An automated sorting method for circuit board recycling.

Abstract

An automated method for sorting circuit boards for recycling is described. The method includes scanning a layout design of a circuit board and comparing the scanned layout design to a database of circuit board layout designs. Each layout design is associated with a respective precious metal content value. A match between the scanned layout design and one of the circuit board layout designs in the database is identified. The method then assigns a precious metal designation to the scanned circuit board based on the identified match. The precious metal designation corresponds to a precious metal content value associated with the matching circuit board layout from the database. The method also includes classifying the scanned circuit board into a group associated with the assigned precious metal designation.

Description

[Technical Field]

[0001] Description of Related Inventions This application claims priority to U.S. Provisional Patent Application No. 63 / 366969, filed June 24, 2022, which is incorporated herein by reference in its entirety. [Background technology]

[0002] FIELD OF THE INVENTION The present invention relates generally to a method and system for sorting circuit boards for recycling purposes, and more particularly to an automated method and system for sorting circuit boards based on factors such as design, layout, size, weight, composition, precious metal content, etc., where these factors are evaluated and referenced to a database from which the boards are aggregated and sorted quickly and efficiently.

[0003] background This section is intended to provide background or context. The description may include concepts that could be pursued, but not necessarily those that have been previously conceived or pursued. Unless otherwise expressly stated, the material described in this section is not considered prior art to the description and claims, and is not admitted to be prior art by its inclusion in this section.

[0004] As our use of and reliance on electronic devices increases, so does the amount of electronic devices that must be disposed of. Such devices include circuit boards that require special handling when disposed of. Furthermore, such circuit boards often contain valuable precious metals, the recycling and recovery of which has become a profitable business. Typically, discarded circuit boards are sent to factories for destruction, where the precious metals are extracted and the remaining components are crushed, shredded, or otherwise destroyed for disposal. [Prior art documents] [Patent documents]

[0005] Circuit boards are purchased according to the precious metal content of the board per metric ton. Precious metals include gold, silver, palladium, and the base metal copper. After the boards are purchased, they are sorted, shredded into 30mm pieces, and sent to a smelter for sampling and analysis to determine the precious metal content. After the boards are sorted and processed, buyers typically purchase the processed precious metal material.

[0006] Precious metal content is determined by a fire assay process. Knowing the precious metal content allows individual boards to be sorted into similar categories for shredding. Shredding similar categories of circuit boards with similar precious metal content will yield better results when samples are taken at the smelter.

[0007] In comprehensive processing of circuit boards for disposal and recycling, it is desirable to sort the circuit boards based on precious metal content or at least similar design (e.g., grouping all boards with the same design or at least similar appearance for processing). However, such facilities typically process such large volumes of circuit boards that sorting each individual board is not time- or cost-effective. For example, such facilities typically process over 1 million pounds of circuit boards per month. In this regard, there is a need for a more efficient method of sorting circuit boards based on factors such as design, size, weight, composition, and precious metal content, so that the circuit boards can be quickly and efficiently grouped based on such factors.

[0008] Currently, all circuit board sorting is done manually. This means that workers are assigned to an assembly line where discarded circuit boards are placed on a conveyor belt. Each worker looks at the boards and determines how to sort them strictly based on their appearance. This approach relies heavily on each worker's ability to accurately recognize the circuit board's design in order to properly sort them based on their precious metal content. However, such systems are highly susceptible to human error. There are thousands of different circuit board designs, and it is impossible for a human worker to memorize and accurately recognize every design, especially when the boards are moving quickly along the conveyor belt. Furthermore, humans cannot completely determine the precious metal content of a circuit board based solely on vision and memory. Even if a worker can accurately recognize the board's design, they often place the board in the wrong pile. Finding employees is difficult enough, but finding someone willing to learn all the categories and codes required for accuracy is nearly impossible. A separate quality control employee is required to review every box before shredding to ensure quality. As such, the current circuit board sorting method is highly inefficient. Furthermore, there are currently no automated systems in the world that sort circuit boards according to their precious metal content.

[0009] If the efficiency of the sorting process could be improved, recycling circuit boards could be profitable, given the sheer volume of circuit boards that need to be disposed of. However, barriers to entry have existed. Many companies, including Sims Metal Management, one of the world's largest electronics recyclers, have attempted to enter the market by purchasing circuit boards for cash from other dismantlers and recyclers, losing millions of dollars and going bankrupt. In Sims' case, they closed that division and pivoted to other recycling methods simply because of the inefficiencies mentioned above. Without accurate sorting of circuit boards, the benefits of precious metal recovery cannot be fully realized. A proven system for sorting circuit boards without sampling would open up the option to purchase circuit boards for cash worldwide.

[0010] There is a general need for an automated sorting method and system for recycling circuit boards that can efficiently sort such boards based on common factors such as design, layout, size, weight, composition, and most desirable precious metal content. Accordingly, it is a general object of the present invention to provide a method and system for sorting circuit boards by reference to a database, where relevant factors are evaluated and boards are automatically and accurately aggregated for fast and efficient sorting, thereby overcoming the problems, drawbacks, and limitations associated with conventional approaches and significantly improving the accuracy of sorting such boards. Summary of the Invention

[0011] overview The following summary is merely representative and not limiting. Using embodiments, the above-mentioned problems are overcome and other advantages are realized. Various embodiments of the present invention provide a means to address these problems and avoid the drawbacks associated with manual sorting methods. In particular, such embodiments may rely on a database of thousands of circuit board designs, layouts, and compositions, in which the content and amount of precious metals can be precisely specified. During the sorting process, boards may be scanned, compared to the database, matched to known designs based on comparison of the specified elements, and classified accordingly. If a board does not match a known design in the database, the individual board may be inspected and added to the database to improve the accuracy of the system.

[0012] In a first aspect, an embodiment provides an automated method for sorting circuit boards for recycling. The method includes scanning a layout design of a circuit board and comparing the scanned layout design to a database of circuit board layout designs. Each layout design is associated with a respective precious metal content value. A match between the scanned layout design and one of the circuit board layout designs in the database is identified. The method then assigns a precious metal designation to the scanned circuit board based on the identified match. The precious metal designation corresponds to the precious metal content value associated with the matched circuit board layout from the database. The method also includes sorting the scanned circuit board into a group associated with the assigned precious metal designation.

[0013] In another aspect, embodiments provide an automated device for sorting circuit boards for recycling. The automated device includes at least one camera configured to scan a layout design of the circuit board and at least one conveyor configured to move the circuit board. The automated device may also include a processor and memory storing computer program code. The memory and computer program code, together with the processor, are configured to cause the automated device to scan the layout design of the circuit board using the camera, compare the scanned layout design to a database of circuit board layout designs associated with respective precious metal content values, and determine whether a match exists between the scanned layout design and one of the circuit board layout designs in the database. If a match is identified, the automated device assigns a precious metal designation to the scanned circuit board based on the identified match. The precious metal designation corresponds to the precious metal content value associated with the matched circuit board layout from the database. The automated device also classifies the scanned circuit board into a group associated with the assigned precious metal designation and uses a conveyor to move the scanned circuit board to a location assigned to the group.

[0014] Aspects of the described embodiments will become more apparent from the following description when read in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0015] [Figure 1] 1 illustrates a classification process according to an embodiment. [Figure 2] A first view of the sorting station is shown. [Figure 3] 1 shows another view of the sorting station. [Figure 4] 1 shows a scan of the first circuit board. [Figure 5] 10 shows a scan of another circuit board. [Figure 6] 10 shows a scan of yet another circuit board. [Figure 7] FIG. 1 is a logic flow diagram illustrating a method according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0016] According to various embodiments of the present invention, a method and system for sorting circuit boards for recycling is provided. The method and system sorts circuit boards by identical or similar design, composition, and / or precious metal content based on similarity of specified factors. More specifically, the sorting process compares each circuit board to a database of circuit board designs, layouts, and contents to identify how these boards should be grouped for further processing. The database contains information about all boards considered, and new designs, layouts, and contents are added to the database as they are identified.

[0017] The database is programmable and can be continuously updated with information from the classification lab. As each board is scanned, the system can identify the board type, map the board's layout and composition, determine the precious metal content, and enter the precious metal content into the database as it is scanned.

[0018] A schematic 100 of the classification process according to an embodiment is shown in FIG. 1. Generally, each substrate is scanned and its image is compared to images of the substrate in a database. The substrate is received at a Gaylord chip area 110. The substrate is then moved to a substrate location area 120 and advanced to an imaging area 130. In the imaging area 130, the substrate is scanned and identification is attempted. Identified substrates are sorted into associated bins / boxes 142 by a robotic substrate sorting area 140. Unrecognized substrates are sent to an unidentified substrate area 150 for analysis.

[0019] 2-3 shows a scanning station 200 for sorting circuit boards, which consists of a conveyor belt 210, an operator station 220, and a camera 230 for scanning the circuit boards. The circuit boards are preferably laid flat on the conveyor belt 210, and the camera 230, positioned above the conveyor belt 210, can capture an image of the circuit board and transmit the image to a computer where a circuit board database is stored for the comparison and matching step of the process.

[0020] As shown, the scanning station 200 is a rolling extrusion frame with leveling casters. The frame includes a light 232 that helps illuminate the conveyor 210. The frame also houses a main electrical enclosure 240 for powering the various components. A conveyor controller 212 can be used to control the conveyor 210. The conveyor controller 212 can move the conveyor 210 to advance the substrate (e.g., move it to the box 202) and / or position the substrate for scanning by the camera 230.

[0021] The operator station 220 may include a computer system with a processor and memory. The computer system may operate various components of the scanning station 200, such as the camera 230 and the conveyor 210. Additionally, the operator station 220 may include a database of circuit board layouts and / or may communicate with another computer (e.g., via the Internet) to access the database of circuit board layouts. The computer system may also include a screen or other output device to provide instructions to the operator (e.g., confirming that the board has been identified and / or requesting that the board be flipped over for further imaging).

[0022] Representative scans of the circuit board are shown in Figures 4-6, illustrating the general design, layout, and size of the circuit board. Figure 4 shows two sides 410 and 412 of sample number 2126. The circuit board layout database lists the following potential metal contents: 10.08 Tb / MT of Au, 32.00 Tb / MT of Ag, and 3.57 Tb / MT of Pd. Figure 5 shows sample 500, ID number 2127, which is listed as having 13.62 Tb / MT of Au, 30.65 Tb / MT of Ag, and 8.77 Tb / MT of Pd. Figure 6 shows sample 600, ID number 1615, which is listed as having 8.01 Tb / MT of Au, 42.56 Tb / MT of Ag, and 6.70 Tb / MT of Pd.

[0023] Once a match is determined, the precious metal content of the board is determined based on information contained in a database and associated with the matched design. This information is determined based on a preliminary analysis of the board design, which is described below. Once the system has information about each board to be classified based on the scan and comparison, the boards are sorted into one Gaylord box per category. While only one box 202 is shown in Figures 2-3, in operation, the conveyor belt 210 can be positioned near multiple boxes, and a robot (not shown) can move the circuit boards to the appropriate box.

[0024] Additionally, additional conveyor belts can be provided to transport additional circuit boards, increasing the number of Gaylord boxes available for sorting purposes. In operation, when a box into which material is sorted becomes full, the system moves it out and replaces it with an empty box. Gaylord boxes are typically 4 feet by 4 feet by 4 feet and can be installed alongside a long conveyor belt, which tosses or places the boards into each box according to category as they are scanned and matched. Once sorted, the boards are shredded and sold in troy ounces per metric ton.

[0025] The precious metal content of a circuit board is determined by known fire assay processes. For example, in the process of the present invention, the board is scanned and then the scan is compared to designs in a database for a match. If a close match is not found, the board is stored for analysis. The analysis process includes the following steps:

[0026] 1) A representative sample of the substrate is taken. 2) The sample is burned or ashed with a mixture of sulfur, which makes all base metals brittle and easy to grind. 3) The sample is crushed and ground to 100 mesh powder to make all precious metals in the sample homogeneous and equal in all parts. 4) A small sample is taken, lead is added to the sample, and when heated to 1200 degrees for a certain period of time, all the precious metals are collected. 5) The lead is then cupelled in another oven, which sucks all the lead and base metals into the cupellation, leaving only the precious metal beads. 6) The beads are dissolved in acid to separate the gold from the silver and palladium. 7) Gold flakes are weighed on a scale. 8) Dissolved silver and palladium samples are sprayed in an ICP (inductively coupled plasma) device for pm content. 9) All information is entered into the system and associated with a photograph of the board showing its gold, silver and palladium content. 10) The board will be registered in the system and buyers will have access to the supplier's photos when purchasing materials.

[0027] The method and system of the present invention also allows tracking of metal content as materials are shipped.

[0028] An automated system for sorting circuit boards reduces labor and therefore costs, while improving accuracy and profits. For example, a company using 12 sorters to sort just over 500,000 pounds of high-quality circuit boards each month would incur sorting fees of approximately $0.10 per pound. The system of the present invention is estimated to reduce this cost by approximately 75%.

[0029] Another benefit of this system is that it creates a new way of purchasing substrates according to their precious metal content, reducing refining and processing costs. After sorting, the material (e.g., one full Gaylord box) simply needs to be weighed and entered into the economic analysis. The precision of the sorting process ensures accurate content, and therefore the precious metal content can be accurately and easily determined.

[0030] The scanning process records and identifies each circuit board using deep learning software, facial recognition, and a virtual imaging high-resolution camera to classify boards into similar categories. The system can scan the board and record an image of the board while using information from a database to input the category into the system. This process can use single-sided scanning or double-sided scanning for increased accuracy by comparing with the database. When identifying boards, the system uses a variety of techniques, including reading identification labels and comparing component locations and solder patterns.

[0031] As images of the boards are recorded, they are added to a database and programmed into a sorting scanner, which is part of the sorting system. The boards are stacked on a table by a robot, oriented, and passed through the sorting scanner. The scanned image of each board is compared to images in the database, matching them based on pre-specified factors such as design, layout, size, and precious metal content. Once the system identifies the board, it is transported and released into the Gaylord box category to which it belongs. There are weight sensors underneath each Gaylord box, and when they are full, an automated forklift lifts the box and places it for processing in the shredder.

[0032] If the scanner finds a board that it cannot identify or does not match the database, the conveyor will eject the board into a marked Gaylord box, which will send the board to a lab for fire assay analysis of precious metal content, after which it can be scanned into a database for future reference.

[0033] This method and system reduces labor costs, eliminates all human error, increases the efficiency of estimation and final analysis, and makes anyone using the system extremely competitive.

[0034] A variation or next version of this invention could be used to identify a specific processor that can be detached from a board and resold for reuse on another board.

[0035] In yet another embodiment of the present invention, memory sticks and other components can be identified and tested for resale. This process can identify memory sticks by image scan, product code, and / or chipset to determine which memory sticks or components to sort for testing and resale. As with other embodiments described herein, this process saves significant time that would normally be required for manual sorting.

[0036] As described above, various embodiments provide methods, apparatus, and computer programs for sorting circuit boards for recycling.

[0037] 7 is a logic flow diagram illustrating a method and the results of executing computer program instructions according to various embodiments. According to an embodiment, the method performs the step of scanning a circuit board layout design at block 710. The scanned layout design is compared to a database of circuit board layout designs at block 720. Each layout design is associated with a respective precious metal content value. The method performs the step of identifying a match between the scanned layout design and one of the circuit board layout designs in the database at block 730. The method also performs the step of assigning a precious metal designation to the scanned circuit board based on the identified match at block 740. The precious metal designation corresponds to a precious metal content value associated with the matching circuit board layout from the database. The scanned circuit board is classified into a group associated with the assigned precious metal designation at block 750.

[0038] The various blocks illustrated in FIG. 7 may be viewed as one or more logic circuit elements constructed to perform method steps, operations resulting from the use of computer program code, and / or related functions.

[0039] In a first embodiment, an automated method for sorting circuit boards for recycling is provided. The method includes scanning a layout design of a circuit board and comparing the scanned layout design to a database of circuit board layout designs. Each layout design is associated with a respective precious metal content value. A match between the scanned layout design and one of the circuit board layout designs in the database is identified. The method then assigns a precious metal designation to the scanned circuit board based on the identified match. The precious metal designation corresponds to the precious metal content value associated with the matched circuit board layout from the database. The method also includes classifying the scanned circuit board into a group associated with the assigned precious metal designation.

[0040] In a further embodiment of the above method, a match is identified based on one or more elements assigned to the circuit board layout designs in the database, including layout, size, composition, and / or precious metal content of the circuit board.

[0041] In another embodiment of any of the above methods, the method includes determining whether there is a match between the scanned layout design and a circuit board layout design in the database, and if no match is identified, analyzing the scanned circuit board to determine a value for precious metal content, and adding the scanned layout design of the scanned circuit board to the database.

[0042] In a further embodiment of any of the above methods, sorting the scanned circuit boards into groups associated with the assigned precious metal designations includes moving the circuit boards into boxes associated with the groups. The circuit boards may be moved to the boxes using a conveyor belt and / or a robot.

[0043] In another embodiment of any of the above methods, scanning the layout design of the circuit board includes scanning a first side of the circuit board, flipping the circuit board over, and scanning a second side of the circuit board.

[0044] In a further embodiment of any of the above methods, the precious metal content value indicates the content of gold, silver, palladium, and / or base metal copper in the circuit board.

[0045] In another embodiment of any of the above methods, sorting the scanned circuit boards into groups may be further based on at least one of design, size, weight, and composition.

[0046] A further embodiment provides an automated device for sorting circuit boards for recycling. The automated device includes at least one camera configured to scan layout designs of the circuit boards and at least one conveyor configured to move the circuit boards. The automated device may also include a processor and memory storing computer program code. The memory and computer program code, together with the processor, are configured to cause the automated device to scan the layout designs of the circuit boards using the camera, compare the scanned layout design with a database of circuit board layout designs associated with respective precious metal content values, and determine whether a match exists between the scanned layout design and one of the circuit board layout designs in the database. If a match is identified, the automated device assigns a precious metal designation to the scanned circuit board based on the identified match. The precious metal designation corresponds to the precious metal content value associated with the matched circuit board layout from the database. The automated device also classifies the scanned circuit boards into groups associated with the assigned precious metal designations and uses a conveyor to move the scanned circuit boards to locations assigned to the groups.

[0047] In another embodiment of the automated apparatus described above, a match is identified based on at least one element assigned to the circuit board layout design in the database, the at least one element including one of the layout, size, composition, or precious metal content of the circuit board.

[0048] In further embodiments of any of the above automated devices, the at least one memory and computer program code are further configured to: if the automated device determines that a match does not exist between the scanned layout design and the circuit board layout design in the database, move the scanned circuit board using a conveyor to a location where the scanned circuit board is analyzed to determine a value for precious metal content, and add the scanned layout design of the scanned circuit board to the database.

[0049] In another embodiment of any of the above automated devices, moving the scanned circuit board to a location assigned to the group includes moving the circuit board to a box associated with the group using a conveyor, which may include at least one of a conveyor belt and a robot.

[0050] In a further embodiment of any of the above automated apparatus, scanning the layout design of the circuit board includes scanning a first side of the circuit board and scanning a second side of the circuit board.

[0051] In another embodiment of any of the above automated devices, the precious metal content value indicates the content in the circuit board of at least one of gold, silver, palladium, and the base metal copper.

[0052] In further embodiments of any of the above automated devices, sorting the scanned circuit boards into groups may be further based on at least one of design, size, weight, and composition.

[0053] In another embodiment of any of the above automated devices, the automated device also includes a storage device configured to store a database of circuit board layout designs.

[0054] The foregoing description of the embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications and variations are possible in light of the above disclosure. Moreover, various features of the described embodiments can be used without the corresponding use of other features. The described embodiments were selected to best explain the principles of the invention and its practical application, and to enable those skilled in the art to utilize the invention in various embodiments and various modifications to suit the particular applications envisioned.

Claims

1. 1. An automated method for sorting circuit boards for recycling, comprising: scanning a circuit board layout design; comparing the scanned layout design to a database of circuit board layout designs, each of the circuit board layout designs being associated with a respective precious metal content value; identifying a match between the scanned layout design and one of the circuit board layout designs in the database; assigning a precious metal designation to the scanned circuit board based on the identified match, the precious metal designation corresponding to the precious metal content value associated with the matched circuit board layout from the database; and sorting the scanned circuit boards into groups associated with the assigned precious metal designations.

2. The method of claim 1 , wherein the match is identified based on at least one element assigned to the circuit board layout design in the database.

3. The method of claim 2 , wherein the at least one factor includes one of the layout, size, composition, or precious metal content of the circuit board.

4. determining whether there is a match between the scanned layout design and the circuit board layout design in the database; and if no match is identified, analyzing the scanned circuit board to determine a precious metal content value; and adding the scanned layout design of the scanned circuit board to the database.

5. The method of claim 1 , wherein sorting the scanned circuit board into the group associated with the assigned precious metal designation comprises moving the circuit board into a box associated with the group.

6. The method of claim 5 , wherein the circuit board is moved into the box using at least one of a conveyor belt and a robot.

7. Scanning the layout design of a circuit board includes: scanning a first side of the circuit board; turning the circuit board over; and scanning a second side of the circuit board.

8. The method of claim 1 , wherein the precious metal content value indicates the content of at least one of gold, silver, palladium, and base metal copper in the circuit board.

9. The method of claim 1 , wherein sorting the scanned circuit boards into groups can be further based on at least one of design, size, weight, and composition.

10. 1. An automated apparatus for sorting circuit boards for recycling, comprising: at least one camera configured to scan a circuit board layout design; at least one conveyor configured to move the circuit board; at least one processor and at least one memory containing computer program code; The at least one memory and the computer program code, together with the at least one processor, cause the automated device to scanning a circuit board layout design using said camera; comparing the scanned layout design to a database of circuit board layout designs, each of the circuit board layout designs being associated with a respective precious metal content value; determining whether a match exists between the scanned layout design and one of the circuit board layout designs in the database; if a match is identified, assigning a precious metal designation to the scanned circuit board based on the identified match, the precious metal designation corresponding to the precious metal content value associated with the matched circuit board layout from the database; classifying the scanned circuit boards into groups associated with the assigned precious metal designations; using the conveyor to move the scanned circuit boards to locations assigned to the groups; 2. An automatic device configured to cause

11. The automated apparatus of claim 10 , wherein the match is identified based on at least one element assigned to the circuit board layout design in the database.

12. 12. The automated apparatus of claim 11, wherein the at least one element comprises one of a layout, a size, a composition, or a precious metal content of the circuit board.

13. The at least one memory and the computer program code may, if it is determined that no match exists between the scanned layout design and the circuit board layout design in the database, cause the automated device to: using the conveyor to move the scanned circuit board to a location where the scanned circuit board is analyzed to determine a precious metal content value; adding the scanned layout design of the scanned circuit board to the database; The automated device of claim 10 , further configured to:

14. 11. The automated apparatus of claim 10, wherein moving the scanned circuit board to the location assigned to the group includes using the conveyor to move the circuit board to a box associated with the group.

15. The automated apparatus of claim 14 , wherein the conveyor comprises at least one of a conveyor belt and a robot.

16. Scanning the layout design of a circuit board includes: scanning a first side of the circuit board; scanning a second side of the circuit board; 11. The automated device of claim 10, comprising:

17. 11. The automated apparatus of claim 10, wherein the precious metal content value indicates a content in the circuit board of at least one of gold, silver, palladium, and base metal copper.

18. 11. The automated apparatus of claim 10, wherein sorting the scanned circuit boards into groups is further capable of being based on at least one of design, size, weight, and composition.

19. The automated apparatus of claim 10 further comprising a storage device configured to store the database of circuit board layout designs.

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