Spray cap

Abstract

A system includes an ejection cap configured to be coupled to an ejection tool (10, 12), where the ejection cap includes a body and an air shaping passage (20) extending through the body. The air shaping passage (20) includes a flow control passage (14), a dilation chamber (18) downstream of the flow control passage, and one or more air shaping outlets downstream of the dilation chamber (18).

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit and priority of U.S. Provisional Patent Application No. 62,325,061, filed Apr. 20, 2016, entitled "SYSTEM FOR CONTROLLING AIR SHAPING FLOW IN SPRAY CAP OF SPRAYTOOL", which is hereby incorporated by reference in its entirety. Background of the Invention

[0003] The present invention generally relates to spraying devices, and more particularly, to a spray cap of a spray tool.

[0004] This chapter is intended to introduce the reader to aspects of the technology that may be relevant to aspects of the present disclosure described below. This discussion is believed to be helpful to the reader in providing background information to better understand aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this context and are not admitted as prior art.

[0005] Spraying devices are used to apply a spray coating to various target objects. To achieve a desired finish quality of the spray coating, a spraying device may output a spray of coating material having a particular shape. Unfortunately, the shape may be non - uniform or sub - optimal due to various factors, such as non - uniform flow or distribution of air through the spraying device. Summary of the Invention

[0006] Certain embodiments are outlined below that are commensurate in scope with the initially claimed invention. These embodiments are not intended to limit the scope of the invention, and in fact, these embodiments are only intended to provide a brief overview of possible forms of the invention. Indeed, the invention may encompass various forms that may be similar to or different from the embodiments set forth below.

[0007] In certain embodiments, a system includes a spray cap configured to be coupled to a spray tool, wherein the spray cap includes a body and an air - shaping channel passing through the body. The air - shaping channel includes a flow - control channel, an expansion chamber downstream of the flow - control channel, and one or more air - shaping outlets downstream of the expansion chamber.

[0008] In some embodiments, a system includes a spraying tool, where the spraying tool includes 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. The head portion includes a spray cap having a fluid nozzle recess, an air atomization passage, and an air shaping passage. The air shaping passage includes a flow control passage, a dilation chamber downstream of the flow control passage, and one or more air shaping outlets downstream of the dilation chamber. The head portion also includes a fluid nozzle disposed in the fluid nozzle recess.

[0009] In some embodiments, a system includes a flow control insert configured to be mounted in a recess in a body of a spray cap of a spraying tool. The flow control insert includes an air shaping passage, where the air shaping passage has a flow control passage, a dilation chamber downstream of the flow control passage, and one or more air shaping outlets downstream of the dilation chamber.

[0010] Brief Description of the Drawings

[0011] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings, in which like reference numerals represent like parts throughout the drawings, and in which:

[0012] Figure 1 is a cross-sectional side view of an embodiment of a spraying tool, where the spraying tool has a spray cap having flow control features along an air shaping passage;

[0013] Figure 2 is taken within section line 2-2 Figure 1 partial cross-sectional side view of an embodiment of the spraying tool, illustrating details of the air shaping passage, where the air shaping passage includes a flow control passage, a dilation chamber downstream of the flow control passage, and one or more air shaping outlets downstream of the dilation chamber;

[0014] Figure 3 is taken along section line 3-3 Figure 2 cross-sectional front view of an embodiment of the spray cap, illustrating an upstream portion of the air shaping passage leading to the flow control passage;

[0015] Figure 4 is taken along section line 4-4 Figure 2 cross-sectional front view of an embodiment of the spray cap, illustrating a portion of the air shaping passage at the flow control passage;

[0016] Figure 5 is taken along section line 5-5 Figure 2Cross-sectional front view of an embodiment of a spray cap, showing the downstream portion of the air shaping channel at the expansion chamber downstream of the flow control channel;

[0017] Figure 6 is Figure 1 Cross-sectional side view of an embodiment of a spray cap, showing a flow control insert disposed in a recess in the body of the spray cap, wherein the flow control channel is partially disposed along the flow control insert and the expansion chamber is disposed between the flow control insert and the recess;

[0018] Figure 7 taken along section line 7-7 Figure 6 Top view of an embodiment of a spray cap, showing the annular shape of the flow control channel and a plurality of alignment features, wherein the alignment features facilitate alignment between the flow control insert and the recess in the body of the spray cap;

[0019] Figure 8 is Figure 1 Cross-sectional side view of an embodiment of a spray cap, showing a flow control insert disposed within a recess in the body of the spray cap, wherein the flow control insert includes an inner insert portion and an outer insert portion coupled together by one or more connecting portions, and the flow control channel is disposed between the inner insert portion and the outer insert portion;

[0020] Figure 9 taken along section line 9-9 Figure 8 Top view of an embodiment of a spray cap, showing the generally annular shape (e.g., segmented annular shape) of the flow control channel between the inner insert portion and the outer insert portion, and one or more connecting portions coupling the inner insert portion and the outer insert portion;

[0021] Figure 10 is Figure 1 Cross-sectional side view of an embodiment of a spray cap, showing a one-piece construction (e.g., one-piece structure) of an air cap having an air shaping channel, wherein the air shaping channel has a flow control channel, an expansion chamber, and one or more air shaping outlets;

[0022] Figure 11 taken along section line 11-11 Figure 10 Top view of an embodiment of a spray cap;

[0023] Figure 12 is Figure 2 Partial cross-sectional side view of an embodiment of a flow control channel, wherein the flow control channel has a channel of constant width, the channel of constant width having a radial width that is constant in the axial direction along the central axis of the spray cap;

[0024] Figure 13 is Figure 2 A partial cross-sectional side view of an embodiment of a flow control channel, wherein the flow control channel has a channel with a narrowed width, and the channel with the narrowed width has a radial width that increases or decreases in the axial direction along the central axis of the injection cap;

[0025] Figure 14 is Figure 2 A partial cross-sectional side view of an embodiment of a flow control channel, wherein the flow control channel has a narrowed channel portion, a throat portion, and an expanding channel portion, such that the radial width of the flow control channel decreases and then increases in the axial direction along the central axis of the injection cap;

[0026] Figure 15 is taken along section line 4-4 Figure 2 A front cross-sectional view of an embodiment of an injection cap, illustrating another embodiment of a portion of an air shaping channel at a flow control channel, wherein the flow control channel has a radial width that varies in the circumferential direction around the central axis of the injection cap such that the radial width increases toward an air shaping convex corner of the injection cap; and

[0027] Figure 16 is taken along section line 4-4 Figure 2 A front cross-sectional view of an embodiment of an injection cap, illustrating another embodiment of a portion of an air shaping channel at a flow control channel, wherein the flow control channel has a radial width that varies in the circumferential direction around the central axis of the injection cap such that the radial width decreases toward an air shaping convex corner of the injection cap. DETAILED DESCRIPTION

[0028] One or more specific embodiments of the present invention will be described below. To provide a concise description of these embodiments, not all features of actual implementations may be described in this specification. It should be understood that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developer's specific goals, e.g., to comply with system-related and business-related constraints, which are different in different implementations. Additionally, it should be understood that such development work may be complex and time-consuming, but would still be routine work for those of ordinary skill in the art who would benefit from this disclosure to design, construct, and manufacture.

[0029] When introducing the elements of the various embodiments of the present invention, the words "a" and "the" are intended to mean that there may be one or more elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0030] The present disclosure generally relates to spraying tools, and more particularly, to a spray tip or air cap for spray atomization. The spray tip has a body and an air shaping passage that supplies air to a corner of the spraying tool, where the air shaping passage may include a flow control passage or an annular gap, an expansion chamber downstream of the flow control passage, and one or more air shaping outlets downstream of the expansion chamber. In some embodiments, the flow control passage, the expansion chamber, and the air shaping outlets may be integrally formed as part of the spray tip (e.g., a one-piece structure). In some embodiments, the flow control passage may be formed at least partially or completely through a flow control insert that is fitted within a recess in the body of the spray tip. The flow control passage and the expansion chamber help to more evenly regulate and distribute the air shaping flow around the spray tip, thus improving the shape of the spray of the coating material and the quality of the coating formed by the spray. For example, the flow control passage may be a substantially annular passage (e.g., a continuous annular passage or a segmented annular passage), where the substantially annular passage restricts the air shaping passage prior to expansion in the expansion chamber. In this way, the flow control passage and the expansion chamber help to remove variations in pressure, velocity, and flow rate of the air shaping flow caused by various upstream features (e.g., one or more discrete air supply passages upstream of the spray tip). Thus, due to the substantially annular shape and flow restriction, the flow control passage helps to more evenly distribute the air shaping flow to the air shaping outlets. Therefore, a more even air shaping flow through the air shaping outlets helps to improve the shape of the spray and the quality of the coating applied by the spray. Additionally, the flow control passage and the expansion chamber may help to reduce the noise generated by the air shaping flow through the spraying tool.

[0031] Figure 1 FIG. 4 is a cross-sectional side view of an embodiment of a spraying tool assembly 10 (e.g., a spray gun) having a flow control portion 11 in a spraying tool 12, where the flow control portion 11 has a flow control passage 14 between an upstream chamber 16 (e.g., an air shaping supply chamber) and a downstream chamber 18 (e.g., an expansion chamber), and the downstream chamber 18 leads to one or more air shaping outlets 20. As discussed in more detail below, the flow control portion 11 is configured to more evenly regulate and distribute the air shaping flow to improve the shape of the spray of the coating material and the quality of the coating formed by the spray.

[0032] The spray tool assembly 10 includes an air supply 13 and a gravity feed container assembly 15 coupled to the spray tool 12. As shown, the spray tool 12 includes a spray tip assembly 17 coupled to a body 19. The spray tip assembly 17 includes a fluid nozzle or liquid delivery tip assembly 22, where the fluid nozzle or liquid delivery tip assembly 22 is removably inserted into a socket 24 of the body 19. For example, a variety of different types of spray tool devices can be configured to receive and use the fluid nozzle 22. The spray tip assembly 17 also includes a spray forming assembly 26 coupled to the fluid nozzle 22. The spray forming assembly 26 can include various spray forming mechanisms, such as, for example, an air atomization mechanism, a rotary atomization mechanism, and an electrostatic atomization mechanism. However, the illustrated spray forming assembly 26 includes a head portion 28 fluidly coupled to a fluid / liquid passage and an air passage. The head portion 28 is removably fastened to the body 19 via a retaining assembly 30 (e.g., threads, bolts and nuts, retaining rings, etc.). The head portion 28 includes a spray cap 29, where the spray cap 29 includes various air atomization holes, such as, for example, one or more central air holes or atomization outlets 32 that are disposed around a fluid end outlet 34 (e.g., a liquid outlet) of the fluid nozzle 22 along a central portion of the spray cap 29. The spray cap 29 may also have one or more air shaping outlets or holes 20, where the one or more air shaping outlets or holes 20 use air jets to force the spray to form a desired spray pattern (e.g., a flat spray). The spray forming assembly 26 may also include various other atomization mechanisms to provide a desired spray pattern and droplet distribution.

[0033] The body 19 of the spray tool 12 includes various control and supply mechanisms for the spray tip assembly 17. As shown, the body 19 includes a liquid delivery assembly 38, where the liquid delivery assembly 38 has a liquid passage 40 extending from a liquid inlet coupler 42 to the fluid nozzle 22. The body 19 also includes a liquid valve assembly 44, where the liquid valve assembly 44 has a needle valve 46 that extends movably through the body 19 between the fluid nozzle 22 and a liquid valve adjuster 48. The liquid valve adjuster 48 is rotatably adjustable against a spring 50 disposed between a rear section 52 of the needle valve 46 and an interior portion 54 of the liquid valve adjuster 48. The needle valve 46 is also coupled to a trigger 56 such that the needle valve 46 can move inwardly away from the fluid nozzle 22 as the trigger 56 rotates counterclockwise about a pivot joint 58. However, any suitable valve assembly that can be opened inwardly or outwardly can be used within the scope of the present technology. The liquid valve assembly 44 may also include various packing and sealing assemblies (e.g., packing assembly 60), where the various packing and sealing assemblies are disposed between the needle valve 46 and the body 19.

[0034] An air supply assembly 62 is also disposed in the body 19 to assist in air-driven atomization and shaping at the spray forming assembly 26. The illustrated air supply assembly 62 extends from an air inlet coupler 64 to a spray cap 29 via air channels 66 and 68. The air supply assembly 62 also includes various seal assemblies, air valve assemblies, and air valve regulators to maintain and regulate the air pressure and flow rate through the spray tool 12. For example, the illustrated air supply assembly 62 includes an air valve assembly 70 coupled to the trigger 56 such that rotation of the trigger 56 about the pivot joint 58 opens the air valve assembly 70 to effect air flow from the air channel 66 to the air channel 68. The air supply assembly 62 further includes an air valve regulator 72 to regulate the air flow to the spray cap 29. As illustrated, the trigger 56 is coupled to both the liquid valve assembly 44 and the air valve assembly 70 such that as the trigger 56 is pulled towards the handle 74 of the body 19, liquid and air flow simultaneously to the spray tip assembly 17. Once pulled, the spray tool 12 produces an atomized spray with a desired spray pattern and droplet distribution.

[0035] The gravity feed container assembly 15 and the air supply 13 supply a respective coating material (e.g., a liquid or powder coating material) and air to the spray tool 12. The air supply 13 enables the spray tool 12 to eject and shape the coating material exiting the gravity feed container assembly 15. The air supply 13 is coupled to the spray tool 12 at the air inlet coupler 64 and supplies air via an air conduit 76. Embodiments of the air supply 13 may include an air compressor, a compressed air tank, a compressed inert gas tank (e.g., a nitrogen tank), or a combination thereof. In the illustrated embodiment, the gravity feed container assembly 15 is directly mounted to the spray tool 12 to supply a coating material (e.g., a solvent, paint, sealant, stain, etc.) to the spray tool 12. The illustrated gravity feed container assembly 15 includes a spray coating supply container 78, a cap 80, a filter assembly 82, and an adapter 86.

[0036] Figure 2 is Figure 1Partial cross-sectional side view of an embodiment of a spraying tool, showing details of the spray-forming assembly 26 of the spray cap 29. As shown, the spray-forming assembly 26 includes a head portion 26, wherein the head portion 26 has a mounting insert 101, a fluid nozzle 22, a spray cap 29, and a retaining assembly 30. The fluid nozzle 22 extends into a recess 102 (e.g., an annular recess) in the body 19, through a central hole 103 in the mounting insert 101, through a central hole 104 in the spray cap 29, and partially into a fluid outlet 34 in the spray cap 29. The fluid nozzle 22 can be manually inserted, press-fitted, threadedly coupled, or otherwise fixedly or removably coupled to the recess 102 in the body 19. Similarly, the mounting insert 101 extends circumferentially 124 around the fluid nozzle 22 and is removably or fixedly coupled to a recess 105 (e.g., an annular recess) in the body 19. For example, the mounting insert 101 can be press-fitted or threadedly coupled to the recess 105 in the body 19. The fluid nozzle 22 also includes an outer flange portion 106 (e.g., a tapered annular flange portion), wherein the outer flange portion 106 is fitted between the mounting insert 101 and the spray cap 29. For example, the outer flange portion 106 can abut against a tapered portion 107 (e.g., a tapered annular surface) on the body 108 of the spray cap 29. In the illustrated embodiment, the tapered portion 107 is provided on an inner wall 109 (e.g., an internal annular wall) of the body 108. Thus, the outer flange portion 106 and the tapered portion 107 create a tapered interface (e.g., a press-fit interface) between the spray cap 29 and the fluid nozzle 22 after the complete assembly of the mounting insert 101, the fluid nozzle 22, the spray cap 29, and the retaining assembly 30. For example, the retaining assembly 30 can include a retaining nut 125, wherein the retaining nut 125 is coupled to an outer wall 111 (e.g., a radially protruding outer annular flange) of the body 108 of the spray cap 29 and is also coupled to the mounting insert 101 (e.g., via a threaded interface 113). As the retaining nut 125 is threaded onto the mounting insert 101 via the threaded interface 113, the retaining nut 125 pulls the spray cap 29 inwardly towards the body 19 and axially 120 squeezes the fluid nozzle 22 between the spray cap 29 and the mounting insert 101.

[0037] In the illustrated embodiment, a coating material passage 112 (e.g., a fluid or liquid passage), an air atomization passage 114, and one or more air shaping passages 116 extend through the body 19 of the spraying tool 12, the mounting insert 101, and the body 108 of the spray cap 29. During a spraying operation, at the needle valve 46 (see Figure 1)When actuated to retract away from the fluid outlet 34, the coating material (e.g., liquid or powder coating material, such as paint) exits the spraying tool 12 at the fluid outlet 34. At the same time, the air passing through the air atomization channel 114 exits from the air atomization outlet 32 to atomize the liquid coating material. Substantially simultaneously, the air passing through the air shaping channel 116 exits from the air shaping outlet 20 to shape or force the spray (e.g., atomized liquid coating material) into a desired spray pattern (e.g., flat spray).

[0038] The spray cap 29 can be described with reference to the central longitudinal axis 119, the axial direction or axis 120, the radial direction or axis 122, and the circumferential direction or axis 124. As shown, the spray cap 29 is configured to output atomized air and liquid coating material in the axial direction 120, and the air atomization channel 114 and the air shaping channel 116 are generally annular channels that extend circumferentially around the central axis 119. Specifically, the air atomization channel 114 and the air shaping channel 116 are concentrically arranged one after another around the fluid channel 112 in the radial direction 122. The spray cap 29 includes a plurality of convex corners or axial protrusions 110 (e.g., 2, 3, 4, 5, 6, or more protrusions), where the plurality of convex corners or axial protrusions 110 extend downstream in the axial direction 120 away from the central region 31 having the outlets 32 and 34, such that the air shaping channel 116 extends downstream beyond the outlets 32 and 34 to the downstream portion 118 (e.g., the end portion) of the protrusions 110 at one or more downstream positions having the air shaping outlet 20. Thus, the spraying tool 12 outputs atomized air and coating material (e.g., liquid coating material) through the outlets 32 and 34 at the central region 31 to form a spray of the coating material upstream of the air shaping outlet 20, such that the air shaping outlet 20 then guides the air shaping flow (e.g., jet) from the downstream portion 118 of the protrusions 110 toward the spray and the axis 119 inwardly to shape the spray into a desired spray pattern.

[0039] In the illustrated embodiment, the air shaping channel 116 includes a flow control channel 14 disposed between an upstream chamber 16 (e.g., an air shaping supply chamber) and a downstream chamber 18 (e.g., an expansion chamber), wherein the downstream chamber 18 leads to one or more air shaping outlets 20 (e.g., 2, 3, 4, 5, 6 or more outlets) in the downstream portion of each protrusion 110. The flow control channel 14 may be disposed in the upstream region or bottom of the protrusion 110, e.g., in the upstream portion 126 of the ejection cap 29. In certain embodiments, the flow control channel 14 may be disposed at least partially within or along a flow control structure 115 (e.g., an annular structure portion), wherein the flow control structure 115 may be integrally formed with or separate from the ejection cap 29. For example, the flow control structure 115 and the flow control channel 14 may be an integral part of the ejection cap 29 (e.g., form a single-piece structure with the ejection cap 29 or be fixedly coupled to the ejection cap 29). As another example, the flow control structure 115 may be a flow control insert configured to be coupled to the ejection cap 29, wherein the flow control channel 14 may be disposed at least partially within or along the flow control insert (e.g., entirely within the insert or disposed between the insert and the ejection cap 29).

[0040] The upstream chamber 16, the flow control channel 14, and the expansion chamber 18 may be substantially annular chambers or channels, wherein the substantially annular chambers or channels extend circumferentially 124 about a central axis 119. The size of the flow control channel 14 may be smaller relative to both the upstream chamber 16 and the expansion chamber 18 (e.g., reduced or restricted cross-sectional area and radial 122 width). For example, the cross-sectional area or radial 122 width of the flow control channel 14 may be less than 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55% or 60% of the corresponding cross-sectional area or radial 122 width of the upstream chamber 16 and / or the downstream chamber 18. As another example, the cross-sectional area or radial 122 width of the expansion chamber 18 may be equal to, less than, or greater than the corresponding cross-sectional area or radial 122 width of the upstream chamber 16. In certain embodiments, the cross-sectional area or radial 122 width of the expansion chamber 18 may be at least about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 90% or 100% greater than the corresponding cross-sectional area or radial 122 width of the upstream chamber 16. Additionally, the radial 122 widths of the flow control channel 14, the upstream chamber 16, and the expansion chamber 18 may be uniform or vary in the circumferential direction 124 about the central axis 124, thus providing an air shaping flow for desired regulation and fluid distribution to the air shaping outlets 20.

[0041] In operation, the flow control portion 11 directs the air shaping flow to sequentially pass through the upstream chamber 16, the flow control channel 14, and the expansion chamber 18. In this manner, the flow control portion 11 forces the air shaping flow to spread to achieve better distribution in the upstream chamber 16, extruded through the reduced radial 122 width of the flow control channel 14, the extruded air shaping flow having a correspondingly increased velocity and a reduced static pressure to achieve improved regulation and distribution of the air shaping flow, and then expanding in the expansion chamber before being delivered to the air shaping outlet 20, the expanded air shaping flow having a corresponding rate reduction and pressure recovery. Thus, compared to configurations without the flow control portion 11, the air shaping flow is more uniform (e.g., pressure, velocity, flow rate, etc.) at each outlet 20 and between different outlets 20. In some embodiments, the flow control portion 11 can reduce turbulence in the air shaping flow and / or provide a more laminar flow to the air shaping outlet 20. For example, air turbulence can exist in the air flow upstream of the flow control portion 11 (e.g., due to fluctuations in the air supplier 13; changes in the flow channels, e.g., bends, interruptions, intersections of channels, changes in geometry, etc.). However, the flow control portion 11 (e.g., the flow control channel 14 and the chambers 16 and 18) can help improve the air flow distribution (e.g., more uniform velocity, pressure, flow rate, etc.), which can help reduce the turbulence generated upstream and / or provide a more laminar flow. Additionally, the expansion chamber 18 can help reduce the noise generated by the air flow upstream of the flow control portion 11 and / or the noise that would occur in the jet tool 12 without the flow control portion 11.

[0042] Figure 3 , Figure 4 and Figure 5 is Figure 2 a front cross-sectional view of the head portion 28 of, further illustrating details of the air shaping channel 116, the cross-sectional area of which changes as the air shaping channel 116 passes through the upstream chamber 16, the flow control channel 14, and the expansion chamber 18 in the jet cap 29. Figure 3 is a front cross-sectional view taken along Figure 2 section line 3-3 of, illustrating the upstream portion of the air shaping channel 116 leading to the flow control channel 14 (e.g., the upstream chamber 16). The air shaping channel 116 (specifically, the upstream chamber 16) can be configured to receive (e.g., from the air channel 68) air supplied via one or more discrete air holes 150 disposed at different discrete locations along the upstream chamber 16 (e.g., an annular chamber). Given the discrete locations of the air holes 150, air is supplied to the upstream chamber 16 (e.g., an annular chamber) in a non-uniform manner. Similarly, at more downstream locations, the flow control portion 11 (specifically, the flow control channel 14 and the expansion chamber 18) is configured to help regulate and control the distribution of the air flow to the air shaping outlet 20.

[0043] As Figure 3 illustrated, a fluid passage 112 (e.g., an annular fluid passage) is circumferentially 124 disposed (e.g., coaxially arranged) around a needle valve 46. A fluid nozzle 22 (e.g., an annular wall 128) is circumferentially disposed around the fluid passage 112 to assist in guiding a fluid flow through the fluid passage 112 around the needle valve 46 to a fluid outlet 34. The fluid nozzle 22 also includes portions of an air atomization passage 114, specifically, a plurality of air atomization passages 114 disposed in the annular wall 128 of the fluid nozzle 22 in a circumferential arrangement 130. The air atomization passages 114 are configured to feed an air flow into a central hole 104 of an injection cap 29 and then into an air atomization outlet 32. An upstream chamber 16 (e.g., an annular chamber or fluid passage) of an air shaping passage 116 is circumferentially 124 disposed around an upstream portion 126 of the fluid nozzle 22 and the injection cap 29. Thus, the upstream portion 126 of the fluid nozzle 22 and the injection cap 29 generally define an inner wall (e.g., an inner annular wall) of the upstream chamber 16. A retaining assembly 30 (e.g., a retaining nut 125) is circumferentially 124 disposed around the upstream chamber 16 and thus defines an outer annular wall of the upstream chamber 16. Similarly, the upstream chamber 16 (e.g., an annular chamber) assists in guiding an air flow into a flow control passage 14 to achieve improved flow distribution and regulation or control (e.g., pressure, rate, flow rate, etc.) of the air flow.

[0044] Figure 4 is a cross-sectional front view taken along section line 4-4 of Figure 2 illustrating portions of the air shaping passage 116 at the flow control passage 14. As illustrated, the flow control passage 14 has an annular cross-section (e.g., an annular flow control passage), wherein a radial width 132 of the annular cross-section is less than a radial width 134 of the upstream chamber 16 (see Figure 3 ). For example, the radial width 132 (or cross-sectional area) of the flow control passage 14 may be less than 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, or 60% of the radial width 134 (or cross-sectional area) of the upstream chamber 16. Thus, the flow control passage 14 restricts the air flow, resulting in an increase in rate and a decrease in static pressure, thus assisting in regulating the air flow and better distributing the air flow into a downstream expansion chamber 18. In some embodiments, the flow control passage 14 and a flow control structure 115 may be an integral part of the injection cap 29 (e.g., formed as a single piece with the injection cap 29 or fixedly coupled to the injection cap 29), or the flow control passage 14 may be at least partially within or along a flow control insert (e.g., fully within the insert or disposed between the insert and the injection cap 29).

[0045] Figure 5is taken along Figure 2 section line 5-5 and is a front cross-sectional view showing the downstream portion of the air shaping channel 116 at the expansion chamber 18 downstream of the flow control channel 14. As shown, the air shaping channel 116 extends from the flow control channel 14 into the expansion chamber 18, where the expansion chamber 18 is defined between two different portions (e.g., the inner wall 109 and the outer wall 111) of the body 108 of the spray cap 29. The expansion chamber 18 has an annular cross-section (e.g., an annular chamber or channel), wherein the radial width 136 of the annular cross-section is greater than the radial width 132 of the flow control channel 14 (see Figure 4 ). For example, the radial width 136 (or cross-sectional area) of the expansion chamber 18 can be at least about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 90% or 100% greater than the radial width 132 (or cross-sectional area) of the flow control channel 14. Thus, the expansion chamber 18 expands the air flow, resulting in a decrease in velocity and a pressure recovery, thus further helping to regulate the air flow and better distribute the air flow into the downstream projections 110 and the air shaping outlet 20. As the air flow leaves the expansion chamber 18 and enters the projections 110, the spray cap 29 guides the air flow through a plurality of air corner channels or holes 162 of the air shaping channel 116. Each air corner or projection 110 includes at least one channel 162 of the air shaping channel 116, and at least one channel 162 in turn leads to the air shaping outlet 20.

[0046] As described above, the flow control channel 14 can be integrally formed with the body 108 of the spray cap 29 or separate from the body 108 of the spray cap 29. In the following Figures 6 to 10 , the embodiments of the air shaping channel 116 shown in Figure 2 will be discussed in detail. Figure 6 is Figure 1Cross-sectional side view of an embodiment of the spray cap 29. As shown, the spray cap 29 includes a body 108, where the body 108 has an outer wall 172 (e.g., an outer annular wall 111), an inner wall 174 (e.g., an inner annular wall 109), and a central end wall 176. A fluid nozzle cavity 170 in the body 108 is configured to receive a fluid nozzle 22, where the fluid nozzle 22 outputs fluid through a fluid outlet 34 at the central end wall 176 to be atomized into a spray. An air atomizing channel 114 is circumferentially disposed within the fluid nozzle cavity 170 around the fluid channel 112, where the air atomizing channel 114 feeds an air stream through the spray cap 29 and outputs it through an air atomizing outlet 32 at the central end wall 176 to assist in atomizing the fluid leaving the fluid outlet 34. Between the inner wall 174 and the outer wall 172, an air shaping channel 116 is circumferentially disposed around the air atomizing channel 114. As discussed above, at least a portion of the air shaping channel 116 is a substantially annular channel (e.g., an upstream chamber 16, a flow control channel 14, and a diffuser chamber 18) that circumferentially 124 extends around the central axis 119 of the spray cap 29, while a downstream portion of the air shaping channel 116 axially 120 extends through a protrusion 110 (e.g., Figure 5 the channel 162 shown). The air flow within the air shaping channel 116 passes through the protrusion 110 and exits the air shaping channel 116 at one or more air shaping outlets 20 (e.g., the axial channel 162) to shape the atomized fluid spray into a desired spray pattern (e.g., a flat spray). The body 108 of the spray cap 29 further includes a mounting flange 178 (e.g., along the walls 111, 172), where the mounting flange 178 is configured to couple the spray cap 29 to the head portion 28 of the spray tool 12 such that the spray cap 29 is removably fastened via threads, bolts and nuts, retaining rings, etc. via a retaining nut 125 (see Figure 2 ).

[0047] In the illustrated embodiment, the flow control passage 14 is provided or formed between a flow control insert 180 (e.g., a removable embodiment of the flow control structure 115) and the body 108 of the spray cap 29. The flow control insert 180 includes a first retainer portion 182 and a flow control portion 184. The first retainer portion 182 is configured to be coupled to a second retainer portion 186 of the body 108 of the spray cap 29, while the flow control portion 184 extends toward the inner wall 174 to form the flow control passage 14 (e.g., the flow control passage 14 is provided between the flow control portion 184 and the inner wall 174). The first retainer portion 182 may include an annular protrusion 188 (e.g., an outward radial protrusion) provided on an outer surface 190 (e.g., an external annular surface) of the flow control insert 180. The second retainer portion 186 of the body 108 may include an internal recessed surface 192 (e.g., an internal annular recess) along the inner wall 174 and an external recessed surface 194 (e.g., an external annular recess) along the outer wall 172, thus defining an annular recess or mounting area 195 configured to receive the flow control insert 180. Additionally, an annular recess 196 is provided on the external recessed surface 194 and is configured to receive the annular protrusion 188 of the flow control insert 180. Alternatively or additionally, the annular recess 196 may be provided on the flow control insert 180, and the annular protrusion 188 may be provided on the body 108 of the spray cap 29. Alternatively or additionally, the annular recess 196 and the annular protrusion 188 may be provided at the interface between the flow control insert 180 and the spray cap 29 at the inner wall 174. In some embodiments, the first retainer portion 182 of the flow control insert 180 and the second retainer portion 186 of the body 108 of the spray cap 29 may include a snap-fit coupling, a press-fit or interference-fit connection, or a threaded connection (e.g., mating threads) that couples the first retainer portion 182 and the second retainer portion 186 together.

[0048] The expansion chamber 18 is disposed downstream of the flow control channel 14 and the flow control insert 180. Specifically, the expansion chamber 18 is disposed between the flow control insert 180 and the annular recess 195 (e.g., the inner recessed surface 192 and the outer recessed surface 194) of the body 108. Thus, the air shaping channel 116 has a varying radial width (or cross-sectional area) along the axial direction 120. Specifically, the air shaping channel 116 has a radial width 132, 198 (or cross-sectional area) at the flow control channel 14, a radial width 136, 200 (or cross-sectional area) at the expansion chamber 18, and a radial width 202 (or cross-sectional area) at the protrusion 110 section. Generally speaking, the radial width 132, 198 (or cross-sectional area) is less than the radial width 136, 200 (or cross-sectional area). However, the radial width 202 may be equal to or less than the radial width 136, 200, while the cross-sectional area 202 may be significantly less than the cross-sectional area 200 (e.g., due to restricting the air shaping channel 116 into the axial channel 162, as Figure 5 shown). In addition, the radial width 132, 198 (or cross-sectional area) of the flow control channel 14 may be equal to or less than the upstream radial width adjacent to the upstream side of the flow control channel 14 (e.g., Figure 3 the radial width or cross-section 134 of the upstream chamber 16 shown) and about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, or 60% of the downstream radial width of the expansion chamber 18 (e.g., the radial width 136, 200).

[0049] Figure 7 is taken along the cutting line 7-7 Figure 6Top view of an embodiment of the ejection cap 29. As shown, the flow control insert 180 may further include a first alignment feature 220, wherein the first alignment feature 220 is configured to interface with a second alignment feature 222 in the body 108 (e.g., the outer wall 172) to ensure proper alignment of the flow control insert 180 with the ejection cap 29. Specifically, the first alignment feature 220 may include a plurality of alignment protrusions 224 (e.g., radial lugs, keys, or projections), the second alignment feature 222 may include a plurality of slots 226 (e.g., radial recesses, keyways, or grooves), and the plurality of alignment protrusions 224 are configured / sized to be received by the plurality of slots 226. In some embodiments, the total number of the plurality of protrusions 224 may be equal to or less than the total number of the plurality of slots 226. The flow control insert 180 may be made of any suitable material (e.g., plastic, metal, etc.) such that the flow control insert 180 may also provide a substantial seal (e.g., watertight and airtight) to seal the air shaping channel 116 relative to the environment / atmosphere. For example, the flow control insert 180 may be a cast metal (e.g., aluminum), an injection molded plastic (e.g., nylon, PEEK, polymer, etc.), an elastomeric material (e.g., rubber or other elastomer), a composite material (e.g., hard particles distributed in a matrix material), or any combination thereof.

[0050] Figure 8 is Figure 1 Cross-sectional side view of an embodiment of the ejection cap 29, showing Figure 2 an embodiment of the air shaping channel 116, wherein the flow control channel 14 passes through the flow control insert 180 and is disposed inside the flow control insert 180. In the illustrated embodiment, the flow control insert 180 includes an internal insert portion 240 (e.g., an internal annular insert portion) and an external insert portion 242 (e.g., an external annular insert portion) coupled together by a structural support or connection portion 244 between the axial end walls 246 (see Figure 9 ), wherein the flow control channel 14 is disposed between the internal insert portion 240 and the external insert portion 242. Assuming that the internal insert portion 240 and the external insert portion 242 are connected by the structural support 244 (e.g., circumferentially spaced radial arms, struts, links, or lugs), the flow control channel 14 may be described as a segmented annular flow control channel 14 and / or a substantially annular flow control channel 14 due to the minimal obstruction caused by the structural support 224. Refer to Figure 9 to further illustrate and describe this segmented or substantially annular configuration of the flow control channel 14.

[0051] The external insert portion 242 includes a first retainer portion 182 and a flow control portion 184, wherein the first retainer portion 182 and the flow control portion 184 are configured to be in the same manner as described above in Figure 6function in the same manner as discussed above. For example, the first retainer portion 182 is configured to couple with the second retainer portion 186 of the body 108 of the injection cap 29, and the flow control portion 184 extends inwardly toward the inner insert portion 240 to form a flow control passage 14 (e.g., the flow control passage 14 is provided between the flow control portion 184 and the inner insert portion 240). As described above, the first retainer portion 182 includes an annular protrusion 188 disposed on the outer surface 190 of the flow control insert 180. The second retainer portion 186 of the body 108 includes an inner recessed surface 192 along the inner wall 174 and an outer recessed surface 194 along the outer wall 172. An annular recess 196 is disposed on the outer recessed surface 194 and is configured to receive the annular protrusion 188 of the flow control insert 180.

[0052] The inner insert portion 240 has an inner insert wall or surface 248, where the inner insert wall or surface 248 is configured to contact the inner recessed surface 192 along the inner wall 174. These surfaces 192 and 248 may be configured to couple together with an interference fit or press fit connection, a threaded interface (e.g., mating threads), or any combination thereof. In some embodiments, the inner recessed surface 192 may include an annular recess or groove sized to receive the inner insert portion 240 along the inner insert wall 248 between the axial end walls 246. In some embodiments, the first retainer portion 182 of the flow control insert 180 and the second retainer portion 186 of the body 108 of the injection cap 29 may include any retaining features that snap fit, press fit, or interference fit, or screw together the first retainer portion 182 and the second retainer portion 186. It should also be understood that each of the inner insert portion 240 and the outer insert portion 242 of the flow control insert 180 may include any suitable retaining features that snap fit, press fit, or interference fit, or screw together with the second retainer portion 186 along the inner recessed surface 192 and the outer recessed surface 194, respectively.

[0053] As described above, the expansion chamber 18 is disposed between the flow control insert 180 and the annular recess 195 (e.g., the inner recessed surface 192 and the outer recessed surface 194) of the body 108. The air shaping channel 116 has a varying radial width along the axial direction 120. As shown, the flow control channel 14 includes a first channel 250 and a second channel 252 disposed one after another through the flow control insert 180. The first channel 250 is between the flow control portion 184 of the outer insert portion 242 and the inner insert portion 240, and has a radial width (or cross-sectional area) 254. The second channel 252 is between the first retainer portion 182 of the outer insert portion 242 and the inner insert portion 240, and has a radial width (or cross-sectional area) 256. As should be understood, the radial width (or cross-sectional area) 254 is less than the radial width 256, wherein the radial width 256 is less than the radial width (or cross-sectional area) 200 at the expansion chamber 18. Furthermore, the radial width (or cross-sectional area) 254 of the first passage 250 of the flow control passage 14 may be equal to or smaller than the upstream radial width (eg, Figure 3 Approximately 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55 or 60% of the radial width or cross-section 134 of the upstream chamber 16 shown and the downstream radial width of the expansion chamber 18 (e.g., radial widths 136, 200).

[0054] Figure 9 It is cut along the section line 9-9 Figure 8 29. As shown, the flow control insert 180 includes alignment features 220, 222, 224, and 226 to ensure proper alignment of the flow control insert 180 with the spray cap 29, as described above with reference to Figure 7 In addition, Figure 9Also illustrated is the configuration of an internal insert portion 240 and an external insert portion 242 coupled together by a structural support 244. Since very little of the flow control channel 14 is blocked by the structural support 244 (e.g., discontinuous and discrete), the flow control channel 14 can be described as a substantially annular flow control channel 14 or a segmented annular flow control channel 14. For example, the flow control channel 14 (e.g., the first channel 250 and / or the second channel 252) includes a plurality of channel portions 260 (e.g., a first channel portion, a second channel portion, a third channel portion, and a fourth channel portion) circumferentially 124 spaced about the central axis 119 of the ejection cap 29, thus defining a segmented or substantially annular channel. In certain embodiments, the ejection cap 29 can include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more structural supports 244, and thus can include 2, 3, 4, 5, 6, 7, 9, 9, 10, 11, or more channel portions 260. The total cross-sectional area of the structural support 244 can be relatively small compared to the total cross-sectional area of the plurality of channel portions 260 (e.g., 5%, 10%, 15%, or 20% smaller). For example, the flow control channel 14 can be at least 80%, 85%, 90%, or 95% continuous to define a substantially annular flow control channel. Additionally, although the flow control channel 14 is composed of a plurality of channel portions 260, the flow control insert 180 can still provide a substantially sealed (e.g., watertight and airtight) seal to seal the air shaping channel 116 relative to other flow channels and the external environment. In some embodiments, the flow control insert 180 can include an internal insert portion 240 and an external insert portion 242 without any intermediate structural support 244, where each of the insert portions 240 and 242 is coupled to the body 108 of the ejection cap 29 via a press fit or interference fit, a threaded interface, a snap fit or latch coupling, a retaining ring, or any combination thereof. In these embodiments, the flow control channel 14 can be a continuous annular channel rather than a segmented annular channel.

[0055] Figure 10 is Figure 1 A cross-sectional side view of an embodiment of an ejection cap 29, where the ejection cap 29 is a one-piece structure 280 having an air shaping channel 116 with a flow control channel 14 and an expansion chamber 18. Generally speaking, the one-piece structure 280 described herein can have a body 108, where the body 108 is as described above in Figures 6 to 9coincide with any of the structural features / shape of the spray cap 29 discussed in [e.g., the flow control insert 180 is integrally formed as part of a one-piece structure 280]. For example, the one-piece structure 280 has a body 108, where the body includes an outer wall 172 and an inner wall 172 that generally define an air shaping channel 116. Specifically, the outer wall 172 extends around a channel portion 282 of the air shaping channel 116. The outer wall 172 also includes a mounting flange 178, where the mounting flange 178 is configured to couple with a retaining nut 125. Similar to the flow control structure 115 and the flow control insert 180, the spray cap 29 also includes a flow control portion 284, where the flow control portion 284 defines a flow control channel 14. The channel portion 282 extends along a protrusion 110 from the mounting flange 178 in the axial 120 direction, while the flow control portion 284 extends from the mounting flange 178 toward the inner wall 174 in the radial direction 122. The flow control portion 284 ends at an inner annular surface 286 such that the flow control channel 14 is disposed between the inner wall 174 and the inner annular surface 286 and is annular with respect to the central axis 119 of the spray cap 29.

[0056] In addition, the one-piece structure 280 also includes an annular recess or cavity 288 downstream of the flow control channel 14, thus defining a plenum chamber 18 (e.g., an annular plenum chamber). Accordingly, the air shaping channel 116 of the one-piece structure 280 has a radial width 198 at the flow control channel 14, a radial width 200 at the plenum chamber 18, and a radial width 202 at the fillet 100 section. The radial widths (or cross-sectional areas) 132, 134, 136, 198, 200, and 202 are generally the same as those described in detail above. Figure 11 shown in [taken along the cutting plane 10-10] Figure 10 top view of an embodiment of the spray cap 29 of []. As shown, the spray cap 29 includes a one-piece structure 280, where the one-piece structure 280 has a flow control channel 14 disposed between the inner wall 174 and the flow control portion 284 of the outer wall 172.

[0057] It should be understood that the spray cap 29 formed of the one-piece structure 280 can be constructed using additive manufacturing techniques such as, for example, direct metal laser sintering (DMLS) process, where the spray cap 29 can include any suitable laser sintered metal material (e.g., stainless steel, nickel-chromium alloy, aluminum alloy, etc.). The structural features discussed above can be constructed in a layer-by-layer manner. The one-piece structure 280 can also be constructed using any other additive manufacturing technique such as, for example, 3D printing, where the spray cap 29 can include any suitable plastic or metal material for the additive manufacturing technique. Irrespective of the alternative manufacturing technique, the constructed spray cap 29 can provide a substantial seal (e.g., watertight and airtight) to seal the air shaping channel 116 relative to other fluid channels and the external environment.

[0058] In addition, although the flow control channels 14 discussed above in Figures 1 to 11 may have a constant radial width (or cross-sectional area) 132, 198, 254 along the central axis 119 of the ejection cap 29 in the axial direction 120, some embodiments of the flow control channels 14 may have a radial width (or cross-sectional area) 132, 198, 254 that varies (e.g., increases and / or decreases) along the central axis 119 of the ejection cap 29 in the axial direction 120. Figures 12 to 14 Respectively showing Figures 1 to 11 Cross-sectional side views of embodiments of the flow control channel 14. As Figure 12 illustrated, the flow control channel 14 is a constant-width channel 300, where the constant-width channel 300 has a constant radial width (or cross-sectional area) 132, 198, 254, 302 along the axial direction 120. In Figure 13 , the flow control channel 14 is a narrowing channel 304, where the narrowing channel 304 has a decreasing radial width (or cross-sectional area) 132, 198, 254, 306 along the axial direction 120. In Figure 14 , the flow control channel 14 includes a venturi-type configuration, where the venturi-type configuration has a series of narrowing channel portions 308, a throat portion 310, and a diverging channel portion 312 arranged one after another. The narrowing channel portion 308 has a decreasing radial width (or cross-sectional area) 314 along the axial direction 120, the throat portion 310 has a constant radial width (or cross-sectional area) 316 along the axial direction 120, and the diverging channel portion 312 has an increasing radial width (or cross-sectional area) 318 along the axial direction 120. Similarly, in Figures 12 to 14 each of the illustrated embodiments, the flow control channel 14 can be a continuous annular channel or a substantially annular channel or a segmented annular channel, as described in detail above. In addition, it should be understood that the transitions between adjacent portions (e.g., 308 / 310 and 310 / 312) can be relatively smooth (e.g., curved) transitions.

[0059] In addition, although the flow control channels 14 discussed above in Figures 12 to 14 may have a constant or varying (e.g., increasing and / or decreasing) radial width (or cross-sectional area) 132, 198, 254 along the central axis 119 of the ejection cap 29 in the axial direction 120, some embodiments of the flow control channels 14 may also have a constant or varying radial width 132, 198, 254 around the central axis 119 of the ejection cap 29 in the circumferential direction 124, as Figures 15 to 16 shown. Figure 15 is taken along the cutting plane 4-4 Figure 2Cross-sectional front view of an embodiment of the spray cap 29, illustrating another embodiment of the flow control channel 14. As illustrated, the radial width (or cross-sectional area) 132, 198, 254 of the flow control channel 14 varies (e.g., increases) in the circumferential direction 124 towards the air lobe channel 162 such that the radial width (or cross-sectional area) 132, 198, 254 is maximum around or near the air lobe channel 162 and minimum between the air lobe channels (e.g., at approximately the mid-position between the air lobe channels or at a position 90 degrees relative to the air lobe channel 162). Conversely, in another embodiment, Figure 16 the radial width (or cross-sectional area) 132, 198, 254 of the flow control channel 14 in varies (e.g., decreases) in the circumferential direction 124 towards the air lobe channel 162 such that the radial width (or cross-sectional area) 132, 198, 254 is minimum around or near the air lobe channel 162 and maximum between the air lobe channels (e.g., at approximately the mid-position between the air lobe channels or at a position 90 degrees relative to the air lobe channel 162). In Figures 15 to 16 each illustrated embodiment, the flow control channel 14 can be a continuous annular channel or a substantially annular channel or a segmented annular channel, as described in detail above. Additionally, the radial width or cross-sectional area (e.g., 132, 198, 254) can change gradually or vary in a substantially smooth manner (e.g., with a curved transition).

[0060] Although only certain features of the invention have been illustrated and described herein, many modifications and changes will be apparent to those skilled in the art. Accordingly, it is to be understood that the appended claims are intended to cover all such modifications and changes that fall within the true spirit of the invention.

Claims

1. A system, the system comprising: A nozzle, wherein the nozzle is separated from a spray cap through an interface, and wherein the spray cap is configured to be coupled to a spraying tool, wherein the spray cap includes: 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 one-piece structure including an inner insert portion and an outer insert portion; A flow control channel formed within the flow control insert body and extending therethrough, wherein the flow control channel is defined by a first surface of the inner insert portion and a second surface of the outer insert portion, the flow control channel including a first channel and a second channel downstream of the first channel, the first channel including a first radial width, the second channel including a second radial width, and the second radial width being greater than the first radial width; An expansion chamber extending through the one-piece spray cap body, wherein the expansion chamber is downstream of the flow control channel, and the expansion chamber includes a constant third radial width greater than the second radial width; and, wherein the first radial width of the first channel is less than an upstream radial width of an upstream chamber of the spraying tool adjacent to an upstream side of the flow control insert body; 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 of the expansion chamber.

2. The system according to 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 according to claim 1, wherein both the first channel and the second channel of the flow control channel are partially defined by a continuous common wall.

4. The system according to claim 1, wherein the flow control insert body includes a first retainer portion configured to be coupled to a second retainer portion of the one-piece spray cap body, wherein the first retainer portion includes a protrusion, and the second retainer portion includes a recess.

5. The system according to claim 4, wherein the first retainer portion and the second retainer portion are configured to snap-fit together, and wherein the protrusion is an annular protrusion.

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

7. The system according to claim 2, wherein the flow control insert body is screwed into the recess in the one-piece spray cap body.

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

9. The system according to claim 1, wherein the first radial width of the first channel is equal to or less than about 50% of the upstream radial width of the upstream chamber of the injection tool adjacent to the upstream side of the flow control insert body and the constant third radial width of the expansion chamber adjacent to the downstream side of the flow control insert body.

10. The system according to claim 1, wherein the first radial width of the first channel is equal to or less than about 25% of the upstream radial width of the upstream chamber of the injection tool adjacent to the upstream side of the flow control insert body and the constant third radial width of the expansion chamber adjacent to the downstream side of the flow control insert body.

11. The system according to claim 1, wherein the flow control channel is a substantially annular channel that extends circumferentially around the central axis of the injection cap.

12. The system according to claim 1, wherein both the first radial width and the second radial width are constant in the axial direction along the central axis of the injection cap.

13. The system according to claim 1, the system comprising a fluid nozzle cavity in the single-piece injection cap body, wherein the fluid nozzle cavity is configured to receive the nozzle, and wherein the nozzle outputs fluid atomized into a spray.

14. The system according to claim 1, the system comprising the injection tool having the injection cap.

15. A system, the system comprising: An injection tool, the injection tool comprising: A body portion having a fluid channel and an air channel; and A head portion fluidly coupled to the fluid channel and the air channel, wherein the head portion comprises: A single-piece injection cap body including a fluid nozzle receptacle; An air atomization channel; A flow control insert body disposed within the single-piece injection cap body, wherein the flow control insert body is a single-piece structure including an inner insert portion and an outer insert portion; and An air shaping channel, wherein the air shaping channel includes a flow control channel, an expansion chamber, and one or more air shaping outlets, the expansion chamber extending through the single-piece injection cap body and disposed downstream of the flow control channel, the one or more air shaping outlets formed in an air lobe of the single-piece injection cap body and disposed downstream of the expansion chamber, wherein the flow control channel extends through the flow control insert body, wherein the flow control channel includes a first channel and a second channel downstream of the first channel, wherein the first channel, the second channel, the expansion chamber, and the one or more air shaping outlets are fluidly connected in series, wherein the first channel includes a first radial width, the second channel includes a second radial width, and the second radial width is greater than the first radial width, and wherein the expansion chamber includes a constant third radial width greater than the second radial width; wherein the first radial width of the first channel is less than the upstream radial width of the upstream chamber of the injection tool adjacent to the upstream side of the flow control insert body; and a fluid nozzle disposed in the fluid nozzle receptacle of the single-piece injection cap body, wherein the fluid nozzle is separated from the single-piece injection cap body by an interface.

16. A system comprising: a flow control insert disposed within a single-piece body of an injection cap of an injection tool, wherein the flow control insert is a single-piece structure having a first axial end and a second axial end opposite the first axial end, and the flow control insert includes an inner insert portion, an outer insert portion, and a flow control channel that extends 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 channel, wherein the flow control channel includes a first channel and a second channel downstream of the first channel, wherein the first channel includes a first radial width, the second channel includes a second radial width, and the second radial width is greater than the first radial width, wherein the flow control channel extends internally from an upstream axial wall of the first axial end to a downstream axial wall of the second axial end, and wherein the first radial width of the first channel is less than the upstream radial width of the upstream chamber of the injection tool adjacent to the upstream side of the flow control insert; an expansion chamber extending through the single-piece body of the injection cap, wherein the expansion chamber is downstream of the flow control channel and the expansion chamber includes a constant third radial width greater than the second radial width; and a fluid nozzle disposed in a fluid nozzle receptacle of the single-piece body of the injection cap, wherein the fluid nozzle is separated from the injection cap by an interface.

17. The system of claim 1, wherein the flow control channel 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.

18. The system of claim 1, including a retainer nut configured to couple the single-piece injection cap body to the injection tool.

19. The system of claim 4, wherein the first retainer portion radially overlaps the second channel.

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