Seat assembly

Abstract

A seat assembly for a vehicle interior is disclosed. The seat assembly comprises a seat base comprising a composite structure and a seat back comprising a composite structure; the composite structure comprises a pad and a cover. The composite structure may comprise a feature comprising a perforation, channel, indentation, projection, image / icon, light element and / or set of features in pattern, etc. The feature / pattern and / or the exterior surface of the cover may provide a decorative / visual effect, etc. The seat assembly may comprise a base for mounting / movement. The seat assembly may comprise a functional module for ventilation, heating, cooling, lighting, etc. The pad may comprise a foam material formed on the cover; the composite structure may be configured to retain shape / form and surface effect such as texture (e.g. reduce defects). A method of forming the seat assembly may comprise forming a composite structure of pad and cover for seat base and / or seat back.

Description

PATENT APPLICATIONSEAT ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to and incorporates by reference in full the following patent application: U.S. Provisional Patent Application No. 63 / 653,506 titled “SEAT FOR VEHICLE INTERIOR” filed May 30, 2024.FIELD

[0002] The present invention relates to a seat assembly.BACKGROUND

[0003] It is known to provide a seat assembly for an occupant in a vehicle interior.

[0004] It would be advantageous to provide an improved seat assembly with a composite structure for the seat base and / or seat back and / or seat headrest comprising a pad and a cover.

[0005] It would be advantageous to provide a seat assembly with a composite structure for the seat base and / or seat back and / or seat headrest comprising a pad formed on a cover.

[0006] It would be advantageous to provide an improved seat assembly with a composite structure for the seat base and / or seat back and / or seat headrest comprising a pad comprising a foam material formed on a cover.

[0007] It would be advantageous to provide a seat assembly with a composite structure for the seat base and / or seat back and / or seat headrest comprising a pad and a cover and a feature.

[0008] It would be advantageous to provide a seat assembly with a composite structure for the seat base and / or seat back and / or seat headrest comprising a pad and a cover and a feature such as perforation, channel, indentation, projection, light element, set of features / pattem, etc.

[0009] It would be advantageous to provide a seat assembly with a composite structure for the seat base and / or seat back and / or seat headrest comprising a pad and a cover and a feature to facilitate ventilation, heating, cooling, lighting, decorative / visual effect, etc.SUMMARY

[0010] A seat assembly for a vehicle interior may comprise a seat base that may comprise a composite structure and a seat back that may comprise a composite structure. The composite structure for the seat base may comprise a pad and a cover. The composite structure for the seat back may comprise a pad and a cover. The cover may comprise an exterior surface. The composite structure may be formed with the cover and the pad. The cover may comprise a cover material. The pad may comprise a foam material. The pad may be formed onto the cover. The foam material may be formed onto the cover material. The cover may be coupled to the pad. The composite structure may comprise a feature. The composite structure for the seat base may comprise a feature. The composite structure for the seat back may comprise a feature. The feature may be provided at the cover and may be provided in the pad. The feature may comprise a set of features and a pattern of features and a set of features at the cover and a feature formed in the composite structure and a set of features formed in the composite structure and a set of features formed in the pad and a set of features formed in the cover and a set of features formed in the cover and in the pad etc. The feature may comprise an aperture. The aperture may comprise a perforation. The feature may comprise a perforation and a perforation at the cover and a perforation for ventilation at the cover and a perforation for illumination at the cover etc. The feature may comprise a channel through the composite structure and a set of channels through the composite structure and a pattern of channels through the composite structure and a set of channels through the pad and the cover of the composite structure etc. The feature may comprise a set of apertures through the cover and a set of channels through the pad and a set of perforations through the cover and a set of channels through the pad etc. The assembly may further comprise a fan configured to facilitate air flow through the set of channels. The air flow may comprise a vacuum flow. The assembly may further comprise a HVAC module configured to facilitate heating and / or cooling by air flow through the set of channels. The light source may comprise an LED light. The assembly may further comprise a functional module configured to provide a light source. The functional module may comprise a light source. The feature may comprise a heating element for the composite structure. The assembly may further comprise a heating element for the composite structure. The heating element may comprise a heating mat under the cover of the composite structure and a permeable mat between the cover and the pad etc. The feature may comprise a decorative element at the cover and an image and / or icon and indicia and / or a logo and / or a word etc. The feature may be configured to be illuminated. The feature may be formed at the cover. The feature may comprise an indentation at the coverand a projection at the cover and a protrusion at the cover and an indentation and a protrusion at the cover and a rib at the cover and a pattern of indentations at the cover and a pattern of projections at the cover etc. The feature may be formed at the cover or in the pad or in the composite structure, by molding, at molding, by deep drawing, by foaming, by a laser tool, by a punch and / or needle etc. The feature may be formed in the cover and in the pad. The feature may comprise a light element. The light element may be provided at the seat base and at the seat back etc. The light element may comprise a light guide and a light pipe. The light guide may be provided at the exterior surface of the seat back and at the exterior surface of the seat base. The light guide may comprise a set of light guides and a set of light pipes etc. The light element may comprise multi-segment light elements and multi-color elements and an image and / or icon and / or logo etc. The light element may be configured to provide a visual effect. The visual effect may comprise a light effect. The light element may comprise an electroluminescent element and an electroluminescent panel and an illuminated element and an image and / or icon and a pattern and a set of light elements etc. The assembly may further comprise a light source configured to illuminate the light element. The light source may comprise an LED light. The assembly may further comprise a functional module configured to provide a light source. The functional module may comprise a light source etc. The assembly may further comprise a functional module for the seat base and / or the seat back and a functional module for the seat base and a functional module for the seat back etc. The functional module may comprise a fan and an HVAC unit and a light source and a power source etc. The assembly may further comprise an operator control and a control panel and a control panel for the functional module etc. The composite structure may comprise a support assembly and a pad bonded to the cover and a foam formed on the cover etc. The assembly may further comprise an intermediate layer under the cover. The intermediate layer may comprise a non-woven layer. The cover may comprise an exterior surface and may be configured to provide a visual effect. The visual effect may comprise a surface effect. The exterior surface may comprise a surface effect. The cover may comprise a cover material and may be configured to provide the surface effect. The cover material may be configured to provide the surface effect. The cover may be configured to retain the surface effect when formed onto the pad. The exterior surface of the cover may be configured to retain the surface effect when formed onto the pad. The surface effect may comprise a texture and a uniform visual effect and a uniform texture and the texture may comprise a grain effect and the surface effect may comprise softness and a decorative effect etc. The surface effect may be configured to provide ventilation and to facilitate drainage and to be breathable etc. Theassembly may further comprise a base configured to mount to the vehicle interior. The base may comprise a structure configured to mount a floor in the vehicle interior. The structure may comprise a mounting structure. The mounting structure may comprise a chassis. The chassis may be configured to be movable relative to the floor. The seat base may be configured to be mounted to the chassis of the mounting structure of the base and to the structure etc. The seat back may be configured to be mounted to the structure and the seat base may be configured to be mounted to the structure and the seat back may be configured to be mounted to the seat base. The seat back may be configured to be mounted for pivotal movement relative to the seat base etc. The seat base may comprise a seat cushion. The assembly may further comprise a seat base assembly comprising the seat base and a seat base assembly comprising the seat cushion etc. The seat base may comprise a seat cushion assembly. The assembly may further comprise a seat cushion assembly comprising the seat cushion. The seat cushion assembly may comprise a frame. The frame may be configured to be mounted to the base. The seat base assembly may comprise a frame, and the frame may be configured for mounting to a base and / or to a chassis of the base etc. The assembly may further comprise a seat back assembly comprising the seat back cushion. The seat back cushion may comprise a composite structure. The composite structure may comprise a pad and a cover, and the pad may comprise a foam material, and the cover may comprise a cover material etc. The seat back assembly may comprise a front cover and a back cover. The composite structure may comprise a front portion, a rear portion and a connecting portion, and an opening configured to receive the frame etc. The composite structure may be configured to be pulled over the frame. The cover of the seat back assembly may comprise a front cover and a back cover, and the seat back assembly may comprise a frame, and the frame may be configured to be mounted to the seat base and for pivoting movement of the seat back relative to the seat base etc. The assembly may further comprise a seat headrest assembly comprising a headrest and a headrest comprising a composite structure etc. The headrest may comprise a composite structure that may comprise a pad and a cover and the pad may comprise a foam material and the cover may comprise a cover material etc. The assembly may further comprise a headrest assembly comprising the headrest and a frame, and the frame may be configured to be mounted to the seat back and for movement relative to the seat back etc. The foam material of the pad may comprise a polymer material and / or a polyurethane material and the cover material of the cover may comprise a polymer material etc. The foam material of the pad may comprise a formed polyurethane material and / or a thermoset material or a thermoplastic material and the cover material of the cover maycomprise a molded polymer material and / or a molded polymer material and a deep drawn or blow molded or vacuum formed polymer material and / or a thermoplastic material etc. The foam material of the pad may comprise a TPU material, a TPE material, a polyolefin material etc. The cover material of the cover may comprise a TPO material, a TPE material, a TPU material etc. The foam material of the pad may comprise a TPU material formed on the cover. The cover material of the cover may comprise a TPO material bonded to the pad etc. The cover may comprise a sheet and a sheet material and a sheet material coupled to the pad and to the frame and a sheet material chemically bonded to the pad and mechanically coupled to the frame by means of a connector etc. The cover may be coupled by a connector that may comprise a clip and a retainer and a retainer clip and a bar and a tape and an adhesive tape etc. The cover may be coupled by an adhesive material. The cover may be bonded by an adhesive material. The frame for the seat base may comprise a structure and may comprise a metal structure and a spring structure etc. The frame for the seat back may comprise a structure and may comprise a metal structure and a spring structure etc. The seat base assembly may be configured for movement relative to the base. The seat base may be configured for movement forward and / or backward relative to the base and may be configured for movement up and / or down relative to the base and may be configured for adjustable movement relative to the base etc. The seat back may be configured for movement relative to the seat base and may be configured for pivoting movement relative to the seat base and may be configured for pivoting mounting to the seat base and may be configured for pivoting movement forward and / or backward relative to the seat base etc. The seat back may be configured to provide adjustment of lumbar support and may be configured to provide a massage effect etc. The seat headrest may be configured for movement relative to the seat back and may be configured for movement up and / or down relative to the seat back and may be configured for movement forward and / or backward relative to the seat back etc. The assembly may further comprise a support assembly that may comprise at least one of the seat base and / or the seat back etc. The seat base may comprise a seat cushion. The cover may comprise an exterior surface. The cover may comprise a skin. The cover may comprise a molded skin. The cover may comprise a vacuum-formed skin. The exterior surface of the cover may comprise a grained surface and a textured surface etc. The cover material of the cover may comprise an artificial leather material. The cover may comprise a laminate and a bilaminate etc. The cover material of the cover may comprise a TPO laminated with the foam of the pad etc. The pad may comprise a polyurethane material and a bio-urethane material and a TPE material and a compressible pad etc. The composite structure maycomprise a concave surface and an indentation in the exterior surface etc. The indentation in the exterior surface may be formed in the cover and may be formed in the pad etc. The indentation in the exterior surface may comprise an indentation formed in the cover, and the indentation formed in the cover may be configured to form an indentation in the pad etc. The indentation may comprise at least one of an image and / or a logo and / or an icon and may comprise a groove etc. The groove may be configured to facilitate expansion of the exterior surface of the composite structure and may comprise a set of grooves and a set of inboard grooves and a set of outboard grooves etc. The indentation may be formed in a sidewall of the composite structure and the sidewall of the composite structure may be configured to be visible from outside of the vehicle interior etc. The indentation may comprise a dimple and the dimple may comprise a set of dimples in a pattern and the pattern may comprise a “U” shape etc. The dimple may be formed in the cover and may be formed in the pad etc. The composite structure may be configured for a compressed state when the seat base is occupied by an occupant and may be configured for a retracted state when the seat base is occupied by an occupant and an expanded state when the seat is unoccupied etc. The composite structure may be configured to expand to change the shape of the support assembly and to expand to increase a length of the outer surface etc. The composite structure may comprise a channel and a channel passing through the cover and the pad and a set of channels and a set of channels passing through the cover and the pad and an aperture and a set of apertures and a pattern of apertures etc. The aperture may comprise a perforation and the composite structure may comprise a set of perforations and a pattern of perforations etc. The assembly may further comprise a light source and the light source may be configured to provide illumination through the aperture and may be configured to illuminate an indentation at the cover or in the cover and may provide illumination at the cover and may be configured to illuminate at least one of an image at the cover and / or a logo at the cover and / or an icon at the cover and may be configured to illuminate at least one of an image on the cover and / or a logo on the cover and / or an icon on the cover and may be configured to illuminate a simulated seam in the cover etc. The composite structure may comprise at least one of a simulated seam and / or a simulated French seam and / or a simulated deck seam and / or a simulated join seam etc. The composite structure may comprise a protrusion at the exterior surface and a protrusion in the exterior surface etc. The protrusion in the exterior surface may be formed at the cover and may be formed in the cover and may be formed in the pad etc. The protrusion may comprise a protrusion formed in the cover, with the protrusion formed in the cover being configured to form a protrusion in the pad etc. The protrusion in the exterior surface may be configured toprovide a visual effect and the visual effect may comprise at least one of a simulated seam, a simulated French seam, a simulated deck seam etc. The visual effect in the outer surface may comprise at least one of an image and / or a logo and / or an icon etc. The composite structure may be configured for recycling and may comprise a recyclable assembly etc. The recyclable assembly may be configured to be shredded or chopped for reuse of materials into recycled material etc. A method of forming a seat assembly may comprise the steps of forming a composite structure for a seat base, where the composite structure for the seat base may comprise a cover and a pad formed on the cover, and where the pad may comprise a foam material and the cover may comprise a cover material etc. The method may further comprise the step of forming a composite structure for a seat back to be coupled to the seat base and further comprising the step of forming a feature for the composite structure where the feature may comprise at least one of a perforation and / or a channel and / or an indentation and / or a projection and / or an image and / or a set of features etc. The feature may comprise a set of features formed by a tool at the cover and / or the pad etc. The composite structure for the seat back may comprise a cover and a pad formed on the cover. The composite structure may comprise a frame. The method may further comprise the step of assembling the seat base to a frame and further comprising the step of assembling the seat back to a frame etc. The method may further comprise the step of assembling the seat base to a base structure. The cover may comprise an exterior surface and the exterior surface of the cover may comprise a surface effect and the surface effect may be preserved during forming and assembly and may comprise a form and a texture and may provide a visual effect etc. The seat assembly is configured for efficient production of the pad for the composite structure with the foam material comprising polyurethane foam; the seat assembly is configured for efficient assembly from the composite structure comprising the seat base. The foam material may comprise a reduced-cost foam material and / or the cover material may comprise a reduced- cost cover material. The cover material may comprise a synthetic leather material configured to facilitate recyclability. The foam material and the cover material may be selected to facilitate end of life recycling. The foam material may comprise a bio-foam material; the biofoam material may comprise castor oil and / or soybean oil and / or recycled content polyols. The foam material and the cover material may comprise recyclable material. Forming of the composite structure comprises forming in a mold tool. The foam material comprises a reduced-weight material. The pad may be formed directly on the cover; the pad may be formed in an apparatus configured for production of multiple components. The composite structure may comprise a concave shape. The compositestructure may comprise a surface effect comprising a pattern and / or a grain and / or a logo. The seat back may comprise a thin seat back construction. A seat for an occupant in a vehicle interior may comprise a support assembly for the occupant, where the support assembly may comprise a pad bonded to a cover and may comprise an outer surface visible to the occupant etc. The support assembly may comprise at least one of a seat cushion and / or a seat back and / or a composite structure etc. The cover may comprise a skin and a molded skin and a vacuum formed skin and may comprise a grained surface and a textured surface and an artificial leather material and a laminate and a bilaminate etc. The bilaminate may comprise a TPO laminated with a foam etc. The pad may comprise a polyurethane material and may comprise a bio-urethane material and a TPE material and a low Shore A substrate material etc. The pad may comprise a hardness between 30 Shore A and 60 Shore A etc. The support assembly may comprise a concave surface and an indentation in the outer surface etc. The indentation in the outer surface may be formed in the cover and may be formed in the pad etc. The indentation in the outer surface may comprise an indentation formed in the cover with the indentation formed in the cover being configured to form an indentation in the pad etc. The indentation may comprise at least one of an image, a logo, an icon etc. The indentation may comprise a groove etc. The groove may be configured to facilitate expansion of the outer surface of the support assembly and may comprise a set of grooves and a set of inboard grooves and a set of outboard grooves etc. The indentation may be formed in a sidewall of the support assembly and the sidewall of the support assembly may be configured to be visible from outside of the vehicle interior etc. The indentation may comprise a dimple and a set of dimples in a pattern and the pattern may comprise a “U” shape and the dimple may be formed in the cover and / or the pad etc. The support assembly may be configured for a retracted state when the seat is unoccupied and an expanded state when the seat is occupied etc. The support assembly may be configured to provide a discontinuous support surface in the retracted state and a continuous support surface in the expanded state and may be configured to provide a generally flat support surface in the retracted state and a concave support surface in the expanded state etc. The support assembly may be configured to expand to change the shape of the support assembly and to expand to increase a length of the outer surface etc. The support assembly may comprise an aperture passing through the cover and the pad and the aperture may comprise a perforation etc. The support assembly may further comprise a light source and the light source may be configured to provide illumination through the aperture and to illuminate an indentation in the cover and to illuminate at least one of an image in the cover, a logo in the cover, or an icon in the cover and may beconfigured to illuminate a simulated seam in the cover etc. The support assembly may comprise at least one of a simulated seam, a simulated French seam, a simulated deck seam, or a simulated join seam etc. The support assembly may comprise a protrusion in the outer surface and the protrusion in the outer surface may be formed in the cover or the pad etc. The protrusion in the outer surface may comprise a protrusion formed in the cover and the protrusion formed in the cover may be configured to form a protrusion in the pad etc. The protrusion in the outer surface may be configured to provide a visual effect comprising at least one of a simulated seam, a simulated French seam, or a simulated deck seam or may comprise at least one of an image, a logo, or an icon etc. The support assembly may be configured for recycling and may comprise a recyclable assembly etc. The recyclable assembly may be configured to be shredded or chopped for reuse of materials into recycled material etc. The seat may be formed by a process of forming the cover and molding the pad on the cover and forming the cover may comprise vacuum forming a sheet of material and the process may comprise creating a hole through the cover and the pad etc. The seat assembly for a vehicle interior may comprise a seat base and a seat back, each of which may comprise a composite structure formed of a pad and a cover, where the pad may be a foam material molded directly onto the cover such that the pad and cover may be bonded together to form a unitary component and the cover may define an exterior surface configured to retain a surface effect selected from the group consisting of a texture, a grain, a simulated seam, an image, or a decorative pattern etc. during and after the foam molding process and the composite structure may include at least one functional feature selected from the group consisting of a pattern of perforations or channels passing through both the cover and the pad to enable ventilation or illumination and an integrated heating element disposed between the cover and the pad and a light guide or light pipe extending through the composite structure and configured to illuminate an image, icon, logo, or seam at the exterior surface etc. At least one of the pad and the cover may comprise a polymeric material selected from the group consisting of TPU, TPO, TPE, or polyurethane etc. The seat assembly may further comprise a functional module selected from the group consisting of a fan, an HVAC unit, and an LED light source, each operably coupled to the composite structure and the functional module may be configured to provide air flow, heating, cooling, or illumination through the perforations or channels etc. The surface effect of the cover may comprise a simulated seam and at least one light guide may be configured to provide visual illumination to the simulated seam from an internal light source etc. The pad and the cover may be both formed from recyclable materials selected from the group consisting of TPO, TPE, and polyurethane and theassembly may be configured such that the pad and cover can be separated or processed for recycling at end of life etc. The pad may comprise a compressible polyurethane foam having a Shore A hardness between 30 and 60 etc. The composite structure may further comprise a pattern of channels interconnecting with the perforations to facilitate distributed ventilation or illumination across the exterior surface etc. The composite structure may be configured such that the pad may be molded onto a pre-formed, vacuum-formed, or deep-drawn cover comprising a grained or textured surface, and the grained or textured surface may be retained after molding etc. The method of forming a seat assembly for a vehicle interior may comprise forming a cover having a desired exterior surface effect selected from the group consisting of texture, grain, simulated seam, image, or decorative pattern and molding a foam pad directly onto the inner side of the cover to bond the pad to the cover and create a unitary composite structure and forming at least one functional feature selected from the group consisting of a pattern of perforations, channels, a light guide, or a heating element integrally within the composite structure during molding and assembling the composite structure as part of a seat base or seat back etc.

[0011] The present invention relates to a seat for an occupant in a vehicle interior comprising a support assembly for the occupant. The support assembly may comprise a pad bonded to a cover. The support assembly may comprise an outer surface visible to the occupant. The support assembly may comprise at least one of (a) a seat cushion and / or (b) a seat back. The cover may comprise a skin. The cover may comprise a molded skin. The cover may comprise a vacuum formed skin. The cover may comprise a grained surface. The cover may comprise a textured surface. The cover may comprise an artificial leather material. The cover may comprise a laminate. The cover may comprise a bilaminate. The bilaminate may comprise a TPO laminated with a foam. The pad may comprise a polyurethane material. The pad may comprise a bio-urethane material. The pad may comprise a TPE material. The pad may comprise a low shore A substrate material. The pad may comprise a hardness between 30 Shore A and 60 Shore A. The support assembly may comprise a concave surface. The support assembly may comprise an indentation in the outer surface. The indentation in the outer surface may be formed in the cover. The indentation in the outer surface may be formed in the pad. The indentation in the outer surface may comprise an indentation formed in the cover; the indentation formed in the cover may be configured to form an indentation in the pad. The indentation may comprise at least one of (a) an image, (b) a logo, and / or (c) an icon. The indentation may comprise a groove. The groove may be configured to facilitate expansion of the outer surface of the support assembly. The groove may comprise a set ofgrooves. The groove may comprise a set of inboard grooves and a set of outboard grooves. The indentation may be formed in a sidewall of the support assembly. The sidewall of the support assembly may be configured to be visible from outside of the vehicle interior. The indentation may comprise a dimple. The dimple may comprise a set of dimples in a pattern. The pattern may comprise a “U” shape. The dimple may be formed in the cover. The dimple may be formed in the pad. The support assembly may be configured for (a) a retracted state when the seat is unoccupied and (b) an expanded state when the seat is occupied. The support assembly may be configured to provide a discontinuous support surface in the retracted state and a continuous support surface in the expanded state. The support assembly may be configured to provide a generally flat support surface in the retracted state and a concave support surface in the expanded state. The support assembly may be configured to expand to change the shape of the support assembly. The support assembly may be configured to expand to increase a length of the outer surface. The support assembly may comprise an aperture passing through the cover and the pad. The aperture may comprise a perforation. The seat may comprise a light source; the light source may be configured to provide illumination through the aperture. The light source may be configured to illuminate an indentation in the cover. The light source may be configured to illuminate at least one of(a) an image in the cover, (b) a logo in the cover, and / or (c) an icon in the cover. The light source may be configured to illuminate a simulated seam in the cover. The support assembly may comprise at least one of (a) a simulated seam, (b) a simulated French seam, (c) a simulated deck seam, and / or (d) a simulated join seam. The support assembly may comprise a protrusion in the outer surface. The protrusion in the outer surface may be formed in the cover. The protrusion in the outer surface may be formed in the pad. The protrusion in the outer surface may comprise a protrusion formed in the cover; the protrusion formed in the cover may be configured to form a protrusion in the pad. The protrusion in the outer surface may be configured to provide a visual effect comprising at least one of (a) a simulated seam,(b) a simulated French seam, and / or (c) a simulated deck seam. The protrusion in the outer surface may comprise at least one of (a) an image, (b) a logo, and / or (c) an icon. The support assembly may be configured for recycling. The support assembly may comprise a recyclable assembly. The recyclable assembly may be configured to be shredded or chopped for reuse of materials into recycled material. The seat may be formed by a process of forming the cover and molding the pad on the cover. Forming the cover may comprise vacuum forming a sheet of material. The process may comprise creating a hole through the cover and the pad.

[0012] The present invention relates to a method of forming a seat assembly for a vehicle interior comprising the steps of forming a cover having an exterior surface effect comprising a texture grain and / or a simulated seam image and / or a decorative pattern and molding a foam pad on the cover to bond the foam pad to the cover and create a composite structure and forming a feature comprising a functional feature and / or a pattern of perforations and / or a pattern of channels and / or a pattern of indentations and / or a pattern of projections and / or a light guide for the composite structure and assembling the composite structure as part of a seat base or seat back.

[0013] The present invention relates to a seat assembly for a vehicle interior comprising a composite structure comprising a seat base and a composite structure comprising a seat back; each composite structure comprises a pad formed on a cover; the pad comprises a foam material molded onto the cover such that the pad and cover are bonded together to form a unitary component; the cover comprises an exterior surface configured to provide a surface effect comprising a texture and / or a grain and / or a simulated seam and / or an image and / or a decorative pattern; the cover is configured to retain the surface effect at the exterior surface after the pad is formed from the foam material; the composite structure comprises a feature comprising a functional feature and / or a set of indentations and / or a set of projections and / or a set of perforations and / or a set of channels passing through both the cover and the pad to enable ventilation or illumination and / or an integrated heating element between the cover and the pad and / or a light guide extending along the composite structure and configured to illuminate an light element; the light element may be configured to provide an image and / or icon and / or logo and / or a seam at the exterior surface; the pad and / or the cover comprise a polymeric material; the polymeric material may comprise TPU and / or TPO and / or TPE and / or polyurethane.

[0014] The present invention relates to a seat for an occupant in a vehicle interior comprising a support assembly for the occupant; the support assembly comprises a pad bonded to a cover; the support assembly comprises an outer surface visible to the occupant; the support assembly comprises at least one of a seat cushion comprising a composite structure and / or a seat back comprising a composite structure.

[0015] The present invention relates to a method of forming a seat assembly comprising the steps of forming a composite structure for a seat base; the composite structure for the seat base comprises a cover and a pad formed on the cover; the pad comprises a foam material; the cover comprises a cover material; the foam material may comprise a bio-foam materialcontaining castor oil (e.g. BASF 20 percent) and / or soybean oil (DOW) and / or recycled content polyols.FIGURES

[0016] FIGURE 1 A is a schematic perspective view of a vehicle according to an exemplary embodiment.

[0017] FIGURE IB is a schematic perspective cut-away view of a vehicle showing a vehicle interior according to an exemplary embodiment.

[0018] FIGURES 2A and 2B are schematic perspective views of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0019] FIGURE 3 is a schematic cut-away perspective view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0020] FIGURES 4A and 4B are schematic perspective views of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0021] FIGURE 5 is a schematic cut-away perspective view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0022] FIGURE 6 is a schematic perspective view of a control panel for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0023] FIGURES 7A and 7B are schematic perspective views of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0024] FIGURE 8 is a schematic cut-away perspective view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0025] FIGURE 9 is a schematic perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0026] FIGURE 10A through 10C are schematic perspective views of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0027] FIGURES 11 through 12B are schematic section perspective views of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0028] FIGURE 12C is a system block diagram of a system for a component for a vehicle interior according to an exemplary embodiment.

[0029] FIGURES 13 A and 13B are schematic perspective views of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0030] FIGURE 14 is a schematic cut-away perspective view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0031] FIGURE 15 is a schematic perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0032] FIGURE 16 is a schematic exploded perspective view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0033] FIGURE 17 is a schematic perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0034] FIGURES 18 and 19 are schematic section perspective views of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0035] FIGURE 20 is a schematic top plan view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0036] FIGURE 21 is a schematic section top plan view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0037] FIGURE 22 is a schematic perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0038] FIGURE 23 is a schematic section perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0039] FIGURE 24 is a schematic top plan view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0040] FIGURE 25 is a schematic section top plan view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0041] FIGURE 26A is a schematic section perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0042] FIGURE 26B is a schematic section top plan view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0043] FIGURE 27 is a schematic perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0044] FIGURE 28 is a schematic exploded perspective view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0045] FIGURES 29 and 30A are schematic perspective views of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0046] FIGURE 30B is a schematic exploded perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0047] FIGURES 30C and 30D are schematic perspective views of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0048] FIGURE 30E is a schematic exploded perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0049] FIGURE 31 is a schematic section side elevation view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0050] FIGURE 32 is a schematic section top plan view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0051] FIGURE 33 A is a schematic perspective view of a seat assembly for vehicle interior according to an exemplary embodiment.

[0052] FIGURE 33B is a schematic exploded perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0053] FIGURE 34A is a schematic perspective view of a composite structure for a seat assembly for vehicle interior according to an exemplary embodiment.

[0054] FIGURE 34B is a schematic exploded perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0055] FIGURE 35 A is a schematic perspective view of a seat assembly for vehicle interior according to an exemplary embodiment.

[0056] FIGURE 35B is a schematic perspective view of a seat assembly for vehicle interior according to an exemplary embodiment.

[0057] FIGURE 35C is a schematic exploded perspective view of a composite structure for a seat assembly for vehicle interior according to an exemplary embodiment.

[0058] FIGURES 36A and 36B are schematic side elevation view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0059] FIGURE 36C is a schematic exploded side elevation view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0060] FIGURE 37A is a schematic perspective view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0061] FIGURE 37B is a schematic exploded perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0062] FIGURE 38A is a schematic side elevation view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0063] FIGURE 38B is a schematic perspective view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0064] FIGURES 39A through 39E are schematic partial perspective views of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0065] FIGURES 40A through 40E are schematic partial perspective views of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0066] FIGURES 41 A through 43 C are schematic perspective views of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0067] FIGURES 44A through 46C are schematic side elevation views of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0068] FIGURES 47A through 47J are schematic section side elevation views of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0069] FIGURE 48A is a schematic section perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0070] FIGURE 48B is a schematic detail side elevation view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0071] FIGURE 49A is a schematic section perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0072] FIGURE 49B is a schematic detail side elevation view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0073] FIGURE 50A is a schematic section perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0074] FIGURE 50B is a schematic detail side elevation view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0075] FIGURE 51 A is a schematic section perspective view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0076] FIGURE 5 IB is a schematic detail side elevation view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0077] FIGURES 52A through 53C are schematic section views of a method of manufacturing a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0078] FIGURES 54A through 561 are schematic section side elevation views of a method of manufacturing a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0079] FIGURES 57A through 57F are schematic perspective views of a method of manufacturing a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0080] FIGURES 58 through 60 are schematic views of a method of manufacturing a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0081] FIGURE 61 is a schematic section side elevation view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0082] FIGURES 62A through 62D are schematic side elevation views of a composite structure for a vehicle interior according to an exemplary embodiment.

[0083] FIGURES 63A through 63C are schematic top plan views of a composite structure for a vehicle interior according to an exemplary embodiment.

[0084] FIGURE 64 is a schematic section side elevation view of a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0085] FIGURES 65 through 67 are schematic detail top plan views of a composite structure for a vehicle interior according to an exemplary embodiment.

[0086] FIGURE 68 is a schematic section side elevation view of a composite structure for a vehicle interior according to an exemplary embodiment.

[0087] FIGURES 69 A through 75B are schematic perspective views of a composite structure for a vehicle interior according to an exemplary embodiment.

[0088] FIGURES 76A is a schematic perspective view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0089] FIGURE 76B is a schematic exploded perspective view of a seat assembly for a vehicle interior according to an exemplary embodiment.

[0090] FIGURE 77 is a schematic view of a method of recycling a composite structure for a seat assembly for a vehicle interior according to an exemplary embodiment.

[0091] FIGURES 78A through 80 are flow diagrams of a method of manufacturing a seat assembly for a vehicle interior according to an exemplary embodiment.DESCRIPTION

[0092] Referring to FIGURES 1 A-1B, 2A-2B and 3, a vehicle V comprising a vehicle interior VI providing components such as seat assembly SZ is shown according to an exemplary embodiment.

[0093] According to an exemplary embodiment as shown in FIGURES IB, 2A-2B, 3, 4A- 4B, 5, 7A-7B, 8, 10A-10C, 13A-13B, 14 and 16, the seat assembly SZ may comprise a substrate SB shown as base assembly / base B configured to be mounted in the vehicle interior; the base B / SB comprises a structure for attachment / mounting of the seat assembly SZ; the seat assembly SZ mounted on the base B / SB may comprise a composite structure SC comprising a seat base / assembly SC (configured to be movable relative to the base) and a composite structure SC comprising a seat back / assembly SK (configured to be movable relative to the base / seat base) and a composite structure SC comprising a seat headrest / assembly SR (configured to be movable relative to the seat back); the seat assembly SZ may comprise a seat frame SF comprising seat frame SFb for the seat base SC and seat frame SFk for the seat back SK; the seat assembly SZ may comprise an operator control / panel CP for providing a user interface for interaction / control of operation / movement for the seat base SC and / or seat back SK and / or seat headrest SR and / or for functional features of the seat assembly SZ. See also FIGURES 28, 29, 30A-30E, 33A-33B, 34A-34B, 35A-35C, 36A-36C, 37A-37B, 38A-38B, 39A-39D and 40A-40D.

[0094] As indicated schematically in FIGURES 2A-2B, 3, 4A-4B, 5, 7A-7B, 8, 10A-10C, 13A-13B, 14, 18, 21, 23, 25, 26A-26B, 31 and 32, each composite structure SC for the seat assembly SZ may comprise a seat pad PD and a cover T; the composite structure CS may comprise seat pad PD comprising a foam material FM formed on a cover T comprising a cover material formed from a sheet material SH configured to provide an external surface TX to provide a surface effect; the pad PD and cover T may be configured to provide a compressible / cushion effect for the composite structure CS of the seat base SC and / or the seat back SK and / or the seat headrest SR. See also FIGURES 16, 17, 19, 20, 22, 24, 27, 28, 29, 30A-30E, 52A-52C, 53A-53C, 54A-54I, 55A-55H and 56A-56H.

[0095] As indicated schematically in FIGURES 2A-2B, 3, 4A-4B, 5, 7A-7B, 8, 10A-10C, 13A-13B, 14, 53A-53C, 54A-54I, 55A-55H and 56A-56H, 57A-57F, 58, 59 and 60, composite structure CS comprising seat base SC and / or seat back SK and / or seat headrest SR for seat assembly SZ may be provided by providing cover T from a cover / sheet material SH in a manufacturing apparatus M with section MT (top) and section MB (bottom) and forming pad PD / FM on cover T / SH in a mold / apparatus M with section MT and section MB byproviding foam material FMp to form / fill for composite structure CS. See also FIGURES 18, 21, 23, 25, 26A-26B, 31, 32, 78A-78C, 79 and 80.

[0096] As indicated schematically in FIGURES 2A-2B, 3, 4A-4B, 5, 7A-7B, 8, 10A-10C, 13A-13B, 14, 53A-53C, 54A-54I, 55A-55H and 56A-56H, 57A-57F, 58, 59 and 60, features FT such as indentations ND and / or projections PR and / or perforations PF and / or channels CH of composite structure CS for seat base SC and / or seat back SK and / or seat headrest SR of seat assembly SZ may be provided at formation of the composite structure (e.g. by molding, forming, within tool, with slider elements, etc.); features FT such as perforations PF and / or channels CH of composite structure CS for seat base SC and / or seat back SK and / or seat headrest SR of seat assembly SZ may be provided at formation of the composite structure (e.g. by molding, forming, within tool, with slider elements, etc.) and / or after formation of the composite structure by a tool MX such as by laser-forming by laser tool LZ or mechanical operation by tool (e.g. perforation, punching, drilling, etc.). See also FIGURES 18, 21, 23, 25, 26A-26B, 31, 32, 78A-78C and 79.

[0097] As indicated schematically in FIGURES 2A-2B, 3, 4A-4B, 5, 6, 7A-7B, 8, 9, 10A- 10C, 11, 12A-12C, 13A-13B, 14, 15, 551, 561, 68, 78A-78C and 79, features FT such as lighting elements LG / LF of composite structure CS for seat base SC and / or seat back SK and / or seat headrest SR of seat assembly SZ may be provided at formation of the composite structure (e.g. within tool, with slider elements, etc.) or at complete assembly of the seat assembly SZ; functional module MD with light source LS, power source PS, heating element / mat HT, fan unit VF, HVAC unit, etc. may be assembled together with the composite structure CS for seat base SC and seat back SK and seat headrest SR on base B / SB with the completion of assembly of the seat assembly SZ.

[0098] According to an exemplary embodiment as indicated schematically in FIGURES 2A- 2B, 3, 4A-4B, 5, 7A-7B, 8, 10A-10C, 13A-13B, 14, 18, 21, 23, 25, 26A-26B, 31 and 32, the pad PD and cover T of the composite structure CS for the seat base SC and / or seat back SK and or seat headrest SR of the seat assembly SZ may be bonded at formation and / or connected to and with the base / substrate B / SB with a connector CN and / or an adhesive material AH (e.g. adhesive layer, material, tape, strip, epoxy, coating, etc.). See FIGURES 54A-54I, 55A-55H, 56A-56H, 61, 62A-62D, 63A-63C, 64, 78A-78B and 79.

[0099] As indicated schematically in FIGURES 2A-2B, 3, 4A-4B, 5, 7A-7B, 8, 10A-10C, 13A-13B and 14, the composite structure CS of seat pad PD and cover T may comprise a feature FT and / or a module MD such as a functional module for the seat assembly SZ (e.g for operation of functional features); feature FT or set of features provided at the compositestructure CS may comprise a projection PR, indentation ND, perforation PF, channel CH, light element LG, pattern of features PT, etc.; the surface effect at exterior surface TX of cover T of a composite structure CS of the seat assembly SZ may comprise a texture, grain, decorative effect, color, pattern, etc. See also FIGURES 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26A-26B, 27, 28, 29, 30A-30E, 31, 32, 65, 66 and 67.

[0100] As indicated schematically in FIGURES 2A-2B, 3, 4A-4B, 5, 7A-7B, 8, 10A-10C, 13A-13B, 14, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26A-26B, 27, 28, 29, 30A-30E, 31 and 32, the feature FT or set of features provided at the composite structure CS may be arranged in various positions / forms on the seat base SC and / or the seat back SK; the features FT or set of features may be configured to provide decorative effect and / or function such as projection PR and / or indentation ND for structure / reinforcement and / or design / aesthetic effect, perforation PF and / or channel CH to for ventilation and / or heating / cooling and / or visual / lighting effect, light element LG such as light pipes / segments to provide visual / lighting effect, etc. See also FIGURES 41A-41C, 42A-42C, 43A-43C, 44A-44C, 45A-45C, 46A- 46C, 47A-47J, 48A-48B, 49A-49B, 50A-50B, 51A-51B, 551, 561 and 68.

[0101] As indicated schematically in FIGURES 2A-2B, 3, 4A-4B, 5, 6, 7A-7B, 8, 9, 10A- 10C, 11, 12A-12C, 13A-13B, 14, 15, 551, 561 and 68, the functional module MD of the seat assembly SZ may comprise a blower / fan VF, an HVAC unit, heating element / mat HT, a light source / panel LS with a power supply PS; the surface effect at exterior surface TX of cover T of composite structure CS may be provided for the seat base SC and / or the seat back SK and / or the seat headrest SR. See also FIGURES 41 A-41C, 42A-42C, 43A-43C, 44A-44C, 45A-45C, 46A-46C, 47A-47J, 48A-48B, 49A-49B, 50A-50B and 51A-51B.

[0102] As indicated schematically in FIGURES 2A-2B, 3, 4A-4B, 5, 7A-7B, 8, 10A-10C, 13A-13B, 14, 16, 18, 18, 19, 20, 21, 22, 23, 24, 25, 26A-26B, 27, 28, 29, 30A-30E, 31 and 32, the configuration and / or combination of features FT such as in pattern PT for the composite structure SC of seat base SC and / or seat back SK and / or seat headrest SR may provide for functional operation (e.g. comfort, venting / ventilation, heating / cooling, lighting, etc.) and / or design / visual effect (e.g. surface effect, texture, aesthetics, lighting, etc.) for the seat assembly SZ. See also FIGURES 41 A-41C, 42A-42C, 43A-43C, 44A-44C, 45A-45C, 46A-46C, 47A-47J, 48A-48B, 49A-49B, 50A-50B, 51A-51B, 551, 561 and 68.

[0103] As indicated schematically in FIGURES 2A, 3, 7A-7B, 10B, 28, 29, 30A-30E, 31 and 32, a visual effect provided at the external surface TX of cover T of composite structure CS for seat base SC and / or seat back SK and / or seat headrest SR or seat assembly SZ may comprise a visual feature such as an image IM and / or icon IC (e.g. indicia, mark, word, logo,etc.) formed by a projection PR and / or an indentation ND or a pattern PT (e.g. set of projections and / or indentations, etc.) or a surface element / effect (e.g. applied material, etc.); as indicated schematically, the visual feature such as image / icon IM / IC may comprise a light element (e.g. an illuminated image, icon, indicia, word, etc.) configured to be illuminated by a light source LS and / or material such as an illuminated panel / film LF (e.g. light sheet, electroluminescent film, etc.). See also FIGURES 11 and 12A-12C.

[0104] According to an exemplary embodiment as indicated schematically in FIGURES 41A-41C, 42A-42C, 43A-43C, 44A-44C, 45A-45C, 46A-46C, 47A-47J, 48A-48B, 49A-49B, 50A-50B, 51A-51B, 551, 561 and 68, the seat assembly SZ will comprise a composite structure CS with pad PD and cover T for seat base SC and seat back SK and seat headrest SR configured to provide features for a variety of functional operations including venting through perforations PF and channels CH, heating / cooling through perforations PF and channels, lighting through perforations PF and channels CH, lighting through light elements LG / LF, heating through heating element HT, etc. (including with integration of functional module MD and power source PS and control panel / operator control). See also FIGURES 2A-2B, 3, 4A-4B, 5, 6, 7A-7B, 8, 9, 10A-10C, 11, 12A-12C, 13A-13B, 14 and 15.

[0105] According to an exemplary embodiment as indicated schematically in FIGURES 2A- 2B, 3, 4A-4B, 5, 7A-7B, 8, 10A-10C, 13A-13B, 14, 65, 66, 67, 69A-69B, 70A-70B, 71A- 7 IB, 72A-72B, 73A-73B, the method / process of forming seat assembly SZ from composite structure CS for seat base SC and / or seat back SK and / or seat headrest SR with pad PD / FM and cover T comprises reduction of defects DF such as uneven texture (FIGURES 69A-69B, 70A-70B and 72A-72B), wrinkles (FIGURES 69A-69B, 73A-73B and 75A-75B), voids (FIGURES 71A-71B and 74A-74B), etc. According to an exemplary embodiment as indicated schematically in FIGURES 2A-2B, 3, 4A-4B, 5, 7A-7B, 8, 10A-10C, 13A-13B, 14, 69B, 70B, 71B, 72B, 73B, 74B and 75B, the cover T on the pad PD of the composite structure CS of the seat assembly will be configured to be produced with intended uniform appearance of form / shape for the composite structure CS and at exterior surface TX including with texture and with features FT such as indentations ND, projections PR, perforations PF in pattern PT and with image / icon IM / IC (presented as / where intended); seat assembly SZ as intended will show no visible defects. See also FIGURES 65, 66 and 67.

[0106] As indicated schematically in FIGURES 76A-76B and 77, the composite structure CS for the seat base SC and / or seat back SK and / or seat headrest SR of the seat assembly SZ may comprise construction and materials configured for efficient disassembly (e.g. removal frombase and / or frame) and recycling (e.g. through conventional cycle for material separation, processing, reformulation, reuse, etc.).Exemplary Embodiments - A

[0107] According to an exemplary embodiment as shown in the FIGURES, a seat assembly for a vehicle interior may comprise a seat base comprising a composite structure and a seat back comprising a composite structure; the composite structure may comprise a pad and a cover; the cover may comprise an exterior surface. The composite structure may comprise a feature comprising a perforation, channel, indentation, projection, image / icon, light element and / or set of features in a pattern, etc. The feature and / or the exterior surface of the cover may provide a decorative / visual effect, etc. The seat assembly may comprise a base for mounting / movement in the vehicle interior. The seat assembly may comprise a functional module for ventilation, heating, cooling, lighting, etc. The composite structure may comprise the pad as a foam material formed on the cover; the composite structure may be configured to retain shape / form and intended surface effect such as texture (e.g. to reduce defects). A method of forming the seat assembly may comprise forming a composite structure of pad and cover for a seat base and seat back and assembly of the composite structure for the seat base and seat back onto a base / substrate. The feature such as perforation, channel, indentation, projection, light element, set of features / pattem, etc. may be formed in the composite structure of the seat assembly to facilitate ventilation, heating, cooling, lighting, decorative / visual effect, etc. The method of forming / assembly may facilitate efficient production techniques and reduce cost of materials, labor, etc. Materials may facilitate improved sustainability including efficient end-of-life recycling / reuse of materials such as the pad and cover (e.g. polyurethane, TPU, TPO, etc.) and use of biomaterials (e.g. such as bio foam ingredient, castor oil (20 percent / BASF supply, soybean oil / DOW supply, recycled content polyols etc.) The seat assembly may comprise reduced weight construction and reduced complexity for design / assembly; unique / variety form / shape and design may be facilitated by the composite structure configuration with pad / cover (e.g. unique seating designs may be achieved and the ability to make concave shapes, different surface effects, patterns, etc.); thin / shape form may be facilitated for the seat back, etc. and construction of the seat assembly. The method may facilitate retaining form / shape and texture for the composite structure formed and provided for seat base and / or seat back and / or seat headrest; functional performance of the seat assembly may be facilitated by thecomposite structure and selection of materials and feature / combination of features (with functional module / modules.Exemplary Embodiments - B

[0108] According to an exemplary embodiment as shown schematically in the FIGURES, a seat assembly for a vehicle interior may comprise a seat base that may comprise a composite structure and a seat back that may comprise a composite structure. The composite structure for the seat base may comprise a pad and a cover. The composite structure for the seat back may comprise a pad and a cover. The cover may comprise an exterior surface. The composite structure may be formed with the cover and the pad. The cover may comprise a cover material. The pad may comprise a foam material. The pad may be formed onto the cover. The foam material may be formed onto the cover material. The cover may be coupled to the pad. The composite structure may comprise a feature. The composite structure for the seat base may comprise a feature. The composite structure for the seat back may comprise a feature. The feature may be provided at the cover and may be provided in the pad. The feature may comprise a set of features and a pattern of features and a set of features at the cover and a feature formed in the composite structure and a set of features formed in the composite structure and a set of features formed in the pad and a set of features formed in the cover and a set of features formed in the cover and in the pad etc. The feature may comprise an aperture. The aperture may comprise a perforation. The feature may comprise a perforation and a perforation at the cover and a perforation for ventilation at the cover and a perforation for illumination at the cover etc. The feature may comprise a channel through the composite structure and a set of channels through the composite structure and a pattern of channels through the composite structure and a set of channels through the pad and the cover of the composite structure etc. The feature may comprise a set of apertures through the cover and a set of channels through the pad and a set of perforations through the cover and a set of channels through the pad etc. The assembly may further comprise a fan configured to facilitate air flow through the set of channels. The air flow may comprise a vacuum flow. The assembly may further comprise a HVAC module configured to facilitate heating and / or cooling by air flow through the set of channels. The light source may comprise an LED light. The assembly may further comprise a functional module configured to provide a light source. The functional module may comprise a light source. The feature may comprise a heating element for the composite structure. The assembly may further comprise a heating element for the composite structure. The heating element may comprise a heating mat under thecover of the composite structure and a permeable mat between the cover and the pad etc. The feature may comprise a decorative element at the cover and an image and / or icon and indicia and / or a logo and / or a word etc. The feature may be configured to be illuminated. The feature may be formed at the cover. The feature may comprise an indentation at the cover and a projection at the cover and a protrusion at the cover and an indentation and a protrusion at the cover and a rib at the cover and a pattern of indentations at the cover and a pattern of projections at the cover etc. The feature may be formed at the cover or in the pad or in the composite structure, by molding, at molding, by deep drawing, by foaming, by a laser tool, by a punch and / or needle etc. The feature may be formed in the cover and in the pad. The feature may comprise a light element. The light element may be provided at the seat base and at the seat back etc. The light element may comprise a light guide and a light pipe. The light guide may be provided at the exterior surface of the seat back and at the exterior surface of the seat base. The light guide may comprise a set of light guides and a set of light pipes etc. The light element may comprise multi-segment light elements and multi-color elements and an image and / or icon and / or logo etc. The light element may be configured to provide a visual effect. The visual effect may comprise a light effect. The light element may comprise an electroluminescent element and an electroluminescent panel and an illuminated element and an image and / or icon and a pattern and a set of light elements etc. The assembly may further comprise a light source configured to illuminate the light element. The light source may comprise an LED light. The assembly may further comprise a functional module configured to provide a light source. The functional module may comprise a light source etc. The assembly may further comprise a functional module for the seat base and / or the seat back and a functional module for the seat base and a functional module for the seat back etc. The functional module may comprise a fan and an HVAC unit and a light source and a power source etc. The assembly may further comprise an operator control and a control panel and a control panel for the functional module etc. The composite structure may comprise a support assembly and a pad bonded to the cover and a foam formed on the cover etc. The assembly may further comprise an intermediate layer under the cover. The intermediate layer may comprise a non-woven layer. The cover may comprise an exterior surface and may be configured to provide a visual effect. The visual effect may comprise a surface effect. The exterior surface may comprise a surface effect. The cover may comprise a cover material and may be configured to provide the surface effect. The cover material may be configured to provide the surface effect. The cover may be configured to retain the surface effect when formed onto the pad. The exterior surface of the cover may be configured to retain thesurface effect when formed onto the pad. The surface effect may comprise a texture and a uniform visual effect and a uniform texture and the texture may comprise a grain effect and the surface effect may comprise softness and a decorative effect etc. The surface effect may be configured to provide ventilation and to facilitate drainage and to be breathable etc. The assembly may further comprise a base configured to mount to the vehicle interior. The base may comprise a structure configured to mount a floor in the vehicle interior. The structure may comprise a mounting structure. The mounting structure may comprise a chassis. The chassis may be configured to be movable relative to the floor. The seat base may be configured to be mounted to the chassis of the mounting structure of the base and to the structure etc. The seat back may be configured to be mounted to the structure and the seat base may be configured to be mounted to the structure and the seat back may be configured to be mounted to the seat base. The seat back may be configured to be mounted for pivotal movement relative to the seat base etc. The seat base may comprise a seat cushion. The assembly may further comprise a seat base assembly comprising the seat base and a seat base assembly comprising the seat cushion etc. The seat base may comprise a seat cushion assembly. The assembly may further comprise a seat cushion assembly comprising the seat cushion. The seat cushion assembly may comprise a frame. The frame may be configured to be mounted to the base. The seat base assembly may comprise a frame, and the frame may be configured for mounting to a base and / or to a chassis of the base etc. The assembly may further comprise a seat back assembly comprising the seat back cushion. The seat back cushion may comprise a composite structure. The composite structure may comprise a pad and a cover, and the pad may comprise a foam material, and the cover may comprise a cover material etc. The seat back assembly may comprise a front cover and a back cover. The composite structure may comprise a front portion, a rear portion and a connecting portion, and an opening configured to receive the frame etc. The composite structure may be configured to be pulled over the frame. The cover of the seat back assembly may comprise a front cover and a back cover, and the seat back assembly may comprise a frame, and the frame may be configured to be mounted to the seat base and for pivoting movement of the seat back relative to the seat base etc. The assembly may further comprise a seat headrest assembly comprising a headrest and a headrest comprising a composite structure etc. The headrest may comprise a composite structure that may comprise a pad and a cover and the pad may comprise a foam material and the cover may comprise a cover material etc. The assembly may further comprise a headrest assembly comprising the headrest and a frame, and the frame may be configured to be mounted to the seat back and for movement relative to theseat back etc. The foam material of the pad may comprise a polymer material and / or a polyurethane material and the cover material of the cover may comprise a polymer material etc. The foam material of the pad may comprise a formed polyurethane material and / or a thermoset material or a thermoplastic material and the cover material of the cover may comprise a molded polymer material and / or a molded polymer material and a deep drawn or blow molded or vacuum formed polymer material and / or a thermoplastic material etc. The foam material of the pad may comprise a TPU material, a TPE material, a polyolefin material etc. The cover material of the cover may comprise a TPO material, a TPE material, a TPU material etc. The foam material of the pad may comprise a TPU material formed on the cover. The cover material of the cover may comprise a TPO material bonded to the pad etc. The cover may comprise a sheet and a sheet material and a sheet material coupled to the pad and to the frame and a sheet material chemically bonded to the pad and mechanically coupled to the frame by means of a connector etc. The cover may be coupled by a connector that may comprise a clip and a retainer and a retainer clip and a bar and a tape and an adhesive tape etc. The cover may be coupled by an adhesive material. The cover may be bonded by an adhesive material. The frame for the seat base may comprise a structure and may comprise a metal structure and a spring structure etc. The frame for the seat back may comprise a structure and may comprise a metal structure and a spring structure etc. The seat base assembly may be configured for movement relative to the base. The seat base may be configured for movement forward and / or backward relative to the base and may be configured for movement up and / or down relative to the base and may be configured for adjustable movement relative to the base etc. The seat back may be configured for movement relative to the seat base and may be configured for pivoting movement relative to the seat base and may be configured for pivoting mounting to the seat base and may be configured for pivoting movement forward and / or backward relative to the seat base etc. The seat back may be configured to provide adjustment of lumbar support and may be configured to provide a massage effect etc. The seat headrest may be configured for movement relative to the seat back and may be configured for movement up and / or down relative to the seat back and may be configured for movement forward and / or backward relative to the seat back etc. The assembly may further comprise a support assembly that may comprise at least one of the seat base and / or the seat back etc. The seat base may comprise a seat cushion. The cover may comprise an exterior surface. The cover may comprise a skin. The cover may comprise a molded skin. The cover may comprise a vacuum-formed skin. The exterior surface of the cover may comprise a grained surface and a textured surface etc. The cover material of thecover may comprise an artificial leather material. The cover may comprise a laminate and a bilaminate etc. The cover material of the cover may comprise a TPO laminated with the foam of the pad etc. The pad may comprise a polyurethane material and a bio-urethane material and a TPE material and a compressible pad etc. The composite structure may comprise a concave surface and an indentation in the exterior surface etc. The indentation in the exterior surface may be formed in the cover and may be formed in the pad etc. The indentation in the exterior surface may comprise an indentation formed in the cover, and the indentation formed in the cover may be configured to form an indentation in the pad etc. The indentation may comprise at least one of an image and / or a logo and / or an icon and may comprise a groove etc. The groove may be configured to facilitate expansion of the exterior surface of the composite structure and may comprise a set of grooves and a set of inboard grooves and a set of outboard grooves etc. The indentation may be formed in a sidewall of the composite structure and the sidewall of the composite structure may be configured to be visible from outside of the vehicle interior etc. The indentation may comprise a dimple and the dimple may comprise a set of dimples in a pattern and the pattern may comprise a “U” shape etc. The dimple may be formed in the cover and may be formed in the pad etc. The composite structure may be configured for a compressed state when the seat base is occupied by an occupant and may be configured for a retracted state when the seat base is occupied by an occupant and an expanded state when the seat is unoccupied etc. The composite structure may be configured to expand to change the shape of the support assembly and to expand to increase a length of the outer surface etc. The composite structure may comprise a channel and a channel passing through the cover and the pad and a set of channels and a set of channels passing through the cover and the pad and an aperture and a set of apertures and a pattern of apertures etc. The aperture may comprise a perforation and the composite structure may comprise a set of perforations and a pattern of perforations etc. The assembly may further comprise a light source and the light source may be configured to provide illumination through the aperture and may be configured to illuminate an indentation at the cover or in the cover and may provide illumination at the cover and may be configured to illuminate at least one of an image at the cover and / or a logo at the cover and / or an icon at the cover and may be configured to illuminate at least one of an image on the cover and / or a logo on the cover and / or an icon on the cover and may be configured to illuminate a simulated seam in the cover etc. The composite structure may comprise at least one of a simulated seam and / or a simulated French seam and / or a simulated deck seam and / or a simulated join seam etc. The composite structure may comprise a protrusion at the exterior surface and a protrusion in theexterior surface etc. The protrusion in the exterior surface may be formed at the cover and may be formed in the cover and may be formed in the pad etc. The protrusion may comprise a protrusion formed in the cover, with the protrusion formed in the cover being configured to form a protrusion in the pad etc. The protrusion in the exterior surface may be configured to provide a visual effect and the visual effect may comprise at least one of a simulated seam, a simulated French seam, a simulated deck seam etc. The visual effect in the outer surface may comprise at least one of an image and / or a logo and / or an icon etc. The composite structure may be configured for recycling and may comprise a recyclable assembly etc. The recyclable assembly may be configured to be shredded or chopped for reuse of materials into recycled material etc. A method of forming a seat assembly may comprise the steps of forming a composite structure for a seat base, where the composite structure for the seat base may comprise a cover and a pad formed on the cover, and where the pad may comprise a foam material and the cover may comprise a cover material etc. The method may further comprise the step of forming a composite structure for a seat back to be coupled to the seat base and further comprising the step of forming a feature for the composite structure where the feature may comprise at least one of a perforation and / or a channel and / or an indentation and / or a projection and / or an image and / or a set of features etc. The feature may comprise a set of features formed by a tool at the cover and / or the pad etc. The composite structure for the seat back may comprise a cover and a pad formed on the cover. The composite structure may comprise a frame. The method may further comprise the step of assembling the seat base to a frame and further comprising the step of assembling the seat back to a frame etc. The method may further comprise the step of assembling the seat base to a base structure. The cover may comprise an exterior surface and the exterior surface of the cover may comprise a surface effect and the surface effect may be preserved during forming and assembly and may comprise a form and a texture and may provide a visual effect etc. The seat assembly is configured for efficient production of the pad for the composite structure with the foam material comprising polyurethane foam; the seat assembly is configured for efficient assembly from the composite structure comprising the seat base. The foam material may comprise a reduced-cost foam material and / or the cover material may comprise a reduced- cost cover material. The cover material may comprise a synthetic leather material configured to facilitate recyclability. The foam material and the cover material may be selected to facilitate end of life recycling. The foam material may comprise a bio-foam material; the biofoam material may comprise castor oil and / or soybean oil and / or recycled content polyols. The foam material and the cover material may comprise recyclable material. Forming of thecomposite structure comprises forming in a mold tool. The foam material comprises a reduced-weight material. The pad may be formed directly on the cover; the pad may be formed in an apparatus configured for production of multiple components. The composite structure may comprise a concave shape. The composite structure may comprise a surface effect comprising a pattern and / or a grain and / or a logo. The seat back may comprise a thin seat back construction. A seat for an occupant in a vehicle interior may comprise a support assembly for the occupant, where the support assembly may comprise a pad bonded to a cover and may comprise an outer surface visible to the occupant etc. The support assembly may comprise at least one of a seat cushion and / or a seat back and / or a composite structure etc. The cover may comprise a skin and a molded skin and a vacuum formed skin and may comprise a grained surface and a textured surface and an artificial leather material and a laminate and a bilaminate etc. The bilaminate may comprise a TPO laminated with a foam etc. The pad may comprise a polyurethane material and may comprise a bio-urethane material and a TPE material and a low Shore A substrate material etc. The pad may comprise a hardness between 30 Shore A and 60 Shore A etc. The support assembly may comprise a concave surface and an indentation in the outer surface etc. The indentation in the outer surface may be formed in the cover and may be formed in the pad etc. The indentation in the outer surface may comprise an indentation formed in the cover with the indentation formed in the cover being configured to form an indentation in the pad etc. The indentation may comprise at least one of an image, a logo, an icon etc. The indentation may comprise a groove etc. The groove may be configured to facilitate expansion of the outer surface of the support assembly and may comprise a set of grooves and a set of inboard grooves and a set of outboard grooves etc. The indentation may be formed in a sidewall of the support assembly and the sidewall of the support assembly may be configured to be visible from outside of the vehicle interior etc. The indentation may comprise a dimple and a set of dimples in a pattern and the pattern may comprise a “U” shape and the dimple may be formed in the cover and / or the pad etc. The support assembly may be configured for a retracted state when the seat is unoccupied and an expanded state when the seat is occupied etc. The support assembly may be configured to provide a discontinuous support surface in the retracted state and a continuous support surface in the expanded state and may be configured to provide a generally flat support surface in the retracted state and a concave support surface in the expanded state etc. The support assembly may be configured to expand to change the shape of the support assembly and to expand to increase a length of the outer surface etc. The support assembly may comprise an aperture passing through the cover and the pad and theaperture may comprise a perforation etc. The support assembly may further comprise a light source and the light source may be configured to provide illumination through the aperture and to illuminate an indentation in the cover and to illuminate at least one of an image in the cover, a logo in the cover, or an icon in the cover and may be configured to illuminate a simulated seam in the cover etc. The support assembly may comprise at least one of a simulated seam, a simulated French seam, a simulated deck seam, or a simulated join seam etc. The support assembly may comprise a protrusion in the outer surface and the protrusion in the outer surface may be formed in the cover or the pad etc. The protrusion in the outer surface may comprise a protrusion formed in the cover and the protrusion formed in the cover may be configured to form a protrusion in the pad etc. The protrusion in the outer surface may be configured to provide a visual effect comprising at least one of a simulated seam, a simulated French seam, or a simulated deck seam or may comprise at least one of an image, a logo, or an icon etc. The support assembly may be configured for recycling and may comprise a recyclable assembly etc. The recyclable assembly may be configured to be shredded or chopped for reuse of materials into recycled material etc. The seat may be formed by a process of forming the cover and molding the pad on the cover and forming the cover may comprise vacuum forming a sheet of material and the process may comprise creating a hole through the cover and the pad etc. The seat assembly for a vehicle interior may comprise a seat base and a seat back, each of which may comprise a composite structure formed of a pad and a cover, where the pad may be a foam material molded directly onto the cover such that the pad and cover may be bonded together to form a unitary component and the cover may define an exterior surface configured to retain a surface effect selected from the group consisting of a texture, a grain, a simulated seam, an image, or a decorative pattern etc. during and after the foam molding process and the composite structure may include at least one functional feature selected from the group consisting of a pattern of perforations or channels passing through both the cover and the pad to enable ventilation or illumination and an integrated heating element disposed between the cover and the pad and a light guide or light pipe extending through the composite structure and configured to illuminate an image, icon, logo, or seam at the exterior surface etc. At least one of the pad and the cover may comprise a polymeric material selected from the group consisting of TPU, TPO, TPE, or polyurethane etc. The seat assembly may further comprise a functional module selected from the group consisting of a fan, an HVAC unit, and an LED light source, each operably coupled to the composite structure and the functional module may be configured to provide air flow, heating, cooling, or illumination through the perforations or channels etc. The surface effectof the cover may comprise a simulated seam and at least one light guide may be configured to provide visual illumination to the simulated seam from an internal light source etc. The pad and the cover may be both formed from recyclable materials selected from the group consisting of TPO, TPE, and polyurethane and the assembly may be configured such that the pad and cover can be separated or processed for recycling at end of life etc. The pad may comprise a compressible polyurethane foam having a Shore A hardness between 30 and 60 etc. The composite structure may further comprise a pattern of channels interconnecting with the perforations to facilitate distributed ventilation or illumination across the exterior surface etc. The composite structure may be configured such that the pad may be molded onto a preformed, vacuum-formed, or deep-drawn cover comprising a grained or textured surface, and the grained or textured surface may be retained after molding etc. The method of forming a seat assembly for a vehicle interior may comprise forming a cover having a desired exterior surface effect selected from the group consisting of texture, grain, simulated seam, image, or decorative pattern and molding a foam pad directly onto the inner side of the cover to bond the pad to the cover and create a unitary composite structure and forming at least one functional feature selected from the group consisting of a pattern of perforations, channels, a light guide, or a heating element integrally within the composite structure during molding and assembling the composite structure as part of a seat base or seat back etc.Exemplary Embodiments - C

[0109] According to an exemplary embodiment as shown schematically in the FIGURES, a seat / seat assembly for an occupant in a vehicle interior may comprise a composite structure comprising a support assembly for the occupant. The support assembly may comprise a pad bonded to a cover. The support assembly may comprise an outer surface visible to the occupant. The support assembly may comprise at least one of (a) a seat cushion and / or (b) a seat back. The cover may comprise a skin. The cover may comprise a molded skin. The cover may comprise a vacuum formed skin. The cover may comprise a grained surface. The cover may comprise a textured surface. The cover may comprise an artificial leather material. The cover may comprise a laminate. The cover may comprise a bilaminate. The bilaminate may comprise a TPO laminated with a foam. The pad may comprise a polyurethane material. The pad may comprise a bio-urethane material. The pad may comprise a TPE material. The pad may comprise a low shore A substrate material. The pad may comprise a hardness between 30 Shore A and 60 Shore A. The support assembly maycomprise a concave surface. The support assembly may comprise an indentation in the outer surface. The indentation in the outer surface may be formed in the cover. The indentation in the outer surface may be formed in the pad. The indentation in the outer surface may comprise an indentation formed in the cover; the indentation formed in the cover may be configured to form an indentation in the pad. The indentation may comprise at least one of (a) an image, (b) a logo, and / or (c) an icon. The indentation may comprise a groove. The groove may be configured to facilitate expansion of the outer surface of the support assembly. The groove may comprise a set of grooves. The groove may comprise a set of inboard grooves and a set of outboard grooves. The indentation may be formed in a sidewall of the support assembly. The sidewall of the support assembly may be configured to be visible from outside of the vehicle interior. The indentation may comprise a dimple. The dimple may comprise a set of dimples in a pattern. The pattern may comprise a “U” shape. The dimple may be formed in the cover. The dimple may be formed in the pad. The support assembly may be configured for (a) a retracted state when the seat is unoccupied and (b) an expanded state when the seat is occupied. The support assembly may be configured to provide a discontinuous support surface in the retracted state and a continuous support surface in the expanded state. The support assembly may be configured to provide a generally flat support surface in the retracted state and a concave support surface in the expanded state. The support assembly may be configured to expand to change the shape of the support assembly. The support assembly may be configured to expand to increase a length of the outer surface. The support assembly may comprise an aperture passing through the cover and the pad. The aperture may comprise a perforation. The seat may comprise a light source; the light source may be configured to provide illumination through the aperture. The light source may be configured to illuminate an indentation in the cover. The light source may be configured to illuminate at least one of (a) an image in the cover, (b) a logo in the cover, and / or (c) an icon in the cover. The light source may be configured to illuminate a simulated seam in the cover. The support assembly may comprise at least one of (a) a simulated seam, (b) a simulated French seam, (c) a simulated deck seam, and / or (d) a simulated join seam. The support assembly may comprise a protrusion in the outer surface. The protrusion in the outer surface may be formed in the cover. The protrusion in the outer surface may be formed in the pad. The protrusion in the outer surface may comprise a protrusion formed in the cover; the protrusion formed in the cover may be configured to form a protrusion in the pad. The protrusion in the outer surface may be configured to provide a visual effect comprising at least one of (a) a simulated seam, (b) a simulated French seam,and / or (c) a simulated deck seam. The protrusion in the outer surface may comprise at least one of (a) an image, (b) a logo, and / or (c) an icon. The support assembly may be configured for recycling. The support assembly may comprise a recyclable assembly. The recyclable assembly may be configured to be shredded or chopped for reuse of materials into recycled material. The seat may be formed by a process of forming the cover and molding the pad on the cover. Forming the cover may comprise vacuum forming a sheet of material. The process may comprise creating a hole through the cover and the pad.

[0110] A seat for a vehicle interior may comprise a support assembly for an occupant comprising a pad bonded to a cover. The cover may comprise a vacuum formed skin comprising a grained and / or textured surface. The support assembly may comprise a concave surface. The support assembly may comprise an indentation formed in the cover and / or the pad. The indentation may comprise an image, logo, and / or icon. The indentation may comprise a set of grooves and / or dimples to facilitate expansion of an outer surface of the support assembly. The support assembly may be retracted / flat when the seat is unoccupied and expanded / concave when the seat is occupied. The support assembly may expand to change its shape and / or increase its length. The support assembly may comprise an aperture through the cover and pad. The aperture may comprise a perforation. The seat may comprise a light source to provide illumination through the aperture.[OHl] A forming process (e.g. in-mold graining / IMG) may be used to make a cover (e.g. a TPU skin). The cover may be placed into a foam tool. Foam may be poured behind the skin to form a pad and complete a seat shape. The pad / foam may adhere to the cover / skin and set the A-Surface cover / skin and pad / foam geometry.

[0112] Forming / IMG and foam-in-place processes may enable unique shapes on and or in the seat surface to improve seat comfort and / or appearance including concave surfaces, dimples and protrusions; assembly components to connect the skin / cover to the foam may not be necessary; the cover may comprise a bilaminate (e.g. TPO / laminated with foam); the foam may comprise a bio-urethane; the foam may comprise a low shore A substrate material (e.g. TPE 30 - 60 Shore A); the cover / foam assembly may be 100 percent urethane; the cover / foam assembly may be recycled at the end of life (e.g. for carpet underlay type products); a laser process may be used to perforate the cover after foaming to allow air flow permeability; dimples may be formed in the cover; the seat cover and foam may have dimples or protrusions in many different configurations that improve comfort by flattening out in local areas versus larger areas across the entire seat; geometry may provide better air flow for cooling; a 100 percent urethane seat cover / cushion assembly may be provided for easier endof life recycling or scrap reuse; laser perforation may be used after the cover is foamed to create holes in the cover (e.g. to allow for better air flow and permeability); logos, writing, and / or different patterns of holes may be back lit and / or change colors; different hole designs / pattens / hole sizes / hole density, etc. may be incorporated; a flood light may be created under the seat; stitching and / or other A-surface features may be illuminated; logos / icons may be incorporated in seat cover and / or on seat surface.

[0113] The labor opportunity may be reduced and the cost of JIT seating assembly may be reduced and the seat cost may be reduced and the use of leather may be eliminated for improved sustainability story etc. A 100 percent urethane seat may be provided and may facilitate end of life recycling and bio foam chemistry may be used and the bio foam may contain one of BASF Castor Oil, DOW Soybean Oil, recycled content polyols etc. The CO2 footprint may be reduced and the cross functionality of interiors and seating processes or business units may be achieved and the weight of seating assembly may be reduced and the complexity may be reduced and the ability for unique seating designs may be achieved and the ability to make concave shapes may be achieved and the ability for different A surface patterns or grains or logos may be achieved and a thin seat back construction may be enabled etc.Exemplary Embodiments - D

[0114] According to an exemplary embodiment as shown schematically in the FIGURES, a seat assembly for a vehicle interior comprising a seat base may comprise a composite structure and a seat back comprising a composite structure; the composite structure for the seat base may comprise a pad and a cover; the composite structure for the seat back may comprise a pad and a cover; the cover may comprise an exterior surface, the composite structure may be formed with the cover and the pad; the cover may comprise a cover material; the pad may comprise a foam material; the pad may be formed onto the cover; the foam material may be formed onto the cover material; the cover may be coupled to the pad; the composite structure may comprise a feature; the composite structure for the seat base may comprise a feature; the composite structure for the seat back may comprise a feature; the feature may be provided at the cover; the feature may be provided in the cover; the feature may be provided in the pad; the feature may comprise a set of features; the feature may comprise a pattern of features; the feature may comprise a set of features at the cover; the feature may comprise a feature formed in the composite structure; the feature may comprise aset of features formed in the composite structure; the feature may comprise a set of features formed in the pad; the feature may comprise a set of feature formed in the cover; the feature may comprise a set of features formed in the pad and in the cover; the feature may comprise an aperture; the aperture may comprise a perforation; the feature may comprise a perforation; the feature may comprise a perforation at the cover; the feature may comprise a perforation for ventilation at the cover; the feature may comprise a perforation for illumination at the cover; the feature may comprise a channel through the composite structure; the feature may comprise a set of channels through the composite structure; the feature may comprise a pattern of channels through the composite structure; the feature may comprise a set of channels through the pad and the cover of the composite structure; the feature may comprise a set of apertures through the cover and a set of channels through the pad; the feature may comprise a set of perforations through the cover and a set of channels through the pad. the seat assembly may comprise a fan configured to facilitate air flow through the set of channels; the air flow may comprise a vacuum flow; the seat assembly may comprise a HVAC module configured to facilitate heating and / or cooling by air flow through the set of channels; the light source may comprise an LED light; the seat assembly may comprise a functional module configured to provide a light source; the functional module may comprise a light source; the feature may comprise a heating element for the composite structure; the seat assembly may comprise a heating element for the composite structure; the heating element may comprise a heating mat under the cover of the composite structure; the heating element may comprise a permeable mat between the cover and the pad; the feature may comprise a decorative element at the cover; the feature may comprise an image and / or icon; the feature may comprise indicia and / or a logo and / or a word; the feature may be configured to be illuminated; the feature may be formed at the cover; the feature may comprise an indentation at the cover; the feature may comprise a projection at the cover; the feature may comprise a protrusion at the cover; the feature may comprise an indentation and a protrusion at the cover; the feature may comprise a rib at the cover; the feature may comprise a pattern of indentations at the cover; the feature may comprise a pattern of projections at the cover; the feature may be formed at the cover; the feature may be formed in the cover; the feature may be formed in the pad; the feature may be formed in the composite structure; the feature may be formed by molding; the feature may be formed at molding; the feature may be formed by a laser tool; the feature may be formed by a punch and / or needle; the feature may be formed in the cover and in the pad; the feature may comprise a light element; the light element may be provided at the seat base; the light element may be provided at the seat back;the light element may comprise a light guide; the light element may comprise a light pipe; the light guide may be provided at the exterior surface of the seat back; the light guide may be provided at the exterior surface of the seat base; the light guide may comprise a set of light guides; the light guide may comprise a set of light pipes; the light element may comprise multi-segment light elements; the light element may comprise multi-color elements; the light element may comprise an image and / or icon and / or logo; the light element may be configured to provide a visual effect; the visual effect may comprise a light effect; the light element may comprise an electroluminescent element; the light element may comprise an electroluminescent panel; the light element may comprise an illuminated element; the light element may comprise an image and / or icon; the light element may comprise a pattern; the light element may comprise a set of light elements; the seat assembly may comprise a light source configured to illuminate the light element; the light source may comprise an LED light; the seat assembly may comprise a functional module configured to provide a light source; the functional module may comprise a light source; the seat assembly may comprise a functional module for the seat base and / or the seat back; the seat assembly may comprise a functional module for the seat base; the seat assembly may comprise a functional module for the seat back; the functional module may comprise a fan; the functional module may comprise an HVAC unit; the functional module may comprise a light source; the functional module may comprise a power source; the seat assembly may comprise an operator control; the seat assembly may comprise a control panel; the seat assembly may comprise a control panel for the functional module; the composite structure may comprise a support assembly; the composite structure may comprise the pad bonded to the cover; the seat assembly may comprise an intermediate layer under the cover; the intermediate layer may comprise a nonwoven layer; the cover may comprise an exterior surface; the cover may be configured to provide a visual effect; the visual effect may comprise a surface effect; the exterior surface may comprise a surface effect; the cover may comprise a cover material; the cover may be configured to provide the surface effect; the cover material may be configured to provide the surface effect; the cover may be configured to retain the surface effect when formed onto the pad; the exterior surface of the cover may be configured to retain the surface effect when formed onto the pad; the surface effect may comprise a texture; the surface effect may comprise a uniform visual effect; the surface effect may comprise a uniform texture; the texture may comprise a grain effect; the surface effect may comprise softness; the seat assembly may comprise a base configured to mount to the vehicle interior; the base may comprise a structure configured to mount a floor in the vehicle interior; the structure maycomprise a mounting structure; the mounting structure may comprise a chassis; the chassis may be configured to be movable relative to the floor; the seat base may be configured to be mounted to the chassis of the mounting structure of the base; the seat base may be configured to be mounted to the structure; the seat back may be configured to be mounted to the structure; the seat base may be configured to be mounted to the structure and the seat back may be configured to be mounted to the seat base; the seat back may be configured to be mounted for pivotal movement relative to the seat base; the seat base may comprise a seat cushion; the seat assembly may comprise a seat base assembly comprising the seat base; the seat assembly may comprise a seat base assembly comprising the seat cushion; the seat base may comprise a seat cushion assembly; the seat assembly may comprise a seat cushion assembly comprising the seat cushion; the seat cushion assembly may comprise a frame; the frame may be configured to be mounted to the base; the seat base assembly may comprise a frame; the frame may be configured for mounting to a base; the frame may be configured for mounting to a chassis of the base; the seat assembly may comprise a seat back assembly comprising the seat back; the seat back may comprise a composite structure; the composite structure may comprise a pad and a cover; the pad may comprise a foam material; the cover may comprise a cover material; the seat back assembly may comprise a front cover and a back cover; the cover of the seat back assembly may comprise a front cover and a back cover; the seat back assembly may comprise a frame; the frame may be configured to be mounted to the seat base; the frame may be configured to be mounted for pivoting movement of the seat back relative to the seat base; the seat assembly may comprise a seat headrest assembly comprising a headrest; the seat assembly may comprise a headrest comprising a composite structure; the headrest may comprise a composite structure; the composite structure may comprise a pad and a cover; the pad may comprise a foam material; the cover may comprise a cover material; the seat assembly may comprise a headrest assembly comprising the headrest and a frame; the frame may be configured to be mounted to the seat back; the frame may be configured to be mounted for movement relative to the seat back; the foam material of the pad may comprise a polyurethane material; the cover material of the cover may comprise a polymer material; the foam material of the pad may comprise a formed polyurethane material; the cover material of the cover may comprise a molded polymer material; the foam material of the pad may comprise a thermoplastic material; the cover material of the cover may comprise a thermoplastic material; the foam material of the pad may comprise a TPU material; the cover material of the cover may comprise a TPO material; the foam material of the pad may comprise a TPU material formed on the cover; the cover material of the covermay comprise a TPO material bonded to the pad; the cover may comprise a sheet; the cover may comprise a sheet material; the cover may comprise a sheet material coupled to the pad and to the frame; the cover may be coupled by a connector; the connector may comprise a clip; the connector may comprise a retainer; the connector may comprise a retainer clip; the connector may comprise a bar; the connector may comprise a tape; the connector may comprise an adhesive tape; the cover may be coupled by an adhesive material; the cover may be bonded by an adhesive material; the frame for the seat base may comprise a structure; the frame may comprise a metal structure; the frame may comprise a spring structure; the frame for the seat back may comprise a structure; the frame may comprise a metal structure; the frame may comprise a spring structure; the seat base assembly may be configured for movement relative to the base; the seat base may be configured for movement forward and / or backward relative to the base; the seat base may be configured for movement up and / or down relative to the base; the seat base may be configured for adjustable movement relative to the base; the seat back may be configured for movement relative to the seat base; the seat back may be configured for pivoting movement relative to the seat base; the seat back may be configured for pivoting mounting to the seat base; the seat back may be configured for pivoting movement forward and / or backward relative to the seat base; the seat back may be configured to provide adjustment of lumbar support; the seat back may be configured to provide a massage effect; the seat headrest may be configured for movement relative to the seat back; the seat headrest may be configured for movement up and / or down relative to the seat back; the seat headrest may be configured for movement forward and / or backward relative to the seat back; the seat assembly may comprise a support assembly comprising at least one of the seat base and / or the seat back; the seat base may comprise a seat cushion; the cover may comprise an exterior surface; the cover may comprise a skin; the cover may comprise a molded skin; the cover may comprise a vacuum-formed skin; the exterior surface of the cover may comprise a grained surface; the exterior surface of the cover may comprise a textured surface; the cover material of the cover may comprise an artificial leather material; the cover may comprise a laminate; the cover may comprise a bilaminate; the cover material of the cover may comprise a TPO laminated with the foam of the pad; the pad may comprise a polyurethane material; the pad may comprise a foam material; the foam material may comprise a polyurethane material; the foam material may comprise a TPU material; the pad may comprise a bio-urethane material; the pad may comprise a TPE material; the pad may comprise a compressible pad; composite structure may comprise a concave surface; the composite structure may comprise an indentation in the exterior surface; the indentation inthe exterior surface may be formed in the cover; the indentation in the exterior surface may be formed in the pad; the indentation in the exterior surface may comprise an indentation formed in the cover; the indentation formed in the cover may be configured to form an indentation in the pad; the indentation may comprise at least one of an image and / or a logo and / or an icon; the indentation may comprise a groove; the groove may be configured to facilitate expansion of the exterior surface of the composite structure; the groove may comprise a set of grooves; the groove may comprise a set of inboard grooves and a set of outboard grooves; the indentation may be formed in a sidewall of the composite structure; the sidewall of the composite structure may be configured to be visible from outside of the vehicle interior; the indentation may comprise a dimple; the dimple may comprise a set of dimples in a pattern; the pattern may comprise a “U” shape; the dimple may be formed in the cover; the dimple may be formed in the pad; the composite structure may be configured for a compressed state when the seat base is occupied by an occupant; the composite structure may be configured for a retracted state when the seat base is occupied by an occupant and an expanded state when the seat is unoccupied; the composite structure may be configured to expand to change the shape of the support assembly; the composite structure may be configured to expand to increase a length of the outer surface; the composite structure may comprise a channel; the composite structure may comprise a channel passing through the cover and the pad; the composite structure may comprise a set of channels; the composite structure may comprise a set of channels passing through the cover and the pad; the composite structure may comprise an aperture; the composite structure may comprise a set of apertures; the composite structure may comprise a pattern of apertures; the aperture may comprise a perforation; the composite structure may comprise a set of perforations; the composite structure may comprise a pattern of perforations; the seat assembly may comprise a light source; the light source may be configured to provide illumination through the aperture; the light source may be configured to illuminate an indentation at the cover; the light source may be configured to illuminate an indentation in the cover; the seat assembly may comprise a light source that may be configured to provide illumination at the cover; the light source may be configured to illuminate at least one of an image at the cover and / or a logo at the cover and / or an icon at the cover; the light source may be configured to illuminate at least one of an image on the cover and / or a logo on the cover and / or an icon on the cover; the light source may be configured to illuminate a simulated seam in the cover; the composite structure may comprise at least one of a simulated seam and / or a simulated French seam and / or a simulated deck seam and / or a simulated join seam; the composite structure maycomprise a protrusion at the exterior surface; the composite structure may comprise a protrusion in the exterior surface; the protrusion in the exterior surface may be formed at the cover; the protrusion in the exterior surface may be formed in the cover; the protrusion in the exterior surface may be formed in the pad; the protrusion in the exterior surface may comprise a protrusion formed in the cover; the protrusion formed in the cover may be configured to form a protrusion in the pad; the protrusion in the exterior surface may be configured to provide a visual effect; the visual effect may comprise at least one of a simulated seam and / or a simulated French seam and / or a simulated deck seam, etc.; the visual effect in the outer surface may comprise at least one of an image and / or a logo and / or an icon, etc.; the composite structure may be configured for recycling; the composite structure may comprise a recyclable assembly; the recyclable assembly may be configured to be shredded or chopped for reuse of materials into recycled material.* * *

[0116] It is important to note that the present inventions (e.g. inventive concepts, etc.) have been described in the specification and / or illustrated in the FIGURES of the present patent document according to exemplary embodiments; the embodiments of the present inventions are presented by way of example only and are not intended as a limitation on the scope of the present inventions. The construction and / or arrangement of the elements of the inventive concepts embodied in the present inventions as described in the specification and / or illustrated in the FIGURES is illustrative only. Although exemplary embodiments of the present inventions have been described in detail in the present patent document, a person of ordinary skill in the art will readily appreciate that equivalents, modifications, variations, etc. of the subject matter of the exemplary embodiments and alternative embodiments are possible and contemplated as being within the scope of the present inventions; all such subject matter (e.g. modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the present inventions. It should also be noted that various / other modifications, variations, substitutions, equivalents, changes, omissions, etc. may be made in the configuration and / or arrangement of the exemplary embodiments (e.g. in concept, design, structure, apparatus, form, assembly, construction, means, function, system, process / method, steps, sequence of process / method steps, operation, operating conditions, performance, materials, composition, combination, etc.) without departing from the scope of the present inventions; all such subject matter (e.g. modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the present inventions. The scope of the present inventions is not intended to be limited to the subject matter (e.g. details, structure, functions, materials, acts, steps, sequence, system, result, etc.) described in the specification and / or illustrated in the FIGURES of the present patent document. It is contemplated that the claims of the present patent document will be construed properly to cover the complete scope of the subject matter of the present inventions (e.g. including any and all such modifications, variations, embodiments, combinations, equivalents, etc.); it is to be understood that the terminology used in the present patent document is for the purpose of providing a description of the subject matter of the exemplary embodiments rather than as a limitation on the scope of the present inventions.

[0117] It is also important to note that according to exemplary embodiments the present inventions may comprise conventional technology (e.g. as implemented and / or integrated in exemplary embodiments, modifications, variations, combinations, equivalents, etc.) or maycomprise any other applicable technology (present and / or future) with suitability and / or capability to perform the functions and processes / operations described in the specification and / or illustrated in the FIGURES. All such technology (e.g. as implemented in embodiments, modifications, variations, combinations, equivalents, etc.) is considered to be within the scope of the present inventions of the present patent document.

Claims

CLAIMSThe invention claimed is:

1. A seat assembly for a vehicle interior comprising: a seat base comprising a composite structure; a seat back comprising a composite structure; wherein the composite structure for the seat base comprises a pad and a cover; wherein the composite structure for the seat back comprises a pad and a cover; wherein the cover comprises an exterior surface.

2. The seat assembly of Claim 1 wherein the composite structure is formed with the cover and the pad.

3. The seat assembly of Claim 1 wherein the cover comprises a cover material.

4. The seat assembly of Claim 1 wherein the pad comprises a foam material.

5. The seat assembly of Claim 1 wherein the pad is formed onto the cover.

6. The seat assembly of Claim 1 wherein a foam material is formed onto a cover material.

7. The seat assembly of Claim 1 wherein the cover is coupled to the pad.

8. The seat assembly of Claim 1 wherein the composite structure comprises a feature.

9. The seat assembly of Claim 1 wherein the composite structure for the seat base comprises a feature.

10. The seat assembly of Claim 1 wherein the composite structure for the seat back comprises a feature.

11. The seat assembly of Claim 8 wherein the feature is provided at the cover.

12. The seat assembly of Claim 8 wherein the feature is provided in the pad.

13. The seat assembly of Claim 8 wherein the feature comprises a set of features.

14. The seat assembly of Claim 8 wherein the feature comprises a pattern of features.

15. The seat assembly of Claim 8 wherein the feature comprises a set of features at the cover.

16. The seat assembly of Claim 8 wherein the feature comprises a feature formed in the composite structure.

17. The seat assembly of Claim 8 wherein the feature comprises a set of features formed in the composite structure.

18. The seat assembly of Claim 8 wherein the feature comprises a set of features formed in the pad.

19. The seat assembly of Claim 8 wherein the feature comprises a set of features formed in the cover.

20. The seat assembly of Claim 8 wherein the feature comprises a set of features formed in the cover and in the pad.

21. The seat assembly of Claim 8 wherein the feature comprises an aperture.

22. The seat assembly of Claim 21 wherein the aperture comprises a perforation.

23. The seat assembly of Claim 8 wherein the feature comprises a perforation.

24. The seat assembly of Claim 8 wherein the feature comprises a perforation at the cover.

25. The seat assembly of Claim 8 wherein the feature comprises a perforation for ventilation at the cover.

26. The seat assembly of Claim 8 wherein the feature comprises a perforation for illumination at the cover.

27. The seat assembly of Claim 8 wherein the feature comprises a channel through the composite structure.

28. The seat assembly of Claim 8 wherein the feature comprises a set of channels through the composite structure.

29. The seat assembly of Claim 8 wherein the feature comprises a pattern of channels through the composite structure.

30. The seat assembly of Claim 8 wherein the feature comprises a set of channels through the pad and the cover of the composite structure.

31. The seat assembly of Claim 8 wherein the feature comprises a set of apertures through the cover and a set of channels through the pad.

32. The seat assembly of Claim 8 wherein the feature comprises a set of perforations through the cover and a set of channels through the pad.

33. The seat assembly of Claim 28 further comprising a fan configured to facilitate air flow through the set of channels.

34. The seat assembly of Claim 33 wherein the air flow comprises a vacuum flow.

35. The seat assembly of Claim 33 further comprising a HVAC module configured to facilitate heating and / or cooling by air flow through the set of channels.

36. The seat assembly of Claim 1 further comprising a functional module configured to provide a light source.

37. The seat assembly of Claim 36 wherein the functional module comprises a light source.

38. The seat assembly of Claim 36 wherein the light source comprises an LED light.

39. The seat assembly of Claim 8 wherein the feature comprises a heating element for the composite structure.

40. The seat assembly of Claim 1 further comprising a heating element for the composite structure.

41. The seat assembly of Claim 40 wherein the heating element comprises a heating mat under the cover of the composite structure.

42. The seat assembly of Claim 39 wherein the heating element comprises a permeable mat between the cover and the pad.

43. The seat assembly of Claim 8 wherein the feature comprises a decorative element at the cover.

44. The seat assembly of Claim 8 wherein the feature comprises an image and / or icon.

45. The seat assembly of Claim 8 wherein the feature comprises indicia and / or a logo and / or a word.

46. The seat assembly of Claim 8 wherein the feature is configured to be illuminated.

47. The seat assembly of Claim 8 wherein the feature is formed at the cover.

48. The seat assembly of Claim 8 wherein the feature comprises an indentation at the cover.

49. The seat assembly of Claim 8 wherein the feature comprises a projection at the cover.

50. The seat assembly of Claim 8 wherein the feature comprises a protrusion at the cover.

51. The seat assembly of Claim 8 wherein the feature comprises an indentation and a protrusion at the cover.

52. The seat assembly of Claim 8 wherein the feature comprises a rib at the cover.

53. The seat assembly of Claim 8 wherein the feature comprises a pattern of indentations at the cover.

54. The seat assembly of Claim 8 wherein the feature comprises a pattern of projections at the cover.

55. The seat assembly of Claim 8 wherein the feature is formed at the cover.

56. The seat assembly of Claim 8 wherein the feature is formed in the pad.

57. The seat assembly of Claim 8 wherein the feature is formed in the composite structure.

58. The seat assembly of Claim 8 wherein the feature is formed by molding.

59. The seat assembly of Claim 8 wherein the feature is formed at molding.

60. The seat assembly of Claim 8 wherein the feature is formed by deep drawing.

61. The seat assembly of Claim 8 wherein the feature is formed by foaming.

62. The seat assembly of Claim 8 wherein the feature is formed by a laser tool.

63. The seat assembly of Claim 8 wherein the feature is formed by a punch and / or needle.

64. The seat assembly of Claim 8 wherein the feature is formed in the cover and in the pad.

65. The seat assembly of Claim 8 wherein the feature comprises a light element.

66. The seat assembly of Claim 65 wherein the light element is provided at the seat base.

67. The seat assembly of Claim 65 wherein the light element is provided at the seat back.

68. The seat assembly of Claim 65 wherein the light element comprises a light guide.

69. The seat assembly of Claim 65 wherein the light element comprises a light Pipe-70. The seat assembly of Claim 68 wherein the light guide is provided at the exterior surface of the seat back.

71. The seat assembly of Claim 68 wherein the light guide is provided at the exterior surface of the seat base.

72. The seat assembly of Claim 68 wherein the light guide comprises a set of light guides.

73. The seat assembly of Claim 68 wherein the light guide comprises a set of light pipes.

74. The seat assembly of Claim 65 wherein the light element comprises multi- segment light elements.

75. The seat assembly of Claim 65 wherein the light element comprises multi- color elements.

76. The seat assembly of Claim 65 wherein the light element comprises an image and / or icon and / or logo.

77. The seat assembly of Claim 65 wherein the light element is configured to provide a visual effect.

78. The seat assembly of Claim 77 wherein the visual effect comprises a light effect.

79. The seat assembly of Claim 65 wherein the light element comprises an electroluminescent element.

80. The seat assembly of Claim 65 wherein the light element comprises an electroluminescent panel.

81. The seat assembly of Claim 65 wherein the light element comprises an illuminated element.

82. The seat assembly of Claim 65 wherein the light element comprises an image and / or icon.

83. The seat assembly of Claim 65 wherein the light element comprises a pattern.

84. The seat assembly of Claim 65 wherein the light element comprises a set of light elements.

85. The seat assembly of Claim 65 further comprising a light source configured to illuminate the light element.

86. The seat assembly of Claim 85 wherein the light source comprises an LED light.

87. The seat assembly of Claim 1 further comprising a functional module configured to provide a light source.

88. The seat assembly of Claim 87 wherein the functional module comprises a light source.

89. The seat assembly of Claim 1 further comprising a functional module for the seat base and / or the seat back.

90. The seat assembly of Claim 1 further comprising a functional module for the seat base.

91. The seat assembly of Claim 1 further comprising a functional module for the seat back.

92. The seat assembly of Claim 89 wherein the functional module comprises a fan.

93. The seat assembly of Claim 89 wherein the functional module comprises an HVAC unit.

94. The seat assembly of Claim 89 wherein the functional module comprises a light source.

95. The seat assembly of Claim 89 wherein the functional module comprises a power source.

96. The seat assembly of Claim 1 further comprising an operator control.

97. The seat assembly of Claim 1 further comprising a control panel.

98. The seat assembly of Claim 89 further comprising a control panel for the functional module.

99. The seat assembly of Claim 1 wherein the composite structure comprises a support assembly.

100. The seat assembly of Claim 1 wherein the composite structure comprises the pad bonded to the cover.

101. The seat assembly of Claim 1 wherein the composite structure comprises a foam formed on the cover.

102. The seat assembly of Claim 1 further comprising an intermediate layer under the cover.

103. The seat assembly of Claim 102 wherein the intermediate layer comprises a non-woven layer.

104. The seat assembly of Claim 1 wherein the cover is configured to provide a visual effect.

105. The seat assembly of Claim 104 wherein the visual effect comprises a surface effect.

106. The seat assembly of Claim 1 wherein the exterior surface comprises a surface effect.

107. The seat assembly of Claim 106 wherein the cover is configured to provide the surface effect.

108. The seat assembly of Claim 106 wherein the cover material is configured to provide the surface effect.

109. The seat assembly of Claim 106 wherein the cover is configured to retain the surface effect when formed onto the pad.

110. The seat assembly of Claim 106 wherein the exterior surface of the cover is configured to retain the surface effect when formed onto the pad.

111. The seat assembly of Claim 106 wherein the surface effect comprises a texture.

112. The seat assembly of Claim 106 wherein the surface effect comprises a uniform visual effect.

113. The seat assembly of Claim 106 wherein the surface effect comprises a uniform texture.

114. The seat assembly of Claim 111 wherein the texture comprises a grain effect.

115. The seat assembly of Claim 106 wherein the surface effect comprises softness.

116. The seat assembly of Claim 106 wherein the surface effect comprises a decorative effect.

117. The seat assembly of Claim 106 wherein the surface effect is configured to provide ventilation.

118. The seat assembly of Claim 106 wherein the surface effect is configured to facilitate drainage.

119. The seat assembly of Claim 106 wherein the surface effect is configured to be breathable.

120. The seat assembly of Claim 1 further comprising a base configured to mount to the vehicle interior.

121. The seat assembly of Claim 120 wherein the base comprises a structure configured to mount to a floor in the vehicle interior.

122. The seat assembly of Claim 121 wherein the structure comprises a mounting structure.

123. The seat assembly of Claim 122 wherein the mounting structure comprises a chassis.

124. The seat assembly of Claim 123 wherein the chassis is configured to be movable relative to the floor.

125. The seat assembly of Claim 123 wherein the seat base is configured to be mounted to the chassis of the mounting structure of the base.

126. The seat assembly of Claim 121 wherein the seat base is configured to be mounted to the structure.

127. The seat assembly of Claim 121 wherein the seat back is configured to be mounted to the structure.

128. The seat assembly of Claim 121 wherein the seat base is configured to be mounted to the structure and the seat back is configured to be mounted to the seat base.

129. The seat assembly of Claim 121 wherein the seat back is configured to be mounted for pivotal movement relative to the seat base.

130. The seat assembly of Claim 1 wherein the seat base comprises a seat cushion.

131. The seat assembly of Claim 130 further comprising a seat base assembly comprising the seat base.

132. The seat assembly of Claim 130 further comprising a seat base assembly comprising the seat cushion.

133. The seat assembly of Claim 1 wherein the seat base comprises a seat cushion assembly.

134. The seat assembly of Claim 130 further comprising a seat cushion assembly comprising the seat cushion.

135. The seat assembly of Claim 133 wherein the seat cushion assembly comprises a frame.

136. The seat assembly of Claim 135 wherein the frame is configured to be mounted to the base.

137. The seat assembly of Claim 131 wherein the seat base assembly comprises a frame.

138. The seat assembly of Claim 137 wherein the frame is configured for mounting to a base.

139. The seat assembly of Claim 137 wherein the frame is configured for mounting to a chassis of the base.

140. The seat assembly of Claim 1 further comprising a seat back assembly comprising a seat back cushion.

141. The seat assembly of Claim 140 wherein the seat back cushion comprises a composite structure.

142. The seat assembly of Claim 141 wherein the composite structure comprises a pad and a cover.

143. The seat assembly of Claim 142 wherein the pad comprises a foam material.

144. The seat assembly of Claim 142 wherein the cover comprises a cover material.

145. The seat assembly of Claim 140 wherein the seat back assembly comprises a front cover and a back cover.

146. The seat assembly of Claim 141 wherein the composite structure comprises a front portion a rear portion and a connecting portion.

147. The seat assembly of Claim 141 wherein the composite structure comprises an opening configured to receive a frame.

148. The seat assembly of Claim 147 wherein the composite structure is configured to be pulled over the frame.

149. The seat assembly of Claim 145 wherein the cover of the seat back assembly comprises a front cover and a back cover.

150. The seat assembly of Claim 140 wherein the seat back assembly comprises a frame.

151. The seat assembly of Claim 150 wherein the frame is configured to be mounted to the seat base.

152. The seat assembly of Claim 150 wherein the frame is configured to be mounted for pivoting movement of the seat back relative to the seat base.

153. The seat assembly of Claim 1 further comprising a seat headrest assembly comprising a headrest.

154. The seat assembly of Claim 153 further comprising a headrest comprising a composite structure.

155. The seat assembly of Claim 154 wherein the headrest comprises a composite structure wherein the composite structure comprises a pad and a cover wherein the pad comprises a foam material wherein the cover comprises a cover material.

156. The seat assembly of Claim 153 further comprising a headrest assembly comprising the headrest and a frame.

157. The seat assembly of Claim 156 wherein the frame is configured to be mounted to the seat back.

158. The seat assembly of Claim 156 wherein the frame is configured to be mounted for movement relative to the seat back.

159. The seat assembly of Claim 143 wherein the foam material of the pad comprises a polymer material.

160. The seat assembly of Claim 143 wherein the foam material of the pad comprises a polyurethane material.

161. The seat assembly of Claim 144 wherein the cover material of the cover comprises a polymer material.

162. The seat assembly of Claim 143 wherein the foam material of the pad comprises a formed polyurethane material.

163. The seat assembly of Claim 144 wherein the cover material of the cover comprises a molded polymer material.

164. The seat assembly of Claim 144 wherein the cover material of the cover comprises a deep drawn blow molded vacuum formed polymer material.

165. The seat assembly of Claim 144 wherein the cover material of the cover comprises a molded polymer material.

166. The seat assembly of Claim 143 wherein the foam material of the pad comprises a thermoset material or a thermoplastic material.

167. The seat assembly of Claim 144 wherein the cover material of the cover comprises a thermoplastic material.

168. The seat assembly of Claim 143 wherein the foam material of the pad comprises a TPU material.

169. The seat assembly of Claim 143 wherein the foam material of the pad comprises a TPE material.

170. The seat assembly of Claim 143 wherein the foam material of the pad comprises a polyolefin material.

171. The seat assembly of Claim 144 wherein the cover material of the cover comprises a TPO material.

172. The seat assembly of Claim 144 wherein the cover material of the cover comprises a TPE material.

173. The seat assembly of Claim 144 wherein the cover material of the cover comprises a TPU material.

174. The seat assembly of Claim 168 wherein the foam material of the pad comprises a TPU material formed on the cover.

175. The seat assembly of Claim 171 wherein the cover material of the cover comprises a TPO material bonded to the pad.

176. The seat assembly of Claim 1 wherein the cover comprises a sheet.

177. The seat assembly of Claim 1 wherein the cover comprises a sheet material.

178. The seat assembly of Claim 177 wherein the cover comprises a sheet material coupled to the pad and to a frame.

179. The seat assembly of Claim 177 wherein the cover comprises a sheet material chemically bonded to the pad and mechanically coupled to the frame by means of a connector.

180. The seat assembly of Claim 1 wherein the cover is coupled by a connector.

181. The seat assembly of Claim 180 wherein the connector comprises a clip.

182. The seat assembly of Claim 180 wherein the connector comprises a retainer.

183. The seat assembly of Claim 180 wherein the connector comprises a retainer clip.

184. The seat assembly of Claim 180 wherein the connector comprises a bar.

185. The seat assembly of Claim 180 wherein the connector comprises a tape.

186. The seat assembly of Claim 180 wherein the connector comprises an adhesive tape.

187. The seat assembly of Claim 1 wherein the cover is coupled by an adhesive material.

188. The seat assembly of Claim 1 wherein the cover is bonded by an adhesive material.

189. The seat assembly of Claim 1 wherein further comprising a frame for the seat base comprising a structure.

190. The seat assembly of Claim 189 wherein the frame comprises a metal structure.

191. The seat assembly of Claim 189 wherein the frame comprises a spring structure.

192. The seat assembly of Claim 1 further comprising a frame for the seat back comprising a structure.

193. The seat assembly of Claim 192 wherein the frame comprises a metal structure.

194. The seat assembly of Claim 192 wherein the frame comprises a spring structure.

195. The seat assembly of Claim 131 wherein the seat base assembly is configured for movement relative to the base.

196. The seat assembly of Claim 1 wherein the seat base is configured for movement forward and / or backward relative to a base.

197. The seat assembly of Claim 1 wherein the seat base is configured for movement up and / or down relative to a base.

198. The seat assembly of Claim 1 wherein the seat base is configured for adjustable movement relative to a base.

199. The seat assembly of Claim 1 wherein the seat back is configured for movement relative to the seat base.

200. The seat assembly of Claim 1 wherein the seat back is configured for pivoting movement relative to the seat base.

201. The seat assembly of Claim 1 wherein the seat back is configured for pivoting mounting to the seat base.

202. The seat assembly of Claim 1 wherein the seat back is configured for pivoting movement forward and / or backward relative to the seat base.

203. The seat assembly of Claim 1 wherein the seat back is configured to provide adjustment of lumbar support.

204. The seat assembly of Claim 1 wherein the seat back is configured to provide a massage effect.

205. The seat assembly of Claim 153 wherein the seat headrest is configured for movement relative to the seat back.

206. The seat assembly of Claim 153 wherein the seat headrest is configured for movement up and / or down relative to the seat back.

207. The seat assembly of Claim 153 wherein the seat headrest is configured for movement forward and / or backward relative to the seat back.

208. The seat assembly of Claim 1 further comprising a support assembly comprising at least one of the seat base and / or the seat back.

209. The seat assembly of Claim 1 wherein the seat back comprises a cushion.

210. The seat assembly of Claim 1 wherein the cover comprises an exterior surface.

211. The seat assembly of Claim 1 wherein the cover comprises a skin.

212. The seat assembly of Claim 1 wherein the cover comprises a molded skin.

213. The seat assembly of Claim 1 wherein the cover comprises a vacuum-formed skin.

214. The seat assembly of Claim 210 wherein the exterior surface of the cover comprises a grained surface.

215. The seat assembly of Claim 210 wherein the exterior surface of the cover comprises a textured surface.

216. The seat assembly of Claim 144 wherein the cover material of the cover comprises an artificial leather material.

217. The seat assembly of Claim 1 wherein the cover comprises a laminate.

218. The seat assembly of Claim 1 wherein the cover comprises a bilaminate.

219. The seat assembly of Claim 144 wherein the cover material of the cover comprises a TPO laminated with the foam of the pad.

220. The seat assembly of Claim 1 wherein the pad comprises a polyurethane material.

221. The seat assembly of Claim 1 wherein the pad comprises a bio-urethane material.

222. The seat assembly of Claim 1 wherein the pad comprises a TPE material.

223. The seat assembly of Claim 1 wherein the pad comprises a compressible pad.

224. The seat assembly of Claim 1 wherein the composite structure comprises a concave surface.

225. The seat assembly of Claim 1 wherein the composite structure comprises an indentation in the exterior surface.

226. The seat assembly of Claim 225 wherein the indentation in the exterior surface is formed in the cover.

227. The seat assembly of Claim 225 wherein the indentation in the exterior surface is formed in the pad.

228. The seat assembly of Claim 225 wherein the indentation in the exterior surface comprises an indentation formed in the cover wherein the indentation formed in the cover is configured to form an indentation in the pad.

229. The seat assembly of Claim 225 wherein the indentation comprises at least one of an image and / or a logo and / or an icon.

230. The seat assembly of Claim 225 wherein the indentation comprises a groove.

231. The seat assembly of Claim 230 wherein the groove is configured to facilitate expansion of the exterior surface of the composite structure.

232. The seat assembly of Claim 230 wherein the groove comprises a set of grooves.

233. The seat assembly of Claim 230 wherein the groove comprises a set of inboard grooves and a set of outboard grooves.

234. The seat assembly of Claim 225 wherein the indentation is formed in a sidewall of the composite structure.

235. The seat assembly of Claim 234 wherein the sidewall of the composite structure is configured to be visible from outside of the vehicle interior.

236. The seat assembly of Claim 225 wherein the indentation comprises a dimple.

237. The seat assembly of Claim 236 wherein the dimple comprises a set of dimples in a pattern.

238. The seat assembly of Claim 237 wherein the pattern comprises a “U” shape.

239. The seat assembly of Claim 236 wherein the dimple is formed in the cover.

240. The seat assembly of Claim 236 wherein the dimple is formed in the pad.

241. The seat assembly of Claim 1 wherein the composite structure is configured for a compressed state when the seat base is occupied by an occupant.

242. The seat assembly of Claim 1 wherein the composite structure is configured for a retracted state when the seat base is occupied by an occupant and an expanded state when the seat is unoccupied.

243. The seat assembly of Claim 1 wherein the composite structure is configured to expand to change the shape of a support assembly.

244. The seat assembly of Claim 1 wherein the composite structure is configured to expand to increase a length of the exterior surface.

245. The seat assembly of Claim 1 wherein the composite structure comprises a channel.

246. The seat assembly of Claim 1 wherein the composite structure comprises a channel passing through the cover and the pad.

247. The seat assembly of Claim 1 wherein the composite structure comprises a set of channels.

248. The seat assembly of Claim 1 wherein the composite structure comprises a set of channels passing through the cover and the pad.

249. The seat assembly of Claim 1 wherein the composite structure comprises an aperture.

250. The seat assembly of Claim 1 wherein the composite structure comprises a set of apertures.

251. The seat assembly of Claim 1 wherein the composite structure comprises a pattern of apertures.

252. The seat assembly of Claim 249 wherein the aperture comprises a perforation.

253. The seat assembly of Claim 1 wherein the composite structure comprises a set of perforations.

254. The seat assembly of Claim 1 wherein the composite structure comprises a pattern of perforations.

255. The seat assembly of Claim 249 further comprising a light source wherein the light source is configured to provide illumination through the aperture.

256. The seat assembly of Claim 255 wherein the light source is configured to illuminate an indentation at the cover.

257. The seat assembly of Claim 256 wherein the light source is configured to illuminate an indentation in the cover.

258. The seat assembly of Claim 1 further comprising a light source is configured to provide illumination at the cover.

259. The seat assembly of Claim 255 wherein the light source is configured to illuminate at least one of an image at the cover and / or a logo at the cover and / or an icon at the cover.

260. The seat assembly of Claim 255 wherein the light source is configured to illuminate at least one of an image on the cover and / or a logo on the cover and / or an icon on the cover.

261. The seat assembly of Claim 255 wherein the light source is configured to illuminate a simulated seam in the cover.

262. The seat assembly of Claim 1 wherein the composite structure comprises at least one of a simulated seam and / or a simulated French seam and / or a simulated deck seam and / or a simulated join seam.

263. The seat assembly of Claim 1 wherein the composite structure comprises a protrusion at the exterior surface.

264. The seat assembly of Claim 1 wherein the composite structure comprises a protrusion in the exterior surface.

265. The seat assembly of Claim 264 wherein the protrusion in the exterior surface is formed at the cover.

266. The seat assembly of Claim 264 wherein the protrusion in the exterior surface is formed in the cover.

267. The seat assembly of Claim 264 wherein the protrusion in the exterior surface is formed in the pad.

268. The seat assembly of Claim 264 wherein the protrusion in the exterior surface comprises a protrusion formed in the cover wherein the protrusion formed in the cover is configured to form a protrusion in the pad.

269. The seat assembly of Claim 264 wherein the protrusion in the exterior surface is configured to provide a visual effect.

270. The seat assembly of Claim 269 wherein the visual effect comprises at least one of a simulated seam and / or a simulated French seam and / or a simulated deck seam.

271. The seat assembly of Claim 269 wherein the visual effect in the exterior surface comprises at least one of an image and / or a logo and / or an icon.

272. The seat assembly of Claim 1 wherein the composite structure is configured for recycling.

273. The seat assembly of Claim 1 wherein the composite structure comprises a recyclable assembly.

274. The seat assembly of Claim 273 wherein the recyclable assembly is configured to be shredded or chopped for reuse of materials into recycled material.

275. A method of forming a seat assembly comprising the steps of forming a composite structure for a seat base; wherein the composite structure for the seat base comprises a cover and a pad formed on the cover; wherein the pad comprises a foam material; wherein the cover comprises a cover material.

276. The method of Claim 275 further comprising the step of forming a composite structure for a seat back to be coupled to the seat base.

277. The method of Claim 275 wherein a feature of the composite structure comprises at least one of a perforation and / or a channel and / or an indentation and / or a projection and / or an image and / or a set of features.

278. The method of Claim 275 wherein the feature of the composite structure comprises a set of features formed by a tool at the cover and / or the pad.

279. The method of Claim 276 wherein the composite structure for the seat back comprises a cover and a pad formed on the cover.

280. The method of Claim 275 wherein the composite structure comprises a frame.

281. The method of Claim 275 further comprising the step of assembling the seat base to a frame.

282. The method of Claim 276 further comprising the step of assembling the seat back to a frame.

283. The method of Claim 275 further comprising the step of assembling the seat base to a base structure.

284. The method of Claim 275 further comprising the step of assembling the seat back to a base structure.

285. The method of Claim 275 wherein the cover comprises an exterior surface.

286. The method of Claim 285 wherein the exterior surface of the cover comprises a surface effect.

287. The method of Claim 286 wherein the surface effect is preserved during forming and assembly.

288. The method of Claim 286 wherein the surface effect comprises a form.

289. The method of Claim 286 wherein the surface effect comprises a texture.

290. The method of Claim 286 wherein the surface effect provides a visual effect.

291. The method of Claim 275 configured for efficient production of the pad for the composite structure with the foam material comprising polyurethane foam.

292. The method of Claim 275 configured for efficient assembly of the seat assembly from the composite structure comprising the seat base.

293. The method of Claim 275 wherein the foam material comprises a reduced-cost foam material and / or the cover material comprises a reduced-cost cover material.

294. The method of Claim 275 wherein the cover material comprises a synthetic leather material configured to facilitate recyclability.

295. The method of Claim 275 wherein the foam material and the cover material are selected to facilitate end of life recycling.

296. The method of Claim 275 wherein the foam material comprises a bio-foam material.

297. The method of Claim 296 wherein the bio-foam material comprises castor oil and / or soybean oil and / or recycled content polyols.

298. The method of Claim 275 wherein the foam material and the cover material comprise recyclable material.

299. The method of Claim 275 wherein forming of the composite structure comprises forming in a mold tool.

300. The method of Claim 275 wherein the foam material comprises a reduced- weight material.

301. The method of Claim 275 wherein the pad is formed directly on the cover.

302. The method of Claim 275 wherein the pad is formed in an apparatus configured for production of multiple components.

303. The method of Claim 275 wherein the composite structure comprises a concave shape.

304. The method of Claim 275 wherein the composite structure comprises a surface effect comprising a pattern and / or a grain and / or a logo.

305. The method of Claim 276 wherein the seat back comprises a thin seat back construction.

306. A seat for an occupant in a vehicle interior comprising a support assembly for the occupant; wherein the support assembly comprises a pad bonded to a cover; wherein the support assembly comprises an outer surface visible to the occupant.

307. The seat of Claim 306 wherein the support assembly comprises at least one of a seat cushion comprising a composite structure and / or a seat back comprising a composite structure.

308. The seat of Claim 306 wherein the cover comprises a skin.

309. The seat of Claim 306 wherein the cover comprises a molded skin.

310. The seat of Claim 306 wherein the cover comprises a vacuum formed skin.

311. The seat of Claim 306 wherein the cover comprises a grained surface.

312. The seat of Claim 306 wherein the cover comprises a textured surface.

313. The seat of Claim 306 wherein the cover comprises an artificial leather material.

314. The seat of Claim 306 wherein the cover comprises a laminate.

315. The seat of Claim 306 wherein the cover comprises a bilaminate.

316. The seat of Claim 315 wherein the bilaminate comprises a TPO laminated with a foam.

317. The seat of Claim 306 wherein the pad comprises a polyurethane material.

318. The seat of Claim 306 wherein the pad comprises a bio-urethane material.

319. The seat of Claim 306 wherein the pad comprises a TPE material.

320. The seat of Claim 306 wherein the pad comprises a low shore A substrate material.

321. The seat of Claim 306 wherein the pad comprises a hardness between 30 Shore A and 60 Shore A.

322. The seat of Claim 306 wherein the support assembly comprises a concave surface.

323. The seat of Claim 306 wherein the support assembly comprises an indentation in the outer surface.

324. The seat of Claim 323 wherein the indentation in the outer surface is formed in the cover.

325. The seat of Claim 323 wherein the indentation in the outer surface is formed in the pad.

326. The seat of Claim 323 wherein the indentation in the outer surface comprises an indentation formed in the cover wherein the indentation formed in the cover is configured to form an indentation in the pad.

327. The seat of Claim 323 wherein the indentation comprises at least one of an image and / or a logo and / or an icon.

328. The seat of Claim 323 wherein the indentation comprises a groove.

329. The seat of Claim 328 wherein the groove is configured to facilitate expansion of the outer surface of the support assembly.

330. The seat of Claim 328 wherein the groove comprises a set of grooves.

331. The seat of Claim 328 wherein the groove comprises a set of inboard grooves and a set of outboard grooves.

332. The seat of Claim 323 wherein the indentation is formed in a sidewall of the support assembly.

333. The seat of Claim 332 wherein the sidewall of the support assembly is configured to be visible from outside of the vehicle interior.

334. The seat of Claim 323 wherein the indentation comprises a dimple.

335. The seat of Claim 334 wherein the dimple comprises a set of dimples in a pattern.

336. The seat of Claim 335 wherein the pattern comprises a U shape.

337. The seat of Claim 334 wherein the dimple is formed in the cover.

338. The seat of Claim 334 wherein the dimple is formed in the pad.

339. The seat of Claim 306 wherein the support assembly is configured for a retracted state when the seat is unoccupied and an expanded state when the seat is occupied.

340. The seat of Claim 306 wherein the support assembly is configured to provide a discontinuous support surface in the retracted state and a continuous support surface in the expanded state.

341. The seat of Claim 306 wherein the support assembly is configured to provide a generally flat support surface in the retracted state and a concave support surface in the expanded state.

342. The seat of Claim 306 wherein the support assembly is configured to expand to change the shape of the support assembly.

343. The seat of Claim 306 wherein the support assembly is configured to expand to increase a length of the outer surface.

344. The seat of Claim 306 wherein the support assembly comprises an aperture passing through the cover and the pad.

345. The seat of Claim 344 wherein the aperture comprises a perforation.

346. The seat of Claim 344 further comprising a light source wherein the light source is configured to provide illumination through the aperture.

347. The seat of Claim 346 wherein the light source is configured to illuminate an indentation in the cover.

348. The seat of Claim 346 wherein the light source is configured to illuminate at least one of an image in the cover and / or a logo in the cover and / or an icon in the cover.

349. The seat of Claim 346 wherein the light source is configured to illuminate a simulated seam in the cover.

350. The seat of Claim 306 wherein the support assembly comprises at least one of a simulated seam and / or a simulated French seam and / or a simulated deck seam and / or a simulated join seam.

351. The seat of Claim 306 wherein the support assembly comprises a protrusion in the outer surface.

352. The seat of Claim 351 wherein the protrusion in the outer surface is formed in the cover.

353. The seat of Claim 351 wherein the protrusion in the outer surface is formed in the pad.

354. The seat of Claim 351 wherein the protrusion in the outer surface comprises a protrusion formed in the cover wherein the protrusion formed in the cover is configured to form a protrusion in the pad.

355. The seat of Claim 351 wherein the protrusion in the outer surface is configured to provide a visual effect comprising at least one of a simulated seam and / or a simulated French seam and / or a simulated deck seam.

356. The seat of Claim 351 wherein the protrusion in the outer surface comprises at least one of an image and / or a logo and / or an icon.

357. The seat of Claim 306 wherein the support assembly is configured for recycling.

358. The seat of Claim 306 wherein the support assembly comprises a recyclable assembly.

359. The seat of Claim 358 wherein the recyclable assembly is configured to be shredded or chopped for reuse of materials into recycled material.

360. The seat of Claim 306 formed by a process of forming the cover and molding the pad on the cover.

361. The seat of Claim 306 wherein forming the cover comprises vacuum forming a sheet of material.

362. The seat of Claim 306 wherein the process comprises creating a hole through the cover and the pad.

363. A seat assembly for a vehicle interior comprising: a composite structure comprising a seat base; a composite structure comprising a seat back; wherein each composite structure comprises a pad formed on a cover; wherein the pad comprises a foam material molded onto the cover such that the pad and cover are bonded together to form a unitary component; wherein the cover comprises an exterior surface configured to provide a surface effect comprising a texture and / or a grain and / or a simulated seam and / or an image and / or a decorative pattern; wherein the cover is configured to retain the surface effect at the exterior surface after the pad is formed from the foam material; wherein the composite structure comprises a feature comprising a functional feature and / or a set of indentations and / or a set of projections and / or a set of perforations and / or a set of channels passing through both the cover and the pad to enable ventilation or illumination and / or an integrated heating element between the cover and the pad and / or a light guide extending along the composite structure and configured to illuminate an light element; wherein the light element is configured to provide an image and / or icon and / or logo and / or a seam at the exterior surface; wherein the pad and / or the cover comprise a polymeric material; wherein the polymeric material comprises TPU and / or TPO and / or TPE and / or polyurethane.

364. The seat assembly of Claim 363 further comprising a functional module selected from the group consisting of a fan, an HVAC unit and a light source each operably coupled to the composite structure wherein the functional module is configured to provide air flow heating, cooling or illumination through the perforations or channels.

365. The seat assembly of Claim 363 wherein the surface effect of the cover comprises a simulated seam and at least one light guide is configured to provide visual illumination to the simulated seam from an internal light source.

366. The seat assembly of Claim 363 wherein the pad and the cover are both formed from recyclable materials selected from the group consisting of TPO, TPE and polyurethane and wherein the assembly is configured such that the pad and cover can be separated or processed for recycling at end of life.

367. The seat assembly of Claim 363 wherein the pad comprises a compressible polyurethane foam having a Shore A hardness between 30 and 60.

368. The seat assembly of Claim 363 wherein the composite structure further comprises a pattern of channels interconnecting with the perforations to facilitate distributed ventilation or illumination across the exterior surface.

369. The seat assembly of Claim 363 wherein the composite structure is configured such that the pad is molded onto a pre-formed vacuum-formed or deep-drawn cover comprising a grained or textured surface and wherein the grained or textured surface is retained after molding.

370. A method of forming a seat assembly for a vehicle interior comprising the steps of: forming a cover having an exterior surface effect comprising a texture grain and / or a simulated seam image and / or a decorative pattern; molding a foam pad on the cover to bond the foam pad to the cover and create a composite structure; forming a feature comprising a functional feature and / or a pattern of perforations and / or a pattern of channels and / or a pattern of indentations and / or a pattern of projections and / or a light guide for the composite structure; assembling the composite structure as part of a seat base or seat back.

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