Lens carrier and optical module for a light curtain and fabrication method

1. An optical module for a light curtain associated with monitoring a protective field, said optical module comprising:

a lens carrier having:

at least one lens for focusing a radiation beam associated with the light curtain;

a lens mask having at least one opening for shaping the radiation beam to have a predetermined aperture; and

wherein said lens carrier is formed by overmolding said lens mask with a transparent material; and

a module body for mounting said lens carrier and a radiation transmitter/receiver carrier that comprises at least one transmitter and/or receiver for transmitting and/or receiving said radiation and positionally associated with the lens carrier; and

wherein said module body comprises a stabilization element that is integrated into the module body for enhancing mechanical stability of the module body and wherein said lens mask and said stabilization element are fabricated from an electrically conductive material for forming an electromagnetic shielding.

2. The optical module according to claim 1 , wherein said lens mask is fabricated from a stamped metal sheet.

3. The optical module according to claim 1 , wherein said at least one lens is a biconvex lens, a plano-convex lens, or a Fresnel lens.

4. The optical module according to claim 1 , further comprising at least one of an optical functional element and a mechanical functional element.

5. The optical module according to claim 1 , wherein said transparent material is further defined as at least one of a polymethylmethacrylate (PMMA) material and a polycarbonate (PC) material.

6. The optical module according to claim 1 , wherein said module body and said lens carrier are fabricated as one integral molded part.

7. The optical module according to claim 1 , further comprising an optical stop element having at least one opening for letting radiation from/to said at least one radiation transmitter and/or receiver pass therethrough.

8. The optical module according to claim 1 , further comprising a mechanical fixing means for attaching said radiation transmitter/receiver carrier.

9. The optical module according to claim 1 , further comprising an optical shielding element for optically shielding a propagation path associated with the radiation beam between said module body and said lens carrier.

10. The optical module according to claim 9 , wherein said optical shielding element is fabricated as a part separate from the module body and the lens carrier.

11. A method for fabricating an optical module, said method comprising:

fabricating a lens carrier that comprises at least one lens for focusing a radiation beam, and a lens mask having at least one opening for shaping a radiation beam to have a predetermined aperture, by overmolding the lens mask with a transparent material;

fabricating a module body for mounting the lens carrier and a radiation transmitter/receiver carrier comprising at least one transmitter and/or receiver for transmitting and/or receiving radiation associated with the radiation beam;

wherein said module body is fabricated by overmolding said lens carrier or said lens carrier is fabricated by overmolding said module body;

fabricating the lens mask and a stabilization element from an electrically conductive material for forming an electromagnetic shielding; and

integrating the stabilization element into the module body to enhance mechanical stability of the module body.

12. The method according to claim 11 , wherein fabricating the module body further comprises:

inserting the stabilization element into a molding tool after the lens carrier has been fabricated and without removing the lens carrier from said molding tool; and

overmolding said lens carrier and said stabilization element for forming said optical module.

13. The method according to claim 12 , wherein said stabilization element is formed by stamping and bending a metal sheet.

14. The method according to claim 11 , wherein fabricating the lens carrier further comprises:

producing the at least one lens mask by stamping and bending a metal sheet, said at least one lens mask having at least one opening for shaping the radiation beam to have a predetermined aperture; and

overmolding said at least one lens mask, thereby forming the at least one lens to be aligned with the at least one opening.

15. The method according to claim 11 , further comprising fabricating the module body from a polybutyleneterephthalate (PBT) material.

16. The method according to claim 11 , further comprising:

fabricating an optical shielding element from an opaque material; and

inserting the optical shielding element between the lens carrier and the module body such that the optical shielding element is aligned for optically shielding a propagation path of the radiation between said module body and said lens carrier.

17. An optical module for a light curtain associated with monitoring a protective field, said optical module comprising:

a lens carrier having at least one lens for focusing a radiation beam associated with the light curtain and a lens mask that is overmolded with a transparent material for shaping the radiation beam;

a module body for mounting a radiation transmitter/receiver carrier that comprises at least one transmitter and/or receiver for transmitting and/or receiving said radiation and positionally associated with the lens carrier;

wherein said module body comprises a stabilization element that is integrated into the module body for enhancing mechanical stability of the module body; and

wherein said lens mask and said stabilization element are fabricated from an electrically conductive material for forming an electromagnetic shielding.