GB2615614A

GB2615614A - Wall mounting system

Info

Publication number: GB2615614A
Application number: GB2206941.3A
Authority: GB
Inventors: Burns Michael
Original assignee: L A M N Solutions Ltd
Current assignee: L A M N Solutions Ltd
Priority date: 2022-05-12
Filing date: 2022-05-12
Publication date: 2023-08-16
Also published as: GB202206941D0

Abstract

The mounting system includes a mounting plate 12 with a number of mounting holes 24 and a number of mounting rods 14 which are inserted into the mounting holes. A number of internally threaded anchors are for embedding into a wall 20. The mounting rods have a threaded end for receipt into the anchors. A number of clamping members 16, such as a pair of nuts 16a, 16b, clamp the mounting plate at a certain distance from the mounting rods. The mounting plate has a set of mounting elements 34 for mounting a load thereon. A layer of insulation may be behind the mounting plate. Also claimed is a method of installing a wall mounting system and a method of installing insulation. Also claimed is a kit of parts for the mounting system.

Description

Wall Mounting System

Field of the Invention

The invention relates to an improved wall mounting system (also referred to as a wall mounting device or pattress), a kit of parts for such a wall mounting system, a method of 5 installing such a wall mounting system particularly for use when retrofitting insulation to buildings, and a method of installing insulation to a building.

Background

Mounting items to external building walls is relatively straightforward because the walls provide a directly accessible substrate of suitable strength and composition to provide a foundation to which something can be attached. Difficulties arise when the external surface of the building wall is covered with external insulation. Such difficulties include the insulation being insufficiently strong to serve as a substrate or foundation to which items may be mounted (as might otherwise easily be mounted to a building wall). Further, the building wall is not directly accessible. Further, the building wall is no longer visible.

Attachment of items to buildings after the insulation is installed is problematic. Other problems include efficiency of the method of installing insulation.

It is known to apply a façade or cladding to a building wall and various ways exist. For example, DE3127736 FINK describes a device for fastening a façade or cladding supporting substructure composed of horizontal and/or vertical profile rails at a predetermined distance from a building wall. But this does not address the challenges of attaching items to building walls that intended to have, or already include, external insulation.

EP2278173 MITTERHUBER shows a mounting device for attaching external elements to a solid wall with external wall insulation. A wall mounted plate is held immediately adjacent to a wall by screws into the wall. An internally threaded tube protrudes into the insulation and a threaded tube of a mounting plate serves as an external support and is screwed into the threaded tube, so that the thickness of the insulation can be compensated for. This provides a small plate on a single threaded tube arrangement. The diameter of the threaded tube arrangement is quite wide. The mounting plate itself appears to rotate. This is unlikely to be able to support heavier loads. It appears this is installed at the same time as the insulation.

EP1482188 STICH describes a device for attaching gutters etc. onto façades with heat insulation which provides a tube arrangement mounted on anchors which may be a rod mounted in the wall. The diameter of the tube arrangement is quite wide.

US2020308827 EJOT describes a system for fastening attachments (which seem to be a 5 small flat plate) to a substrate with an insulation layer. This is not able to support heavier items. Further, it appears this must be installed at the same time as the insulation.

W02013011497 GAUTHIER describes a method and system for fastening an object to a façade using a cylinder extending through insulation. This also is to be installed at the same time as the insulation.

W02017153049 GILLER describes a spacer and fastener for parts fixed through a façade of a building using different connection plates. Embodiments typically have two or three-part spacers or a rod glued into the wall surrounded by wide reinforcement. It appears that this is installed contemporaneously with insulation. Further, it is very difficult to remove such glued-in rods.

EP3011115A1 HUNTER describes a metal attachment system for a ventilated rain screen cladding system. A threaded rod is secured to a threaded aperture and traverses the external foam insulation and an aperture in a flat dispersal plate which appears to spread any load on the insulation and, spaced out from this are the supports of the cladding system. It seems, this system is installed after the insulation.

W02012097392 DESSL describes a spacer for securing an object to a base with an insulation layer, the spacer comprises a supporting base plate element adjacent to the wall and rod elements anchored within the wall. The spacer also has bridging elements which are connected to the base plate element, and a mounting element that can be fastened to the bridging elements at variable distances from the wall element. This is a complex spacer system which is typically installed at the same time as the insulation.

DE19947913 FINGERLING describes a fastening element for attaching loads. It uses a hardenable adhesive to mount threaded rods in a wall. These are not easily removable. The fastening elements have limited utility, and cannot support heavier loads or, indeed, differing kinds of loads.

DE19636447 KOCH describes a mounting part for attaching a component on an insulating wall. A tension and compression resistant reinforcing member is embedded in insulation, a first fastener attaches the reinforcing member to a wall and the component is attached by a second set of fasteners onto the reinforcing member. This is complex to manufacture and install. Furthermore, it is difficult to install insulation afterwards. It is also difficult to install insulation (e.g. in a roll or batts) afterwards around the mounting structure.

EP1724412A2 FISCHER describes spacers which each have a threaded rod anchored by a hardenable compound in a wall. These are not particularly strong arrangements. Further, these are difficult to remove and, typically, also present difficulties when installing insulation, after first installing rods.

In many prior art examples above, it is difficult as well as time consuming to install insulation (e.g. in a roll or batts) after installing a mounting system, and difficult as well as time consuming to install the mounting system after the insulation. Indeed, in many prior art examples, it is likely to be very difficult to install a mounting system, at the same time as the insulation, requiring specialist skills. Many prior art methods are inefficient and/or risk provision of services. This restricts flexibility in construction and/or retrofitting.

The present invention seeks to alleviate one or more of the problems noted above or elsewhere in this document and/or of the known art.

Statements of the Invention

In a first aspect of the invention there is provided a mounting system for mounting a load to a wall (e.g. an upstanding wall e.g. of a building) fitted, or to be fitted, with an insulation 20 layer, the system comprising: a mounting plate having a plurality of mounting holes for receipt of mounting rods (such as in a first predetermined two-dimensional pattern which, for example, in use, may have a spaced horizontal and/or vertical extent); a plurality of internally threaded (e.g. expandable) anchors (e.g. drop-in anchors) for 25 anchoring in a wall (such as in the spaced horizontal and vertical first predetermined pattern); a plurality of mounting rods each rod having at least one (e.g. optionally two) threaded end(s) for receipt (e.g. received or receivable) in a respective anchor (e.g. in the first predetermined pattern), a plurality of clamping members for clamping the mounting plate at a predetermined distance from the anchors on the mounting rods; the mounting plate comprising a set of mounting elements (e.g. threaded holes optionally in a second predetermined two-dimensional pattern) for mounting a load thereon.

The plurality of mounting holes for receipt of mounting rods may be in a first predetermined two-dimensional pattern (e.g., in use, having a spaced horizontal and/or 5 vertical extent) and the plurality of internally threaded (e.g. expandable) anchors (e.g. drop-in anchors) may be configurable for anchoring in a wall in the first predetermined two-dimensional pattern, and the plurality of mounting rods may be receivable in respective anchor(s) in the first predetermined pattern. In this way, the first predetermined pattern can be chosen to facilitate insertion of insulation, which may have one or more 10 predetermined slots in a suitable pattern, from the side. The rods may be circular in cross section, or other shapes such as polygonal shapes (e.g. nearly circular polygonal shapes), hexagonal, octagonal, square and so on.

The first predetermined pattern may comprise at least two mounting rods in a straight line in a first direction (e.g. in a horizontal and/or vertical direction). The first predetermined pattern may comprise at least two mounting rods in a straight line in each of two respective directions. The two respective directions may be generally, or substantially, orthogonal.

The mounting system (10) may comprise an expandable, internally threaded anchor (e.g. a drop-in anchor), optionally of a size to be recessed into a sufficiently deep hole in the wall so as not protrude beyond the wall e.g. should later removal be desired. A setting tool or other tool such as a centre punch may be used to set the expandable anchors by moving an internal wedge to expand wall segments (e.g. wall engaging surface structures such as shaped protrusions) into the surrounding wall. The system may comprise an internally threaded anchor which may be glued in suitable recessed holes in the wall.

The position of the mounting plate on the mounting rod(s) may be variable. VVhere a fully threaded rod is provided, the mounting plate may be slotted over the threaded rods to any suitable location at a particular distance from the wall before being locked' in position by one or more clamping mechanisms. Preferably, a pair of locking nuts (e.g. poly nuts) about the mounting plate are used on each rod. Where a rod with one or both ends threaded is provided, location of the mounting plate may be more limited and/or other clamping mechanisms may need to be used. The clamping member(s) may comprise locking nut(s) and the position of the mounting plate on the mounting rod(s) may be fixed by locking nut(s) (e.g. poly nuts). In this way, the distance of the mounting plate from the wall (and from the insulation, if needed) can be decided at the time of installation. Any excess rod length may be removed (e.g. by sawing or cutting).

The mounting system may comprise a layer of insulation (40) behind the mounting plate and a front surface of the insulation may lie spaced from the rear surface of the mounting plate (e.g. to accommodate a sealing and/or decorative layer such as render and/or cladding on the insulation, and/or to facilitate inspection and or access behind the mounting plate) and/or to provide a small tolerance in the distance of the mounting plate to the wall to facilitate insertion of the insulation from the side.

In a further aspect there is provided a method of installing a wall mounting system on a wall (e.g. on an external wall such as an upstanding external wall of, for example, a 10 building) using a mounting system as described herein, the method comprising: installing the plurality of anchors in a wall, optionally using the mounting plate, e.g. its holes for receipt of rods, as a pattern installing the plurality of mounting rods into respective anchor(s); installing the mounting plate on the plurality of rod(s); - clamping the mounting plate at a predetermined distance from the anchors on the mounting rods.

In a further aspect there is provided a method of installing insulation on a wall (e.g. on an external wall such as an upstanding external wall of, for example, a building) using a mounting system as described herein, or a method of installing a wall mounting system 20 as described herein, the method comprising: installing the plurality of anchors in a wall, optionally using the mounting plate e.g. its holes as a pattern; installing the plurality of mounting rods into respective anchor(s); installing the mounting plate on the plurality of rod(s); clamping the mounting plate at a predetermined distance from the anchors on the mounting rods (e.g. using locking nuts such as poly nuts); inserting (e.g. slotting or sliding) insulation (e.g. rigid or semi rigid) insulation) behind the mounting plate from the side.

It will be understood that although the mounting system and method are described in 30 relation to an upstanding such as a vertical wall, typically an external wall, it may be used on a sloped or horizontal wall structure (e.g. the horizontal surface below a beam) which may be external or internal to an actual building. The invention finds particular application for fitting and retro fitting of insulation to external walls of existing buildings.

The method of installing insulation may comprise: installing the plurality of mounting holes for receipt of mounting rods in a first 5 predetermined two-dimensional pattern (e.g., in use, having a spaced horizontal and/or vertical extent); installing the plurality of internally threaded (e.g. expandable) anchors (e.g. drop-in anchors) in the wall in the first predetermined two-dimensional pattern; and, installing the plurality of mounting rods in respective anchor(s) in the first two-10 dimensional predetermined pattern; clamping the mounting plate at a predetermined distance from the anchors on the mounting rods (e.g. using locking nuts such as poly nuts); providing one or more slots in the insulation (which may be rigid or semi-rigid insulation in batts or panels or rolls) and inserting the insulation behind the mounting 15 plate so that at least two rods are received in at least one slot.

At least one slot may be a straight slot.

In a further aspect, there is provided a kit of parts for a mounting system as described herein, comprising: a mounting plate having a plurality of mounting holes for receipt of mounting rods 20 in a first predetermined two-dimensional pattern (e.g. in use, having a spaced horizontal and/or vertical extent); a plurality of mounting rods each rod having at least one (optionally two) threaded ends; and optionally further comprising one or more of: - a plurality of clamping members (e.g. locking nuts) for clamping the mounting plate at a predetermined distance from the anchors on the mounting rods; a plurality of internally threaded (e.g. expandable) anchors (e.g. drop-in anchors) for anchoring in a wall an insulation panel comparing at least one slot.

Several embodiments of the invention are described and any one or more features of any one or more embodiments may be used in any one or more aspects of the invention as described above.

Brief Description of the Invention

The present invention will now be described, by way of example only, with reference to the following figures. In the figures, the same reference numerals refer to the same features.

Figure 1 is a perspective view from the side of the mounting system of the invention on a wall, before insulation is installed.

Figure 2 is a perspective view from the front, and from slightly above, of the mounting system of Figure 1 with a satellite dish mounted on it, before insulation is installed.

Figure 3 is a plan view of a kit for the mounting system of Figure 1.

Figures 4A and 4B are perspective views of an anchor bolt (e.g. an expanding drop-in 10 bolt) for use in the mounting system of Figure 1 (and which may be part of the kit of Figure 3).

Figures 5A and 5B show perspective views of a wall in which, respectively, anchor bolts have been installed (Figure 5A) and mounting rods have been installed (Figure 53) with in this example, a partly formed mounting system (without a mounting plate) but with locking nuts installed. Thus in one or more embodiments the mounting system may be partially constructed, with or without a mounting plate, before installation of insulation to an external wall.

Figure 6 is a perspective view from above of the mounting system of Figure 1, illustrating how, in one or more embodiments, the mounting rods are aligned along one or more 20 axes, here, in this example embodiment, along a first axis X (e.g. horizontally), and also along a second axis Y (e.g. vertically).

Figure 7A and 7B show, respectively, a plan view from the front and a perspective view from the side of the mounting system on a wall with insulation installed behind it.

Detailed Description of the Invention

It will be understood by those skilled in the art that any dimensions and relative orientations such as lower and higher, above and below, and any directions, such as vertical, horizontal, upper, lower, axial, radial, longitudinal, tangential, orthogonal etc., and any properties e.g. planar, straight, flat, rigid, semi-rigid, solid etc. referred to in this application are within expected structural tolerances and limits for the technical field and the apparatus and methods described, and these should be interpreted with this in mind.

Efficiently and effectively retrofitting insulation to walls of buildings, particularly occupied buildings, is problematic. The cost of retrofitting is high and yet the need great to tackle heat loss from buildings because of climate change is great. There are many systems for fitting decorative facades and cladding to buildings, but these may or may not offer any 5 insulafive benefit. One way of retrofitting insulation is to attach, e.g. using an adhesive, insulation, typically in the form of one or more insulation panels (e.g. batts) to external walls of the buildings. Typically, and as preferred in this invention, the insulation panels are rigid and lightweight, e.g. rigid foam such as polystyrene. These can be cut and shaped to fit the shape of the external wall and around recesses e.g. for windows, or 10 protrusions, such as decorative external wall features.

Existing buildings especially domestic houses, often have a number of external services provided on external walls, typically upstanding e.g. vertical walls. These services include such services as down pipes for gutters, external lights, tv ariels and satellite dishes and such like. Removing these is time consuming and costly, as is reinstallation. Furthermore, removal of such services, even temporarily, is undesirable to building and house owners. Once removed it may not be known when these will be reinstalled. Further when insulation is installed, these may be difficult to re-install and re-connect to provide the original service (e.g. drainage from a down pipe, or tv cable into the house), especially when the original holes, or cables are hidden by insulation.

Some solutions involve cutting or drilling through the insulation to reach the wall beneath. This enables bigger holes to be drilled in the insulation e.g. to provide two or more-part, telescopic spacers which may be insulated to reduce cold bridging. But this carries a risk of hitting an undesirable area of the external wall, and prevents the services being used in between removal of the services and their re-installation.

Indeed, in preparing a building for external insulation, if services are removed, there may be quite a time gap, e.g. several days or weeks, before these are reinstalled. If the services removed include gutters or down pipes for gutters this carries the risk of flooding and water damage to external walls immediately before installation of insulation. If the services removed are television (TV) ariels or satellite dishes, this is undesirable for the users of the building and carries the risk that the original alignment, or even parts of the removed equipment, may be lost.

Furthermore, the skills and time required to address bespoke removal and careful reinstallation of services and associated equipment e.g. downpipes and communications equipment such as tv ariels and satellite dishes, adds cost and complexity of retrofitting 35 external wall insulation.

Indeed, if there are constructional efficiencies and cost savings to be gained from a non-bespoke installation (using non-bespoke equipment, skills and methods), this may be crucial to more extensive, widespread adaption of such technologies.

The present invention seeks to resolve some of the challenges of known systems.

Figure 1 shows a mounting system 10 comprising a mounting plate 12, rods 14, clamping members 16, here in the form of locking nuts 16A (best seen in Figure 6), 16B, washers 17 (see Figure 6), and wall anchors 18 embedded in wall 20.

Wall 20 is typically an upstanding external wall which may or may not be provided with a surface render (render is seen in Figure 1). The mounting system may be used with internal or external walls which may or may not be upstanding, sloping, or even horizontal, but it is of particular benefit for use with external walls where fitting or retrofitting of insulation is required Mounting plate 12 may be of any suitable shape and is, in this example embodiment, square. For example, plate 12 may be rectangular, hexagonal, octagonal, circular and so 15 on. It may have straight sides and rounded corners (not shown) to reduce sharp edges.

Mounting rods 14 are typically threaded rods, in other words these are threaded along their entire length. Alternatively, and advantageously, in one or more embodiments, mounting rods 14 may be threaded at each end but provided with a smooth outer surface in between those ends. The extent of threading from each end of rod 14 towards a central portion of rod 14 may be a few centimetres and may be adjusted for particular applications. The smoother (unthreaded) central portion may be helpful when sliding in insulation from the side as will be described below.

In the embodiment shown in Figure 1, four lock nuts 16B are seen and these are supplemented by four supplementary lock nuts 16A (best seen in Figure 6) and associated (optional) washers 17. Mounting plate 12 is provided with a plurality of holes or through-bores 24 in a first predetermined pattern 60. In the example shown, pattern 60 is generally square having through-bores 24 (best seen in Figure 3) one at each corner. The first predetermined pattern 60 has been chosen to provide, in this example, two rows and two columns of through-bores 24 into which corresponding rods 14 can be received, in two rows and two columns. A first row is indicated by arrow XX' and a first column is indicated by arrow YY'. Thus pattern 60 is two dimensional in plan view (here when viewed from the front).

As can be seen in Figure 2, mounting plate 12 is rigidly fixed to upstanding wall 20 and provides a solid foundation element on which a load 30, here a satellite dish, can be mounted. Load 30 has a shaped mounting element 32 which attaches to mounting plate 12 via, here internally threaded holes 34 arranged optionally in a second predetermined pattern 70 to match corresponding holes in mounting element 32.

Figure 3 shows a kit of parts comprising a mounting plate 12 with through-bores 25 in the first predetermined pattern 60, and a set of threaded holes 34 in a second predetermined pattern 70. Also included in the kit are a plurality of threaded rods 14, here four of them to match the four through-bores 24 provided, one at each corner in mounting plate 12. A set of clamping elements, here poly locking nuts 16A, 16B, are provided, two per rod. Typically, washers 17, here eight of them, are also provided.

Referring now to Figures 4A and 4B, expandable wall anchors 18 may also be provided in such a kit. Typically anchors 18 are drop-in anchors having an internal thread 19 at one end and expandable arms 21 at another (distal) end. Typically, such wall anchors are expandable by means of a cone or pyramid-shaped movable element situated within the anchor which can be tapped or set into position using a setting tool 28 and a hammer 38, as shown in Figure 5A. In some embodiments, glued in wall anchors may be used. The wall anchors are typically internally threaded to receive rods 14. Other forms of cooperating mechanisms may be considered e.g. bayonet fitting.

Figure 5B shows some elements of the kit in place on a wall 20. Four holes (not labelled) have been drilled to a suitable depth in wall 20 and wall anchors 18 slotted in before being set using setting tool 28 and hammer 38. In some embodiments, adhesive may also be used to hold anchors 18 in place.

In a first step, the mounting plate 12, and its through bores 24 in first predetermined pattern 60, can be used to mark the wall to show where the holes for receipt of wall anchors 18 should be made. Next, the wall anchors 18 are slotted into the holes. These then follow the first predetermined pattern 60 of through-bores 24, which may be two rows of two columns, providing an overall square shape or any other suitable shape using, preferably straight, lines to form rows and/or columns and/or diagonals and so on.

To provide sufficient strength, it is preferred that the first predetermined pattern is two dimensional (when seen in plan view from the front, see Figure 3).

It will be understood by those skilled in the art that, whereas Figure 5B shows four rods 14 arranged in two horizontal rows and two vertical columns, more rods per row and/or more rods per column may be provided if additional support is needed. More rods per row and/or rods per column may be provided if a load is particularly heavy or particularly large and more fixing points into wall 20 are required, or further rows or columns, or diagonals or sloped lines e.g. three or four, and so on. All of this can be pre-set in a factory by the choice of the first predetermined pattern to match particular loads.

Referring now to Figure 6, it can be seen in this example embodiment that the rows and columns of mounting rods 14 are arranged orthogonally with respect to each other, this will be further described later. Also in Figure 6, the arrangement of the rear of plate 12 is at a predetermined distance D from wall 20. The rear locking nuts 16A are slightly closer to wall 20. Once mounting plate 12 has been located on rods 14 against the now installed locking nuts 16A, all at the same distance D from wall 20, further locking nuts 16B, typically proceeded by washer 17, may be used to hold mounting plate 12 in position. If mounting rods 14 of too long a length have been used, these may now be cut or sawn off.

Once complete, the entire structure of the wall mounting system 10, comprising anchors 18, rods 14, locking nuts 16A and 16B and mounting plate 12, is rigid for securely 15 attaching load 30 to wall 20.

It can be seen in Figure 6, particularly on the right-hand side of Figure 6, that two columns of rods have been provided when viewed from a particular selected direction. From above, the two mounting rods on the right-hand side lie immediately one above the other. Similarly, when viewed along direction X, the mounting rods 14 in the upper row lie directly one behind the other. This facilitates the use of slots in the insulation 50 to slot insulation 40, e.g. from the side or from above, behind the mounting plate 12 without disturbing the mounting plate 12 or potentially any load 30 mounted on it. Thus, the mounting system can be prepared and mounted in advance, with a limited break in services. The steps of installation may be separated by several days or weeks with very little if any loss of service. Further fewer specialist skills are required.

This can be seen more clearly in Figures 7A and 7B in which two spaced-apart horizontal slots 50 are shown. In this case, a batt (or panel) of insulation 40 may be slotted in behind mounting plate 12 from the right-hand side to the left-hand side as seen in Figures 7A and 7B. This means that the space behind mounting plate 12 is covered with rigid insulation with very small gaps in slot(s) 50. Any remaining cavities formed by slot(s) 50 may be filled either with further rigid insulation (such as that previously removed to provide slots 50) or with expandable foam. The slots 50 may be prepared on site or beforehand in the factory.

In one or more embodiments therefore, neither the mounting plate 12 nor load 30 have to be removed from the building. Indeed, the building may be prepared with mounting plates 12 and loads in situ ready for receipt of insulation 40 with minimal disruption in services. Typically, the services are removed and the mounting system 10 installed and the load 30 providing the service such as satellite service or downpipe provision from gutters may be reinstalled the same day. This allows the separation of the later step of installing insulation from an earlier preparation step. Thus, in one or more embodiments, it is possible to use the mounting system of the invention to continue to provide services (e.g. supporting a load such as a satellite dish), even before insulation is installed, and potentially also during installation, as well as after installation of insulation.

Referring now to Figures 7A and 7B, provision of suitably placed and sized slots 50 in the insulation facilitates sliding or slotting in of the insulation in between the wall and the mounting plate, about the aligned rods 14 (along a row or column of a line of rods). Indeed, the wall mounting system of the of the invention provides narrow rods, preferably in alignment with one another from at least one, and preferably two, directions. Where rods with a smooth central portion are provided, this also facilitates slotting of the insulation in behind mounting plate 12 from the side.

Where adhesive or glue are used on the rear surface of the insulation, or the initially exposed external surface of the building wall, or both, the insulation is placed against the wall. In one or more embodiments, this placement involves sliding the insulation in behind the mounting plate 12 when the adhesive is still unset (e.g. wet). The provision of a slight gap to the rear of the mounting plate (occupied in some embodiments by locking nuts 16A) also facilitates a small tolerance when sliding insulation into the gap between the wall and the rear of the mounting plate.

The anchors may be configured so as to be capable of not protruding, or not protruding to any significant extent, in front of the external (initially) exposed) surface of the building wall. The anchors are typically recessed in the building wall. Thus, these do not inhibit sliding in of insulation from the side. Further, the entire system and insulation can be removed leaving little visible trace.

In preferred embodiments, provision of a two-dimensional pattern of rods facilitates a strong mounting for multiple types of loads e.g. heavier loads, but nevertheless by enabling rods to fall in line with one another, typically a straight line (although the lines may be curved this is less preferred), enables the easier installation of insulation behind the plate without disturbing it, or the services mounted on it. The preparation for installing insulation can be done in advance. Once insulation is installed rough casting can be done, around or indeed to the rear of mounting plate 12 if a gap has been left between the front surface of the insulation panel and the rear surface of the insulation panel.

Variations can be envisaged, for example, the small gap to the rear of the mounting plate can be dispensed with. The mounting plate 12 (and associated load) may be removed for rough casting to be carried out. Immediately this has been carried out, the mounting plate 12 and load 30 may be re-installed with minimal loss of service and low risk of losing parts. The rods and/or mounting plates may be installed after the insulation and so on. The numbers and arrangement of rods may be varied in the first predetermined pattern. The rods are preferably arranged in straight lines. The lines are preferably horizontal or vertical but these may be at an angle to the horizontal. Some or all of the lines are preferably parallel to one another. Preferably the pattern provides at least one direction in which two or more rods are in alignment (e.g. in a straight line) for receipt of insulation with suitably positioned and sized slot(s) in it. The wall mounting system may be termed a pattress, offering a secure strong mounting surface in front of relatively weak insulation.

Typically, the components of mounting system may be (predominantly) made from metals such as steel, preferably stainless steel, galvanised steel, or material of similar rigidity strength and longevity. The rods are typically solid all the way through and of one material e.g. metals such as steel as used for the plate. But they may have one or more intermediate portions that are insulating. So rods of insulating material with two threaded ends, which may be of metal, may be provided. Indeed, the plate may be made from other materials of high strength such as plastic or plastic type material e.g. recycled plastic or polycarbonate plastic.

By mounting of loads at suitable (e.g. variable) distance(s), and in some embodiments, in a suitable way on a wall, the wall mounting system of the invention enables the process for installing insulation to be broken down into discrete steps that may be carried out at entirely separate times, days or weeks apart. This increases the ease of delivery of retrofitting insulation activities, reducing expense, reducing risk of loss of services and increasing likelihood of uptake of such retro-fitting.

Indeed, when the wall insulation is being fitted, unless it is a bungalow, there is a scaffolding. This blocks the signal going to say a satellite dish and therefore the dish needs to be moved. Typically it is attached onto the scaffolding for example using clamps while the work is being carried out. Advantageously, when the dish is removed from the building wall, the wall mounting system of the invention can be installed on the building wall at same time, along with a back plate (also known more generally as mounting element) 32. This means that when the scaffolding is being taken down, the dish can be immediately attached e.g. slotted, into the already fitted backplate, saving a lot of time. Indeed, the cabling may be adapted to the wall mounting system at this time.

This and other advantages will be apparent to those skilled in the art from this disclosure.

mounting system 12 mounting plate 14 mounting rod(s) 16, 16A, 16B clamping member(s) (e.g. locking nuts) 17 washer(s) 18 anchor(s) 19 internal thread (s) wall 21 expandable arm(s) 24 holes e.g. through bore(s) in mounting plate 28 setting tool 30 load e.g. satellite dish 32 mounting element 34 threaded hole(s) 38 hammer insulation 50 slots first predetermined two-dimensional pattern (e.g. of through bores 24 and/or of rods 14) second two-dimensional predetermined pattern (e.g. of, preferably threaded, holes 34 D -distance from rear of mounting plate to front of wall h -height of locking nut (and of any associated washer) T -thickness of insulation (preferably rigid or semi-rigid insulation e.g. solid foam insulation, typically in batts or panels or rolls)

Claims

Claims 1. A mounting system (10) for mounting a load (30) to a wall (20) fitted, or to be fitted, with an insulation layer (40), the system comprising: a mounting plate (12) having a plurality of mounting holes (24) for receipt of mounting rods (14); a plurality of internally threaded anchors (18) for anchoring in a wall (20); a plurality of mounting rods (14) each rod (14) having at least one threaded end(s) for receipt in a respective anchor (18), a plurality of clamping members (16) for clamping the mounting plate at a predetermined distance from the anchors on the mounting rods; the mounting plate (12) comprising a set of mounting elements (34) for mounting a load (20) thereon.
2. A mounting system (10) according to claim 1 in which the plurality of mounting holes (24) for receipt of mounting rods (14) are in a first predetermined two-dimensional pattern and the plurality of internally threaded anchors (18) are configurable for anchoring in a wall (20) in the first predetermined two-dimensional pattern, and the plurality of mounting rods (14) are receivable in respective anchor(s) (18) in the first predetermined pattern.
3. A mounting system (10) according to claim 2 in which the first predetermined pattern comprises at least two mounting rods (14) in a straight line in a first direction.
4. A mounting system (10) according to claim 2 or 3 in which the first predetermined pattern comprises at least two mounting rods (14) in a straight line in each of two respective directions.
5. A mounting system (10) according to claim 4 in which the two respective directions are generally, or substantially, orthogonal.
6. A mounting system (10) according to any preceding claim in which the internally threaded anchors (18) are expandable.
7. A mounting system (10) according to any preceding claim in which the position of the mounting plate (12) on the mounting rod(s) is variable.
8. A mounting system (10) according to any preceding claim in which the clamping member(s) comprise locking nut(s) and the position of the mounting plate (12) on the mounting rod(s) is fixed by locking nut(s).
9. A mounting system (10) according to any preceding claim comprising a layer of insulation (40) behind the mounting plate (12) and in which a front surface of the insulation lies spaced from the rear surface of the mounting plate (12).
10. A method of installing a wall mounting system on a wall (20) using a mounting system (10) according to any of claims 1 to 9, the method comprising: installing the plurality of anchors (18) in a wall (20); installing the plurality of mounting rods (14) into respective anchor(s) (18); installing the mounting plate (12) on the plurality of rod(s) (14); clamping the mounting plate (12) at a predetermined distance from the anchors (18) on the mounting rods (14).
11.A method of installing insulation on a wall (20) using a mounting system (10) according to any of claims 1 to 9, or the method of claim 10, the method comprising: installing the plurality of anchors (18) in a wall (20); installing the plurality of mounting rods (14) into respective anchor(s) (18); installing the mounting plate (12) on the plurality of rod(s) (14); clamping the mounting plate (12) at a predetermined distance from the anchors (18) on the mounting rods (14); inserting insulation behind the mounting plate (12) from the side.
12. A method of installing insulation on a wall according to claim 11 comprising: - installing the plurality of mounting holes (24) for receipt of mounting rods (14) in a first predetermined two-dimensional pattern (60); installing the plurality of internally threaded anchors (18) in the wall (20) in the first predetermined two-dimensional pattern (60); and, - installing the plurality of mounting rods (14) in respective anchor(s) (18) in the first two-dimensional predetermined pattern (60); clamping the mounting plate (12) at a predetermined distance from the anchors (18) on the mounting rods (14); providing one or more slots (50) in the insulation and inserting the insulation behind the mounting plate (12) so that at least two rods (14) are received in at least one slot (50).
13. A method according to claim 12 in which at least one slot (50) is a straight slot.
14. A kit of parts for a mounting system (10) according to any of claims 1 to 9 comprising: a mounting plate (12) having a plurality of mounting holes (24) for receipt of mounting rods (14) in a first predetermined two-dimensional pattern; a plurality of mounting rods (14) each rod (14) having at least one threaded end; and optionally further comprising one or more of: a plurality of clamping members (16) for clamping the mounting plate at a predetermined distance from the anchors on the mounting rods; a plurality of internally threaded anchors (18) for anchoring in a wall (20) an insulation panel comparing at least one slot (50).
15. A kit of parts according to claim 14 further comprising: instructions for carrying out the method of any of claims 10 to 12.