Emblem assembly and method of forming same

An emblem assembly configured for attachment to a vehicle, the emblem assembly comprising:

• a first element configured for attachment to the vehicle and having a first surface and a second surface recessed from said first surface, wherein said second surface is substantially U-shaped;
• a transparent second element configured for attachment to said first element and having;
• a third surface;
• a fourth surface spaced apart from said first surface, said second surface, and said third surface;
• and
• a fifth surface extending between said third surface and said fourth surface, wherein said fifth surface abuts said third surface to form a corner and wherein said fifth surface is spaced apart from said second surface to define a channel therebetween;
• wherein said fifth surface does not abut said second surface, and is spaced apart from said second surface along an entirety of said fifth surface to thereby define a channel between said first element and said second element;
• a coating disposed on said third surface, wherein said coating includes vacuum metalized aluminum and is substantially free from corrosion;
• a molded resin disposed adjacent and in fixed contact with each of said fifth surface and said coating so as to contiguously encapsulate said coating and at least a portion of said fifth surface to thereby wrap around said corner and fill at least a portion of said channel, wherein said molded resin is a cured pressure-moldable thermoplastic resin that is injection moldable at a pressure of from about 75 psi to about 175 psi;
• and
• an adhesive sandwiched between and disposed in contact with each of said molded resin and said second surface to thereby bond said second element to said first element.

A method of forming an emblem assembly configured for attachment to a vehicle, the method comprising:

• depositing a coating on a second element that is different from a first element configured for attachment to the vehicle;
• wherein the first element has a first surface and a second surface that is substantially U-shaped and recessed from said first surface;
• wherein the second element has;
• a third surface;
• a fourth surface spaced apart from the first surface, the second surface, and the third surface;
• and
• a fifth surface extending between the third surface and the fourth surface;
• wherein the fifth surface does not abut the second surface, and is spaced apart from the second surface along an entirety of the fifth surface to thereby define a channel between the first element and the second element;
• wherein the coating is disposed on the third surface;
• after depositing, forming a molded resin on the second element so that the molded resin is disposed adjacent and in fixed contact with each of the fifth surface and the coating so as to contiguously encapsulate the coating and at least a portion of the fifth surface;
• after forming, bonding the molded resin to the first element to thereby form the emblem assembly, wherein the molded resin is a cured pressure-moldable thermoplastic resin.