System for controlling air shaping flow in spray cap of spray tool

1. A system, comprising:

a nozzle, wherein the nozzle is segregated from a spray cap by an interface, wherein the spray cap is configured to couple to a spray tool,

wherein the spray cap comprises:

a one-piece spray cap body;

a flow control insert body disposed within the one-piece spray cap body, wherein the flow control insert body is a single piece comprising an inner insert portion and an outer insert portion;

a flow control passage formed within and extending through the flow control insert body, wherein the flow control passage is defined by a first surface of the inner insert portion and a second surface of the outer insert portion, the flow control passage comprises a first passage and a second passage downstream from the first passage, the first passage comprises a first radial width, the second passage comprises a second radial width, and the second radial width is greater than the first radial width;

an expansion chamber extending through the one-piece spray cap body, wherein the expansion chamber is downstream from the flow control passage and the expansion chamber comprises a constant third radial width greater than the second radial width; and

one or more air shaping outlets formed in the one-piece spray cap body, wherein the one or more air shaping outlets are downstream from the expansion chamber.

2. The system of claim 1 , wherein the flow control insert body is disposed in a recess in the one-piece spray cap body, and the expansion chamber is disposed downstream of the flow control insert body.

3. The system of claim 1 , wherein the flow control insert body comprises a first retainer portion configured to couple with a second retainer portion of the one-piece spray cap body, wherein the first retainer portion comprises a protrusion, and the second retainer portion comprises a recess.

4. The system of claim 3 , wherein the first and second retainer portions are configured to snap-fit together, and wherein the protrusion is an annular protrusion.

5. The system of claim 2 , wherein the flow control insert body is press-fit or interference fit into the recess in the one-piece spray cap body.

6. The system of claim 2 , wherein the flow control insert body is threaded into the recess in the one-piece spray cap body.

7. The system of claim 1 , wherein the flow control insert body comprises a first alignment feature configured to interface with a second alignment feature in the one-piece spray cap body.

8. The system of claim 1 , wherein the first radial width of the first passage is equal to or less than approximately 50 percent of an upstream radial width of an upstream chamber of the spray tool adjacent an upstream side of the flow control insert body and the constant third radial width of the expansion chamber adjacent a downstream side of the flow control insert body.

9. The system of claim 1 , wherein the first radial width of the first passage is equal to or less than approximately 25 percent of an upstream radial width of an upstream chamber of the spray tool adjacent an upstream side of the flow control insert body and the constant third radial width of the expansion chamber adjacent a downstream side of the flow control insert body.

10. The system of claim 1 , wherein the flow control passage is a substantially annular passage extending circumferentially about a central axis of the spray cap.

11. The system of claim 1 , wherein the first radial width and the second radial width are each constant in an axial direction along a central axis of the spray cap.

12. The system of claim 1 , comprising a fluid nozzle cavity in the one-piece spray cap body, wherein the fluid nozzle cavity is configured to receive the nozzle, wherein the nozzle outputs a fluid that is atomized into a spray.

13. A system, comprising:

a flow control insert disposed within a one-piece body of a spray cap of a spray tool, wherein the flow control insert is a single piece having a first axial end and a second axial end opposite the first axial end and comprises an inner insert portion, an outer insert portion, and a flow control passage extending internally through the flow control insert, wherein a first surface of the inner insert portion and a second surface of the outer insert portion define the flow control passage, wherein the flow control passage comprises a first passage and a second passage downstream from the first passage, wherein the first passage comprises a first radial width, the second passage comprises a second radial width, and the second radial width is greater than the first radial width, and wherein the flow control passage extends internally from an upstream axial wall of the first axial end to a downstream axial wall of the second axial end; and

a fluid nozzle disposed in the fluid nozzle receptacle, wherein the fluid nozzle is segregated from the spray cap by an interface.

14. The system of claim 1 , wherein the flow control passage extends through the flow control insert body from an upstream axial end wall of the flow control insert body to a downstream axial end wall of the flow control insert body.

15. The system of claim 1 , wherein the first passage and the second passage of the flow control passage are both partially defined by a continuous common wall.

16. The system of claim 1 , comprising a retainer nut configured to couple the one-piece spray cap body to the spray tool.

17. The system of claim 3 , wherein the first retainer portion radially overlaps with the second passage.

18. The system of claim 1 , comprising the spray tool having the spray cap.

19. A system, comprising:

a spray tool, comprising:

a body portion having a fluid passage and an air passage; and

a head portion fluidly coupled to the fluid passage and the air passage, wherein the head portion comprises:

a one-piece spray cap body comprising a fluid nozzle receptacle, an air atomization passage;

a flow control insert body disposed within the one-piece spray cap body, wherein the flow control insert body is a single piece comprising an inner insert portion and an outer insert portion; and

an air shaping passage, wherein the air shaping passage comprises a flow control passage, an expansion chamber extending through the one-piece spray cap body and disposed downstream from the flow control passage, and one or more air shaping outlets formed in an air horn of the one-piece spray cap body and disposed downstream from the expansion chamber, wherein the flow control passage extends through the flow control insert body, wherein the flow control passage comprises a first passage and a second passage downstream from the first passage, wherein the first passage, the second passage, the expansion chamber, and the one or more air shaping outlets are fluidly connected in series, and wherein the first passage comprises a first radial width, the second passage comprises a second radial width, and the second radial width is greater than the first radial width; and

a fluid nozzle disposed in the fluid nozzle receptacle, wherein the fluid nozzle is segregated from the spray cap by an interface.