Wall panel, tray for wall panel and method for manufacturing wall panel

Abstract

To minimize a warp in a wall panel caused by being thinned and prevent shirasu from falling from a tray due to a secular change or the like.SOLUTION: A wall panel 1 comprises a tray 7 having a bottom wall part 13, a lateral wall part 15 erected from a margin of the bottom wall part 13 and forming a recessed part 19 with the bottom wall part 13 and a rib 17 erected at the same side of the lateral wall part 15 from the bottom wall part 13, a wall forming material 9 filled in the recessed part 19 of the tray 7 and a tray installation material 11 provided at the bottom wall part 13 of the tray 7 at the opposite side of the lateral wall part 15 and used to install the tray 7 at a wall 5.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a wall panel, a tray for a wall panel and a method for manufacturing a wall panel. [Background technology]

[0002] Conventionally, a wall panel has been known that is configured with a bottomed frame body consisting of a bottom plate and side walls, shirasu filled in the recess of the bottomed frame body, and a neodymium magnet attached to the bottom plate of the bottomed frame body on the opposite side of the shirasu (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Registered Utility Model No. 3216877 Summary of the Invention [Problem to be solved by the invention]

[0004] Conventional wall panels have the problem that their thinness can lead to warping, and that the shirasu may fall off the tray due to aging, etc. Falling off of the shirasu occurs when, for example, repeated temperature changes cause gaps to form between the shirasu and the tray, weakening the bonding strength of the shirasu to the tray.

[0005] The present invention has been made in consideration of the above-mentioned problems, and aims to provide a wall panel, a tray for a wall panel, and a method for manufacturing a wall panel that minimizes the amount of warping that occurs when the panel is made thin and can prevent shirasu from falling off the tray even due to changes over time, etc. [Means for solving the problem]

[0006] The invention described in claim 1 is a wall panel having a tray having a bottom wall portion, a side wall portion standing up from the edge of the bottom wall portion and forming a recess together with the bottom wall portion, and a rib standing up from the bottom wall portion on the same side as the side wall portion, a wall forming material filled in the recess of the tray, and a tray installation material provided on the bottom wall portion of the tray on the opposite side from the side wall portion and used when installing the tray on a wall.

[0007] The invention described in claim 2 is the wall panel described in claim 1, wherein the bottom wall portion is configured to include a flat bottom wall portion main body portion and a flat bottom wall portion protrusion portion, the thickness dimension value of the bottom wall portion protrusion value is smaller than the thickness dimension value of the bottom wall portion main body portion, the thickness directions of the bottom wall portion main body portion and the bottom wall portion protrusion portion are aligned with each other, the bottom wall portion protrusion portion protrudes slightly from the bottom wall portion main body portion on the opposite side to the side wall portion, and when viewed in the thickness direction of the bottom wall portion main body portion and the bottom wall portion protrusion portion, a ring-shaped recess formed by the side wall portion and the bottom wall portion protrusion portion is formed around the bottom wall portion main body portion.

[0008] The invention described in claim 3 is a wall panel described in claim 1 or claim 2, in which, when viewed in the thickness direction of the bottom wall portion, the rib is spaced apart from the side wall portion.

[0009] The invention as set forth in claim 4 is the wall panel as set forth in claim 1, wherein the rib also stands upright from the bottom wall portion on the side opposite to the side wall portion.

[0010] The invention described in claim 5 is the wall panel described in claim 4, wherein a plurality of front-side recesses are provided on the surface on the same side as the side wall portion, and a rib standing up from the bottom wall portion on the same side as the side wall portion is formed between adjacent front-side recesses that are slightly spaced apart from each other among the plurality of front-side recesses, and a plurality of back-side recesses are provided on the surface opposite the side wall portion, and a rib standing up from the bottom wall portion on the opposite side to the side wall portion is formed between adjacent back-side recesses that are slightly spaced apart from each other among the plurality of back-side recesses.

[0011] The invention described in claim 6 is a wall panel described in claim 5, wherein, when viewed in the thickness direction of the bottom wall portion, the back side recess is positioned at a different position from the front side recess.

[0012] The invention described in claim 7 is a wall panel described in any one of claims 1 to 6, wherein the outer peripheral surface of the side wall portion is formed in the shape of a side surface of a quadrangular pyramid, the size of the rectangle of the outer peripheral surface of the side wall portion changes in the thickness direction of the bottom wall portion, and the size of the rectangle of the outer peripheral surface of the side wall portion is larger on the bottom wall portion side and smaller on the tip side of the side wall portion.

[0013] The invention described in claim 8 is a wall panel described in any one of claims 1 to 7, wherein the tray mounting material is provided only in the center of the bottom wall portion when viewed in the thickness direction of the bottom wall portion.

[0014] The invention described in claim 9 is a container having a bottom wall portion, a side wall portion standing from an edge portion of the bottom wall portion and forming a recess together with the bottom wall portion, and a rib standing from the bottom wall portion. A tray comprising: This is a wall panel tray configured so that the recessed portion of the tray is filled with a wall-forming material, and the bottom wall portion of the tray opposite the side wall portion is provided with a tray installation material used when installing the tray on a wall.

[0015] The invention described in claim 10 is a method for manufacturing a wall panel, which includes a tray installation step of installing a tray having a flat bottom wall portion, side wall portions standing from the edge of the bottom wall portion and forming a recess together with the bottom wall portion, and ribs standing from the bottom wall portion, on a tray installation body having a flat upper surface so that the lower surface of the bottom wall portion, which is the surface of the bottom wall portion opposite the side from which the side wall portion stands, faces the upper surface of the tray installation body and so that the lower surface of the bottom wall portion conforms to the upper surface of the tray installation body; a wall forming material filling step of filling a fluid wall forming material into the recess of the tray after installing the tray on the tray installation body in the tray installation step; a wall forming material hardening step of hardening the filled wall forming material after filling the wall forming material in the wall forming material filling step; and a tray removal step of removing the tray from the tray installation body after hardening the wall forming material in the wall forming material hardening step. [Effects of the Invention]

[0016] According to the present invention, the amount of warping that occurs due to the thinning is minimized, and the shirasu can be prevented from falling off the tray even due to changes over time, etc. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 2 is a perspective view of a tray constituting a wall panel according to an embodiment of the present invention, seen from the front side. [Figure 2] FIG. 2 is a perspective view of a tray constituting a wall panel according to an embodiment of the present invention, seen from the back side. [Figure 3] FIG. 3(a) is a plan view of a tray constituting a wall panel according to an embodiment of the present invention, and FIG. 3(b) is a view taken along the arrow IIIB in FIG. [Figure 4] 3(a) is a view showing a cross section taken along line IVA-IVA in FIG. 3(a), and FIG. 3(b) is a view seen from the arrow IVB in FIG. 3(b). [Figure 5](a) is a figure corresponding to Figure 4(a) and shows a cross section of a wall panel formed by filling shirasu into the recesses of the tray, (b) is an enlarged view of the VB portion in Figure 5(a), and (c) is a figure corresponding to the enlarged view of the VC portion in (b) and shows a modified example of the filled shirasu. [Figure 6] 1A and 1B are diagrams showing an example of installation of a wall panel on a wall according to an embodiment of the present invention, where FIG. 1B is a cross-sectional view taken along line VIB-VIB in FIG. 1A. [Figure 7] 1A to 1C are diagrams illustrating a method for manufacturing a wall panel according to an embodiment of the present invention. [Figure 8] FIG. 10 is a front view of a tray constituting a wall panel according to an embodiment of the present invention, showing a wall panel provided with ribs according to a modified example. [Figure 9] FIG. 10 is a front view of a tray of a wall panel according to a modified example. [Figure 10] FIG. 10 is a rear view of a tray constituting a wall panel according to a modified example. [Figure 11] 9. (a) is a view showing the XIA-XIA cross section in FIG. 9, and (b) is a view showing the XIB-XIB cross section in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0018] The wall panel 1 according to the embodiment of the present invention is used by being installed on the wall 5 of a building 3, for example, as shown in FIG. 6, and is configured with a tray (tray for the wall panel) 7, a wall forming material (wall forming material for the wall panel) 9, and a tray installation material (tray installation material for the wall panel; connecting member) 11, as shown in FIG. 5, etc.

[0019] Here, for ease of explanation, one predetermined direction in the wall panel 1 is referred to as the vertical direction, another predetermined direction perpendicular to this vertical direction is referred to as the horizontal direction, and the direction perpendicular to the vertical and horizontal directions is referred to as the front-to-back direction (height direction).

[0020] As shown in Figures 1 to 5, the tray 7 has a bottom wall 13, side walls 15, and ribs (surface ribs) 17. The thickness direction of the bottom wall 13 coincides with the front-to-back direction. The side walls 15 stand upright from the edge (outer periphery) of the bottom wall 13 toward the front side in the front-to-back direction, and the side walls 15 form a recess 19 together with the bottom wall 13. This gives the tray 7 the shape of a bottomed frame.

[0021] The ribs 17 stand upright from the bottom wall 13 on the same side (front side in the front-back direction) as the side wall 15. When viewed in the thickness direction (front-back direction) of the bottom wall 13, the ribs 17 are spaced apart from the side wall 15, as shown in Figure 3. The wall-forming material 9 is filled in the recesses 19 of the tray 7. The wall-forming material 9 is also filled in the area indicated by reference numeral 20 in Figure 5(b) (areas where the ribs 17 are absent).

[0022] The tray installation material 11 is used when installing the tray 7 (wall panel 1) on the wall 5 (flat surface of the wall 5) of the building 3. The tray installation material 11 is provided on the bottom wall 13 of the tray 7 on the opposite side to the protruding direction of the side wall 15 (the back side in the front-to-back direction). In addition, the tray installation material 11 is provided only in the center of the bottom wall 13 when viewed in the thickness direction of the bottom wall 13.

[0023] As shown in FIG. 5(b), the bottom wall 13 is configured with a flat bottom wall main body 21 and a flat bottom wall protrusion 23. The thickness dimension L15 of the bottom wall protrusion 23 (the dimension in the front-to-back direction) is smaller than the thickness dimension L14 of the bottom wall main body 21 (the dimension in the front-to-back direction). The thickness directions of the bottom wall main body 21 and the bottom wall protrusion 23 are the same. The bottom wall protrusion 23 protrudes slightly backward in the front-to-back direction from the bottom wall main body 21 on the side opposite the protruding direction of the side wall 15. In other words, the bottom wall protrusion 23 overlaps the bottom wall main body 21 on the side opposite the protruding direction of the side wall 15.

[0024] When viewed in the thickness direction (front-to-back direction) of bottom wall main body 21 and bottom wall protrusion 23, a rectangular annular recess (a "L"-shaped recess; recess in side wall / bottom wall protrusion) 25 is formed around bottom wall main body 21 by side wall 15 and bottom wall protrusion 23. As already understood, bottom wall protrusion 23 is provided to increase the thickness dimension of bottom wall 13, and increasing the thickness of bottom wall 13 can reduce the amount of warping of tray 7 (wall panel 1).

[0025] The outer peripheral surface 16 of the side wall portion 15 is formed in the shape of a side surface of a quadrangular pyramid. As a result, the size of the rectangle of the outer peripheral surface 16 of the side wall portion 15 (the rectangle existing on the outer peripheral surface 16) changes in the thickness direction of the bottom wall portion 13. That is, the vertical and horizontal dimension values ​​between the outer peripheral surfaces 16 of the pair of side wall portions 15 change in the thickness direction of the bottom wall portion 13. Furthermore, the size of the rectangle of the outer peripheral surface 16 of the side wall portion 15 is larger on the bottom wall portion 13 side and smaller on the tip side of the side wall portion 15.

[0026] To explain the wall panel 1 in more detail, the bottom wall portion 13 is formed, for example, in the shape of a rectangular flat plate. More specifically, when viewed in the thickness direction (front-to-back direction), the bottom wall portion 13 is formed in a square shape. When the bottom wall portion 13 is viewed in this thickness direction, the outer periphery of the "R"-shaped (rectangular ring) bottom wall portion 13 becomes the edge portion (side portion) of the bottom wall portion 13.

[0027] The side wall 15 stands (protrudes) a predetermined height from the bottom wall 13 on the front side, which is one side in the thickness direction of the bottom wall 13. Since the side wall 15 is provided around the entire periphery of the edge of the bottom wall 13, the side wall 15 is also formed in a square shape when viewed from the front to back direction (thickness direction of the bottom wall 13). The square-shaped side wall 15 is configured to include a pair of side wall longitudinal extension portions 27 extending vertically and a pair of side wall lateral extension portions 29 extending horizontally.

[0028] 5 and other figures, the cross-sectional shape (cross-section taken along a plane perpendicular to the longitudinal direction) of the side wall longitudinally extending portion 27 is a generally obtuse triangle. When a cross-section (cross-section taken along a plane perpendicular to the longitudinal direction) of the portion where the side wall longitudinally extending portion 27 and the bottom wall 13 are connected to each other and the vicinity thereof is taken, the positional relationship between the side wall longitudinally extending portion 27 and the bottom wall 13 is as follows:

[0029] One side 31 of the side wall longitudinal extension portion 27, which is separated by an obtuse angle, is joined to a line segment 33 that represents the side surface (a plane perpendicular to the horizontal direction) of the bottom wall portion 13 (bottom wall main body portion 21). The other side 35 of the side wall longitudinal extension portion 27, which is separated by the obtuse angle, extends from a corner 39 of the bottom wall portion 13 (bottom wall main body portion 21) toward the front side, at an angle relative to the line segment 33 that represents the side surface of the bottom wall portion 13 (bottom wall main body portion 21) and the line segment 37 that represents the surface (front surface) of the bottom wall portion 13. The angle 39 is a 90° angle formed by the line segment 33 that represents the side surface of the bottom wall main body portion 21 and the line segment 37 that represents the surface of the bottom wall portion 13.

[0030] The value of the horizontal distance L1 between the other edges 35 of the pair of side wall longitudinal extensions 27 gradually increases as the distance from the bottom wall 13 to the front side increases (toward the top in FIG. 5). The remaining edge 41 opposing the obtuse angle of the side wall longitudinal extensions 27 forms the horizontal end face of the tray 7 (the outer peripheral surface 16 of the side wall 15).

[0031] The cross-sectional shape (cross-section taken along a plane perpendicular to the horizontal direction) of the side wall portion horizontally extending portion 29 is the same as the cross-sectional shape of the side wall portion vertically extending portion 27, and when a cross-section (cross-section taken along a plane perpendicular to the horizontal direction) is taken of a point where the side wall portion horizontally extending portion 29 and the bottom wall portion 13 (bottom wall portion main body portion 21) are connected to each other, the positional relationship between the side wall portion horizontally extending portion 29 and the bottom wall portion 13 (bottom wall portion main body portion 21) is also the same as the positional relationship between the side wall portion horizontally extending portion 29 and the bottom wall portion 13 (bottom wall portion main body portion 21).

[0032] The shapes of the bottom wall portion 13 and the side wall portion 15 are as described above, and the positional relationship between the bottom wall portion 13 and the side wall portion 15 is as described above, so that the shape of the recess 19 formed by the bottom wall portion 13 and the side wall portion 15 is a quadrangular pyramid shape (a quadrangular pyramid shape with the lengths of the four inclined surfaces being equal to each other).

[0033] The amount of protrusion of the side wall 15 from the bottom wall 13 in the front-to-back direction is significantly smaller than the dimensions of the side wall longitudinal extending portions 27 and the side wall transverse extending portions 29 in the extension directions and the dimensions of the bottom wall 13 in the longitudinal and transverse directions. As a result, the height of the truncated quadrangular pyramid of the recess 19 is significantly smaller than the dimensions of the recess 19 in the longitudinal direction and the transverse direction.

[0034] The thickness dimension of the bottom wall 13, as well as the amount of protrusion of the side wall 15 from the bottom wall 13 in the front-to-back direction, is also considerably smaller than the vertical and horizontal dimensions of the bottom wall 13. As a result, the thickness dimension of the wall panel 1 is sufficiently small compared to the vertical and horizontal dimensions, and the shape of the wall panel 1 is wide and thin, appropriately for covering the wall 5.

[0035] Furthermore, the upper surface (e.g., a square-shaped upper surface) of the truncated quadrangular pyramid forming the recess 19 coincides with the front surface 37 of the bottom wall portion 13, and the lower surface (e.g., a square-shaped upper surface) of the truncated quadrangular pyramid forming the recess 19 forms an opening 43 of the recess 19 located at the tip of the side wall portion 15 in the front-to-back direction (the end farthest from the bottom wall portion).

[0036] Furthermore, when viewed from the front to the back, the upper surface of the truncated quadrangular pyramid forming the recess 19 is located inside the lower surface of the truncated quadrangular pyramid forming the recess 19, and the center of the upper surface of the truncated quadrangular pyramid and the center of the lower surface of the truncated quadrangular pyramid coincide with each other.

[0037] Furthermore, a finely textured pattern (not shown) is formed on surface 37 (for example, the entire surface) of bottom wall 13 (bottom wall main body 21) corresponding to the upper surface of the truncated quadrangular pyramid forming recess 19. As a result, surface 37 of bottom wall 13 corresponding to the upper surface of the truncated quadrangular pyramid forming recess 19 has a so-called matte-like rough texture. Furthermore, the surface of side wall 15 corresponding to the side surface of the truncated quadrangular pyramid forming recess 19 (surface indicated by side 35) may also be matte-like.

[0038] Since the surface 37 of the bottom wall portion 13 is formed in a matte finish, the contact area between the wall forming material 9 and the tray 7 increases when the wall forming material 9 is filled into the recess 19 of the tray 7, thereby preventing the wall forming material 9 from falling off the tray 7.

[0039] The ribs 17 are provided to reduce the amount of warping of the tray 7 (wall panel 1) (improving the flatness of the flat back surface 45 of the bottom wall portion 13 of the tray 7) and, similar to the case of a matte finish, to increase the contact area between the wall forming material 9 and the tray 7 when the wall forming material 9 is filled into the recess 19 of the tray 7, thereby preventing the wall forming material 9 from falling off the tray 7.

[0040] The ribs 17 stand (protrude) from the bottom wall 13 on the same side as the side wall 15 within the recess 19 of the tray 7. The amount of protrusion of the ribs 17 is sufficiently smaller than the amount of protrusion of the side wall 15. Also, when viewed from the front to back direction, as described above and as shown in FIG. 3(a), the ribs 17 are separated from the side wall 15 and are provided only on the bottom wall 13 (bottom wall main body 21).

[0041] Furthermore, the rib 17 is configured to include a plurality of rib longitudinally extending portions 47 extending in the vertical direction and a plurality of rib laterally extending portions 49 extending in the horizontal direction. The rib longitudinally extending portions 47 are formed in the shape of an elongated rectangular parallelepiped, and the rib laterally extending portions 49 are formed in the same shape as the rib longitudinally extending portions 47. Furthermore, the cross section of the rib longitudinally extending portions 47 (a cross section taken along a plane perpendicular to the vertical direction) is formed in a rectangular shape. The cross section of the rib laterally extending portions 49 is formed in the same shape as the cross section of the rib longitudinally extending portions 47.

[0042] As shown in Figure 3, the multiple rib longitudinal extension regions 47 are arranged at a constant interval L2 in the horizontal direction and are aligned with each other in the vertical direction. The multiple rib transverse extension regions 49 are arranged at a constant interval L2 in the vertical direction and are aligned with each other in the horizontal direction. When viewed from the front to back, the multiple rib longitudinal extension regions 47 and the multiple rib transverse extension regions 49 form a lattice pattern.

[0043] The wall forming material 9 (the portion of the wall forming material 9 on the bottom wall portion 13 side) is divided in the vertical and horizontal directions by arranging the multiple rib longitudinal extending portions 47 and the multiple rib transverse extending portions 49 in a lattice pattern. This means that the wall forming material 9 is firmly fixed to the tray 7, and expansion and contraction of the wall forming material 9 relative to the tray 7 in the vertical and horizontal directions due to temperature changes and the like is suppressed.

[0044] One end in the extension direction of each of the plurality of rib longitudinal extension portions 47 (the lower end in FIG. 3(a)) is spaced a predetermined distance L3 from one of the pair of side wall laterally extending portions 29A of the pair of side wall laterally extending portions 29. The other end in the extension direction of each of the plurality of rib longitudinal extension portions 47 (the upper end in FIG. 3(a)) is spaced a predetermined distance L4 from the other of the pair of side wall laterally extending portions 29B of the pair of side wall laterally extending portions 29.

[0045] Similarly, one end in the extension direction of the multiple rib laterally extending portions 49 (the end on the left in FIG. 3(a)) is spaced a predetermined distance L5 from one side wall longitudinally extending portion 27A of the pair of side wall longitudinally extending portions 27. The other end in the extension direction of the multiple rib laterally extending portions 49 (the end on the right in FIG. 3(a)) is spaced a predetermined distance L6 from the other side wall longitudinally extending portion 27B of the pair of side wall longitudinally extending portions 27.

[0046] The value of the separation distance L7 between the side wall 15 and the rib 17 in the longitudinal direction and the lateral direction is approximately equal to the value of the interval L2 between the rib longitudinal extension portion 47 and the rib lateral extension portion 49. The values ​​of the distances L3, L4, L5, and L6 are equal to one another. Furthermore, the values ​​of the distances L3, L4, L5, and L6 are smaller than the value of the distance L7 between the rib lateral extension portion 49 and the side wall 15 in the longitudinal direction and the value of the distance L7 between the rib longitudinal extension portion 47 and the side wall 15 in the longitudinal direction.

[0047] The tray 7 is made of synthetic resin such as ABS resin, but may also be made of wood, metal, glass, ceramic, etc. If made of wood, it may be made of wood chips or wood waste solidified. When the tray 7 is molded using a mold, the tray 7 is formed in a shape that does not have any undercuts.

[0048] Examples of the wall forming material 9 include materials (wet wall materials) containing shirasu as a main component. More specifically, examples of interior materials include "Satsuma Nakakirishima Wall," "Biocera," "Nakakirishima Wall Light," "Nakakirishima Wall Light (Biocera Color)," "Shirasukui Plaster," and "Nakakirishima Wall Wild," all manufactured by Takachiho Shirasu Co., Ltd.

[0049] Shirasu forms the vast Shirasu Plateau, piled up to 150 meters thick from Kagoshima Prefecture to southern Miyazaki Prefecture. It was deposited all at once as a massive pyroclastic flow, and is a powdered substance formed from magma before it turned into rock. It can be described as a "primitive soil" that lacks nutrients.

[0050] Furthermore, when Shirasu is used as an interior material, it has good humidity control and deodorizing properties, a long lifespan, and can easily form walls with a genuine texture. However, ordinary plaster wall materials (wet wall materials) such as plaster can also be used as wall materials.

[0051] As shown in Figure 5, the wall-forming material 9 fills all of the recesses 19, and some small irregularities are formed on the surface (front surface; exposed surface) of the wall-forming material 9. Even though some small irregularities are formed on the surface of the wall-forming material 9, the surface of the wall-forming material 9 is generally flat. Furthermore, in the front-to-back direction, the position of the surface of the wall-forming material 9 and the position of the bottom surface of the truncated pyramidal recess 19 (opening 43 of the tray 7) are approximately aligned with each other, or the position of the surface of the wall-forming material 9 is located farther from the bottom wall 13 (upper side in Figure 5(b)) than the position of the bottom surface of the truncated pyramidal recess 19 (opening 43 of the tray 7).

[0052] That is, in the front-to-back direction, the value of the distance L8 between the surface of the wall-forming material 9 and the bottom wall portion 13 and the value of the distance L9 between the bottom surface of the truncated pyramidal recess 19 (opening 43 of the tray 7) and the bottom wall portion 13 are the same, or the value of the distance L8 between the surface (front surface) of the wall-forming material 9 and the bottom wall portion 13 is slightly larger than the value of the distance L9 between the bottom surface of the truncated pyramidal recess 19 (opening 43 of the tray 7) and the bottom wall portion 13.

[0053] Since the wall forming material 9 is filled into the recesses 19 of the tray 7, the outer shape of the wall panel 1 is a truncated quadrangular pyramid in which no recesses 19 exist.

[0054] The tray mounting member 11 is formed in the shape of a thin, rectangular plate, and is integrally provided on the bottom wall 13 (bottom wall protrusion 23) with its thickness direction coinciding with the thickness direction of the bottom wall 13. When viewed from the front to the back, the tray mounting member 11 is located inside the bottom wall 13 (bottom wall protrusion 23), and of the four sides that make up the periphery of the tray mounting member 11, one pair of opposing sides extend vertically, and of the four sides that make up the periphery of the tray mounting member 11, the other pair of opposing sides extend horizontally. Furthermore, when viewed from the front to the back, the center of the tray mounting member 11 and the center of the bottom wall 13 coincide with each other.

[0055] The tray installation member 11 is composed of a magnetic sheet 51 and an adhesive or pressure-sensitive adhesive 53. The magnetic sheet 51 is a thin, rectangular, flat plate with some elasticity. The adhesive or pressure-sensitive adhesive 53 is in the form of a thin film and is provided between the tray 7 and the magnetic sheet 51 (bottom wall protrusion 23).

[0056] As shown in Figure 6, the wall 5 of the building 3 is made of a magnetic material such as an iron plate, and a magnetic sheet 51 is attached to the wall 5 of the building 3, so that the wall panel 1 is installed integrally with the wall 5.

[0057] For example, a magnet sheet manufactured by Nichirei Magnet Corporation can be used as the tray installation material 11. Magne sheet is rust-resistant and generates a strong magnetic force. By using a magnet sheet as the tray installation material 11, the wall panel 1 can be easily attached and detached to the wall 5 of the building 3. However, once the wall panel 1 is installed on the wall 5 of the building 3, the wall panel 1 will not come off the wall 5 of the building 3 or become displaced relative to the wall 5 even if a person applies force with their bare hands.

[0058] Instead of forming the tray mounting material 11 from the rust-resistant magnetic sheet 51, double-sided tape, hook-and-loop fasteners, or hot melt adhesives such as thermoplastic resin containing aluminum foil may be used as the tray mounting material 11. This allows the wall panel 1 to be mounted on the wall 5 even if the wall 5 is made of non-magnetic concrete or gypsum board.

[0059] Here, the bottom wall portion 13, the side wall portion 15, the wall forming member 9, etc. of the tray 7 will be described in more detail.

[0060] In the above description, the cross-sectional shape (cross-section taken along a plane perpendicular to the longitudinal direction) of the side wall longitudinally extending portion 27 (side wall transversely extending portion 29) is generally an obtuse triangle, but more precisely, the cross-sectional shape of the side wall longitudinally extending portion 27 is a pentagon, as shown in Figure 5(b). That is, the cross-sectional shape of the side wall longitudinally extending portion 27 is a pentagon surrounded by sides 31, 35, 41, 55, and 57.

[0061] The recess 25 mentioned above faces the side 55 and the line segment 59 indicating the side surface of the bottom wall protrusion 23. The side 57 is located between the side 35 and the side 41, and is located at the tip of the side wall 15. The side 57 extends slightly in the horizontal direction (vertical direction). As a result, the side 57 forms a square-shaped flat surface 61 at the tip of the side wall 15. The length dimension L11 of the side 57 is equal to the width dimension of each of the four sides of the square-shaped flat surface 61. The wall-forming material 9 also covers the flat surface 61.

[0062] As shown in Figure 5(c), the wall forming material 9 may protrude slightly (approximately the value of the length dimension L11 of the side 57) from both ends of the tray 7 in the vertical and horizontal directions. By, for example, trimming the protruding wall forming material 9, it becomes easier to fine-tune the vertical and horizontal dimensions of the wall panel 1. Furthermore, even in an embodiment in which the wall forming material 9 does not protrude, as shown in Figure 5(b), since the wall panel 1 is formed in a quadrangular pyramid shape, it is easy to fine-tune the vertical and horizontal dimensions of the wall panel 1 by slightly trimming the vertical and horizontal ends of the wall panel 1.

[0063] Here, we will provide an example of the dimensions of the wall panel 1. The value of the vertical and horizontal dimensions L13 of the wall panel 1 is 300 mm. Note that this 300 mm is the value obtained by dividing 900 mm by 3. Note that the value of the dimension L13 of the wall panel 1 may be the value obtained by dividing 900 mm by an integer other than "1" or "3", or the value obtained by multiplying 900 mm by an integer other than "1", or it may be some other value.

[0064] The thickness L14 of the bottom wall main body 21 of the tray 7 is 3 mm, and the thickness L15 of the bottom wall protrusion 23 is 1 mm. The height L16 of the rib 17 of the wall panel 1 is 1 mm, and the width L17 of the rib 17 of the wall panel 1 is 1.5 mm. The height L18 of the tray 7 is 8 mm, and the width L11 of the square-shaped flat surface 61 at the tip of the side wall 15 is 1 mm. The height dimension L19 of the portion of the wall forming material 9 covering the flat surface 61 is 1 mm. The inclination angle α of the side 41 relative to the front-to-back direction is approximately 10°, and the inclination angle β of the side 35 relative to the vertical and horizontal directions is approximately 50°.

[0065] The ratio of the vertical and horizontal dimensions L13 of the wall panel 1 to the other dimensions of the wall panel 1 may be changed as appropriate within a range of ±50% (preferably ±30%, more preferably ±10%). Furthermore, if the vertical and horizontal dimensions L13 of the wall panel 1 are set to a value other than 300 mm, the values ​​of the other dimensions of the wall panel 1 will be changed as appropriate. Furthermore, the angles α and β may be changed as appropriate within a range of ±30% (preferably ±10%).

[0066] Next, a method for manufacturing the wall panel 1 will be described with reference to FIG.

[0067] First, the tray 7 is placed on the tray installation body 63 (tray installation process; see Figures 7(a) and (b)). The tray 7 that exists alone before being placed on the tray installation body 63 may be warped, and a warped tray 7, for example, has a lower surface 65 (backside of 45) that is not flat and is distorted (see Figure 7(a)). The lower surface 65 is the surface of the bottom wall portion 13 opposite the side on which the side wall portion 15 stands. Note that the tray installation material 11 is not shown in Figure 7(a).

[0068] The upper surface 67 of the tray installation body 63 is flat. In the tray installation process, the tray 7 is installed on the tray installation body 63 so that the lower surface 65 of the bottom wall portion 13 and the upper surface 67 of the tray installation body 63 face each other and the lower surface 65 of the bottom wall portion 13 conforms to the upper surface 67 of the tray installation body 63 (see FIG. 7(b)).

[0069] When the tray 7 is installed on the tray installation body 63 in the tray installation step, the thickness direction of the bottom wall 13 is vertical, and the recess 19 of the tray 7 is located above the bottom wall 13. In addition, the rigidity of the tray installation body 63 is sufficiently high compared to the rigidity of the tray 7. Therefore, as described above, even if the lower surface 65 of the bottom wall 13 of the tray 7 alone is slightly warped (even if the flatness of the lower surface 65 of the bottom wall 13 is slightly deteriorated), when the tray 7 is installed on the tray installation body 63 in the tray installation step, the lower surface 65 of the bottom wall 13 deforms (e.g., elastically deforms) in accordance with the upper surface 67 of the tray installation body 63, and the slight warp of the lower surface 65 of the bottom wall 13 is almost eliminated.

[0070] In the tray setting step, the tray 7 is set on the tray setting body 63 using, for example, the tray setting member 11 described above.

[0071] Next, after the tray 7 is placed on the tray placement body 63 in the tray placement process, the tray 7 is left placed on the tray placement body 63, and the recess 19 of the tray 7 is filled with pre-hardened fluid wall-forming material 9 (wall-forming material filling process; see Figure 7(c)).

[0072] Next, after filling the wall forming material 9 in the wall forming material filling process, the filled wall forming material 9 is hardened while the tray 7 remains installed in the tray installation body 63 (wall forming material hardening process).

[0073] Next, after the wall forming material 9 is hardened in a wall forming material hardening step, the tray 7 is removed from the tray installation body 63 (tray removal step; see FIG. 7(d)). Even after this removal, the rigidity of the hardened wall forming material 9 allows the flatness of the lower surface 65 of the tray 7 to be maintained in a good state. Note that, in the wall panel 1, it is desirable that the internal stress of the wall forming material 9 be compressive stress while the flatness of the lower surface 65 of the tray 7 is maintained in a good state.

[0074] Next, the installation of the wall panel 1 on the wall 5 of the building 3 will be described with reference to FIG.

[0075] The wall panel 1 is used, for example, as an interior material (decorative wall) for the wall 5 of a room 69 in a building 3. The plane of the wall 5 is perpendicular to a predetermined horizontal direction, but in this specification, the ceiling and floor are also considered to be included in the wall. The planes of the ceiling and floor are perpendicular to the vertical direction. Furthermore, the plane of the wall may be perpendicular to a predetermined direction that is oblique to the horizontal or vertical direction.

[0076] Since the area of ​​the wall 5 is larger than the vertical and horizontal dimensions of the wall panel 1, multiple wall panels 1 are installed on the wall 5. When multiple wall panels 1 are installed on the wall 5, the tray installation material 11 contacts the wall 5, and the wall forming material 9 on the surface (front surface) of the wall panel 1 faces the room 69.

[0077] Furthermore, when multiple wall panels 1 are installed on a wall 5, the vertical and horizontal directions of the wall panels 1 match the direction in which the surface (hide surface) of the wall 5 is deployed, and the multiple wall panels 1 are lined up vertically and horizontally with no gaps between them. This makes it almost impossible to discern the boundary between one wall panel 1 and another wall panel 1 adjacent to it with the naked eye.

[0078] The wall panel 1 comprises a tray 7 having a bottom wall portion 13, a side wall portion 15, and a rib 17, and a wall forming material 9 filled in the recess 19 of the tray 7, so that even if the tray 7 is made thin, the value of the second moment of area of ​​the bottom wall portion 13 of the tray 7 can be increased by the rib 17, and the amount of warping can be minimized.

[0079] Furthermore, the provision of the ribs 17 increases the contact area between the tray 7 and the wall forming material 9 filled in the recesses 19 of the tray 7, thereby preventing the wall forming material 9 from falling off the tray 7 due to aging or the like. Furthermore, if internal stress is generated between the wall forming material 9 and the tray 7, the degree of adhesion between the wall forming material 9 and the tray 7 can be further increased.

[0080] In addition, since a tray installation material 11 is provided, even a person without any special skills can skillfully install the wall panel 1 on the wall 5, and the wall panel 1 can give the appearance of a plastered wall.

[0081] In addition, in the wall panel 1, the bottom wall portion 13 is configured to include a flat bottom wall main body portion 21 and a flat bottom wall protrusion portion 23, and the bottom wall protrusion portion 23 protrudes slightly from the bottom wall main body portion 21 on the opposite side of the side wall portion 15, and when viewed in the thickness direction of the bottom wall main body portion 21 and the bottom wall protrusion portion 23, a rectangular annular recess 25 formed by the side wall portion 15 and the bottom wall protrusion portion 23 is formed around the bottom wall main body portion 21.

[0082] This allows the thickness of bottom wall 13 to be increased, albeit slightly, by the thickness of bottom wall protrusion 23, thereby increasing the second moment of area of ​​bottom wall 13 of tray 7 and further increasing the amount of warping. Note that although the thickness L15 of bottom wall protrusion 23 is slight, the second moment of area is proportional to the cube of the thickness (L14+L15) of bottom wall 13, so the second moment of area of ​​bottom wall 13 of tray 7 will be larger than it actually is.

[0083] For example, even if the ratio of the value of the thickness dimension L15 of the bottom wall protrusion 23 to the value of the thickness dimension L14 of the bottom wall main body 21 is approximately 1 / 3, the value of the second moment of area of ​​the bottom wall 13 (bottom wall main body 21 + bottom wall protrusion 23) is approximately twice or more the value of the second moment of area of ​​the bottom wall main body 21 alone.

[0084] Furthermore, a "R"-shaped recess 25 is formed in the wall panel 1. As a result, when removing the wall panel 1 installed on the wall 5 from the wall 5, a tool can be hooked onto part of the "R"-shaped recess 25, making it easier to remove the wall panel 1 from the wall 5.

[0085] Furthermore, with the wall panel 1, the ribs 17 are spaced apart from the side walls 15 when viewed in the thickness direction of the bottom wall 13 (the front-to-back direction; the direction in which the side walls 15 protrude from the bottom wall 13), making it easier to mold the tray 7 using a mold. That is, because the ribs 17 are spaced apart from the side walls 15 and protrude only from the bottom wall 13, the residual stress generated in the ribs 17 can be reduced when the synthetic resin injected into the mold core hardens or when the synthetic resin has completely hardened. This reduces the occurrence of warping in the bottom wall 13 (tray 7) compared to when the ribs 17 are connected to the side walls 15. Furthermore, the occurrence of sink marks in the tray 7 can be suppressed.

[0086] In addition, in the wall panel 1, the outer surface 16 of the side wall portion 15 is formed in the shape of a side surface of a quadrangular pyramid, and the size of the rectangle of the outer surface 16 of the side wall portion 15 changes in the thickness direction of the bottom wall portion 13, and the size of the rectangle of the outer surface 16 of the side wall portion 15 is smaller on the bottom wall portion 13 side and smaller on the tip side of the side wall portion 15.

[0087] This allows a finger or tool to be hooked on the outer peripheral surface (side surface; inclined surface) 16 of the inclined side wall portion 15 of the wall panel 1 when removing the wall panel 1 installed on the wall 5 from the wall 5, making it easy to remove the wall panel 1 from the wall 5.

[0088] When removing the wall panel 1 installed on the wall 5 from the wall 5, a moment is applied to the wall panel 1 when the end of the wall panel 1 is pulled in a direction away from the wall 5 in order to remove the wall panel 1 from the wall 5 by hooking a finger or the like on one end of the side of the wall panel 1.

[0089] In the wall panel 1, the tray mounting material 11 is provided only in the center of the bottom wall portion 13 when viewed in the thickness direction of the bottom wall portion 13, so that the value of the force applied to the tray mounting material 11 (the value of the force peeling off the wall panel 1) becomes large due to the above-mentioned moment and the principle of leverage, making it easier to remove the wall panel 1 from the wall 5.

[0090] In the wall panel 1, the shape of the ribs 17 may be changed as appropriate, as shown in Figure 8. In the wall panel 1 shown in Figure 8(a), the ribs 17 extend diagonally relative to the vertical and horizontal directions. In the wall panel 1 shown in Figure 8(b), the ribs 17 are composed of multiple circles and multiple line segments connecting these circles. In the wall panel 1 shown in Figure 8(c), the ribs 17 are composed of multiple rectangles of different sizes and multiple line segments connecting these rectangles. The centers of the multiple rectangles of different sizes are aligned. In Figure 8(d), the ribs 17 are honeycomb-shaped.

[0091] In addition, in the above description, the rib 17 and the side wall portion 15 are separated from each other, but the end of the rib 17 may be in contact with the side wall portion 15. In other words, the rib 17 may extend from the side wall portion 15 to the surface of the bottom wall portion 13.

[0092] In addition, in the above description, the shape of the wall panel 1 when viewed from the front to the back is a square, but the shape of the wall panel 1 when viewed from the front to the back may be formed into a plane-filling shape such as a rectangle, an equilateral triangle, or a regular hexagon.

[0093] Next, a wall panel 81 according to a modified example will be described with reference to Figures 9 to 11. Note that the tray mounting material 11 is not shown in Figures 9 to 11. The wall forming material 9 and the tray mounting material 11 are not shown in Figures 9 and 10.

[0094] The wall panel 81 according to the modified example differs from the wall panel 1 according to the embodiment of the present invention in that ribs 87 are provided on both sides (front and back surfaces) in the thickness direction of the bottom wall portion 85 of the tray 83. In other respects, the wall panel 81 is configured in almost the same way as the wall panel 1 according to the embodiment of the present invention.

[0095] That is, the wall panel 81 of the modified example is configured to include a tray 83 having a bottom wall portion 85, a side wall portion 89, and a rib 87, a wall forming material, and a tray installation material 11, similar to the wall panel 1 of the embodiment of the present invention.

[0096] The side wall 89 stands upright from the edge of the bottom wall 85 toward the front side, and together with the bottom wall 85 forms a recess 95. The wall-forming material is filled into the recess 95 of the tray 83. The tray installation material is provided on the bottom wall 85 of the tray 83 on the opposite side (back side) from the side wall 89. The tray installation material is used when installing the tray 83 on a wall.

[0097] The ribs 87 also stand upright on the bottom wall 85 on the side opposite to the side wall. That is, the ribs 87 include a front rib 87 (87A) provided on the front surface of the bottom wall 85 and a back rib 87 (87B) provided on the back surface of the bottom wall 85.

[0098] Furthermore, a plurality of front-side recesses 91 (91A) are provided on the surface on the same side as the side wall 89 (the front surface, which is the surface on one side in the thickness direction of the bottom wall 85). A front-side rib 87A standing from the bottom wall 85 on the same side as the side wall 89 is formed between adjacent front-side recesses 91A that are slightly spaced apart from each other.

[0099] A plurality of back-side recesses 91 (91B) are provided on the surface opposite to the side wall 89 (the back surface, which is the surface on the other side in the thickness direction of the bottom wall 85). Ribs (back-side ribs) 91B standing up from the bottom wall 85 on the side opposite to the side wall 89 are formed between adjacent back-side recesses 91B that are slightly spaced apart from each other among the plurality of back-side recesses 91B.

[0100] Furthermore, in the wall panel 81 according to the modified example, the rear recess 91B is disposed at a different position from the front recess 91A when viewed in the thickness direction of the bottom wall portion 85.

[0101] As a result, when viewed in the thickness direction of the bottom wall portion 85, the back-side ribs 87B are disposed at positions different from the front-side ribs 87A. More specifically, when viewed in the thickness direction of the bottom wall portion 85, all of the back-side recesses 91B are disposed at positions different from all of the front-side recesses 91A. Furthermore, when viewed in the thickness direction of the bottom wall portion 85, the front-side recesses 91A are formed in all of the areas where the back-side recesses 91B are not formed. In other words, if the back-side recesses 91B were moved to the front side of the bottom wall portion 85 in the thickness direction of the bottom wall portion 85, a plurality of recesses 91 would be formed lined up at slight intervals across the entire front surface of the bottom wall portion 85.

[0102] In the above description, all of the back-side recesses 91B are arranged at positions different from all of the front-side recesses 91A when viewed in the thickness direction of the bottom wall 85, but some of the back-side recesses 91B may overlap some of the front-side recesses 91A. Also, when viewed in the thickness direction of the bottom wall 85, there may be portions of the bottom wall 85 where no back-side recesses 91B or front-side recesses 91A are formed.

[0103] 9, when the tray 83 is viewed from the front side in the thickness direction of the bottom wall 85, the ends of some of the front-side ribs 87A are attached to the side wall 89. As a result, some of the front-side ribs 87A extend from the side wall 89.

[0104] 10, when the tray 83 is viewed from the back side in the thickness direction of the bottom wall 85, the ends of some of the back ribs 87B are attached to the side wall 89. As a result, some of the back ribs 87B extend from the side wall 89.

[0105] Here, the wall panel 81 will be described in more detail. When the tray 83 is viewed from the front side in the thickness direction of the bottom wall 85, as shown in FIG. 9, each of the front recesses 91A constituting the plurality of front recesses 91A is formed in a rectangular shape. The rectangular front recesses 91A are arranged vertically and horizontally at small intervals. However, a rectangular blank area 93 (93A) is formed on the front surface of the bottom wall 85. The blank area 93A is an area where no front recess 91A is formed.

[0106] The vertical dimension of one rectangular blank area 93A is greater than the vertical dimension of one rectangular front-side recess 91 A. The horizontal dimension of one rectangular blank area 93A is also greater than the horizontal dimension of one rectangular front-side recess 91 A.

[0107] A plurality of blank areas 93A are provided, and are arranged in the vertical and horizontal directions at predetermined intervals. The horizontal and vertical dimensions between adjacent blank areas 93A are greater than the horizontal and vertical dimensions of a single rectangular front-side recess 91A.

[0108] When roughly viewing the tray 83 from the front side in the thickness direction of the bottom wall portion 85, the arrangement of multiple front side recesses 91A, which are arranged slightly apart from each other, appears to be in a grid pattern, as shown in Figure 9.

[0109] Furthermore, four of the plurality of (16) void regions 93A are located at the four corners of the rectangular bottom wall portion 85, respectively.

[0110] When viewing the tray 83 from the back side in the thickness direction of the bottom wall 85, as shown in Fig. 10, each of the multiple back recesses 91B is formed in a rectangular shape. The rectangular back recesses 91B are aligned vertically and horizontally at small intervals. However, a rectangular blank area 93 (93B) is formed on the back surface of the bottom wall 85. The blank area 93B is an area where no back recess 91B is formed.

[0111] The vertical and horizontal dimensions of one back-side recess 91B and the vertical and horizontal dimensions of one front-side recess 91A are approximately equal to each other. The vertical dimension of one rectangular blank area 93B is larger than the vertical dimension of one rectangular back-side recess 91B. The horizontal dimension of one rectangular blank area 93B is also larger than the horizontal dimension of one rectangular back-side recess 91B.

[0112] When viewing tray 83 in the thickness direction of bottom wall 85, blank area 93A on the front side and multiple rear recesses 91B arranged slightly apart from each other generally overlap each other. Also, when viewing tray 83 in the thickness direction of bottom wall 85, blank area 93B on the rear side and multiple front recesses 91A arranged slightly apart from each other generally overlap each other.

[0113] 9, the front-side ribs 87A are formed in a lattice pattern in the areas where the front-side recesses 91A are formed and spaced slightly apart from each other, excluding the blank areas 93A. The vertical and horizontal dimensions of the front-side ribs 87A are smaller than the vertical and horizontal dimensions of the front-side recesses 91A.

[0114] 10, the back-side ribs 87B are formed in a lattice pattern where the back-side recesses 91B are formed and spaced slightly apart from each other, excluding the blank areas 93B. The vertical and horizontal dimensions of the back-side ribs 87B are smaller than those of the back-side recesses 91B and are approximately equal to those of the front-side ribs 87A.

[0115] Alternatively, the front-side recesses 91A shown in FIG. 9 may be entirely removed, with the front-side recesses 91A provided only at the blank areas 93A shown in FIG. 9, and the back-side recesses 91B shown in FIG. 10 may be entirely removed, with the back-side recesses 91B provided only at the blank areas 93B shown in FIG. 10.

[0116] Here, the dimensions of the wall panel 81 will be illustrated. The value of dimension L31 is approximately 6.0 mm. The value of dimension L33 is approximately 300 mm, the same as wall panel 1. The value of dimension L35 is also approximately 300 mm, the same as wall panel 1. The value of dimension L37 is 2.5 mm. The value of dimension L39 is 2.0 mm. The value of dimension L41 is 1.5 mm. The value of dimension L43 is 2.0 mm.

[0117] In the wall panel 81, the ribs 87 stand not only on the front side of the bottom wall 85 of the tray 83 but also on the back side of the bottom wall 85. This increases the rigidity of the bottom wall 85 (increasing the value of the second moment of area), further reducing the amount of warping of the wall panel 81.

[0118] In addition, in the wall panel 81, ribs 87 are formed by recesses 91 formed in the bottom wall portion 85. This reduces the amount of material constituting the bottom wall portion 85, thereby reducing the weight of the wall panel 81 (tray 83).

[0119] Furthermore, in the wall panel 81, the rear recess 91B is positioned differently from the front recess 91A when viewed in the thickness direction of the bottom wall 85. This minimizes the difference in thickness between locations on the bottom wall 85, thereby reducing the amount of warping. [Explanation of symbols]

[0120] 1 wall panel 5. Walls (building walls) 7 trays 9 Wall forming material 11 Tray installation material 13 Bottom wall 15 Side wall 16 Outer surface (outer surface of side wall) 17 Ribs 19 Concave (quadratic pyramidal concave) 21 Bottom wall body 23 Bottom wall protrusion 25 Recess (annular recess) 63 Tray installation body 65 Bottom surface (bottom surface of bottom wall) 67 Top surface (top surface of tray installation body) 81 Wall Panel 83 Tray 85 Bottom wall 87, 87A, 87B Ribs 89 Side wall 91, 91A, 91B recesses L15 Thickness of bottom wall protrusion L14 Bottom wall body thickness

Claims

1. a tray including a bottom wall, a side wall rising from an edge of the bottom wall and forming a recess together with the bottom wall, and a rib rising from the bottom wall on the same side as the side wall; a wall-forming material filling the recess of the tray; a tray installation member provided on a bottom wall of the tray on the opposite side to the side wall, the tray installation member being used when installing the tray on a wall; A wall panel comprising:

2. 2. A wall panel according to claim 1, The bottom wall portion is configured to include a flat bottom wall portion main body portion and a flat bottom wall portion protruding portion, the thickness dimension of the bottom wall protrusion is smaller than the thickness dimension of the bottom wall main body, the thickness directions of the bottom wall main body and the bottom wall protrusion are aligned with each other, and the bottom wall protrusion protrudes slightly from the bottom wall main body on the opposite side to the side wall, A wall panel characterized in that, when viewed in the thickness direction of the bottom wall main body and the bottom wall protrusion, a ring-shaped recess formed by the side wall and the bottom wall protrusion is formed around the periphery of the bottom wall main body.

3. A wall panel according to claim 1 or claim 2, A wall panel characterized in that, when viewed in the thickness direction of the bottom wall portion, the rib is spaced apart from the side wall portion.

4. 2. A wall panel according to claim 1, A wall panel characterized in that the rib stands up from the bottom wall portion on the opposite side to the side wall portion.

5. 5. A wall panel according to claim 4, a plurality of front-side recesses are provided on the surface on the same side as the side wall portion, and a rib standing from the bottom wall portion on the same side as the side wall portion is formed between adjacent front-side recesses of the plurality of front-side recesses that are slightly spaced apart from each other, A wall panel characterized in that a plurality of rear recesses are provided on the surface opposite the side wall portion, and a rib standing from the bottom wall portion on the side opposite the side wall portion is formed between adjacent rear recesses of the plurality of rear recesses that are slightly spaced apart from each other.

6. 6. A wall panel according to claim 5, A wall panel characterized in that, when viewed in the thickness direction of the bottom wall portion, the back side recess is located at a position different from that of the front side recess.

7. A wall panel according to any one of claims 1 to 6, The outer peripheral surface of the side wall portion is formed in a side shape of a quadrangular pyramid, The size of the rectangular outer peripheral surface of the side wall portion changes in the thickness direction of the bottom wall portion, and A wall panel characterized in that the size of the rectangular outer peripheral surface of the side wall portion is larger on the bottom wall portion side and smaller on the tip side of the side wall portion.

8. A wall panel according to any one of claims 1 to 7, A wall panel characterized in that, when viewed in the thickness direction of the bottom wall portion, the tray installation material is provided only in the center of the bottom wall portion.

9. A bottom wall portion; a side wall portion standing upright from an edge of the bottom wall portion and forming a recess together with the bottom wall portion; and a rib extending from the bottom wall, A wall panel tray, characterized in that the recess of the tray is filled with a wall forming material, and the bottom wall portion of the tray opposite the side wall portion is configured to be provided with a tray installation material used when installing the tray on a wall.

10. a tray installation process for installing a tray having a flat bottom wall, side walls rising from an edge of the bottom wall and forming a recess together with the bottom wall, and ribs rising from the bottom wall, on a tray installation body having a flat upper surface, such that a lower surface of the bottom wall, which is the surface opposite to the side on which the side wall rises, faces an upper surface of the tray installation body, and the lower surface of the bottom wall follows the upper surface of the tray installation body; a wall-forming material filling step of filling a recess of the tray with a fluid wall-forming material after the tray is placed on the tray placement body in the tray placement step; a wall-forming material hardening step of hardening the wall-forming material filled in the wall-forming material filling step; a tray removing step of removing the tray from the tray installation body after the wall forming material is hardened in the wall forming material hardening step; A method for manufacturing a wall panel, comprising the steps of:

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