Optical scanning system and integrated optics module therefor

An optics module for an optical code scanner, the scanner having a scanning mechanism for generating a scan pattern and for directing return light reflected from an item being scanned, the optics module comprising:

• an-optics block;
• a laser source mounted on the optics block for emitting a laser beam along a first outgoing path;
• routing optics mounted on the optics block in the first outgoing path for receiving the laser beam and directing the laser beam along a second outgoing path;
• a first collection element disposed on a surface of the optics block in the second outgoing path, the first collection element including a center area through which the routing optics direct the laser beam out along the second outgoing path;
• and
• mounting connectors on the optics block configured to removably mount the optics module to the scanner in a fixed position such that (a) the scanning mechanism is located and precisely aligned in the second optical path for receiving the laser beam and scanning the laser beam over a scan angle and (b) the first collection element is located and precisely aligned with the scanning mechanism for collecting return light reflected from the scanning mechanism.

An optical scanning system for scanning a laser beam toward an item to be scanned and for collecting return laser light reflected from the item, comprising:

• a housing at least partially enclosing an interior;
• a window disposed in the housing;
• mounting fixtures on the interior of the housing;
• an interchangeable optics module comprising
• an optics block,
• a laser source mounted on the optics block for producing a laser beam,
• routing optics mounted on the optics block for routing the laser beam along an outgoing optical path, and
• a collection element mounted on the optics block for collecting laser light reflecting off the item,
• connectors on the optics block for removably mounting the optics module onto the mounting fixtures;
• a plurality of pattern mirrors mounted in the interior of the housing;
• a scanning mechanism, mounted in the interior of the housing and positioned in the outgoing optical path of the laser beam for scanning the laser beam across the pattern mirrors for projecting a scan pattern out through the window,
• wherein the optics module is constructed and arranged such that when the optics module is mounted onto the mounting fixtures, (a) the laser source and routing optics of the optics module optically align the laser beam along the optical path onto the scanning mechanism at a proper angle and position;
• and (b) the collection element is optically aligned with the scanning mechanism for receiving laser light reflected from the item being scanned.

A method of replacing a first optics module in an optical scanner with a second optics module, the scanner including a housing, a scanning mechanism mounted in the housing, and mounting fixtures mounted in the housing, comprising the steps of:

• accessing the first optics module;
• removing the first optics module from the mounting fixtures;
• providing the second optics module with optical components including a light beam source, beam routing optics and a collection element which are pre-aligned prior to installation of the second optics module into the scanner;
• removably mounting the second optics module onto the mounting fixtures, the mounting fixtures aligning the second optics module with the scanning mechanism without requiring additional alignment of optical components of the scanner.

A method of constructing an interchangeable optics module for an optical scanner, comprising the steps of

• providing the scanner with a housing, a scanning mechanism disposed in the housing, and internal module mounting fixtures disposed within the housing;
• providing the optics module with an optics block having complementary external mounting fixtures configured to removably mount to the internal module mounting fixtures in the housing;
• mounting a laser source onto the optics block, the laser source adapted to generate a laser beam along an optical path;
• mounting routing optics onto the optics block in the optical path;
• mounting a collection lens having an aperture therethrough onto the optics block;
• pre-aligning the routing optics with the laser source and the collection lens prior to installation of the optics block into the housing, such that the routing optics are adapted to receive a laser beam from the laser source and direct the laser beam out through the aperture in the collection lens at a predetermined angle and location onto the scanning mechanism when the optics module is installed in the housing.