Lattice reinforced foam rubber seat bun and method of molding same

Claim 1

In a seat bun or the like formed of a foamed plastic material molded and shaped into a seat cushion form having an upper seat surface, a forward edge and an indented lower support face upon which the bun is supported by a support means, the improvement comprising: a plurality of thin, elongated vertical strands intersected and joined by a plurality of thin horizontal strands to form an open lattice; each of said strands being formed of a material characterized by being flexible, of limited resiliency, slippery and being uniaxially stretch-oriented in its longitudinal direction; said lattice lying in a first plane with all the intersections being integral joints partially lying in said first plane and having projections extending above said plane; said lattice being embedded within the foamed plastic material to reinforce the foamed plastic material against deterioration, tearing and crumbling, said lattice positioned just interiorly of the indented lower support face so that the foamed plastic material extends through the lattice openings and forms a thin coating over the lattice; and at least some of the projections on said integral joints being interlocked into said foamed plastic material for securing said lattice within said bun against slippage in a direction transverse to said first plane.