Flooring panel and flooring panel assembly

Abstract

Flooring panel 14 for a floor heating system, comprising a planar body 16 comprising first 16a and second 16b opposed surfaces, at least one channel 18 within the body for receiving a conduit C, the a

Description

The present invention relates to a flooring panel for a flooring heating system. The invention also relates to a flooring assembly, a method of installing a flooring heating system, and a kit of parts. Background Floor heating systems are commonly used to heat enclosed spaces due to their more even distribution of heat across a space when compared to traditional heat sources such as fires and radiators. Floor heating systems are typically provided as underfloor 10 heating systems, where the heating system is located underneath a floor covering of the enclosed space. The heating system typically comprises a pipe or series of pipes arranged in a path across the floor space which act as a passage for a heat transfer medium, such as water. In this way, the heat transfer medium is distributed along a flow path around the C\j floor space, transferring heat to the enclosed space. In a known flooring heating system, OO5 the pipe or series of pipes are retained in flooring panels. Referring to Figure 1 of the drawings there is illustrated a cross-section of a known xl flooring panel for a floor heating system. The flooring panel 2 comprises a substantially rectangular, planar body 4 comprising a plurality of channels 6 which extend along the body. The channels 6 comprises an opening 8 which extends along an upper surface of the 20 body, the channel 6 being sized to receive a conduit (not shown). The flooring panel 2 also comprises a foil layer 10 coupled with the upper surface of the body 4. The foil layer 10 is typically provided as a continuous layer across the upper surface of the body 4 with the exception of continuous slits 12 formed in the foil adjacent to the opening 8 of the channels 6, which extend along the length of the panel. The slits 12 act as a guide for inserting the 25 conduit into the channels 6, and once the conduit is inserted into the channel, the edges 10a of the foil layer 10 at the slit 12 fold inwardly of the channel and act as a "barb" to hold the conduit in place within the channel. A significant drawback of this known flooring panel 2 is that the region of the body 4 at the base of the channel 6 (namely the region 4a opposite the opening 8 of the channel) 30 is relatively thin, making it more prone to breakage during transport or installation. This requires, at best, additional time and effort to repair the damaged flooring panel or, at worst, replacement of the entire flooring panel. We have now devised an improved flooring panel which addresses the above mentioned problems. Statement of Invention According to a first aspect of the present invention, there is provided a flooring panel for a floor heating system, the flooring panel comprising: - a substantially planar body, the body comprising a first surface and second 10 surface disposed opposite the first surface, at least one channel formed within the body for receiving a conduit, the at least one channel extending along the body in a plane substantially parallel with the first and second surfaces and comprising an opening formed in the first surface which extends along the first surface; and J 5 - a foil layer disposed upon the first surface which extends across the opening 5 of the at least one channel; wherein the foil layer comprises a plurality of perforations formed therein adjacent 1 to the opening of the at least one channel. The present inventors have found that by providing a foil layer, that can be a 20 continuous layer, upon the first surface with a series of perforations adjacent to the opening of the at least one channel, a flooring panel can be provided that facilitates installation of a conduit within the at least one channel whilst maintaining the structural integrity of the flooring panel during transport and installation. The perforations provide an intermittent slit within the foil adjacent the opening of the channel. The perforations 25 thus enable a tradesperson for example, to suitably align a conduit adjacent the opening to the channel and then press the conduit into the channel by breaking the perforations. Moreover, the perforations preserve a structural integrity of the panel by minimizing any flexing of the panel about the region of the body adjacent the base thereof, opposite to the opening of the channel. The perforations can extend along a direction substantially parallel with the opening of the at least one channel. In an embodiment, the perforations extend substantially opposite a central region of the opening of the at least one channel. The body can comprise a plurality of channels and the foil layer can comprise a 5 plurality of perforations, the plurality of perforations comprising a respective series of perforations adjacent to the opening of each channel. The at least one channel can comprise at least one arcuate channel defining a curved path within the body. The at least one channel can comprise a plurality of arcuate channels, each arcuate channel defining a curved path within the body. Alternatively, or in addition thereto, the at least one channel 10 can comprise a linear channel. The body can comprise a foam material. The foam material can comprise expanded polystyrene (EPS). The body can have a thickness of at least 20mm. The body can have a thickness of about 20mm. The at least one channel can have a substantially U-shaped cross-section. The at least one channel can have a maximum width of 16mm. The term J5 "maximum width" refers to the largest width of a cross-section of the channel. For 5 example, the at least one channel can have a maximum width of 16mm, 14mm, 12mm, 10mm or 8mm. 1 The foil layer can be formed from a metal or a metal alloy. The metal or metal alloy can comprise aluminium. The metal or metal alloy can comprise aluminium alloy. The foil 20 layer can have a thickness of at least 100pm. The foil layer can have a thickness of substantially 100pm. The flooring panel can further comprise an acoustic insulation layer disposed upon the second surface. The acoustic insulation layer can comprise an elastomeric layer. The elastomeric layer can comprise a neoprene (or polychloroprene) rubber. 25 The flooring panel can further comprise an underlay layer disposed upon the foil layer, the underlay layer comprising at least one opening adjacent to the plurality of perforations in the foil layer. The underlay layer can comprise a foam material. Alternatively, the flooring panel can further comprise a mesh layer disposed upon the foil layer, the mesh layer comprising at least one opening adjacent to the plurality of 30 perforations. The mesh layer can comprise a fibre-re inforced material. The fibre-reinforced material can comprise a fiberglass material. According to a second aspect of the invention, there is provided a flooring assembly comprising: at least one flooring panel according to the first aspect of the invention; and - at least one conduit, 5 wherein the at least one channel of the at least one flooring panel is configured to receive the at least conduit. 10 According to a third aspect of the invention, there is provided a method of installing a floor heating system, the method comprising the steps of: providing at least one flooring panel according to the first aspect of the invention and locating the at least one flooring panel on a flooring substrate; providing at least one conduit adjacent to a series of perforations in the foil layer; and applying pressure to the at least one conduit towards the flooring substrate, such that the foil layer tears in the region of the series of perforations to at least partially locate the at least one conduit within the at least one channel. Once inserted within the channel the at least one conduit is retained within the channel by an interference fit between the at least one conduit and the at least two foil edge regions. The method can further comprise the step of connecting the at least one conduit to a source of a heat transfer fluid. Whilst the invention has been described above, it extends to any inventive combination of the features set out above, or in the following description, drawings or claims. For example, any features disclosed in relation to the first aspect of the invention may be combined with any features of the second aspect of the invention and vice versa. 25 Description of Figures Embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings, in which: Figure 1 is a schematic representation of a cross-section through a known flooring 30 panel; Figure 2 is a schematic representation of a cross-section through a flooring panel in accordance with an embodiment of the invention; Figure 3 is a schematic representation of a combination of flooring according to an embodiment of the invention; 5 Figure 4 is a schematic representation of a combination of flooring panels according to a further embodiment of the invention; Figure 5 is a schematic representation of a combination of flooring panels according to a further embodiment of the invention ; and Figure 6 is a flowchart representing the steps associated with a method of installing 10 a floor heating system according to an embodiment of the present invention. Detailed Description Referringto Figure 2 of the drawings, there is illustrated a schematic representation of a flooring panel 14 for a floor heating system in accordance with an embodiment the present invention. The flooring panel 14 comprises a substantially rectangular, planar body 16 comprising a first and second surface which in use constitute and upper and lower surface (16a, 16b) of the body 16, respectively. The body 16 comprises a plurality of channels 18 which extend along the body in a plane substantially parallel with the first and second surfaces, each channel 18 having an opening 20 on the upper surface of the body 16 which extends along the upper surface. The channels 18 extend through the longitudinal ends of the panel 14 and the dimensions and cross-sectional shape of the channel are determined by the cross-sectional shape and dimensions of an associated conduit C which is arranged to locate within the channel 18 through the opening 20. For example, in the illustrated embodiment, each channel 18 has a substantially U-shaped cross-section having 25 a maximum width w. However, other cross-sectional shapes and dimensions may be chosen to accommodate different conduits C. Moreover, the channels 18 associated with each panel 14 can take a different longitudinal form. For example, one panel 14 may comprises a plurality of linear channels 18 which extend longitudinally along the panel, and which are equally spaced across the panel 14. In this respect, panels 14 may be placed end-30 to-end along a floor so that the channels 18 within each panel 14 align. Other panels 14a (as shown in figure 3 of the drawings) may comprise curved or arcuate channels which extend within the body 16. These "return" panels can be placed at opposite ends of a floor and enable a conduit to turn to extend back and forth along a floor. The panel body 16 can be formed from a foam material, such as expanded polystyrene (EPS) foam, as it helps minimise heat transfer in the lateral direction and is 5 easily recyclable. The body 16 can have a thickness depending on a variety of factors, including the diameter of the conduit which it is adapted to accommodate. For example, the body 16 can have a thickness of at least 20mm to accommodate a conduit of 16mm in diameter, such that the channels 18 do not extend through the thickness of the body 16. One or more layers can be disposed upon the body 16 at the second surface 16b. 10 For example, as shown in Figure 2, the flooring panel 14 can further comprise an acoustic insultation layer 22 disposed upon the body 16 at the second or lower surface 16b to help reduce acoustic transmission through the flooring panel 14. This is considered to be particularly beneficial when the panels are installed in multistorey buildings, for example. The acoustic insulation layer 22 can be coupled with the body 16 by any means known in J5 the art, such as through application of adhesive between the acoustic insulation layer 22 5 and the body 16. The acoustic insulation layer can be formed from an elastomeric material, such as a neoprene rubber. 1 The panel 14 further comprise a foil layer disposed on the first or upper surface 16a of the body 16. The foil layer 24 can be coupled with the body 16 by any means known in 20 the art, such as through application of adhesive between the foil layer 24 and the upper surface of the body 16. The foil layer 24 is preferably a continuous layer, with the exception of the provision of a series of perforations 26 formed within the foil layer, as illustrated in figure 3. The perforations are provided adjacent to the opening 20 of the channels 18. In the illustrated embodiment, the perforations 26 are provided approximately at the centre 25 of the channel opening 20, and follow the channels 18 along their entire length. However, different configurations of perforations 26 are possible, as long as perforations are provided adjacent to the opening 20 of each channel 18. The present inventors have determined that the perforations 26 act both as a guide for aligning a conduit C adjacent an opening 20 of a channel 18 and also as a weak point in 30 the foil layer 24 that preferentially tears when the conduit C is pushed into the channel, so that the conduit C can locate within the channel 18. It is also found that upon inserting the conduit, the opposing edges of the foil layer 24 forming the original perforations, turn inwardly of the channel 18 and act as a barb to retain the conduit C within the channel 18. In an alternative embodiment, the foil layer can be provided as an integral, continuous layer coupled with the upper surface of the body 16 and the perforations can 5 be formed in situ using a perforating tool T, once the flooring panels 14 have been placed on a flooring substrate. The foil layer 24 can be formed of a metal or metal alloy foil, such as an aluminium foil, and can have a thickness of at least 100pm. The present inventors have determined that the combination of a metal or metal alloy foil having a thickness of at least 100pm is 10 particular effective at retaining a conduit C in the channels 18. Referring to figure 3 of the drawings, there is illustrated a combination of a flooring panel 14 with a linear arrangement of channels 18, the position of which are illustrated by the perforations 26, and a return panel 14a comprising a plurality of arcuate channels which turn through 180°, the position of which illustrated through the series of arcuate J5 perforations 28. The linear channels 18 of the panel 14 extend out through the longitudinal 5 ends of the body 16 and the arcuate channels 28 similarly extend out through side edges of the panel 14a. The channels 18 which extend out through the longitudinal end of the 1 panel 14 are arranged to align with the channels 28 which extend out through the side edges of the panel 14a. In this manner, a conduit C which passes along a channel 18 of 20 panel 14 can turn through 180° by extending along an arcuate channel 28 of panel 14a and pass back along a separate channel 18 in panel 14. The combination of the panel 14 and return panel 14a therefore enables a conduit C to meander back and forth along a floor. Referring to Figure 3, the panel 14 would be expected to form the majority of the flooring panels of a floor heating system which extend along a floor. The return panel 14a 25 would typically be arranged at the edge of the floor. When the panels 14 and return panels 14a are placed in situ upon a floor, the channels align to form a serpentine path across the floor for receiving a conduit C. When the conduit C is coupled to a source of heated fluid, the heated fluid is permitted to flow along the conduit C within the channels 18, 28. The heat within the fluid can then pass out to the channel 18, 28 for distribution across the floor 30 for an even distribution of heat across the floor. Referring to figure 4 of the drawings, there is illustrated a similar arrangement of a panel 14 and return panel 14a, as shown in figure 3. However, in this embodiment the flooring panels 14, 14a comprise an underlay layer 40 disposed upon an upper surface of the foil layer 24. The underlay layer 40 comprises a plurality of elongate openings 42 5 formed adjacent to the plurality of perforations 26 in the foil layer 24, to allow the 10 perforations 26 to remain exposed for insertion of the conduit C during the installation of the floor heating system. In the illustrated embodiment, the at least one opening 42 is in the form of several elongate channels formed in the underlay layer 40 that extend through the thickness of the underlay layer 40. The underlay layer 40 can comprise a foam material or a fabric felt material, and is found to facilitate the placement of a laminate flooring layer for example upon the flooring panels 14, 14a. The underlay layer 40 can be coupled with the foil layer 24 by any means known in the art, such as through application of adhesive between the underlay layer 40 and the foil layer 24. Referring to figure 5 of the drawings, there is illustrated a similar arrangement of a panel and return panel 14a, as shown in figure 3. However, in this embodiment the flooring panels 14,14a comprise a mesh layer 44 coupled with an upper surface of the foil layer 24. The mesh layer 46 comprises at least one opening 42, similar to the underlay layer 40 described above, adjacent to the perforations 26 in the foil layer 24, to allow the perforations 26 to remain exposed for insertion of the conduit during assembly of a floor heating system. In the illustrated embodiment, the at least one opening 42 is in the form of several channels formed in the mesh layer 44 that extend through the thickness of the mesh layer 44. The mesh layer 44 can comprise a fibre-reinforced material, such as a fiberglass material. The mesh layer 46 can be in the form of a grid of fiberglass material to facilitate the placement of floor tiles upon the flooring panels 14,14a by acting as both a 25 support and a guide for locating the tiles in a regular pattern on the flooring panels 14,14a. The mesh layer 44 can be joined to the foil layer 24 by any means known in the art, such as through application of adhesive between the mesh layer 46 and the foil layer 24. Referring to figure 6 of the drawings, there is illustrated a method 100 of installing a floor heating system according to an embodiment of the present invention. In a first step 30 102, a plurality of flooring panels 14,14a are located on a flooring substrate that acts as a base for the floor heating system. The panels are configured such that the channels 18, 28 formed therein become aligned to form a continuous channel path for a conduit C back and forth across the arrangement of panels, with the panels 14, 14a and conduit C forming a flooring assembly. In a second step 104, a conduit C is located adjacent to the series of perforations in 5 the foil layer of the flooring panels, such that the conduit is located adjacent to a channel in the panels 14,14a. The conduit C can comprise a plurality of conduits C, which may be joined together prior to or during the second providing step 104 by any means known in the art, such as through an interference fit or a screw fit. In an insertion step 106, pressure is applied to the conduit in a direction towards 10 the flooring substrate, such that the foil layer tears in the region of the perforations to form so that the conduit C can locate in the channel 18, 28 located therebeneath. During this step, the foil edge regions forming the perforations fold inwardly of the channel 18, 28 forming a barb which acts to retain the conduit C within the channel 18, 28. - Ina connection step 108, the conduit is connected to a source of a heat transfer J 5 fluid, such as heated water, to enable the water to pass along the conduit C and exchange J heat with the conduit for heating the space above the floor heating system. The method can further comprise the step of providing a flooring surface layer upon the flooring panels to form a finished flooring surface.

Claims

101. A flooring panel for a floor heating system, the flooring panel comprising:- a substantially planar body, the body comprising a first surface and second surface disposed opposite the first surface, at least one channel formed within the body for receiving a conduit, the at least one channel extending along the body in a plane substantially parallel with the first and second surfaces and comprising an opening formed in the first surface which extends along the first surface; and- a foil layer disposed upon the first surface which extends across the opening of the at least one channel;wherein the foil layer comprises a plurality of perforations formed therein adjacent to the opening of the at least one channel.

2. A flooring panel according to claim 1, wherein the perforations extend along a direction substantially parallel with the opening of the at least one channel.

3. A flooring panel according to claim 1 or 2, wherein the perforations extend substantially opposite a central region of the opening of the at least one channel.

4. A flooring panel according to any preceding claim, wherein the body comprises a plurality of channels and the foil layer can comprise a plurality of perforations, the plurality of perforations comprising a respective series of perforations adjacent to the opening of each channel.

5. A flooring panel according to any preceding claim, wherein the at least one channel comprises at least one arcuate channel defining a curved path within the body.

6. A flooring panel according to any preceding claim, wherein the at least one channel30 comprises a linear channel.14 08 247. A flooring panel according to any preceding claim, wherein the body comprises a foam material.

8. A flooring panel according to claim 7, wherein the foam material comprises5 expanded polystyrene9. A flooring panel according to any preceding claim, wherein the foil layer is formed from a metal or a metal alloy.10 10. A flooring panel according to any preceding claim further comprising an acousticinsulation layer disposed upon the second surface.

11. A flooring panel according to claim 10, wherein the acoustic insulation layer comprises an elastomeric layer.

512. A flooring panel according to any preceding claim further comprising an underlay layer disposed upon the foil layer.13 A flooring panel according to claim 12, wherein the underlay layer comprises at least 20 one opening adjacent to the plurality of perforations in the foil layer.

14. A flooring panel according to any of claims 1-11, further comprising a mesh layer disposed upon the foil layer.25 15. A flooring panel according to claim 14, wherein the mesh layer comprises at leastone opening adjacent to the plurality of perforations.

16. A flooring assembly comprising:- at least one flooring panel according to any preceding claim; and30 - at least one conduit,wherein the at least one channel of the at least one flooring panel is configured to receive the at least conduit.

17. A method of installing a floor heating system, the method comprising the steps of: 5 - providing at least one flooring panel according to any of claims 1-15 andlocating the at least one flooring panel on a flooring substrate;providing at least one conduit adjacent to a series of perforations in the foil layer; and- applying pressure to the at least one conduit towards the flooring substrate, 10 such that the foil layer tears in the region of the series of perforations to atleast partially locate the at least one conduit within the at least one channel.

18. A method according to claim 17, further comprising the step of connecting the at least one conduit to a source of a heat transfer fluid.(NsCO

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