Hybrid system and method for particle sorting

Abstract

A hybrid system for separating particles includes at least one deflected-stream aerodynamic particle sorting device having two or more collection bins, wherein the particles are separated into the two or more collection bins, wherein bin-fellow particles separated into any of said bins substantially exhibit aerodynamic similarity based on said particle properties. The system further includes at least one sieving device having at least one sieve, wherein the particles are sorted by size.

Description

TITLEHYBRID SYSTEM AND METHOD FOR PARTICLE SORTINGHELD

[0001] This disclosure relates to systems and methods for particle sorting.BACKGROUND

[0002] This disclosure relates to a hybrid system for separating particles having a variation of properties, such as size, density, and coefficient of drag (related to shape) comprising a combination of a deflected-stream particle sorting device, that separates the particles according to an aerodynamic relationship involving all the particle properties, and a sieving device, which separates the particles by size alone.

[0003] Contamination of materials during manufacturing processes and elsewhere cause many problems including inferior products, premature breakdown of machinery, impure products, and other problems. Extensive refinement of materials can be too costly in many applications leaving manufacturers to decide what level of contamination is acceptable. This can cause major issues and create negative publicity. In an example, contamination of powder metallurgy (PM) nickel alloys used in turbine rotors has drawn significant attention recently because these alloys play a critical role in the performance and safety of turbine engines. When contamination occurs, it can lead to severe consequences, including reduced efficiency and potential failure of these essential components.

[0004] One of the primary sources of contamination in these nickel alloys is non- metallic inclusions (NMIs). These NMIs are typically ceramics, but could include particles of other contaminants that inadvertently become mixed with the powdered metal during the manufacturing process. Their presence as foreign particles in the metal matrix formed as the powders are sintered together can create weak points that compromise the structural integrity of the alloy.

[0005] Traditionally, the approach to managing contamination in PM nickel alloys has involved sieving out all particles larger than a certain size. This method is based on the idea that larger contaminants are more likely to initiate fatigue cracks, which can propagate over time and lead to catastrophic failures in turbine rotors. By limiting the size of contaminants through sieving, manufacturers aim to reduce the likelihood of such failures. However, this approach has limitations, as it does not account for smaller contaminants that may still pose a significant risk, or the inadvertent introduction of unexpected, potentially more damaging types of contaminants due processing hardware malfunction or degradation or other manufacturing escape.

[0006] There is growing interest in developing technologies that can exclude and inspect contaminants regardless of their size. Such advancements would represent a major step forward in ensuring the purity and reliability of PM nickel alloys used in critical applications like turbine rotors. By being able to identify and remove even the smallest contaminants, manufacturers could permanently mitigate the threat of contaminant-induced fatigue crack initiation, thereby enhancing the durability and safety of these vital components. This would not only improve the performance of turbine engines but also extend their operational life, reducing maintenance costs and increasing reliability for end-users.

[0007] In the field of additive manufacturing (AM), the recycling of metal powders is a critical aspect of the process. One of the main challenges in this area is the presence of partially sintered materials (PSM) left over from previous AM runs. These PSMs are typically composed of multiple partially fused particles that have not fully melted or bonded during the manufacturing process. Their presence in the recycled powder can negatively impact the quality of subsequent AM runs, leading to defects or inconsistencies in the final products.

[0008] Before recycled powder can be reused, it is essential to remove these partially sintered materials. The current approach to doing this involves sieving out objects that are larger than the maximum particle size allowed for powder metallurgy (PM) processes. This method aims to filter out the bulk of the unwanted PSMs, ensuring that the remaining powder is as uniform and free of contaminants as possible. However, this approach has its limitations, as smaller PSMs still pass through the sieve.

[0009] Due to the limitations of sieving, the number of times powders can be reused in AM is often restricted. This is because the level of contamination from partially sintered materials increases with each reuse, potentially compromising the quality of the final products. Limiting reuse helps mitigate this risk, but it also means that a significant amount of potentially usable material is discarded, reducing the overall efficiency and sustainability of the manufacturing process.

[0010] To improve the recycling of metal powders in AM, there is a need for more thorough methods of eliminating partially sintered materials across a range of sizes. By developing more advanced techniques for detecting and removing these contaminants, it would be possible to recycle more material without compromising quality. This would not only enhance the sustainability of AM processes but also lead to better-quality final products, as the powder used in production would be more consistent and free from defects caused by residual PSMs. In turn, this could reduce costs, increase efficiency, and promote more widespread adoption of AM technologies across various industries.

[0011] In the context of mineral deposits including placer and ore deposits, impurities such as gangue refer to the unwanted materials that are naturally mixed with the valuable target minerals. These materials typically have little or no economic value and must be separated during the beneficiation or ore processing stage to efficiently extract the desired metal. Gangue is a technical term used to describe these non-metallic or non-valuable substances, which commonly include materials like silica, alumina, limestone, clay, and other rock fragments. For example, placer gold is commonly found among sands of silicon or other gangue minerals. Monazite, the primary mineral from which rare-earth elements are derived, is often found with gangue materials including silicates, carbonates, and iron oxides.

[0012] Removing gangue is important because its presence reduces the concentration of the target metal, increases the cost and complexity of extraction, and creates additional challenges in terms of waste disposal and environmental impact. Several mineral processing techniques are employed to separate gangue from target minerals, including gravity separation, froth flotation, magnetic separation, and chemical leaching, depending on the physical and chemical properties of the target mineral and gangue. Applications of the present embodiments include separating a target mineral from gangue.

[0013] The present invention comprehends, but is not limited to, improvements to remedy the above deficiencies in the prior art, and any application where mixedparticles varying in size, but also varying in density and / or drag coefficient, need to be separated by density and / or drag coefficient.BRIEF SUMMARY

[0014] Disclosed herein is a hybrid system for separating particles. The hybrid system for separating particles includes at least one deflected-stream aerodynamic particle sorting device having two or more collection bins, wherein the particles are separated into the two or more collection bins, wherein bin-fellow particles separated into any of said bins substantially exhibit an aerodynamic similarity relationship based on said particle properties. The system includes at least one sieving device having at least one sieve, wherein the particles are sorted by size. The preceding subject matter of this paragraph characterizes example 1 of the present disclosure.

[0015] The at least one deflected-stream aerodynamic particle sorting device comprises one or more of the following; an aerodynamic vector particle sorting device, a coanda jet particle sorting device, a spinning wheel separator, a double cone separator, a cyclone separator. The preceding subject matter of this paragraph characterizes example 2 of the present disclosure, wherein example 2 also includes the subject matter according to example 1 , above.

[0016] Variation of particle properties substantially comprises at least two different densities, whereby particles of different size are sorted by density. The preceding subject matter of this paragraph characterizes example 3 of the present disclosure, wherein example 3 also includes the subject matter according to any one of examples 1-2, above.

[0017] Variation of particle properties includes at least two different drag coefficients, whereby particles having a low drag coefficient are separated from particles having a higher drag coefficient, thereby sorting particles of different size by shape. The preceding subject matter of this paragraph characterizes example 4 of the present disclosure, wherein example 4 also includes the subject matter according to any one of examples 1-3, above.

[0018] The particles are first directed through at least one of said at least one deflected-stream aerodynamic particle sorting devices and separated into the collection bins. At least one of said collection bins is further configured to direct the bin-fellow particles of said bin into at least one of said at least one sieves in said at least one sieving device, whereby the particles separated according to said aerodynamic relationship, but having different size, are further separated by size. The preceding subject matter of this paragraph characterizesexample 5 of the present disclosure, wherein example 5 also includes the subject matter according to any one of examples 1-4, above.

[0019] At least one collection bin comprises a plurality of bins so configured. The preceding subject matter of this paragraph characterizes example 6 of the present disclosure, wherein example 6 also includes the subject matter according to any one of examples 1-5, above.

[0020] At least one sieve comprises a plurality of sieves. The preceding subject matter of this paragraph characterizes example 7 of the present disclosure, wherein example 7 also includes the subject matter according to any one of examples 1-6, above.

[0021] At least one sieve is configured to comprise a mesh size chosen to separate said bin- fellow particles at a size corresponding to a predetermined difference in density. All references to mesh size refer to the aperture size within a sieve (not apertures per unit length as often cited in industry standards). The preceding subject matter of this paragraph characterizes example 8 of the present disclosure, wherein example 8 also includes the subject matter according to any one of examples 1-7, above.

[0022] The particles are directed through the at least one of the sieving devices having at least one mesh size, and whereby the particles are divided into size groups having size substantially bounded by adjacent sieve mesh sizes. The at least one sieving device is configured to have the particles of at least one of said size groups directed into at least one of said at least one deflected-stream aerodynamic particle sorting devices, whereby the particles first separated by size are further separated by density and drag coefficient. The preceding subject matter of this paragraph characterizes example 9 of the present disclosure, wherein example 9 also includes the subject matter according to any one of examples 1-8, above.

[0023] At least one sieve in said first sieving device comprises a plurality of sieves, each having a smaller mesh size than the one preceding, wherein the particles are sorted into a plurality of size ranges. The preceding subject matter of this paragraph characterizes example 10 of the present disclosure, wherein example 10 also includes the subject matter according to any one of examples 1-9, above.

[0024] At least two adjacent sieves having two mesh sizes of said plurality of mesh sizes are configured to have a minimum-to-maximum mesh aperture ratio greater than the square root of a predetermined density ratio equal to a lesser density divided by a greater density. The preceding subject matter of this paragraph characterizes example 11 of the present disclosure, wherein example 11 also includes the subject matter according to any one of examples 1-10, above.

[0025] The particles excluded from the second of said two adjacent sieves are directed into one of said at least one deflected- stream particle sorting devices. The deflected- stream particle sorting device is configured to substantially separate particles having density ratios less than said predetermined density ratio. The preceding subject matter of this paragraph characterizes example 12 of the present disclosure, wherein example 12 also includes the subject matter according to any one of examples 1-11, above.

[0026] The particles having a variation of particle properties comprise a mixture of particulate product and impurities, wherein at least a portion of the impurities are removed from the particulate product. The preceding subject matter of this paragraph characterizes example 13 of the present disclosure, wherein example 13 also includes the subject matter according to any one of examples 1-12, above.

[0027] The particulate product is powdered metal. The preceding subject matter of this paragraph characterizes example 14 of the present disclosure, wherein example 14 also includes the subject matter according to any one of examples 1-13, above.

[0028] The impurities removed include one or more of the following; sand, ceramic particles, partially sintered powder metal particles, non-metallic particles. The preceding subject matter of this paragraph characterizes example 15 of the present disclosure, wherein example 15 also includes the subject matter according to any one of examples 1-14, above.

[0029] Disclosed herein is a hybrid method of separating particles. The method includes passing the particles through at least one deflected-stream aerodynamic particle sorting device having two or more collection bins, wherein the particles are separated into the two or more collection bins, wherein bin-fellow particles separated into any of said bins substantially exhibit aerodynamic similarity based on said particle properties. The method includes passing the particles through at least one sieving device having at least one sieve, wherein the particles are sorted by size. The preceding subject matter of this paragraph characterizes example 16 of the present disclosure.

[0030] At least one deflected-stream aerodynamic particle sorting device comprises one of the following; an aerodynamic vector particle sorting device, a coanda jet particle sorting device, a spinning wheel separator, a double cone separator, a cyclone separator. The preceding subject matter of this paragraph characterizes example 17 of the present disclosure, wherein example 17 also includes the subject matter according to example 16, above.

[0031] The particles comprise a mixture of a particulate product and impurities, wherein at least a portion of the impurities are removed from the particulate product, thereby enhancing the quality of the product. The preceding subject matter of this paragraphcharacterizes example 18 of the present disclosure, wherein example 18 also includes the subject matter according to any one of examples 16-17, above.

[0032] The particulate product is a powdered metal. The preceding subject matter of this paragraph characterizes example 19 of the present disclosure, wherein example 19 also includes the subject matter according to any one of examples 16-18, above.

[0033] The impurities removed include one or more of the following; ceramic particles, partially sintered powder metal particles, non-metallic particles. The preceding subject matter of this paragraph characterizes example 20 of the present disclosure, wherein example 20 also includes the subject matter according to any one of examples 16-19, above.

[0034] The method further includes reprocessing a portion of the material aerodynamically to further separate the product from the impurities. The preceding subject matter of this paragraph characterizes example 21 of the present disclosure, wherein example 21 also includes the subject matter according to any one of examples 16-20, above.

[0035] The method further includes inspection of the impurities as a process control measure. The preceding subject matter of this paragraph characterizes example 22 of the present disclosure, wherein example 22 also includes the subject matter according to any one of examples 16-21 , above.

[0036] At least one of the said at least one deflected-stream aerodynamic particle sorting device is configured to entrain the particles in an inert gas. The preceding subject matter of this paragraph characterizes example 23 of the present disclosure, wherein example 23 also includes the subject matter according to any one of examples 16-22, above.

[0037] Other aspects and advantages of embodiments of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrated by way of example of the principles of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order that the advantages of the subject matter may be more readily understood, a more particular description of the subject matter briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the subject matter and are not therefore to be considered limiting of its scope, the subject matter will be described and explained with additional specificity and detail through the use of the drawings.

[0039] Figure 1 depicts a schematic diagram of a hybrid system according to one or more embodiments of the present disclosure.

[0040] Figure 2 depicts a schematic diagram of a second example of a hybrid system according to one or more embodiments of the present disclosure.

[0041] Figure 3 depicts a schematic diagram of a hybrid system according to one or more embodiments of the present disclosure.

[0042] Figure 4 depicts a schematic diagram of a multistage hybrid system according to one or more embodiments of the present disclosure.

[0043] Throughout the description, similar reference numbers may be used to identify similar elements. Throughout this application, similar designations or vocabulary may be used to identify similar elements, although the breadth of this disclosure should be understood to incorporate any alternatives and variations referenced within the specification (including the claims) and the accompanying drawings.DETAILED DESCRIPTION

[0044] The illustrations presented herein are not actual views of any particular device or method, but are merely idealized representations employed to describe example embodiments of the present disclosure. The following description provides specific details of embodiments of the present disclosure in order to provide a thorough description thereof. However, a person of ordinary skill in the art will understand that the embodiments of the disclosure may be practiced without employing many such specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional techniques employed in the industry. In addition, the description provided below does not include all elements to form a complete structure or assembly. Only those process acts and structures necessary to understand the embodiments of the disclosure are described in detail below. Additional conventional acts and structures may be used. Also note, any drawings accompanying the application are for illustrative purposes only, and are thus not drawn to scale. Additionally, elements common between figures may have corresponding numerical designations.

[0045] As used herein, the terms “comprising,” “including,” “containing,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, un-recited elements or method steps, but also include the more restrictive terms “consisting of,” “consisting essentially of,” and grammatical equivalents thereof.

[0046] As used herein, the term “may” with respect to a material, structure, feature, or method act indicates that such is contemplated for use in implementation of an embodimentof the disclosure, and such term is used in preference to the more restrictive term “is” so as to avoid any implication that other compatible materials, structures, features, and methods usable in combination therewith should or must be excluded.

[0047] As used herein, the term “configured” refers to a size, shape, material composition, and arrangement of one or more of at least one structure and at least one apparatus facilitating operation of one or more of the structure and the apparatus in a predetermined way.

[0048] As used herein, the singular forms following “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0049] As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0050] As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a degree of variance, such as within acceptable manufacturing tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least 90.0% met, at least 95.0% met, at least 99.0% met, or even at least 99.9% met.

[0051] As used herein, the term “about” used in reference to a given parameter is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the given parameter).

[0052] Additional non-limiting example embodiments of the disclosure are described below.

[0053] Useful embodiments of the present invention include a hybrid system for separating particles that have a variation of particle properties, including size, density, and drag coefficient, where drag coefficient is related to particle shape. The system is described as a hybrid system because it combines the utility of at least one aerodynamic sorting device, which sorts the particles into two or more bins according to aerodynamic similarity — including the effects of size, density, and shape, and at least one sieving device having at least one sieve, which sieving device sorts based on size alone.

[0054] Among aerodynamic sorting devices, deflected- stream aerodynamic sorting devices are useful for the hybrid system. Deflected-stream aerodynamic sorting devices include, but are not limited to, an aerodynamic vector particle sorting device, a coanda jet particle sorting device, a spinning wheel separator, a double cone separator, or a cyclone separator.

[0055] A deflected- stream aerodynamic sorting device is an aerodynamic sorting device wherein the particles are entrained in a fluid or gas stream, which stream is subsequently deflected to move along a curved path. While inertial forces act to keep the particles moving in a straight line, the curved path of the stream acts to deflect the particle trajectory by drag forces. The actual trajectory of each particle is dependent upon a balance between these forces. Because the inertial and drag forces are dependent on size, density and drag coefficient, individual particle trajectory within a given stream is a function of all three properties.

[0056] The combined effect of all three properties can be represented as a single aerodynamic similarity parameter known as the aerodynamic diameter, dautilized in the aerosol industry (https: / / en.wikipedia.Org / wiki / Aerosol#Aerodynamic_diameter).Where deis the equivalent spherical diameter of the particle (the diameter of a sphere with the same volume as the particle), ppis the particle density, p0is a reference density (equal to the density of water), and % is the dynamic shape factor. For approximately spherical particles, is approximately equal to the ratio of the coefficient of drag of the particle, CDto the coefficient of drag of a sphere, CDo.

[0057] Particles having the same aerodynamic diameter will theoretically navigate an aerodynamic system along the same path. In the medical application of aerosols, for example, aerosol particles having the same aerodynamic diameter are known to arrive at the same location in the respiratory tract when inhaled. By the same principle, particles having the same aerodynamic diameter will arrive at the same sorting bin when sorted with an aerodynamic sorting device. For the purpose of this discussion, particles that substantially follow the same sorting path are referred to as bin-fellows. Bin-fellows may be thus said to substantially exhibit aerodynamic similarity.

[0058] Applying Equation (1 ) for two particles with the same aerodynamic diameter, e2 PplX2Pp2Xlor, for approximately spherical bin-fellows

[0059] Equation (4) will be referred to herein as the aerodynamic bin-fellow relationship, or, simply, the bin-fellow relationship. Equation (4), as written, is based on Stokes’ assumption that the gas porosity is zero at the surface of the particle, which is likely of sufficient accuracy for particle sizes down to about 5 pm, depending on the gas used in the gas stream. For smaller particles, the Cunningham correction, which accounts for the mean free path of the gas, can be included in the numerator, but will be neglected for the present discussion.

[0060] As a first example to illustrate the use of the bin-fellow relationship in connection with the present invention, consider a mixed particle stream of substantially spherical particles (Cp = Cp0) with a range of particle sizes, but with particles of two different densities that is passed through a deflected-stream aerodynamic sorting device that sorts the particles into a plurality of very narrow bins. We will refer to the ratio of the lighter density to the heavier density as the density ratio. According to the bin-fellow relationship, if the density ratio is q, then particles sorting to the same bin will have the lighter density particles of a diameter substantially ^1 / q multiplied by that of the heavier density particles. Thus, a density ratio of 14 will yield a diameter ratio of two and so forth. Particles from any of the bins can thus be separated by density by further passing them through a sieve having an aperture size between the larger and smaller particle sizes pertaining to that bin according to the binfellow relationship.

[0061] Note that if our example included additional particles of further reduced density, these particles would be even larger size compared to their higher-density bin-fellows, and would also be sorted out by the sieving process. Thus, we see how a hybrid system including a deflected-stream aerodynamic sorting device and a sieving device can be used to sort mixtures of particles having different densities.

[0062] As a second example, consider a mixed particle stream of particles that differ in shape or roughness in such a way that a portion of the particles have a substantially larger drag coefficient than a remaining portion, but with the same density, that is passed through a deflected-stream aerodynamic sorting device that sorts the particles into at least two bins,where particles separated into any of the bins substantially exhibit aerodynamic similarity by the bin-fellow relationship. According to the bin-fellow relationship, particles having the higher drag coefficient will be larger in diameter than their lower drag bin-fellows. Particles from any of the bins can thus be substantially separated by shape by passing them through a sieve having an aperture size between the larger and smaller particle sizes pertaining to that bin.

[0063] The above first and second example illustrate that the hybrid system can be configured where particles pass first through the aerodynamic sorting device and are sorted into the collection bins, and where at least one of the collection bins is further configured to direct the bin-fellow particles of that bin into a sieving device, so that particles separated according to aerodynamic symmetry, but having different size, are further separated by size.

[0064] It is useful to sort multiple bins by size. Thus, it is useful to have more than one bin that can be so configured. It is further useful to have more than one sieve, for example if it is desired to separate more than two densities or shapes within the mixture of particles.

[0065] Referring now to Figure 1 , a schematic diagram of a hybrid system 200 for separating particles is shown. Although the system 200 is shown and described with certain components and functionality, other embodiments of the system 200 may include fewer or more components to implement less or more functionality.

[0066] In some embodiments, the particles have a variation of particle properties. In some embodiments, one of the properties include size. In some embodiments, one of the properties include density. In some embodiments, one of the properties include drag coefficient. In some embodiments, the properties include a combination of the properties described above and other properties that are separable via an aerodynamic particle sorting device and a sieving device.

[0067] Referring to Figure 1, a hybrid system 200 is shown. The hybrid system includes a deflected- steam aerodynamic particle sorting device 100 and a sieving device 150. In this Figure, the aerodynamic particle sorting device is a aerodynamic vector particle sorting (A VPS) device. Although the aerodynamic particle sorting device 100 is shown and described with certain components and functionality, other embodiments of the aerodynamic particle sorting device 100 may include fewer or more components to implement less or more functionality. In the illustrated embodiment, a particle stream 202 is directed to the aerodynamic particle sorting device 100 in a direction indicated by arrow 201. The particle stream comprises a plurality of particles with variable properties as described above. Airflow 203 is produced to generate a flow within the aerodynamic particle sorting device 100. Theaerodynamic particle sorting device 100 may include various channels and physical obstructions 205 that redirect the airflow and particle stream 202 along a general path represented by line 204. In some embodiments, the airflow includes an inert gas or is an inert gas.

[0068] As the airflow is deflected by suction 206, the particles are separated into streams. This separation creates separate paths for particles with varying properties. These aerodynamically separated particle streams 212, 214, 220, and 222 are directed generally to collection bins 232. Tn some embodiments, the system includes two collection bins 232. Tn some embodiments, the system includes two or more collection bins 232.

[0069] As can be seen, the particle streams are deflected into different bins 232. The particle stream 204 is deflected into multiple aerodynamically separated particle streams 212, 214, 220, and 222. The bins 232 may be located such that the varying size particles (or whatever property is dictating the separation of the particle stream) are collected in distinct bins 232. In some embodiments, the particles are separated into the two or more collection bins 232. Particles that are collected into a particular bin 232 are referred to as bin-fellows. The bin-fellow particles separated into any of the bins 232 substantially exhibit aerodynamic similarity based on said particle properties. As shown, the aerodynamically separated particle streams 212, 214, 220, and 222 are each separated and as such each particular separated particle stream is a collection of bin-fellows.

[0070] This is only one part of the hybrid system 200. The hybrid system 200 further includes at least one sieving device 150. In some embodiments, each individual bin 232 has a corresponding sieving device 150. In the illustrated embodiment, a single sieving device 150 is shown for a single bin 232. The sieving device 150 includes at least one sieve 152. In the illustrated embodiment, the sieving device 150 includes two sieves 152. The use of the sieving device 150 after the aerodynamic particle sorting device 100, allows for a single bin 232 of particles including bin-fellows to be separated further based on size. Such further refinement allows for more precise separation of particles and leads to reduction or elimination of contaminants as the components of the particle stream 202 end up in separate groups as shown by particles 262 above the first coarser sieve 152 and the smaller particles 264 above the finer sieve 152. A third group of particles 266 is located below the finer sieve.

[0071] In some embodiments, at least one deflected- stream aerodynamic particle sorting device 100 includes an aerodynamic vector particle sorting device. In some embodiments, at least one deflected-stream aerodynamic particle sorting device 100 includes a coanda jet particle sorting device. In some embodiments, at least one deflected-streamaerodynamic particle sorting device 100 includes a spinning wheel separator. In some embodiments, at least one deflected-stream aerodynamic particle sorting device 100 includes a double cone separator. In some embodiments, at least one deflected- stream aerodynamic particle sorting device 100 includes a cyclone separator.

[0072] In some embodiments, variation of particle properties substantially comprises at least two different densities, whereby particles of different size are sorted by density.

[0073] In some embodiments, variation of particle properties includes at least two different drag coefficients, whereby particles having a low drag coefficient are separated from particles having a higher drag coefficient, thereby sorting particles of different size by shape.

[0074] In some embodiments, the particles are first directed through at least one aerodynamic particle sorting device 100 and separated into the collection bins 232. In some embodiments, at least one of said collection bins is further configured to direct the bin-fellow particles into at least one sieving device 150. In some embodiments, the particles separated according to said aerodynamic relationship, but having different size, are further separated by size within the sieving device. The use of the aerodynamic particle sorting device 100 and the at least one sieving device 150 allows for automated separation of particles to a user’s specifications. The sieve size and the location of the bins within the deflected-stream can dictate the granularity with which the particle stream is separated into separate particles exhibiting different sizes and properties.

[0075] In some embodiments, a plurality of bins are configured to be further sorted by a sieving device. In some embodiments, at least one sieve is configured to comprise a mesh size chosen to separate said bin-fellow particles at a size corresponding to a predetermined difference in density.

[0076] In some embodiments, the particles are directed through a first of the at least one of the sieving devices. In some embodiments, a first sieving device is configured to have the particles excluded by at least one of said at least one sieves in said first sieving device directed into at least one of said at least one deflected-stream aerodynamic particle sorting devices. In some embodiments, the particles first separated by size are further separated by density and drag coefficient. In some embodiments, the particles are directed through the at least one of the sieving devices having at least one mesh size, whereby the particles are divided into size groups having size substantially bounded by adjacent sieve mesh sizes. The at least one sieving device is configured to have the particles of at least one of said size groups directed into at least one of said at least one deflected-stream aerodynamic particle sorting devices,whereby the particles first separated by size are further separated by density and drag coefficient

[0077] In some embodiments, at least one sieve in said first sieving device comprises a plurality of sieves, each having a different mesh size, wherein the particles are sorted into a plurality of size ranges.

[0078] In some embodiments, at least one sieve in said first sieving device comprises a plurality of sieves, each having a smaller mesh size than the one preceding, wherein the particles are sorted into a plurality of size ranges. In such embodiments, the material sifted through each sieve is further sifted in a subsequent sieve. The sifting in such environments occurs with the sifting out of the largest particles first.

[0079] In some embodiments, at least one sieve in said first sieving device comprises a plurality of sieves, each having a larger mesh size than the one preceding, wherein the particles are sorted into a plurality of size ranges. In such embodiments, the material that is restricted from going through the first sieve is presented at the next sieve. The sifting in such environments occurs with the sifting out of the smallest particles first.

[0080] In some embodiments, at least two adjacent sieves having two mesh sizes of said plurality of mesh sizes are configured to have a minimum-to-maximum mesh aperture ratio greater than the square root of a predetermined density ratio equal to a lesser density divided by a greater density.

[0081] In some embodiments, the particles excluded from the second of said two adjacent sieves are directed into one of said at least one deflected-stream particle sorting devices. In some embodiments, the deflected-stream particle sorting device is configured to substantially separate particles having density ratios less than said predetermined density ratio.

[0082] In some embodiments, the particles having a variation of particle properties comprise a mixture of particulate product and impurities, wherein at least a portion of the impurities are removed from the particulate product.

[0083] In some embodiments, the particulate product is powdered metal. Other particulate products are contemplated herein.

[0084] In some embodiments, the impurities removed include one or more of the following; sand, ceramic particles, partially sintered powder metal particles, non-metallic particles.

[0085] Referring now to Figure 2, a schematic diagram of a hybrid system 200 for separating particles is shown. Although the system 200 is shown and described with certaincomponents and functionality, other embodiments of the system 200 may include fewer or more components to implement less or more functionality.

[0086] The embodiment of Figure 2 is similar to Figure 1 but with a single coanda sorter as the aerodynamic particle sorting device 100. In some embodiments, at least one deflected-stream aerodynamic particle sorting device 100 includes an aerodynamic vector particle sorting device. In some embodiments, at least one deflected-stream aerodynamic particle sorting device 100 includes a coanda jet particle sorting device. In some embodiments, at least one deflected-stream aerodynamic particle sorting device 100 includes a spinning wheel separator. In some embodiments, at least one deflected-stream aerodynamic particle sorting device 100 includes a double cone separator. In some embodiments, at least one deflected- stream aerodynamic particle sorting device 100 includes a cyclone separator.

[0087] In the illustrated embodiment, a particle stream 202 is directed to the aerodynamic particle sorting device 100 in a direction indicated by arrows 201. The particle stream comprises a plurality of particles with variable properties as described above. Airflow is produced to generate a flow within the aerodynamic particle sorting device 100 in the direction shown by arrows 201. The aerodynamic particle sorting device 100 may include various channels and physical obstructions that redirect the airflow and particle stream 202 along a general path. As the particle stream 202 enters the aerodynamic particle sorting device 100, the airflow is deflected by coanda surface 210, together with additional airflow 204 and, based on the individual properties of the particles, the particle stream 202 is separated into aerodynamically separated particle streams 212, 214, 216, 218, 220, and 222. Each separated stream is directed to a collection bin 232.

[0088] At least one individual bin 232 has a corresponding sieving device 150. In the illustrated embodiment, a single sieving device 150 is shown for a single bin 232. The sieving device 150 includes at least one sieve 152. In the illustrated embodiment, the sieving device 150 includes two sieves 152. The use of the sieving device 150 after the aerodynamic particle sorting device 100, allows for a single bin 232 of particles including bin- fellows to be separated further based on size. Such further refinement allows for more precise separation of particles and leads to reduction or elimination of contaminants as the components of the particle stream 202 end up in separate groups as shown by particles 262 above the first coarser sieve 152 and the smaller particles 264 above the finer sieve 152. A third group of particles 266 is located below the finer sieve.

[0089] In the illustrated embodiment, the sieving device 150 is separating the largest particles first but the order of sieving may be reversed such that the smallest mesh size is used first using methods commonly known in the art.

[0090] In some embodiments, variation of particle properties substantially comprises at least two different densities, whereby particles of different size are sorted by density.

[0091] In some embodiments, variation of particle properties includes at least two different drag coefficients, whereby particles having a low drag coefficient are separated from particles having a higher drag coefficient, thereby sorting particles of different size by shape.

[0092] In some embodiments, the particles are first directed through at least one aerodynamic particle sorting device and separated into the collection bins. In some embodiments, at least one of said collection bins is further configured to direct the bin-fellow particles into at least one sieving device. In some embodiments, the particles separated according to said aerodynamic relationship, but having different size, are further separated by size.

[0093] In some embodiments, a plurality of bins are configured to be further sorted by a sieving device. In some embodiments, at least one sieve is configured to comprise a mesh size chosen to separate said bin-fellow particles at a size corresponding to a predetermined difference in density.

[0094] In some embodiments, the particles are directed through a first of the at least one of the sieving devices. In some embodiments, a first sieving device is configured to have the particles excluded by at least one of said at least one sieves in said first sieving device directed into at least one of said at least one deflected-stream aerodynamic particle sorting devices. In some embodiments, the particles first separated by size are further separated by density and drag coefficient. In some embodiments, the particles are directed through the at least one of the sieving devices having at least one mesh size, whereby the particles are divided into size groups having size substantially bounded by adjacent sieve mesh sizes. The at least one sieving device is configured to have the particles of at least one of said size groups directed into at least one of said at least one deflected-stream aerodynamic particle sorting devices, whereby the particles first separated by size are further separated by density and drag coefficient

[0095] In some embodiments, at least one sieve in said first sieving device comprises a plurality of sieves, each having a different mesh size, wherein the particles are sorted into a plurality of size ranges.

[0096] In some embodiments, at least one sieve in said first sieving device comprises a plurality of sieves, each having a smaller mesh size than the one preceding, wherein the particles are sorted into a plurality of size ranges. In such embodiments, the material sifted through each sieve is further sifted in a subsequent sieve. The sifting in such environments occurs with the sifting out of the largest particles first.

[0097] In some embodiments, at least one sieve in said first sieving device comprises a plurality of sieves, each having a larger mesh size than the one preceding, wherein the particles are sorted into a plurality of size ranges. In such embodiments, the material that is restricted from going through the first sieve is presented at the next sieve. The sifting in such environments occurs with the sifting out of the smallest particles first.

[0098] In some embodiments, at least two adjacent sieves having two mesh sizes of said plurality of mesh sizes are configured to have a minimum-to-maximum mesh aperture ratio greater than the square root of a predetermined density ratio equal to a lesser density divided by a greater density.

[0099] In some embodiments, the particles excluded from the second of said two adjacent sieves are directed into one of said at least one deflected-stream particle sorting devices. In some embodiments, the deflected- stream particle sorting device is configured to substantially separate particles having density ratios less than said predetermined density ratio.

[0100] In some embodiments, the particles having a variation of particle properties comprise a mixture of particulate product and impurities, wherein at least a portion of the impurities are removed from the particulate product.

[0101] In some embodiments, the particulate product is powdered metal. Other particulate products are contemplated herein.

[0102] In some embodiments, the impurities removed include one or more of the following; sand, ceramic particles, partially sintered powder metal particles, non-metallic particles.

[0103] A third example is similar to the first example, but where the mixture of particles includes both a range of diameters and a range of densities, and the sieve mesh size is configured using the bin-fellow relationship to divide the particles at a density ratio that is predetermined by the user. Thus, the bin-fellow relationship can be utilized in the hybrid system to configure the sieve to have a mesh size chosen to substantially separate bin-fellow particles at a size corresponding to a predetermined difference in density.

[0104] In a generic sense, the system can be configured to have the particles first pass through the aerodynamic sorting device as described in examples above. However in analternate, reversed configuration, it is useful to have the system configured so that the particles are directed through a first of the at least one sieving devices, wherein the first sieving device is configured to have the particles excluded by at least one of the at least one sieves in the first sieving device directed into at least one of the at least one deflected-stream aerodynamic particle sorting devices, so that the particles first separated by size are further separated by density and drag coefficient.

[0105] For this reverse configuration, it is further useful that the at least one sieve in the first sieving device includes a plurality of sieves, each having a different mesh size than the one proceeding, so that the particles are sorted into a plurality of size ranges.

[0106] Additionally, for this reverse configuration, it is further useful that the at least one sieve in the first sieving device includes a plurality of sieves, each having a smaller mesh size than the one proceeding, so that the particles are sorted into a plurality of size ranges. In such embodiments, the material sifted through each sieve is further sifted in a subsequent sieve. The sifting in such environments occurs with the sifting out of the largest particles first.

[0107] Finally, for this reverse configuration, it is further useful that the at least one sieve in the first sieving device includes a plurality of sieves, each having a larger mesh size than the one proceeding, so that the particles are sorted into a plurality of size ranges. In such embodiments, the material that is restricted from going through the first sieve is presented at the next sieve. The sifting in such environments occurs with the sifting out of the smallest particles first.

[0108] In order to sort mixed particle streams in the reverse configuration by density, application of the bin-fellow relationship suggests that it is useful to have at least two adjacent sieves having two mesh sizes of said plurality of mesh sizes configured to have a minimum-to- maximum mesh aperture ratio greater than the square root of a predetermined density ratio.

[0109] It is further useful that the reverse system be further configured so that the particles excluded from the second of said two adjacent sieves are directed into one of said at least one deflected- stream particle sorting devices, and wherein the deflected-stream particle sorting device is configured to substantially separate particles having density ratios less than the predetermined density ratio.

[0110] Referring now to Figure 3, a schematic diagram of a hybrid system 200 for separating particles is shown. Although the system 200 is shown and described with certain components and functionality, other embodiments of the system 200 may include fewer or more components to implement less or more functionality.

[0111] The embodiment of Figure 3 is similar to Figures 1 and 2 but with a sieving device 150 preceding the aerodynamic particle sorting device 100. In some embodiments, at least one deflected-stream aerodynamic particle sorting device 100 includes an aerodynamic vector particle sorting device. In some embodiments, at least one deflected- stream aerodynamic particle sorting device 100 includes a coanda jet particle sorting device. In some embodiments, at least one deflected-stream aerodynamic particle sorting device 100 includes a spinning wheel separator. In some embodiments, at least one deflected-stream aerodynamic particle sorting device 100 includes a double cone separator. In some embodiments, at least one deflected-stream aerodynamic particle sorting device 100 includes a cyclone separator.

[0112] In the illustrated embodiment, a sieving device 150 is shown with a particle stream 202 introduced in direction shown by arrows 201. The sieving device 150 includes at least one sieve 152. In the illustrated embodiment, the sieving device 150 includes five sieves 152. The use of the sieving device 150 before the aerodynamic particle sorting device 100, allows for the particle stream 202 to be separated based on size first with similar size particles separated into size groups 251, 252, 253, 254, 255 and 256. Similar size particles may then be introduced into the deflected-stream aerodynamic particle sorting device 100. Such further refinement allows for more precise separation of particles and leads to reduction or elimination of contaminants as the components of the particle stream 202 end up in separate groups as shown by particles 272, 274 and 276 in separate collection bins.

[0113] In the illustrated embodiment, the size group 251 is introduced into the deflected-stream aerodynamic particle sorting device 100. As the size group 251 enters the aerodynamic particle sorting device 100, it is deflected as previously described, separating the particles based on the individual properties of the particles in the size group 251. The group is separated into aerodynamically separated particle streams 212, 216, and 222. Each separated stream is directed to a collection bin 232. As shown, the separated particle stream 222 is deflected more than the separated particle stream 212. This may be because of density of the particles or aerodynamic shape or another property that affects the amount of deflection. Thus particles 272, 274 and 276 are grouped by these properties.

[0114] In some embodiments, variation of particle properties substantially comprises at least two different densities, whereby particles of different size are sorted by density.

[0115] In some embodiments, variation of particle properties includes at least two different drag coefficients, whereby particles having a low drag coefficient are separated from particles having a higher drag coefficient, thereby sorting particles of different size by shape.

[0116] In some embodiments, the particles are directed through at least one aerodynamic particle sorting device and separated into the collection bins only after being separated first by a sieving device. In some embodiments, the particles are directed into at least one sieving device with a plurality of sieves. In some embodiments, the particles are separated according to size by the sieving device.

[0117] In some embodiments, at least one sieve in said first sieving device comprises a plurality of sieves, each having a different mesh size, wherein the particles are sorted into a plurality of size ranges.

[0118] In some embodiments, at least one sieve in said first sieving device comprises a plurality of sieves, each having a smaller mesh size than the one preceding, wherein the particles are sorted into a plurality of size ranges. In such embodiments, the material sifted through each sieve is further sifted in a subsequent sieve. The sifting in such environments occurs with the sifting out of the largest particles first.

[0119] In some embodiments, at least one sieve in said first sieving device comprises a plurality of sieves, each having a larger mesh size than the one preceding, wherein the particles are sorted into a plurality of size ranges. In such embodiments, the material that is restricted from going through the first sieve is presented at the next sieve. The sifting in such environments occurs with the sifting out of the smallest particles first.

[0120] In some embodiments, at least two adjacent sieves having two mesh sizes of said plurality of mesh sizes are configured to have a minimum-to-maximum mesh aperture ratio greater than the square root of a predetermined density ratio equal to a lesser density divided by a greater density.

[0121] In some embodiments, the particles excluded from the second of said two adjacent sieves are directed into one of said at least one deflected-stream particle sorting devices. In some embodiments, the deflected-stream particle sorting device is configured to substantially separate particles having density ratios less than said predetermined density ratio.

[0122] In some embodiments, the particles having a variation of particle properties comprise a mixture of particulate product and impurities, wherein at least a portion of the impurities are removed from the particulate product.

[0123] In some embodiments, the particulate product is powdered metal. Other particulate products are contemplated herein.

[0124] In some embodiments, the impurities removed include one or more of the following; sand, ceramic particles, partially sintered powder metal particles, non-metallic particles.

[0125] In an exemplary application of any of the systems above described, the particles having a variation of particle properties consist of a mixture of particulate product and impurities, and at least a portion of the impurities are separated from the particulate product, thus improving product quality and value. This is applicable to a wide variety of particulate products, including, but not limited to pharmaceuticals, toner for printing applications, ceramic powders, food products, and powdered metals.

[0126] Applications for powdered metals include, but are not limited to the removal of sand or other impurities from particles of gold or other metals or ores in a mining application, the removal of ceramic or other nonmetallic particles from nickel alloy powders, or the removal of partially sintered particles from used additive manufacturing powder metal feedstock before re-use.

[0127] In applications where a single pass through the hybrid particle sorting system does not sufficiently separate the particles having a variation of particle properties, into groups of particles with the desired properties, a portion of the material can be reprocessed aerodynamically through the one or more deflected-stream aerodynamic particle sorting devices to further separate the particles. This is useful when removing impurities, and a portion of the material is reprocessed aerodynamically to further separate the product from the impurities.

[0128] Referring now to Figure 4, a schematic diagram of a hybrid system 200 for separating particles is shown. Although the system 200 is shown and described with certain components and functionality, other embodiments of the system 200 may include fewer or more components to implement less or more functionality.

[0129] The embodiment of Figure 4 is similar to Figure 2 but with a second coanda sorter function as a second aerodynamic particle sorting device 100B.

[0130] In the illustrated embodiment, a particle stream 202 is directed to the aerodynamic particle sorting device 100A. The particle stream comprises a plurality of particles with variable properties as described above. Airflow is produced to generate a flow within the aerodynamic particle sorting device 100. The aerodynamic particle sorting device 100 may include various channels and physical obstructions that redirect the airflow and particle stream 202 along a general path. As the particles stream 202 enters the aerodynamic particle sorting device 100A an airflow is presented to the stream represented by lines 204 that deflect the stream and based on the individual properties of the particles, the particle stream 202 is separated into aerodynamically separated particle streams 212, 216, and 222. Each separated stream is funneled through a separate channel as shown. Separated particle stream212 is directed into a channel 242 that directs the separated stream to the first sieving device 150A. Separated particle stream 216 is directed to bin 232.

[0131] Separated particle stream 222 is directed to a second aerodynamic particle sorting device 100B. As the separated particle stream 222 enters the second aerodynamic particle sorting device 100B an airflow is presented to the stream represented by lines 204B that deflect the stream and based on the individual properties of the particles the separated particle stream 222 are separated into aerodynamically separated particle streams 212B, 216B, and 222B. Each separated stream is funneled through a separate channel as shown. Separated particle stream 212B is directed into a channel 242B that directs the separated stream to the second sieving device 150B. Separated particle streams 222B and 216B are directed to bins 232B.

[0132] In some embodiments, each individual bin 232 has a corresponding sieving device 150. In the illustrated embodiment, two sieving devices 150 A and 150B are shown. They function similarly. The sieving device 150 includes at least one sieve 152. In the illustrated embodiment, the sieving device 150 includes two sieves 152. The use of the sieving device 150 after the aerodynamic particle sorting device 100, allows for a single bin 232 of particles including bin-fellows to be separated further based on size. Such further refinement allows for more precise separation of particles and leads to reduction or elimination of contaminants as the components of the particle stream 202 end up in separate groups as shown by particles 262 above the first coarser sieve 152 and the smaller particles 264 above the finer sieve 152. A third group of particles 266 is located below the finer sieve. In the second sieving device 150B, there are particles 262B above the first coarser sieve 152, and smaller particles 264B above the finer sieve 152, and even smaller particles 266B below the finer sieve.

[0133] In the illustrated embodiment, the sieving device 150 is separating the largest particles first but the order of sieving may be reversed such that the smallest mesh size is used first using methods commonly known in the art.

[0134] The utility of separating impurities from a product, in addition to improving product quality, further enables inspection of the impurities themselves as a process control measure. Such an inspection can be useful in detecting poor feedstock quality, an unexpected fouling of the product, possibly associated with failure or degradation of mechanical components associated with product manufacture, or other conditions affecting product quality. Adverse findings discovered during such an inspection can inform corrective actions and prevent process escapes.

[0135] Further, in some applications, the chemistry of the product requires that the aerodynamic sorting device be configured to operate with a particular type of gas, such as an inert gas.

[0136] The invention also comprehends a method of separating particles having a variation of particle properties, comprising at least two steps in any order comprising: passing the particles through at least one deflected- stream aerodynamic particle sorting device having two or more collection bins, wherein the particles are separated into the two or more collection bins, wherein bin-fellow particles separated into any of the bins substantially exhibit aerodynamic similarity based on the particle properties; and, passing the particles through at least one sieving device having at least one sieve, wherein the particles are sorted by size.

[0137] The method further comprehends use of the system described in any of the above embodiments.

[0138] While the present invention has been described herein with respect to certain illustrated embodiments, those of ordinary skill in the art will recognize and appreciate that it is not so limited. Rather, many additions, deletions, and modifications to the illustrated embodiments may be made without departing from the scope of the invention as claimed, including legal equivalents thereof. In addition, features from one embodiment may be combined with features of another embodiment while still being encompassed within the scope of the invention as contemplated by the inventors. Further, embodiments of the disclosure have utility with different and various test methods and systems.

[0139] Although specific embodiments of the invention have been described and illustrated, the invention is not to be limited to the specific forms or arrangements of parts so described and illustrated. The scope of the invention is to be defined by the claims appended hereto and their equivalents.

[0140] In the above description, certain terms may be used such as "up," "down," "upper," "lower," "horizontal," "vertical," "left," "right," and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and / or orientations. For example, with respect to an object, an "upper" surface can become a "lower" surface simply by turning the object over. Nevertheless, it is still the same object. Further, the terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and / or mutually inclusive, unlessexpressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise.

[0141] As used herein, the phrase “at least one of”, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one oT’ means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.

[0142] As used herein, a system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any alteration, rather than merely having potential to perform the specified function after further modification. In other words, the system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing the specified function. As used herein, “configured to” denotes existing characteristics of a system, apparatus, structure, article, element, component, or hardware which enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as being “configured to” perform a particular function may additionally or alternatively be described as being “adapted to” and / or as being “operative to” perform that function.

[0143] Although the operations of the method(s) or processes herein are shown and described in a particular order, the order of the operations of each method may be altered so that certain operations may be performed in an inverse order or so that certain operations may be performed, at least in part, concurrently with other operations.

Claims

CLAIMSWhat is claimed is:

1. A hybrid system for separating particles, the particles having a variation of particle properties, said properties including size, density, and drag coefficient, the system comprising: at least one deflected-stream aerodynamic particle sorting device having two or more collection bins, wherein the particles are separated into the two or more collection bins, wherein bin-fellow particles separated into any of said bins substantially exhibit aerodynamic similarity based on said particle properties; and, at least one sieving device having at least one sieve, wherein the particles are sorted by size.

2. The system of claim 1 , wherein the at least one deflected-stream aerodynamic particle sorting device comprises one or more of the following; an aerodynamic vector particle sorting device, a coanda jet particle sorting device, a spinning wheel separator, a double cone separator, or a cyclone separator.

3. The system of claim 1 , wherein said variation of particle properties substantially comprises at least two different densities, whereby particles of different size are sorted by density by the at least one deflected-stream aerodynamic particle sorting device.

4. The system of claim 1, wherein said variation of particle properties includes at least two different drag coefficients, whereby particles having a low drag coefficient are separated from particles having a higher drag coefficient by the at least one deflected-stream aerodynamic particle sorting device, thereby sorting particles of different size by shape.

5. The system of claim 1, configured so that the particles are first directed through at least one of said at least one deflected-stream aerodynamic particle sorting devices and separated into the collection bins; and wherein at least one of said collection bins is further configured to direct the binfellow particles of said bin into at least one of said at least one sieves in said at least one sieving device, whereby the particles separated according to said aerodynamic relationship, but having different size, are further separated by size.

6. The system of claim 5, wherein said at least one collection bin comprises a plurality of bins so configured.

7. The system of claim 5, wherein said at least one sieve comprises a plurality of sieves.

8. The system of claim 5, wherein said at least one sieve is configured to comprise a mesh size chosen to separate said bin-fellow particles at a size corresponding to a predetermined difference in density.

9. The system of claim 1 , configured so that particles are directed through one of the at least one sieving devices, said at least one sieve having at least one mesh size, whereby the particles are divided into size groups having size substantially bounded by adjacent sieve mesh sizes; and wherein said at least one sieving device is configured to have the particles of at least one of said size groups directed into at least one of said at least one deflected-stream aerodynamic particle sorting devices, whereby the particles first separated by size are further separated by density and drag coefficient.

10. The system of claim 9, wherein the at least one sieve in said at least one sieving device comprises a plurality of sieves, each having a different mesh size, wherein the particles are sorted into a plurality of size groups.

11. The system of claim 10, wherein at least two adjacent sieves having two mesh sizes of said plurality of mesh sizes are configured to have a minimum-to-maximum mesh aperture ratio greater than the square root of a predetermined density ratio equal to a lesser density divided by a greater density.

12. The system of claim 11, further configured so that particles in a size group between said two adjacent sieves are directed into one of said at least one deflected-stream particle sorting devices; and wherein the deflected-stream particle sorting device is configured to substantially separate particles having density ratios less than said predetermined density ratio.

13. The system of claim 1, wherein the particles having a variation of particle properties comprise a mixture of particulate product and impurities, wherein at least a portion of the impurities are removed from the particulate product.

14. The system of claim 13, wherein the particulate product is powdered metal.

15. The system of claim 14, wherein the impurities removed include one or more of the following; sand, ceramic particles, partially sintered powder metal particles, non- metallic particles.

16. A hybrid method of separating particles, the particles having a variation of particle properties, said properties including size, density, and drag coefficient, the method comprising at least two steps in any order comprising: passing the particles through at least one deflected- stream aerodynamic particle sorting device having two or more collection bins, wherein the particles are separated into the two or more collection bins, wherein bin-fellow particles separated into any of said bins substantially exhibit aerodynamic similarity based on said particle properties; and, passing the particles through at least one sieving device having at least one sieve, wherein the particles are sorted by size.

17. The method of claim 16, wherein the at least one deflected-stream aerodynamic particle sorting device comprises one of the following; an aerodynamic vector particle sorting device, a coanda jet particle sorting device, a spinning wheel separator, a double cone separator, a cyclone separator.

18. The method of claim 16, wherein the particles comprise a mixture of a particulate product and impurities, wherein at least a portion of the impurities are removed from the particulate product, thereby enhancing the quality of the product.

19. The method of claim 18, wherein the particulate product is a powdered metal.

20. The method of claim 19, wherein the impurities removed include one or more of the following; ceramic particles, partially sintered powder metal particles, non-metallic particles.

21. The method of claim 18, further comprising reprocessing a portion of the material aerodynamically to further separate the product from the impurities.

22. The method of claim 18, further comprising inspection of the impurities as a process control measure.

23. The method of claim 16, wherein at least one of the said at least one deflected- stream aerodynamic particle sorting device is configured to entrain the particles in an inert gas.

24. The method of claim 16, wherein the particles separated by the at least one deflected-stream aerodynamic particle sorting device and the at least one sieving device separate a target mineral from gangue.

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