Numerical Simulation and Experimental Research of the Hot-Wire Method for Thermal Insulation Materials

TY - JOUR

T1 - Numerical Simulation and Experimental Research of the Hot-Wire Method for Thermal Insulation Materials

AU - Che, Jiaxuan

AU - Zhang, Yaxin

AU - Yao, Junbang

AU - Li, Xiaojing

AU - Liu, Xing

AU - Liu, Boxiang

AU - Yang, Tao

N1 - Publisher Copyright: © 2026 by the authors.

PY - 2026/4

Y1 - 2026/4

N2 - The thermal conductivity of thermal insulation materials is a critical parameter for assessing energy efficiency and performance in building, industrial, and aerospace applications. This study combined numerical simulation, parameter inversion optimization and experimental measurement to evaluate the transient hot-wire method for measuring the thermal conductivity of expanded polystyrene (EPS) foam. Using a nickel wire as the hot wire, the effects of various parameters—including wire length and width, heating power, Kapton film thickness and end effect—were systematically analyzed through finite element analysis and Bayesian optimization algorithm. Following the simulation and inversion conclusions, a series of hot-wire sensors with a fixed length of 30 mm and widths of 25 μm, 50 μm, 100 μm, 150 μm, and 200 μm were fabricated for experimental validation. Measurement results were compared against a reference value obtained by the guarded hot plate method. It was found that the sensor with a length of 30 mm and a width of 100 μm demonstrated optimal performance among the configurations tested, with deviations between the experimental measurements and the reference value remaining within approximately ±1.5%.

AB - The thermal conductivity of thermal insulation materials is a critical parameter for assessing energy efficiency and performance in building, industrial, and aerospace applications. This study combined numerical simulation, parameter inversion optimization and experimental measurement to evaluate the transient hot-wire method for measuring the thermal conductivity of expanded polystyrene (EPS) foam. Using a nickel wire as the hot wire, the effects of various parameters—including wire length and width, heating power, Kapton film thickness and end effect—were systematically analyzed through finite element analysis and Bayesian optimization algorithm. Following the simulation and inversion conclusions, a series of hot-wire sensors with a fixed length of 30 mm and widths of 25 μm, 50 μm, 100 μm, 150 μm, and 200 μm were fabricated for experimental validation. Measurement results were compared against a reference value obtained by the guarded hot plate method. It was found that the sensor with a length of 30 mm and a width of 100 μm demonstrated optimal performance among the configurations tested, with deviations between the experimental measurements and the reference value remaining within approximately ±1.5%.

KW - Bayesian optimization algorithm

KW - expanded polystyrene foam

KW - hot-wire method

KW - low thermal conductivity materials

KW - thermal conductivity

UR - https://www.scopus.com/pages/publications/105035505265

U2 - 10.3390/buildings16071299

DO - 10.3390/buildings16071299

M3 - Article

AN - SCOPUS:105035505265

SN - 2075-5309

VL - 16

JO - Buildings

JF - Buildings

IS - 7

M1 - 1299

ER -