JP2002052552A - Method for manufacturing photosetting resin sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a photosetting resin sheet having good quality inclusive of surface smoothness, facilitating the reduction of the thickness of the photosetting resin sheet usable as a substrate for a liquid crystal display, a touch panel sheet, a transparent conductive sheet or the like, and capable of molding the photosetting resin sheet having a wide area without damaging the same. SOLUTION: A pair of plate-shaped molds 2a and 2b, at least one of which permits active energy beam to transmit, are opposed to each other at a predetermined interval, and the peripheral parts of them are sealed to form a molding cavity. A photosetting resin is injected in the molding cavity and irradiated with active energy beam through the plate-shaped molds permitting active energy beam to transmit to be cured and, subsequently, the photosetting resin molded object is released from the plate-shaped molds to obtain the photosetting resin sheet. In this manufacturing method, films 4a and 4b of which the surface roughness Ra is 20 nm or less are preliminarily provided to the inner surfaces of a pair of the plate-shaped molds.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of forming a smooth photocurable resin sheet by injecting a photocurable resin between molds, curing the photocurable resin, removing the mold, and forming a smooth photocurable resin sheet. The present invention relates to a method for producing a photocurable resin sheet that can be taken out without damaging the photocurable resin sheet, and particularly to a method for providing a photocurable resin sheet having excellent surface smoothness. The photocurable resin sheet obtained by the present invention is
Optical members for liquid crystal display panels, organic EL display panels, displays for touch panels, etc., storage and recording of optical disks, etc., for solar cell panels, etc., especially low birefringence optical members,
Particularly, it is suitably used for a liquid crystal display panel.

[0002]

2. Description of the Related Art Conventionally, a photo-curable resin sheet is prepared by injecting a photo-curable resin between molding dies and curing the photo-curable resin.
The light-cured resin sheet is molded by releasing the mold and the molded body,
Manufactured. However, in the above molding method, when the photocurable resin sheet is released from the molding die, since the adhesive force between the molding die and the cured photocurable resin sheet is strong, when the photocurable resin sheet is released from the molding die. In addition, there is a problem that the sheet is easily damaged. Further, the problem is more remarkable when the thickness of the sheet is small and when the area of the sheet is large.

[0003] A technique is known in which a photocurable resin is molded in a state where a film is interposed between the inner surfaces of a pair of plate-shaped molds, and a photocurable resin sheet is obtained without breakage. For example, Japanese Patent Application Laid-Open No. 2000-832 discloses that the surface roughness Ra is 100
A production method has been proposed in which a photocurable resin sheet is released from a mold without damage using a film having a thickness of about nm or less. However, when a film having such a surface roughness is used, it is difficult to obtain a photocurable resin sheet having a high surface smoothness, and it is important to have a surface smoothness in applications such as a liquid crystal display sheet and a touch panel sheet. It is difficult to apply to

[0004]

DISCLOSURE OF THE INVENTION In view of the above situation, the present invention relates to a method of forming a cavity by using a molding die, and injecting a photocurable resin into a casting die having a peripheral portion sealed therewith. After irradiating the line to cure the photocurable resin,
An object of the present invention is to provide a method for producing a photocurable resin sheet having a small surface roughness, which can be used as a sheet for a liquid crystal display or a touch panel in a method for releasing a molding die to form a smooth photocurable resin sheet.

[0005]

As a result of intensive studies, the present inventors have found that a very smooth film having a surface roughness Ra of 20 nm or less is formed on each inner surface of a pair of plate-shaped molds in a specific molding method. When molding in the state of being interposed, it was found that a resin sheet having the expected surface smoothness was obtained,
The present invention has been reached.

That is, the gist of the present invention is to form a molding cavity by facing a pair of plate-shaped molds, at least one of which transmits an active energy ray, at a predetermined interval and sealing the peripheral portion. Inject the photocurable resin into the tee, pass the active energy ray through the plate-shaped mold that transmits the active energy ray, irradiate the photocurable resin with the active energy ray to cure the photocurable resin, and then mold the photocurable resin molded body. In the method of obtaining a photocurable resin sheet by releasing from a plate-shaped molding die, the inner surface of each of the pair of plate-shaped molding dies has a surface roughness Ra of 20.
The present invention resides in a method for producing a photocurable resin sheet, which is formed by interposing a film having a thickness of at least nm.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION As the photocurable resin used in the present invention, a resin which is cured by irradiation with active energy rays such as ultraviolet rays is used. For example, a photocurable resin composition comprising an acrylate compound having a radically reactive unsaturated bond, a photocurable resin composition comprising an acrylate compound having a radically reactive unsaturated bond and a mercapto compound having a thiol group, epoxy acrylate, Examples include a photocurable resin composition in which an oligomer such as urethane acrylate, polyester acrylate, or polyether acrylate is melted into a polyfunctional acrylate monomer.

Above all, a photocurable resin composition comprising an acrylate compound and a mercapto compound having a thiol group is preferred in terms of heat resistance, moldability, optical performance and the like. Examples of the acrylate compound include compounds represented by the following general formula (I). It is preferable to use the following general formulas (I) and (II) in combination.

[0009]

Embedded image

(Wherein, R ¹ and R ² each independently represent a hydrogen atom or a methyl group, m represents 1 or 2, n represents 0 or 1, p and q each independently represent In the compounds represented by the general formula (I), bis (hydroxymethyl) tricyclo [5.2.1.0 ^2,6 ] decane = diacrylate, bis (hydroxy Methyl) tricyclo [5.2.1.0 ^2,6 ] decane = dimethacrylate, bis (hydroxymethyl) tricyclo [5.2.
1.0 ^2,6 ] decane acrylate methacrylate and mixtures thereof are preferred. ,

Embedded image (Wherein, R ³ represents a hydrogen atom or a methyl group, m represents 1 or 2, n represents 0 or 1, r and s each independently represent 0, 1 or 2) Among the compounds represented by the formula (II), bis (hydroxymethyl) tricyclo [5.2.1.0 ^2,6 ] decane = monoacrylate, bis (hydroxymethyl) tricyclo [5.2.1.0 ^{2 , 6} ] decane = monomethacrylate and mixtures thereof.

The compounding ratio of the compound represented by the general formula (I) and the compound represented by the general formula (II) is the sum of the compound represented by the general formula (I) and the compound represented by the general formula (II) The amount of the compound of the formula (I) is usually 70 to 99 parts by weight, preferably 80 to 9 parts by weight, per 100 parts by weight.
8 parts by weight, more preferably 90 to 96 parts by weight, and the compound represented by formula (II) is usually 1 to 30 parts by weight, preferably 2 to 20 parts by weight, more preferably 4 to 10 parts by weight. If the proportion of the compound represented by the general formula (II) is too small, the effect of improving the mechanical strength of the cured resin cannot be obtained. If the proportion is too large, the heat resistance of the cured resin may be reduced.

Examples of the mercapto compound having a thiol group include compounds represented by the following general formulas (III), (IV) and (V).

[0013]

Embedded image

(Wherein, R ⁴ represents a methylene group or an ethylene group, R ⁵ represents a hydrocarbon residue having 2 to 15 carbon atoms which may contain ether oxygen, and a represents an integer of 2 to 6) In the formula (III), R ⁵ is a hydrocarbon residue having 2 to 15 carbon atoms which may contain ether oxygen. Specific examples thereof include, for example, a pentaerythritol residue and a dipentaerythritol residue. , A trimethylolpropane residue,
Ethylene glycol residue, diethylene glycol residue,
Triethylene glycol residues, butanediol residues, and the like.

The mercapto compound of the formula (III) has 2 to 6
And thioerythritol tetrakis (β-thiopropionate), pentaerythritol tetrakis (thioglycolate), and trimethylolpropane tris (β). -Thiopropionate), trimethylolpropane tris (thioglycolate), ethylene glycol bis (β-thiopropionate), ethylene glycol bis (thioglycolate), diethylene glycol bis (β-thiopropionate), diethylene glycol Bis (thioglycolate), triethylene glycol bis (β-thiopropionate), triethylene glycol (thioglycolate), butanediol bis (β-thiopropionate), butanediol bis (thio Rikoreto), dipentaerythritol hexakis (beta-thiopropionate), dipentaerythritol hexakis (thioglycolate), and the like.

[0016]

Embedded image

Wherein X is HS— (CH ₂ ) _b —CO—
_{(OCH 2 CH 2) d -} (CH 2) c - shows a. However,
b and c each independently represent an integer of 1 to 8,
d represents 0, 1 or 2) The compound of the formula (IV) is a β-thiol group-containing isocyanate. Specific examples of the compound of the formula (IV) include, for example, tris [2- (β-thiopropionyloxy) ethyl] isocyanurate, tris [2- (thioglyconyloxyethyl) isocyanurate, tris [2- (β −
Thioglyconyloxyethoxy) ethyl] isocyanurate, tris (2-thioglyconyloxyethoxy) ethyl) isocyanurate, tris [3- (β-thiopropionyloxy) propyl] isocyanurate, tris (3-thioglyconyloxy Propyl) isocyanurate and the like.

[0018]

Embedded image

(Wherein, R ⁶ and R ⁷ each independently represent an alkylene group, e and f each independently represent 0 or 1, and g represents 1 or 2). The compound V) is a thiol group-containing hydrocarbon. Specific examples of the compound of the formula (V) include, for example, benzenedimercaptan, xylylenedimercaptan, 4,4'-dimercaptodiphenylsulfide and the like.

The mixing ratio of the mercapto compound is usually 1 to 10 parts by weight, preferably 4 to 8 parts by weight, based on 100 parts by weight of the acrylate compound. If the proportion of the mercapto compound is too small, the birefringence of the cured resin increases, and if it is too large, the heat resistance of the cured resin may decrease. Usually, the photocurable resin composition is mixed with a photopolymerization initiator that generates radicals by active energy rays.

Known compounds can be used as the photopolymerization initiator. The mixing ratio of the photopolymerization initiator is usually 0.01 to 1 part by weight, preferably 0.02 to 0.3 part by weight, based on 100 parts by weight of the monomer in the photocurable resin composition. If the proportion of the photopolymerization initiator is too small, the composition cannot be sufficiently cured, and if it is too large, the polymerization proceeds rapidly and not only increases the birefringence,
Hue may also deteriorate.

The photocurable resin composition contains an antioxidant, an ultraviolet absorber, a surfactant, a dye, a pigment, a leveling agent,
An additive such as a thixotropic agent may be mixed. As shown in the figure, a molding die 1 used for molding a photocurable resin composition has a pair of plate-shaped molding dies 2a and 2b opposed to each other at a predetermined interval, and the peripheral portion thereof is a sealing material 3.
Sealed with.

The plate-shaped molds 2a and 2b can be formed as flat plates as shown in FIG. 1, or can be formed into a curved or corrugated plate state according to the purpose. Further, only the inner surface can be provided with an article shape or pattern such as a waveform, a grating lens structure or the like. At least one of the plate-shaped molds 2a and 2b is made of a material through which active energy rays transmit and is not easily deformed by heat or a solvent. For example, glass and a plastic plate such as an acrylic resin plate can be used. A glass plate is preferred in terms of heat resistance and low thermal expansion.

The other plate-shaped mold may be made of the same material as the one plate-shaped mold, or a material different from the other plate-shaped mold that does not transmit active energy rays such as metal. You may. A plate-shaped molding die 2a provided to face the
The material of the sealing material 3 for sealing the peripheral portion of 2b is not particularly limited, and rubber, plastic, metal, or the like can be used. If a thick sealing material 3 is used, it acts as a spacer for regulating the interval between the plate-shaped molds 2a, 2b.
A spacer or the like (not shown) is interposed between b and a tape or the like can be used as a sealing material.

Films 4a, 4b are formed on the inner surfaces of the plate-shaped molds 2a, 2b used in the present invention. In the present invention, the film may be interposed in advance on at least one inner surface of the plate-shaped mold, but it is preferable that the film is interposed in advance on any of the inner surfaces. Film 4
For a and 4b, a material that transmits an active energy ray sufficient to cure the photocurable resin is used. Usually, the transparency (light transmittance) of the films 4a and 4b is 80% or more, preferably 85% or more. In addition, films 4a, 4b
Is made of an active energy ray for curing the photocurable resin, or a substance that does not easily deform its shape due to heat generated at the time of curing, etc., and has a glass transition temperature (T
g) is usually 100 ° C. or higher, preferably 150 ° C. or higher, and usually 250 ° C. or lower.

As materials suitable for this purpose, polyethylene terephthalate, polymethylpentene, polycarbonate and the like can be used, but they are low in transparency, heat resistance, strength and adhesion to a photocurable resin. Polyethylene terephthalate is particularly preferred. Further, the surfaces of the films 4a and 4b may be subjected to surface treatment such as coating treatment and corona treatment for various purposes such as imparting releasability, improving slipperiness, improving surface roughness and improving gas barrier properties. Good.

The surfaces of the films 4a and 4b need to have a surface roughness Ra of 20 nm or less, preferably 10 nm or less. The smaller Ra is, the easier it is to release from the plate-shaped mold in which the photocurable resin sheet and the film are fixed, and a sheet having a good surface condition can be obtained. If Ra is greater than this,
The surface smoothness of the obtained photocurable resin sheet cannot be obtained, which is not preferable.

The surface roughness Rmax of the surfaces of the films 4a and 4b is usually 150 nm or less, preferably 100 nm.
m or less. Usually, a filler such as calcium carbonate powder, silica powder, and titanium oxide powder is filled in the resin film in an amount of about several hundred ppm in order to prevent scratches and other scratches and to improve handling properties. If the filler loading is large, the surface smoothness of the film is lost, which is not preferable. Films 4a and 4b having a surface roughness Ra of 10 nm or less
The preferred filler loading for obtaining
pm or less, preferably 50 ppm or less, usually 3p
pm or more, preferably 5 ppm or more.

The thickness of the films 4a and 4b used in the present invention is usually 10 to 500 μm. 5 film thickness
When it is larger than 00 μm, the flexibility of the film is insufficient, and the photocurable resin sheet tends to be damaged when the photocurable resin sheet is released from the mold. This is particularly noticeable. On the other hand, when the thickness of the film is less than 10 μm, the film portion is easily damaged when the film is removed from the plate-shaped mold.

The films 4a and 4b are preferably used fixed to a molding die in order to improve the shape stability of the molded product or to facilitate repeated use as a molding die. As the fixing method, (1) a method of fixing with a spacer, (2) a method of fixing a film with an adhesive layer made of an adhesive, an adhesive or an adsorbent applied to the plate-shaped molds 2a, 2b, 3) Film 4
a, a method of fixing a film in which an adhesive layer is applied and formed in advance to the plate-shaped molds 2a, 2b, etc., in that the film is not easily bent or wrinkled,
The method of fixing the films of (2) and (3) to each inner surface of a pair of plate-shaped molds via an adhesive layer is preferable, and particularly the method of (3)
Is preferred.

In the above (2) and (3), as a means for fixing the film, a method of laminating with a laminator or the like is preferably used. In this case, it is preferable to set the lamination pressure relatively high in order to ensure the surface smoothness of the molded product.
It is about 5 MPa or more and about 0.5 MPa or less. The laminating roll can be heated for the purpose of performing good lamination.

When a photocurable resin sheet is formed using such a mold 1, a polymerization initiator and other components are provided in a cavity 5 defined by the opposing plate-shaped molds 2a and 2b and the sealing material 3. Is injected, and the active energy ray 6 is irradiated from the direction of the active energy ray-transmitting plate-shaped mold 2a to cure the photocurable resin. At this time, the mold 1 can be heated or cooled as needed.

The active energy ray may be any as long as it cures the photocurable resin used, and examples thereof include ultraviolet rays and electron beams. The irradiation amount of the active energy ray may be an amount that cures the photocurable resin to be used, and the wavelength is, for example, 20 in consideration of the types and amounts of the monomer and the polymerization initiator.
Ultraviolet rays of 0 to 400 nm are usually applied in a range of 0.1 to 200 j.

Irradiation with active energy rays may be carried out in one step, but in order to obtain a photocurable resin sheet having good surface properties, it is preferable to carry out irradiation in a plurality of steps, at least two steps. When the irradiation is carried out in two stages, the first stage is usually 15% or less, preferably 1% or less of the required amount of the active energy ray for curing.
Irradiation is performed at 0% or less, particularly preferably at 7% or less, to gel the photocurable resin composition in the mold so that the resin composition has a self-preserving formation, that is, the resin does not leak even if the spacer is removed. In the specification, the required curing amount of the active energy ray refers to the irradiation amount required to eliminate 80% of the ethylenic carbon-carbon double bond of the photocurable resin composition in the mold. . The rate of disappearance of the ethylenic carbon-carbon double bond due to irradiation with active energy rays is calculated by the following equation.

The loss amount = (1-K / M) × 100 (%) M = A M / B M A M: the peak area of the double bonds prior to irradiation active energy ray in the infrared absorption B _M: active energy ray C- in infrared absorption before irradiation
H bond peak area _{K = A K / B K A} K: the peak area of the double bond in the infrared absorption after irradiation with an active energy ray B _K: C-in infrared absorption after active energy ray irradiation
The peak area of the H bond is 1658.5 to 1591 cm.
^-1 and the peak of CH bond is 3210-280.
Appears at 9.8 cm ^-1 .

In the second stage, 95-100% of the monomer
Irradiation is carried out so as to react to complete the polymerization. The atmosphere for irradiating the active energy ray may be either a normal atmosphere or an inert gas atmosphere. The temperature at the time of irradiation is usually from room temperature to 100 ° C. in the first stage and from room temperature to 300 ° C. in the second stage. And the irradiation time is usually 1 in the first stage.
The second stage is 10 seconds to 10 minutes.

As a light source of the active energy ray, a chemical lamp, a xenon lamp, a low-pressure mercury lamp, a high-pressure mercury lamp, a metal halide lamp, or the like is used. After curing by irradiation with the active energy ray 6, the plate-shaped molds 2 a and 2 b are released from the photocurable resin sheet 7. Normal,
With the plate-shaped molds 2a, 2b and the films 4a, 4b fixed, only the photocurable resin sheet 7 is released. When the photocurable resin sheet is released from the mold while being usually heated to about 100 to 150 ° C., the film is softened, the flexibility increases, and the release becomes easy.

After the photocurable resin sheet 7 with the films 4a and 4b attached thereto is released from the plate-shaped molds 2a and 2b, the films 4a and 4b may be peeled off. In this case, if the adhesive layer for fixing the films 4a and 4b to the plate-shaped molds 2a and 2b, the adhesive strength of which is reduced by irradiating active energy rays is used, This is preferable because the mold can be easily released between the films 4a and 4b.

The photocurable resin sheet thus obtained has a surface roughness Ra of usually 20 nm or less, preferably 1 nm or less.
5 nm or less, and the surface roughness Rmax is usually 150 n
m, preferably 100 nm or less, and is excellent in surface smoothness. The thickness of the obtained photocurable resin sheet is usually 50 to 3000 μm, and the birefringence is usually 10 nm or less, preferably 5 nm or less.

[0040]

According to the method of the present invention, a photocurable resin sheet which can be suitably used as a substrate such as a liquid crystal display, a sheet for a touch panel, and a transparent conductive sheet can be easily thinned and has a large area. In addition, it is possible to form a photocurable resin sheet of good quality including surface smoothness with good productivity while also forming without damage.

[0041]

EXAMPLES Hereinafter, the content of the present invention will be described in more detail with reference to examples, but the present invention is not limited to the following examples unless it exceeds the gist. The evaluation method is as follows. Releasability: When releasing the cured photocurable resin sheet from the mold, the sheet was visually inspected for breakage or not. Surface roughness: Ra and Rmax were measured with a Surfcom surface roughness meter (manufactured by Tokyo Seimitsu Co., Ltd.).

<Example 1> Two glass flat plates (length 30)
A 25 μm-thick polyethylene terephthalate film (surface roughness Ra = 8 nm; manufactured by Mitsubishi Chemical Polyester Film Co., Ltd.) coated with an adhesive on one side was fixed by lamination using a laminator. The two glass flat plates are opposed to each other so that the surface on which the polyethylene terephthalate film is fixed is the inner surface, and the spacer is 5 mm wide and 1 mm thick.
A cavity was formed by using a silicone plate having a thickness of 0.1 mm, and the periphery was sealed with a tape to form an injection mold.

99 parts by weight of p-bis (β-methacryloyloxyethylthio) xylylene, 1 part by weight of pentaerythritol tetrakis (β-thiopropionate), 2,4,6-trimethylbenzoyldiphenylphosphine as a photopolymerization initiator 0.1 parts by weight of oxide (manufactured by BASF) and 0.1 parts by weight of benzophenone were uniformly stirred and mixed, and then defoamed to obtain a photocurable resin composition. This photocurable resin composition is injected into an injection mold, and the distance from the glass surface is 4 mm.
UV irradiation was carried out in two stages of 30 seconds and then 5 minutes using a metal halide lamp having a power of 80 W / cm from both upper and lower sides at 00 mm and cured. Thereafter, the entire casting mold was put into an oven at 150 ° C. to soften the polyethylene terephthalate film and release the photocurable resin sheet. Table 1 shows the evaluation results of the obtained photocurable resin sheet.

<Example 2> A spacer having a width of 5 mm was used.
Example 1 except that a 0.5 mm thick silicone plate was used.
The same was done. Table 1 shows the evaluation results of the obtained photocurable resin sheet. <Example 3> Bis (oxymethyl) tricyclo [5.
2.1.0 ^2,6 ] decanedimethacrylate 95 parts by weight,
5 parts by weight of pentaerythritol tetrakis (β-thiopropionate) and 0.2 parts of 2,4,6-trimethylbenzoyldiphenylphosphine oxide as a photopolymerization initiator.
1 part by weight and 0.1 part by weight of benzophenone were uniformly stirred and mixed, and the same procedure as in Example 1 was carried out except that a photocurable resin composition obtained by defoaming was used. Table 1 shows the evaluation results of the obtained photocurable resin sheet. <Example 4> Bis (oxymethyl) tricyclo [5.
2.1.0 ^2,6 ] decane dimethacrylate 94 parts by weight,
Bis (oxymethyl) tricyclo [5.2.1.
0 ^2,6 ] decane monomethacrylate 6 parts, pentaerythritol tetrakis (β-thiopropionate) 5 parts by weight, photopolymerization initiator 2,4,6-trimethylbenzoyldiphenylphosphine oxide 0.1 parts by weight, benzophenone 0.1 part by weight was uniformly stirred and mixed, and the same procedure as in Example 1 was carried out except that the photocurable resin composition obtained by defoaming was used. Table 1 shows the evaluation results of the obtained photocurable resin sheet.

<Comparative Example 1> A procedure was performed in the same manner as in Example 1 except that the polyethylene terephthalate film was not used. Table 1 shows the evaluation results of the obtained photocurable resin sheet. <Comparative Example 2> Instead of a polyethylene terephthalate film, a commercially available film (manufactured by Lintec Corporation;
m; surface roughness Ra = 40 nm)
The same was done. Table 1 shows the evaluation results of the obtained photocurable resin sheet. <Comparative Example 3> Instead of a polyethylene terephthalate film, a commercially available film (manufactured by Lintec Co .;
m; surface roughness Ra = 40 nm)
The same was done. Table 1 shows the evaluation results of the obtained photocurable resin sheet.

<Comparative Example 4> The procedure of Example 3 was repeated, except that a commercially available film (manufactured by Lintec; thickness: 65 µm; surface roughness Ra: 40 nm) was used instead of the polyethylene terephthalate film. Table 1 shows the evaluation results of the obtained photocurable resin sheet. <Comparative Example 5> Instead of a polyethylene terephthalate film, a commercially available film (manufactured by Lintec Co .;
m; surface roughness Ra = 40 nm)
The same was done. Table 1 shows the evaluation results of the obtained photocurable resin sheet.

[0047]

[Table 1]

[Brief description of the drawings]

FIG. 1 is a partially cutaway perspective view of a molding die showing an embodiment of the present invention.

[Description of Signs] 1 Mold 2a, 2b Plate-shaped mold 3 Sealing material 4a, 4b Film 5 Cavity 6 Active energy ray 7 Photocurable resin sheet

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F202 AA44 AD08 AG01 AJ06 AK03 CA01 CB01 CD21 CD30 CK86 CK90 CL02 CM90 CN01 CN12 CN25 4F204 AA44 AD08 AG02 AJ06 AK03 EA03 EB01 EB12 EF01 EF05 EF27 EK13 EK18 EW06

Claims (6)

[Claims] 1. A molding cavity is formed by opposing a pair of plate-shaped molds, at least one of which transmits an active energy ray, at predetermined intervals and sealing a peripheral portion thereof, and a photocurable resin is formed in the cavity. Is injected, and the photocurable resin is irradiated with active energy rays through a plate-shaped mold that transmits active energy rays to cure the photocurable resin, and then the photocured resin molded body is separated from the plate-shaped mold. A method for obtaining a photo-curable resin sheet by molding, wherein a photo-curable resin sheet is formed on each inner surface of a pair of plate-shaped molds in advance with a film having a surface roughness Ra of 20 nm or less interposed therebetween. Manufacturing method. 2. The method according to claim 1, wherein the film is made of polyethylene terephthalate resin. 3. The film has a filler content of 100 ppm.
The method for producing a photocurable resin sheet according to claim 1 or 2, which is the following film. 4. The light according to claim 1, wherein the film is removed by heating the photocurable resin molding when releasing the photocurable resin molded product from the plate-shaped mold. A method for producing a cured resin sheet. 5. The method for producing a photocurable resin sheet according to claim 1, wherein the film is fixed to a mold and used. 6. A photocurable resin sheet for a liquid crystal display panel having a surface roughness Ra of 20 nm or less.