Method for producing a carrier element with an integrated optical element

Abstract

The invention relates to a method for producing a carrier element (2) with an integrated optical element (27) for capturing a luminous flux emitted by a light source and deflecting it in the direction of a roadway of a vehicle headlight (4). The method comprises inserting (S100) a material layer (11) with an optical effect into an open shaping cavity (10) of a molding tool (1), closing (S200) the shaping cavity (10) of the molding tool (1) and clamping (S200) the material layer (11). Furthermore, the material layer (11) is back-injected (S300) with a melt (12) of a thermoplastic material, followed by opening (S400) the molding tool (1) and demolding (S400) the formed carrier element (2).The shaping cavity (10) is designed to create a shape for the support element (2), so that the demolded support element (2) comprises two side elements (21) arranged opposite one another, a front element (22) extending between front ends (211) of the side elements (21), and a base element (23) extending between lower ends (212) of the side elements (21). The front element (22) has a recess (221) for receiving an intermediate light disc (222) for emitting the luminous flux in the direction of the roadway, and the support element (2) comprises an outer surface (29) and an inner surface (26) which comprises the material layer (11).

Description

[0001] The invention relates to a method for producing a carrier element with an integrated optical element and to a vehicle headlight comprising a carrier element produced by such a method.

[0002] Today's vehicle headlights must meet a wide range of requirements. These include the number of lighting functions to be implemented, normative and / or legal specifications, and, in particular, the limitations of the available installation space. In addition, design and aesthetic requirements are growing. Vehicle headlights typically comprise modules that implement the various lighting functions. A frontal vehicle headlight, for example, has a module that contains a high beam, a module that contains a low beam, and a module for a daytime running light and / or a signature. Among other things, the latest design trends feature the design of daytime running lights and / or repeating patterns such as stripes in the distinctive headlight and taillight functions, which are also referred to as signatures.

[0003] Due to the advancement of lighting technology, the demands placed on the lighting components in vehicle headlights are growing. The lighting functions must meet and fulfill current design / styling trends. To meet user needs, the vehicle headlight should have smaller dimensions, particularly in the z-direction, and therefore be designed flat, thus reducing the remaining installation space for the lighting technology. This poses a major challenge for the implementation of all required lighting functions. In particular, very stringent design requirements must be met when designing signal light functions and signatures in the headlight.

[0004] DE 10 2015 015 360 A1 describes a headlight for a motor vehicle comprising a light source, a projection lens, an optical element correcting a chromatic aberration of the projection lens and a diaphragm arranged between the light source and the projection lens for generating a light cone with a sharp upper boundary, on which the corrective optical element is mounted at a distance from the projection lens.

[0005] DE 20 2016 106 599 U1 describes a cover plate for a motor vehicle headlight, comprising a translucent plate body and at least one film covering the plate body at least in sections.

[0006] Known solutions for characteristic or repetitive structures for signatures include repeating identical or varying optical elements. In other words, a light source is equipped with primary optics, such as a reflector, which projects the light onto a light-conducting element, where it is then coupled. Gaps between the individual elements are masked, e.g., by multiple apertures.

[0007] Such components are usually manufactured in the form of two-component components using the injection molding process or by chrome plating, vapor deposition or metallizing of apertures to ensure the lighting functions.

[0008] Vehicle headlights are therefore becoming increasingly complex and heavy. Current solutions are also not suitable for integration into a single component. For this reason, the lighting components are covered with additional covers. This often results in double material and double wall thickness. In addition, the components must be manufactured in various process steps including injection molding, vapor deposition, and metallization to ensure all functions are met.

[0009] The invention is based on the object of providing a method for producing a carrier element with an integrated optical element, which at least partially overcomes the aforementioned disadvantages of the prior art.

[0010] The objects are achieved entirely or at least partially by a method for producing a one-piece carrier element with an integrated optical element, as well as by a vehicle headlight comprising a carrier element produced by such a method, having the features of the independent claim. Further preferred embodiments of the invention emerge from the remaining features recited in the subclaims.

[0011] According to the invention, a method is provided for producing a carrier element with an integrated optical element for capturing a luminous flux emitted by a light source and deflecting it toward a roadway of a vehicle headlight. The method comprises inserting a material layer with an optical effect into an open shaping cavity of a mold, closing the shaping cavity of the mold, and clamping the material layer. Furthermore, the material layer is back-injected with a melt of a thermoplastic material, followed by opening the mold and demolding the formed carrier element.The shaped cavity is formed to create a form for the carrier element, such that the demolded carrier element comprises two side elements arranged opposite to each other, a front element that extends between front ends of the side elements, and a bottom element that extends between lower ends of the side elements. The front element has a recess for receiving an intermediate light disc for radiating the light flux in the direction of the road surface, and the carrier element comprises an outer surface and an inner surface, wherein the inner surface comprises the material layer.

[0012] In other words, the shaping cavity is designed to create a shape for the carrier element, whereby a carrier element is created which represents a one-piece module for implementing the lighting functions or a compact housing for implementing the lighting functions or a housing with an integrated optical element for implementing the lighting functions, wherein the optical element is formed by the material layer.

[0013] The process applies the basic principle of in-mold decoration (IMD), which is an extension of conventional thermoplastic injection molding. This involves decorating a support part with a layer of material. The layer of material is inserted into the mold, also known as the injection mold, and clamped between the mold halves when the mold is closed. When the melt is injected, the pressure forces the layer of material against the inner wall of the cavity. The high temperature of the melt causes the layer of material to bond with the injected plastic. After cooling, the finished, decorated support element can be removed.

[0014] The technique of in-mold decoration, or film back-injection, is possible with minor modifications to an existing injection molding machine familiar to those skilled in the art. This requires an automatic feed device for the material layer to be attached to a fixed clamping plate of the machine. The feed, i.e., the application, of the material layer can usually be regulated via an external control unit.

[0015] Accordingly, the method according to the invention produces a carrier element of a vehicle headlight with an integrated optical element, wherein the carrier element is formed in one piece, comprising the two side elements arranged opposite one another, the front element which extends between the front ends of the side elements and the base element which extends between the lower ends of the side elements.

[0016] Due to the one-piece design, the outer surface and the inner surface are formed by the respective inner and outer surfaces of the corresponding elements. In other words, the outer surface and the inner surface are composed of the respective outer and inner surfaces of the elements.

[0017] In other words, the outer surface of the support element is an A-side, or class A surface. In automotive design, a class A surface is any series of freeform surfaces of high efficiency and quality. Although strictly speaking, it simply means that the surfaces have curvature and a tangent orientation. Class A surfaces are modeled using computer-aided industrial design applications. Class A surface modelers are also known in the industry as "digital sculptors." Industrial designers develop their design style through the A-surface, the physical surface that the end user can feel, touch, see, etc. Class A surfaces are therefore defined as any surface that has a design intent that is either seen, touched, or both. In automotive design, Class A surfaces are used on all visible exterior surfaces (e.g.,Body panels, bumpers, grille, headlights, etc.) and on all visible surfaces of touchable parts in the interior (e.g., dashboard, seats, door upholstery, etc.). This may also include engine compartment covers, mud flaps, trunk linings, and carpeting.

[0018] In other words, the inner surface of the support element is a B-side, or Class B surface. A Class B surface is a high-quality surface with only minimal defects.

[0019] Preferably, the thermoplastic comprises an opaque, i.e., light-impermeable material. This provides a carrier element whose entire body is opaque, thus fulfilling a covering and light-shielding function.

[0020] Until now, comparable components have been manufactured by connecting and assembling several, particularly more than three, separate components to meet lighting and aesthetic requirements. The production of such a component involves the manufacture of a cover, a separate reflector, and a circuit board. This is currently achieved using conventional injection molding processes to create a cover with a grained surface, which is then mechanically connected to the separate reflector and the circuit board.

[0021] The support element serves the function of concealing an interior area, thereby improving the user experience and preventing unwanted light leakage. The support element thus combines the function of a cover and an illumination function, while simultaneously reducing material and parts requirements. This makes it possible to manufacture a single component instead of multiple components, which conceals areas as required and fulfills the lighting function. The process thus provides a support element or housing that is particularly weight-saving and uses less material. This reduces the economic footprint on the one hand and manufacturing costs on the other. This has a significant impact, as it is a component that is manufactured and used in correspondingly large quantities.Furthermore, the single-piece design and combination of functions in a single component allows for significant space savings, particularly in the z-direction relative to a vehicle in which the component manufactured according to the invention is installed. Furthermore, an increase in the size of the intermediate lens or light exit area is possible by using fewer panels or smaller frames. Furthermore, production and assembly take place in a single operation.

[0022] In addition, the ridges, steps, and protrusions used in current panel components to conceal separate lighting components can be eliminated. These serve to conceal internal areas, such as a reflector surface, to prevent unwanted light from escaping or to shield unwanted components from the outside. Depending on the design, the reflectors include chrome-plated surfaces that, on the one hand, reflect light into areas where it is undesirable or disruptive, and, on the other hand, contradict the user's visual needs.

[0023] During production, for example, these are vapor-deposited, which causes irregularities such as droplet formation, which leads to the adverse effects described above. User needs and the user experience are also improved by concealing unsightly internal components. Another disadvantage is that such webs generally increase the space required by the panel, particularly in the z-direction, which counteracts the demand for panels with a lower height. These webs can be avoided through one-piece production. The outer side of the support element, for example, is then designed with aesthetic aspects in mind so that it also meets visible user requirements and no disruptive light can escape to the outside. In addition, the height of the component is reduced. Savings of several millimeters can be achieved in this way.

[0024] Preferably, at least one inner surface of the base element, forming part of the inner surface of the support element, comprises the material layer. Particularly preferably, additionally or alternatively, inner surfaces of the respective side elements and / or the front element, forming another part of the inner surface of the support element, comprise the material layer. As a result, the lighting effect of the first material layer affects the luminous flux emitted by the light source, which is modified according to a desired lighting function.

[0025] Preferably, the front element is connected to the front ends of the side elements in a material-to-material, gap-free manner, while the base element is connected to the lower ends of the side elements in a material-to-material, gap-free manner, and / or the front element is connected to the base element in a material-to-material, gap-free manner. This achieves a gap-free design, preventing unwanted or disruptive light leakage. In other words, the elements continuously conceal an interior area defined by them. They form a formwork or housing.

[0026] In a preferred embodiment of the invention, the shaping cavity is designed to create a mold for the support element, so that the outer surface of the demolded support element has a surface texture, preferably a grain. Graining refers to the structuring of a surface, which is essentially responsible for the haptic and visual properties. Characteristic features include recurring height differences, which can be both irregularly and regularly geometrically designed. These can also be associated with differences in brightness.

[0027] This improves the user experience by providing an attractive surface with a covering function.

[0028] According to a further preferred embodiment of the invention, the shaping cavity is designed to create a shape for the support element, such that the demolded support element comprises a ceiling element arranged opposite the base element and extending between the upper ends of the side elements. This increases shielding and further reduces the escape of light at undesired locations. In addition, light conduction within an interior region formed by the elements and within which the luminous flux propagates is improved, particularly if a part of the inner surface attributable to the ceiling element also comprises the material layer. Preferably, the shaping cavity is designed to create a shape for the support element, such that the ceiling element comprises a recess for receiving a circuit board.

[0029] Preferably, the shaping cavity is designed to create a shape for the support element, so that the demolded support element comprises a rear element arranged opposite the front element and extending between the rear ends of the side elements. This ensures a rear cover of the support element, which is particularly suitable for directing the luminous flux toward the recess of the front element in order to improve the lighting function.

[0030] In a further preferred embodiment of the invention, the shaping cavity is designed to create a shape for the support element, such that the support element comprises a bending region extending between the side elements, wherein the bending region forms a materially integral connection between the rear element and the base element or the ceiling element and comprises a film hinge. The film hinge is a geometric thinning. In other words, the thickness of the support element in the region of the film hinge is reduced compared to the surrounding or remaining regions of the support element. Film hinges, also called film joints, are band hinges and have no mechanical parts. They are a flexible, thin-walled joint groove between two parts to be connected. This is particularly preferred when combined with a thermoplastic material in the bending region.This significantly simplifies production in connection with the back-injection of the material layer for forming the support element. Demolding is made considerably more difficult, especially with more complex geometric structures. By creating a bending area with a film hinge, the cavity can be designed such that the demolded support element and its base element and / or cover element are arranged in an unfolded position; in other words, they are not arranged opposite each other, the base element and cover element. Only after demolding is the corresponding element folded closed using the film hinge, so that the cover element and base element are then arranged opposite each other.

[0031] In a preferred embodiment of the invention, the rear element comprises a partial surface of the inner surface, and at least the partial surface comprises the material layer with optical effect. This ensures a simple yet effective structure of the manufactured support element, which captures the luminous flux emitted by the light source and deflects it toward the intermediate lens to radiate the luminous flux toward the roadway. This simple structure simultaneously provides a compact support element.

[0032] According to a further preferred embodiment of the invention, the material layer comprises a first section with a first optical effect and a second section with a second optical effect, wherein the first and / or the second section is / are light-reflecting, light-conducting, light-scattering and / or light-refracting. In other words, a material layer is used which comprises two regions, each having its own optical effect, wherein the two sections have the same optical effect but preferably different optical effects. Accordingly, this embodiment of the material layer ensures the possibility of realizing various lighting functions and thus illumination functions. For example, the first section is preferably light-conducting or light-refracting and the second section is light-reflecting.Particularly preferably, at least one of the elements comprises a partial surface of the inner surface, wherein at least the partial surface comprises the first section of the material layer with the first optical effect. At least one other of the elements comprises another partial surface of the inner surface, wherein at least the other partial surface comprises the second section of the material layer with the second optical effect.For example, the previously described rear element comprises a partial area of ​​the inner surface that comprises the material layer with the first section having the first optical effect, which is designed to redirect the light in the direction of the recess, wherein the previously described floor element and / or ceiling element comprises another partial area of ​​the inner surface that comprises the material layer with the second section having the second optical effect, which is designed to guide light that has been scattered from the rear element towards the recess. Preferably, the material layer with the second section comprises a white, shiny and / or silver material, so that this area particularly fulfills the light-guiding function.

[0033] Preferably, the material layer with an optical effect is designed to generate a signal light function and / or a signature. Accordingly, the method according to the invention produces a carrier element that is particularly compact, space-saving, and environmentally friendly, while simultaneously being suitable for generating the signature as a light function.

[0034] The material layer with optical effect preferably comprises a film, preferably a decorative film, and / or a plate. The film is then fed through the injection mold, preferably from top to bottom or vice versa. It is clamped between the mold halves when the mold is closed. When the melt is injected, the pressure presses the film against the inner wall of the cavity. The high temperature of the melt, meanwhile, causes the lacquer layer of the hot stamping film to bond with the injected plastic. When the molded part cools, the lacquer layer of the hot stamping film separates from a preferably used carrier film. The used carrier film is then preferably wound up beneath a clamping unit, while at the same time a new decorative area is positioned in the intended area of ​​the mold. The films can be provided with individual decorations or continuous decorations.When using continuous decorations, it is necessary to control the film feed with absolute precision. This is the only way to produce series parts with exactly the same appearance and properties, as the decoration is then always positioned precisely in the same place within the mold cavity. This results in a particularly effective overall process that provides the carrier element with the corresponding advantages.

[0035] A second aspect of the invention relates to a carrier element produced by the method according to the invention.

[0036] A further aspect of the invention relates to a vehicle headlight comprising a carrier element produced by the method according to the invention.

[0037] Further preferred embodiments of the invention result from the remaining features mentioned in the subclaims.

[0038] The various embodiments of the invention mentioned in this application can be advantageously combined with one another, unless stated otherwise in the individual case.

[0039] The invention is explained below in exemplary embodiments with reference to the accompanying drawings. They show: Fig. 1a a schematic representation of a method according to the invention, Fig. 1b a schematic representation of an implementation of the method according to the invention from Fig. 1a, Fig. 2 a carrier element produced by a method according to the invention according to a first embodiment, Fig. 3a a support element produced by a method according to the invention in a folded position according to a second embodiment, Fig. 3b the carrier element produced by the method according to the invention from Fig. 3a in an unfolded position, Fig. 3c the carrier element produced by the method according to the invention from Fig. 3a in the closed position with a circuit board, Fig. 4a is a schematic front view of a vehicle headlight comprising a carrier element produced by the method according to the invention, Fig. 4b a schematic sectional view of the vehicle headlight from Fig. 4a.

[0040] Fig. 1a shows a schematic representation of a method according to the invention for producing a carrier element 2 with an integrated optical element 27 for capturing a luminous flux emitted by a light source and deflecting it in the direction of a roadway of a vehicle headlight 4.

[0041] The method begins in step S100 with the insertion of a material layer 11 with an optical effect into an open shaping cavity 10 of a mold 1. Subsequently, in step S200, the shaping cavity 10 is closed and the material layer 11 is clamped. In the subsequent step S300, the material layer 11 is back-injected with a melt 12 of a thermoplastic, which in this case comprises an opaque, i.e., light-impermeable material, to form the carrier element 2. Subsequently, the mold 1 is opened, and the formed carrier element 2 is demolded after cooling.

[0042] Fig. 1b shows a schematic representation of an implementation of the method according to the invention from Fig. 1a. For this purpose, in step S100, the material layer 11, preferably a film 11 in this case, is introduced into the molding tool 1, also referred to as an injection molding tool, and in step S200, when the tool 1 is closed, it is clamped between its halves. If the melt 12 is then injected in step S300, the material layer 11 is pressed against an inner wall of the molding cavity 10 by its pressure. The high temperature of the melt 12, meanwhile, causes the material layer 11 to bond with the injected plastic. After cooling, the finished decorated carrier element 2, which comprises an inner surface 26, also referred to here as B-side 26, with the material layer 11 forming an optical element 27 and an outer surface 29, also referred to here as A-side 29, which has a surface structuring 291, can be removed in step S400.

[0043] Fig. Figure 2 shows a carrier element 2 produced using a method according to the invention according to a first embodiment. The shaping cavity 10 of the molding tool 1 used during the method is designed to create a shape for the carrier element 2, so that the demolded carrier element 2 comprises two oppositely arranged side elements 21, a front element 22 extending between front ends 211 of the side elements 21, and a bottom element 23 extending between lower ends 212 of the side elements 21. Furthermore, the support element 2 comprises a rear element 25 arranged opposite the front element 22 and extending between rear ends 214 of the side elements 21. The front element 22 has a recess 221 for receiving an intermediate light disc 222 for emitting the luminous flux in the direction of the roadway and the support element 2 comprises an outer surface 29 and an inner surface 26 which comprises the material layer 11.

[0044] This produces the carrier element 2, which according to this embodiment is shell-shaped. When this carrier element 2 is used in a vehicle headlight, light strikes the material layer 11, which is arranged, among other things, on the rear element 25 and is formed in this case by a film 11, thereby forming an optical element 27 or a signature 27. The light is reflected by the optical element 27 and directed toward the recess 221, where it exits the carrier element 2 through an intermediate light disc 222.

[0045] In the present case, all inner surfaces of the existing elements 21, 22, 23 and 25 forming the inner surface 26 of the carrier element 2 comprise the material layer 11. Due to the inventive production, the front element 22 is connected in a materially bonded and gap-free manner to the front ends 211 of the side elements 21, the base element 23 is connected in a materially bonded and gap-free manner to the lower ends 212 of the side elements 21, and the front element 22 is connected in a materially bonded and gap-free manner to the base element 23. Due to the inventive production, the rear element 25 is connected in a materially bonded and gap-free manner to the rear ends 214 of the side elements 21 and in a materially bonded and gap-free manner to the base element 23. This achieves a gap-free design, thereby preventing the undesirable or disruptive escape of light. In other words, elements 21, 22, 23 and 25 continuously conceal an interior area delimited by them.They form a shell or housing. Preferably, a cover and a circuit board are arranged on an upper region of the support element 2, which close off the interior area; the cover and circuit board are not shown here.

[0046] The shaping cavity 10 is also designed to produce a shape for the carrier element 2, so that the outer surface 29 of the demolded carrier element 2 has a surface structuring 291, preferably a grain 291.

[0047] Fig. Figure 3a shows a support element 2 produced by a method according to the invention in a folded position according to a second embodiment. Regarding matching features, reference is made to the description of Fig. 2, so that only different features of the second version will be explained in more detail below.

[0048] According to the second embodiment, the shaping cavity 10 is designed to create a shape for the support element 2, so that the demolded support element 2 comprises a cover element 24 arranged opposite the base element 23 and extending between upper ends 213 of the side elements 21. Due to the inventive production, the cover element 24 is not materially connected to the upper ends 213 of the side elements 21 in this embodiment, but is materially connected and gap-free to the back element 25. The connection to the back element 25 is created by the shaping cavity 10 being designed to create a shape for the support element 2, so that the support element 2 comprises a bending region 28 extending between the side elements 21, wherein the bending region 28 forms the materially connected connection between the back element 25 and the cover element 24 and comprises a film hinge 281.The demolded support element 2 and its cover element 24 are arranged in a folded position in the present case. After demolding, it was folded closed using the film hinge 281, so that the cover element 24 and the base element 23 are then arranged opposite one another. Furthermore, the cover element 24 includes a recess 31 that serves to accommodate a circuit board 3.

[0049] Fig. 3b shows the carrier element 2 produced by the method according to the invention from Fig. 3a in an unfolded position. This shows the base element 23 as well as an inner surface 26 with a partial surface 261, which is formed by an inner surface of the back element 25. The material layer 11 comprises a first section 111 with a first optical effect and a second section 112 with a second optical effect. The partial surface 261 comprises the first section 111 of the material layer 11 with the first optical effect. The remaining surface of the inner surface 26 comprises the second section 112 of the material layer 11 with the second optical effect. The first section 111 is preferably designed to redirect the light in the direction of the recess 221. The second section 112 is preferably designed to guide light that was scattered from the back element 25 in the direction of the recess 221.Preferably, the material layer 11 with the second section 112 comprises a light or white, shiny and / or silver material, so that this area particularly fulfills the light-conducting function.

[0050] Fig. 3c shows the carrier element 2 produced by the method according to the invention from Fig. 3a in the closed position. It can be seen that the circuit board 3 is arranged within the recess 31 of the ceiling element 24 by subsequent assembly.

[0051] Fig. 4a shows a schematic front view of a vehicle headlight 4 comprising a carrier element 2 produced by the method according to the invention as well as a high beam module 41 and a low beam module 42. Fig. 4b shows a schematic sectional view of the vehicle headlight 4 from Fig.4a. This illustrates the difference between the modules 41, 42 and the support element 2, which has a significantly lower height, which is advantageously made possible by the production using the method according to the invention. List of reference symbols 1 mold 10 forming cavity 11 Material layer / film 111 first section 112 second section 12 Melt 2 support element 21 page element 211 front end 212 lower end 213 upper end 214 rear end 22 Front element 221 recess 222 intermediate lens 23 Floor element 24 ceiling element 25 rear element 26 Inner surface / B-side 261 Partial area of ​​the inner surface 27 optical element / signature 28 Bending area 281 film hinge 29 Outer surface / A-side 291 Surface structuring / graining 3 circuit boards 31 recess 4 vehicle headlights 41 High beam module 42 Low beam module S100 Inserting a material layer S200 Closing the forming cavity and clamping the material layer S300 Back-injection of the material layer S400 Opening the mold and demolding the formed support element QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2015 015 360 A1

[0004] FROM 20 2016 106 599 U1

[0005]

Claims

Method for producing a carrier element (2) with an integrated optical element (27) for capturing a luminous flux emitted by a light source and deflecting it in the direction of a roadway of a vehicle headlight (4), comprising the following steps: inserting (S100) a material layer (11) with an optical effect into an open shaping cavity (10) of a mold (1); closing (S200) the shaping cavity (10) and clamping (S200) the material layer (11); back-injecting (S300) the material layer (11) with a melt (12) of a thermoplastic material to form the carrier element (2);Opening (S400) the molding tool (1) and demolding (S400) the formed carrier element (2) after cooling, wherein the shaping cavity (10) is configured to create a shape for the carrier element (2), such that the demolded carrier element (2) comprises two side elements (21) arranged opposite one another, a front element (22) extending between front ends (211) of the side elements (21), and a bottom element (23) extending between lower ends (212) of the side elements (21), wherein the front element (22) has a recess (221) for receiving an intermediate light disc (222) for emitting the luminous flux in the direction of the roadway, and wherein the carrier element (2) has an outer surface (29) and an inner surface (26) comprising the material layer (11); Method according to claim 1, wherein the shaping cavity (10) is designed to produce a shape for the carrier element (2), so that the outer surface (29) of the demolded carrier element has a surface structuring (291), preferably a grain (291). Method according to one of the preceding claims, wherein the shaping cavity (10) is designed to produce a shape for the support element (2), so that the demolded support element (2) comprises a cover element (24) arranged opposite the base element (23) and extending between upper ends (213) of the side elements (21). Method according to one of the preceding claims, wherein the shaping cavity (10) is designed to produce a shape for the carrier element (2), so that the demolded carrier element (2) comprises a rear element (25) arranged opposite the front element (22) and extending between rear ends (214) of the side elements (21). Method according to claim 4, wherein the back element (25) comprises a partial surface (261) of the inner surface (26) and wherein at least the partial surface (261) comprises the material layer (11) with optical effect. Method according to one of claims 4 or 5, wherein the shaping cavity (10) is designed to produce a shape for the carrier element (2), so that the carrier element (2) comprises a bending region (28) extending between the side elements (21), wherein the bending region (28) forms a material-locking connection between the rear element (25) and the base element (23) or the cover element (24) and comprises a film hinge (281). Method according to one of the preceding claims, wherein the material layer (11) comprises a first portion (111) having a first optical effect and a second portion (112) having a second optical effect, wherein the first and / or the second portion (111, 112) are / is light-reflecting, light-conducting, light-scattering and / or light-refracting. Method according to one of the preceding claims, wherein the material layer (11) with optical effect is designed to produce a signal light function and / or a signature (27). Method according to one of the preceding claims, wherein the material layer (11) with optical effect comprises a film (11), preferably a decorative film, and / or a plate. Vehicle headlight (4) comprising a carrier element (2) produced by a method according to one of the preceding claims.

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