GB2547636A

GB2547636A - Flooring system

Info

Publication number: GB2547636A
Application number: GB1602785.6A
Authority: GB
Inventors: Nixon Leslie
Original assignee: Sip Building Systems Ltd
Current assignee: Sip Building Systems Ltd
Priority date: 2016-02-17
Filing date: 2016-02-17
Publication date: 2017-08-30
Also published as: GB201602785D0

Abstract

An insulated floor panel 200 comprises an insulation portion 201 formed of a thermally insulating material, a longitudinally extending support member 204, 205 and a protection layer 202 to mask an elongate face of the floor panel. The panel is supported by a foundation of a building. The support may be a timber beam having a portion 206 extending beyond the insulation. The protection layer may be of an impermeable, metallic material. The panel may be supported by a beam of a flooring system. Also claimed are: a beam comprising a central insulated portion and a support portion for supporting a floor panel; a floor panel comprising first and second supports defining a void; and a flooring system comprising a joist supporting a floor panel and surrounded by an impermeable layer.

Description

Flooring System

The present invention relates to an insulated beam, and in particular an insulated beam for use with a flooring system; an insulated floor panel suitable for use with said insulating beam and corresponding method of constructing a floor; and a flooring system and method of constructing a floor.

Floors for buildings may be constructed using a plurality of different flooring techniques such as, for example, a solid floor construction or a suspended floor construction. Often, the first step in the construction of a floor for a building is to clear an area of ground upon which the building and floor are to be constructed. Foundations of the building are then laid, typically using concrete, which outlines a perimeter of the building. The lower courses of bricks (concrete masonry unit and/or standard bricks) are then laid on the foundations.

Solid floors may be constructed by laying construction material directly upon the ground in solid layers. As such, before laying the foundations of the building, the ground may first be levelled to create an even surface upon which the floor can be constructed. Once the foundations are in place, hard core is laid directly upon the ground between the foundations and is compacted to form a strong, dense and level base for the floor. Sand is poured upon the hard core and a damp proof membrane is laid above it. Concrete is then poured upon the damp proof membrane, levelled, and left to set. Once it has set, a damp-proof membrane is laid on top of the concrete, and a layer of insulation is applied above the damp-proof membrane. To finish the floor, a layer of screed (typically concrete) is applied above the insulation and levelled. Once the screed has set the solid floor is complete.

Suspended floors are typically constructed by laying beams at equally spaced intervals between the foundations of the building to create a grate-like structure upon which flooring can be laid. As such, unlike solid floors, suspended floors may trap a region of air between the floor of the building and the ground. It is known to provide beams composed of reinforced concrete. In some examples it is known to provide the foundations of the building with inwardly-extending ledges, often referred to as sleeper-walls, configured to support the concrete beams at either end. Slabs of flooring material are placed within the gaps formed between the beams such that the slabs are supported by the concrete beams. A layer of insulation and a layer of screed may be applied above the beams and slabs to form the finished floor.

It will be appreciated that during construction of a concrete suspended floor, manual and mechanical handling (e.g. by crane etc.) of the concrete beams may be laborious due to the weight and length of the concrete beams, often requiring multiple workers to move a single beam. Furthermore, the concrete beams themselves may not provide adequate thermal shielding against heat transfer through the floor, and so it is often necessary to apply insulation above the beams. It will further be appreciated that it is difficult to secure a flooring surface such as plywood board or timber planks to the concrete beams and slabs, and therefore it is often necessary to provide a layer of screed in order to create a level floor surface. Construction of a screed layer may be undesirable as such a layer will require time to set, during which the floor cannot be used.

It is an object of the present invention to provide an insulated beam for use with a flooring system, an insulated floor panel for use with a flooring system, a flooring system, or a method of construction of a floor which obviate or mitigate the problems described above. It is a further object of the present invention to provide an alternative insulated beam for use with a flooring system, an insulated floor panel for use with a flooring system, a flooring system, or a method of construction of a floor. In particular it is an object of the present invention to provide an alternative lightweight insulated beam for use with a flooring system, a lightweight insulated floor panel for use with a flooring system, a lightweight flooring system, or a method of construction of a lightweight floor.

According to a first aspect of the invention there is provided an insulated floor panel for support by a foundation of a building formed as a generally elongate cuboid defining a longitudinal axis, the floor panel comprising: an insulation portion formed of a thermally insulating material configured to substantially impede heat transfer through the floor panel; a longitudinally extending support member configured to support the floor panel; and a protection layer configured to substantially mask an elongate face of the floor panel; wherein the floor panel is configured for support by a foundation of a building.

It will be appreciated that because the floor panel comprises both a structural support member configured to support the floor panel upon a foundation of the building and an insulation portion configured to substantially impede heat transfer through the floor panel, the support member of the floor panel overcomes the need to support the floor panel upon a separate support member (e.g. support beam) that is external to the floor panel. As such, the structural support provided by the support member is integral with the floor panel and therefore the number of steps required to install a floor comprising a floor panel according to the first aspect of the invention is reduced, since both the insulation element of the floor and the structural element of the floor are installed in the same assembly step. That is to say, rather than installing a structural element of the floor first and subsequently supporting an insulating element of the floor upon the structural element, the present invention saves installation time by allowing both the structural and insulating elements of the floor to be assembled in the same step. It will be appreciated that is made possible by the inclusion of both an insulation portion and a support member within the floor panel.

Within the present specification the term foundation should be construed broadly. It is meant to include not only groundworks that are located below ground level, but also structure which extends above ground level. It can be any structure which is in some way located in the earth and which provides a surface to support a portion of a flooring system (e.g. a floor panel or a beam or a joist). The foundation may be formed as a single piece (for example a concrete structure) or may be formed as separate pieces (for example a base, formed of concrete or the like, upon which a lower portion of a wall is formed).

By substantially masking an elongate face of the floor panel, what is meant is that the protection layer is capable from protecting an elongate face of the floor panel. Such protection may be any suitable type of protection. For example, it may be protection against impact, wear and/or ingress of moisture.

It will be appreciated that the term “thermally insulating material” may be taken to refer to any material with a low thermal transmittance. In particular, a material having low thermal transmittance will be a material having a lower thermal transmittance than typical building materials such as brick, wood, concrete etc. The thermal transmittance of a construction material is typically given in terms of that material’s lambda-value, measured in W.m"1.K"1. The thermally insulating material preferably has a lambda-value of less than 0.05 W.m"1.K'1, or more preferably is 0.03 W.m"1.K'1 or less. The thermal transmittance of the floor panel as a whole may be given in terms of the floor panel’s U-Value, measured in W.m"2.K'1. The U-value of the floor panel is preferably less than 0.30 W.m"2.K"1, or more preferably is such that a floor comprising the floor panels meets the requirements of the relevant building regulations in the territory concerned. It will be appreciated that the thermal transmittance of the floor panel is lower than the thermal transmittance of a floor panel comprising alternative materials such as concrete. As such, less heat will be transferred through the floor panel and therefore heat loss in a building containing the floor panel of the first aspect of the invention will be reduced.

The support member may be an elongate timber beam. It will be appreciated that timber is a lightweight support material when compared to alternative support materials such as concrete. As such, a floor panel comprising a timber support member is lighter than an equivalent floor panel comprising a concrete support member. It will be appreciated that this allows a floor panel comprising a timber support member to be more easily manoeuvred by a user installing the floor. Furthermore, such a floor panel may require fewer users to lift and place the floor panel when compared to a heavier floor panel comprising a concrete support member. It will further be appreciated that the use of timber provides an environmental benefit in that the production of timber support members results in lower C02 emissions than the production of concrete support members.

The support member may be a first support member and the floor panel may further comprise a second longitudinally extending support member configured to support the floor panel. It will be appreciated that by having two support members, the load supported by one of the support members is halved. As such, heavier loads may be supported by the floor panel. The second support member may be a second elongate timber beam.

The first and second support members may be arranged either side of the insulation portion. In other words, the insulation portion may be located between the first and second support members.

The thermally insulating material may be polyurethane or any other rigid insulating material such as, for example, polyisocyanurate or polystyrene.

The protection layer may extend between the first and second support members. The protection layer may cover a portion of each of the first and second support members.

The protection layer may be configured to substantially mask a lower face of the floor panel, and during normal use the protection layer may be supported by the foundation of the building. The protection layer may be formed of a substantially impermeable material. It will be appreciated that where the protection layer is impermeable, the protection layer may be impermeable to moisture such that it acts to substantially prevent moisture ingress from below the floor panel into the floor panel itself and the parts of the building above the floor panel. That is to say, the protection layer may act as a damp-proof layer. The protection layer may be composed of a metallic material, for example, aluminium or steel. Alternatively, the protection layer may be formed of any other suitable impermeable material, such as for example a ceramic, polymer, or composite material

The protection layer may comprise a bent flange portion which is bent around an edge of the support member. It will be appreciated that such a flange portion may act to further prevent moisture ingress into the floor panel, by extending / lengthening the physical barrier to moisture ingress that is provided by the protection layer. Furthermore, the flange portion may provide some lateral structural support to the floor panel. That is to say, because the flange portion is bent around an edge of the floor panel, the flange portion may act to contain the support member and the insulation portion within the floor panel (i.e. to prevent separation of the support member and the insulation portion).

In the case where the floor panel includes first and second support members the protection layer may include two bent flange portions - the first bent flange portion being bent around an edge of the first support member and the second bent flange portion being bent around an edge of the second support member.

The protection layer may be a first protection layer, and wherein the panel further comprises a second protection layer configured to mask a further elongate face of the floor panel. The first and second protection layers may be arranged on opposite sides of the floor panel such that the insulation portion is located between the first protection layer and the second protection layer. For example, the first protection layer may be arranged on a bottom face of the floor panel and the second protection layer may be arranged on a top face of the floor panel. The second protection layer may be substantially identical to first protection layer such that the second protection layer also comprises flange portions. Alternatively, the second protection layer may be different to the first protection layer. For example, the second protection layer may comprise only one, or zero flange portions.

The floor panel may be configured for support by the foundation of the building at first and second opposite ends of the floor panel, the first and second ends being longitudinally spaced from one another. The insulated floor panel may be configured to be at least partially supported by a beam of a flooring system. For example, the floor panel may be supported upon a beam of the flooring system which is laid upon the foundation of the building. The beam of the flooring system may be an intermediate beam (i.e. a beam which substantially traverses a footprint of the building foundations). According to a second aspect of the invention there is provided a method of constructing a floor, wherein the method comprises supporting an insulated floor panel according to the first aspect of the invention upon a foundation of a building.

It will be appreciated that because the floor panel of the first aspect of the invention comprises both a structural element (the support member) and an insulating element (the insulation portion), it is not necessary to install the structural and insulating elements of the floor separately. As such, installation of the floor is simple and fast.

The method may further comprise supporting the insulated floor panel upon the foundation of the building at first and second substantially opposite ends of the floor panel, the first and second ends being longitudinally spaced from one another. The method may further comprise supporting a plurality of insulated floor panels upon a foundation of a building.

According to a third aspect of the invention there is provided an insulated beam for a flooring system, the insulated beam comprising: a central portion; and a first support portion; wherein the insulated beam is formed as a generally elongate member defining a longitudinal axis; the first support portion projects from the central portion in a direction generally perpendicular to the longitudinal axis, the first support portion configured to at least partially support a floor panel of the flooring system; and the central portion includes an insulation portion composed of a thermally insulating material configured to substantially impede heat transfer through the insulated beam.

It will be appreciated that the term “thermally insulating material” may be taken to refer to any material with a low thermal transmittance. The thermally insulating material preferably has a lambda-value of less than 0.05 W.m'1.K'1, or more preferably is 0.03 W.m'1.K'1. The thermal transmittance of the insulated beam as a whole preferably has a U-value of less than 0.30 W.m"2.K"1, or more preferably is such that a floor comprising the insulated beams meets the requirements of the relevant building regulations in the territory concerned. Because the insulated beam comprises a portion of thermally insulating material, the thermal transmittance of the insulated beam is lower than the thermal transmittance of alternative beams for suspended floors, such as those composed of concrete. It will be appreciated that where the insulated beam is used within a building, a lower thermal transmittance is advantageous as less heat will be lost from the building. It will further be appreciated that because of the relatively low thermal transmissivity of the insulated beam, an additional layer of thermally insulating material (such as a layer of screed) is not necessary, thus saving construction time and cost.

The central portion may have a height perpendicular to the longitudinal axis. The first support portion may extend away from the central portion in a direction which is generally perpendicular to the height of the central portion. The first support portion may extend away from the central portion in a direction which is generally perpendicular to longitudinal axis.

In other words, the first support portion may extend away from the central portion in a generally horizontal direction. It will be understood that the term “generally horizontal” refers to the orientation of the insulated beam when the insulated beam is used within a flooring system. As such, “generally horizontal” may be interpreted to mean generally level with a foundation of a building.

The first support portion may comprise a support surface configured to at least partially support the floor panel of the flooring system. For example, the flooring system may comprise a plurality of insulated beams, and a floor panel of the flooring system may be partially supported by a support surface of a first insulated beam and partially supported by a support surface of a second insulated beam. The support surface may support the floor panel by contacting a lower face of the floor panel, which may, in some embodiments, be a lower protection layer of the floor panel.

The central portion may have a height perpendicular to the longitudinal axis. The support surface may extend in a direction which is generally perpendicular to the height of the central portion. The support surface may extend in a direction which is generally perpendicular to the longitudinal axis. In other words, in use, the first support surface may be generally horizontal. The first support portion may be formed of a longitudinally extending member. The central portion may define a length of the insulated beam, and the first support portion may extend along the whole of the length of the insulated beam. It will be appreciated that where the first support portion extends along the whole of the length of the insulated beam, the surface area of the support portion which may contact the floor panel is increased.

The central portion and the support portion may be formed as separate members. For example, the support portion may be formed of timber, and may be attached to the central portion my nailing, screwing and/or gluing.

The support portion and the central portion may be substantially aligned so as to define a bottom surface configured to rest upon a foundation of a building. It will be appreciated that the foundation of the building may therefore support the insulated beam. The bottom surface may comprise a protection layer composed of an impermeable and/or impact resistant material.

The support portion may be a first support portion and the insulated beam may further comprise a second support portion substantially identical to the first support portion, the second support portion configured to at least partially support a further floor panel of the flooring system. The second support portion may project from the central portion in a direction substantially opposite to that in which the first support portion projects from the central portion.

The central portion may further comprise: a top stringer arranged along a top surface of the central portion; a bottom stringer arranged along a bottom surface of the central portion; a first side panel arranged along a first side of the central portion; and a second side panel arranged along a second side of the central portion substantially opposite the first side of the central portion; and the top stringer, the bottom stringer, the first side panel, and the second side panel may cooperate to define an interior of the central portion. The interior of the central portion may comprise the portion of thermally insulating material.

The top stringer, the first side panel, and the second side panel may be formed of a penetrable (or fixing-penetrable) material. It will be appreciated that the term “penetrable material” is intended to mean a material suitable for penetration by a fixing such as a screw or nail, and as such may be a pliable, non-brittle material. For example, a penetrable material may be timber, oriented strand board, chipboard or plywood. It will be appreciated that by being composed of such a material, a flooring layer of the flooring system, for example chipboard, oriented strand board, or plywood, may be mechanically fixed to the central portion of the insulated beam by screws and/or nails. This is advantageous in that a layer of screed is not required to complete the assembled floor, thus saving construction time.

The insulated beam may be configured to support a floor panel according to the first aspect of the invention.

According to a fourth aspect of the invention there is provided an insulated floor panel comprising: first and second longitudinally extending support members; and an insulation portion comprising a thermally insulating material disposed between the first and second support members; wherein the first and second support members define a region of empty space disposed between the first and second support members and adjacent the insulation portion.

It will be appreciated that the term “thermally insulating material” may be taken to refer to any material with a low thermal transmittance. The thermally insulating material preferably has a lambda-value of less than 0.05 W.m"1.K"1, or more preferably is 0.03 W.m'1.K'1. The thermal transmittance of the floor panel as a whole preferably has a U-value of less than 0.30 W.m"2.K"1, or more preferably is such that a floor comprising the floor panels meets the requirements of the relevant building regulations in the territory concerned. It will be appreciated that the thermal transmittance of the floor panel is lower than the thermal transmittance of a floor panel comprising alternative materials such as concrete. As such, less heat will be transferred through the floor panel and therefore heat loss in a building containing the floor panel of the first aspect of the invention will be reduced.

It will be appreciated that the region of empty space may be configured to receive a further insulation portion. Alternatively, the region of empty space may be configured to receive a portion of a heating system of the building, such as for example an underfloor heating system. The empty space may also be referred to as a void. The void may be configured to receive cabling/pipework for utility supply or waste extraction. In use, the void may be located such that it is above the thermally insulating material disposed between the first and second support members. In alternative embodiments the void may be located such that it is below the thermally insulating material disposed between the first and second support members. A flooring layer of the building may be provided vertically above the first and second support members.

It will be appreciated that top surfaces of the first and second support members may be configured to support a flooring layer of the flooring system. As such, air may be trapped within the void between the floor panel and the flooring layer which may act to further impede heat transfer through the floor panel. As previously discussed, the void may be configured to receive an underfloor heating system and/or the void may comprise a further layer of insulating material.

According to a fifth aspect of the invention there is provided a flooring system comprising: an insulated beam according to the third aspect of the invention, and a floor panel; wherein the floor panel is at least partially supported by the insulated beam.

The floor panel may be a first floor panel and the flooring system may further comprise a second floor panel. The second floor panel may be at least partially supported by a second floor panel support portion of the insulated beam. The second floor panel may be supported on a substantially opposite side of the central portion to the first floor panel.

The flooring system may comprise a plurality of insulated beams, and the floor panel may be at least partially supported by a first insulated beam of the plurality of insulated beams and may be at least partially supported by a second insulated beam of the plurality of insulated beams. The floor panel may be a floor panel according to the first or fourth aspect of the invention.

According to a sixth aspect of the invention there is provided a method of constructing a floor, wherein the floor comprises: a plurality of insulated beams according the third aspect of the invention; wherein the method comprises arranging the plurality of insulated beams to define a plurality of spacings between adjacent beams; and supporting a floor panel within each spacing.

The floor panel may be a floor panel according to the first or fourth aspect of the invention.

According to a seventh aspect of the invention there is provided a flooring system comprising: a joist formed as an elongate member and defining a longitudinal axis; and a floor panel at least partially supported by the joist; wherein the joist comprises a substantially impermeable protection layer substantially surrounding the joist about the longitudinal axis.

It will be appreciated that by comprising an impermeable protection layer, moisture ingress from below the flooring system into the joist or into a part of the building above the flooring system is substantially prevented. As such, the protection layer may be a damp-proof layer of the building. Furthermore, by preventing moisture ingress into the joist, this may prevent the joist deforming due to moisture ensuring that the joist and any supported floor panel remain flat.

The joist may be a multiple (e.g. double) joist comprising a plurality of elongate timber beams arranged side by side and joined to one another, each timber beam contacting an adjacent timber beam along a contact surface which extends in a direction generally parallel to the longitudinal axis. The beams may be joined to one another by any appropriate fixing or by glue/adhesive or the like. It will be appreciated that a double joist may provide an increased load carrying capacity over a single joist. Each of the plurality of timber beams may define a grain direction, and the plurality of timber beams may be arranged such that the grain direction of each timber beam substantially opposes the grain direction of a timber beam to which it is joined. It will be appreciated that the grain direction of each timber beam may result in twisting of the timber beam. By arranging the timber beams such that the grain direction of each of the timber beams opposes the grain direction of the adjacent timber beam, twisting of the timber beams may be minimised. That is to say, the resultant twisting of the joist is reduced because any twisting force exerted by the first timber beam will be counteracted by a twisting force produced by the second timber beam which acts upon the first timber beam.

The protection layer may be composed of polyethylene. The protection layer may comprise a membrane formed of plastics material or a sheet plastics material. The floor panel may be an insulated floor panel comprising a portion of thermally insulating material. The flooring system may comprise a plurality of floor panels. Each floor panel may comprise a tongue and groove arrangement. For example, each panel may include a tongue arrangement arranged along a side of the floor panel and configured to connect the floor panel to a corresponding groove arrangement of an adjacent floor panel to form a join between the floor panels. The tongue and groove arrangements may be formed by a portion of thermally insulating material of the respective floor panel. The floor panels may be arranged such that the join between adjacent floor panels runs parallel to the longitudinal axis of the joist.

Specific embodiments of the invention will now be described, by way of example only, with reference to the following accompanying drawings, in which:

Figure 1 is a schematic cross-sectional view of a first embodiment of an insulated beam for use within a flooring system;

Figure 2 is a schematic cross-sectional view of a second embodiment of an insulated beam 100 for use within a flooring system;

Figure 3A is a schematic cross-sectional view of an insulated floor panel;

Figure 3B is a schematic perspective view of an insulated floor panel;

Figure 4 is a schematic cross-sectional view of a flooring system;

Figure 5 is an enlarged schematic cross-sectional view of a portion of a flooring system and a foundation of a building;

Figure 6A is a schematic cross-sectional view of a third embodiment of an insulated floor panel for use with a flooring system;

Figure 6B is a schematic cross-sectional view of a fourth embodiment of an insulated floor panel for use with a flooring system; and

Figure 7 is schematic cross-sectional view of a flooring system according to an embodiment of the present invention.

The equivalent features of the specific embodiments of invention are referred to by the same reference signs throughout the description. As such, an equivalent feature which is present in multiple embodiments of the invention is referred to by the same reference sign in all of the embodiments in which that feature is present.

Figure 1 shows a schematic cross-sectional view of a first embodiment of an insulated beam 100 for use within a flooring system. The insulated beam 100 has a substantially constant cross-section and is generally formed as a T-shape comprising a central portion 101, a first support portion 102, and a second support portion 103. The first support portion 102 is mounted to a first side 104 of the central portion 101, and the second support portion 103 is mounted to a second side 105 of the central portion 101, the second side 105 being opposite to the first side 104. The first and second support portions 102, 103 define first and second support surfaces 114, 115 configured to support a floor panel of the flooring system. The first and second support portions 102, 103 are formed as separate pieces to the central portion 101 and are mechanically fixed to the central portion 101. The first and second support portion 102, 103 may be fixed to the central portion 101 by adhesive, nails, bolts or screws etc.

The central portion 101 comprises a top stringer 106 and a bottom stringer 107. The top stringer 106 defines a top surface 113 of the insulated beam 100. The bottom stringer 107, first support portion 102, and second support portion 103 are substantially aligned so as to define a bottom surface 116 of the insulated beam 100 configured to rest upon a foundation of a building. In other embodiments the bottom stringer 107 may not be aligned with the first support portion 102 and second support portion 103 such that only the bottom stringer defines the bottom surface configured to rest upon a foundation of a building. A first side panel 108 is disposed between the top and bottom stringers 106, 107 on the first side 104 of the central portion 101, and a second side panel 109 is disposed between the top and bottom stringers 106, 107 on the second side 105 of the central portion 101. A first runner 110 is attached to the top stringer 106 and a second runner 111 is attached to the bottom stringer 107. The first and second runners 110, 111 may be secured to the top and bottom stringers 106,107 respectively by gluing and/or nailing. The first and second side panels 108, 109 contact the first and second runners so as to define an interior 112 of the central portion 101.

To secure the first and second side panels 108, 109 to the first and second runners 110, 111, the side panels 108, 109 and runners 110, 111 are assembled in a jig to form a cavity in the interior 112. Insulating material is then injected into the interior cavity 112 as a liquid, whereupon the insulating material expands to entirely fill the interior 112. The thermally insulating material automatically adheres (auto-bonds) to the internal surfaces of the runners 110, 111 and side panels 108, 109 which it touches. The thermally insulating material then solidifies. Alternatively, the first and second side panels 108, 109 may be secured to the first and second runners 110, 111 by gluing and/or nailing.

Figure 2 shows a schematic cross-sectional view of a second embodiment of an insulated beam 100 for use within a flooring system. In the second embodiment of the insulated beam 100 the top stringer 106 and bottom stringer 107 are disposed between the first and second side panels 108, 109 in order to define the interior 112 of the central portion 101. As such, the second embodiment of the insulated beam 100 does not comprise runners 110, 111. The first and second side panels 108, 109 may be secured to the top and bottom stringers 106, 107 by gluing and/or nailing. The top stringer 106, first side panel 108, and second side panel 109 are substantially aligned so as to define the top surface 113 of the central portion 101. Likewise, the bottom stringer 107, first side panel 108, second side panel 109, first support portion 102 and second support portion 103 are substantially aligned so as to define the bottom surface 116 of the insulated beam 100. In other embodiments the bottom stringer 107 may not be aligned with the first support portion 102 and second support portion 103 such that only the bottom stringer, first side panel 108 and second side panel 109 define the bottom surface configured to rest upon a foundation of a building. The top stringer 106, bottom stringer 107, first side panel 108 and second side panel 109 are typically composed of a lightweight, penetrable material such as timber, oriented strand board, or plywood.

In both of the embodiments of the insulated beam 100 described above, the interior 112 is filled with a thermally insulating material configured to substantially impede heat transfer through the central portion 101. The thermally insulating material of the interior 112 may be, for example polyurethane, polyisocyanurate, or polystyrene. The thermally insulating material may be injected into the interior 112 as a liquid such that it fills the entire of the interior 112 before setting to form a solid, or it may be manufactured as one or more solid pieces and placed into the interior 112. It will be appreciated that, in these examples, the solid nature of the thermally insulating material substantially prevents transfer of heat through the insulated beam 100 by convection, and as such any heat transfer through the insulated beam 100 is primarily due to conduction.

The thermal transmittance of a construction material is typically given in terms of that material’s lambda-value, measured in W.m"1.K"1. The thermally insulating material preferably has a lambda-value of 0.03 W.m"1.K"1. The thermal transmittance of the insulated beam 100 may be given in terms of the beam’s U-Value, measured in W.m" 2.K"1. The U-value of the insulated beam 100 is preferably such that a floor comprising the insulated beam 100 meets the requirements of the relevant building regulations in the territory concerned. It will be appreciated that the thermal transmittance of the insulated beam 100 is lower than the thermal transmittance of alternative beams such as concrete beams. As such, less heat will be transferred through the insulated beam 100 and therefore heat loss in a building containing a flooring system incorporating the insulated beam 100 will be reduced.

Although not shown, it will be appreciated that the insulated beam 100 defines a longitudinal axis which runs normal to the plane of the cross-section of Figure 1. The insulated beam 100 further comprises ends which define the longitudinal extremes of the beam 100. The ends of the beam 100 may be capped by end pieces which further co-operate with the side panels 108,109 and the stringers 106,107 or the runners 110, 111 to define the interior 112.

The first support portion 102, second support portion 103, top stringer 106, bottom stringer 107, and end pieces are typically composed of timber. The first side panel 108 and second side panel 109 are typically composed of oriented strand board. The first and second runners 110, 111 may be composed of timber. It will be appreciated that because the exemplary materials of the insulated beam 100 given above are of a generally lightweight construction, the insulated beam 100 is easier to move and place than a beam for a flooring system composed of heavier materials such as concrete, or structurally reinforced concrete. The insulated beams 100 are therefore easier to handle than concrete beams, and therefore require fewer workers to move and place them.

Figure 3A shows schematic cross-sectional view of an insulated floor panel 200. The floor panel 200 may be for use within a flooring system comprising the insulated beams 100 described above, or the floor panel 200 may be laid directly upon the foundations of a building (i.e. without the need for supporting beams). The insulated floor panel 200 is formed as a generally rectangular prism, and defines a longitudinal axis running generally normal to the plane of the cross-section of Figure 3A. The insulated floor panel 200 comprises an insulation portion 201 composed of a thermally insulating material configured to substantially impede the transfer of heat through the insulated floor panel 200. The insulated floor panel 200 comprises an upper protection layer 202 and a lower protection layer 203 which substantially cover an upper and a lower face of the insulated floor panel 200 respectively, so as to substantially mask the upper and lower faces of the insulation portion 201. The protection layers 202, 203 each comprise two longitudinally extending flange portions (202a, 202b, 203a, 203b) that are bent around a longitudinally extending edge of the floor panel 200. The protection layers 202, 203 may be joined to the insulation portion by auto-bonding of the thermally insulating material to the protection layers 202, 203 or alternatively by adhesive.

The insulated floor panel 200 further comprises a first support member in the form of a first side beam 204, and a second support member in the form of a second side beam 205 arranged on a substantially opposite side of the insulation portion 201 to the first side beam 204. The first and second side beams 204, 205 are disposed between the upper and lower protection layers 202, 203 and are configured to substantially cover two longitudinally extending sides of the insulated floor panel 200 respectively. The longitudinally extending flanges of the protection layers 202, 203 are bent around the side beams 204, 205 such that the side beams 204, 205 and insulation portion 201 are encompassed within a space bounded by the protection layers 202, 203. The protection layers 202, 203 may be joined to the first and second side beams 204, 205 by auto-bonding of the thermally insulating material to the side beams 204, 205 or alternatively by gluing and/or nailing.

The side beams 204, 205 are preferably composed of a high strength and lightweight construction material such as timber. It will be appreciated that because timber is a relatively lightweight material compared to other construction materials such as concrete or steel, the floor panel 200 is also lightweight. As such, it will be appreciated that the floor panel 200 may be easily handled by one or two workers. In contrast, heavy floor panels composed of concrete or steel may require a team of people or mechanical handling to move them. Furthermore, timber is cheaper to produce than alternative materials such as concrete or steel, and has lower associated C02 emissions.

The thermally insulating material of the insulation portion 201 may be the same material as the thermally insulating material of the insulated beam 100 (i.e. polyurethane, polyisocyanurate, or polystyrene). The overall U-Value of the insulated floor panel 200 is preferably less than 0.30 W.m'2.K'1, or more preferably the overall U-Value of the floor panel 200 is such that a floor comprising the floor panel 200 meets the requirements of the relevant building regulations in the territory concerned.

The upper protection layer 202 and lower protection layer 203 are preferably formed of an impermeable material configured to substantially impede or prevent moisture ingress into the insulation portion 201 and side beams 204, 205. It will be appreciated that moisture which is absorbed into the insulation portion 201 and side beams 204, 205 may have a detrimental effect on the thermally insulating properties of the floor panel 200 (i.e. the floor panel 200 may transmit more heat). It will further be appreciated that where the floor panel 200 is to be used within a building, it is preferable to prevent moisture ingress from the ground and foundations of the building through the floor panel 200 and into the building itself. As such, the floor panel 200 may be used to aid damp-proofing of the building.

It is also preferred that the upper and lower protection layers 202, 203 are formed of an impact-resistant material configured to prevent damage to the insulation portion. It will be appreciated that the term “impact-resistant material” is intended to mean a material suitable for preventing accidental damage to the insulation portion 201. However, such an impact-resistant material may be a material that is suitable for penetration by a screw or nail so as to secure the upper and lower protection layers 202, 203 to the floor panel 200, although it should be noted that the protection layers 202, 203 may be secured to the insulation portion 201 by auto-bonding of the thermally insulating material to the protection layers 202, 203. An example material for the upper and lower protection layers 202, 203 that is both impermeable and impact-resistant may be a metal such as aluminium or steel. Alternatively, the upper and lower protection layers 202, 203 may be formed of a glass-reinforced plastic or any appropriate impermeable material.

It will be appreciated that although the upper and lower protection layers 202, 203 are described as being both impermeable and impact-resistant, the upper and lower protection layers 202, 203 may be formed of any substantially impermeable material. Alternatively, the upper and lower protection layers 202, 203 may be formed from a combination of an impermeable material and an impact resistant material, such as, for example, oriented strand board or plywood that is coated or wrapped with a layer of polythene. It will be appreciated that the impermeable material may be impermeable to gas and/or moisture.

During normal use, the floor panel 200 may be supported at longitudinally opposite ends of the floor panel 200 by a portion of the foundations of a building. A plurality of floor panels 200 may be laid side by side to substantially cover an entire footprint of the building so as to form a continuous section of floor. It will be appreciated that during such use, the side beams 204, 205 are configured to provide structural support to the floor panels 200. It will be appreciated that the protection layers 202, 203 may also provide some structural support to the floor panel 200; however protection layers 202, 203 mainly function to prevent moisture ingress into the floor panel 200 and to prevent damage to the insulation portion 201.

It will be appreciated that whilst the side beams 204, 205 provide most of the structural support to the floor panel 200, the floor panel 200 may comprise further or alternative structural elements that are configured to provide structural support to the floor panel 200. For example, the floor panel 200 may additionally comprise a central beam separating the insulation portion 201 into two separate insulation portions. It will be appreciated that whilst the structural supports (i.e. the beams 204, 205) of the floor panel 200 may be arranged in in alternative ways, it is desirable that the structural supports are encompassed within a space bounded by the protection layers 202, 203.

Figure 3B shows a schematic perspective view of an alternative embodiment of the floor panel 200. The side beams 204, 205 of the floor panel 200 comprise extension portions 206 which extend beyond the insulation portion 201 and protection layers 202, 203 in a longitudinal direction. The extension portions 206 are configured for support by a foundation of a building. For example, the extension portions 206 may be supported within apertures formed in between bricks of a masonry wall. As such, the extension portions 206 may extend beyond the insulation portion 201 and protection layers 202, 203 in a longitudinal direction by an amount sufficient for the extension portions 206 to be accommodated by the apertures of the masonry wall. The extension portions 206 may each be accommodated by a damp proof shoe, the extension portions and corresponding shoes being accommodated by the corresponding aperture of the wall. Alternatively or additionally, the extension portions 206 may be wrapped with a damp proof membrane to substantially prevent moisture ingress into the timber side beams 204, 205.

In some embodiments, the insulated floor panel 200 of Figure 3A (i.e. not comprising extension portion 206) may be modified after manufacture to include extension portions. For example, two further support members in the form of elongate timber beams may be connected in any appropriate manner (e.g. by gluing or using nails, screws or other fixings) to the floor panel 200 such that the support members run longitudinally along the floor panel 200 adjacent the side beams 204, 205 (e.g. along the sides of the floor panel or along the upper and lower protection layers). The two further support members may be sized such that they extend beyond the floor panel 200 to define extension portions configured for support by a foundation of a building or within apertures defined in between bricks of a masonry wall.

Figure 4 shows a schematic cross-sectional view of a flooring system 300. The flooring system 300 comprises a plurality of insulated beams 100 and a plurality of floor panels 200. In use, the plurality of insulated beams 100 are spaced apart from one another, as shown, such that the insulated beams 100 run parallel to one another in order to form a grill-like pattern between the foundations of a building. The insulated beams 100 are spaced wide enough such that a floor panel 200 of the flooring system may be partially supported upon a first support surface 114 of a first insulated beam 100(1) and partially supported upon a second support surface 115 of a second insulated beam 100(2). In particular, the floor panels 200 are supported upon the first and second support surfaces 114, 115 within a space defined between a first side 104 of the first insulated beam 100 and a second side 105 of the second insulated beam 100. The insulated beams 100 are supported at either end upon a part of a foundation 400 of the building via the bottom surface 116 (see Figure 5).

It will be appreciated that when the floor panels 200 are placed upon the first and second support portions 102,103 a top surface 206 of the floor panels 200 is level with the top surface 113 of the insulated beams 100. It is desirable that the floor panels 200 are aligned with the top surfaces 113 of the insulated beams 100 to define a level surface upon which a flooring layer 301 may be laid.

Referring back to Figures 1 to 3, the central portion 101 of the insulated beam 100 defines a height A, the first and second support portions 102, 103 of the insulated beam 100 define a height B, and the insulated floor panels 200 define a height C. As such, the height A is equal to the sum of the height B and the height C. For example, the height A of the central portion 101 may be 295 mm, the height B of the support portions 102, 103 may be anywhere generally within the range 50 mm - 250 mm, and the height C of the floor panels 200 may be anywhere generally within the range 245 mm - 45 mm. It will be appreciated that where the insulated floor panels 200 are used independently of the insulated beams 100, the height C of the floor panels 200 is not dependent upon the height A of the insulated beam 100 or the height B of the support portions 102,103. Such an arrangement is described below with respect to Figure 5.

In the embodiment shown in Figure 4, the plurality insulated beams 100 are spaced apart from one another at regular intervals. However, it will be appreciated that the spacing of the plurality of insulated beams 100 is dependent upon a width D (see Figure 3A) of the floor panels 200. In particular, the spacing between the insulated beams 100 is equal to the sum of the width D of the floor panels 200 and a width F (see Figures 1 and 2) of the central portion 101 of the insulated beams 100. The width F of the central portions 101 of the insulated beams 100 is preferably 70 mm, and the width D of the insulated floor panels may be anywhere generally within the range 350 mm - 650 mm. It will be appreciated that the spacing between the insulated beams may additionally include a clearance to allow the floor panels 200 to be inserted between the insulated beams 100. Furthermore, it will be appreciated that the spacing between the insulated beams 100 may vary between each pair of insulated beams depending upon the width D of the particular floor panel 200 disposed between the insulated beams 100 and as such the insulated beams 100 may be spaced at irregular intervals.

Once all of the floor panels 200 have been placed upon the support portions 102, 103 of the insulated beams 100, a flooring layer 301 is laid over the insulated beams 100 and floor panels 200. The flooring layer 301 is typically composed of oriented strand board, chipboard, plywood, or any suitable floor finish. The flooring layer 301 may additionally comprise a non-slip coating 302 on an upper side of the flooring layer 301, configured to provide high-friction contact between the flooring layer 301 and a floor covering placed on top of the flooring layer 301. The flooring layer 301 may be configured to provide extra grip for workers using the floor before the floor covering is applied. Additionally or alternatively, the flooring layer 301 may comprise a non-slip coating (not shown) on a lower side of the flooring layer 301, configured to provide high-friction contact between the top surfaces 113 of the insulated beams 100 and flooring layer 301, and the top surfaces 206 of the floor panels 200. The flooring layer 301 typically has a thickness of about 18 to 22 mm, and therefore the flooring system 300 defines a total height E which is typically about 313 to 317 mm. It will be appreciated that the non-slip coating 302 is an optional feature of the flooring layer 301. That is to say, the flooring layer 301 may or may not comprise a non-slip coating 302.

The top stringer 106, first side panel 108 and second side panel 109 of the insulated beams 100 are composed of fixing-penetrable materials, such as for example timber, oriented strand board or plywood etc. Likewise, the floor panels 200 and flooring layer 301 are also composed of fixing-penetrable materials such as those described above. As such, the flooring layer 301 may be joined to the insulated beams 100 and floor panels 200 using appropriate fixings such as nails or screws. This is advantageous in comparison to beams and panels composed of brittle materials (i.e. non-fixing-penetrable materials), such as concrete, which often require a layer of screed be applied above the beams and panels to complete the floor because a flooring layer cannot be fixed in place using fixings. It will be understood that applying the layer of screed and allowing it to set requires considerably more time than fixing (e.g. nailing and/or screwing) of the flooring layer 301 to the insulated beams 100 and/or floor panels 200. Alternatively or additionally, the flooring layer 301 may be joined to the insulated beams 100 and floor panels 200 by gluing.

The floor panels 200 of the flooring system 300 are preferably the insulated floor panels 200 shown in Figure 3 and described above, although it will be appreciated that the floor panels 200 may be any floor panel configured for receipt between the insulated beams 100. In particular, the floor panels 200 may be composed of a solid block of thermally insulating material (i.e. not comprising upper and lower layers 202, 203 or side pieces 204, 205). Alternatively, the floor panels 200 may be uninsulated floor panels which do not comprise a portion of thermally insulating material.

Figure 5 shows a schematic cross-sectional side view of a portion of an insulated beam 100 and a foundation 400 of a building. The foundation 400 comprises an outer layer 401 and an inner layer 402 separated by a small gap of approximately 50 mm (although, of course, there may be any appropriate spacing). The outer layer faces the outside of the building of which the foundation forms part, whereas the inner layer faces the inside of the building. The outer and inner layers 401, 402 are typically composed of bricks, although it will be appreciated that the outer and inner layers 401, 402 of the foundation 400 may be composed of alternative materials such as, for example, concrete. The inner layer 402 defines a ledge 403 configured to support an end of the insulated beam 100. As described above with respect to Figure 4, the insulated beam 100 is supported at an opposite end by a separate similar part of the foundations 400 of the building.

The foundation 400 defines a distance G, typically between 150 and 300 mm, measured between the ledge 403 of the inner layer and a top surface 405 of the outer layer 401. As described above, the insulated beam 100 defines a height A which is preferably 295 mm. As such, if the beam 100 is rested directly on the ledge 403, the top surface 113 of the central portion 101 of the insulated beam 100 (and the top surface 206 of a floor panel 200 supported by the beam 100) will typically rest 5 mm lower than the top surface 405 of the outer layer 401 of the foundation 400. It is desirable that the top surfaces 113, 206 and 405 are substantially aligned, and therefore a shim 404 is inserted between the insulated beam 100 and the ledge 403 in order to increase the height of the insulated beam 100 relative to the top surface 405 of the outer layer 401 of the foundation 400. In this way, the top surfaces 113, 206 and 405 of the insulated beam 100, floor panel 200 and outer layer 401 of the foundation 400 respectively may be substantially aligned.

It will be appreciated that the distance G between the top surface 405 and the ledge 403 may vary due to construction differences of the foundation 400 between different buildings, or even at different parts of the foundation 400 within the same building. As such, shims 404 of different thicknesses may be used to ensure that the top surfaces 113, 206 and 405 of the insulated beam 100, floor panel 200 and foundation 400 respectively are substantially aligned. It is therefore desirable that the height A of the insulated beam 100 is smaller than the distance G between the top surface 405 and the ledge 403 of the foundation 400, so that the flooring system 300 can be raised up using the shims 404 to account for any misalignment between the top surfaces 113, 206 and 405 of the insulated beam 100, floor panel 200 and foundation 400 respectively. Once the top surface 405 and the flooring surface 300 are aligned, a wall of the building (not shown) may be constructed upon the foundation 400.

It will be appreciated that the distance G between the top surface 405 of the outer layer 401 and the ledge 403 of the inner layer 402 may be dependent upon the construction materials used to create the outer layer 401. In particular, the distance G may depend upon the number of courses of bricks which are used to construct the outer layer 401. For example, the distance G described above is 300 mm, which is approximately equal to a height typically defined by four courses of bricks and mortar (standard sized British bricks with 10mm mortar joints). Alternatively the distance G may be 225 mm (equivalent to three courses of bricks) or 150 mm (equivalent to two courses of bricks).

It will be appreciated that where the floor panels 200 are laid upon the foundations 400 of a building without the insulated beams 100, the height C of the floor panel 200 may be dependent upon the distance G between the top surface 405 and the ledge 403 of the foundations 400. That is to say, the height C of the floor panel 200 may be equivalent to the height of any appropriate number of courses of bricks. The height C of the floor panel 200 may be between about 150mm and about 300mm inclusive. It will be appreciated that values of the dimensions A-G described above are examples only, and are not intended to limit the scope of the claimed invention.

Figure 5 shows a flooring system in which insulated beam 100 is supported by the foundation 400, the insulated beam then supporting one or more floor panels 200. In other embodiments of flooring system according to the present invention the insulated beams 100 can be omitted, such that the flooring system includes a plurality of floor panels 200 (such as those shown in either Figures 3A and 3B) supported by the foundation in a side-to-side manner.

Figures 6A and 6B show alternative embodiments of a floor panel 250a, 250b for use with the flooring system of the present invention. The floor panels 250a, 250b comprise an insulation portion 251 formed as a generally elongate member composed of a thermally insulating material such as polyurethane, polyisocyanurate, or polystyrene. The thermally insulating material of the insulation portion 251 may be the same material as the thermally insulating material of the insulated beam 100. The overall U-Value of the insulated floor panel 250 is preferably less than 0.30 W.rrf2.K'1, or more preferably the overall U-Value of the floor panel 200 is such that a floor comprising the floor panels 250a, 205b meets the requirements of the relevant building regulations in the territory concerned.

The insulation portion 251 is disposed between an upper layer 252 and a lower layer 253, the upper and lower layers 252, 253 being configured to substantially cover the insulation portion 251 and prevent damage to the thermally insulating material. The upper layer 252 and lower layer 253 are further connected to a pair of inner beams 254 disposed between the upper and lower layers 252, 253 on substantially opposite sides of the central portion 251. The inner beams 254 run substantially parallel to the central portion 251 and are configured to provide structural support to the floor panels 250a, 250b. The upper and lower layers 252, 253 may be composed of oriented strand board or plywood, and the inner beams 254 may be composed of timber. Alternatively, the upper and lower layers 252, 253 may be composed of a metallic material such as aluminium or steel. The upper and lower layers 252, 253 and inner beams 254, 253 may be secured to the insulation portion 251 by auto-bonding of the thermally insulating material. Alternatively, the upper and lower layers 252, 253 and the inner beams 254 may be connected in any appropriate manner, e.g. by nailing, screwing and/or gluing.

The floor panels 250a, 250b further comprise a first side portion 261 and a second side portion 262 arranged at substantially opposite sides of the insulation portion 251. The first and second side portions 261, 262 are formed as generally elongate beams and are typically composed of timber. The first and second side portions 261, 262 each comprise a bottom surface 264, and may be connected to the inner beams 254 by nailing and/or gluing. According to the embodiment shown in Figure 6A, the bottom surfaces 264 are substantially aligned with an outer surface of the lower layer 253. Alternatively, as shown in Figure 6B, the lower layer 253 may be configured to substantially cover both the insulation portion 251 and the first and second side portions 261, 262 such that the bottom surfaces 264 (as well as bottom surfaces of the inner beams 254) contact the lower layer 253 (in particular an inner surface of the lower layer 253).

It will be appreciated that the upper and lower layers 252, 253 of the floor panels 250a, 250b may comprise flange portions such as those described with reference to Figure 3A. For example, in the floor panel 250a of Figure 6A, the flange portions may be bent around the inner beams 254 such that the flange portions are disposed between the side portions 261,262 and the inner beams 254. Put another way, in the floor panel 250a shown in Figure 6A, the upper layer 252, lower layer 253, inner beams 254 and insulation portion 251 may be replaced by a floor panel 200 of the type shown in Figure 3A. Alternatively, in the floor panel 250b of Figure 6B, the flange portions of the lower layer 253 may be bent around the side portions 261,262.

The side portions 261,262 each define a top surface 263 generally aligned with a top surface 263 of the other of the side portions 261, 262. The side portions 261, 262 each define a height such that the top surfaces 263 are vertically spaced from the upper layer 252 of the floor panels 250a, 250b. In a first orientation of the floor panels 250a, 250b, the top surfaces 263 are configured to support a flooring layer such as a plywood, oriented strand board, or chipboard deck (not shown); and the lower layer 253 and/or the bottom surfaces 264 are configured to rest upon a foundation of a building (e.g. end portions of each bottom surface 264 resting upon a ledge formed by an inner layer of a foundation in a similar manner to that discussed above). Alternatively, in a second orientation of the floor panels 250a, 250b, the top surfaces 263 are configured to rest upon a foundation of a building (e.g. again, end portions of each top surface 263 resting upon a ledge formed by an inner layer of a foundation in a similar manner to that discussed above), and the bottom surfaces 264 and/or the lower layer 253 is configured to support a flooring layer. That is to say, the second orientation of the floor panels 250a, 250b is when the floor panels 250a, 250b are placed upside-down upon a foundation of a building, with a flooring layer laid above.

The side portions 261, 262, upper layer 252 and flooring layer cooperate to define a region of empty space, hereinafter referred to as void 260, located adjacent to the insulation portion 251. The void 260 is configured to trap air, and therefore acts to provide a further layer of insulation for the floor panels 250a, 250b. In some embodiments, an underfloor heating system may be installed within the void 260, the underfloor heating system being configured to transfer heat into a building within which the floor is constructed. In such embodiments the void 260 may receive a further layer of insulating material positioned above the upper layer 252 so as to reduce the distance between the underfloor heating system and the flooring layer (i.e. when the floor panel is assembled in the first orientation). The underfloor heating system may be of any suitable kind known in the art, for example a system which comprises piping configured to transfer a heated fluid beneath the flooring layer. In some embodiments the void may also provide a space within which pipework and/or cabling for utility supply and/or waste extraction can be located.

Figure 7 shows a flooring system 500 according to an embodiment of the present invention. The flooring system 500 comprises a plurality of elongate rectangular joists 510 configured to support a plurality of floor panels 520. Each of the joists 510 defines a longitudinal axis (not shown - perpendicular to the plane of the figure) and is composed of two substantially identical timber beams 511,512. The timber beams 511, 512 are generally rectangular in cross-section and are joined together by gluing along an interface between the beams 511,512 which runs parallel to the longitudinal axis.

Each timber beam 511, 512 has a grain direction, defined by the orientation of natural fibres from which the beams are composed. It will be appreciated that the arrangement of these natural fibres may result in twisting or warping of the timber beams 511, 512, and that such twisting or warping may be likely to increase as the beams age, become weathered, or absorb moisture. As such, although the beams 511, 512 above are described as being substantially identical (i.e. uniform in shape), in reality each of the beams 511,512 is likely to be slightly twisted or warped (or become slightly twisted or warped due to environmental conditions) due to the arrangement of the natural fibres within the beam. Within the flooring system 500, each of the timber beams 511, 512 within the joists 510 are arranged such that the grain directions of adjacent beams substantially oppose one another. As such, this enables the warping or twisting of one of the timber beams 511, 512 to work against and substantially oppose the warping or twisting of the other of the timber beams 511, 512. It will therefore be appreciated that the overall warping or twisting of the joists 510 may be substantially reduced in comparison to a joist formed of only a single timber beam.

As discussed above, it will be appreciated that the twisting or warping of the timber beams 511, 512 of the joists 510 may be exacerbated by the beams absorbing moisture. This may occur, for example, when the joists 510 are stored outdoors on a building site where they may be exposed to rain. In order to prevent the absorption of moisture by the joists 510, the joists 510 are provided with a substantially waterproof protection layer 513 arranged to surround the timber beams 511, 512 about the longitudinal axis of the joists 510. The protection layer may be composed of any substantially waterproof material, for example polythene.

The floor panels 520 are supported by the plurality of joists 510. Each of the floor panels 520 rests upon an upper surface 514 of the joists 510; the upper surfaces 514 of the joists 510 being aligned such that they are generally coplanar. Each of the joists 510 further comprises a lower surface 515 configured to rest upon a foundation of a building (not shown - for example, end portions of each lower surface 515 resting upon a ledge formed by an inner layer of a foundation in a similar manner to that discussed above). The floor panels 520 comprise an inner portion 521 formed of a thermally insulating material, such as for example polystyrene, polyisocyanurate, or polyurethane. The floor panels 520 further comprise an upper layer 522, and a lower layer 523 which are typically formed of a hardwearing, durable material such as oriented strand board or plywood. The upper and lower layers 522 and 523 sandwich the inner portion 521. The lower layer 523 rests upon the upper surfaces 514 of the joists 510 to support the floor panel 520.

Each floor panel 520 comprises first and second substantially opposite sides defining a tongue and groove arrangement configured to join adjacent floor panels 520 within the flooring system 500. A first side 524 of the floor panel 500 comprises a tongue portion, formed as a raised (or protruding) portion of the first side 524, which is configured to be received by a corresponding groove portion formed as a recess within a second side 525 of an adjacent floor panel 520. The floor panels 520 are arranged such that the join formed between the adjacent floor panels 520 runs generally parallel to the longitudinal axis of the joists 510. In the embodiment shown in Figure 6, the joins formed between the adjacent floor panels 520 are substantially aligned along a centreline of the joists 510 (i.e. vertically above the interface between the timber beams 511, 512). However, it will be appreciated that the join between the floor panels 520 may be offset from the centreline of the joists 510. For example, the join maybe located between a pair of joists 510.

While several embodiments of the present invention have been described above, it will be appreciated that modifications or alterations may be made to those embodiments without departing scope of the present invention.

Claims

CLAIMS:

1. An insulated floor panel for support by a foundation of a building formed as a generally elongate cuboid defining a longitudinal axis, the floor panel comprising: an insulation portion formed of a thermally insulating material configured to substantially impede heat transfer through the floor panel; a longitudinally extending support member configured to support the floor panel; and a protection layer configured to substantially mask an elongate face of the floor panel.

2. An insulated floor panel according to claim 1, wherein the support member is an elongate timber beam.

3. An insulated floor panel according to any preceding claim, wherein a portion of the support member extends longitudinally beyond the insulation portion, and wherein the portion of the support member which extends longitudinally beyond the insulation portion is configured for support by a foundation of a building.

4. An insulated floor panel according to any preceding claim, wherein the support member is a first support member and wherein the floor panel further comprises a second longitudinally extending support member configured to support the floor panel.

5. An insulated floor panel according to claim 4, wherein the first and second support members are arranged either side of the insulation portion.

6. An insulated floor panel according to any preceding claim, wherein the thermally insulating material is polyurethane, polystyrene, or polyisocyanurate.

7. An insulated floor panel according to any preceding claim, wherein the protection layer is configured to substantially mask a lower face of the floor panel, such that, in use, the protection layer is supported by the foundation of the building.

8. An insulated floor panel according to any preceding claim wherein the protection layer is formed of a substantially impermeable material.

9. An insulated floor panel according to claim 8, wherein the protection layer is composed of a metallic material.

10. An insulated floor panel according to any preceding claim, wherein the protection layer comprises a bent flange portion which is bent around an edge of the support member.

11. An insulated floor panel according to any preceding claim, wherein the protection layer is a first protection layer, and wherein the panel further comprises a second protection layer configured to mask a further elongate face of the floor panel.

12. An insulated floor panel according to claim 11, wherein the first and second protection layers are arranged on opposite sides of the floor panel such that the insulation portion is located between the first protection layer and the second protection layer.

13. An insulated floor panel according to any preceding claim, wherein the floor panel is configured for support by the foundation of the building at first and second opposite ends of the floor panel, the first and second ends being longitudinally spaced from one another.

14. An insulated floor panel according to any preceding claim, wherein the insulated floor panel is configured to be at least partially supported by a beam of a flooring system.

15. A method of constructing a floor, wherein the method comprises supporting an insulated floor panel according to any preceding claim upon a foundation of a building.

16. The method of claim 15 further comprising, supporting the insulated floor panel upon the foundation of the building at first and second substantially opposite ends of the floor panel, the first and second ends being longitudinally spaced from one another.

17. The method of either claim 15 or 16, further comprising supporting a plurality of insulated floor panels according to any of claims 1 to 14 upon a foundation of a building.

18. An insulated beam for a flooring system, the insulated beam comprising: a central portion; and a first support portion; wherein the insulated beam is formed as a generally elongate member defining a longitudinal axis; wherein the first support portion projects from the central portion in a direction generally perpendicular to the longitudinal axis, the first support portion configured to at least partially support a floor panel of the flooring system; and wherein the central portion includes an insulation portion composed of a thermally insulating material configured to substantially impede heat transfer through the insulated beam.

19. An insulated beam according to claim 18, wherein the central portion has a height perpendicular to the longitudinal axis and wherein the first support portion extends away from the central portion in a direction which is generally perpendicular to the height of the central portion.

20. An insulated beam according to either claim 18 or 19 wherein the first support portion defines a support surface configured to at least partially support the floor panel of the flooring system.

21. An insulated beam according to claim 20 wherein the central portion has a height perpendicular to the longitudinal axis and wherein the support surface extends in a direction which is generally perpendicular to the height of the central portion.

22. An insulated beam according to any of claims 18 to 21, wherein the first support portion is formed of a longitudinally extending member.

23. An insulated beam according to any of claims 18 to 22, wherein the central portion defines a length of the insulated beam, and wherein the first support portion extends along the whole of the length of the insulated beam.

24. An insulated beam according to any of claims 18 to 23, wherein the central portion and the support portion are formed as separate members

25. An insulated beam according to any of claims 18 to 24, wherein the support portion and the central portion are substantially aligned so as to define a bottom surface configured to rest upon a foundation of a building.

26. An insulated beam according to any of claims 18 to 25, wherein the support portion is a first support portion and wherein the insulated beam further comprises a second support portion substantially identical to the first support portion, the second support portion configured to at least partially support a further floor panel of the flooring system.

27. An insulated beam according to claim 26, wherein the second support portion projects from the central portion in a direction substantially opposite to that in which the first support portion projects from the central portion.

28. An insulated beam according to any of claims 18 to 27, wherein the central portion further comprises: a top stringer arranged along a top surface of the central portion; a bottom stringer arranged along a bottom surface of the central portion; a first side panel arranged along a first side of the central portion; and a second side panel arranged along a second side of the central portion substantially opposite the first side of the central portion; wherein the top stringer, the bottom stringer, the first side panel, and the second side panel cooperate to define an interior of the central portion.

29. An insulated beam according to claim 28, wherein the interior of the central portion comprises the portion of thermally insulating material.

30. An insulated beam according to any of claims 18 to 29 wherein the insulated beam is configured to support a floor panel according to any of claims 1 to 14.

31. An insulated floor panel comprising: first and second longitudinally extending support members; and an insulation portion comprising a thermally insulating material disposed between the first and second support members; wherein the first and second support members define a region of empty space disposed between the first and second support members and adjacent the insulation portion.

32. A flooring system comprising: an insulated beam according to any of claims 18 to 30; and a floor panel; wherein the floor panel is at least partially supported by the insulated beam.

33. A flooring system according to claim 32, wherein the floor panel is a first floor panel and wherein the flooring system further comprises a second floor panel.

34. A flooring system according to claim 33 when indirectly dependent on claim 26, wherein the second floor panel is at least partially supported by the second support portion of the insulated beam.

35. A flooring system according to claim 34, wherein the second floor panel is supported on a substantially opposite side of the central portion to the first floor panel.

36. A flooring system according to any of claims 32 to 35, wherein the flooring system comprises a plurality of insulated beams, and wherein the floor panel is at least partially supported by a first insulated beam of the plurality of insulated beams and is at least partially supported by a second insulated beam of the plurality of insulated beams.

37. A flooring system according to any of claims 32 to 36, wherein the floor panel is a floor panel according to any of claims 1 to 14.

38. A method of constructing a floor, wherein the floor comprises: a plurality of insulated beams according to any of claims 18 to 30; wherein the method comprises arranging the plurality of insulated beams to define a plurality of spacings between adjacent beams; and supporting a floor panel within each spacing.

39. A method of constructing a floor according to claim 38, wherein the floor panel is a floor panel according to any of claims 1 to 14.

40. A flooring system comprising: a joist formed as an elongate member and defining a longitudinal axis; and a floor panel at least partially supported by the joist; wherein the joist comprises a substantially impermeable protection layer substantially surrounding the joist about the longitudinal axis.

41. A flooring system according to claim 40, wherein the joist is a multiple joist comprising a plurality of elongate timber beams arranged side by side and joined to one another, each timber beam contacting an adjacent timber beam along a contact surface which extends in a direction generally parallel to the longitudinal axis.

42. A flooring system according to claim 41, wherein each of the plurality of timber beams defines a grain direction, and wherein the plurality of timber beams are arranged such that the grain direction of each timber beam substantially opposes the grain direction of a timber beam to which it is joined.

43. A flooring system according to any of claims 40-42, wherein the protection layer is composed of polyethylene.

44. A flooring system according to any of claims 32-43, wherein the floor panel is an insulated floor panel comprising a portion of thermally insulating material.

45. A flooring system according to any of claims 32-44, wherein the flooring system comprises a plurality of floor panels and wherein each floor panel comprises a tongue arrangement arranged along a side of the floor panel and configured to connect the floor panel to a corresponding groove arrangement of an adjacent floor panel to form a join between the floor panels.

46. A flooring system according to claim 45, wherein the tongue and groove arrangements are formed by a portion of thermally insulating material of the respective floor panel.

47. A flooring system according to any of claims 45 or 46, wherein the floor panels are arranged such that the join between adjacent floor panels runs parallel to the longitudinal axis of the joist.