Abstract: A vehicle seat assembly including a seat cushion suspension assembly consisting of a flexible elastic fabric sheet having a foam body molded thereto forming a bun. The bun is formed by attaching the fabric sheet to retainers and in turn the retainers to spaced apart receivers on the inside of a mold. The mold is closed, expandable foam is injectd, and the positioned fabric sheet is thus molded to and bonded to the fabric. The bun so formed is then positioned on a vehicle seat frame by attaching the retainers to laterally separated side rails of the frame thus forming a support for seating loads.

Abstract: The method and apparatus for forming at least a portion of a seat wherein an envelope cover comprising a generally tubular shape fabric member having an open end and inner and outer sides is positioned on a cantilever supported forming tool so as to shape at least a portion of the outer side to a desired shape. A foam pad which has been molded to a shape conforming to the predetermined shape of the cover is then positioned in firm surface-to-surface engagement with the shaped cover portion and secured by glue thereto. The envelope can then be removed from the cantilever supported forming tool with the foamed pad adhered thereto and then turned inside out and assembled with a seat frame to provide a desired portion of a seat. This eliminates the need for fasteners or hard plastic back panels in the seat portion.