axis and is formed on the same plane as the flat surface portion 452a. The light receiving sub-gap 481 that is wider in the light receiving direction RD than the light receiving main gap 480 is formed between the flat surface portion 3452b and the inclined surface portion 422b. Therefore, in the arrangement step S201, the light receiving adhesive 48 is sandwiched between the adhesive surfaces 3452, 422 in an orientation in which the inclined surface portion 422b of the other light receiving adhesive surface 422, which is set lower in the direction of gravity, is gradually spaced away from one light receiving adhesive surface 3452, which is set upper in the direction of gravity in the opposite direction to that in FIG. 16 , toward the outer periphery around the light receiving optical axis ROA.

[0075] (Fourth embodiment) The fourth embodiment is a modification of the first embodiment.

[0076] 17 , in the light-projecting light source module 4022 of the fourth embodiment, a portion of the light-projecting adhesive surface 4222 that defines the light-projecting sub-gap 281 has a flat surface portion 4222b that is substantially perpendicular to the geometric central axis and is formed by a crank-shaped recessed structure extending from the flat surface portion 222a. Meanwhile, in the light-projecting lens module 4026 of the fourth embodiment, a portion of the light-projecting adhesive surface 4262 that defines the light-projecting sub-gap 281 has a flat surface portion 4262b that is substantially perpendicular to the geometric central axis and is formed by a crank-shaped recessed structure extending from the flat surface portion 262a. Between these flat surface portions 4222b and 4262b, a light-projecting sub-gap 281 that is wider in the light-projecting direction PD than the light-projecting main gap 280 is formed. Therefore, in the arrangement step of S101, the light-projecting adhesive 28 is arranged between the light-projecting adhesive surfaces 4222 and 4262 that are set opposite each other vertically in the direction of gravity.

[0077] 18 , in the light receiving detection module 4045 of the fourth embodiment, the portion of the light receiving adhesive surface 4452 that defines the light receiving sub-gap 481 has a flat surface portion 4452b that is substantially perpendicular to the geometric central axis and is formed by a crank-shaped recessed structure extending from the flat surface portion 452a. Similarly, in the light receiving lens module 4042 of the fourth embodiment, the portion of the light receiving adhesive surface 4422 that defines the light receiving sub-gap 481 has a flat surface portion 4422b that is substantially perpendicular to the geometric central axis and is formed by a crank-shaped recessed structure extending from the flat surface portion 422a. Between these flat surface portions 4452b and 4422b, the light receiving sub-gap 481 is formed, which is wider in the light receiving direction RD than the light receiving main gap 480. Therefore, in the arrangement step S201, the light receiving adhesive 48 is arranged between the light receiving adhesive surfaces 4452 and 4422 that are set opposite each other vertically in the direction of gravity.

[0078] (Other embodiments) Although multiple embodiments have been described above, the present disclosure should not be construed as being limited to those embodiments, and can be applied to various embodiments and combinations within the scope that does not deviate from the gist of the present disclosure.

[0079] In the modified examples of the first to fourth embodiments, as shown in Fig. 19 (which representatively shows a modified example of the first embodiment), a light-projecting sub-gap 281 may be formed not only on the outer circumferential side of the light-projecting main gap 280 around the light-projecting optical axis POA but also on the inner circumferential side, thereby allowing the light-projecting adhesive 28 to escape. In the modified examples of the first to fourth embodiments, as shown in Fig. 20 (which representatively shows a modified example of the first embodiment), a light-receiving sub-gap 481 may be formed not only on the outer circumferential side of the light-receiving main gap 480 around the light-receiving optical axis ROA but also on the inner circumferential side, thereby allowing the light-receiving adhesive 48 to escape.

[0080] In a modification of the first embodiment, as shown in Fig. 21 , the light-projecting sub-gap 281 may be expanded between the other inclined surface portion 262b or 222b that extends to a position more inward than one of the inclined surface portions 222b, 262b in the radial direction about the light-projecting optical axis POA and the flat surface portion 222a or 262a connected to the other inclined surface portion 262b or 222b. In a modification of the first embodiment, as shown in Fig. 22 , the light-receiving sub-gap 481 may be expanded between the other inclined surface portion 422b or 452b that extends to a position more inward than one of the inclined surface portions 452b, 422b in the radial direction about the light-receiving optical axis ROA and the flat surface portion 452a or 4222a connected to the other inclined surface portion 422b or 452b.

[0081] In the modified examples of the first to fourth embodiments, the taper angles Pθ and Rθ may be set to an acute angle other than approximately 45 degrees. In the modified examples of the first and second embodiments, the inclined surface portions 222b and 452b may be replaced by the crank-shaped recesses 4222b and 4452b of the fourth embodiment. In the modified examples of the first and third embodiments, the inclined surface portions 262b and 422b may be replaced by the crank-shaped recesses 4262b and 4422b of the fourth embodiment.

[0082] In the modified examples of the first to fourth embodiments, a Y-axis direction along the horizontal direction and an X-axis direction along the vertical direction may be defined. In the modified examples of the first to fourth embodiments, the moving body to which the optical sensor 10 is applied may be, for example, a traveling robot whose traveling can be remotely controlled. In the modified examples of the first to fourth embodiments, the moving body to which the optical sensor 10 is applied may be, for example, a stationary structure other than a moving body.

[0083] (Additional remarks) This specification discloses the following technical ideas and combinations thereof.

[0084] (Technical thought 1) An optical sensor (10) that detects an external environment by projecting a projected beam (PB) toward the external environment and receiving a reflected beam (RB) that is reflected from the external environment in response to the projected beam, a light projecting light source module (22, 3022, 4022) that generates the light projecting beam; a projection lens module (26, 2026, 4026) that guides the projection beam from the projection light source module to the outside world along a projection optical axis (POA); a light-projection adhesive (28) of ultraviolet and heat curing type interposed between the light-projection adhesive surfaces (222, 262, 2262, 3222, 4222, 4262) of the light-projection light source module and the light-projection lens module that face each other in a light-projection direction (PD) along the light-projection optical axis, The optical sensor has between each of the light-projecting adhesive surfaces a light-projecting main gap (280) filled with the light-projecting adhesive, and a light-projecting sub-gap (281) that is wider than the light-projecting main gap in the light-projecting direction and is open to the outer periphery around the light-projecting optical axis, and in which the light-projecting adhesive that continues from the light-projecting main gap spans both sides of the gap.

[0085] (Technical thought 2) The optical sensor described in Technical Idea 1 has a light-projecting inclined surface portion (222b, 262b) in which at least one of the light-projecting adhesive surfaces is gradually spaced away from the opposing light-projecting adhesive surface toward the outer periphery around the light-projecting optical axis, thereby forming the light-projecting sub-gap.

[0086] (Technical Thought 3) The optical sensor according to Technical Idea 2, wherein the light projection inclined surface portion is inclined along a bisector (PL) of an angle between the light projection direction and a direction perpendicular to the light projection direction (POD).

[0087] (Technical Thought 4) a light receiving and detecting module (45, 3045, 4045) that receives the reflected beam and detects the external environment; a light receiving lens module (42, 2042, 4042) that guides the reflected beam from the external environment side toward the light receiving and detecting module side along a light receiving optical axis (ROA); a photosensitive adhesive (48) of ultraviolet and heat curing type interposed between the photosensitive adhesive surfaces (422, 452, 2422, 3452, 4422, 4452) of the photosensitive detection module and the photosensitive lens module that face each other in a photosensitive direction (RD) along the photosensitive optical axis, An optical sensor described in any one of technical ideas 1 to 3, in which each of the light-receiving adhesive surfaces forms a light-receiving main gap (480) filled with the light-receiving adhesive and a light-receiving sub-gap (481) between them, the light-receiving sub-gap being wider in the light-receiving direction than the light-receiving main gap and open to the outer periphery around the light-receiving optical axis, with the light-receiving adhesive continuing from the light-receiving main gap spanning both sides.

[0088] (Technical Thought 5) An optical sensor (10) that senses an external environment by projecting a projected beam (PB) toward the external environment and receiving a reflected beam (RB) that is reflected from the external environment in response to the projected beam, a light receiving and detecting module (45, 3045, 4045) that receives the reflected beam and detects the external environment; a light receiving lens module (42, 2042, 4042) that guides the reflected beam from the external environment side toward the light receiving and detecting module side along a light receiving optical axis (ROA); a photosensitive adhesive (48) of ultraviolet and heat curing type interposed between the photosensitive adhesive surfaces (422, 452, 2422, 3452, 4422, 4452) of the photosensitive detection module and the photosensitive lens module that face each other in a photosensitive direction (RD) along the photosensitive optical axis, An optical sensor in which each of the light-receiving adhesive surfaces forms a light-receiving main gap (480) filled with the light-receiving adhesive and a light-receiving sub-gap (481) between them, the light-receiving sub-gap being wider in the light-receiving direction than the light-receiving main gap and open to the outer periphery around the light-receiving optical axis, with the light-receiving adhesive continuing from the light-receiving main gap spanning both sides.

[0089] (Technical Thought 6) An optical sensor described in Technical Idea 4 or 5, in which at least one of the light-receiving adhesive surfaces has a light-receiving inclined surface portion (422b, 452b) that is inclined in a shape such that it gradually moves away from the opposing light-receiving adhesive surface toward the outer periphery around the light-receiving optical axis, thereby forming the light-receiving sub-gap.

[0090] (Technical Thought 7) The optical sensor according to Technical Idea 6, wherein the light-receiving inclined surface portion is inclined along a bisector (RL) of an angle formed by the light-receiving direction and a direction perpendicular to the light-receiving direction (ROD).

[0091] (Technical Thought 8) A manufacturing method for manufacturing the optical sensor according to any one of Technical Ideas 1 to 3, disposing the light-projecting adhesive in the light-projecting main gap and the light-projecting sub-gap; irradiating the light-projecting sub-gap with ultraviolet light from an outer circumferential side around the light-projecting optical axis to temporarily harden a portion of the light-projecting adhesive; and thermally curing the remaining portion of the light-projecting adhesive after the temporary curing.

[0092] (Technical Thought 9) The disposing of the light-flooding adhesive includes: A manufacturing method described in Technical Idea 8, which includes a light-projecting inclined surface portion (222b, 262b) that gradually moves away from the light-projecting adhesive surface set on the upper side in the direction of gravity toward the outer periphery around the light-projecting optical axis, and sandwiching the light-projecting adhesive between the light-projecting adhesive surface set on the lower side in the direction of gravity and the light-projecting adhesive surface on the upper side in the direction of gravity.

[0093] (Technical Thought 10) A manufacturing method for manufacturing the optical sensor according to any one of Technical Ideas 4 to 7, disposing the light-projecting adhesive in the light-receiving main gap and the light-receiving sub-gap; irradiating the light-receiving sub-gap with ultraviolet light from an outer periphery around the light-receiving optical axis to temporarily harden a portion of the light-receiving adhesive; and thermally curing the remaining portion of the light-receiving adhesive after the temporary curing.

[0094] (Technical Thought 11) The disposing of the light-receiving adhesive material includes: A manufacturing method described in technical idea 10, which includes a light-receiving inclined surface portion (422b, 452b) that gradually moves away from the light-receiving adhesive surface set on the upper side in the direction of gravity toward the outer periphery around the light-receiving optical axis, and sandwiching the light-receiving adhesive between the light-receiving adhesive surface set on the lower side in the direction of gravity and the light-receiving adhesive surface on the upper side in the direction of gravity. [Explanation of symbols]

[0095] 10: Optical sensor, 22, 3022, 4022: Light-emitting light source module, 26, 2026, 4026: Light-emitting lens module, 28: Light-emitting adhesive, 42, 2042, 4042: Light-receiving lens module, 45, 3045, 4045: Light-receiving detection module, 48: Light-receiving adhesive, 222, 262, 2262, 3222, 4222, 4262: Light-emitting adhesive surface, 222b, 262b: Light-emitting inclined surface portion, 280: Light-emitting Main light gap, 281: Light-emitting sub-gap, 422, 452, 2422, 3452, 4422, 4452: Light-receiving adhesive surface, 422b, 452b: Light-receiving inclined surface, 480: Light-receiving main gap, 481: Light-receiving sub-gap, PB: Light-emitting beam, PD: Light-emitting direction, PL: Bisector, POA: Light-emitting optical axis, POD: Orthogonal direction, RB: Reflected beam, RD: Light-receiving direction, RL: Bisector, ROA: Light-receiving optical axis, ROD: Orthogonal direction

Claims

1. An optical sensor (10) that detects an external environment by projecting a projected beam (PB) toward the external environment and receiving a reflected beam (RB) reflected from the external environment in response to the projected beam, a light projecting light source module (22, 3022, 4022) that generates the light projecting beam; a projection lens module (26, 2026, 4026) that guides the projection beam from the projection light source module to the outside world along a projection optical axis (POA); a light-projecting adhesive (28) of ultraviolet and heat curing type interposed between the light-projecting adhesive surfaces (222, 262, 2262, 3222, 4222, 4262) of the light-projecting light source module and the light-projecting lens module that face each other in a light-projecting direction (PD) along the light-projecting optical axis, The light-projecting adhesive surfaces are provided with a light-projecting main gap (280) between them, in which the light-projecting adhesive is interposed so as to straddle each of the light-projecting adhesive surfaces on the inner circumferential side around the light-projecting optical axis, and a light-projecting sub-gap (281) which is wider than the light-projecting main gap in the light projection direction and is open to the outer circumferential side around the light-projecting optical axis, and in which the light-projecting adhesive, continuing from the light-projecting main gap, is interposed so as to straddle each of the light-projecting adhesive surfaces, Each of the light-projecting adhesive surfaces has a light-projecting inclined surface portion (222b, 262b) that is inclined in a shape such that it gradually separates from the opposing light-projecting adhesive surface toward the outer periphery around the light-projecting optical axis to form the light-projecting sub-gap, An optical sensor in which the light-projecting inclined surface portion of one of the light-projecting adhesive surfaces extends to a position more inward than the light-projecting inclined surface portion of the other light-projecting adhesive surface.

2. The optical sensor according to claim 1 , wherein the light-projecting inclined surface portion is inclined along a bisector (PL) of an angle between the light-projecting direction and a direction (POD) orthogonal to the light-projecting direction.

3. a light receiving and detecting module (45, 3045, 4045) that receives the reflected beam and detects the external environment; a light receiving lens module (42, 2042, 4042) that guides the reflected beam from the external environment side to the light receiving and detecting module side along a light receiving optical axis (ROA); a light-receiving adhesive (48) of ultraviolet and heat curing type interposed between the light-receiving adhesive surfaces (422, 452, 2422, 3452, 4422, 4452) of the light-receiving detection module and the light-receiving lens module that face each other in a light-receiving direction (RD) along the light-receiving optical axis, The light-receiving adhesive surfaces are provided with a light-receiving main gap (480) between them, in which the light-receiving adhesive is interposed so as to straddle the light-receiving adhesive surfaces on the inner circumferential side around the light-receiving optical axis, and a light-receiving sub-gap (481) which is wider than the light-receiving main gap in the light-receiving direction and is open to the outer circumferential side around the light-receiving optical axis, and in which the light-receiving adhesive is interposed so as to straddle the light-receiving adhesive surfaces, the light-receiving sub-gap being continuous with the light-receiving main gap; Each of the light-receiving adhesive surfaces has a light-receiving inclined surface portion (422b, 452b) that is inclined in a shape such that the light-receiving adhesive surface is gradually spaced from the opposing light-receiving adhesive surface toward the outer periphery around the light-receiving optical axis to form the light-receiving sub-gap, The optical sensor according to claim 1 , wherein the light-receiving inclined surface portion of one of the light-receiving adhesive surfaces extends to a position on the inner periphery side of the light-receiving inclined surface portion of the other light-receiving adhesive surface.

4. An optical sensor (10) that detects an external environment by projecting a projected beam (PB) toward the external environment and receiving a reflected beam (RB) reflected from the external environment in response to the projected beam, a light receiving and detecting module (45, 3045, 4045) that receives the reflected beam and detects the external environment; a light receiving lens module (42, 2042, 4042) that guides the reflected beam from the external environment side to the light receiving and detecting module side along a light receiving optical axis (ROA); a light-receiving adhesive (48) of ultraviolet and heat curing type interposed between the light-receiving adhesive surfaces (422, 452, 2422, 3452, 4422, 4452) of the light-receiving detection module and the light-receiving lens module that face each other in a light-receiving direction (RD) along the light-receiving optical axis, The light-receiving adhesive surfaces are provided with a light-receiving main gap (480) between them, in which the light-receiving adhesive is interposed so as to straddle the light-receiving adhesive surfaces on the inner circumferential side around the light-receiving optical axis, and a light-receiving sub-gap (481) which is wider than the light-receiving main gap in the light-receiving direction and is open to the outer circumferential side around the light-receiving optical axis, and in which the light-receiving adhesive is interposed so as to straddle the light-receiving adhesive surfaces, the light-receiving sub-gap being continuous with the light-receiving main gap; Each of the light-receiving adhesive surfaces has a light-receiving inclined surface portion (422b, 452b) that is inclined in a shape such that the light-receiving adhesive surface is gradually spaced from the opposing light-receiving adhesive surface toward the outer periphery around the light-receiving optical axis to form the light-receiving sub-gap, An optical sensor in which the light-receiving inclined surface portion of one of the light-receiving adhesive surfaces extends to a position more inward than the light-receiving inclined surface portion of the other light-receiving adhesive surface.

5. 5. The optical sensor according to claim 4, wherein the light-receiving inclined surface portion is inclined along a bisector (RL) of an angle formed by the light-receiving direction and a direction (ROD) perpendicular to the light-receiving direction.

6. A method for manufacturing the optical sensor according to claim 1 or 2, comprising the steps of: disposing the light-projecting adhesive in the light-projecting main gap and the light-projecting sub-gap; irradiating the light-projecting sub-gap with ultraviolet light from an outer circumferential side around the light-projecting optical axis to temporarily harden a portion of the light-projecting adhesive; and thermally curing the remaining portion of the light-projecting adhesive after the temporary curing.

7. The disposing of the light-flooding adhesive comprises:

7. The manufacturing method according to claim 6, wherein a light-projecting inclined surface portion (222b, 262b) that gradually moves away from the light-projecting adhesive surface set on the upper side in the direction of gravity toward the outer periphery around the light-projecting optical axis is provided, and the light-projecting adhesive is sandwiched between the light-projecting adhesive surface set on the lower side in the direction of gravity and the light-projecting adhesive surface on the upper side in the direction of gravity.

8. A method for manufacturing the optical sensor according to any one of claims 3 to 5, comprising the steps of: disposing the light-receiving adhesive in the light-receiving main gap and the light-receiving sub-gap; irradiating the light-receiving sub-gap with ultraviolet light from an outer periphery around the light-receiving optical axis to temporarily harden a portion of the light-receiving adhesive; and thermally curing the remaining portion of the light-receiving adhesive after the temporary curing.

9. The disposing of the light-receiving adhesive material includes:

9. The manufacturing method of claim 8, wherein a light-receiving inclined surface portion (422b, 452b) that gradually moves away from the light-receiving adhesive surface set on the upper side in the direction of gravity toward the outer periphery around the light-receiving optical axis is provided, and the light-receiving adhesive is sandwiched between the light-receiving adhesive surface set on the lower side in the direction of gravity and the light-receiving adhesive surface on the upper side in the direction of gravity.

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