Seat assembly including a modular foam arrangement and method for fabricating the same

A seat assembly comprising:

• a seat base portion comprising a seat base structure portion and a seat base cushion supported by the seat base structure portion, wherein the seat base cushion comprises:
• a modular foam arrangement comprising a first modular foam section having a first interlocking feature and a second modular foam section having a second interlocking feature engaged with the first interlocking feature, wherein the second modular foam section is disposed adjacent to the first modular foam section along an interface, and wherein the interface is free of any adhesive and is defined by corresponding unbonded trimmed surfaces of the first and second modular foam sections that are in direct contact with each other;
• and
• an outer covering that at least partially covers the modular foam arrangement;
• and wherein the seat assembly further comprises:
• a seat backrest portion coupled to the seat base portion and configured to extend substantially upright from a rearward section of the seat base portion, and wherein the first modular foam section overlies the second modular foam section and extends generally forward of the seat backrest portion.

A method for fabricating a seat assembly, the method comprising the steps of:

• engaging a first interlocking feature of a first modular foam section with a second interlocking feature of a second modular foam section for forming a modular foam arrangement, wherein the second modular foam section is disposed adjacent to the first modular foam section along an interface, and wherein the interface is free of any adhesive and is defined by corresponding unbonded trimmed surfaces of the first and second modular foam sections that are in direct contact with each other;
• at least partially covering the modular foam arrangement with an outer covering for forming a seat cushion;
• and
• supporting the seat cushion by a seat frame.