Sector - Energy, Fuel & Utilities

Can we improve the design of an age-old method of heating?

21 Jul 25

Underfloor heating has been a growing trend over the past two decades. Offering benefits such as enhanced home comfort, energy efficiency, and lower running costs, there has been an especially significant rise in the popularity of underfloor heating in the last ten years. Although floor heating systems as a concept have been around for centuries, notably existing in the Roman Era, the technology and mechanics behind the systems have adapted and evolved over time.

The innovations in system designs, materials and controls have drastically improved the performance and efficiency of underfloor heating, almost entirely eliminating the need for radiators for those who choose to install it.

Today, flooring panels, often created with channels for receiving heating conduits, are one of the most commonly used panel types in the construction of underfloor heating systems. However, there is a drawback to using such flooring panels, particularly when it comes to transportation. Each panel is made up of thicker and thinner areas and are susceptible to breakage during transport or installation, particularly in thinner regions of the panel close to the channels.

Minor damage to the panels may be easier to fix, but major damage such as a broken or cracked heating element could lead to system failure or cold spots on the floor. Damage to the flooring panels will ultimately lead to increased costs and delays on site.

To address this issue, a new flooring panel design is outlined in UK patent GB2628688B, which was granted to Wunda Group Plc in June 2025. The patent protects a flooring panel (14) in the form of a planar body (16) with an upper surface (16a) and a lower surface (16b). The body (16) includes channels (18) which form openings (20) in the upper surface (16a). A foil layer (24) is provided on the upper surface (16a) and spans the openings (20) of the channels (18). The foil layer (24) includes a series of perforations (26) adjacent to the openings (20) of the channels (18).

A diagram of a line drawing

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By having a foil layer (24) spanning the openings (20) of the channels (18), this improves the structural integrity of the panel (14) and reduces the risk of breakage below the channels (18) during transport and installation. Furthermore, once the panel (14) has been installed, heating conduits (C) can be pushed into the channels (18) by breaking the perforations (26). In this way, the foil layer (24) provides an improved structural integrity during transport and handling, without significantly impacting installation of the heating conduits (C).

This new patented design serves as a useful reminder that even in a well-established field such as underfloor heating, there is always the possibility to refine designs to improve durability and ease of installation. In some cases, this new design could give construction companies a competitive edge and reduce installation time and costs in the long run. Furthermore, by obtaining patent protection, the owner will have exclusive rights to the invention and the benefits derived from it for a period of 20 years.

Chris Hambley is a senior associate and patent attorney in the Advanced Engineering group at European IP firm, Withers & Rogers.