Abstract:
A thermally conductive trim cover is provided for use on a seat assembly. The trim cover comprises a layer of leather material having a top surface and a bottom surface and thermally conductive particles embedded in the leather material between the top and bottom surface for dispersing heat therethrough.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to and all the benefits of U.S. Provisional Application No. 62/315,239, filed on Mar. 30, 2016. 
     
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
       [0002]    The present invention relates to a thermally conductive leather material. More particularly, the invention relates to a thermally conductive leather trim cover for an automotive seat assembly having embedded conductive particles for efficiently dispersing the heat from the surface of the seat assembly. 
       2. Description of Related Art 
       [0003]    Automotive vehicles include one or more seat assemblies having a seat cushion and a seat back for supporting a passenger or occupant above a vehicle floor. The seat assembly is commonly mounted to the vehicle floor by a riser assembly. The seat back is typically operatively coupled to the seat cushion by a recliner assembly for providing selective pivotal adjustment of the seat back relative to the seat cushion. 
         [0004]    It is commonly known to provide seat assemblies with heating and cooling mechanisms for selectively heating and cooling the surface of the seat for seat occupant comfort. These known heating and cooling mechanisms are typically independent mechanisms. For example, it is common to provide an electric wire heating pad between the foam pad and trim cover of the seat cushion or seat back which is electrically actuated by the power from the vehicle battery to electrically charge the heating pad and provide heat to the surface of the seat cushion or seat back. It is also known to provide fans and air ducts to force cool air through the foam pad and trim cover and provide cool air to the surface of the seat cushion or seat back. It is also known to provide fans and ducts to draw warm, moist air away from the seating surface to provide a gradual cooling effect. 
         [0005]    Leather trim is commonly used in automotive seating applications for covering the foam pad of the seat assembly to provide occupant comfort, styling and aesthetics. The leather provides a soft surface, comfort to the user, durability for the life of the surface, and a luxurious appearance and experience. However, leather also has the disadvantage of having very low thermal conductivity. As a result, heat can build up between the user and the leather material. Additionally, when there are heating and cooling mechanisms present under the seating surface, the leather acts as an insulator. Therefore, the desired heating and cooling effects take considerable time to be felt by the seat occupant. The heating and cooling mechanisms also have to operate at a higher power level to overcome the insulative effects of the leather trim cover. 
         [0006]    Therefore, it is desirable to provide a thermally conductive leather trim cover for dispersing the heat to and from the surface of the seat assembly and reduce the undesirable insulative effects thereof. 
       SUMMARY OF THE INVENTION 
       [0007]    A thermally conductive trim cover is provided for use on a seat assembly. The trim cover comprises a layer of leather material having a top surface and a bottom surface and thermally conductive particles embedded in the leather material between the top and bottom surface for dispersing heat therethrough. 
         [0008]    A seat assembly is also provided for use in an automotive vehicle. The seat assembly comprises a resilient cellular foam pad for supporting an occupant on the seat assembly, a trim cover covering the foam pad, and a heat and cooling mechanism positioned between the foam pad and the trim cover for selectively providing thermal effects to the seat assembly. The trim cover comprises a layer of leather material having a top surface and a bottom surface and thermally conductive particles embedded in the leather material between the top and bottom surface for dispersing heat from the heating and cooling mechanism through the trim cover. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
           [0010]      FIG. 1  is a fragmentary perspective view of a seat assembly for an automotive vehicle; 
           [0011]      FIG. 2  is a magnified cross-sectional view of a leather trim cover as known in the prior art; and 
           [0012]      FIG. 3  is a magnified cross-sectional view of a thermally conductive leather trim cover with embedded conductive particles according to one embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0013]    Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a seat assembly  10  for use in an automotive vehicle is generally shown in  FIG. 1  and includes a generally horizontal seat cushion  12  and a generally upright seat back  14  for supporting a seat occupant within the vehicle as is commonly known in the art. The seat back  14  is typically operatively coupled to the seat cushion  12  by a recliner assembly  16  for providing pivotal movement between an upright seating position and a plurality of reclined seating positions. 
         [0014]    Each of the seat cushion  12  and seat back  14  commonly include a molded resilient cellular foam pad  18  encased in a trim cover assembly  20 , commonly of cloth, vinyl, or leather. A heating and cooling mechanism (shown schematically at  22 ) is generally operatively coupled to the seat cushion  12  and/or seat back  14  between the foam pad  18  and trim cover  20  for selectively heating and cooling the surface of the seat assembly  10 . 
         [0015]    Referring to  FIG. 2 , a magnified cross-sectional view of a traditional prior art leather trim cover is shown at  30 . The cross-section of leather is magnified at approximately 60× and illustrates a 3-dimensional weave formed by the skin of the animal. Tanning of the leather is done to add stable oils for softness, color and other desired effects as is commonly known in the art. The finished leather surface is very soft and durable, however, is also highly insulative. 
         [0016]    The present invention relates to providing additives to the leather tanning process to enhance the thermal properties of the leather trim cover  20 . Referring to  FIG. 3 , a magnified cross-sectional view of a leather trim cover according to one embodiment of the invention is shown at  20  having a top surface  24  and a bottom surface  26 . The cross-section of leather is also magnified at approximately 60×. However, the leather trim cover  20  shown includes randomly dispersed and embedded thermally conductive particles  40  spread throughout the 3-dimensional weave of the leather and spread between the top surface  24  and bottom surface  26 . More specifically, the leather trim cover  20  is embedded with particles  40  consisting of aluminum, aluminum oxide, graphite, graphene, silver, copper, carbon nanotubes, or any other suitable conductive filler material to enhance the thermal conductivity of the leather material. The addition of the embedded particles  40  increases the thermal conductivity of the leather trim cover from 0.098 W/m-K for untreated leather to 0.1308 W/m-K for the leather treated with the embedded conductive particles  40 , a 33% improvement in thermal conductivity. Further, in addition to improving the thermal conductivity of the leather trim cover  20 , the embedded particles  40  also electrically isolate the heating and cooling mechanism within the seat assembly  10 . It should also be appreciated that the leather trim cover  20  may be used in automotive seating applications, residential or commercial furniture, garment, or upholstery leather applications. 
         [0017]    The following formulation chart illustrates the preferred embodiment of the formulation and processing of the thermally conductive leather trim cover  20  using various sizes of graphite embedded particles  40  to improve the thermal conductivity of the leather material. 
         [0000]    
       
         
               
               
               
               
             
               
             
               
               
               
               
             
               
               
               
               
             
               
             
               
               
               
               
             
               
             
               
               
               
               
             
               
             
               
               
               
               
             
               
             
               
               
               
               
             
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 Thermal Conductivity Initial: 
                 0.0980 
                 W/m-K 
               
             
          
           
               
                 (Note: Formula % is based off of initial hide weight) 
               
             
          
           
               
                 Formula % 
                 Product 
                 Dilution 
                 Time 
               
               
                   
               
             
          
           
               
                 200.0% 
                 Water 35° C. 
                   
                   
               
               
                 0.2% 
                 Peltec ADN (wetting agent) 
                 1:4 
               
               
                 0.3% 
                 Formic Acid (reduces pH) 
                  1:10 
                 30 min 
               
             
          
           
               
                 Drain 
               
             
          
           
               
                 100.0% 
                 Water 50° C. 
                   
                   
               
               
                 1.5% 
                 Tanigan PAK (syntan) 
               
               
                 1.0% 
                 Sodium Formate (raises pH) 
                   
                 20 min 
               
               
                 2.0% 
                 Eureka 950-R (fatliquor) 
                 1:4 
               
               
                 40.0% 
                 0.6 micron Graphite 
               
               
                 40.0% 
                 5.0 micron Graphite 
               
               
                 20.0% 
                 20 micron Graphite 
               
               
                 1.0% 
                 Sodium Bicarbonate (raises pH) 
                   
                 180 min  
               
             
          
           
               
                 Drain &amp; Wash 
               
             
          
           
               
                 70.0% 
                 Water 50° C. 
                   
                   
               
               
                 4.0% 
                 Leukotan 1084 (syntan) 
                 1:3 
               
               
                 40.0% 
                 0.6 micron Graphite 
               
               
                 40.0% 
                 5.0 micron Graphite 
               
               
                 20.0% 
                 20 micron Graphite 
               
               
                 2.0% 
                 Eureka 950-R (fatliquor) 
                 1:4 
                 20 min 
               
               
                 40.0% 
                 0.6 micron Graphite 
               
               
                 40.0% 
                 5.0 micron Graphite 
               
               
                 20.0% 
                 20 micron Graphite 
               
               
                 8.0% 
                 Tanigan VR (syntan) 
                   
                 20 min 
               
               
                 40.0% 
                 0.6 micron Graphite 
               
               
                 40.0% 
                 5.0 micron Graphite 
               
               
                 20.0% 
                 20 micron Graphite 
               
               
                 4.0% 
                 Tara (tannin) 
               
               
                 3.0% 
                 Baykanol PFM/Retingan ZF Plus 
               
               
                 1.5% 
                 Tanigan PR (syntan) 
                   
                 40 min 
               
             
          
           
               
                 Drain 
               
             
          
           
               
                 100.0% 
                 Water 60° C. 
                   
                   
               
               
                 2.0% 
                 Formic Acid (reduces pH) 
                  1:10 
               
               
                 10.0% 
                 Tannesco FC (tanning agent) 
                   
                 overnight 
               
             
          
           
               
                 Drain &amp; Wash 
               
             
          
           
               
                 150.0% 
                 Water 60° C. 
                   
                   
               
               
                 3.0% 
                 Lubritan SP (syntan) 
               
               
                 40.0% 
                 0.6 micron Graphite 
               
               
                 40.0% 
                 5.0 micron Graphite 
               
               
                 20.0% 
                 20 micron Graphite 
               
               
                 7.0% 
                 Eureka 950-R (fatliquor) 
                 1:5 
                 120 min  
               
               
                 40.0% 
                 0.6 micron Graphite 
               
               
                 40.0% 
                 5.0 micron Graphite 
               
               
                 20.0% 
                 20 micron Graphite 
               
               
                 10.0% 
                 Tannesco FC (tanning agent) 
               
               
                 2.0% 
                 Formic Acid (reduces pH) 
                 1:5 
                 120 min  
               
             
          
           
               
                 Drain &amp; Wash 
               
             
          
           
               
                 Thermal Conductivity Final: 
                 0.1308 
                 W/m-K 
               
               
                   
               
             
          
         
       
     
         [0018]    In a typical leather tanning process, as is commonly known in the art, the leather hide is soaked in a water solution in large slowly turning or agitating drums for predetermined amounts of time. The water solution includes various added chemicals, such as lime, sodium sulphide, ammonium sulphate, sulphuric acid, sodium bicarbonate, and others to desalt, delime and neutralize the leather. The leather is then allowed to drain and dry and may be buffed as desired to correct surface defects. The above chart illustrates the formulation of the water solution with the added chemicals and graphite particles for saturating and dispersing the graphite into the leather during the tanning process. 
         [0019]    Specifically, by reference to the formulation chart, the leather hide is soaked in a water solution at a specific temperature with the additives, chemicals, and materials listed for a specified period of soaking time. As shown in the chart, the dilution ratios of the chemicals are listed along with the weight of each ingredient in the solution (based as a percentage of the total hide weight), and the specified soaking times for each step of the process. For example, the leather hide is initially soaked in a drum with a solution of water at 35 degrees Celsius, Peltec AND, and Formic Acid at the listed percentages by weight and dilution ratios for a time period of 30 minutes. Each additional step in the process then adds the specified solution, chemicals, materials, or ingredients of the formulation for the next specified period of soaking time. For example, the chart shows the next step to include an additional water solution at 50 degrees Celsius with the other listed chemicals for another 20 minutes of soaking time. The third step includes the addition of Eureka  950 -R, Sodium Bicarbonate and the three different micron sizes of Graphite particles to the solution for an additional 180 minutes of soaking time. The leather hide is then drained and washed. The process continues as illustrated in the formulation chart with additional soaking and saturation with varying micron sizes of Graphite particles into the leather for specified amounts of soaking time until the final draining and washing of the leather hide. The process and formulation includes the various steps of adding different sizes of Graphite particles into the solution for various periods of soaking time to allow the Graphite particles to fully saturate, disperse and be embedded into the leather hide thereby increasing the thermal conductivity from an initial level of 0.0980 W/m-K to the resulting level of 0.1308 W/m-K. 
         [0020]    The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described.