Mounting device and washer

Abstract

A fixing-component based mounting device, or a washer for such a device, is disclosed for coupling to a panel. The fixing component includes a body with a threaded bore and at least one panel-engagement arm movable between an insertable condition for passage through a panel aperture and an extended condition bearing on the panel's second side. A threaded mounting component engages the bore. The washer defines a main-axis aperture, includes a contact formation arranged to support the mounting component so that off-axis loads are transferred into the washer, and includes at least one radially projecting pivot-support formation bearing on the panel's first side to resist tilt. The panel is clamped between the extended arm(s) and the washer head, distributing cantilever loads, particularly for friable panels and stand-off fixings. Locating, anti-rotation and over-insertion formations may be provided.

Description

[0001] MOUNTING DEVICE AND WASHER

[0002] TECHNICAL FIELD

[0003] The present invention relates to mounting devices and washers for mounting devices, particularly but not exclusively fixing component-based wall fixings for panels such as plasterboard walls or similar.

[0004] BACKGROUND ART

[0005] The construction, home improvement, and do-it-yourself (DIY) industries frequently employ fastening systems to attach fixtures to various wall materials, including masonry and panels. Traditional methods, such as self-tapping screws, face challenges when used with different substrates. Panels made from fibrous or granular materials often lack the necessary structural strength to securely hold screws under load, which can result in oversized holes and the subsequent requirement for specialized anchors to provide stability.

[0006] Conventional plastic inserts, for example, are commonly hammered into a predrilled hole in a wall, after which a screw is driven into the plastic. As the screw threads into the insert, the plastic expands, thereby securing the screw and any attached fixture. While simple and cost-effective, these inserts may prove unreliable in friable materials, such as gypsum board, especially under heavier loads.

[0007] To address these challenges, a range of anchors has been developed in which one or more arms or wings are manoeuvrable between an insertable position, aligned for passing through a panel aperture, and an engageable position, where the arms pivot or expand behind the panel to provide a stable bearing surface. The arms may be pivotably mounted to a central “nut” feature, or they may include a pivoting body with a central bore rigidly attached to arms, said body captured within a chassis.

[0008] Toggle-type anchors, often referred to as “toggle bolts”, provide a more robust solution for hollow or low-density walls. A typical toggle bolt comprises a threaded bolt (or screw) and a pair of wings pivotably connected to a “nut.” These wings collapse during insertion through a hole in the panel and then springoutward once inside. By tightening the bolt from the front, the item being mounted, along with the panel itself, can be clamped between the bolt head and the expanded wings, creating a firm hold in materials of varying thicknesses. Another approach appears in gripit style anchors, based on patent GB 2530303. These typically include a cylindrical or disc-like body with a central threaded bore and rotating arms connected to the rear of the body. When placed into a suitably sized hole, these arms are pivoted or rotated behind the panel, forming a broad bearing surface for improved hold. A washer or front flange can prevent overinsertion on the visible side, while a mounting bolt threads into the body’s central for mounting items to wall. As with toggle bolts, this arrangement commonly secures a fixture flush against the panel, distributing load over a larger area. A further example is disclosed in GB 2581539A, wherein the anchor’s arms also pivot on a central body but do so in a reverse direction compared to standard toggle bolts. This still facilitates insertion in a folded state, followed by expansion behind the panel in an alternative orientation, distributing force across the anchor’s wings differently from conventional designs.

[0009] In addition, certain mounting devices employ a washer to form a convenient and potentially reusable mounting point for a separate fastener. For instance, GB 2626191A describes a mounting device particularly suited for plasterboard or drywall panels. The disclosed device uses a dedicated washer (or similar locating element) together with a pivoting or expandable anchor component. Once the anchor is inserted and tightened behind the panel, the washer remains at the front face of the board, providing a stable platform or mounting point into which a separate bolt, screw, or other fastener can be introduced.

[0010] Although these anchors generally excel at flush-mounted applications, challenges arise when the fastener utilised has a mounting point or engagement feature positioned away from the wall, namely, where a stand-off distance exists between the panel and the item being mounted. Examples include threaded hooks, eyebolts, or stand-off fixings where the attachment point of an item is distanced from the panel surface. In such scenarios, particularly in vertical walls, the fixing component’s nut or body that engages with the fastener can become a pivot point under distanced angled or downward loads, causing the device’scentral body to experience a pivot load. This can allow the fastener (e.g. threaded bolt) to tilt (as with a typical toggle bolt) or concentrate stress on a single wing (or even a portion of that wing) rather than distributing forces evenly across wings. Longer stand-off distances magnify the cantilever effect, thereby increasing bending moments and exacerbating these problems further.

[0011] Some devices attempt partial mitigation of this issue. For example, toggle bolts with hooks may include a washer and nut, tightening the washer against the panel aperture, an arrangement that works well in ceilings but can be more prone to movement in vertical walls under heavier or angled loads. Other embodiments, such as those in GB 2626191A, utilise a threaded insert that engages a hollow body washer recessed in the panel, creating a longer pivot region that helps dissipate some of the bolt’s moment forces. Nevertheless, since these designs do not primarily focus on supporting cantilever reaction forces, their effectiveness depends on the size and geometry of the hollow body walls or over-insertion features and are therefore still prone to movement or unbalanced arm load.

[0012] Consequently, there remains a need for improved anchor systems that can mitigate these pivoting and cantilever effects, ensuring a more even load distribution across the panel particularly when the fastener or item being mounted makes no or limited contact with the panel. The present invention seeks to address these concerns by providing an anchor system, particularly suited to friable materials like plasterboard, that can accommodate angled or downward loads without causing the fastener to shift or imposing excessive stress on any single portion of the panel under expected loads.

[0013] SUMMARY OF THE INVENTION

[0014] When viewed from a first aspect, embodiments of the present invention provide a mounting device configured to be coupled to a panel (for example, plasterboard or drywall). The mounting device comprises:

[0015] A fixing component, which includes:

[0016] a body having a threaded bore; and

[0017] at least one panel-engagement arm connected to the body,wherein the at least one panel-engagement arm is movable between: an insertable condition, in which the arm is aligned to pass from a first side of the panel through a panel aperture; and

[0018] an extended condition, in which the arm extends radially beyond the aperture’s periphery and bears against a second side of the panel. A mounting component, having a threaded portion configured to engage the threaded bore of the fixing component’s body.

[0019] A washer, having:

[0020] a head portion at a proximal end, the head portion defining a mounting component receiving aperture that establishes a main axis of the mounting device;

[0021] at least one contact formation arranged to contact the mounting component in use, such that pivot or tilt loads acting on the mounting component are at least partially transmitted into the washer; and

[0022] at least one pivot support formation projecting radially from the washer’s head portion and arranged to bear against the first side of the panel over a region and in an orientation configured to provide a reaction force in at least one direction resisting pivot or tilt of the mounting component.

[0023] When the mounting device is installed in the panel aperture, the panel is effectively clamped between the washer on the first side and the fixing component on the second side (with the at least one panel-engagement arm in its extended condition). This arrangement helps distribute loads, including cantilever or off-axis forces, across a wider portion of the panel, reducing the likelihood of tilt or pivoting of the mounting component relative to the panel. The first aspect of the invention further extends to a washer, configured to receive a mounting component that is, in turn, engageable with a fixing component to form a mounting device for coupling to a panel, the washer comprising:a head portion at a proximal end, the head portion defining a mounting component receiving aperture that establishes a main axis of the mounting device;

[0024] at least one contact formation arranged to contact the mounting component in use, such that pivot or tilt loads acting on the mounting component are at least partially transmitted into the washer; and

[0025] at least one pivot support formation projecting radially from the washer’s head portion and arranged to bear against the first side of the panel over a region and in an orientation configured to provide a reaction force in at least one direction resisting pivot or tilt of the mounting component.

[0026] Wherein the washer is configured such that, when the fixing component is engaged on an opposite side of the panel, the pivot support formation bears on the first side of the panel to reduce or inhibit undesired tilting of the mounting component relative to the panel under off-axis loads.

[0027] The first aspect of the invention also extends to a kit of parts for forming a mounting device configured to be coupled to a panel, the kit of parts comprising the washer described hereinabove, the fixing component, and the mounting component.

[0028] The first aspect of the invention also extends to a panel assembly comprising a panel having a panel aperture extending therethrough, and the mounting device described herein, coupled to the panel such that at least a portion of the washer is positioned at the first side of the panel, while the fixing component is situated at the second side. At least one contact formation of the washer extends into or seats against the perimeter of the panel aperture to receive the mounting component, and a pivot support formation on the washer bears upon the first side of the panel. The mounting component passes through the washer’s aperture to engage the fixing component on the second side. A panel engagement arm of the fixing component is in an extended condition behind the panel, thereby clamping the panel between the washer and the fixing component when installed, ensuring load stresses are more evenly distributed across the panel, particularly under off-axis or cantilevered loads.Thus, it will be appreciated by those skilled in the art that embodiments of the present invention provide a robust wall mounting device or “anchor” that can be easily inserted into a panel aperture and significantly improve the load distribution applied to the panel during use. In accordance with the invention, the washer supports loads from the mounting component, particularly where the mounted item is spaced away from the panel and makes no direct contact with it, thereby ensuring better stress distribution. Consequently, the resulting wall fixing can be installed in an aperture in a vertically oriented panel (for example, a plasterboard wall) and more effectively accommodate loads placed away from the panel’s surface.

[0029] The panel may be an outer panel of a hollow wall. The panel may, for example, be a plasterboard panel. However, the fastening anchor of the present invention may also be used to mount items to other types of walls and panels, especially panels having a comparatively low thickness, including, for example, wooden panels.

[0030] The present invention may be used in conjunction with typical or “standard” fixing components that are readily available on the market, and does not necessarily require any particular modification to those components. This approach enables the advantages provided by the invention to be realized using widely available parts, simplifying manufacture and reducing costs compared to systems that demand bespoke fixing components. Nevertheless, it should be understood that in certain embodiments, the fixing component is integral to the mounting device, where the particular features or geometry of the fixing component interact or interface with the washer and / or other elements to achieve robust mounting functionality and / or support installation.

[0031] In certain embodiments, the washer (sometimes referred to as a “chassis”) is provided with a coupling portion specifically designed to receive and retain the fixing component (e.g., a toggle bolt or pivoting anchor) in a manner that promotes stable alignment and prevents unwanted rotation, even when the fixing component is only lightly or not yet fully engaged with the panel. The coupling portion may include one or more axial channels, slots, or guide features extending along the washer’s body, dimensioned to accommodate protrusions such as flanges, pivot pins, or wings on the fixing component. In this way, thecoupling portion permits axial and, where applicable, pivoting movement of the fixing component between an insertable condition (aligned, rotated, or folded to pass through the panel aperture) and an extended condition (with one or more arms extending behind the panel), while restricting rotational freedom that might otherwise allow the fixing component to rotate relative to the washer during installation.

[0032] In certain embodiments, the washer includes a pivot support formation extending radially from its head portion to contact the first (visible) side of the panel, thereby resisting pivot / tilt loads that arise from angled or downward forces on the mounting component. In some embodiments this pivot support formation can take the form of one or more tabs, bars, strips, or lips - rectangular, flared, or otherwise shaped. In preferred embodiments, the pivot support formation extends sufficiently beyond the washer’s head to provide an enlarged bearing surface on the panel’s first side, distributing pivot / tilt loads across a wider area and thereby reducing localized stress.

[0033] Additionally, in some embodiments, the same pivot support formation may serve as an over-insertion stop, preventing the washer (or a portion thereof) from being pushed too far into the aperture, assuming the aperture is appropriately sized. In some embodiments, the washer’s head portion may also include a flared or flanged lip that abuts the outer (visible) surface of the panel as a physical stop. In further embodiments, panel engagement features such as fins (for instance, radially extending fins) may “bite” into or engage the panel’s thickness, thereby inhibiting over-insertion and / or preventing rotation of the washer within the aperture. Where present, these features advantageously minimize the risk of damage to the installation surface and enhance the mounting device’s overall stability

[0034] The washer may comprise additional features to prevent the washer rotating relative to the panel after it has been installed. In some embodiments, the head portion comprises one or more radially extending fins, wherein said fins are configured to engage with the panel when in use to restrict rotational movement of the washer relative to the panel. The fin(s) may cut through a portion of the panel from the first side to the second side, “biting” into the panel through itsentire thickness. The fin (s) may provide for additional grip, preventing the washer from rotating within the panel aperture. As above, this may be beneficial when screwing the mounting component (e.g., a bolt) into the nut of the fixing component.

[0035] Regarding the mounting component, in some implementations it may have a threaded shank, while the fixing component (e.g., a nut) provides a threaded bore in a manner known per se. By way of example, such a mounting component may be a bolt, a machine screw, a hook, an eyehook, a standoff fixing, or a threaded insert, the latter configured to receive secondary fasteners (for instance, bolt hooks). The threaded portion may extend fully or partially along the axial length of the mounting component. In other embodiments, the mounting component may have a mounting point, for instance in the form of an axial bore (extending partially or completely through the component) that includes internal threads, thereby allowing a subsequent mounting component to be coupled once the mounting component is installed. This versatility supports a wide array of mounting scenarios, from flush-mounted brackets to protruding or “stand-off” installations, including cases where the item to be mounted is spaced away from the panel for functional or aesthetic reasons.

[0036] The washer incorporates at least one contact formation arranged to engage at least a portion of the mounting component and thereby transfer off-axis or pivot loads into the washer. In some embodiments, this contact formation extends axially from the head portion so as to contact an axially extending feature of the mounting component. Alternatively, or additionally, in some embodiments the contact formation may be formed to engage an underside region of the mounting component such as the head, a flange or attached retaining nut and washer. The contact formation may be realized as a hollow or tubular body sized to capture or at least partially enclose the mounting component’s shank, or it may be arranged around or adjacent the periphery of the washer aperture, optionally being distally recessed from the washer’s proximal face. In other embodiments, the contact formation includes an end wall or lip, which may be chamfered, angled, or otherwise shaped, configured to bear against an underside portion of the mounting component’s head or flange, thereby enhancing load distribution and mitigating undesirable tilt under off-axis forces.In some embodiments, the washer also comprises at least one locating formation, extending axially from the head portion and sized to seat at least a portion of the washer within the panel aperture. The locating formation is arranged to seat or site the washer in the panel aperture, ensuring the washer remains correctly positioned. In some embodiments, the locating formation comprises one or more tabs configured to engage the panel’s inner surfaces, providing a frictional fit to stabilize the washer within the aperture. In other, potentially overlapping embodiments, the locating formation takes the form of an annular portion extending from the head portion, wherein an outer radial surface of this annular protrusion bears against the aperture’s inner surfaces. Such an annular portion may be a substantially continuous ring-shaped extension, or it may be formed by multiple arcuate segments. In some embodiments, the locating formation is integrated into the contact formation itself, sizing the external dimension of the hollow tube or shaped feature so that it at least partially matches the panel aperture.

[0037] In certain embodiments, the washer may comprise one or more lateral retention formations configured to restrain the washer against lateral displacement (e.g., upward / downward, side-to-side, or other off-axis directions) during installation and use. In some embodiments, these may take the form of spikes that extend axially from the washer’s head portion and / or the pivot-support formation so as to press into or “bite” the surface of the panel, thereby adding frictional or mechanical engagement. In another arrangement, strips or tabs may project radially outward around the panel aperture, effectively embedding into or gripping the first side of the panel adjacent the aperture. These gripping features may be shaped and dimensioned to match the panel’s material properties, ensuring that the washer remains securely located and does not shift laterally during installation or use.

[0038] The washer, the fixing component, and / or the mounting component may, in some embodiments, be formed from metals such as steel, stainless steel, or brass, or from plastics (e.g., nylon, polylactic acid (PLA), polyethylene terephthalate (PET), or acrylonitrile butadiene styrene (ABS)). These components can be manufactured via conventional or 3D printing processes.The various components can be sized according to need. For instance, commercially available fixing components may have bores sized up to M12 (or beyond) for specialized applications.

[0039] Overall, embodiments of the present invention seek to combine a washer having a head, contact, pivot support and optionally locating formations with a fixing component (including at least one pivotable or foldable arm) and a mounting component that securely fastens them all in place. By doing so, it becomes possible to handle angled or downward loads effectively, increase load capabilities, minimize panel damage, and accommodate a wide range of standoff distances and fixture types.

[0040] In the context of this specification “comprising” is to be interpreted as “including.” Approximately as employed herein is defined as ± 10%.

[0041] Aspects of the invention comprising certain elements are also intended to extend to alternative embodiments “consisting” or “consisting essentially” of the relevant elements.

[0042] The term “couple” (and by extension derivatives such as “coupling,” “coupled,” etc.) should be understood to include both direct connections and indirect connections via one or more intervening components. Components are considered, at least for the purposes of the present invention, to be coupled to one another if their connection (whether direct or indirect, mechanically) yields the relevant function. Any references to “couple” (or equivalent derivatives such as “coupling,” “coupled,” “couplable,” etc.) may be limited to “connect” (or corresponding derivatives such as “connection,” “connected,” “connectable,” etc.) and may be further limited to “directly” or “indirectly” connect.

[0043] The term “restrict” and its derivatives as used herein means to inhibit at least partially and potentially completely, depending on the technical context.

[0044] The term “proximal end” and its derivatives as used herein means at the end of the mounting device that is closest to the first side of the panel when the device is installed. Conversely, the term “distal end” and its derivatives as used herein means at the end of the mounting device that is furthest from the first side of the panel when the device is installed.The term “axial” and its derivatives as used herein refer to directions or movements along the major axis of the washer. When the mounting device is installed in a flat panel, this major axis typically aligns with the normal (i.e., perpendicular) to the panel. Conversely, “off-axis” loads or directions include any component not aligned with this major axis, thereby encompassing lateral, angled, or cantilever-type movements or forces relative to the normal axis of the panel.

[0045] The term “radial” and its derivatives as used herein mean along the direction radiating or converging on a common centre. As used typically herein, this common centre is the major axis of the washer.

[0046] The term “lateral” and its derivatives as used herein mean along directions in a plane normal to the major axis and parallel to the panel when in use. In general, when the mounting device is installed in a substantially vertical panel (e.g., a wall) and being viewed face on, lateral motions are those along the directions that would be seen as upward, downward, leftward, and rightward relative to the panel (rather than into or out of the panel, which are axial), i.e., in a plane parallel to the wall. In a substantially horizontal panel (e.g., a ceiling), the lateral directions would be the directions in a plane parallel to the ceiling.

[0047] The term “circumferentially discontinuous” and its derivatives as used herein means not extending continuously around the full circumference of the relevant portion, and instead being provided by one or more portions separated by at least one circumferential gap.

[0048] The term “principal radial direction” and its derivatives as used herein, in respect of a discrete extended portion, means the radial direction from the common centre (typically the major axis) towards the region of that discrete extended portion having the greatest radial projection.

[0049] The term “reaction force” and its derivatives as used herein means a force generated by contact between components that opposes relative movement, for example a force generated at the interface between the pivot support formation and the first side of the panel that opposes pivoting or tilting under off-axis loads.The term “substantially aligned” and its derivatives as used herein means aligned within normal manufacturing, assembly and / or installation tolerances.

[0050] References to components being configured to be able to achieve a particular function, for example in respect of the washer absent the fixing component and / or mounting component, should be understood to mean that the function is present when the mounting device is assembled and / or in use as appropriate.

[0051] Where technically appropriate, embodiments of the invention may be combined.

[0052] Embodiments are described herein as comprising certain features / elements. The disclosure also extends to separate embodiments consisting or consisting essentially of said features / elements.

[0053] Any embodiments specifically and explicitly recited herein may form the basis of a disclaimer either alone or in combination with one or more further embodiments.

[0054] BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Certain embodiments of the present invention will now be described with reference to the accompanying drawings, in which:

[0056] Figures 1A-1G are schematic illustrations of a first embodiment of a mounting device according to the present invention, showing how a washer, a fixing component (in the form of a toggle with pivoting arms), and a hook-type mounting component engage a panel and distribute off-axis loads.

[0057] Figures 2A-2B illustrate a second embodiment of a washer having an arched or curved contact formation and lateral retaining tabs, demonstrating how the washer can be retained against a front face of a panel without a separate flange or locating formation

[0058] Figures 3A-3B show a third embodiment of a washer formed as an elongated strip, which has an extended lower pivot support and a locating formation to prevent over-insertion and assist with load distribution.

[0059] Figures 4A-4D depict a fourth embodiment of a mounting device in which a rigid -arm fixing component is pivotably coupled to a coupling portion of the washer. The washer head features an outer wall for locating within a panel aperture and an inner wall serving as a contact formation.

[0060] Figures 5A-5G illustrate a fifth embodiment having a threaded insert as the mounting component, with formations on the washer that provide both pivot support and over-insertion functions. These figures also show how a secondary fastener can be added once the washer and fixing component are clamping the panel.

[0061] Figure 6A is a schematic illustration of a sixth embodiment of a mounting device, in which the fixing component includes a single, rigid pivoting wing pivotably connected to a threaded nut.

[0062] DETAILED DESCRIPTION

[0063] Described in detail below are several embodiments of the present invention. It will be appreciated that the specific embodiments shown are exemplary, and that various individual features of the different embodiments may be combined in any suitable manner unless technical context dictates otherwise.

[0064] Each of the following embodiments illustrates a respective mounting device including a washer that can be installed in a panel such as a plasterboard wall. Typically, this is achieved by drilling or forming a suitable hole or aperture in the panel with a diameter sufficient to allow passage of the fixing component’s arm(s) when they are in an insertable condition. In many embodiments, a portion of the washer has a radially extending portion such as a flange, at least one tab and / or the actual pivot support formation described below, such that a portion proximal end of the washer extends beyond the periphery of the aperture.

[0065] Consequently, while the fixing component’s arm(s) can pass through the panel from a first side to a second side, the washer’s head portion (or an equivalent enlarged section) remains at the first side of the panel. Alternatively, or in addition, the head portion may include fins or similar features that bite into the panel’s thickness to prevent over-insertion of the device, potentially allowing the mounting device to sit more or less flush with the outer surface of the panel.

[0066] In each embodiment, the washer is configured to cooperate with a fixingcomponent, which may be a standard, commercially available item (e.g. a toggle bolt or similar) or an integrated fixing component. In some embodiments, the fixing component may be capable of moving partly or wholly outside the washer, while in others it remains housed within the washer at all times. Regardless of the exact arrangement, the washer is typically designed to couple with the mounting component (e.g., a bolt or screw) so that pivoting or tilting of the mounting component, due to off-axis loads (sometimes referred to as “cantilever-type loads”), is at least partially supported by the washer in at least one direction. In some embodiments, the washer may also include a coupling portion that engages the fixing component directly to control rotation, axial travel, and / or controlled pivoting, whereas in others the washer’s primary connection is indirect via the mounting component itself.

[0067] As outlined previously, a fixing component will typically include a body with a substantially central threaded bore, together with at least one (often two) panelengagement arm(s). In many embodiments, these arms are pivotably mounted so they can fold or flatten into an insertable condition, allowing the fixing component to pass through the panel aperture. Once inserted, the arms can be biased outward into an engagement or extended condition, in which they abut the second side of the panel. In other embodiments, the arms (or wings) may be integrally formed with, or otherwise rigidly connected to, the fixing component’s body, so that the entire fixing component itself pivots relative to the washer or another portion of the mounting device. In this arrangement, the fixing component can pivot between an insertable condition, where the arms are aligned and fit through the panel aperture, and an extended condition, where the arms extend beyond the aperture’s periphery, anchoring against the panel’s second side.

[0068] The mounting component may be any suitable threaded item capable of mating with the fixing component’s bore, for example, a machine screw, bolt, bolt hook, eyehook, threaded insert (capable of accepting and retaining another mounting component), stand-off, or similar. By way of illustration, an M8 threading (with a nominal shank diameter of approximately 8 mm) might be used, though the exact size and profile can vary according to the application. It will of course be appreciated by those skilled in the art that, as long as the mounting component’sthreading matches that of the fixing component, a range of thread sizes and types can be employed.

[0069] Common to all of the following embodiments of the present invention is that they share at least the following overarching principle: The washer is configured such that when the mounting component (e.g., a bolt, machine screw, hook, eyehook, stand-off, or threaded insert) pivots or tilts under an off-axis or cantilever-type load, at least part of that pivoting action is resisted by the washer and its contact with the panel. This arrangement increases load capacity, reduces stress concentration, and stabilizes the fixing arrangement under anticipated load conditions, particularly where the mounted item does not directly contact the panel’s surface.

[0070] For ease of illustration, not all reference numerals are shown on every figure. Figures 1A-1G are schematic illustrations of a mounting device (100) in accordance with a first embodiment, featuring a central contact formation and a single downward pivot support formation. The mounting device (100) comprises a washer (102), a fixing component (104), and a mounting component (106) that together engage with a wall panel during use. As outlined above, the washer (102) is arranged to contact the threaded bolt hook (106) (including its retaining nut 130), which in turn engages the fixing component (104), here exemplified by a spring toggle. Consequently, when the hook (106) pivots under off-axis loads (e.g., from an item attached to its shaped mounting point 119), at least part of that pivoting action is transmitted through the washer (102) and resisted by its engagement with a portion of the panel aligned with the direction of load. In other words, the washer helps resist the hook’s tilt, more effectively distributing stress across the first side of the panel.

[0071] The fixing component (104) is constructed from a nut (103) and a pair of pivotable arms (105) that rotate about protrusions (107) extending from the nut (103). The nut (103) is threaded in a manner known in the art. Meanwhile, the hook (106) includes a threaded shank (109) that matches the thread of the retaining nut (130), allowing it to screw into that nut. In this embodiment, the retaining nut (130) is part of the mounting component (106). It not only helps define how far the mounting device protrudes from the panel once installed, butalso serves to secure the entire assembly, as described in detail later.

[0072] The washer (102) features a head portion (108) at its proximal end, comprising a flange (116) and a downward-extending pivot support (112). Both the flange (116) and the pivot support (112) are relatively wider than the remainder of the washer, and they are configured to physically abut the panel’s first side when in use. In this embodiment, the pivot support (112) forms as a wide tab spans a larger radial area than the flange (116) in at least one direction. The washer (102) also includes a contact formation (111), in the form of a hollow tube extending from the head portion (108). This contact formation (111) is arranged to receive the mounting bolt (106), which passes through an aperture (117) in the head portion (108) at the front of the device (100). In use, this contact formation (111) helps stabilize the mounting bolt (106) and transfer load into the washer. Once assembled, the hook bolt (106) extends through aperture (117) to engage the fixing component’s nut (103), allowing the washer (102) to handle pivot motions and help prevent excessive stress on the panel.

[0073] During tightening, the screwing action of the mounting component (106) and / or the retaining nut (130) draws the washer (102) and fixing component (104) together, causing the toggle arms (105) (in their extended condition) to bear against the panel’s second side, while the washer’s over-insertion arrangement, formed by its flange (116) and pivot support (112), abuts the first side. In so doing, the device clamps or “sandwiches” the panel between the washer (102) and the fixing component (104), creating a stable anchoring arrangement.

[0074] The washer (102) further includes a locating portion (110), shaped as an additional tubular extension that projects axially from the head portion (108) toward the distal end. This locating portion has an outer diameter sized to fit within the inner diameter of the panel aperture, thereby enabling it to seat securely during installation. Consequently, the locating portion (110) helps align and stabilize the washer (102) in the aperture, ensuring proper positioning relative to the panel. The head portion (108) also incorporates fins (114), which in this embodiment extend radially from the locating formation (110). These fins (114) are configured to engage, or “bite into”, the panel surface, thus preventing rotation of the washer (102), and by extension the entire device (100), within thepanel aperture.

[0075] In Figure ID, the mounting device (100) is shown with its fixing component (104) arranged in an insertable condition, allowing the folded arms (105) to pass through the panel aperture from the first side (152) to the second side (153). Figure IE provides a rear perspective once installation is complete, with the arms (105) now in their extended condition, bearing against the second side (153) of the panel. Meanwhile, the panel aperture (151) accommodates the threaded portion (109) of the fixing component (104). In Figure IF, viewed from the first side (152), the washer (102), including its flange (116) and downward pivot support (112), is visible on the panel’s outer face, while the hook portion (119) of the mounting component (106) protrudes outward, positioned to receive a downward or off-axis load. Tightening the retaining nut (130) on the first side clamps the washer (102) and panel against the fixing component (104)’s arms on the second side (153), effectively sandwiching the panel between them.

[0076] Consequently, any load applied to the hook (119), including one directed downward and offset from the panel surface, is at least partially borne by the washer, helping distribute forces and stabilizing the entire arrangement under pivoting or tilting conditions.

[0077] In Figure 1G, once the mounting component’s retaining nut (130) is fully tightened against the washer (102), the device is securely clamped within the panel aperture. From this sectional view, it is clear that as the hook (106) threads further into the nut (103) of the fixing component (104), the retaining nut (130) presses firmly against the washer’s head portion (108), effectively trapping the washer and panel between the retaining nut (130) on the first side (152) and the expanded arms (105) of the fixing component on the second side (153). Also visible in Figure 1G is how the contact formation (111), shaped as a hollow tube, envelops or contacts the hook’s threaded shank (109). This tubular region ensures that pivoting of the hook (106), caused by off-axis loads, is at least partially channelled into the washer (102) instead of concentrating solely on the panel or fixing component (104). Moreover, the downward-extending pivot support (112) is oriented substantially perpendicular to the axis of the hook (106) in the anticipated load direction, thereby helping transfer a significant portion of any pivot-induced force through the washer’s head portion (108) and into thefirst side of the panel (152). This arrangement reduces stress concentration and improves load-bearing capacity by distributing forces more broadly across the washer’s contact footprint, rather than relying solely on the fixing component’s pivot point or the panel aperture.

[0078] In the final installed state, forming an example of a panel assembly, the panel (150) with aperture (151) accommodates the fixing component (102) and mounting component (106) remain on or near the first side (152). The washer (102) bears against the first side (or slightly recessed), transferring pivot-based and other applied forces through the washer’s head portion (108) and any pivot support formation (112). Meanwhile, the arms (105) of the fixing component (104) engage the panel’s second side (153), locking the entire mounting device (100) in place. The mounting component (106) (e.g., a hook bolt) is thereby clamped into the panel via the nut (130), creating a stable anchoring arrangement capable of withstanding downward or angled loads.

[0079] Figures 2A and 2B illustrate another embodiment of a washer (202) in which the contact formation takes the form of an arched upper wall (211) reinforced by an additional element (211a). In this design, there is no dedicated flange or locating formation; instead, lateral retaining formations (216), shaped as curved tabs, are arranged to bite into the first side of the panel, thereby holding the washer (202) in position during installation. In these embodiments, over-insertion is effectively prevented by the pivot support, which projects beyond the washer’s main body and abuts the front face of the panel.

[0080] Figures 3A and 3B show yet another variation of a washer (302) formed as an elongated strip. Here, the contact formation (311) is created by two axially oriented tabs, one upper and one lower, while the locating formation consists of two formed tabs (310) projecting forward to engage the panel aperture. The pivot support is provided by an extended lower portion of the strip, which extends beyond the washer’s main periphery to abut the first side of the panel. In addition to distributing angled or downward loads through an extended perpendicular contact surface, this extended lower portion also serves as the over-insertion feature, preventing the washer (302) from being pushed too far into the panel aperture.Figures 4A-4D are schematic illustrations of a mounting device (400) in accordance with a fourth embodiment, in which an integrally formed rigid-arm fixing component (404) is pivotably coupled to a coupling portion (440) of the washer (402). In this embodiment, the washer’s head (408) has a diameter substantially matching that of the panel aperture and extends axially from its proximal face, thereby providing both a locating function (outer wall 410) and a contact formation (inner walls 411).

[0081] A bore (403), located substantially in line with the pivot axis defined by the two protrusions (407) of the fixing component (404), serves as the threaded engagement for the mounting component (e.g., a standoff with hex head 406). During installation, the fixing component (404) pivots into an insertable condition, with arms (405) aligned so that they can pass through the panel aperture from the first side (the side of initial insertion), as shown in Figure 4A. Once beyond the panel, the fixing component (404) pivots such that the arms extend outward into an extended condition, anchoring themselves against the second side (the rear side) of the panel, as depicted in Figure 4B.

[0082] The mounting component (406) in this embodiment has a shank (409) that threads into the bore (403) of the fixing component. As the mounting component is tightened from the first side and its head (406) engages the washer head (408), the fixing component (404) is drawn axially toward the washer head (408). Consequently, the rigid arms (405) of the fixing component engage the second side of the panel, while the washer head abuts the first side via the pivot support formation (412), thus sandwiching the panel between them. In this manner, the device is locked in place without requiring the mounted item (e.g., the standoff head) to directly contact the panel surface.

[0083] Moreover, the washer’s cantilever formation (412) in this embodiment projects downward and flares out from the washer head (408), abutting the first (front) side of the panel when a downward or angled load is applied to the standoff (406). By contacting the panel, it redistributes angled loads and helps prevent the washer (402) from tilting excessively. Thus, when the standoff head (406) or the fixing component (404) is subjected to off-axis forces, a portion of those loads is transmitted through the washer’s cantilever formation (412) into the panel,improving stability and reducing stress concentration.

[0084] Figures 5A-5G illustrate a fifth embodiment of a mounting device (500), similar in overall pivot function to the fourth embodiment, in which the mounting component is a threaded insert (506) capable of accepting and retaining a further mounting component. In this embodiment, the washer (502) again features two asymmetrical cantilever formations (512a, 512b) that project radially from its head portion on the first (insertion) side (152) of the panel. The washer further comprises a recessed contact formation configured to receive at least a portion of the head of a mounting component.

[0085] These pivot support formations fulfil two key roles. First, they distribute any off-axis or pivot-based loads over a broader region on the panel’s first side, rather than allowing such forces to concentrate exclusively around the panel aperture. Second, they serve as over-insertion stops, preventing the washer (502) from being driven or pulled too far through the aperture, thus ensuring secure engagement with the panel. By abutting the first side (152), the panel is effectively sandwiched between the washer (502), via its pivot support, and the fixing component (504), which is anchored on the second side (153) when tightened by the mounting component (in this embodiment, the insert (506)). A recessed contact formation, formed here by an angled or tapered inner wall (511), further enhances load management by engaging the underside of the insert’s head (522), which in this embodiment has a chamfered or similarly compatible shape. Consequently, any downward or angled force acting on the insert (506) is redirected into the washer, rather than straining the panel aperture. Should the insert tilt, these angled walls (511) bear a significant portion of the stress, safeguarding the aperture and improving overall load-bearing performance.

[0086] Turning to the fixing component (504), it comprises a rigid body (503) with integrally attached arms (505a, 505b). Similar to the fourth embodiment, the fixing component pivots between an insertable condition, where the arms (505a, 505b) align to pass through the aperture from the first side, and an extended condition, where the arms spread out behind the panel on the second side (153), extending beyond the aperture’s periphery. An axial channel, defined by upperand lower posts extending axially from the washer’s head and a curved end feature (546) connecting these posts, enables axial movement, pivoting, and rotation-stopping of the fixing component when it is coupled to this coupling portion of the washer.

[0087] In Figures 5C and 5D, the threaded insert (506) is shown separately, highlighting its external threads (520) and an axial bore (519) (exiting at 519a), each capable of receiving a secondary fastener. Once installed (Figures 5E and 5F), with the insert (506) engaged with the fixing component (504) in its extended condition, and the head of the insert abutting the washer (502) via the contact formation (511), tightening the mounting component pulls the arms (505a, 505b) on the second side (153) and the cantilever / over-insertion formations (512a, 512b) on the first side (152) toward one another, thereby clamping the panel between them to secure the mounting device.

[0088] With the mounting device thus secured, a subsequent mounting component (e.g., 556) can be coupled to the threaded insert (506) such that any load on this component transfers pivot-based forces first into the insert head. The insert head then channels these forces through the contact formation (511) and into the washer (502). No additional retaining nut or similar feature is required on the secondary fastener, since the insert-to-washer coupling along with the fixing component already clamps the panel from both sides, yielding a robust anchor that does not rely on direct panel contact by the mounted item.

[0089] Turning now to Figure 6A, a sixth embodiment is shown in which the fixing component (604) comprises a pivoting toggle bar formed by a single, rigid wing (605), illustrated with an upper portion (605a) and a lower portion (605b), pivotally connected to a threaded nut (603) around protrusions (607). As in the first embodiment, the fixing component (604) is not directly coupled to the washer (602) but is instead indirectly connected via a mounting bolt (606). Here, however, only a single rigid wing (605) is employed, similar to the single-arm arrangement of the fifth embodiment. In the insertable condition, the wing (605) aligns axially with the nut (603) to pass through the panel aperture; once through, it pivots into its extended condition, preventing retraction through the panel. As in earlier embodiments, a mounting component (606) threads into thenut (603), drawing the chassis (602) and the pivoted wing (605) together on opposite sides of the panel to clamp it securely.

[0090] Additionally, in this embodiment, the elongated cantilever / over-insertion formations (612a and 612b) on the washer (602), are oriented to better support the shorter portion of the wing (605b) that engages the wall, thereby enhancing load distribution in that direction. This arrangement allows for a more compact toggle installation while still providing reliable load transfer via the washer (602), particularly in friable materials.

[0091] In certain embodiments, the present invention further provides a kit of parts comprising the washer as described, the fixing component, and the mounting component. This kit ensures all necessary elements are supplied for straightforward installation in a panel aperture.

[0092] In certain embodiments, once the mounting device is installed in the aperture, the panel together with the assembled washer, fixing component, and mounting component forms a panel assembly. This arrangement ensures the fixing component’s arm(s) anchor on the second side of the panel, while the washer and pivot support formation abut the first side

[0093] Thus, it will be appreciated by those skilled in the art that embodiments of the present invention may provide a user-friendly wall mounting device (or “anchor”) that significantly improves load-bearing capabilities, particularly in situations where the mounted item (e.g., a hook or stand-off) pivots off the panel under off-axis loads. By offering a greater range of secure installations in thin or friable panels, especially vertically oriented walls, these embodiments ensure robust performance across a variety of load conditions.

[0094] Moreover, the present invention may be used in conjunction with typical, commercially available (or “standard”) fixing components or implemented as a customized fastening anchor, allowing wide versatility and compatibility. While specific embodiments have been described in detail, such descriptions are nonlimiting; many variations, modifications, or substitutions may be made without departing from the spirit and scope of the invention as set forth in the ccompanying claims.

Claims

CLAIMS1. A mounting device configured to be coupled to a panel, the mounting device comprising:a fixing component, which includes:a body comprising a threaded bore; andat least one panel-engagement arm connected to the body, wherein said at least one panel-engagement arm is movable between:an insertable condition, in which the at least one panel-engagement arm is aligned to pass from a first side of the panel through a panel aperture; andan extended condition, in which the at least one panelengagement arm extends radially beyond the aperture’s periphery and is arranged to bear against a second side of the panel;a mounting component having a threaded portion configured to engage the threaded bore of the fixing component’s body; anda washer having:a head portion at a proximal end, the head portion including a mounting component receiving aperture that defines a main axis of the mounting device;at least one contact formation arranged to contact the mounting component in use, such that pivot or tilt loads acting on the mounting component are at least partially transferred into the washer; andat least one pivot support formation provided by a discrete extended portion that is circumferentially discontinuous with respect to the head portion, the extended portion projectingradially beyond the head portion to provide a bearing region of greater radial extent than circumferentially adjacent regions of the head portion, and being arranged to bear against the first side of the panel and oriented to provide a reaction force in at least one lateral direction substantially aligned with a principal radial direction of the extended portion, so as to resist pivot or tilt of the mounting component in that direction,wherein, when the mounting device is installed in the panel aperture, the panel is clamped between the at least one panel-engagement arm on the second side and the washer on the first side, and the pivot support formation is configured to resist pivoting or tilting of the mounting component relative to the panel in at least one direction under off-axis loads.

2. A washer, configured to receive a mounting component that is, in turn, engageable with a fixing component to form a mounting device for coupling to a panel, the washer comprising:a head portion at a proximal end, the head portion including a mounting component receiving aperture that defines a main axis of the washer; at least one contact formation arranged to contact the mounting component in use, such that pivot or tilt loads acting on the mounting component are at least partially transferred into the washer; and at least one pivot support formation provided by a discrete extended portion that is circumferentially discontinuous with respect to the head portion, the extended portion projecting radially beyond the head portion to provide a bearing region of greater radial extent than circumferentially adjacent regions of the head portion, and being arranged to bear against the first side of the panel and oriented to provide a reaction force in at least one lateral direction substantially aligned with a principal radial direction of the extended portion, so as to resist pivot or tilt of the mounting component in that direction,wherein the washer is configured such that, when the fixing component isengaged on a second side of the panel, the pivot support formation bears on the first side of the panel to resist pivoting or tilting of the mounting component relative to the panel in at least one direction under off-axis loads.

3. The mounting device or washer as claimed in Claim 1 or Claim 2, further comprising a locating formation extending axially from the head portion, the locating formation being dimensioned to engage an inner surface of the panel aperture so as to maintain positional alignment of the washer relative to the panel.

4. The mounting device or washer as claimed in Claim 3, wherein the locating formation comprises:one or more axially extending tabs configured to frictional ly engage the panel’s aperture; oran annular portion protruding from the head portion, an outer radial surface of which bears against the aperture’s inner surface.

5. The mounting device or washer as claimed in any one of Claims 1 to 4, further comprising at least one lateral retention formation configured to restrain lateral movement of the washer relative to the panel.

6. The mounting device or washer as claimed in Claim 5, wherein the at least one lateral retention formation comprises at least one of:spikes,fins, oraxially extending strips,each arranged to bite into or frictional ly engage the panel surface.

7. The mounting device or washer as claimed in any preceding claim, wherein the at least one pivot support formation extends radially from the head portion of the washer to contact the first side of the panel such that at least a portion of the pivot support formation is oriented substantiallyperpendicular to the mounting component’s axis in an anticipated direction of load.

8. The mounting device or washer as claimed in any preceding claim, wherein the at least one pivot support formation is provided by a discrete extended portion in the form of a tab, a bar, a strip or a lip, the extended portion being circumferentially discontinuous with respect to the head portion and projecting radially beyond the head portion to bear against the first side of the panel and provide a reaction force against off-axis pivot or tilt loads.

9. The mounting device or washer as claimed in any preceding claim, wherein the device or washer comprises a plurality of pivot-support formations, each provided by a discrete extended portion that is circumferentially discontinuous with respect to the head portion and projecting radially beyond the head portion to bear against the first side of the panel, the extended portions being disposed symmetrically or asymmetrically around the head portion to accommodate different directional loads.

10. The mounting device or washer as claimed in any preceding claim, wherein the at least one contact formation extends axially from the head portion so as to contact an axially extending feature of the mounting component or a part connected thereto, thereby providing a support reaction against lateral or pivot loads.

11. The mounting device or washer as claimed in Claim 10, wherein the at least one contact formation comprises a hollow or tubular body sized and shaped to capture or at least partially enclose a shank of the mounting component.

12. The mounting device or washer as claimed in any preceding claim, wherein the at least one contact formation extends around or adjacent the periphery of the washer aperture so as to bear against an underside of the mounting component in use, optionally being distally recessed from the proximal end face of the washer head to accommodate variations in mounting component geometry.

13. The mounting device or washer as claimed in any preceding claim, wherein the at least one contact formation comprises an end wall or a lip, said endwall or lip including a chamfered or angled surface formed on a portion that extends axially from the washer’s head portion, the end wall or lip being configured to engage an underside region of the mounting component or a part connected thereto.

14. The mounting device or washer as claimed in any preceding claim, further comprising a coupling portion configured to couple with the fixing component, said coupling portion extending from the head portion toward a distal end of the washer, and being further configured to:receive the mounting component therethrough;extend through the panel aperture when in use;enable axial movement of the fixing component along an axis between the proximal end and the distal end; andrestrict rotational movement of the fixing component relative to the head portion.

15. The mounting device or washer as claimed in Claim 14, wherein the coupling portion is further configured to enable the fixing component to pivot about a pivot axis relative to the washer.

16. The mounting device as claimed in any preceding claim, wherein the fixing component body has the at least one panel-engagement arm pivotably mounted thereto, each arm being arranged to move between the insertable condition and the extended condition.

17. The mounting device as claimed in any preceding claim, wherein the fixing component is a toggle bolt comprising two pivotably mountedpanel-engagement arms that are biased to pivot outward into the extended condition behind the panel upon passing through the panel aperture.

18. The mounting device as claimed in any one of Claims 1 to 15, wherein the at least one panel-engagement arm is rigidly connected to the fixing component, and the fixing component is configured to pivot relative to the washer.

19. The mounting device as claimed in any preceding claim, further comprising a restraint mechanism configured to resist axial travel of the fixing component beyond a predetermined range within the washer.

20. The mounting device as claimed in Claim 19, wherein the restraint mechanism comprises an end feature located at a distal end of the coupling portion, said end feature being configured to prevent the fixing component from moving axially beyond it.

21. The mounting device as claimed in Claim 19, wherein the restraint mechanism includes at least one of:a frictional interface,a ratchet arrangement, ora spring-biased element,each being arranged to resist or arrest an axial force acting on the fixing component in a direction toward the distal end of the washer.

22. The mounting device or washer as claimed in any preceding claim, further comprising at least one over-insertion formation arranged to abut the first side of the panel, thereby preventing the washer from being axially inserted beyond a predetermined depth.

23. The mounting device or washer as claimed in Claim 22, wherein the at least one over-insertion formation comprises at least one of:a radially extending flange at or near the head portion; orone or more tabs projecting from a periphery of the head portion.

24. The mounting device or washer as claimed in any preceding claim, further comprising at least one anti-rotation formation configured to resist rotational movement of the washer relative to the panel.

25. The mounting device or washer as claimed in Claim 24, wherein the at least one anti-rotation formation comprises one or more fins or spikesdimensioned to bite into the panel aperture wall.

26. The mounting device or washer as claimed in any preceding claim, wherein the mounting component is at least one selected from a group consisting of:a machine screw,a bolt,a protruding threaded bolt portion,an eyebolt,a standoff fixing,a hook having a threaded bolt portion, ora threaded insert capable of accepting and retaining a further fastener.

27. A kit of parts for forming a mounting device configured to be coupled to a panel, the kit comprising the washer, the fixing component, and the mounting component as claimed in any of the preceding claims, optionally together with at least one compatible secondary fastener.

28. A panel assembly comprising:a panel having an aperture extending from a first side of the panel to a second side of the panel; andthe mounting device as claimed in any one of Claims 1 to 26,wherein the mounting component of the mounting device extends through the panel aperture, the washer engages the first side of the panel so as to resist movement of the mounting component in a first direction from the first side toward the second side, and the at least one panel engagement arm of the fixing component engages the second side of the panel so as to resist movement of the mounting component in a second, opposite direction, thereby clamping the panel between the washer on the first side and the at least one panel engagement arm on the second side

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