FLOOR PANEL FOR FORMING A FLOOR COVERING

Abstract

A floor panel for forming a floor covering, such that the floor covering includes floor panels, which, on at least one pair of edges, are provided with coupling parts. The coupling parts are substantially manufactured from the material of the floor panel. The coupling parts are configured such that two floor panels, at the pair of edges, can be installed and locked to each other by a downward movement and/or by using a fold-down principle.

Claims

1.-75. (cancelled)

76. A floor panel for forming a floor covering, wherein this floor panel comprises a first pair of opposite edges, and a second pair of opposite edges; wherein the first pair of opposite edges comprises coupling parts, which allow that two of such floor panels mutually can be coupled to each other, and wherein said coupling parts show the following characteristics: the coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges; the coupling parts also comprise a vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the coupling parts substantially are realized from the material of the floor panel itself; and wherein the second pair of opposite edges also comprises coupling parts on both edges, which allow that two of such floor panels mutually can be coupled to each other, wherein said coupling parts show the following characteristics: the coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges; the coupling parts also comprise a vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the coupling parts substantially are realized from the material of the floor panel itself; the horizontally active locking system of the second pair of edges is formed at least of an upward-directed lower hook-shaped part which is situated on one of said two edges, and a downward-directed upper hook-shaped part, which is situated on the opposite edge, wherein the upward-directed lower hook-shaped part consists of a lip with an upward-directed locking element, which proximally thereof defines a female part in the form of a recess, whereas the downward-directed upper hook-shaped part consists of a lip with a downward-directed locking element forming a male part; the coupling parts of the second pair of opposing edges are configured such that two of such floor panels can be coupled to each other at their respective edges by a downward movement involving a downward snapping movement—of the one floor panel in respect to the other; the vertically active locking system of the second pair of opposing edges comprises vertically active locking parts, which, by respective locking surfaces, define at least a first vertical locking zone and a second vertical locking zone, wherein in coupled condition of two such panels the first vertical locking zone is located at the distal end of the upward-directed locking element and wherein in coupled condition of two such panels the second vertical locking zone is situated at the distal end of the downward-directed locking element; wherein the aforementioned vertically active locking parts comprise a first locking part at the edge of the panel at the proximal end of the lip of the upper hook-shaped part, a second locking part at the distal end of the downward-directed locking element, and a third locking part at the distal end of the lip of the lower hook-shaped part and a fourth locking part at the proximal end of the female part; the first and third locking part, in the coupled condition of two of such floor panels, define said first vertical locking zone; the second and fourth locking part, in the coupled condition of two of such floor panels, define said second vertical locking zone.

77. The floor panel according to claim 76, wherein in coupled condition at the second pair of edges of two such floor panels, no vertical locking is provided between the proximal end of the downward-directed locking element and the proximal end of the upward-directed locking element and/or wherein the floor panel is configured such that the first vertical locking zone and the second vertical locking zone are the only zones where a vertical locking is provided in coupled condition of two such floor panels between the edges of the second pair of opposite edges.

78. The floor panel according to claim 76, wherein the first vertical locking zone is provided at least at ⅔ of the thickness of the floor panel from the surface of the floor panel.

79. The floor panel according to claim 76, wherein the angle between the proximal end of the downward-directed locking element and the horizontal direction in the proximal direction of the upper hook-shaped part is less than 90 and/or wherein the angle between the proximal end of the upward-directed locking element and the horizontal direction in the distal direction of the lower hook-shaped part is less than 90°.

80. The floor panel according to claim 76, wherein in coupled condition at the second pair of edges of two such floor panels, the proximal end of the downward-directed locking element contacts the proximal end of the upward-directed locking element.

81. The floor panel according to claim 76, wherein the second locking part is provided by a first undercut at the distal end of the downward-directed locking element; and wherein the fourth locking part is provided by a first protrusion at the proximal end of the female part.

82. The floor panel according to claim 81, wherein the included angle of the first protrusion is larger than the included angle of the first undercut.

83. The floor panel according to claim 81, wherein the first undercut has a triangular shape with rounded corner points.

84. The floor panel according to claim 81, wherein the first protrusion comprises two inclined outer surfaces with in between the two inclined outer surfaces a vertical surface, where the upper inclined surface is more inclined with respect to the surface of the floor panel than the lower inclined surface.

85. The floor panel according to claim 81, wherein the bottom of the first protrusion has an angle between 25° and 35° with the surface of the floor panel.

86. The floor panel according to claim 81, wherein the bottom of the first undercut has an angle between 25° and 35° with the surface of the floor panel.

87. The floor panel according to claim 81, wherein in coupled condition of two such floor panels at the second pair of opposite edges a first space is present between the coupled opposite edges below the contact between the bottom of the first protrusion and the bottom of the first undercut on the one hand and on the other hand distal to the distal end of the downward-directed locking element and wherein the first space continues into a second space between the bottom part of the downward-directed locking element and the upper part of the lip of the lower hook-shaped part.

88. The floor panel according to claim 76, wherein the first locking part is provided by a second protrusion at the proximal end of the downward directed upper hook-shaped part; and wherein the third locking part is provided by a third undercut at the distal end of the upward-directed locking element.

89. The floor panel as in claim 76, wherein a first vertical closing plane is provided at the edge of the second pair of opposite edges comprising the upward-directed lower hook-shaped part, wherein the first vertical closing plane is provided for making contact in coupled condition of two such floor panels with a second vertical closing plane of the corresponding edge of the coupled panel; wherein the ratio of the horizontal distance between the first vertical closing plane and the distal end of the lip comprising the upward-directed locking element over the thickness of the floor panel is less than 1.1.

90. The floor panel as in claim 88, wherein the upper surface of the second protrusion has an angle between 10 and 20° with the surface of the floor panel.

91. The floor panel as in claim 88, wherein the angle with the surface of the floor panel of the upper surface of the third undercut is between 5 and 15°.

92. The floor panel as in claim 88, wherein the angle with the surface of the floor panel of the upper surface of the third undercut is smaller than the angle with the surface of the floor panel of the upper surface of the second protrusion; the difference between these angles is at least 5°.

93. The floor panel according to claim 76, wherein the second vertical locking zone is provided in the bottom half of the thickness of the floor panel.

94. A floor panel as in claim 76, wherein the edge of the second pair of opposite edges comprising the upward-directed lower hook-shaped part comprises a first vertical closing plane; wherein the edge of the second pair of opposite edges comprising the downward-directed upper hook-shaped part comprises a second vertical closing plane; wherein the second vertical closing plane of the floor panel is provided for contacting the first vertical closing plane of another such floor panel with which the floor panel is coupled at its second pair of opposite edges, wherein in coupled condition the contact of the first vertical closing plane of the floor panel with the second vertical closing plane of the another such floor panel defines a closing plane; wherein when during the downward coupling movement of the floor panel relative to the another such floor panel the distal edge of the downward-directed locking element continuously contacts the proximal end of the opposing edge of the another such floor panel with which the floor panel is being coupled, at the moment the lowest point of the downward-directed locking element being moved downwards reaches the same height level as the highest point of the upward-directed locking element of the another such panel, the gap in horizontal direction and measured in the direction perpendicular to the second pair of opposite edges between the second vertical closing plane of the floor panel and the first vertical closing plane of the another such floor panel is less than 0.15 millimeter.

95. The floor panel as in claim 76, wherein the lip of the upward-directed lower hook-shaped part comprises a slit parallel with the surface of the panel and wherein the slit is towards the back of the panel delimited by a lower lip; and wherein the lower lip extends distally less than the distal end of the upward-directed locking element.

Description

[0119] With the intention of better showing the characteristics of the invention, herein below, as an example without any limitative character, some preferred embodiments are described, with reference to the accompanying drawings, wherein:

[0120] FIG. 1 schematically and in perspective represents a portion of a floor covering, which consists of floor panels according to an example of the invention;

[0121] FIG. 2, at a larger scale, represents the portion indicated by F2 in FIG. 1;

[0122] FIG. 3, in top view, represents a floor panel from the floor covering of FIGS. 1 and 2;

[0123] FIGS. 4 and 5, at a larger scale, represent cross-sections according to lines IV-IV and V-V, respectively, of FIG. 3;

[0124] FIG. 6 represents the coupling parts, which are visible in FIG. 4, at a larger scale in coupled condition;

[0125] FIG. 7 shows—in coupled condition—an alternative embodiment according to the invention for the coupling parts shown in FIG. 6;

[0126] FIG. 8 illustrates—in a view similar to FIG. 6—an embodiment of the invention;

[0127] FIG. 9 shows—in a view illustrating the downward movement of two panels for coupling these panels at their second pair of opposite edges—an embodiment of the invention;

[0128] FIG. 10 illustrates an embodiment of the invention;

[0129] FIG. 11 illustrates a feature that can be used advantageously in panels according to the invention.

[0130] As represented in FIGS. 1 and 2, the invention relates to floor panels (1) for forming a floor covering, which floor panels (1) comprise a first pair of opposite edges (2, 3), as well as a second pair of opposite edges (4, 5). The floor panels are rectangular and oblong.

[0131] The represented floor panels (1) are configured such at their edges that they can be mutually coupled according to the so-called fold-down principle, which is a principle known as such and which consists in that such floor panels (1) can be coupled to each other at the first pair of edges (2, 3) by means of a turning movement (R) and can be coupled to each other at the second pair of edges (4, 5) by means of a downward movement (M), wherein the downward movement (M) is the result of the turning movement (R) and thus substantially is realized simultaneously. Herein, the floor panels (1) are configured such that at their edges (2, 3) and (4, 5) a locking in vertical direction (V) as well as in horizontal direction (H) is obtained, this latter perpendicular to the respective edges.

[0132] As represented in FIGS. 3 to 6, such floor panel 1 can be provided with coupling parts (6, 7) at its first pair of edges (2, 3). At the second pair of edges (4, 5) coupling parts (8, 9) are also provided. The coupling parts will be described in greater detail in FIGS. 4 to 6.

[0133] As can be seen in FIG. 5, the coupling parts (6, 7) of the first pair of edges (2, 3) can show

[0134] at least the following characteristics:

[0135] the coupling parts (6, 7) comprise a horizontally active locking system (HL), which, in a coupled condition of two of such floor panels (1), effects a locking in the plane of the floor panels (1) and perpendicular to the respective edges (2, 3);

[0136] the coupling parts (6, 7) also comprise a vertically active locking system (VL), which, in a coupled condition of two of such floor panels (1), effects a locking transverse to the plane of the floor panels, in other words, in vertical direction;

[0137] the coupling parts (6, 7) substantially are realized of the material of the floor panel (1) itself; and

[0138] the coupling parts (6, 7) are configured such that two of such floor panels (1) can be coupled to each other at these edges by means of a turning movement (R).

[0139] The coupling parts (6, 7) at the first pair of opposite edges (2, 3) comprise a tongue (58) and a groove (59), and locking parts (62, 63). The vertically active locking system (VL) and the horizontally active locking system (HL) of the first pair of edges (2, 3) can be realized in any manner. Preferably, as shown in FIG. 5, for the vertically active locking system (VL) use can be made of a tongue (58) and a groove (59), which groove preferably is bordered by a lower lip (60) and an upper lip (61). For the horizontally active locking system, use can be made of locking parts (62, 63), which are provided at the tongue and the groove and which, in coupled condition, hook behind each other. It is preferred that the lower lip (60) distally extends to beyond the upper lip (61) and that the locking part (63) also shows a locking surface, which is situated beyond the distal end of the upper lip (61).

[0140] FIG. 4 represent the cross-section according to lines IV-IV of FIG. 3. FIG. 6 represents the coupling parts (8, 9) of the second pair of edges (4,5), which are visible in FIG. 4, at a larger scale, in coupled condition. The second pair of opposite edges (4-5) comprises coupling parts (8-9) on both edges, which allow that two of such floor panels (1) mutually can be coupled to each other. The coupling parts (8-9) comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels (1), effects a locking in the plane of the floor panels (1) and perpendicular to the respective edges (4-5). The coupling parts (8-9) also comprise a vertically active locking system, which, in a coupled condition of two of such floor panels (1), effects a locking transverse to the plane of the floor panels. The coupling parts (8-9) substantially are realized from the material of the floor panel (1) itself. The horizontally active locking system of the second pair of edges (4, 5) is formed at least of an upward-directed lower hook-shaped part (10) which is situated on one of said two edges (4), as well as a downward-directed upper hook-shaped part (11), which is situated on the opposite edge (5). The upward-directed lower hook-shaped part (10) consists of a lip (12) with an upward-directed locking element (13), which proximally thereof defines a female part (14) in the form of a recess, whereas the downward-directed upper hook-shaped part (11) consists of a lip (15) with a downward-directed locking element (16) forming a male part (17). The male part (17) is not split. The coupling parts (8-9) of the second pair of opposing edges (4,5) are configured such that two of such floor panels (1) can be coupled to each other at their respective edges (4-5) by means of a downward movement (M)—in the example involving a downward snapping movement—of the one floor panel in respect to the other. The vertically active locking system of the second pair of opposing edges (4,5) comprises vertically active locking parts (18-19-20-21), which, by means of respective locking surfaces (22-23-24-25), define at least a first vertical locking zone (C1) and a second vertical locking zone (C2). In coupled condition of two such panels the first vertical locking zone (C1) is located at the distal end of the upward-directed locking element (13); and the second vertical locking zone (C2) is situated at the distal end of the downward-directed locking element (16). The vertically active locking parts comprise a first locking part (18) at the edge of the panel at the proximal end of the lip (15) of the upper hook-shaped part (11), a second locking part (19) at the distal end of the downward-directed locking element (16), as well as a third locking part (20) at the distal end of the lip (12) of the lower hook-shaped part (10) and a fourth locking part (21) at the proximal end of the female part (14). The first and the third locking part (18, 20), in the coupled condition of two of such floor panels (1), define the first vertical locking zone (C1). The second and fourth locking part (19, 21), in the coupled condition of two of such floor panels (1), define said second vertical locking zone (C2).

[0141] In coupled condition at the second pair of edges (4,5) of two such floor panels (1), no vertical locking is provided between the proximal end of the downward-directed locking element (16) and the proximal end of the upward-directed locking element (13). More particularly, the floor panels (1) are configured such that the first vertical locking zone (C1) and the second vertical locking zone (C2) are the only zones where a vertical locking is provided in coupled condition of two such floor panels between the edges of their second pair of opposite edges (4,5).

[0142] The first vertical locking zone (C1) is provided at least at ⅔ of the thickness (T) of the floor panel from the surface of the floor panel.

[0143] In the exemplary embodiment shown in FIGS. 4 and 6, the angle (β) between the proximal end of the downward-directed locking element (16) and the horizontal direction in the proximal direction of the upper hook-shaped part (11) is 75°. The angle (γ) between the proximal end of the upward-directed locking element (13) and the horizontal direction in the distal direction of the lower hook-shaped part (10) is 75°.

[0144] In coupled condition at the second pair of edges (4,5) of two such floor panels, the proximal end of the downward-directed locking element (16) contacts the proximal end of the upward-directed locking element (13). The angle (α) of the contact between the proximal end of the downward-directed locking element (16) and the proximal end of the upward-directed locking element (13); and the horizontal direction in the direction towards the distal end of the upward-directed locking element (13) is 75°. In the example shown, the proximal end of the downward-directed locking element (16) contacts the proximal end of the upward-directed locking element (13) with pretension. Alternatively, embodiments are possible wherein the proximal end of the downward-directed locking element (16) contacts the proximal end of the upward-directed locking element (13) without pretension.

[0145] In the floor panels shown in FIGS. 4 and 6, the second locking part (19) is provided by a first undercut (27) at the distal end of the downward-directed locking element (16) and the fourth locking part (21) is provided by a first protrusion (28) at the proximal end of the female part (14). In coupled condition of two such floor panels (1) at the second pair of opposite edges (4,5), the bottom of the first undercut (27) contacts the bottom of the first protrusion (28).

[0146] In the exemplary embodiment, the included angle (β1) of the first protrusion (28) is larger than the included angle (β2) of the first undercut (27), in the example, β2 equals 84° and the angle β1 equals 90°. The first undercut (27) has a triangular shape with rounded corner points.

[0147] The bottom of the first protrusion (28) in the example is parallel with the surface of the floor panel; the bottom of the first undercut (27) is parallel with the surface of the floor panel. The bottom of the first undercut (27) is substantially parallel with the bottom of the first protrusion (28).

[0148] In coupled condition of two such panels at the second pair of opposite edges (4,5) a space (32) is present in horizontal direction between the distal end of the first protrusion (28) and the proximal end of the first undercut (27); and a space (33) is present between the top end of the first protrusion (28) and the top end of the first undercut (27). Both spaces (32, 33) form one continuous space.

[0149] The first protrusion (28) is provided at its panel edge below a first vertical closing plane (34) of its edge. The first vertical closing plane (34) is provided for making contact in coupled condition of two such floor panels with a second vertical closing plane (35) of the corresponding edge of the coupled panel. The first undercut (27) is provided below the second vertical closing plane (35). In coupled condition of two such floor panels at the second pair of corresponding edges (4,5), a closing plane (S) is provided by the first vertical closing plane (34) contacting the second vertical closing plane (35). The downwards extension of the closing plane (S) runs through the contact zone between the second and fourth locking part (19, 21). The intersection between the downwards extension of the closing plane (S) and the second vertical contact zone (C2) occurs within the middle quarter of the second vertical contact zone (C2).

[0150] At the proximal end of the female part (14), a second undercut (37) is provided above the first protrusion (28). The second undercut (37) is provided between the first protrusion (28) and the first vertical closing plane (34). The second undercut (37) is smaller than the first undercut (27).

[0151] In coupled condition of two such floor panels at the second pair of opposite edges (4,5) a first space (38) is present between the coupled opposite edges (4,5) below the contact between the bottom of the first protrusion (28) and the bottom of the first undercut (27) on the one hand and on the other hand distal to the distal end of the downward-directed locking element (16). The first space (38) continues into a second space (39) between the bottom part of the downward-directed locking element (16) and the upper part of the lip (12) of the lower hook-shaped part (10).

[0152] A section (40) of the distal end of the downward-directed locking element below the first undercut (27) extends in distal direction beyond the second closing plane (35).

[0153] The first locking part (18) is provided by a second protrusion (41) at the proximal end of the downward directed upper hook-shaped part (11). The third locking part (20) is provided by a third undercut (42) at the distal end of the upward-directed locking element (13). The bottom of the upward-directed locking element (13) comprises a fourth undercut (43), extending over substantially the full length of the upward-directed locking element (13). The height of the fourth undercut (43) increases continuously in the distal direction of the upward directed lower hook-shaped part (10). From the bottom of the floor panel, the third undercut (42) extends deeper into the panel than the fourth undercut (43). The third undercut (42) is divided from the fourth undercut (43) by a plane (44) making an angle (β5) of 90° with the horizontal direction of the floor panel.

[0154] The second protrusion (41) extends to the bottom of the floor panel.

[0155] A further undercut (45) is provided at the proximal end of the upper hook-shaped part (11) below the second undercut (37).

[0156] The upper surface of the second protrusion (41) has an angle (β6) 15° with the surface of the floor panel. The angle (β7) with the surface of the floor panel of the upper surface of the third undercut (42) is 10°. Thus, in this exemplary embodiment, the angle (β7) with the surface of the floor panel of the upper surface of the third undercut (42) is smaller than the angle (β6) with the surface of the floor panel of the upper surface of the second protrusion (41); the difference in the example being 5°.

[0157] The floor panel is configured such that in coupled condition of two such panels at the second pair of opposite edges (4,5) no contact is present between the second protrusion (41) and the third undercut (42).

[0158] The second protrusion (41) extends till the level of the bottom surface of the floor panel

[0159] In coupled condition of two such panels at the second pair of opposite edges (4,5) a space (53) is provided along the full upper side of the upward-directed locking element (13) and along the lip (15) of the upper hook-shaped part (11).

[0160] The second undercut (37) comprises an included angle larger than 90° between its top surface and its side surface.

[0161] The bottom of the downward-directed locking element (16) comprises a concave section (46). The bottom of the downward-directed locking element (16) comprises a distal convex section (47) and a proximal convex section (48). The concave section (46) is provided between

[0162] the distal convex section and the proximal distant section. The bottom of the downward-directed locking element (16) is configured according to the following characteristics:

[0163] the distal convex section (47) is configured closer to the surface of the floor panel than the proximal convex section (48);

[0164] the distal convex section (47) and the proximal convex section (48) both comprise a section that is parallel with the surface of the floor panel;

[0165] an inclined plane is provided between the distal convex section and the proximal convex section;

[0166] in coupled condition of two such panels at the second pair of opposite edges (4,5) the proximal convex section (48)—but not the distal convex section (47)—contacts the upper surface of the of the lip (12) of the lower hook-shaped part (10);

[0167] in coupled condition of two such panels at the second pair of opposite edges (4,5) the proximal convex section as well as the distal convex section contact the upper surface of the lip (12) of the lower hook-shaped part (10);

[0168] in coupled condition of two such panels at the second pair of opposite edges (4,5) a space is provided at the concave section between the downward-directed locking element (16) and the upper surface of the lip (12) of the lower hook-shaped part (10).

[0169] The second vertical locking zone (C2) is provided closer to the surface of the floor panel than the first vertical locking zone (C1). The second vertical locking zone (C2) is provided in the bottom half of the thickness (T) of the floor panel.

[0170] At the lower edges of the downward-directed locking element (16), guiding surfaces (49, 50), in the example inclined and rounded parts, are present, which are configured such that the male part during the downward movement thereof is guided automatically into the female part.

[0171] The locking part (19) of the second pair of edges (4-5) has a locking surface (23), which, in downward direction, by means of a bend, merges into a lower-situated distal surface (51), wherein this distal surface (51) in downward direction also extends further in distal direction, more particularly is made sloping in downward direction.

[0172] The upper surface of the lip (12) of the lower hook-shaped part (10) comprises a proximal plane which is substantially parallel with the surface of the floor panel and a distal plane which is substantially parallel with the surface of the floor panel, wherein a flat inclined plane is provided between and separating the proximal plane and the distal plane. The proximal plane is provided closer to the surface of the floor panel than the distal plane. In coupled condition of two such panels at the second pair of opposite edges, the distal plane is in contact with the downward-directed locking element (16), wherein the contact is made with pretension. It is meant the downward-directed locking element (16) pushes during coupling onto the lip (12), resulting in an elastic bending of the lip (12).

[0173] In coupled condition of two such panels at the second pair of opposite edges (4,5) a space is provided at the inclined plane between the lip (12) of the lower hook-shaped part (10) and the downward-directed locking element (16).

[0174] The upward-directed locking element (13) is elastically bendable, in the exemplary embodiment assisted by the presence of the fourth undercut (43) on the lower side of the lip of the lower hook-shaped part (10). The fourth undercut (43) extends substantially along the full length of the upward-directed locking element (13), but not further. The fourth undercut (43) is present on the lower side of the lip of the lower hook-shaped part (10). The height of the fourth undercut (43) increases continuously in the distal direction of the lower hook-shaped part (10).

[0175] In embodiments of the invention, the upward-directed locking element (13) and the downward-directed locking element (16) can be configured such that in coupled condition the proximal end of the downward-directed locking element(16) contacts the proximal end of the upward-directed locking element (13) wherein the upward-directed locking element (13) adopts a somewhat tilted position in respect to its position in uncoupled condition.

[0176] FIG. 7 shows—in coupled condition—an alternative embodiment according to the invention for the coupling parts of the second pair of opposite edges (4, 5) shown in FIG. 6. The coupling parts of the example of FIG. 7 are to a large extent similar to the coupling parts of FIG. 6, however, there are a few differences. The second pair of opposite edges (4, 5)—as shown in FIG. 7—comprises coupling parts (8, 9) on both edges, which allow that two of such floor panels (1) mutually can be coupled to each other. These coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels (1), effects a locking in the plane of the floor panels (1) and perpendicular to the respective edges (4-5). The coupling parts (8, 9) also comprise a vertically active locking system, which, in a coupled condition of two of such floor panels (1), effects a locking transverse to the plane of the floor panels. The coupling parts (8-9) substantially are realized from the material of the floor panel (1) itself. The horizontally active locking system of the second pair of edges (4, 5) is formed of an upward-directed lower hook-shaped part (10) which is situated on one of said two edges (4), as well as a downward-directed upper hook-shaped part (11), which is situated on the opposite edge (5). The upward-directed lower hook-shaped part (10) consists of a lip (12) with an upward-directed locking element (13), which proximally thereof defines a female part (14) in the form of a recess. The downward-directed upper hook-shaped part (11) consists of a lip (15) with a downward-directed locking element (16) forming a male part (17). The male part is not split.

[0177] The coupling parts (8-9) of the second pair of opposing edges (4,5) are configured such that two of such floor panels (1) can be coupled to each other at their respective edges (4-5) by means of a downward movement (M) involving a downward snapping movement of the one floor panel in respect to the other. The vertically active locking system of the second pair of opposing edges (4, 5) comprises vertically active locking parts (18, 19, 20, 21), which, by means of respective locking surfaces (22, 23, 24, 25), define at least a first vertical locking zone (C1) and a second vertical locking zone (C2). In coupled condition of two such panels, the first vertical locking zone (C1) is located at the distal end of the upward-directed locking element (13); and the second vertical locking zone (C2) is situated at the distal end of the downward-directed locking element (16).

[0178] The vertically active locking parts comprise a first locking part (18) at the edge of the panel at the proximal end of the lip (15) of the upper hook-shaped part (11), a second locking part (19) at the distal end of the downward-directed locking element (16), as well as a third locking part (20) at the distal end of the lip (12) of the lower hook-shaped part (10) and a fourth locking part (21) at the proximal end of the female part (14). The first and third locking part (18, 20), in the coupled condition of two of such floor panels (1), define the first vertical locking zone (C1). The second and fourth locking part (19, 21), in the coupled condition of two of such floor panels (1), define the second vertical locking zone (C2).

[0179] In coupled condition at the second pair of edges (4,5) of two such floor panels (1), no vertical locking is provided between the proximal end of the downward-directed locking element (16) and the proximal end of the upward-directed locking element (13).

[0180] The floor panel is configured such that the first vertical locking zone (C1) and the second vertical locking zone (C2) are the only zones where a vertical locking is provided in coupled condition of two such floor panels between the edges of their second pair of opposite edges (4,5).

[0181] The first vertical locking zone (C1) is provided at least at ⅔ of the thickness (T) of the floor panel from the surface of the floor panel.

[0182] The angle (β) between the proximal end of the downward-directed locking element (16) and the horizontal direction in the proximal direction of the upper hook-shaped part (11) is 86° in the example shown in FIG. 7.

[0183] The angle (γ) between the proximal end of the upward-directed locking element (13) and the horizontal direction in the distal direction of the lower hook-shaped part (10) 86° in the example of FIG. 7.

[0184] In coupled condition at the second pair of edges (4, 5) of two such floor panels, the proximal end of the downward-directed locking element (16) contacts the proximal end of the upward-directed locking element (13). The angle (α) of the contact between the proximal end of the downward-directed locking element (16) and the proximal end of the upward-directed locking element (13); and the horizontal direction in the direction towards the distal end of the upward-directed locking element (13) is 86°.

[0185] The second locking part (19) is provided by a first undercut (27) at the distal end of the downward-directed locking element (16). The fourth locking part (21) is provided by a first protrusion (28) at the proximal end of the female part (14). In coupled condition of two such floor panels (1) at the second pair of opposite edges (4, 5), the bottom of the first undercut (27) contacts the bottom of the first protrusion (28).

[0186] The included angle (β1, 90°) of the first protrusion (28) is larger than the included angle (β2, 84°) of the first undercut (27). The first undercut (27) has a triangular shape with rounded corner points. The first protrusion (28) comprises two inclined outer surfaces (29, 30) with in between the two inclined outer surfaces a vertical surface (31). The upper inclined surface (29) is more inclined with respect to the surface of the floor panel than the lower inclined surface (30). The bottom of the first protrusion (28) has an angle (β3) of 30° with the surface of the floor panel. The bottom of the first undercut (27) also has an angle (β4) of 30° with the surface of the floor panel. Thus, in the example shown in FIG. 7, the bottom of the first undercut (27) is substantially parallel with the bottom of the first protrusion (28).

[0187] In coupled condition of two such panels at the second pair of opposite edges (4,5) a space (32) is present in horizontal direction between the distal end of the first protrusion (28) and the proximal end of the first undercut (27). A space (33) is present between the top end of the first protrusion (28) and the top end of the first undercut (27) Both spaces (32, 33) form one continuous space.

[0188] The first protrusion (28) is provided at its panel edge below a first vertical closing plane (34) of its edge. The first vertical closing plane (34) is provided for making contact in coupled condition of two such floor panels with a second vertical closing plane (35) of the corresponding edge of the coupled panel. The first undercut (27) is provided below the second vertical closing plane (35). In coupled condition of two such floor panels at the second pair of corresponding edges (4,5), a closing plane (S) is provided by the first vertical closing plane (34) contacting the second vertical closing plane (35). The downwards extension of the closing plane (S) runs through the contact zone between the second and fourth locking part (19, 21). The intersection between the downwards extension of the closing plane (S) and the second vertical contact zone (C2) occurs within the middle quarter of the second vertical contact zone (C2).

[0189] The ratio (D/T) of the horizontal distance D between the first vertical closing plane (34) and the distal end of the lip (12) comprising the upward-directed locking element (13), over the thickness (T) of the floor panel is 0.81 in the exemplary floor panels shown in FIG. 7.

[0190] At the proximal end of the female part (14), a second undercut (37) is provided above the first protrusion (28). The second undercut (37) is provided between the first protrusion (28) and the first vertical closing plane (34). The second undercut (37) is smaller than the first undercut (27).

[0191] A first space (38) is present between the coupled opposite edges (4,5) below the contact between the bottom of the first protrusion (28) and the bottom of the first undercut (27) on the one hand and on the other hand distal to the distal end of the downward-directed locking element (16). This first space (38) continues into a second space (39) between the bottom part of the downward-directed locking element (16) and the upper part of the lip (12) of the lower hook-shaped part (10).

[0192] A section (40) of the distal end of the downward-directed locking element below the first undercut (27) extends in distal direction beyond the second closing plane (35).

[0193] The first locking part (18) is provided by a second protrusion (41) at the proximal end of the downward directed upper hook-shaped part (11). The third locking part (20) is provided by a third undercut (42) at the distal end of the upward-directed locking element (13).

[0194] The bottom of the upward-directed locking element (13) comprises a fourth undercut (43), extending over substantially the full length of the upward-directed locking element (13). The height of the fourth undercut (43) increases continuously in the distal direction of the upward directed lower hook-shaped part (10). From the bottom of the floor panel, the third undercut (42) extends deeper into the panel than the fourth undercut (43).

[0195] The second protrusion (41) extends to the bottom of the floor panel.

[0196] A further undercut (45) is provided at the proximal end of the upper hook-shaped part (11) below the second undercut (37).

[0197] The upper surface of the second protrusion (41) has an angle (β6) of 30° with the surface of the floor panel. The angle (β7) with the surface of the floor panel of the upper surface of the third undercut (42) is 30°.

[0198] The floor panel is configured such that in coupled condition of two such panels at the second pair of opposite edges (4,5) no contact is present between the second protrusion (41) and the third undercut (42).

[0199] The second protrusion (41) extends till the level of the bottom surface of the floor panel.

[0200] In coupled condition of two such panels at the second pair of opposite edges (4, 5) a space (53) is provided along the full upper side of the upward-directed locking element (13) and along the lip (15) of the upper hook-shaped part (11).

[0201] The bottom of the downward-directed locking element (16) comprises a concave section (46). The bottom of the downward-directed locking element (16) comprises a distal convex section (47) and a proximal convex section (48). The concave section (46) is provided between the distal convex section and the proximal distant section. The bottom of the downward-directed locking element (16) is configured according to the following characteristics:

[0202] the distal convex section is configured closer to the surface of the floor panel than the proximal convex section;

[0203] the distal convex section and the proximal convex section each comprise a section that is parallel with the surface of the floor panel;

[0204] an inclined plane is provided between the distal convex section and the proximal convex section;

[0205] in coupled condition of two such panels at the second pair of opposite edges (4, 5) the proximal convex section—but not the distal convex section—contacts the upper surface of the of the lip (12) of the lower hook-shaped part (10);

[0206] in coupled condition of two such panels at the second pair of opposite edges (4, 5) a space is provided at the concave section between the downward-directed locking element (16) and the upper surface of the lip (12) of the lower hook-shaped part (10).

[0207] The second vertical locking zone (C2) is provided closer to the surface of the floor panel than the first vertical locking zone (C1). The second vertical locking zone (C2) is provided in the bottom half of the thickness (T) of the floor panel.

[0208] At the lower edges of the downward-directed locking element (16), guiding surfaces (49, 50), more particularly inclined parts with rounded parts, are present, which are configured such that the male part during the downward movement thereof automatically is guided into the female part.

[0209] The locking part (19) of the second pair of edges (4, 5) has a locking surface (23), which, in downward direction, by means of a bend, merges into a lower-situated distal surface (51), wherein this distal surface (51) in downward direction also extends further in distal direction, more particularly is made sloping in downward direction.

[0210] The upper surface of the lip (12) of the lower hook-shaped part (10) comprises a proximal plane which is substantially parallel with the surface of the floor panel and a distal plane which is substantially parallel with the surface of the floor panel. An inclined plane—flat in the example of FIG. 7—is provided between and separates the proximal plane and the distal plane. The proximal plane is provided closer to the surface of the floor panel than the distal plane.

[0211] In coupled condition of two such panels at the second pair of opposite edges, the distal plane is in contact with the downward-directed locking element (16), the contact is made with pretension.

[0212] In coupled condition of two such panels at the second pair of opposite edges (4, 5) a space is provided at the inclined plane between the lip (12) of the lower hook-shaped part (10) and the downward-directed locking element (16).

[0213] The upward-directed locking element (13) is elastically bendable, assisted by the presence of a fourth undercut (43) on the lower side of the lip of the lower hook-shaped part (10). The fourth undercut (43) extends substantially along the full length of the upward-directed locking element (13), but not further. A fourth undercut (43) is present on the lower side of the lip of the lower hook-shaped part (10). The height of the fourth undercut (43) increases continuously in the distal direction of the lower hook-shaped part (10).

[0214] FIG. 8 illustrates—in a view similar as in FIG. 6—an embodiment of the invention. The reference numerals of FIG. 8 not explained in this paragraph have the same meaning as in FIG. 6. FIG. 8 illustrates two panels according to the invention coupled at their second pair of opposite edges (4, 5). The edge (4) of the second pair of opposite edges (4, 5) comprising the upward-directed lower hook-shaped part (10) comprises a first vertical closing plane (34). The edge (5) of the second pair of opposite edges (4, 5) comprising the downward-directed upper hook-shaped part (11) comprises a second vertical closing plane (35). The first vertical closing plane (34) of the floor panel is provided for contacting the second vertical closing plane (35) of another such floor panel with which the floor panel is coupled at its second pair of opposite edges. The contact in coupled condition of two such floor panels at their second pair of opposite edges of the first vertical closing plane (34) with the second vertical closing plane (35) defines a closing plane (S). The locking surface (23) of the downward-directed locking element (16) is provided over its full surface proximal to the downwards extension (73) of the second vertical closing plane (35). The locking surface of the downward-directed locking element does not extend from proximal to the downwards extension of the second vertical closing plane beyond the downwards extension of the second vertical closing plane. In the example shown, the locking surface of the downward-directed locking element extends up to the downwards extension of the second vertical closing plane. The downward-directed locking element (16) does not comprise parts extending in distal direction beyond the downwards extension (73) of the second vertical closing plane (35). In coupled condition of two such floor panels at their second pair of opposite edges (4, 5), from the point of view of the edge (5) comprising the downward-directed upper hook-shaped part (11) the second vertical locking zone (C2) is located proximal to the downward extension (73) of the closing plane (S). The panel edges shown in FIG. 8 are provided with bevels (71).

[0215] FIG. 9 shows—in a view illustrating the downward movement (M) of two panels for coupling these panels at their second pair of opposite edges—an embodiment of the invention. The edge (4) of the second pair of opposite edges (4, 5) comprising the upward-directed lower hook-shaped part (10) comprises a first vertical closing plane (34). The edge (5) of the second pair of opposite edges (4, 5) comprising the downward-directed upper hook-shaped part (11) comprises a second vertical closing plane (35). The second vertical closing plane (35) of the floor panel is provided for contacting the first vertical closing plane (34) of another such floor panel with which the floor panel is coupled at its second pair of opposite edges. In coupled condition the contact of the first vertical closing plane (34) of the floor panel with the second vertical closing plane (35) of the another such floor panel defines a closing plane. When during the downward coupling movement of the floor panel relative to the another such floor panel the distal edge of the downward-directed locking element (16) continuously contacts the proximal end of the opposing edge of the another such floor panel with which the floor panel is being coupled, at the moment the lowest point (77) of the downward-directed locking element (16) being moved downwards reaches the same height level (L) as the highest point (78) of the upward-directed locking element (13) of the another such panel, the gap (G) in horizontal direction and measured in the direction perpendicular to the second pair of opposite edges (4, 5) between the second vertical closing plane (35) of the floor panel and the first vertical closing plane (34) of the another such floor panel is less than 0.15 millimeter, preferably less than 0.1 millimeter, more preferably 0.08 millimeter. The panel edges shown in FIG. 8 are provided with bevels (71).

[0216] FIG. 10 illustrates in schematic representation an embodiment of the invention. FIG. 10 shows a view onto the edge (4) of the second pair of opposite edges comprising the upward-directed lower hook-shaped part (10) of a floor panel according to the invention. The coupling parts (6) at the first edge of the first pair of opposite edges comprise a tongue (58) and locking parts (62). Although not shown in FIG. 10, the coupling parts at the second edge of the first pair of opposite edges comprise a groove and locking parts (63). The coupling parts of the first pair of opposite edges are configured such that two of such panels can be coupled to each other at these edges by means of a turning movement, wherein a locking is established in the direction perpendicular to the plane of the so-coupled panels as well as in the direction parallel with the plane of the so-coupled panels and perpendicular to the first pair of opposite edges. Over a certain length (L1), e.g. 12 mm, extending from the first edge of the first pair of opposite edge and measured along the edge comprising the upward-directed lower hook-shaped part (10), the upward-directed lower hook-shaped part (10) consists of a lip (12) devoid of the upward-directed locking element (13).

[0217] FIG. 11, in a view similar to FIG. 4, illustrates a feature that can be used in the panels according to the invention. FIG. 11 illustrates the panel edge (4) comprising the upward-directed lower hook-shaped part (10). The reference numerals of FIG. 11 have the same meaning as in the other figures. In the example of FIG. 11, the panel edge (4) comprising the upward-directed lower hook-shaped part (10) has the additional feature that the lip (12) comprises a slit (75) parallel with the surface of the panel. The slit (75) is provided to enhance the ability of the upward-directed locking element (13) to bend backwards when coupling two such panels. In the example shown in FIG. 11, the slit (75) extends in proximal direction to beyond the upward-directed locking element (13) The slit (75) is towards the back of the panel delimited by a lower lip (76). In the example shown in FIG. 11, the lower lip (76) extends distally less than the distal end of the upward-directed locking element (13). The features of FIG. 11 are of particular interest for panels comprising a substrate out of HDF (High Density Fiberboard).