Reinforcing insert article, kit and method

Abstract

Reinforcing inserts reinforce a frame member, such as a manufactured or metal stud. A reinforcing insert may be inserted into a stud, for example into the interior region between two elongated channel members of the stud to support one or more elements of the stud, thereby reinforcing the stud. The reinforcing insert may be received into one or both ends of the stud. The reinforcing insert may be shaped to engage (e.g., frictional or interference fit) in the interior of the stud. A length and other dimensions or properties of the reinforcing insert may be sized in accordance with the properties of the stud to be reinforced. The reinforcing insert may be tapered at one end, may include recesses to accommodate intrusive fasteners and/or include lightening apertures or pockets.

1 . An insert for use with a stud, the stud having a pair of elongated channel members opposed to one another across a width of the stud, each of the channel members having a major face, a first flange and a second flange, the first and the second flanges extending from the major face and the second flange opposed to the first flange across a thickness of the stud, the insert comprising:
 a block of material having a first end, a second end, a first major face, a second major face, a first side and a second side, the second end opposed across a length of the insert from the first end, the second major face opposed across a thickness of the insert from the first major face, and the second side opposed across a width of the insert from the first side, the first and the second sides spaced from one another to provide at least an interference fit between the major faces of the pair of elongated channel members of the stud when received therebetween over at least a majority of the length of the insert.   
     
     
         2 . The insert of  claim 1  wherein the first and the second major faces of the block are spaced from one another to provide at least an interference fit between the pairs of flanges of the pair of elongated channel members of the stud when the insert is received therebetween over at least a majority of the length of the insert. 
     
     
         3 . The insert of  claim 1  wherein the first and the second sides are parallel to one another over at least a majority of the length of the insert and the first major face and the second major face are parallel to one another over at least a majority of the length of the insert. 
     
     
         4 . The insert of  claim 1  wherein the block is tapered proximate the first end across at least one of the width or the thickness of the insert. 
     
     
         5 . The insert of  claim 4  wherein the block includes at least one outwardly extending stop flange proximate the second end of the insert, the stop flange sized and dimensioned to physically engage an end of the stud when the insert is received therein. 
     
     
         6 . The insert of  claim 4  wherein the stop flange extends outwardly from the first and the second major faces proximate the second end of the insert. 
     
     
         7 . The insert of  claim 1  wherein the block is tapered proximate the first end across both the width or the thickness of the insert. 
     
     
         8 . The insert of  claim 1  wherein the first and the second sides each have a recess formed along at least a portion of the length of the insert. 
     
     
         9 . The insert of  claim 1  wherein the block includes a number of apertures. 
     
     
         10 . The insert of  claim 1  wherein the block includes a number of apertures that extend across the thickness of the insert passing through the first and the second major faces. 
     
     
         11 . The insert of  claim 1  wherein the block of material is selected from the group consisting of metals and polymers. 
     
     
         12 . An insert for use with a stud, the stud having a pair of elongated channels members opposed to one another across a width of the stud, each of the channel members having a major face, a first flange and a second flange, the first and the second flanges extending from the major face and the second flange opposed to the first flange across a thickness of the stud, the insert comprising:
 a trapezoidal prism having a first end, a second end, a first major face, a second major face, a first side and a second side, the second end opposed across a length of the insert from the first end, the second major face parallel to and opposed across a thickness of the insert from the first major face, and the second side parallel to and opposed across a width of the insert from the first side, the first and the second sides spaced from one another to provide at least an interference fit between the major faces of the pair of elongated channel members of the stud when received therebetween over at least a majority of the length of the insert and the first and the second major faces of the block are spaced from one another to provide at least an interference fit between the pairs of flanges of the pair of elongated channel members of the stud when the insert is received therebetween over at least a majority of the length of the insert.   
     
     
         13 . The insert of  claim 12  wherein the block is tapered proximate the first end across the width or the thickness of the insert. 
     
     
         14 . The insert of  claim 13  wherein the block includes at least one stop flange that extends outwardly from the first and the second major faces proximate the second end of the insert, the stop flange sized and dimensioned to physically engage an end of the stud when the insert is received therein. 
     
     
         15 . The insert of  claim 12  wherein the first and the second sides each have a recess formed along at least a portion of the length of the insert. 
     
     
         16 . The insert of  claim 12  wherein the block includes a number of apertures that extend across the thickness of the insert passing through the first and the second major faces. 
     
     
         17 . The insert of  claim 12  wherein the block of material is selected from the group consisting of metals and polymers. 
     
     
         18 . A method of forming an insert for use with a stud, the stud having a pair of elongated channels members opposed to one another across a width of the stud, each of the channel members having a major face, a first flange and a second flange, the first and the second flanges extending from the major face and the second flange opposed to the first flange across a thickness of the stud, the method comprising:
 providing a solid block of thick gauge material, the thick gauge being at least 3 times a gauge of material that forms the elongated channel members;   providing at least one manufacturing operation on the solid block of material to produce a trapezoidal prism having a first end, a second end, a first major face, a second major face, a first side and a second side, the second end opposed across a length of the insert from the first end, the second major face parallel to and opposed across a thickness of the insert from the first major face, and the second side parallel to and opposed across a width of the insert from the first side, the first and the second sides spaced from one another to provide at least an interference fit between the major faces of the pair of elongated channel members of the stud when received therebetween over at least a majority of the length of the insert and the first and the second major faces of the block are spaced from one another to provide at least an interference fit between the pairs of flanges of the pair of elongated channel members of the stud when the insert is received therebetween over at least a majority of the length of the insert.   
     
     
         19 . The method of  claim 18 , further comprising:
 producing a tapered dimension proximate the first end across at least one of the width or the thickness of the insert; and   forming at least one stop flange that extends outwardly from the first and the second major faces proximate the second end of the insert, the stop flange sized and dimensioned to physically engage an end of the stud when the insert is received therein.   
     
     
         20 . The method of  claim 18 , further comprising:
 forming at least one respective recess in the first and the second sides along at least a portion of the length of the insert; and   forming a number of apertures that extend across the thickness of the insert and which pass through the first and the second major faces.