Optical sensor

Abstract

A light projection lens module (26) of the present invention has a metal light projection lens barrel (261) holding a light projection lens member and defining the optical path of a scanning beam (BS). A light projection light source module (22) has a metal light projection holder (221) bonded to the light projection lens barrel (261) via an adhesive (210) around a light projection optical axis (POA). Around the light projection optical axis (POA) of a structural element that is at least one of the light projection lens barrel (261) and the light projection holder (221), a film surface adhesion part (227) covered with a light reflection prevention film (225) to which the adhesive (210) covering a rough surface adhesion part (226) is bonded by protruding is formed on the inner peripheral side than the rough surface adhesion part (226) in a rough surface state.

Description

Optical sensor Cross-reference to Related Applications

[0001] This application is based on Japanese Patent Application No. 2025-52378 filed with Japan on March 26, 2025, and the entire content of the base application is incorporated herein by reference.

[0002] The present disclosure relates to an optical sensor.

[0003] Conventionally, optical sensors that scan the external environment by projecting a scanning beam toward the external environment and receiving the scanning beam reflected from the external environment are widely known. In the technology disclosed in Patent Document 1 as this type of optical sensor, in a photodiode module that receives reflected light serving as a reflected scanning beam, the metal leg of a light-receiving lens is adhered to a through hole of a metal base via an adhesive, thereby optically adjusting the position.

[0004] Japanese Unexamined Patent Publication No. 2020-86375

[0005] In the technology disclosed in Patent Document 1, uneven portions are formed on each adhesive surface between the metal leg of the light-receiving lens and the through hole of the metal base by surface treatment using laser light, thereby increasing the adhesive strength at the adhesive interface. In contrast, in order to suppress stray light of a beam passing through the adhesive interface, a measure of coating at least one of the metal leg and the metal base with an anti-reflection film is conceivable. However, when such a measure is applied to the technology disclosed in Patent Document 1, a trade-off between adhesive strength and the stray light suppression effect is inevitably caused due to the formation of uneven portions on at least one of the metal leg and the metal base whose adhesive surface is coated with the anti-reflection film.

[0006] Based on the above, an object of the present disclosure is to provide an optical sensor that achieves both adhesive strength and a stray light suppression effect at the adhesive interface between structural elements.

[0007] Hereinafter, the technical means of the present disclosure for solving the object will be described.

[0008] A first aspect of the present disclosure is an optical sensor that projects a scanning beam to scan the outside world and receives the scanning beam reflected from the outside world, comprising: a light projection light source module that projects the scanning beam; a light projection lens module that guides the scanning beam from the light projection light source module toward the outside world along the light projection axis; and an adhesive interposed between the light projection light source module and the light projection lens module which are opposite to each other along the light projection axis, wherein the light projection lens module has a metal light projection tube that holds a light projection lens member and defines the optical path of the scanning beam; the light projection light source module has a metal light projection holder that is bonded to the light projection tube via the adhesive around the light projection axis; and a film surface bonding portion covered with an anti-reflective film, on the inner circumference side of the rough surface bonding portion, where the adhesive covering the rough surface bonding portion protrudes and is bonded, is formed around the light projection axis of at least one of the structural elements, which is the light projection tube and the light projection holder, on the inner circumference side of the rough surface bonding portion.

[0009] Thus, in the first embodiment, the light-emitting lens barrel, which holds the light-emitting lens member in the light-emitting lens module and defines the optical path of the scanning beam, is held in the light-emitting light source module by a light-emitting holder which is bonded to it around the light-emitting optical axis via an adhesive. In the first embodiment, around the light-emitting optical axis of at least one of the structural elements, which is the metal light-emitting lens barrel and the light-emitting holder, a film surface adhesive portion covered with an anti-reflective film to which the adhesive covering the rough surface adhesive portion protrudes and adheres is formed on the inner circumference side of the rough surface adhesive portion. This makes it possible to achieve both the stray light suppression effect on the light-emitting side by the anti-reflective film of the film surface adhesive portion on the inner circumference side and the high adhesive strength due to adhesion to the rough surface adhesive portion on the outer circumference side at the adhesive interface between the light-emitting lens barrel and the light-emitting holder.

[0010] A second aspect of the present disclosure, in the first aspect, comprises: a light-receiving detection module that detects the outside world by receiving a scanning beam; a light-receiving lens module that guides the scanning beam from the outside world side toward the light-receiving detection module side along the light-receiving optical axis; and an adhesive interposed between the light-receiving detection module and the light-receiving lens module which are mutually opposed along the light-receiving optical axis, wherein the light-receiving lens module has a metal light-receiving lens barrel that holds a light-receiving lens member and defines the optical path of the scanning beam; the light-receiving detection module has a metal light-receiving holder which is bonded to the light-receiving lens barrel via the adhesive around the light-receiving optical axis; and even around the light-receiving optical axis of the structural element which is at least one of the light-receiving lens barrel and the light-receiving holder, a film surface adhesive portion covered with an anti-reflective coating is formed on the inner circumference side of the rough surface adhesive portion which is a rough surface.

[0011] A third aspect of the present disclosure is an optical sensor that projects a scanning beam to scan the outside world and receives the scanning beam reflected from the outside world, comprising: a light-receiving detection module that detects the outside world by receiving the scanning beam; a light-receiving lens module that guides the scanning beam from the outside world side toward the light-receiving detection module side along the light-receiving optical axis; and an adhesive interposed between the light-receiving detection module and the light-receiving lens module which are mutually opposed along the light-receiving optical axis, wherein the light-receiving lens module has a metal light-receiving lens barrel that holds a light-receiving lens member and defines the optical path of the scanning beam; the light-receiving detection module has a metal light-receiving holder which is bonded to the light-receiving lens barrel via the adhesive around the light-receiving optical axis; and a film surface bonding portion covered with an anti-reflective film, on the inner circumference side of the rough surface bonding portion which is a rough surface bonding portion, is formed on the inner circumference side of the rough surface bonding portion which is a rough surface bonding portion, and the adhesive covering the rough surface bonding portion protrudes and is bonded.

[0012] In the second and third embodiments, the light-receiving lens barrel, which holds the light-receiving lens member in the light-receiving lens module and defines the optical path of the scanning beam, is held in a light-receiving holder that is bonded to the light-receiving optical axis in the light-receiving detection module via adhesive. In the second and third embodiments, around the light-receiving optical axis of at least one of the metal light-receiving lens barrel and light-receiving holder, a film-surface adhesive portion covered with an anti-reflective film, to which the adhesive covering the rough surface adhesive portion protrudes and adheres, is formed on the inner circumference side of the rough surface adhesive portion. This makes it possible to achieve both the stray light suppression effect on the light-emitting side by the anti-reflective film of the film-surface adhesive portion on the inner circumference side and the high adhesive strength due to adhesion to the rough surface adhesive portion on the outer circumference side at the adhesive interface between the light-receiving lens barrel and the light-receiving holder.

[0013] This is an overall configuration diagram showing the optical sensor according to the first embodiment. This is a side view showing the structure of the light-emitting unit and light-receiving unit according to the first embodiment in a partial longitudinal section. This is a schematic diagram showing the light-emitting unit according to the first embodiment. This is a schematic diagram showing the light-receiving unit according to the first embodiment. This is a perspective view showing the external appearance of the light-emitting unit according to the first embodiment. This is a longitudinal cross-sectional view showing the detailed configuration of the light-emitting unit according to the first embodiment. This is a schematic diagram for explaining the cross-sectional structure of the light-emitting unit according to the first embodiment. This is a longitudinal cross-sectional view showing a modified example of Figure 6. This is a longitudinal cross-sectional view showing the manufacturing method of the light-emitting unit according to the first embodiment. This is a schematic diagram for explaining the manufacturing method of the light-emitting unit according to the first embodiment in a longitudinal section. This is a schematic diagram for explaining the manufacturing method of the light-emitting unit according to the first embodiment in a longitudinal section different from that of Figure 10. This is a perspective view showing the external appearance of the light-receiving unit according to the first embodiment. This is a longitudinal cross-sectional view showing the detailed configuration of the light-receiving unit according to the first embodiment. This is a schematic diagram for explaining the cross-sectional structure of the light-receiving unit according to the first embodiment. This is a longitudinal cross-sectional view showing the detailed configuration of the light-emitting unit according to the second embodiment. This is a schematic diagram for explaining the cross-sectional structure of the light-emitting unit according to the second embodiment. This is a schematic diagram illustrating the manufacturing method of the light-emitting unit according to the second embodiment in a longitudinal cross-section. This is a schematic diagram illustrating the manufacturing method of the light-emitting unit according to the second embodiment in a longitudinal cross-section different from that of Figure 17. This is a longitudinal cross-sectional view showing the detailed configuration of the light-receiving unit according to the second embodiment. This is a schematic diagram illustrating the cross-sectional structure of the light-receiving unit according to the second embodiment. This is a longitudinal cross-sectional view showing the detailed configuration of the light-emitting unit according to the third embodiment. This is a schematic diagram illustrating the cross-sectional structure of the light-emitting unit according to the third embodiment. This is a longitudinal cross-sectional view showing the detailed configuration of the light-receiving unit according to the third embodiment. This is a schematic diagram illustrating the cross-sectional structure of the light-receiving unit according to the third embodiment. This is a longitudinal cross-sectional view showing a modified example of Figure 6. This is a longitudinal cross-sectional view showing a modified example of Figure 6. This is a longitudinal cross-sectional view showing a modified example of Figure 13. This is a longitudinal cross-sectional view showing a modified example of Figure 13. This is a schematic diagram illustrating a modified example of Figure 16. This is a schematic diagram illustrating a modified example of Figure 7. This is a schematic diagram illustrating a modified example of Figure 10.

[0014] Hereinafter, several embodiments of this disclosure will be described with reference to the drawings. In each embodiment, the same reference numerals will be used for corresponding components, and redundant explanations may be omitted. Furthermore, if only a part of the configuration is described in each embodiment, the configuration of other embodiments described earlier may be applied to the other parts of that configuration. Moreover, not only the combinations of configurations explicitly stated in the description of each embodiment, but also the configurations of multiple embodiments can be partially combined even if not explicitly stated, as long as there are no particular problems with the combination.

[0015] (First Embodiment) As shown in Figure 1, the optical sensor 10 according to the first embodiment of this disclosure is a LiDAR (Light Detection and Ranging / Laser Imaging Detection and Ranging) mounted on a moving body for optically scanning the outside world. The moving body on which the optical sensor 10 is to be placed is a vehicle such as an automobile that is capable of at least one type of driving from manual driving, automatic driving, and remote driving. In the following description, unless otherwise specified, the directions indicated by front, rear, up, down, left, and right are defined with respect to the vehicle on a horizontal plane. Also, in the following description, the horizontal direction and the vertical direction mean the direction parallel and perpendicular to the horizontal plane of the vehicle, respectively. Furthermore, in the following description, the gravity direction means the downward direction of the vertical direction of the vehicle on a horizontal plane.

[0016] The optical sensor 10 is positioned at least one location on the vehicle, such as the front, left and right sides, rear, and upper roof. The optical sensor 10 projects a scanning beam BS towards a scanning area AS in the outside world, corresponding to its position on the vehicle. The optical sensor 10 receives the scanning beam BS reflected by targets in the scanning area AS in the outside world as reflected light. Therefore, the scanning beam BS is selected to be light in the near-infrared region, which is difficult for humans to see.

[0017] The optical sensor 10 detects an object within the scanning area AS by receiving a scanning beam BS reflected from the external scanning area AS. This detection of an external object means sensing one or more types of information, including at least distance, such as the distance from the optical sensor 10 to the object, the direction in which the object is located, and the reflection intensity of the scanning beam BS from the object. The object targeted by the optical sensor 10 is at least one type of moving object, such as pedestrians, cyclists, animals other than humans, and other vehicles. The object targeted by the optical sensor 10 may further be at least one type of stationary object, such as guardrails, road signs, roadside structures, and fallen objects on the road.

[0018] The optical sensor 10 has a three-dimensional coordinate system defined by three mutually orthogonal axes: the X, Y, and Z axes. In particular, in the three-dimensional coordinate system of the optical sensor 10, the Y-axis direction is defined along the vertical direction of the vehicle, while the X-axis and Z-axis directions are defined along the different horizontal directions of the vehicle. As a result, on a vehicle on a horizontal plane, the XY plane and YZ plane of the three-dimensional coordinate system align with a vertical plane perpendicular to the horizontal plane, and the XZ plane aligns with the horizontal plane. Note that in Figure 1, the portion to the left of the dashed line along the Y-axis direction (the side of the cover panel 12 described later) actually shows a cross-section perpendicular to the portion to the right of the dashed line (the side of the units 21 and 41 described later).

[0019] The optical sensor 10 comprises 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-shielding sensor base 11 is formed in a box shape from, for example, metal or resin. The sensor base 11 is formed of metal in a case shape 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 resin or glass.

[0020] The light-emitting unit 21 comprises a light-emitting light source module 22 and a light-emitting lens module 26. As shown in Figure 2, the light-emitting light source module 22 has a light-emitting holder 221 in combination with a light-emitting substrate 220. The light-emitting holder 221 is fixed to the sensor base 11. The light-emitting holder 221 is formed in a block shape that holds the light-emitting substrate 220, mainly using a metal substrate 224.

[0021] As shown in Figure 3, the light-emitting substrate 220 is constructed by mounting a plurality of laser diodes 24 in an array. In particular, in the light-emitting substrate 220 of the optical sensor 10, each laser diode 24 is arranged in a single row along the Y-axis. Each laser diode 24 generates pulsed laser light that becomes part of the scanning beam BS according to 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).

[0022] The light-emitting substrate 220 has a light-emitting window 25 formed on one side, which is pseudo-defined by a rectangular contour that is longitudinal along the Y-axis and transverse along the X-axis. The light-emitting window 25 is constructed as an aggregate of laser oscillation apertures in each laser diode 24. The laser light projected from the laser oscillation aperture of each laser diode 24 is projected from the light-emitting window 25 as a scanning beam BS that is shaped into a longitudinal line along the vertical direction in the scanning region AS shown in Figure 1.

[0023] The light-emitting lens module 26 has at least one light-emitting lens member 260 in combination with the light-emitting lens barrel 261. The light-transmitting light-emitting lens member 260 is mainly made of a resin substrate or a glass substrate and is formed into a lens shape according to the optical function it is to perform. The light-emitting lens member 260 performs at least one type of optical function, such as focusing, collimating, and shaping, on the scanning beam BS projected from the light-emitting light source module 22. The light-emitting lens barrel 261 is held on the sensor base 11 via the light-emitting holder 221 by being bonded to the light-emitting holder 221.

[0024] As shown in Figure 2, the light-emitting tube 261 is formed in a cylindrical shape, mainly from a metal substrate 264. The light-emitting tube 261 defines the light-emitting path of the scanning beam BS with its inner cylindrical surface. The light-emitting tube 261 holds and positions the light-emitting lens member 260, which is necessary for the optical action on the scanning beam BS, on its inner cylindrical surface.

[0025] In this configuration, the light projection lens module 26 shown in Figures 1 and 2 is aligned with the light projection light source module 22 so as to form the light projection axis POA. Therefore, the scanning beam BS projected from the light projection light source module 22 is guided along the light projection axis POA toward the outside of the vehicle by the optical action of the light projection lens module 26.

[0026] As shown in Figure 1, the scanning unit 31 comprises a scanning mirror 32 and a scanning motor 35. The scanning mirror 32 is formed in the shape of a plate 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 around a rotation centerline along the Y-axis. The scanning mirror 32 oscillates within a finite drive range determined 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 reduction gear. The scanning motor 35 is held by the sensor base 11 so as to be rotatable along with the output shaft of the scanning mirror 32. The scanning motor 35 rotates (i.e., oscillates) the scanning mirror 32 within a finite drive range according to a control signal from the control unit 51.

[0027] The scanning mirror 32 reflects the scanning beam BS incident from the light projection unit 21 by its reflective surface 33 and irradiates the scanning area AS from the cover panel 12, thereby scanning the target within the scanning area AS according to the rotation angle of the scanning motor 35. At this time, the scanning of the scanning area AS by the scanning beam BS is substantially limited to horizontal scanning by the optical sensor 10, depending on the rotational drive direction of the scanning mirror 32.

[0028] The scanning mirror 32 reflects the scanning beam BS, which is incident from a target within the scanning area AS through the cover panel 12, towards the light receiving unit 41 using its reflective surface 33, in accordance with the rotation angle of the scanning motor 35. At this time, the speed of the scanning beam BS is sufficiently large compared to the rotational speed of the scanning mirror 32. As a result, the scanning beam BS reflected from within the scanning area AS is reflected by the scanning mirror 32, which can be simulated to have substantially the same rotation angle as the scanning beam BS at the time it was incident on the scanning mirror AS. Thus, the scanning beam BS reflected by the scanning mirror 32 is guided towards the light receiving unit 41 in a direction opposite to that of the scanning beam BS at the time it was incident from the light source module 22 to the scanning mirror 32.

[0029] The light receiving unit 41 comprises a light receiving lens module 42 and a light receiving detection module 45. The light receiving lens module 42 has at least one light receiving lens member 420 in combination with a light receiving lens barrel 421. The light-transmitting light receiving lens member 420 is mainly made of a resin substrate or a glass substrate and is formed in a lens shape according to the optical effect it is to exert. The light receiving lens member 420 exerts an optical effect to image the scanning beam BS reflected from the scanning mirror 32 onto the light receiving detection module 45.

[0030] As shown in Figure 2, the light-receiving tube 421 is formed in a cylindrical shape, mainly from a metal substrate 424. The light-receiving tube 421 defines the light-receiving optical path of the scanning beam BS with its inner circumferential surface. The light-receiving tube 421 holds and positions the light-receiving lens member 420, which is necessary for the optical action on the scanning beam BS, on its inner circumferential surface.

[0031] In this configuration, the light-receiving lens module 42 shown in Figures 1 and 2 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 offset in the Y-axis direction relative to the light-emitting optical axis POA of the light-emitting lens module 26. As a result, the scanning beam BS reflected from the scanning mirror 32, which is offset in the Y-axis direction from the scanning beam BS at the time of incidence to the scanning mirror 32, is guided towards the light-receiving detection module 45 side along the light-receiving optical axis ROA by the optical action of the light-receiving lens module 42.

[0032] As shown in Figure 2, the light receiving detection module 45 has a light receiving holder 451 in combination with a light receiving substrate 450. The light receiving holder 451 is fixed to the sensor base 11 and is also bonded to the light receiving lens barrel 421. As a result, the light receiving lens barrel 421 is held to the sensor base 11 via the light receiving holder 451. The light receiving holder 451 is formed mainly of a metal substrate 454 in the shape of a case that holds the light receiving substrate 450.

[0033] As shown in Figure 4, the light-receiving substrate 450 is constructed by mounting a plurality of light-receiving pixels 46 in an array. In particular, in the light-receiving substrate 450 of the optical sensor 10, each light-receiving pixel 46 is arranged at least along the Y-axis direction. The light-receiving substrate 450 has a light-receiving surface 450a formed on one side, which has a rectangular contour that is longitudinal along the Y-axis direction and short along the X-axis direction. The light-receiving surface 450a is configured as an aggregate of the incident surfaces of each light-receiving pixel 46.

[0034] In the light-receiving substrate 450, each light-receiving pixel 46 is formed from multiple light-receiving elements 460, such as single-photon avalanche diodes. As shown in Figures 1 and 2, each of these light-receiving pixels 46 receives the scanning beam BS incident from the light-receiving lens module 42 onto the light-receiving surface 450a of the light-receiving substrate 450 in a line that is longitudinal along the Y-axis and longitudinal along the X-axis.

[0035] As shown in Figure 1, the light receiving detection module 45 has an output circuit 47. The output circuit 47 performs sampling processing at each control cycle according to a control signal from the control unit 51 in a detection frame for each scanning line that corresponds to the rotation angle of the scanning mirror 32 and is synchronized with the light emission period of the scanning beam BS from the light emission light source module 22. At this time, the output circuit 47 generates a detection signal by combining the received output from each light receiving pixel 46 that receives the scanning beam BS at each control cycle. The detection signal thus generated is output from the output circuit 47 to the control unit 51 for each scanning line.

[0036] The control unit 51 controls the scanning of targets in the external scanning area AS. The control unit 51 is mainly constructed from at least one computer, including a processor and memory. The control unit 51 is connected to the light source module 22, the scanning motor 35, and the light detection module 45. The control unit 51 controls the light source module 22 to generate a scanning beam BS for each light emission period. At the same time, the control unit 51 controls the scanning motor 35 to control the reflection by the scanning mirror 32 synchronized with the light emission from the light source module 22. Furthermore, the control unit 51 processes the detection signals output from the light detection module 45 in accordance with the light emission from the light source module 22 and the reflection by the scanning mirror 32 to generate detection data that represents targets detected in the external scanning area AS.

[0037] Next, the detailed configuration of the light projection unit 21 will be described.

[0038] As shown in Figures 2, 5, and 6, in the light projection unit 21, the light projection light source module 22 and the light projection lens module 26 are arranged facing each other in the Z-axis direction along the light projection optical axis POA that guides the scanning beam BS. In the light projection light source module 22, the light projection holder 221 forms a light projection bonding surface 222 with an end face that faces the light projection lens module 26 in the Z-axis direction. In the light projection lens module 26, the light projection lens barrel 261 forms a light projection bonding surface 262 with an end face that faces the light projection light source module 22 in the Z-axis direction.

[0039] In the light projection unit 21, an adhesive 210 is interposed between the light projection bonding surface 222 of the light projection holder 221 and the light projection bonding surface 262 of the light projection lens barrel 261, continuously around the entire circumference of the light projection axis POA. The adhesive 210 is a UV-curing type that can be cured by either UV irradiation or heating, and is preferably an epoxy resin.

[0040] The light-emitting adhesive surfaces 222, 262 of the light-emitting holder 221 and the light-emitting tube 261 form a light-emitting gap 212 between them, where adhesive material 210 is placed. The light-emitting gap 212 is defined around the entire circumference of the light-emitting optical axis POA between the light-emitting adhesive surfaces 222, 262. The portions of each light-emitting adhesive surface 222, 262 that define the light-emitting gap 212 are formed as flat surfaces substantially perpendicular to the geometric central axes of each module 22, 26 (hereinafter simply referred to as the geometric central axes of modules 22, 26), which ideally coincide with the light-emitting optical axis POA in the design. These light-emitting adhesive surfaces 222, 262 are continuously bonded to each other around the light-emitting optical axis POA via adhesive material 210 that fills the light-emitting gap 212 in the Z-axis direction.

[0041] As shown in Figure 6, in the light-emitting holder 221, a surface including at least a portion of the light-emitting adhesive surface 222 is formed by an anti-reflective coating 225 covering the metal substrate 224. In the light-emitting lens barrel 261, a surface including the entire light-emitting adhesive surface 262 and the inner circumferential surface is formed by an anti-reflective coating 265 covering the metal substrate 264. The metal substrates 224 and 264 forming the light-emitting holder 221 and the light-emitting lens barrel 261 are made of the same or different silicon-containing aluminum alloy, particularly in the optical sensor 10. Furthermore, the anti-reflective coatings 225 and 265 covering the light-emitting holder 221 and the light-emitting lens barrel 261 are oxide films, preferably anodic oxide films, formed using the aluminum alloy of the corresponding metal substrates 224 and 264 as the base material.

[0042] Here, for example, in the optical sensor 10 in which the metal base material 224 of the light projection holder 221 is formed from a heterogeneous die-cast material with respect to the light projection barrel 261 in which the metal base material 264 is formed from a homogeneous wrought material, the light projection holder 221, which is one of the elements 261 and 221, is selected as a structural element having a specific structure. Therefore, as shown in FIGS. 6 and 7, a set of a rough surface adhesive portion 226 and a film surface adhesive portion 227 is formed on the light projection adhesive surface 222 of the light projection holder 221, each extending along the entire circumference around the light projection optical axis POA.

[0043] The rough surface adhesive portion 226 is formed in a rough surface state composed of a group of fine irregularities, and is entirely covered by the adhesive 210. Therefore, in the light projection holder 221, the anti-reflection film 225 is removed over the film thickness direction by laser cleaning treatment on the light projection adhesive surface 222, whereby the rough surface adhesive portion 226 is preferably formed by the metal base material 224 exposed after being roughened into a rough surface state. Alternatively, as shown in a modification in FIG. 8, the anti-reflection film 225 is roughened by laser polishing treatment on the light projection adhesive surface 222, whereby the rough surface adhesive portion 226 is preferably formed by the anti-reflection film 225 in a rough surface state that remains as a thinner film than the film surface adhesive portion 227 which substantially has the film thickness at the time of film formation as described later. In any of the cases of FIGS. 7 and 8, it is preferable that the porous structure is exposed on the surface of the rough surface adhesive portion 226 by laser cleaning treatment or laser polishing treatment, whereby the adhesive strength by the adhesive 210 is enhanced. Further, here, the porous structure is more preferably a nanoscale structure in terms of enhancing adhesive strength. Such a strength effect is effective particularly in the case of FIG. 7 where the effect is remarkable.

[0044] As shown in FIG. 7, the rough surface adhesive portion 226 of the light projection holder 221 has an annular shape forming straight portions 226b connected in a quadrilateral shape by corner portions 226a curved in a substantially arc shape when viewed in the Z-axis direction along the light projection optical axis POA. Therefore, particularly in the rough surface adhesive portion 226, the width Wa of each corner portion 226a that comes into contact with the adhesive 210 in the radial direction orthogonal to the light projection optical axis POA is set to be equal to or larger than the width Wb of each straight portion 226b that comes into contact with the adhesive 210 in the radial direction.

[0045] As shown in FIGS. 6 and 7, around the light projection optical axis POA of the translucent holder 221, the film surface adhesive portion 227 is formed on the radially inner peripheral side relative to the rough surface adhesive portion 226 along the inner peripheral edge of the portion 226. Here, the film surface adhesive portion 227 of the light projection holder 221 corresponds to an annular portion in contact with the adhesive 210 in the anti-reflection film 225 where a substantial film thickness during film formation is secured on the inner peripheral side of the rough surface adhesive portion 226. Here, as shown in FIG. 7, in the first embodiment, the total contact area S1 between the film surface adhesive portion 227 and the adhesive 210 is set to be smaller than the total contact area S2 between the rough surface adhesive portion 226 and the adhesive 210.

[0046] Among the manufacturing methods for manufacturing the optical sensor 10, in the manufacturing method of the light projection unit 21 described so far, first, as shown in FIG. 9, the light projection holder 221 is set on the lower side in the gravity direction than the light projection lens barrel 261, and the uncured adhesive 210 is filled into the light projection gap 212.

[0047] Next, ultraviolet light controlled to a wavelength such as 300 to 450 nm, for example, is irradiated onto the adhesive 210 from the outer peripheral side of the light projection gap 212 around the light projection optical axis POA. At this time, the ultraviolet irradiation may be performed simultaneously over the entire area around the light projection optical axis POA by an ultraviolet irradiation device surrounding the entire area. Alternatively, the ultraviolet irradiation may be performed sequentially for each driven position by driving the ultraviolet irradiation device over the entire area around the light projection optical axis POA.

[0048] Thus, for example, as shown in FIG. 10, in a region α covering the entire area of the corner portion 226a, the adhesive 210 is temporarily cured by ultraviolet irradiation, while uncured adhesive 210 remains in a region β that protrudes from the region α to the inner peripheral side of the rough surface adhesive portion 226 and covers the film surface adhesive portion 227. At the same time, for example, as shown in FIG. 11, in a region δ that protrudes from a region γ covering the entire area of the straight portion 226b to the inner peripheral side of the rough surface adhesive portion 226 and covers the entire area of the film surface adhesive portion 227, the adhesive 210 is temporarily cured by ultraviolet irradiation.

[0049] Furthermore, the adhesive 210 is heat-treated in the heating chamber. As a result, for example as shown in Figure 10, in region α covering the entire area of ​​the corner portion 226a, the adhesive 210 is completely cured by heating after UV irradiation, while in region β extending beyond region α towards the inner circumference of the rough surface adhesive portion 226 and covering the film surface adhesive portion 227, the uncured adhesive 210 is completely cured by heating alone. At the same time, for example as shown in Figure 11, in region γ covering the entire area of ​​the straight portion 226b and extending beyond the inner circumference of the rough surface adhesive portion 226 to cover the entire area of ​​the film surface adhesive portion 227, the adhesive 210 is completely cured by heating after UV irradiation. Thus, the adhesive strength is higher in region β than in region δ, and even higher in regions α and γ than in region β.

[0050] Next, the detailed configuration of the light receiving unit 41 will be described.

[0051] As shown in Figures 2, 12, and 13, in the light receiving unit 41, the light receiving detection module 45 and the light receiving lens module 42 are arranged facing each other in the Z-axis direction along the light receiving optical axis ROA that guides the scanning beam BS. In the light receiving detection module 45, the light receiving holder 451 forms a light receiving adhesion surface 452 with an end face that faces the light receiving lens module 42 in the Z-axis direction. In the light receiving lens module 42, the light receiving lens barrel 421 forms a light receiving adhesion surface 422 with an end face that faces the light receiving detection module 45 in the Z-axis direction.

[0052] Between the light-receiving adhesive surface 452 of the light-receiving holder 451 and the light-receiving adhesive surface 422 of the light-receiving lens barrel 421, an adhesive material 410 of the same type as that used on the light-emitting unit 21 side is interposed, continuously around the entire circumference of the light-receiving optical axis ROA. That is, the adhesive material 410 is also a UV-curing type, and is preferably an epoxy resin.

[0053] The light-receiving adhesive surfaces 452 and 422 of the light-receiving holder 451 and the light-receiving lens barrel 421 form a light-receiving gap 412 between them, where adhesive material 410 is placed. The light-receiving gap 412 is defined around the entire circumference of the light-receiving optical axis ROA between the light-receiving adhesive surfaces 452 and 422. The portions of each light-receiving adhesive surface 452 and 422 that define the light-receiving gap 412 are formed as flat surfaces substantially orthogonal to the geometric central axes of each module 45 and 42 (hereinafter simply referred to as the geometric central axes of modules 45 and 42), which ideally coincide with the light-receiving optical axis ROA in the design. These light-receiving adhesive surfaces 452 and 422 are continuously bonded to each other around the light-receiving optical axis ROA via adhesive material 410 that fills the light-receiving gap 412 in the Z-axis direction.

[0054] As shown in Figure 13, in the light-receiving holder 451, a surface including at least a portion of the light-receiving adhesive surface 452 is formed by an anti-reflective coating 455 covering the metal substrate 454. In the light-receiving lens barrel 421, a surface including the entire light-receiving adhesive surface 422 and the inner circumferential surface is formed by an anti-reflective coating 425 covering the metal substrate 424. The metal substrates 454 and 424 forming the light-receiving holder 451 and the light-receiving lens barrel 421 are made of the same or different silicon-containing aluminum alloy, particularly in the optical sensor 10, similar to the light-emitting unit 21. Furthermore, the anti-reflective coatings 455 and 425 covering the light-receiving holder 451 and the light-receiving lens barrel 421 are oxide films, preferably anodic oxide films, formed on the aluminum alloy of the corresponding metal substrates 454 and 424, respectively, similar to the light-emitting unit 21.

[0055] Here, for example, in the optical sensor 10 in which the metal base material 454 of the light-receiving holder 451 is formed from a heterogeneous die-cast material, while the metal base material 424 of the light-receiving lens barrel 421 is formed from a homogeneous wrought material, the light-receiving holder 451, which is one of these elements 421 and 451, is selected as a structural element of a specific structure. As shown in Figures 13 and 14, the light-receiving adhesive surface 452 of the light-receiving holder 451 has a set of rough surface adhesive portion 456 and film surface adhesive portion 457, each extending around the entire circumference of the light-receiving optical axis ROA.

[0056] The rough surface bonding portion 456 is formed to a rough surface state by a laser cleaning or laser polishing process similar to that of the rough surface bonding portion 226 of the light projection holder 221, and is covered over its entire surface by the adhesive 410. That is, similar to the light projection unit 21 side, the rough surface bonding portion 456 may be formed from an exposed rough surface metal substrate 454, or from a light-reflection anti-reflective film 455 that remains in a thinner film than the film surface bonding portion 457 which will be the film thickness at the time of film formation, as described later.

[0057] As shown in Figure 14, the rough surface adhesive portion 456 of the light receiving holder 451 exhibits an annular shape when viewed in the Z-axis direction along the light receiving optical axis ROA, with straight portions 456b connected in a quadrilateral manner by substantially arc-shaped curved corner portions 456a. In particular, in the rough surface adhesive portion 456, the width wa of each corner portion 456a that contacts the adhesive material 410 in the radial direction perpendicular to the light receiving optical axis ROA is set to be greater than or equal to the width wb of each straight portion 456b that contacts the adhesive material 410 in the same radial direction.

[0058] As shown in Figures 13 and 14, the film surface adhesive portion 457 of the light receiving holder 451 is formed radially on the inner circumference side of the rough surface adhesive portion 456, along the inner edge of the rough surface adhesive portion 456, around the light receiving optical axis ROA. Here, the film surface adhesive portion 457 of the light receiving holder 451 corresponds to the annular portion of the anti-reflective film 455, where the film thickness during film formation is substantially ensured on the inner circumference side of the rough surface adhesive portion 456, that is in contact with the adhesive 410. Here, as shown in Figure 14, in the first embodiment, the total contact area s1 with the adhesive 410 at the film surface adhesive portion 457 is set to be smaller than the total contact area s2 with the adhesive 410 at the rough surface adhesive portion 456.

[0059] Of the manufacturing methods for the optical sensor 10, the manufacturing method for the light receiving unit 41 described above is carried out in accordance with the manufacturing method for the light emitting unit 21 described above, so a detailed explanation is omitted.

[0060] (Effects) The effects of the first embodiment described above are explained below.

[0061] In the first embodiment, the light-emitting lens barrel 261, which holds the light-emitting lens member 260 in the light-emitting lens module 26 and defines the optical path of the scanning beam BS, is held in the light-emitting light source module 22, which is bonded to the light-emitting holder 221 around the light-emitting optical axis POA via adhesive 210. In the first embodiment, around the light-emitting optical axis POA of the structural element, which is either the metal light-emitting lens barrel 261 or the light-emitting holder 221, a film surface adhesive portion 227 covered with an anti-reflective film 225, to which the adhesive 210 covering the rough surface adhesive portion 226 protrudes and adheres, is formed on the inner circumference side of the rough surface adhesive portion 226. This makes it possible to achieve both the stray light suppression effect on the light-emitting unit 21 side by the anti-reflective film 225 of the film surface adhesive portion 227 on the inner circumference side and the high adhesive strength due to adhesion to the rough surface adhesive portion 226 on the outer circumference side at the adhesive interface between the light-emitting lens barrel 261 and the light-emitting holder 221.

[0062] In the first embodiment, the light-receiving lens barrel 421, which holds the light-receiving lens member 420 in the light-receiving lens module 42 and defines the optical path of the scanning beam BS, is held in a light-receiving holder 451 which is bonded to the light-receiving optical axis ROA in the light-receiving detection module 45 via adhesive 410. In the first embodiment, around the light-receiving optical axis ROA of the structural element which is either the metal light-receiving lens barrel 421 or the light-receiving holder 451, a film surface bonding portion 457 covered with an anti-reflective film 455, to which the adhesive 410 covering the rough surface bonding portion 456 protrudes and is bonded, is formed on the inner circumference side of the rough surface bonding portion 456. According to this, at the adhesive interface between the light-receiving lens barrel 421 and the light-receiving holder 451, it is possible to achieve both the stray light suppression effect on the light-receiving unit 41 side by the light-reflection-preventing film 455 of the film surface adhesive portion 457 on the inner circumference side, and high adhesive strength due to adhesion to the rough surface adhesive portion 456 on the outer circumference side.

[0063] According to the first embodiment, in both the light-emitting unit 21 side and the light-receiving unit 41 side, straight sections 226b, 456b connected by corner sections 226a, 456a are formed on the curved rough surface adhesive sections 226, 456. In these rough surface adhesive sections 226, 456, the widths Wa, wa of the corner sections 226a, 456a are set to be greater than or equal to the widths Wb, wb of the straight sections 226b, 456b. This makes it possible to stabilize the structure by ensuring high adhesive strength, especially with the wide corner sections 226a, 456a, while also achieving the stray light suppression effect of the light-reflection-preventing films 225, 455 covering the film surface adhesive sections 227, 457.

[0064] According to the first embodiment, in both the light-emitting unit 21 side and the light-receiving unit 41 side, the entire area of ​​the rough surface adhesive portion 226, 456 is covered with adhesive material 210, 410. This makes it possible to maximize the adhesive strength at the rough surface adhesive portion 226, 456 and ensure structural stability while maintaining the stray light suppression effect of the light-reflection anti-reflective film 225, 455 covering the film surface adhesive portion 227, 457.

[0065] (Second Embodiment) The second embodiment is a modification of the first embodiment.

[0066] As shown in Figures 15 and 16, in the light-emitting unit 2021 of the second embodiment, the light-emitting adhesive surface 2222 of the light-emitting holder 2221 has sets of rough surface adhesive portions 226 and film surface adhesive portions 227, 2227, each extending around the entire circumference of the light-receiving optical axis ROA. Around the light-emitting optical axis POA of the light-emitting holder 2221, the film surface adhesive portion 2227 is formed radially outward from the rough surface adhesive portion 226, along the outer edge of the portion 226. Here, the film surface adhesive portion 2227 of the light-emitting holder 2221 corresponds to the annular portion of the anti-reflective film 225, which has a substantially sufficient film thickness during film formation on the outer circumference side of the rough surface adhesive portion 226, that is in contact with the adhesive 210. Therefore, as shown in Figure 16, in the second embodiment, the total contact area S1 with the adhesive 210 at both the film surface adhesive portions 227 and 2227 is set to be larger than the total contact area S2 with the adhesive 210 at the rough surface adhesive portion 226.

[0067] According to this method of manufacturing the light projection unit 2021, for example as shown in Figure 17, the adhesive 210 partially hardens upon ultraviolet irradiation in a region ε that extends from a region α1 covering a part of the corner portion 226a outward towards the outer circumference of the rough surface adhesive portion 226 and covers the entire area of ​​the film surface adhesive portion 2227. At the same time, as shown in Figure 17, for example, unhardened adhesive 210 remains in a region β that extends from a region α2 covering the remaining part of the corner portion 226a outward towards the inner circumference of the rough surface adhesive portion 226 and covers the entire area of ​​the film surface adhesive portion 227. Furthermore, as shown in Figure 18, for example, the adhesive 210 partially hardens upon ultraviolet irradiation in a region γ that extends from a region γ covering the entire area of ​​the straight portion 226b outward towards the outer circumference of the rough surface adhesive portion 226 and covers the entire area of ​​the film surface adhesive portion 2227. In addition, as shown in Figure 18, for example, uncured adhesive material 210 remains in the region δ that extends beyond the region γ of the straight portion 226b towards the inner circumference of the rough surface adhesive portion 226 and covers the entire area of ​​the film surface adhesive portion 227.

[0068] Furthermore, according to the manufacturing method of the light projection unit 2021, for example as shown in Figure 17, in region α1 which covers a part of the corner portion 226a, and region ε which extends outward towards the outer circumference of the rough surface adhesive portion 226 and covers the entire area of ​​the film surface adhesive portion 2227, the adhesive 210 is completely cured by heating after ultraviolet irradiation. At the same time, for example as shown in Figure 17, in region α2 which covers the remaining part of the corner portion 226a, and region β which extends outward towards the inner circumference of the rough surface adhesive portion 226 and covers the entire area of ​​the film surface adhesive portion 227, the adhesive 210 is completely cured by heating alone. Furthermore, for example as shown in Figure 18, in region γ which covers the entire area of ​​the straight portion 226b, and region ζ which extends outward towards the outer circumference of the rough surface adhesive portion 226 and covers the entire area of ​​the film surface adhesive portion 2227, the adhesive 210 is completely cured by heating after ultraviolet irradiation. In addition, as shown in Figure 18, for example, in region δ, which extends beyond region γ of the straight portion 226b towards the inner circumference of the rough surface adhesive portion 226 and covers the entire area of ​​the film surface adhesive portion 227, the adhesive 210 is completely cured by heating alone. As a result, the adhesive strength is higher in regions β and δ than in regions ε and ζ, higher in regions α1 and γ than in regions β and δ, and even higher in region α2 than in regions α1 and γ.

[0069] As shown in Figures 19 and 20, in the light-receiving unit 2041 of the second embodiment, the light-receiving adhesive surface 2452 of the light-receiving holder 2451 has sets of rough surface adhesive portions 456 and film surface adhesive portions 457, 2457, each extending around the entire circumference of the light-receiving optical axis ROA. Around the light-receiving optical axis ROA of the light-receiving holder 2451, the film surface adhesive portion 2457 is formed radially outward from the rough surface adhesive portion 456, along the outer edge of the said portion 456. Here, the film surface adhesive portion 2457 of the light-receiving holder 2451 corresponds to the annular portion of the anti-reflective film 455, which has substantially the same film thickness as when the film was formed, that is in contact with the adhesive 410 on the outer circumference side of the rough surface adhesive portion 456. Therefore, as shown in Figure 20, in the second embodiment, the total contact area s1 with the adhesive 410 at both the film surface adhesive portions 457 and 2457 is set to be larger than the total contact area s2 with the adhesive 410 at the rough surface adhesive portion 456.

[0070] Since this method of manufacturing the light-receiving unit 2041 achieves both partial and complete curing in accordance with the method of manufacturing the light-emitting unit 2021 described above, a detailed explanation will be omitted.

[0071] As described above, according to the second embodiment, around the optical axis POA of one of the structural elements, the light-emitting lens barrel 261 and the light-emitting holder 2221, a film-surface adhesive portion 2227 is formed on the outer circumference side of the rough surface adhesive portion 226. This makes it possible to enhance the stray light suppression effect on the light-emitting unit 2021 side, while maintaining the adhesive strength of the rough surface adhesive portion 226, by using the light-reflection-preventing film 225 that covers not only the film-surface adhesive portion 227 on the inner circumference side of the rough surface adhesive portion 226 but also the film-surface adhesive portion 2227 on the outer circumference side.

[0072] Furthermore, according to the second embodiment, a film surface adhesive portion 2457 is formed on the outer circumference side of the rough surface adhesive portion 456, around the optical axis ROA of one of the structural elements, which is either the light-receiving lens barrel 421 or the light-receiving holder 451. This makes it possible to enhance the stray light suppression effect on the light-receiving unit 2041 side, while maintaining compatibility with the adhesive strength of the rough surface adhesive portion 456, by using not only the film surface adhesive portion 2457 on the inner circumference side of the rough surface adhesive portion 456, but also the light-reflection-preventing film 455 covering the film surface adhesive portion 2457 on the outer circumference side.

[0073] (Third Embodiment) The third embodiment is a modification of the second embodiment.

[0074] As shown in Figures 21 and 22, in the third embodiment of the light projection unit 3021, grooves 3228 and 3229 are provided in the anti-reflective film 225 at each film surface adhesive portion 227, 2227 of the light projection holder 3221. The grooves 3228 and 3229 of each film surface adhesive portion 227, 2227 are formed in an annular groove shape that extends around the entire circumference of the light projection optical axis POA. Therefore, in the light projection holder 3221, it is preferable that the grooves 3228 and 3229 are formed by removing the anti-reflective film 225 by laser grooving treatment on the light projection adhesive surface 3222 so that it remains in the film thickness direction of the anti-reflective film 225 or remains thinner than the film surface adhesive portions 227, 2227.

[0075] In this light-emitting holder 3221, on the inner circumference side of the rough surface bonding portion 226, the adhesive 210 in the film surface bonding portion 227 protrudes into the groove portion 3228 and adheres thereto. As a result, the inside of the groove portion 3228 is filled with the inner circumference of the adhesive 210. On the other hand, on the outer circumference side of the light-emitting holder 3221, on the outer circumference side of the rough surface bonding portion 226, the adhesive 210 in the film surface bonding portion 2227 protrudes into the groove portion 3229 and adheres thereto. As a result, the inside of the groove portion 3229 is filled with the outer circumference of the adhesive 210.

[0076] As shown in Figures 23 and 24, in the light receiving unit 3041 of the third embodiment, grooves 3458 and 3459 are provided in the anti-reflective film 455 at each of the film surface adhesive portions 457 and 2457 of the light receiving holder 3451. The grooves 3458 and 3459 of each film surface adhesive portion 457 and 2457 are formed in an annular groove shape that extends around the entire circumference of the light receiving optical axis ROA. Therefore, in the light receiving holder 3451, it is preferable that the grooves 3458 and 3459 are formed by removing the anti-reflective film 455 by laser grooving treatment on the light receiving adhesive surface 3452 so that it remains thinly across the film thickness direction of the anti-reflective film 455 or remains thinner than the film surface adhesive portions 457 and 2457.

[0077] In this light-receiving holder 3451, on the inner circumference side of the rough surface bonding portion 456, the adhesive 410 in the film surface bonding portion 457 protrudes into the groove portion 3458 and adheres thereto. As a result, the inside of the groove portion 3458 is filled with the inner peripheral edge of the adhesive 410. On the other hand, on the outer circumference side of the light-receiving holder 3451, on the outer circumference side of the rough surface bonding portion 456, the adhesive 410 in the film surface bonding portion 2457 protrudes into the groove portion 3459 and adheres thereto. As a result, the inside of the groove portion 3459 is filled with the outer peripheral edge of the adhesive 410.

[0078] As described above, according to the third embodiment, in both the light-emitting unit 21 side and the light-receiving unit 41 side, the adhesive 210, 410 extends from the rough surface adhesive portion 226, 456 and adheres to the grooves 3228, 3229, 3458, 3459 provided in the light-reflection-preventing films 225, 455 of the film surface adhesive portion 227, 2227, 457, 2457. This allows the flow of the adhesive 210, 410 before curing to be blocked by the grooves 3228, 3229, 3458, 3459, thereby constructing an appropriate adhesive interface spanning from the rough surface adhesive portion 226, 456 to the film surface adhesive portion 227, 2227, 457, 2457. Therefore, it becomes possible to reliably achieve both the stray light suppression effect of the anti-reflective coatings 225 and 455 on the film surface adhesive portions 227, 2227, 457, and 2457, and the high adhesive strength of the rough surface adhesive portions 226 and 456 with a rough surface condition.

[0079] (Other Embodiments) Although several embodiments have been described above, this disclosure is not to be construed as being limited to those embodiments, and can be applied to various embodiments and combinations without departing from the spirit of this disclosure.

[0080] In the modifications of the first to third embodiments, as shown in Figure 25 as a representative modification of the first embodiment, the target structural element on which the rough surface adhesive portion 226 and the film surface adhesive portions 227, 2227 are provided may be a light-emitting lens barrel 261 instead of the light-emitting holders 221, 2221, 3221. In the modifications of the first to third embodiments, as shown in Figure 26 as a representative modification of the first embodiment, the target structural element on which the rough surface adhesive portion 226 and the film surface adhesive portions 227, 2227 are provided may be a light-emitting lens barrel 261 in addition to the light-emitting holders 221, 2221, 3221.

[0081] In the modified versions of the first to third embodiments, as shown in Figure 27 as a representative modified version of the first embodiment, the target structural element on which the rough surface adhesive portion 456 and the film surface adhesive portions 457, 2457 are provided may be a light-receiving lens barrel 421 instead of light-receiving holders 451, 2451, 3451. In the modified versions of the first to third embodiments, as shown in Figure 28 as a representative modified version of the first embodiment, the target structural element on which the rough surface adhesive portion 456 and the film surface adhesive portions 457, 2457 are provided may be a light-receiving lens barrel 421 in addition to light-receiving holders 451, 2451, 3451.

[0082] In a modified version of the first embodiment, a groove 3228 filled by the inner periphery of the adhesive 210 may be provided in the film surface adhesive portion 227, in accordance with the third embodiment. In a modified version of the first embodiment, a groove 3458 filled by the inner periphery of the adhesive 410 may be provided in the film surface adhesive portion 457, in accordance with the third embodiment.

[0083] In a modified version of the first embodiment, the rough surface adhesive portions 226 and 456 may be covered with adhesive 210 and 410, but limited to a portion including the inner periphery on the side of the film surface adhesive portions 227 and 457. In modified versions of the first to third embodiments, the rough surface adhesive portion 226 may be provided limited to a portion around the light projection axis POA, as shown in Figure 29 as a representative example of the modified version of the second embodiment. In particular, in the example shown in Figure 29, the rough surface adhesive portion 226 is provided limited to all corners 226a, so that the inner periphery film surface adhesive portion 227 and the outer periphery film surface adhesive portion 2227 are radially connected between each corner 226a. In accordance with this modified version in Figure 29, in modified versions of the first to third embodiments, the rough surface adhesive portion 456 may be provided limited to a portion around the light receiving axis ROA.

[0084] In the modified versions of the first to third embodiments, the widths Wa, wa of each corner portion 226a, 456a may be set to be substantially the same as the widths Wb, wb of each straight portion 226b, 456b. In the modified versions of the first to third embodiments, the widths Wa, wa of each corner portion 226a, 456a may be set to be smaller than the widths Wb, wb of each straight portion 226b, 456b.

[0085] In a modified version of the first embodiment, as shown in Figure 30, the total contact area S1 with the adhesive 210 at the film surface adhesive portion 227 may be set to be larger than the total contact area S2 with the adhesive 210 at the rough surface adhesive portion 226. In a modified version of the first embodiment, following this modified version of Figure 30, the total contact area s1 with the adhesive 410 at the film surface adhesive portion 457 may be set to be larger than the total contact area s2 with the adhesive 410 at the rough surface adhesive portion 456. On the other hand, in modified versions of the second and third embodiments, following the first embodiment, the total contact areas S1, s1 with the adhesive 210, 410 at the film surface adhesive portions 227, 2227, 457, 2457 may be set to be smaller than the total contact areas S2, s2 with the adhesive 210, 410 at the rough surface adhesive portions 226, 456.

[0086] In a modified version of the first embodiment, as shown in Figure 31, in region α1 covering a part of the corner portion 226a, the adhesive 210 partially hardens with ultraviolet irradiation and then fully hardens with heating. Meanwhile, in region β extending from region α2 covering the remaining part of the corner portion 226a to the inner circumference of the rough surface adhesive portion 226 and covering the entire area of ​​the film surface adhesive portion 227, the adhesive 210, which remains unhardened after ultraviolet irradiation, may be fully hardened by heating alone. In this modified version, furthermore, in region γ covering the entire area of ​​the straight portion 226b shown in Figure 11, the adhesive 210 partially hardens with ultraviolet irradiation and then fully hardens with heating. Meanwhile, in region δ extending further than region γ to the inner circumference of the rough surface adhesive portion 226 and covering the entire area of ​​the film surface adhesive portion 227, the adhesive 210, which remains unhardened after ultraviolet irradiation, may be fully hardened by heating alone. The adhesive strength in the above modified versions is higher in regions α1 and γ than in regions β and δ, and even higher in region α2 than in regions α1 and γ.

[0087] In the modified versions of the first to third embodiments, the Y-axis direction along the horizontal direction and the X-axis direction along the vertical direction may be defined. In the modified versions of the first to third embodiments, the moving object to which the optical sensor 10 is applied may be, for example, a mobile robot whose movement can be remotely controlled. In the modified versions of the first to third embodiments, the object to which the optical sensor 10 is applied may be something other than a moving object, such as a stationary structure.

[0088] (Addendum) This specification discloses several technical concepts and several combinations thereof, as listed below.

[0089] (Technical Concept 1) An optical sensor (10) that projects a scanning beam (BS) to scan the outside world and receives the scanning beam reflected from the outside world, comprising: a light projection source module (22) that projects the scanning beam; a light projection lens module (26) that guides the scanning beam from the light projection source module toward the outside world along the light projection axis (POA); and an adhesive material (210) interposed between the light projection source module and the light projection lens module which are mutually opposed along the light projection axis, wherein the light projection lens module has a metal light projection tube (261) that holds a light projection lens member (260) and defines the optical path of the scanning beam; and the light projection source module has a metal light projection holder (221, 2221, 3221) that is bonded to the light projection tube via the adhesive material around the light projection axis. An optical sensor wherein, around the optical axis of a structural element which is at least one of the light-emitting lens barrel and the light-emitting holder, a film surface adhesive portion (227) is formed on the inner circumference side of the rough surface adhesive portion (226) in a rough surface state, and is covered with an anti-reflective film (225) to which the adhesive covering the rough surface adhesive portion protrudes and adheres.

[0090] (Technical idea 2) The optical sensor according to technical idea 1, wherein the film surface adhesive portion (2227) is formed on the outer circumference side of the rough surface adhesive portion, around the optical axis of the structural element which is at least one of the light-emitting lens barrel and the light-emitting holder (2221, 3221).

[0091] (Technical Concept 3) The device comprises: a light-receiving detection module (45) that detects the outside world by receiving the scanning beam; a light-receiving lens module (42) that guides the scanning beam from the outside world side toward the light-receiving detection module along the light-receiving optical axis (ROA); and an adhesive material (410) interposed between the light-receiving detection module and the light-receiving lens module which are mutually opposed along the light-receiving optical axis; the light-receiving lens module has a metal light-receiving lens barrel (421) that holds a light-receiving lens member (420) and defines the optical path of the scanning beam; and the light-receiving detection module has metal light-receiving holders (451, 2451, 3451) that are bonded to the light-receiving lens barrel via the adhesive material (410) around the light-receiving optical axis. The optical sensor according to technical concept 1, wherein, around the optical axis of the light-receiving element, which is at least one of the light-receiving lens barrel and the light-receiving holder, the film surface adhesive portion (457) covered with the light-reflection-preventing film (455) is formed on the inner circumference side of the rough surface adhesive portion (456) in the rough surface state.

[0092] (Technical Concept 4) An optical sensor (10) that emits a scanning beam (BS) to scan the outside world and receives the scanning beam reflected from the outside world, comprising: a light-receiving detection module (45) that detects the outside world by receiving the scanning beam; a light-receiving lens module (42) that guides the scanning beam from the outside world side toward the light-receiving detection module side along the light-receiving optical axis (ROA); and an adhesive material (410) interposed between the light-receiving detection module and the light-receiving lens module which are mutually opposed along the light-receiving optical axis, wherein the light-receiving lens module has a metal light-receiving lens barrel (421) that holds a light-receiving lens member (420) and defines the optical path of the scanning beam; and the light-receiving detection module has a metal light-receiving holder (451, 2451, 3451) that is bonded to the light-receiving lens barrel via the adhesive material around the light-receiving optical axis. An optical sensor in which, around the optical axis of a structural element which is at least one of the light-receiving lens barrel and the light-receiving holder, a film surface adhesive portion (457) is formed on the inner circumference side of the rough surface adhesive portion (456) which is in a rough surface state, and is covered with an anti-reflective film (455) to which the adhesive covering the rough surface adhesive portion protrudes and adheres.

[0093] (Technical idea 5) The optical sensor according to technical idea 4, wherein the film surface adhesive portion (2457) is formed on the outer circumference side of the rough surface adhesive portion, around the light-receiving optical axis of the structural element which is at least one of the light-receiving lens barrel and the light-receiving holder (2451, 3451).

[0094] (Technical Idea 6) The adhesive material covers the entire area of ​​the rough surface adhesive portion, as described in any one of Technical Ideas 1 to 5.

[0095] (Technical Idea 7) The optical sensor according to any one of Technical Ideas 1 to 6, wherein grooves (3228, 3229, 3458, 3459) are provided in the anti-reflective film at the film surface bonding portion, and the adhesive material protrudes from the rough surface bonding portion to the grooves and bonds thereto.

[0096] (Technical Idea 8) An optical sensor according to any one of Technical Ideas 1 to 7, in which annular rough surface adhesive portion forms straight portions (226b, 456b) connected by corner portions (226a, 456a), wherein the width of the corner portion is set to be greater than or equal to the width of the straight portion.

[0097] (Technical Idea 9) The rough surface adhesive portion is formed from a metal substrate in a rough surface state exposed in the structural element, as described in any one of Technical Ideas 1 to 8.

[0098] (Technical idea 10) The optical sensor according to any one of technical ideas 1 to 9, wherein the rough surface bonding portion is formed by the light-reflection-preventing film that remains in a thinner film state than the film surface bonding portion in the structural element.

Claims

1. An optical sensor (10) that emits a scanning beam (BS) to scan the outside world and receives the scanning beam reflected from the outside world, comprising: a light source module (22) that projects the scanning beam; a light lens module (26) that guides the scanning beam from the light source module toward the outside world along the light projection axis (POA); and an adhesive (210) interposed between the light source module and the light projection lens module which are mutually opposed along the light projection axis, wherein the light projection lens module has a metal light projection tube (261) that holds a light projection lens member (260) and defines the optical path of the scanning beam; and the light source module has a metal light projection holder (221, 2221, 3221) that is bonded to the light projection tube via the adhesive around the light projection axis. An optical sensor wherein, around the optical axis of a structural element which is at least one of the light-emitting lens barrel and the light-emitting holder, a film surface adhesive portion (227) is formed on the inner circumference side of the rough surface adhesive portion (226) in a rough surface state, and is covered with an anti-reflective film (225) to which the adhesive covering the rough surface adhesive portion protrudes and adheres.

2. The optical sensor according to claim 1, wherein the film surface adhesive portion (2227) is formed on the outer circumference side of the rough surface adhesive portion, around the optical axis of the structural element which is at least one of the light-emitting lens barrel and the light-emitting holder (2221, 3221).

3. The device comprises: a light-receiving detection module (45) that detects the external environment by receiving the scanning beam; a light-receiving lens module (42) that guides the scanning beam from the external environment towards the light-receiving detection module along the light-receiving optical axis (ROA); and an adhesive material (410) interposed between the light-receiving detection module and the light-receiving lens module, which are mutually opposed along the light-receiving optical axis; the light-receiving lens module has a metal light-receiving lens barrel (421) that holds a light-receiving lens member (420) and defines the optical path of the scanning beam; and the light-receiving detection module has metal light-receiving holders (451, 2451, 3451) that are bonded to the light-receiving lens barrel via the adhesive material (410) around the light-receiving optical axis. The optical sensor according to claim 1, wherein, around the optical axis of the light-receiving element, which is at least one of the light-receiving lens barrel and the light-receiving holder, the film surface adhesive portion (457) covered with the light-reflection-preventing film (455) is formed on the inner circumference side of the rough surface adhesive portion (456) in the rough surface state.

4. An optical sensor (10) that emits a scanning beam (BS) to scan the outside world and receives the scanning beam reflected from the outside world, comprising: a light-receiving detection module (45) that detects the outside world by receiving the scanning beam; a light-receiving lens module (42) that guides the scanning beam from the outside world side toward the light-receiving detection module side along the light-receiving optical axis (ROA); and an adhesive material (410) interposed between the light-receiving detection module and the light-receiving lens module which are mutually opposed along the light-receiving optical axis, wherein the light-receiving lens module has a metal light-receiving lens barrel (421) that holds a light-receiving lens member (420) and defines the optical path of the scanning beam; and the light-receiving detection module has a metal light-receiving holder (451, 2451, 3451) that is bonded to the light-receiving lens barrel via the adhesive material around the light-receiving optical axis. An optical sensor in which, around the optical axis of a structural element which is at least one of the light-receiving lens barrel and the light-receiving holder, a film surface adhesive portion (457) is formed on the inner circumference side of the rough surface adhesive portion (456) which is in a rough surface state, and is covered with an anti-reflective film (455) to which the adhesive covering the rough surface adhesive portion protrudes and adheres.

5. The optical sensor according to claim 4, wherein the film surface adhesive portion (2457) is formed on the outer circumference side of the rough surface adhesive portion, around the optical axis of the structural element which is at least one of the light-receiving lens barrel and the light-receiving holder (2451, 3451).

6. The optical sensor according to any one of claims 1 to 5, wherein the adhesive covers the entire area of ​​the rough surface bonding portion.

7. The optical sensor according to any one of claims 1 to 5, wherein grooves (3228, 3229, 3458, 3459) are provided in the anti-reflective film at the film surface bonding portion, and the adhesive material protrudes from the rough surface bonding portion to the grooves and bonds thereto.

8. An optical sensor according to any one of claims 1 to 5, in which an annular rough surface adhesive portion forms straight portions (226b, 456b) connected by corner portions (226a, 456a), wherein the width of the corner portion is set to be greater than or equal to the width of the straight portion.

9. The optical sensor according to any one of claims 1 to 5, wherein the rough surface adhesive portion is formed from a metal substrate in a rough surface state exposed in the structural element.

10. The optical sensor according to any one of claims 1 to 5, wherein the rough surface adhesive portion is formed by the light-reflection-preventing film that remains in a rougher state as a thin film on the structural element than the film surface adhesive portion.

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