Compact Scan Engine with Integral Circuit Board
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Solution Overview
Problem
Existing imaging-based bar code reader systems require expensive and space-consuming configurations due to the need for fold mirrors or flex circuits to connect the image sensor and circuit board, which increases manufacturing costs and size.
Innovation Solution
A compact scan engine design with an integral printed circuit board connected to both the illumination sources and the linear sensor, eliminating the need for fold mirrors and flex circuits by using surface mount technology and a transversely mounted circuit board, allowing for a more compact and cost-effective structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fold mirror or flex circuit is used to connect the image sensor and circuit board, then the optical path can be achieved, but the manufacturing cost increases and the device size becomes large
Solution Approach 1:
The circuit board is integrated directly with the illumination source and linear sensor array, eliminating the need for separate flex circuits or secondary circuit boards. This merging of components reduces the number of parts, simplifies assembly, and lowers manufacturing costs while maintaining all necessary electrical connections
2Volume of moving object
If a fold mirror or flex circuit is used to connect the image sensor and circuit board, then the optical path can be achieved, but the device occupies more space
Solution Approach 1:
By integrating the circuit board directly with the illumination source and linear sensor array in a compact arrangement, the overall device volume is reduced. The transverse mounting of the circuit board allows for efficient space utilization without requiring additional space for fold mirrors or flex circuits
Solution Approach 2:
The circuit board is mounted transversely (perpendicular) to the optical axis rather than parallel to it, utilizing a different spatial dimension. This dimensional change allows for more compact packaging of components and reduces the overall length of the device in the optical path direction
3Ease of manufacture
If the circuit board is positioned parallel to the optical axis, then the assembly is simple, but the device size increases
Solution Approach 1:
The circuit board is positioned perpendicular (transverse) to the optical axis instead of parallel to it. This dimensional reorientation allows the circuit board to be integrated more compactly within the device housing, reducing the overall device length while maintaining assembly simplicity through direct integration
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables a compact, low-cost scan engine that reduces manufacturing expenses and space requirements while maintaining effective barcode reading capabilities, suitable for various applications including handheld and stationary workstations.
Implementation Method 1
illumination sources for projecting light beams upon a target object
Implementation Method 2
a focusing lens that receives a reflected light from the target object and focuses a reflected image as it passes through the focusing lens along an optical axis
Implementation Method 3
a linear sensor that receives the reflected image from the focusing lens. The linear sensor provides a signal representing the reflected image
Data Source
AI summary
A scan engine (15) includes illumination sources (48, 50) for projecting a light beam (40) upon a target object, a focusing lens (44) that receives a reflected light (34) of the target object and focuses a reflected image (35) as it passes through the focusing lens (44) along an optical axis (A-A), and a linear sensor (46) that receives the reflected image (35) from the focusing lens (44). The linear sensor (46) provides a signal (59) representing the reflected image (34). A circuit board (16) is integrally connected to the illumination sources (48, 50) and the linear sensor (46).