Automated card sorting system

Abstract

An automated card sorting system configured to sort various types of cards includes a feeding chute, scanner, and collection station. The feeding chute is configured to receive a plurality of unsorted cards and sequentially feed cards into the scanner for identification. The scanner identifies key characteristics of each card and sends the information to a processor. The processor controls conveyor sections within the collection station, which transport the cards and discharge them into appropriate collector bins based on sorting criteria. Each conveyor section includes translatory and rotary drives to facilitate card movement and discharge. The collection bins are compartmentalized, allowing the sorted cards to be organized based on different attributes. The system includes sensors, low-friction linings, and removable drawers to enhance card handling and collection. The system is adaptable for various card types and sizes, providing efficient and accurate sorting for trading cards, playing cards, or other collectible cards.

Description

ATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATIONAUTOMATED CARD SORTING SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims benefit of U.S. Provisional Application No. 63 / 704,862, filed October 8, 2024; all of which is incorporated herein in its entirety and referenced thereto.BACKGROUND OF THE INVENTIONFIELD OF THE INVENTION

[0002] The present invention relates to automated sorting systems. More particularly, it pertains to a high-speed card sorting machine designed for the precise sorting of playing and collectible cards, such as Magic: The Gathering and Pokemon cards. The present invention utilizes a tilting conveyor mechanism and integrated card scanning technology for ensuring efficient and damage-free sorting in gaming, tournament, and commercial environments.DESCRIPTION OF THE PRIOR ART

[0003] Playing card sorting machines are increasingly important in environments such as casinos, trading card events, and card manufacturing facilities, where accurate sorting of large volumes of cards is necessary. These machines offer a high level of efficiency by automating the sorting process, which ensures that cards are organized quickly and accurately without manual intervention. Traditional playing card sorting machines rely on various mechanical and automated systems to differentiate, categorize, and sort cards based on criteria such as type, suit, or deck.

[0004] Several sorting systems have been disclosed in the past. One such example is disclosed in U.S. Patent No. 6,193,074, entitled "Automated sorting system using tiltable conveyor units" (“the ‘074 Patent”). The '074 Patent describes a system where items, such as cards, are transported via tiltable conveyor units that can discharge items into designated bins based on sorting parameters. While this system is efficient for basic sorting tasks, it lacks the precision needed to handle the delicateATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATION nature of playing cards and does not accommodate the high-speed requirements of modern gaming environments.

[0005] Another example is disclosed in U.S. Patent No. 6,250,632, entitled "Parcel sorting machine with inclined planes" (“the ‘632 Patent”). The '632 Patent discloses a sorting system where items slide down inclined planes into designated bins, controlled by mechanical gates. While this system may function adequately for bulkier items, its reliance on gravity makes it less suitable for handling thin, lightweight items like playing cards, which can easily become misaligned or damaged during sorting.

[0006] Yet another example is disclosed in U.S. Patent No. 6,554,123, entitled "High-speed parcel sorter" (“the ‘123 Patent”). The '123 Patent presents a high-speed sorting system that combines tilting trays with powered conveyors, designed to handle parcels. While effective for sorting larger and heavier items, this system may not be ideal for playing cards, as it does not account for the fragile and precise nature of cards, which require gentler handling and more refined sorting mechanisms.

[0007] Another example is disclosed in U.S. Patent No. 6,726,205, entitled "Dual level conveyor sorting apparatus" (“the ‘205 Patent”). The '205 Patent discloses a sorting system with two levels of conveyors for sorting items of varying sizes. While this design offers flexibility, it is more suitable for larger items and lacks the necessary precision and speed required for handling small, lightweight items like playing cards.

[0008] Although these prior art disclosures provide various solutions for sorting items, they do not adequately address the specific challenges associated with sorting playing cards. These systems either lack the precision needed for card sorting, are too harsh on delicate cards, or do not provide the necessary speed and accuracy for environments such as casinos and gaming tournaments, where rapid and accurate sorting of large volumes of cards is crucial.

[0009] Therefore, there is a need in the art for an improved playing card sorting machine that provides high-speed, accurate sorting while ensuring the delicate handling of playing cards to prevent damage.ATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATIONSUMMARY OF THE INVENTION

[0010] It is an object of the present invention to provide automated card sorting system that efficiently sorts various cards, such as playing cards, trading cards, or any other cards, based on predefined criteria, allowing for faster and more accurate sorting process compared to manual methods.

[0011] It is another object of the present invention to provide automated card sorting system that integrates feeding chute, scanner, and collection station, which work together to automate sorting process, ensuring cards are sequentially fed, scanned, and deposited into designated collector bins.

[0012] It is another object of the present invention to provide automated card sorting system with scanner capable of identifying card type, serial number, rarity, or any other relevant characteristic, thereby allowing system to make precise sorting decisions based on predefined criteria.

[0013] To achieve one or more of these objects, the present invention provides automated card sorting system that includes plurality of conveyor sections, each equipped with translatory and rotary drives to facilitate movement and discharge of cards into appropriate collector bins. These drives are controlled by processor that operates based on sorting criteria stored in memory.

[0014] In one aspect of the present invention, card sorting system includes adjustable feeding chute that ensures proper alignment and flow of cards into scanner, preventing jamming or multiple cards from entering scanner at the same time. Feeding chute can accommodate cards of varying sizes and thicknesses.

[0015] In another aspect of the present invention, conveyor sections within collection station are modular and capable of handling cards of different dimensions, allowing system to sort wide range of card types, including trading cards, playing cards, business cards, and other types of cards.

[0016] In another embodiment, present invention includes collector bins that are compartmentalized to allow for sorting into multiple compartments, each designated for specific card types or attributes. These bins may include removable drawers for easy access to sorted cards.ATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATION

[0017] In another embodiment, present invention includes software sensor configuration integrated with processor to keep track of how many cards are in each collector bin. As scanner identifies key characteristics of each card and sends this information to processor, processor compares data with local recognition database stored in memory or cloud-based recognition database to determine appropriate collector bin for the card. Processor not only directs card to correct bin but also continuously updates count of cards in each bin, allowing for real-time monitoring of bin capacity. This feature ensures efficient management of sorting process, preventing overflow and ensuring that each bin remains properly organized based on predefined criteria.

[0018] In yet another embodiment, system may include sensors within collector bins to detect when bins are full, which prompts processor to halt sorting process until bins are emptied or replaced, ensuring smooth operation without overflow or damage to cards.

[0019] Automated card sorting system may further include features such as low- friction linings in collector bins and adjustable funnels to guide cards into appropriate compartments, ensuring smooth and accurate card deposition during sorting.

[0020] In one advantageous feature of the present invention, modular design of conveyor sections allows for quick replacement or customization based on type of cards being sorted, offering flexibility for various operational requirements.

[0021] In another advantageous feature of the present invention, card sorting system may be integrated with inventory management systems to track and manage number and type of sorted cards, streamlining card organization for businesses or collectors.

[0022] These and other objects of the present invention will be apparent from review of the following specification and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 is automated card sorting system, in accordance with one exemplary embodiment of the present subject matter.ATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATION

[0024] FIG. 2 is a block diagram illustrating operation of card sorting system, in accordance with one exemplary embodiment of the present subject matter.

[0025] FIG. 3 is a feeding chute used in automated card sorting system, in accordance with one exemplary embodiment of the present subject matter.

[0026] FIG. 4 is a perspective view of collection station used in automated card sorting system, in accordance with one embodiment of the present subject matter.

[0027] FIG. 5 is a perspective view of conveyor section used in automated card sorting system, in accordance with one embodiment of the present subject matter.

[0028] FIG. 6 is a perspective view of collection bin used in collection station of automated card sorting system, in accordance with one embodiment of the present subject matter.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0029] The detailed description set forth below in connection with the appended drawings is intended as a description of exemplary embodiments in which the presently disclosed subject matter may be practiced. The term “exemplary” used throughout this description means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description includes specific details for providing a thorough understanding of the presently disclosed mat. However, it will be apparent to those skilled in the art that the presently disclosed subject matter may be practiced without these specific details. In some instances, well-known structures and devices are shown in functional or conceptual diagram form in order to avoid obscuring the concepts of the presently disclosed automated card sorting system.

[0030] In the present specification, an embodiment showing a singular component should not be considered limiting. Rather, the subject matter preferably encompasses other embodiments including a plurality of the same component, and vice-versa, unless explicitly stated otherwise herein. Moreover, the applicant does not intend for any term in the specification to be ascribed an uncommon or special meaning unless explicitly set forth as such. Further, the present subject matter encompassesATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATION present and future known equivalents to the known components referred to herein by way of illustration.

[0031] The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the subject matter and are not intended to limit the scope of the subject matter.

[0032] Various features and embodiments of an automated card sorting system are explained in conjunction with the description of FIGURES (FIGs) 1-6.

[0033] FIG. 1 illustrates an automated card sorting system 10, in accordance with one exemplary embodiment of the present subject matter. Automated card sorting system 10 is designed to automate the process of sorting a variety of cards, such as playing cards, trading cards, collectible cards, business cards, or any other type of cards that require sorting based on predefined criteria. Automated card sorting system 10 includes a feeding chute 12, which is configured to receive a plurality of cards 14. Plurality of cards 14 may consist of unsorted cards, arranged in a random or non-sequential manner, with the system capable of handling batches of 50 to 500 cards simultaneously. Plurality of cards 14 are loaded into feeding chute 12 manually or via an automated feeding mechanism, depending on the embodiment of the system. Feeding chute 12 is specifically designed to sequentially guide plurality of cards 14 towards a scanner 16, ensuring that only one card enters scanner 16 at a time to avoid misalignment or jamming.

[0034] Scanner 16, positioned downstream from feeding chute 12, is configured to scan each incoming card from plurality of cards 14. Scanner 16 may be an optical card scanner or an advanced image recognition scanner, capable of identifying key features of each card, such as card type, serial number, set identification, rarityATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATION symbols, holographic elements, condition assessment, or any other relevant characteristic through advanced optical character recognition (OCR) and pattern matching algorithms. The scanner may also include mechanisms to detect defects or damages on each card using edge detection algorithms and surface analysis techniques, measuring parameters such as corner wear, surface scratches, and centering deviations. Scanned cards from scanner 16 are then conveyed to a collection station 18. Collection station 18 is comprised of a plurality of collector bins 20, which are designed to hold cards after they are sorted based on criteria determined by card sorting system 10. Each collector bin 20 has a capacity ranging from 100 to 1000 cards depending on card thickness and is constructed from anti-static materials to prevent card damage. Collection station 18 further includes a plurality of conveyor sections, which serve as the transport mechanism for the cards within system 10. In one example, each conveyor section operates at variable speeds from 5 to 50 inches per minute and incorporates precision timing mechanisms synchronized with scanner 16 output. Plurality of conveyor sections are housed within a housing 22, which may be made of metal, plastic, or any suitable durable material. Housing 22 is supported on frame 24, which provides structural stability and can be designed as a stationary or mobile frame, depending on the specific operational requirements of the sorting system.

[0035] Automated card sorting system 10 further includes a user interface media 25, which enables a user to operate and interact with automated card sorting system 10. User interface media 25 allows users to control and monitor various aspects of the sorting process, as well as configure system settings, view sorting status, and make adjustments based on real-time feedback. In one embodiment, user interface media 25 may be a touch screen display that provides an interactive platform for users to input commands and receive system updates.

[0036] FIG. 2 provides a block diagram illustrating the operation of card sorting system 10, in accordance with one exemplary embodiment of the present subject matter. Card sorting system 10 is controlled by a processor 26, which functions as the central processing unit of the system. Processor 26 includes dedicated graphicsATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATION processing unit (GPU) capabilities for image processing tasks and incorporates hardware-accelerated machine learning inference engines. Processor 26 operates with real-time operating system (RTOS) capabilities ensuring deterministic response times within 10 milliseconds for critical sorting decisions. Processor 26 is communicatively coupled to a memory 28, which stores the required instructions and sorting criteria in a database. Memory 28 includes a comprehensive database of cards, wherein each card may be categorized by various attributes such as type, game, edition, condition, market value, print run, artist, or other relevant sorting factors. The database supports relational data structures with indexing capabilities for rapid lookup operations, typically completing searches within 50 milliseconds. Database entries include high-resolution reference images, dimensional specifications, weight parameters, and unique identifiers such as set numbers and collector numbers.. Instructions stored in memory 28 also facilitate the operation of card sorting system 10 by controlling its various components such as scanner 16, conveyor sections 30, and collector bins 20. The instruction set includes motion control algorithms, image processing routines, and safety protocols with fail-safe mechanisms. Processor 26 retrieves these instructions from memory 28, enabling it to make real-time decisions during the card sorting process.

[0037] Processor 26 is communicatively coupled to scanner 16. When scanner 16 scans an incoming card from plurality of cards 14, processor 26 processes the card's data and performs identification of said card. Based on the identification, processor 26 determines which collector bin 20, among the plurality of collector bins within collection station 18, the card should be deposited into using decision algorithms that consider multiple sorting parameters simultaneously. Each card is directed along conveyor sections 30, which are discrete conveyor units, each associated with a specific collector bin 20. Each conveyor section 30 is equipped with two types of drives: a translatory drive and a rotary drive. The translatory drive enables conveyor section 30 to transport the card forward to the next adjacent conveyor section at controlled velocities with acceleration and deceleration profiles optimized to prevent card slippage or damage. This ensures smooth movement of cards throughout theATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATION system, preventing them from becoming jammed or misaligned during the sorting process through continuous monitoring of card position using integrated sensors.

[0038] Rotary drive in conveyor section 30 allows for the rotation of the conveyor sections 30 to an angle where the card can be discharged into the appropriate collector bin 20. The rotary mechanism incorporates harmonic drive gearing systems or precision planetary gearboxes with backlash compensation to ensure repeatable positioning accuracy. Processor 26 controls this movement based on the sorting criteria stored in memory 28. Translatory drive for conveyor section 30 is provided by a translatory drive unit 32, while rotary drive is provided by a rotary drive unit 34. In one embodiment, translatory drive unit 32 and rotary drive unit 34 are both servo motors that are electronically controlled by processor 26 to execute precise movements of conveyor sections 30. The use of servo motors allows for accurate control of the movement speed, position, and angle of conveyor sections 30, ensuring that cards are sorted efficiently and without error through continuous feedback monitoring and adaptive control algorithms. Alternative embodiments may use stepper motors or other types of motorized drive units, depending on cost, precision, or operational needs.

[0039] In some embodiments, conveyor sections 30 may be designed to handle cards of varying sizes, such as playing cards, trading cards, or business cards. Additionally, feeding chute 12, scanner 16, and conveyor sections 30 may be adjustable to accommodate different card sizes or materials through motorized adjustment mechanisms controlled by processor 26 or manual adjustment systems with precision measurement scales. Cards may be sorted based on various attributes, including but not limited to card game type, card rarity, or player preferences. In alternative embodiments, the system may also include sensors to detect card damage or other imperfections, which could trigger separate sorting into a reject bin.

[0040] FIG. 3 illustrates feeding chute 12 used in automated card sorting system 10, in accordance with one exemplary embodiment of the present subject matter. Feeding chute 12 is designed to hold plurality of cards 14 that are to be sorted. Plurality of cards 14 are disposed on feeding chute 12 in a stacked arrangement with capacity ranging from 50 to 500 cards depending on card thickness, which allows forATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATION sequential feeding of cards into scanner 16. In some cases, feeding chute 12 incorporates weight-activated sensors that monitor the remaining card count and provide alerts when refilling is required. The stacked arrangement of plurality of cards 14 ensures that cards are properly aligned before they are fed into scanner 16, minimizing the chances of cards becoming misaligned or jammed during the sorting process through the use of precision guide rails with spring-loaded pressure mechanisms that maintain consistent card contact pressure between 0.5 to 2.0 pounds per square inch.

[0041] Feeding chute 12 interfaces with a gate 36. Gate 36 is a mechanical stop designed to control flow of plurality of cards 14 along feeding chute 12. Gate 36 holds plurality of cards 14 in place, particularly in scenarios where scanner 16 requires maintenance or temporary halting of operations. Gate 36 includes safety interlocks that automatically engage when system errors are detected or during maintenance procedures. Gate 36 allows plurality of cards 14 to remain stationary on feeding chute 12 during maintenance procedures on scanner 16, preventing any cards from entering scanner 16 while it is non-operational through fail-safe mechanisms that default to the closed position during power loss or system faults.

[0042] In another embodiment, feeding chute 12 may include adjustment mechanisms to accommodate cards of different sizes, such as trading cards, playing cards, or collectible cards. In such embodiments, feeding chute 12 may be modified to handle cards with varying thicknesses, widths, and lengths. These adjustment mechanisms may be manually or automatically adjustable, depending on the design of automated card sorting system 10. In certain embodiments, the adjustment of feeding chute 12 may be coupled with gate 36, allowing the system to automatically adjust both components when detecting a change in card size through integrated measurement systems and coordinated control algorithms that ensure proper alignment and clearances are maintained throughout the adjustment process.

[0043] Feeding chute 12 is positioned at an angle designed to allow gravity to assist in moving plurality of cards 14 toward a feeder 19. Feeder 19 is configured to regulate the flow of cards 14 from feeding chute 12 into scanner 16. In oneATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATION embodiment, feeder 19 may be a spring-loaded mechanism that controls the passage of a predetermined number of cards 14. When a certain number of cards 14 abut against feeder 19, pressure is applied to the spring-loaded figure of feeder 19, causing it to depress and create an opening through which cards 14 can pass into scanner 16.

[0044] Feeder 19 serves to prevent multiple cards 14 from entering scanner 16 at once, ensuring that only the correct number of cards 14 are fed into scanner 16 for processing. This mechanism helps to avoid misfeeds, jams, or incorrect readings, thereby maintaining efficiency and accuracy in the sorting process. In some embodiments, the spring-loaded figure of feeder 19 may be adjustable, allowing system operators to modify the sensitivity or resistance of feeder 19 based on the type or thickness of cards 14 being processed. Advanced embodiments may include electronic force control systems using load cells and servo actuators to provide dynamic adjustment of separation force based on real-time feedback from card thickness sensors.

[0045] In one embodiment, the angle of feeding chute 12 can be adjusted depending on the operational speed and capacity of automated card sorting system 10. In cases where the system is processing large volumes of cards, the angle may be increased to allow faster movement of cards, while in lower-speed operations, a gentler angle may be used to maintain controlled card flow and reduce the risk of card damage. The angle optimization algorithms consider factors such as card material properties, ambient temperature and humidity (which affect card flexibility), and desired throughput rates to automatically determine optimal chute positioning.

[0046] Downstream of scanner 16 is buffer conveyor 17. Buffer conveyor 17 serves as an intermediary mechanism between scanner 16 and conveyor section 30. Buffer conveyor 17 is designed to temporarily hold card 14 outside of conveyor section 30, providing additional time for card 14 to be fully recognized by scanner 16 before it progresses to collection station 18. Buffer conveyor 17 also helps prevent potential jams or bottlenecks within conveyor section 30 by ensuring that card 14 is fully processed before entering collection station 18 through coordinated timing control with scanner 16 and collection station 18. In another embodiment, buffer conveyor 17 may have aATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATION holding function, allowing it to temporarily pause the movement of card 14 if scanner 16 detects a need for further analysis or if there is a delay in processing at collection station 18. Processor 26 may then release card 14 from buffer conveyor 17 once the system is ready to resume normal operations through coordinated control signals and status feedback from all system components. This feature adds flexibility to system 10, allowing it to accommodate varying processing times for different types of cards 14.

[0047] FIG. 4 is a perspective view of collection station 18 used in automated card sorting system 10, in accordance with one embodiment of the present subject matter. FIG. 4 depicts a view of collection station 18 without housing 22, thus providing a clear view of plurality of conveyor sections 30 arranged within collection station 18. As shown in FIG. 4, plurality of conveyor sections 30 are arranged in the form of a linear array within collection station 18, which allows for organized and efficient sorting of cards.

[0048] Each conveyor section 30 is designed to perform two main functions: translatory drive and rotary drive. The translatory drive is responsible for advancing card 14 along the length of collection station 18 in a forward direction. This movement ensures that card 14 is passed from one conveyor section 30 to the next until it reaches the designated collection point. Translatory drive is facilitated by translatory drive unit 32, which is a motorized mechanism that pushes or pulls card 14 along the path within collection station 18. The speed and direction of translatory movement may be controlled by processor 26 to ensure cards are moved at a consistent rate without causing any delays or jams in the sorting process.

[0049] The rotary drive, provided by rotary drive unit 34, enables conveyor section 30 to rotate at a specified angle to discharge card 14 into a relevant collector bin 20. As shown in FIG. 4, conveyor section 30A is rotated to demonstrate the discharge of card 14 into a relevant collector bin. Rotary drive unit 34 ensures precise rotation of conveyor section 30, so that card 14 is dropped into the correct bin based on the sorting criteria established by processor 26.

[0050] In alternative embodiments, collection station 18 may include a non-linear arrangement of conveyor sections 30, such as a circular or grid-based configuration.ATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATIONThis alternative arrangement could allow for more compact designs of the sorting system, where space is limited, or for applications requiring sorting into a larger number of collector bins 20. In such configurations, translatory and rotary drive mechanisms would still function in a similar manner, with processor 26 controlling the movement and rotation of conveyor sections 30 to ensure accurate card placement through coordinated multi-axis motion control algorithms and real-time trajectory planning.

[0051] Each collector bin 20 is positioned below or adjacent to conveyor section 30, depending on the overall design of collection station 18. In one embodiment, collector bins 20 may include removable drawers, thereby allowing for easy retrieval and transport of sorted cards. In another embodiment, collector bins 20 may be equipped with sensors to detect when they are full, thus triggering a signal to processor 26 to halt sorting until bins are emptied or replaced. In another embodiment, present invention includes software sensor configuration integrated with processor 26 to keep track of how many cards are in each collector bin 20. As scanner 16 identifies key characteristics of each card and sends this information to processor 26, processor 26 compares data with local recognition database stored in memory 28 or cloud-based recognition database to determine appropriate collector bin 20 for the card. Processor 26 not only directs card to correct bin 20 but also continuously updates count of cards in each bin 20, allowing for real-time monitoring of bin capacity. This feature ensures efficient management of sorting process, preventing overflow and ensuring that each bin 20 remains properly organized based on predefined criteria through predictive algorithms that provide advance warning when bins approach capacity limits.

[0052] In one embodiment, as shown in FIG. 4, collector station 18 includes plurality of indicator media 21 provided adjacent to each collector bin 20. Each collector bin 20 may have one or more corresponding indicator media 21 , where each indicator media 21 corresponds to a specific compartment within collector bin 20. Each collector bin 20, as shown in FIG. 4, is divided into two compartments, with each compartment being associated with its own indicator media 21. Indicator media 21 are configured to display information related to card 14 stored within respective compartments of collector bin 20.ATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATION

[0053] Processor 26 controls indicator media 21 by sending signals related to cards 14 scanned by scanner 16. Once card 14 is sorted into appropriate compartment within collector bin 20, indicator media 21 may display relevant information such as card type, card rarity, card count, estimated value, or any other predefined characteristic. For example, if a compartment of collector bin 20 is dedicated to storing rare cards, indicator media 21 adjacent to that compartment may display a message indicating that rare cards are stored within. This allows users to easily identify and manage the sorted cards.

[0054] In some embodiments, indicator media 21 may include visual indicators, such as lights, which change color based on the type of card stored within each compartment. For example, green light may indicate common cards, while red light may indicate rare cards. Alternatively, indicator media 21 may include digital displays or screens that provide textual information regarding cards sorted into respective compartments of collector bin 20. Processor 26 updates information on these displays in real-time as cards 14 are sorted.

[0055] In other embodiments, indicator media 21 may also provide alerts or notifications when collector bins 20 are nearing capacity. Processor 26 monitors how many cards 14 are in each compartment and, when a threshold is reached, indicator media 21 may display a warning or flash to indicate that bin 20 requires attention, such as emptying or replacing. This embodiment ensures uninterrupted sorting operations by alerting operators when bins are full, preventing overflow or card damage.

[0056] In yet another embodiment, collection station 18 may also be integrated with external systems, such as inventory management software, to track the number and type of cards sorted into each bin.

[0057] FIG. 5 is a perspective view of conveyor section 30 used in automated card sorting system 10, in accordance with one embodiment of the present subject matter. Referring to FIG. 5, conveyor section 30 is responsible for the movement and handling of cards along the path within collection station 18. Conveyor section 30 includes a conveyor section housing 38, which forms the main structural framework of the conveyor section. Conveyor section housing 38 provides support andATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATION positioning for internal components, ensuring the stable and controlled movement of cards during the sorting process.

[0058] Conveyor section housing 38 includes two shafts 40, 41 that are arranged in a spaced-apart configuration. Each shaft 40, 41 has plurality of rollers 42 mounted on it. Rollers 42 serve as the interface between card 14 and the mechanical drive system, allowing card 14 to move smoothly along the conveyor without getting stuck or damaged.

[0059] Belts 44 are placed over rollers 42 and extend between the two shafts 40, 41. Belts 44 provide the actual contact surface on which card 14 is placed. Shaft 41 is a translatory axle and is configured to be coupled to translatory drive unit 32 for providing translatory drive required for facilitating conveyance of card 14 along the length of conveyor station 18. More specifically, the rotation of belts 44 facilitated by rotation of shaft 41 moves card 14 along the length of conveyor section 30 in the desired direction. In one embodiment, belts 44 may be made of a flexible material such as rubber, while in other embodiments, more rigid materials could be used depending on the specific sorting requirements. In an operative configuration, card 14 is placed on top of belts 44 and within the space defined between belts 44 and conveyor section housing 38. The defined space ensures that card 14 remains stable as it moves through conveyor section 30.

[0060] Rotary drive unit 34 provides the required rotary drive to conveyor section housing 38. Rotary drive allows conveyor section 30 to rotate and discharge card 14 into the appropriate collector bin 20. In some embodiments, drive units 32, 34 may include a servo motor, while in other embodiments, stepper motors or other types of motors could be used. The choice of drive unit 32, 34 may depend on factors such as required precision, speed, and operational cost.

[0061] Conveyor section 30 includes a sensor 35, which is mounted on conveyor section housing 38. Sensor 35 is configured to detect presence of card 14 at a predetermined location along length of conveyor section 30, specifically on belts 44. Sensor 35 provides real-time feedback to processor 26 regarding position of card 14 within conveyor section 30. Once sensor 35 detects that card 14 has reached theATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATION designated location, processor 26 sends signal to rotary drive unit 34 to facilitate rotation of conveyor section 30, ensuring precise discharge of card 14 into correct collector bin 20.

[0062] In one embodiment, sensor 35 may be an optical sensor, such as an infrared sensor, which detects when card 14 interrupts beam of light at a specific point along length of conveyor section 30. As seen in FIG. 5, cutout 37 is positioned on conveyor section housing 38 and is designed to allow uninterrupted light travel from sensor 35 across conveyor section 30. Cutout 37 serves to eliminate potential obstructions that may interfere with the light beam emitted by sensor 35, ensuring that the detection of card 14 is accurate and reliable. This configuration ensures accurate detection of card 14 regardless of its size or thickness. Once detection occurs, rotary drive unit 34 rotates conveyor section 30 to appropriate angle required to discharge card 14 into designated compartment of collector bin 20.

[0063] In another embodiment, sensor 35 may be a proximity sensor, which uses electromagnetic fields or capacitive technology to detect presence of card 14 as it moves along belts 44. Proximity sensors may offer an alternative method of detection in environments where dust or debris may interfere with optical sensors. Processor 26 relies on data from sensor 35 to determine optimal timing for rotation of conveyor section 30, ensuring that card 14 is deposited into correct bin 20 without delay or misalignment.

[0064] Conveyor section 30 further includes a protrusion 48, which is configured to facilitate alignment with collector bin 20. Protrusion 48 ensures that conveyor section 30 is properly positioned relative to collector bin 20, thus reducing the risk of misalignment during card discharge. The alignment feature provided by protrusion 48 helps prevent cards from being misplaced or damaged during the transition from conveyor section 30 to collector bin 20. In alternative embodiments, conveyor section 30 may include additional alignment features, such as guide rails or sensors, that enhance the precision of card discharge. Sensors could detect the exact position of conveyor section 30 relative to collector bin 20 and adjust the alignment accordingly.ATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATION

[0065] In some embodiments, conveyor section 30 may be modular, allowing for quick replacement or customization based on the type of cards being sorted or the specific operational requirements. For instance, conveyor sections 30 with wider belts 44 and larger rollers 42 could be used to sort oversized cards, while narrower versions may be used for smaller cards. Furthermore, the materials used in conveyor section housing 38, rollers 42, and belts 44 may vary depending on the type of cards and the environment in which automated card sorting system 10 is used.

[0066] FIG. 6 is a perspective view of collection bin 20 used in collection station of automated card sorting system 10, in accordance with one embodiment of the present subject matter. As shown in FIG. 6, conveyor section 30 is rotated to facilitate the discharge of card 14 into collector bin 20. Conveyor section 30 rotates using rotary drive unit 34 to position the card 14 over the appropriate compartment of collector bin 20. The precise alignment between conveyor section 30 and collector bin 20 ensures that card 14 is directed accurately into one of the compartments, reducing the risk of misplacement or damage to the card during sorting.

[0067] Collector bin 20 is designed with a compartmentalized configuration, defined by a first compartment 50 and a second compartment 52. Partition 54 separates first compartment 50 and second compartment 52, allowing for the sorting of different types of cards into two distinct compartments. The presence of partition 54 ensures that cards deposited into first compartment 50 remain separated from those deposited into second compartment 52, providing a clear organization of cards based on the sorting criteria defined by processor 26. The compartments may be used to sort cards based on factors such as rarity, type, or value, depending on the specific configuration of the system.

[0068] First compartment 50 and second compartment 52 each have corresponding first opening 56 and second opening 58, respectively. First and second openings 56 and 58 serve as entry points for card 14 to be deposited into the compartments. When conveyor section 30 rotates, it positions card 14 over either first opening 56 or second opening 58, depending on the sorting requirements determined by processor 26. The precise positioning of conveyor section 30 ensures that card 14 isATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATION guided smoothly into the correct compartment, minimizing the risk of cards overlapping or becoming misaligned during sorting.

[0069] First funnel 60 is attached to the edge of first opening 56 of first compartment 50, and second funnel 62 is attached to the edge of second opening 58 of second compartment 52. First funnel 60 and second funnel 62 are designed to guide card 14 into the respective compartments, ensuring smooth and controlled deposition. The funnel design helps prevent cards from becoming stuck or damaged as they are deposited into the compartments. In some embodiments, funnels 60and 62 may be adjustable in size to accommodate different types of cards, such as thicker trading cards or standard playing cards. The adjustment could be manual or automated, depending on the specific requirements of the sorting system.

[0070] Each of first funnel 60 and second funnel 62 includes notch 64 to facilitate alignment with protrusion 48 on conveyor section 30. The alignment provided by notch 64 and protrusion 48 ensures that conveyor section 30 is properly positioned over the correct compartment during the sorting process. In alternative embodiments, other alignment mechanisms, such as sensors or guide rails, could be used to ensure precise positioning of conveyor section 30 relative to collector bin 20.

[0071] In one embodiment, an inner surface of second opening 58 is lined with low friction lining 66. Low friction lining 66 is used to ensure smooth and guided deposition of card 14 into second compartment 52. The low friction lining minimizes resistance as card 14 enters second compartment 52, reducing the likelihood of cards becoming stuck or damaged. In alternative embodiments, low friction lining 66 may be applied to both first opening 56 and second opening 58, depending on the specific materials and types of cards being sorted. The choice of material for low friction lining 66 could vary, including options such as Teflon, silicone, or other low-friction materials.

[0072] Each of first compartment 50 and second compartment 52 includes drawers 68, within which card 14 can be collected. Drawers 68 are designed to provide easy access to sorted cards once the sorting process is complete. In one embodiment,ATTORNEY DOCKET NON-PROVISIONALMTEC001WO PATENT APPLICATION drawers 68 may be removable, allowing users to easily transport sorted cards to other locations.

[0073] In some embodiments, drawers 68 may include locking mechanisms to secure sorted cards, preventing them from being accessed until the sorting process is complete. Alternatively, drawers 68 may be equipped with automatic ejection mechanisms that push the sorted cards into a separate collection area once they are full, streamlining the collection and packaging process for large-scale sorting operations.

[0074] It is to be noted that although automated card sorting system 10 has been described as a system having plurality of collector bins 20 within collection station 18, where each collector bin 20 has two compartments, the invention is not limited to this configuration. Other embodiments may include at least one collector bin 20 having more than two compartments, and such configurations fall within the scope of the present disclosure.

[0075] In one alternative embodiment, automated card sorting system 10 may include multiple collector bins 20, where each bin 20 has a greater number of compartments. For example, one embodiment may have two collector bins 20 with five compartments each. Each compartment is designated for sorting cards based on specific attributes such as card type, rarity, or condition. Conveyor section 30 is configured to rotate at precise angles to discharge card 14 into the appropriate compartment of collector bin 20 based on sorting criteria determined by processor 26. The rotation of conveyor section 30 may be controlled by rotary drive unit 34 that adjusts the angle of rotation according to the compartment selected by processor 26.

[0076] In another embodiment, collector bins 20 may include more than five compartments, such as bins with eight or ten compartments, depending on the operational needs of the system. Each compartment can be assigned to a different category of card 14, allowing for more granular sorting. For instance, a system with ten compartments could separate cards not only by type and rarity but also by condition, edition, or value. Processor 26 will determine the appropriate compartment for eachATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATION card 14 based on predefined criteria, and rotary drive unit 34 will rotate conveyor section 30 to align with the designated compartment.

[0077] Collector bins 20 with more compartments may also require more precise control over the rotation and alignment of conveyor section 30. In such embodiments, conveyor sections 30 may include multiple rotary drive units 34 to ensure smooth and accurate movement. The use of sensors such as sensor 35 may also be expanded to detect the position of card 14 with higher precision, ensuring that card 14 is properly aligned for discharge into the relevant compartment.

[0078] In the above description, numerous specific details are set forth such as examples of some embodiments, specific components, devices, methods, in order to provide a thorough understanding of embodiments of the present subject matter. It will be apparent to a person of ordinary skill in the art that these specific details need not be employed, and should not be construed to limit the scope of the subject matter.

[0079] In the development of any actual implementation, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints. Such a development effort might be complex and time-consuming, but may nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill. Hence as various changes could be made in the above constructions without departing from the scope of the subject matter, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

[0080] The foregoing description of embodiments is provided to enable any person skilled in the art to make and use the subject matter. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the novel principles and subject matter disclosed herein may be applied to other embodiments without the use of the innovative faculty. It is contemplated that additional embodiments are within the spirit and true scope of the disclosed subject matter.

[0081] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein.ATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATIONIt is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

Claims

ATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATIONWHAT IS CLAIMED IS:

1. An automated card sorting system, comprising: a feeding chute configured to receive a plurality of cards and sequentially guide said cards; a scanner positioned downstream from said feeding chute and configured to scan each card of said plurality of cards to identify characteristics of said card; a processor communicatively coupled to said scanner; a memory communicatively coupled to said processor and configured to store sorting criteria; a collection station comprising a plurality of conveyor sections, each conveyor section of said plurality of conveyor sections equipped with a translatory drive unit and a rotary drive unit; and a plurality of collector bins positioned to receive said cards from said conveyor sections, wherein said processor is configured to control said translatory drive unit and said rotary drive unit of each conveyor section based on the identified characteristics and the sorting criteria to direct each card to an appropriate collector bin.

2. The automated card sorting system of claim 1 , wherein each conveyor section of said plurality of conveyor sections comprises a conveyor section housing, a first shaft and a second shaft arranged in a spaced-apart configuration within said conveyor section housing, a plurality of rollers mounted on said first shaft and said second shaft, and a plurality of belts extending between said first shaft and said second shaft and positioned over said rollers.

3. The automated card sorting system of claim 2, wherein said second shaft is configured to be coupled to said translatory drive unit for facilitating conveyance of said cards along a length of said conveyor section.ATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATION4. The automated card sorting system of claim 1 , wherein each conveyor section of said plurality of conveyor sections comprises a sensor mounted on said conveyor section and configured to detect presence of a card at a predetermined location along said conveyor section.

5. The automated card sorting system of claim 1 , further comprises a buffer conveyor positioned downstream of said scanner and upstream of said collection station, wherein said buffer conveyor is configured to temporarily hold said cards after scanning and before entry into said conveyor sections.

6. The automated card sorting system of claim 1 , wherein each collector bin of said plurality of collector bins comprises a first compartment and a second compartment separated by a partition, and wherein said first compartment comprises a first opening and said second compartment comprises a second opening.

7. The automated card sorting system of claim 6, wherein a first funnel is attached to said first opening and a second funnel is attached to said second opening, and wherein each of said first funnel and said second funnel is configured to guide said cards into said first compartment and said second compartment.

8. The automated card sorting system of claim 7, wherein each of said first funnel and said second funnel includes an alignment notch configured to facilitate alignment with a protrusion extending from a corresponding conveyor section.

9. The automated card sorting system of claim 6, wherein each of said first compartment and said second compartment comprises a collection drawer configured to store said sorted cards.ATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATION10. The automated card sorting system of claim 1 , further comprising a feeder positioned between said feeding chute and said scanner, wherein said feeder is configured to regulate flow of said cards from said feeding chute into said scanner.

11. The automated card sorting system of claim 10, wherein said feeder comprises a spring-loaded mechanism that controls passage of a predetermined number of said cards and prevents multiple cards from entering said scanner simultaneously.

12. The automated card sorting system of claim 1 , further comprising a plurality of indicator media positioned adjacent to said collector bins, wherein each indicator media of said plurality of indicator media is configured to display information related to said cards stored within respective compartments of said collector bins, and wherein said processor is configured to control said indicator media based on the identified characteristics of sorted cards.

13. An automated card sorting system, comprising: a feeding chute configured to receive a plurality of cards and sequentially guide said cards; a scanner configured to scan each card of said plurality of cards to identify characteristics of said card including card type, serial number, rarity, or condition; a processor communicatively coupled to said scanner; a memory communicatively coupled to said processor and configured to store a database of cards and sorting criteria; a collection station comprising a plurality of conveyor sections arranged in a linear array, each conveyor section of said plurality of conveyor sections including a conveyor section housing with two shafts comprising a plurality of rollers mounted thereon, belts extending between said shafts, a translatory drive unit, a rotary drive unit, and a sensor mounted on said conveyor section housing and configured to detect presence of said cards at a predetermined location along said conveyor section, and wherein each conveyor section of said plurality of conveyor sections comprises a cutoutATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATION positioned to allow uninterrupted light travel from said sensor across said conveyor section; and a plurality of collector bins positioned to receive said cards from said conveyor sections, each collector bin comprising at least two compartments separated by a partition, wherein said processor is configured to control said translatory drive unit and said rotary drive unit of each conveyor section based on the identified characteristics and sorting criteria to rotate said conveyor section and discharge each card into an appropriate compartment of a collector bin.

14. The automated card sorting system of claim 13, wherein said feeding chute includes adjustable side rails with spring-loaded mechanisms that accommodate the width of said card.

15. The automated card sorting system of claim 13, further comprises a buffer conveyor positioned downstream of said scanner and upstream of said collection station, wherein said buffer conveyor is configured to temporarily hold said cards after scanning and before entry into said conveyor sections.

16. The automated card sorting system of claim 13, wherein said sensor is selected from the group consisting of optical sensors, proximity sensors, and capacitive sensors.

17. The automated card sorting system of claim 13, further comprising a feeder positioned between said feeding chute and said scanner, wherein said feeder is configured to regulate flow of said cards from said feeding chute into said scanner.

18. The automated card sorting system of claim 13, wherein each compartment comprises an opening with a funnel attached thereto and including a removable drawer, and wherein each funnel comprises an alignment notch configured to engage with a protrusion extending from a corresponding conveyor section to ensure proper positioning during card discharge.ATTORNEY DOCKET NON-PROVISIONAL MTEC001WO PATENT APPLICATION19. The automated card sorting system of claim 13, further comprising a plurality of indicator media positioned adjacent to said collector bins, wherein each indicator media of said plurality of indicator media is configured to display information related to said cards stored within respective compartments of said collector bins, and wherein said processor is configured to control said indicator media based on the identified characteristics of sorted cards.

20. A method of automatically sorting cards, said method comprising the steps of: receiving a plurality of cards in a feeding chute; sequentially guiding said cards from said feeding chute to a scanner; scanning each card of said plurality of cards with said scanner to identify characteristics of said card; processing said identified characteristics with a processor communicatively coupled to said scanner; comparing said identified characteristics with sorting criteria stored in a memory communicatively coupled to said processor; controlling a translatory drive unit of a conveyor section to transport said card along a collection station; and controlling a rotary drive unit of said conveyor section to rotate said conveyor section and discharge said card into an appropriate collector bin of a plurality of collector bins based on said identified characteristics and sorting criteria.

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