Foam-in-place electro-thermal conversion device

A seating system, comprising:

• a seat frame;
• a cushioned thermal module supported by the seat frame, the cushioned thermal module comprising:
• an electro-thermal conversion device configured to move heat to or from a conductive surface in response to applying a low voltage current;
• a foam structure encasing the electro-thermal conversion device and defining a seat support surface;
• and
• a graphene structure thermally coupled with the conductive surface of the electro-thermal conversion device and at least partially disposed over the seat support surface;
• and
• a seat cover disposed over the seat surface and the graphene structure to define a user support surface, wherein the graphene structure is configured to conductively transfer heat between the electro-thermal conversion device and the seat cover.

A method for forming a cushioned thermal module for a seat, the method comprising:

• providing an electro-thermal conversion device configured to move heat to or from a conductive surface in response to applying a low voltage current;
• positioning a first portion of a flexible graphene structure at a bottom surface of a mold cavity, wherein a second portion of the flexible graphene structure is thermally coupled with the conductive surface of the electro-thermal conversion device;
• suspending the electro-thermal conversion device above the bottom surface of the mold cavity;
• pouring a liquid foam mixture into the mold cavity to at least partially encase the electro-thermal conversion device;
• and
• curing the liquid foam mixture in the mold cavity to form a foam structure that defines a seat support surface with the first portion of the flexible graphene structure is at least partially disposed over the seat support surface.