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.

Description

BACKGROUND

1. Technical Field

This disclosure generally relates to frame members or studs and in particular to reinforcement of frame members or studs.

2. Description of the Related Art

Frame members such as studs are used in construction, mechanical framing and other applications. Studs, and more generally frame members, are used for structural reinforcement and often bear a mechanical load in applications. Studs and frame members may also be used to provide a mechanical framing and may bear or support other elements of a structure.

A light-weight metal stud is described in U.S. patent application Ser. No. 13/767,764, filed Feb. 14, 2013. Metal studs offer a number of advantages over traditional building materials, such as wood. For instance, metal studs can be manufactured to have strict dimensional tolerances, which increase consistency and accuracy during construction of a structure. Moreover, metal studs provide dramatically improved design flexibility due to the variety of available sizes and thicknesses and variations of metal materials that can be used. Moreover, metal studs have an inherent strength-to-weight ratio which allows them to span longer distances and better resist forces such as bending moments.

BRIEF SUMMARY

This disclosure generally describes inserts for use with studs, for example metal studs, as well as kits and methods associated with such inserts. The stud may include 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.

Framing members, for example framing members used to construct frame structures, may buckle or deform under strain or loads. Buckling or deformation of framing members due to physical strain or load(s) is referred to as web buckling or web crippling. Web buckling or crippling is more likely to occur in frame members without a solid or continuous web. Typically, or normally, this failure occurs at the ends of individual framing members. An insert member in the form of a block may reduce or eliminate any tendency of a stud to buckle under load.

An insert for use with the stud may be summarized as including 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. The first and the second major faces of the block may be spaced from one another to provide at least a friction or 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.

The first and the second sides of the block may be 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 may be parallel to one another over at least a majority of the length of the insert. The block may be tapered proximate the first end across at least one of the width or the thickness of the insert. The block may include 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. The stop flange may extend outwardly from the first and the second major faces proximate the second end of the insert. The block may be tapered proximate the first end across both the width or the thickness of the insert.

The first and the second sides may each have a recess formed along at least a portion of the length of the insert, for example to accommodate protruding fasteners received by the stud.

The block may include a number of apertures. For example the block may include a number of apertures that extend across the thickness of the insert passing through the first and the second major faces.

The block of material may be selected from the group consisting of metals and polymers.

An insert for use with the stud may be summarized as including 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 a friction or 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.

The block may be tapered proximate the first end across the width or the thickness of the insert. The block may include 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.

The first and the second sides may each have a recess formed along at least a portion of the length of the insert. The block may include a number of apertures that extend across the thickness of the insert passing through the first and the second major faces.

The block of material may be selected from the group consisting of metals and polymers.

A method of forming an insert for use with a stud may be summarized as including 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.

The method may further include 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.

The method may further include 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.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not intended to convey any information regarding the actual shape of the particular elements, and have been solely selected for ease of recognition in the drawings.

FIG. 1A is a rear, left-side isometric view of a portion of a stud with a reinforcing insert inserted into one end of the stud, according to one illustrated embodiment.

FIG. 1B shows a front, right isometric view of the portion of the stud of FIG. 1A with the reinforcing insert inserted.

FIG. 2A is a front, bottom, right side isometric view of a reinforcing insert, according to another illustrated embodiment.

FIG. 2B is a right side elevational view of the reinforcing insert of FIG. 2A.

FIG. 2C is a front elevational view of the reinforcing insert of FIGS. 2A and 2B.

FIG. 2D is a top plan view of the reinforcing insert of FIGS. 2A, 2B and 2C.

FIG. 3 shows a top plan view of the reinforcing insert of FIGS. 2A-2D inserted into a stud, according to one illustrated embodiment.

FIG. 4 is a rear, bottom left-side isometric view of a reinforcing insert, according to another illustrated embodiment.

DETAILED DESCRIPTION

In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc.

Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, such as “including, but not limited to.”

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.

The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.

Manufactured framing members, for example metal framing members, are used to construct frame structures. U.S. patent application Ser. No. 13/767,764, entitled LIGHT-WEIGHT METAL STUD AND METHOD OF MANUFACTURE, provides an example of a manufactured framing member in the form of a metal stud.

Manufactured framing members may comprise sheet metal, and optionally a wire web connecting two elongated channels. It is economically advantageous to minimize the amount of material in a manufactured framing member, for example by using relative high or light weight gauge sheet metal to form the elongated channels. However, use of thin gauge material may result in the framing member buckling or deforming under strain or loads. Buckling or deforming of framing members due to physical strain or load(s) is referred to as web buckling or web crippling. Web buckling or crippling is more likely to occur in frame members without a solid or continuous web. Typically, or normally, this failure occurs at the ends of individual framing members. In one example of load bearing metal frame members, vertical studs installed in walls may buckle at or proximate a bottom end thereof.

As described herein, reinforcement inserts may strengthen framing members, mitigating web buckling or crippling. The reinforcing insert is inserted at least partially into a framing member to strengthen or reinforce the framing member.

FIGS. 1A and 1B show a framing member in the form of a stud 100 with a reinforcing insert 140 inserted at least partially therein, according to one illustrated embodiment.

The stud 100 comprises a pair of elongated channel members 110a, 110b opposed to one another across a width W100 of stud 100. A first one of the channel members 110a has a major face 112a, first flange 114a and second flange 116a. The first and second flanges 114a, 116a extend from the major face 112a of the first channel member 110a. The first and second flanges 114a, 116a oppose each other across a thickness T100 of the stud 100.

Similarly, a second one of the channel members 110b has a major face 112b (obscured in FIG. 1A by the body of channel member 110b). The second channel member 110b further has a first flange 114b and a second flange 116b. The first and second flanges 114b, 116b extend from the major face 112b of the channel member 110b. The first and second flanges 114b, 116b oppose each other across a thickness T100 of stud 100.

The stud 100 further comprises a web 120. The web 120 couples the elongated channel members 110a, 110b to each other in opposition across a width W100 of the stud 100 such that the major faces 112a, 112b are parallel to each other. For example, the web 120 may be a wire truss physically connecting the elongated channel members 110a, 110b to each other such that the elongated channel members 110a, 110b are in opposition with the major faces 112a, 112b parallel to each other.

A framing member, such as stud 100 which has a discontinuous or nonsolid web physically coupling its constituent elongated channel members, is susceptible to failure such as web buckling as discussed above. For example, the elongated channel members 110a, 110b may be manufactured from light gauge metal, for example a light gauge aluminum. These elongated channel members 110a, 110b may be coupled by one or more wire configurations to form a stud. When under a substantial load or other stress, a framing member with a wire truss web configuration as shown in FIGS. 1A, 1B may deform at one end. As described herein, an insert may be used to provide reinforcement for the structure and structural integrity of a framing member such as stud 100. Such may advantageously increase resistance to load and/or allow an increase in the gauge of materials used for the elongated channel members 110a, 110b and/or web 120.

As illustrated in FIGS. 1A and 1B, the reinforcing insert 140 may take the form of a block of material. The reinforcing insert 140 includes a pair of major faces 144, 145, a pair of sides 146, 147 (obscured by channel members 110a, 110b, respectively) and a pair of ends 148, 149. For example, the reinforcing insert 140 may include a first major face 144 and a second major face 145, the second major face 145 opposed across a thickness of the reinforcing insert 140 from the first major face 144. The first major face 144 and the second major face 145 may be parallel or substantially parallel to one another over all or a predominate portion of the first and the second major faces. Also for example, the reinforcing insert 140 may include a first end 148 and a second end 149, the second end 149 opposed across a length of the reinforcing insert 140 from the first end 148. The first end 148 and the second end 149 may be parallel or substantially parallel to one another over all or a predominate portion of the first and the second ends 148, 149. Also for example, the reinforcing insert 140 may include a first side 146 and a second side 147, the second side 147 spaced across a width of the reinforcing insert 140 from the first side 146. The first side 146 and the second side 147 may be parallel or substantially parallel to one another over all or a predominate portion of the first and the second sides 146, 147.

The width may be sized or dimensioned to provide at least a friction or 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. The thickness may be sized or dimensioned to provide at least a friction or 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.

The reinforcing insert 140 is at least partially inserted or received into a space between the pair of opposed elongated channel members 110a, 110b of the stud 100. The reinforcing insert 140 is inserted into one end, or respective reinforcing inserts 140 are inserted into each end of the stud 100. The reinforcing insert 140 fits snugly in an interior space, between the first and second flanges 114a, 116a; and fits snugly between the first and second flanges 114b, 116b. In this way, the reinforcing insert 140 reinforces the channel members, maintaining the two flanges of an elongated channel member in position when the framing member is under load or compression, thereby increasing relative failure strength. That is, the reinforcing insert 140 strengthens the structural integrity of stud 100 to prevent or minimize web buckling or crippling.

As illustrated in FIGS. 1A and 1B, the reinforcing insert 140 has a number of apertures 142a-142d (four illustrated, collectively 142) which lighten the insert 140 and/or reduce the amount of material constituting the reinforcing insert 140. For example, apertures 142 may extend all the way through the major faces of the reinforcing insert 140. Alternatively, the apertures 142 may only partially extend into the reinforcing insert 140, forming pockets therein. While FIGS. 1A and 1B illustrate the apertures as circular, other shapes may be employed. Additionally or alternatively, the reinforcing insert 140 may have other patterns of apertures, and/or apertures on the minor faces (e.g., sides, top, bottom).

The reinforcing insert 140 may be formed, for example, by machining, casting, extruding or other industrial manufacturing process(es) from steel, aluminum, brass, bronze or other suitable metal or metallic alloy. For example, reinforcing insert 140 may result from machining of a block of aluminum alloy which is then anodized. Also, for example, the insert 200 may result from machining stainless steel or a steel which is subsequently galvanized for corrosion protection. The reinforcing insert 140 could also be made of, for example, a rigid polymer such as PVC, ABS, fiberglass, open or closed cell rigid foams, or other plastic material. The material used to make reinforcing insert 140 might advantageously have a compressive strength in the range of 8000 to 12000 psi.

FIGS. 2A-2D show a reinforcing insert 200 according to another illustrated embodiment. The reinforcing insert 200 is made from a block of material and has a first end 210, a second end 220, a first major face 230, a second major face 240, a first side 250 and a second side 260. The second end 220 opposes the first end 210 across the length L200 of the reinforcing insert 200. The second major face 240 opposes the first major face 230 across a thickness T200 of the reinforcing insert 200. The second side 260 opposes the first side 250 across the width W200 of the reinforcing insert 200. Furthermore, the first side 250 is spaced from the second side 260 (by width W200) to provide at least a friction or interference fit between the major faces of the pair of elongated channel members of a framing member such as stud 100 when received therebetween over at least a majority of the length L200 of the reinforcing insert 200.

More specifically, the first major face 230 is spaced from the second major face 240 (by thickness T200) to provide at least a friction or an interference fit between the pairs of flanges of the pair of elongated channel members of the stud 100 when the reinforcing insert 200 is received therebetween, over at least a majority of the length L of the reinforcing insert 200. The first side 250 is generally or substantially parallel to the second side 260 over at least a majority of the length L200 of reinforcing insert 200. Similarly, the first major face 230 is generally or substantially parallel to the second major face 240 over at least a majority of the length L200 of the reinforcing insert 200.

In contrast to the embodiment of FIGS. 1A and 1B, the reinforcing insert 200 of FIGS. 2A-2D includes a tapered portion 215 proximate a first end 210 thereof, a number of stops 225 extending peripherally from a second end 220 thereof, a single aperture 205, and a pair of recesses 255, 265 formed in and extending along the sides 250, 260 thereof.

The reinforcing insert 200 may have a tapered portion 215 at least proximate the first end 210. For example, the tapered portion 215 may be tapered across at least one of the width W200 and/or the thickness T200 of the reinforcing insert 200. The tapered portion 215 proximate the first end 210 facilitates insertion of reinforcing insert 200 into a framing member such as stud 100.

The tapered portion 215 of the reinforcing insert 200 is visible in FIGS. 2B and 2C. The reinforcing insert 200 tapers from a thickness of approximately T200 at a point on the reinforcing insert 200 removed or spaced from a terminating edge of the first end 210, narrowing in thickness towards the terminating edge of the first end 210. That is, a thickness of the reinforcing insert 200 proximate the first end 210 decreases from a first thickness T200 to a narrower thickness at the terminating edge of the first end 210. A length of the tapered portion 215 may, for example, be about ½ inch. That is, the taper portion 215 begins about ½ inch from the terminating edge of the first end 210, tapering or becoming smaller over the length. Thus, the thickness of the reinforcing insert 200 decreases as the first end 210 is approached. As an example, a thickness of the reinforcing insert 200 may decrease by 3/16 inch on each of the opposing sides of the major faces 230, 240, such that a total thickness of the reinforcing insert 200 at the terminating edge of the first end 210 is ⅜ inch less than the thickness T200.

As further shown in FIGS. 2B and 2C, the tapered portion 215 may also include a decrease in width W200. More specifically, the width of the reinforcing insert 200 decreases along the length of tapered portion 215, culminating in a decreased width of the reinforcing insert 200 at the terminating edge of the first end 210. That is, the width of the reinforcing insert 200 proximate the first end 210 decreases from a first width W200 to a narrower width at the terminating edge of the first end 210. A width of the tapered portion 215 begins about ½ inch from the terminating edge of the first end 210, tapering or becoming smaller over the length. Thus, the width of the reinforcing insert 200 decreases as the first end 210 is approached. As an example, a width of the reinforcing insert 200 may decrease by ⅛ inch on each of the opposing sides 250, 260, such that a total width of the reinforcing insert 200 at the terminating edge of the first end 210 is ¼ inch less than the width W200.

Of course, the tapered portion 215 at the first or inserting end 210 of the reinforcing insert 200 facilitates insertion of the reinforcing insert 200 into an end of a stud or other framing member. Therefore, the dimensions of the tapered portion 215 and whether both the width and thickness are tapered will depend upon the particular application and physical dimensions of the stud to be reinforced. That is, whether the taper will be applied to both the width and thickness of the insert, or to just one dimension, will depend upon the individual application of the reinforcing insert 200. Thus, the reinforcing insert 200 may be viewed as a trapezoidal prism defined by a first end, a second end, a first major face, a second major face, a first side and a second side.

The reinforcing insert 200 may further include at least one outwardly extending stop flange 225 proximate the second end 220. The stop flange(s) 225 is sized and dimensioned to physically engage an end of a stud when the reinforcing insert 200 is received therein. The stop flange(s) 225 prevents the reinforcing insert 200 from sliding into the stud 100. The stop flanges 225 extend peripherally outwardly from first and second major faces 230, 240 proximate second end 220. As shown in FIGS. 2A and 2C, the stop flange(s) 225 are discontinuous flanges on both sides of the second end 220. Of course, this is one illustrative example of a stop flange configuration, and a continuous flange may be used for example, as may a single flange on one side of the reinforcing insert 200.

The stop flange(s) 225 illustrated in FIGS. 2A and 2C are merely one example of insert projections that can be used to engage a stud to prevent the reinforcing insert 200 from sliding into the stud. More generally, projections on the reinforcing insert 200 can be used to ensure that the reinforcing insert 200 is located at a desired insertion in the associated stud. Insert projections such as the illustrated stop flange(s) 225 may have associated score marks to facilitate breaking off, cutting or otherwise removal of the projection if desired by a user or necessitated by the application.

In some implementations, the reinforcing insert 200 may be paired with a wall stud or other framing member likely to receive nails, screws or other invasive fasteners. The reinforcing insert 200 may include one or more recesses 255, 265, as shown in FIGS. 2A-2D, to accommodate intrusive fasteners. More specifically, the reinforcing insert 200 may include recesses 255, 265 formed in the first and second sides 250, 260. The recesses 255, 265 may extend along at least a portion of the length L200 of insert 200. The recesses 255, 265 should be sufficiently deep to accommodate an expected penetration of fasteners through the elongated channel members of the stud. The recesses 255, 265 may be particularly advantageous where the reinforcing insert 200 is a block of metal.

The reinforcing insert 200 may be formed by machining a solid block of material. The reinforcing insert 200 may include one or more aperture(s) 205. Aperture(s) 205 may lighten the reinforcing insert 200 and/or reduce the amount of material needed for the reinforcing insert 200. As shown in FIGS. 2A-2D, aperture 205 extends across the thickness T200 of reinforcing insert 200 and passes through first and second major faces 230, 240. Thus reinforcing insert 200 may be partially hollow in the center, but is otherwise a solid block of material. Of course, the illustrated aperture 205 is merely one example of an aperture or aperture configuration. There may be multiple apertures in an insert, as in the reinforcing insert 140 shown in FIGS. 1A and 1B. Of course, there may also be hidden aperture(s) or pocket(s) that do not extend the full thickness T200. For example, the center of an insert could be a semi-hollow honeycomb structure.

The reinforcing insert 200 may be formed, for example, by machining, casting, extruding or other industrial manufacturing process(es) from steel, aluminum, brass, bronze or other suitable metal or metallic alloy. For example, reinforcing insert 200 may result from machining of a block of aluminum alloy which is then anodized. Also, for example, the insert 200 may result from machining stainless steel or a steel which is subsequently galvanized for corrosion protection. The reinforcing insert 200 could also be made of, for example, a rigid polymer such as PVC, ABS, fiberglass, open or closed cell rigid foams, or other plastic material. The material used to make reinforcing insert 200 might advantageously have a compressive strength in the range of 8000 to 12000 psi.

FIG. 3 shows an insert-reinforced stud 300 combination comprising wire web stud 310 and reinforcing insert 330. The wire web stud 310 has a wire web 315 which couples the opposing elongated channel members of the stud 310. As shown in FIG. 3, the wire web 315 is physically coupled to one major face of each of the elongated channel members, functionally holding the elongated channel members in parallel to form stud 310. More specifically, the wire web 315 is coupled to one side of the inside of each of the elongated channels as defined by the first and second flanges of the channel members. Also shown inserted into the channel members of the stud 310 is the reinforcing insert 330. The reinforcing insert 330 contacts a portion of the wire web 315 in a portion of the channel of the channel members, thereby reinforcing the wire web 315 for at least the portion of the wire web 315 in contact with the reinforcing insert 330 in the channels of the channel members.

When the web of the stud is a type of wire webbing, the length of the insert must be coordinated with the pitch of the wire truss forming the webbing and the number of wires in the truss. In the context of a single wire truss, the length of the reinforcing insert may optimally be approximately one pitch in length. Thus, the insert would reinforce the wire webbing over one pitch of the wire truss of the stud when inserted. In the context of a double wire truss, the length of the reinforcing insert may optimally be approximately a half pitch in length. Thus, the reinforcing insert would reinforce the wire webbing over half the pitch of the wire truss of the stud when inserted. Returning to FIG. 1B, the stud 100 is shown with a double wire truss webbing. As further shown in FIG. 1B, the reinforcing insert 140 has a length which ensures that approximately half a pitch of the double wire truss forming the webbing is supported by the reinforcing insert.

Therefore, depending upon the application, and particularly in the context of studs with wire-type webbings, it may be desirable to have kits with one or more reinforcing inserts sized to provide a desired reinforcement of the stud, and optionally one or more studs. Thus, for example, in the context of a stud with a single wire truss webbing, a corresponding reinforcing insert could be provided in a stud kit, the corresponding insert having a length reinforcing approximately one pitch of the wire webbing when the insert is inserted into the stud. Similarly, in the context of a stud with a double wire truss webbing, a corresponding insert could be provided in a stud kit, the corresponding insert having a length reinforcing approximately a half pitch of the wire webbing when the insert is inserted into the stud.

FIG. 4 shows a reinforcing insert 400 for reinforcing the webbing of a stud, according to another illustrated embodiment.

In contrast to the reinforcing stud 200 of FIGS. 2A-2D, the reinforcing insert 400 includes a pair of substantially continuous stop flanges 425a, 425b (collectively 425) that extend peripherally outwardly from the first and second major faces 230, 240, respectively, proximate second end 220.

The above description of illustrated embodiments, including what is described in the Abstract, is not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. Although specific embodiments and examples are described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the disclosure, as will be recognized by those skilled in the relevant art. The teachings provided herein of the various embodiments can be applied to other systems, not necessarily the exemplary object evaluation system generally described above.

The various embodiments described above can be combined to provide further embodiments. To the extent that they are not inconsistent with the specific teachings and definitions herein, all of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet that are commonly assigned to the same assignee of this application, including U.S. patent application Ser. No. 13/767,764, entitled LIGHT-WEIGHT METAL STUD AND METHOD OF MANUFACTURE are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary, to employ configurations and concepts of the various patents, applications and publications to provide yet further embodiments.

These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.

Claims

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.