A method for insulating a gas-fueled water heater includes providing a tank for storage of water for heating and a combustion chamber adjacent to the tank. The method includes providing a compressed foam barrier circumferentially around the tank. Further, the method includes positioning a covering around the tank from a top end to a bottom end, the covering extending over the compressed foam barrier. Moreover, the method includes decompressing the compressed foam barrier such that an outer diameter of the foam barrier expands up to and seals against the covering so as to separate an internal volume defined between an outer surface of the tank and the covering into a first section and a second section. Then, the method includes injecting a foam material into the first section so as to provide a foam barrier around at least a portion of an outer surface of the tank.

A method for insulating a gas-fueled water heater includes providing a tank for storage of water for heating and a combustion chamber adjacent to the tank. The method includes providing a compressed foam barrier circumferentially around the tank. Further, the method includes positioning a covering around the tank from a top end to a bottom end, the covering extending over the compressed foam barrier. Moreover, the method includes decompressing the compressed foam barrier such that an outer diameter of the foam barrier expands up to and seals against the covering so as to separate an internal volume defined between an outer surface of the tank and the covering into a first section and a second section. Then, the method includes injecting a foam material into the first section so as to provide a foam barrier around at least a portion of an outer surface of the tank.

A vehicle interior panel includes a foam layer formed from a liquid foam precursor between a substrate and a visible decorative skin layer that has perforations formed therethrough. In some cases, the perforations are associated with a line of stitching sewn into and through the skin layer. A sealing film is located beneath the skin layer in the perforated region to prevent the liquid foam precursor from leaking through the perforations during foam formation. The sealing film extends beyond the perforated region and into a non-perforated region, in some cases extending substantially over the entire back side of the skin layer. In this manner, the edges of the sealing film do not cause visual blemishes on the visible surface of the decorative skin layer over time.

A vehicle interior panel includes a foam layer formed from a liquid foam precursor between a substrate and a visible decorative skin layer that has perforations formed therethrough. In some cases, the perforations are associated with a line of stitching sewn into and through the skin layer. A sealing film is located beneath the skin layer in the perforated region to prevent the liquid foam precursor from leaking through the perforations during foam formation. The sealing film extends beyond the perforated region and into a non-perforated region, in some cases extending substantially over the entire back side of the skin layer. In this manner, the edges of the sealing film do not cause visual blemishes on the visible surface of the decorative skin layer over time.

Systems and methods for water heater systems with an insulation dam for restricting flow of injectable insulation are provided. An insulation dam may be positioned around a bottom region of a water tank. A jacket may be formed around and offset from the combustion chamber and the water tank such that a void is created between and interior of the jacket and an exterior surface of the water tank, above the insulation dam. Injectable insulation such as an injectable foam may be inserted in the void to insulate the water tank. The insulation dam may prevent the injectable insulation from entering the area between the combustion chamber and the jacket. The insulation dam may be filled in an open-cell foam such that air may be vacuumed out from the insulation dam to compress the insulation dam before installation, and re-introduced into the insulation dam subsequent to installation to allow the insulation dam to expand again.