Closed cell foam vehicle interior component and method of making same

A seat assembly comprising:

• a seat cushion coupled to a seat cushion frame assembly;
• a backrest coupled to a backrest frame assembly;
• and
• a foam shell being formed from a closed-cell foam and having an integral exterior surface for use as one of said seat cushion and said backrest and wherein said foam shell includes attachment features formed as one piece with said foam shell and extending outwardly from a surface facing opposite a portion of said integral exterior surface, wherein said portion of said integral exterior surface is adapted for engaging a sitting occupant, and wherein said attachment features are configured to attach said foam shell to at least one of said seat cushion frame assembly and said backrest frame assembly, and wherein said attachment features are loops, channels, and hooks for slidably engaging and attaching at least one of said seat cushion and said backrest to said at least one of said seat cushion frame assembly and said backrest frame assembly.

A seat assembly comprising:

• a seat cushion coupled to a seat cushion frame assembly;
• a backrest coupled to a backrest frame assembly;
• a molded foam shell configured to be assembled after molding to one of said seat cushion frame assembly and said backrest frame assembly;
• and
• wherein said molded foam shell is formed from a closed-cell foam and having an integral exterior surface for use as one of said seat cushion and said backrest and wherein said foam shell includes attachment features formed as one piece with said foam shell and located on a surface disposed opposite a portion of said integral exterior surface, wherein said portion of said integral exterior surface is adapted for engaging a sitting occupant and wherein said attachment features are configured to attach said foam shell to at least one of said seat cushion frame assembly and said backrest frame assembly, and wherein said molded foam shell is detachable via said attachment features from said at least one of said seat cushion frame assembly and said backrest frame assembly, and wherein said attachment features are loops, channels, and hooks, and wherein said loops have a first end and a second end extending outwardly from said surface disposed opposite said portion of said integral exterior surface forming a closed u-shape with said surface disposed opposite said portion of said integral exterior surface, wherein said channels have a general u-shape opening rearwardly from said surface disposed opposite said portion of said integral exterior surface, and hooks extend outwardly from said surface disposed opposite said portion of said integral exterior surface, and one opening upwardly and one opening downwardly forming at least one of a generally U-shape and V-shape with said integral exterior surface, and wherein said loops, channels, and hooks provide a retention mechanism for slidably engaging and attaching at least one of said seat cushion and said backrest to said at least one of said seat cushion frame assembly and said backrest frame assembly.

A seat assembly comprising:

• a seat cushion coupled to a seat cushion frame assembly;
• a backrest coupled to a backrest frame assembly;
• a molded foam shell configured to be assembled after molding to one of said seat cushion frame assembly and said backrest frame assembly;
• and
• wherein said molded foam shell is formed from a closed-cell foam and having an integral exterior surface for use as one of said seat cushion and said backrest and wherein said foam shell includes attachment features formed as one piece with said foam shell and located on a surface disposed opposite a portion of said integral exterior surface, wherein said portion of said integral exterior surface is adapted for engaging a sitting occupant and wherein said attachment features are configured to attach said foam shell to at least one of said seat cushion frame assembly and said backrest frame assembly and wherein said attachment features are loops, channels, and hooks, and wherein said loops have a first end and a second end extending outwardly from said surface disposed opposite said portion of said integral exterior surface forming a closed u-shape with said surface disposed opposite said portion of said integral exterior surface, wherein said channels have a general u-shape opening rearwardly from said surface disposed opposite said portion of said integral exterior surface, and wherein said hooks extend outwardly from said surface disposed opposite said portion of said integral exterior surface and opening at least one of upwardly and downwardly forming at least one of a generally U-shape and V-shape with said integral exterior surface, and wherein said loops, channels, and hooks provide a retention mechanism for slidably engaging and attaching at least one of said seat cushion and said backrest to said at least one of said seat cushion frame assembly and said backrest frame assembly.