Method for testing interface bonding mechanism of mixed porcelain insulator

Abstract

The invention discloses a mixed porcelain insulator interface bonding mechanism test method, which is characterized in that a clean glaze surface is coated with a composite solution with a synergistic effect of a silane coupling agent and a surface modifier, so that an interface transition layer with a micro-nano structure is formed, and the bonding reliability of HTV and porcelain glaze is remarkably enhanced; a coating layer cutting test is adopted to replace a traditional mechanical test, the interface bonding quality is visually judged by observing the porcelain surface state of a non-cutting area, and the problem of uneven stress distribution in a thick-layer structure is effectively avoided; the system verifies the long-term stability of the interface in a harsh environment by combining boiling aging and dye penetration tests. According to the method, the interface bonding defect can be accurately identified, the interface failure area after water boiling aging is reduced through optimized process parameters, the service reliability of the mixed porcelain insulator is remarkably improved, the service life of the mixed porcelain insulator is remarkably prolonged, and a powerful guarantee is provided for safe and stable operation of power equipment.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of insulators, in particular to a mixed porcelain insulator interface bonding mechanism test method. BACKGROUND

[0002] In the field of power transmission, disc suspension insulators as key external insulation components, their reliability is directly related to the safe operation of the power grid. In recent years, in order to improve the pollution flashover resistance of traditional porcelain insulators, the industry has begun to develop mixed porcelain insulator technology, that is, a layer of high temperature vulcanized silicone rubber (HTV) is coated on the outside of the porcelain core. However, during the implementation of the HTV coating process, due to the fact that the porcelain glaze surface is too smooth and the injection pressure is too high, the HTV and porcelain glaze interface bonding reliability is insufficient, which is prone to interface debonding in long-term operation, resulting in sealing failure and electrical performance degradation.

[0003] In the prior art, the porcelain surface is usually treated by simple ethanol or acetone wiping, and then HTV injection coating is performed. For interface bonding quality evaluation, the industry generally follows the traditional 180° peeling strength test or shear strength test method. However, the HTV coating layer thickness of mixed porcelain insulators is usually more than 2.5 millimeters, which is far beyond the applicable range of conventional bonding tests. Under this thick layer structure, the traditional test method has a fundamental defect: in the peeling test, the stress is mainly concentrated in the inner layer of the glue layer rather than the interface, which causes cohesive failure to mask the true interface adhesion state; the shear test causes uneven stress distribution due to the large difference in elastic modulus between the porcelain body and the rubber, resulting in poor repeatability of the test results. These limitations make it impossible to accurately identify products with poor interface bonding during production, resulting in a large number of potentially failed insulators flowing into the power grid, which seriously threatens the safety of the power system. SUMMARY

[0004] In view of the deficiencies of the prior art, the present application provides a mixed porcelain insulator interface bonding mechanism test method, which aims to solve the problems in the background art.

[0005] To achieve the above-mentioned purpose, the present application provides the following technical scheme: a mixed porcelain insulator interface bonding mechanism test method, comprising the following steps: physically washing and chemically decontaminating the porcelain insulator substrate to obtain a clean glaze surface, and coating a composite solution of silane coupling agent and surface modifier synergistic effect on the obtained clean glaze surface to form an interface transition layer; injecting high temperature vulcanized silicone rubber onto the surface of the porcelain insulator with the interface transition layer to obtain a complete coating sample, and performing a coating layer separation test on the obtained complete coating sample to evaluate the interface bonding quality by observing the porcelain surface state in the non-knife cutting area; performing water boiling aging treatment on the evaluated sample, and performing a coating layer separation test again on the water boiling aged sample to compare the interface state change; Another batch of the same sample is subjected to a dye penetration test to assist in verifying the interface density, and the optimal interface treatment process parameter combination is determined based on the results of the separation test and the dye penetration test.

[0006] Further, the porcelain insulator substrate is physically cleaned and chemically decontaminated to obtain a clean glaze surface, including: The porcelain insulator is placed in a 40-kilohertz ultrasonic cleaning tank and cleaned with 35-degree Celsius deionized water for 15 minutes; The porcelain insulator after ultrasonic cleaning is immersed in a 3:1 mixed solvent of isopropyl alcohol and acetone for 10 minutes; The soaked porcelain insulator is placed in a 60-degree Celsius constant temperature oven for drying for 30 minutes, and the water contact angle on the surface of the dried porcelain insulator is measured as a quantitative indicator of the initial interface state.

[0007] Further, a composite solution of silane coupling agent and surface modifier synergistically acting on the obtained clean glaze surface is coated to form an interface transition layer, including: γ-aminopropyltriethoxysilane is dissolved in an ethanol-water mixed solvent at a volume fraction of 2% and the pH is adjusted to 4.5 for hydrolysis; Silicon dioxide particles with an average particle size of 20 nanometers are dispersed in deionized water at a mass fraction of 1.5% to form a suspension; The hydrolyzed silane solution and the silicon dioxide suspension are mixed at a volume ratio of 4:1 and an interface active agent is added; The mixed composite coating solution is applied to the clean glaze surface by spin coating process and cured at 80 degrees Celsius for 1 hour.

[0008] Further, high temperature vulcanized silicone rubber is injected and coated on the surface of the porcelain insulator on which the interface transition layer is formed to obtain a complete coated sample, including: The two-component high temperature vulcanized silicone rubber is mixed at a mass ratio of 10:1 and then vacuum degassed; The degassed high temperature vulcanized silicone rubber is injected into a mold containing the treated porcelain insulator at an injection pressure of 12 megapascals at 80 degrees Celsius; After injection is completed, a holding pressure of 5 megapascals is applied for 60 seconds, and the mold is subjected to a stepwise temperature increase program, i.e., 100 degrees Celsius for 30 minutes and then 150 degrees Celsius for 60 minutes to complete vulcanization.

[0009] Further, a coated layer separation test is performed on the obtained complete coated sample, and the interface adhesion quality is evaluated by observing the porcelain surface state in the non-cut area, including: A straight line cut of 2.8 millimeters in depth and 30 millimeters in length is made along the equatorial plane of the sample using a blade, and the cut side of the rubber layer is held with tweezers at a speed of not more than 5 millimeters per second to peel off a length of 20 millimeters at a uniform speed; After the debonding is completed, the non-cut area porcelain surface in the range of 5-25 mm from the cut is observed by optical microscope, and the interface bonding quality is determined according to the length of the continuous smooth porcelain surface in the non-cut area.

[0010] Further, the evaluated sample is subjected to water boiling aging treatment, including: The evaluated sample is completely immersed in 95 degrees Celsius deionized water, and boiling is continued for 168 hours; The sample after water boiling is dried by filter paper to remove surface moisture, and the sample after moisture absorption is placed in a constant temperature oven at 60 degrees Celsius for drying for 24 hours to restore the surface state.

[0011] Further, the sample after water boiling aging is subjected to the coating layer separation test again to compare the interface state change, including: The separation test operation is repeated on the sample after drying and recovery, and the length of the continuous smooth porcelain surface exposed in the non-cut area after water boiling aging is recorded; The recorded length of the continuous smooth porcelain surface is compared with the data before aging to evaluate the interface durability; When the length of the continuous smooth porcelain surface after water boiling aging is not more than 2 mm, it is determined that the interface has good hydrolysis resistance.

[0012] Further, another batch of samples with the same treatment is subjected to dye penetration test to assist in verifying the interface density, including: A 0.5% methylene blue aqueous solution is prepared as a penetration medium; The sample is immersed in a 60 degrees Celsius methylene blue solution for 72 hours, and the sample surface is washed with flowing deionized water for 30 minutes; The HTV and porcelain interface dye coloring condition is observed by cutting the high temperature vulcanized silicone rubber coating layer along the axial direction.

[0013] Further, the interface bonding quality is determined according to the length of the continuous smooth porcelain surface in the non-cut area, including: When the length of the continuous smooth porcelain surface in the non-cut area is not more than 2 mm and the surface is covered with high temperature vulcanized silicone rubber debris, it is determined that the interface bonding is good; When the length of the continuous smooth porcelain surface in the non-cut area is more than 5 mm, it is determined that the interface bonding is poor; The sample with good interface bonding is subjected to water boiling aging test to verify the long-term stability; The sample with poor interface bonding is adjusted to change the silane coupling agent concentration and the ratio of surface modifier for reprocessing.

[0014] Further, the optimal interface treatment process parameter combination is determined according to the results of the separation test and the dye penetration test, including: An orthogonal test is designed to adjust the silane coupling agent concentration in the range of 1% to 3%; The mass fraction of nano-silica particles is controlled within the range of 0.5% to 2.0%; Set the curing temperature of the interface transition layer to the range of 60 degrees Celsius to 100 degrees Celsius; Based on the combined effect of the length of the smooth porcelain surface after boiling and aging and the percentage of dye penetration area, the optimal parameters were determined to be: silane coupling agent concentration of 2.0%, nano silica mass fraction of 1.5%, and curing temperature of 80 degrees Celsius.

[0015] Compared with existing technologies, this invention has the following advantages: By coating a clean glaze surface with a composite solution of silane coupling agent and surface modifier working synergistically, this invention forms an interfacial transition layer with a micro-nano structure, significantly enhancing the adhesion reliability between HTV and porcelain glaze. The invention replaces traditional mechanical testing with a coating layer shearing test, allowing for a direct assessment of interfacial adhesion quality by observing the porcelain surface condition in non-cut areas, effectively avoiding the problem of uneven stress distribution in thick-layer structures. Combined with water boiling aging and dye penetration tests, the long-term stability of the interface under harsh environments is systematically verified. This method can accurately identify interfacial adhesion defects, and the optimized process parameters reduce the interface failure area after water boiling aging, significantly improving the service reliability and service life of hybrid porcelain insulators, providing strong support for the safe and stable operation of power equipment. Attached Figure Description

[0016] Figure 1 This is a flowchart of the method of the present invention. Detailed Implementation

[0017] Example 1

[0018] like Figure 1 As shown, the present invention provides a technical solution: a test method for the interface bonding mechanism of hybrid porcelain insulators, comprising the following steps: To obtain a clean glaze surface, the porcelain insulator substrate is subjected to physical cleaning and chemical decontamination. Specifically, the following steps are taken: the porcelain insulator is placed in a 40 kHz ultrasonic cleaning tank and cleaned with 35°C deionized water for 15 minutes; the ultrasonically cleaned porcelain insulator is immersed in a 3:1 mixture of isopropanol and acetone for 10 minutes; the immersed porcelain insulator is placed in a 60°C constant temperature oven for 30 minutes to dry; and the water contact angle on the dried porcelain insulator surface is measured as a quantitative index of the initial interface state.

[0019] This pretreatment process effectively removes particulate contaminants and organic residues from the glaze of porcelain insulators, significantly improving surface cleanliness and chemical homogeneity. By controlling the cleaning and drying parameters, secondary pollution and thermal stress damage are avoided, providing a stable and repeatable starting state for subsequent interface modification. The introduction of the water contact angle enables the quantitative characterization of surface wettability, providing an objective basis for evaluating the state before interface treatment.

[0020] An interface transition layer is formed on the obtained clean glaze by coating a composite solution of silane coupling agent and surface modifier, specifically including: dissolving γ-aminopropyl triethoxysilane in an ethanol-water mixed solvent at a volume fraction of 2% and adjusting the pH to 4.5 for hydrolysis; dispersing silica particles with an average particle size of 20 nanometers in deionized water at a mass fraction of 1.5% to form a suspension; mixing the hydrolyzed silane solution and the silica suspension at a volume ratio of 4:1 and adding a surfactant; applying the mixed composite coating solution to the clean glaze by spin coating process and curing at 80 degrees Celsius for 1 hour.

[0021] The interface transition layer construction process simultaneously realizes the introduction of chemical bonding sites and the construction of micro-nano rough structure on the smooth porcelain glaze surface, significantly improving the surface energy and the wetting and spreading ability of the HTV rubber; the silane hydrolysis product and the glaze hydroxyl group form a stable covalent bond, while the nano silica particles enhance the mechanical embedding force through physical anchoring, both of which synergistically improve the interface bonding strength; precise control of spin coating and curing parameters ensures uniform thickness and dense structure of the modified layer, effectively blocking the penetration path of water molecules along the interface.

[0022] A complete coated sample is obtained by injecting high-temperature vulcanized silicone rubber onto the surface of the porcelain insulator with an interface transition layer, specifically including: mixing two-component high-temperature vulcanized silicone rubber at a mass ratio of 10:1 and vacuum degassing; injecting the degassed high-temperature vulcanized silicone rubber into a mold containing the treated porcelain insulator at 80 degrees Celsius with an injection pressure of 12 megapascals; after injection, apply a holding pressure of 5 megapascals for 60 seconds, then heat the mold according to a stepwise temperature program, heat at 100 degrees Celsius for 30 minutes and then heat at 150 degrees Celsius for 60 minutes to complete vulcanization.

[0023] The coating process ensures that the rubber flows and fills completely while effectively avoiding the generation of air bubbles and interface voids, ensuring the close fit between the HTV and the interface transition layer; the synergistic effect of high-pressure injection and pressure holding compensates for the volume change caused by the cooling shrinkage of the rubber, preventing interface micro-peeling; the stepwise temperature vulcanization system takes into account the kinetics of rubber crosslinking reaction and the thermodynamic needs of interface chemical bond formation, allowing the HTV body to fully cure while promoting further condensation between the HTV and the silane layer, forming a three-dimensional interpenetrating interface structure with high strength and stability, significantly improving the overall coating quality and interface durability.

[0024] The coating layer separation test is performed on the obtained complete coated sample, and the interface bonding quality is judged by observing the porcelain surface state of the non-knife cutting area; specifically including: using a blade to cut a straight line cutout with a depth of 2.8 millimeters and a length of 30 millimeters along the equatorial plane of the sample, using tweezers to clamp the glue layer on one side of the cutout at a speed of not more than 5 millimeters per second to peel off a length of 20 millimeters at a uniform speed; after the peeling is completed, the non-knife cutting area within a range of 5-25 millimeters from the cutout is observed with an optical microscope, and the interface bonding quality is judged according to the length of the continuous smooth porcelain surface in the non-knife cutting area; specifically including: When the length of the continuous smooth porcelain surface in the non-knife cutting area is not more than 2 millimeters and the surface is covered with high-temperature vulcanized silicone rubber debris, it is determined that the interface bonding is good; When the length of the continuous smooth porcelain surface in the non-knife cutting area is more than 5 millimeters, it is determined that the interface bonding is poor; The water boiling aging test is performed on the sample determined to have good interface bonding to verify the long-term stability; The silane coupling agent concentration and surface modifier ratio are adjusted for the sample determined to have poor interface bonding to reprocess.

[0025] The separation test method breaks through the applicability limitations of traditional mechanical tests in thick coating layer structures, directly reflects the real bonding state of the interface through the natural peeling morphology of the non-knife cutting area, and avoids stress interference and distortion of the failure mode caused by external load; the length of the continuous smooth porcelain surface is used as the judgment threshold to realize the quantification and visualization of the interface bonding quality, which significantly improves the objectivity and repeatability of the test results.

[0026] The judged sample is subjected to water boiling aging treatment, specifically including: completely immersing the judged sample in 95 degrees Celsius deionized water, continuously boiling for 168 hours to simulate severe service environment; after water boiling, the sample is dried with filter paper to remove surface moisture, and the sample with removed moisture is placed in a 60 degrees Celsius constant temperature oven for drying for 24 hours to restore the surface state. The coating layer separation test is performed again on the water boiling aged sample to compare the interface state changes; specifically including: repeating the separation test operation on the dried and restored sample, recording the length of the continuous smooth porcelain surface exposed in the non-knife cutting area after water boiling aging; comparing the recorded length of the continuous smooth porcelain surface with the data before aging to evaluate the interface durability; when the length of the continuous smooth porcelain surface after water boiling aging is not more than 2 millimeters, it is determined that the interface has good hydrolysis resistance.

[0027] The evaluation mode of the water boiling aging combined with the cutting-off test effectively simulates the long-term service conditions of the mixed porcelain insulator in a high-temperature and high-humidity environment, and can truly reflect the stability of the interface under the action of water and heat coupling; by comparing the lengths of the smooth porcelain surface in the non-cutting area before and after aging, the anti-hydrolysis ability of the interface chemical bond and the durability of the bonding structure are directly revealed, avoiding misjudgment caused by relying only on the initial bonding state; taking 2 millimeters of smooth length as the judgment threshold of the water resistance performance, an accelerated aging evaluation standard highly related to the actual operation reliability is established.

[0028] Another batch of the same treated samples is subjected to a dye penetration test to assist in verifying the interface density, specifically including: preparing a 0.5% methylene blue aqueous solution as the penetration medium; immersing the sample in a 60-degree Celsius methylene blue solution for 72 hours, and then rinsing the surface of the sample with flowing deionized water for 30 minutes to remove the adsorbed dye; observing the dye coloring of the HTV and porcelain interface along the axial section of the high-temperature vulcanized silicone rubber coating layer.

[0029] The dye penetration test directly reveals the existence or nonexistence of microscopic defects and potential penetration channels between the HTV and the porcelain glaze through the invasion behavior of methylene blue molecules in the interface area, effectively making up for the deficiency of macro-mechanical tests in characterizing the micro-integrity of the interface; the accelerated penetration conditions of 60 degrees Celsius for 72 hours strengthen the discrimination ability of the interface sealing performance, making weak bonding defects visible; the high consistency of the dye coloring area with the interface failure position in the subsequent cutting-off test verifies the reliability of the method as a rapid screening means for interface density.

[0030] The optimal interface treatment process parameter combination is determined according to the results of the cutting-off test and the dye penetration test; specifically including: designing an orthogonal test to adjust the silane coupling agent concentration to vary within the range of 1% to 3%; controlling the mass fraction of nano-silicon dioxide particles within the range of 0.5% to 2.0%; setting the curing temperature of the interface transition layer within the range of 60 degrees Celsius to 100 degrees Celsius; and comprehensively determining the optimal parameters as silane coupling agent concentration 2.0%, nano-silicon dioxide mass fraction 1.5%, and curing temperature 80 degrees Celsius according to the smooth porcelain surface length after water boiling aging and the area ratio of dye penetration.

[0031] The process parameter optimization method realizes precise matching of the interface treatment conditions through cross-validation of multi-dimensional test data, significantly improving the comprehensive performance of the interface bonding; taking the interface stability after water boiling aging and the microscopic density of dye penetration as dual criteria, it ensures that the determined parameter combination not only performs excellently in the initial state, but also has long-term service reliability.

[0032] Example 2

[0033] The present embodiment is based on a mixed porcelain insulator interface bonding mechanism test method. In view of the interface bonding failure problem caused by too smooth porcelain glaze surface and large injection pressure during high temperature vulcanized silicone rubber (HTV) coating of disc type suspension mixed porcelain insulator, an interface treatment process based on the synergistic effect of silane coupling agent and surface modifier is proposed, and a coating layer separation test method suitable for thick coating layer structure is established to objectively and intuitively evaluate the interface bonding quality, including the following steps: Step 1: porcelain insulator substrate pretreatment and surface state evaluation; This step aims to provide a clean and controllable starting surface state for subsequent interface modification treatment, ensuring that the silane coupling agent and surface modifier can effectively adhere and function. The porcelain insulator substrate needs to undergo a series of standardized pretreatments before HTV coating, including physical cleaning, chemical decontamination, drying, and surface morphology characterization, to eliminate manufacturing residues, transportation pollution, and glaze microdefects that interfere with the bonding performance.

[0034] Step 1.1: Physical cleaning to remove surface particle contaminants; Place the disc type suspension porcelain insulator to be treated in an ultrasonic cleaning tank, use deionized water as the cleaning medium, and continuously clean at a frequency of 40 kHz and a temperature of 35°C for 15 minutes. This process can effectively remove dust, metal debris, and release agent residues attached to the glaze. After cleaning, dry the surface moisture with clean nitrogen to avoid secondary pollution. This operation provides a clean surface free of particles for subsequent chemical treatment, preventing impurities from forming an isolation layer during the coupling agent coating stage, which affects the interface chemical bonding.

[0035] Step 1.2: Chemical decontamination to eliminate organic residues; Based on the clean porcelain body obtained in step 1.1, immerse it in a mixed solvent of isopropyl alcohol and acetone with a volume ratio of 3:1, and soak at room temperature for 10 minutes to dissolve and remove grease, wax, and high molecular organic contaminants adsorbed on the glaze surface. After soaking, rinse with deionized water three more times and dry in a 60°C constant temperature oven for 30 minutes. This step ensures that the glaze surface is free of organic residues, providing active hydroxyl sites for the hydrolysis and condensation reaction of silane coupling agents, and improving the efficiency of subsequent chemical bonding.

[0036] Step 1.3: Surface contact angle measurement to evaluate initial wettability; Based on the dried porcelain body after step 1.2, measure its surface water contact angle (WCA) using the static droplet method. Place a 2 μL deionized water droplet on the center of the glaze, and use an optical contact angle measuring instrument to record the contact angle value at equilibrium . If , it indicates that the glaze surface has strong hydrophobicity and low surface energy, which is not conducive to the wetting and spreading of HTV rubber; if , which indicates that the surface has a certain hydrophilicity, which is beneficial to the subsequent interfacial reaction. This parameter is used as a quantitative indicator of the initial interfacial state and a comparative benchmark for the subsequent modification effect.

[0037] Step 1.4: Surface roughness and micro-morphology characterization; After completing the contact angle measurement in step 1.3, the same porcelain body area is selected, and an atomic force microscope (AFM) or a white light interferometer is used to scan the glaze surface in three dimensions to obtain the surface root mean square roughness and the arithmetic mean roughness . The surface roughness index is defined to characterize the uniformity of the glaze micro-undulation. When , it indicates that the surface undulation is regular; if , there may be local depressions or protrusions, which are easy to form stress concentration points during the HTV injection process.

[0038] Step 2: Synergistic coating treatment of silane coupling agent and surface modifier; On the basis of the standardized porcelain body surface obtained in step 1, this step implements the synergistic coating process of silane coupling agent and surface modifier. This process builds a transition layer with reactive activity and micro-nano structure on the smooth glaze surface through the dual action of chemical grafting and physical anchoring, thereby significantly improving the interfacial bonding strength between HTV and porcelain glaze.

[0039] Step 2.1: Preparation and hydrolysis activation of silane coupling agent solution; According to the glaze roughness index obtained in step 1.4, γ-aminopropyl triethoxysilane (KH-550) is selected as the main coupling agent. It is dissolved in an ethanol-water mixed solvent (ethanol: water = 9:1, v / v) at a volume fraction of , and the pH is adjusted to 4.5 with acetic acid. Stirring at room temperature for 2 hours allows the silane molecules to be fully hydrolyzed to form silanol. The hydrolysis reaction is represented as: ; In the formula, represents the organic functional group part in the silane molecule, which is the amino functional group here; represents the triethoxysilane group, which is the hydrolyzable group part in the silane coupling agent; represents water; represents the silanol group, which is the active group after the hydrolysis of the silane coupling agent; represents ethanol, which is the byproduct of the silane coupling agent hydrolysis reaction; the silanol generated by this reaction has high reactivity and can condense with the silanol groups on the surface of the porcelain glaze to form stable Si–O–Si covalent bonds. This step lays the molecular foundation for the subsequent interfacial chemical bonding.

[0040] Step 2.2: Preparation of surface modifier suspension and particle size control; After the silane solution is prepared in Step 2.1, a suspension of nano-silica (SiO2) surface modifier is prepared simultaneously. Hydrophilic SiO2 particles with an average particle size of 20 nm are selected and dispersed in deionized water at a mass fraction of 1.5%. 0.1% polyvinylpyrrolidone (PVP) is added as a dispersion stabilizer. After ultrasonic dispersion for 30 minutes, a uniform suspension is obtained. The particle dispersion uniformity index is defined as the average particle size (D50) and the standard deviation (D50).

[0041] Step 2.3: Preparation of silane-modifier composite coating solution; The silane hydrolysis solution obtained in Step 2.1 is mixed with the suspension obtained in Step 2.2 at a volume ratio of 4:1. 0.05% sodium dodecyl sulfate (SDS) is added as an interfacial stabilizer. The mixture is stirred at 30°C for 1 hour to form a stable composite coating solution. In this mixed system, silane molecules provide chemical bonding sites, and nano-particles form a micro-nano composite rough structure on the glaze surface. The synergistic effect of the two can significantly improve the surface energy and mechanical embedding ability. The Zeta potential of the coating solution should be controlled between -30mV and -40mV to ensure colloidal stability and prevent particle agglomeration.

[0042] Step 2.4: Uniform interfacial layer construction by spin coating process; Based on the composite coating solution prepared in Step 2.3, the spin coating method is used to uniformly coat the porcelain surface treated in Step 1.2. The spin coating parameters are set as follows: the first stage is 500 rpm for 10 seconds (spreading stage), and the second stage is 3000 rpm for 30 seconds (drying stage). After spin coating, the sample is placed in an 80°C oven for 1 hour to solidify, promoting the condensation of silane with the glaze hydroxyl group and firmly anchoring the nano-particles on the surface. After solidification, the surface contact angle should be reduced to , indicating that the surface energy has been significantly improved, which is beneficial to the wetting of HTV rubber. The interfacial transition layer constructed in this step has both chemical activity and microstructure characteristics, providing an ideal bonding basis for subsequent HTV coating.

[0043] Step 3: High temperature vulcanized silicone rubber (HTV) coating and interface solidification; ​​​​​​​​​​On the basis of the modified interface constructed in step 2, this step implements the injection coating and vulcanization forming of HTV rubber compound, ensuring the formation of a firm and continuous interface between the rubber layer and the porcelain body. The injection parameters and vulcanization conditions need to be accurately controlled to avoid interface peeling caused by excessive pressure or temperature gradient.

[0044] Step 3.1: HTV compound premixing and degassing treatment; According to the size of the modified porcelain body obtained in step 2.4, the two-component HTV compound (the mass ratio of base rubber to vulcanizing agent is 10:1) is weighed and mixed in a vacuum mixer at 500 rpm for 5 minutes, and then degassed at a vacuum degree of -0.095 MPa for 10 minutes to eliminate air bubbles introduced during mixing. The degassed compound should be uniform and bubble-free to avoid interface defects caused by air bubble rupture during injection. This step ensures the flowability and filling property of the compound, providing material support for subsequent high-pressure injection.

[0045] Step 3.2: Mould assembly and porcelain body positioning; After completing the compound preparation in step 3.1, the modified porcelain body is loaded into a special coating mold, ensuring that its axial direction is aligned with the center of the mold and that the glaze surface is completely exposed to the cavity. The inner wall of the mold is pre-sprayed with a release agent to prevent HTV from sticking to the mold. The gap between the porcelain body and the mold is controlled at 2.5±0.2 mm to form a standard thickness of the coating layer. This positioning accuracy directly affects the uniformity of the coating layer thickness, which in turn affects the comparability of the subsequent cutting-off test.

[0046] Step 3.3: High-pressure injection and pressure control; The HTV compound of step 3.1 is injected into the injection machine cylinder and heated to 80°C to ensure good flowability. Then, the compound is injected into the mold cavity assembled in step 3.2 at an injection pressure of 12 MPa and an injection speed of 30 mm / s, and a 5 MPa holding pressure is applied for 60 seconds after injection to compensate for the shrinkage of the compound during cooling and prevent micro-pores or debonding at the interface. During the injection process, the compound spreads rapidly on the modified glaze surface, and its contact angle changes dynamically, which can be described by the Wenzel model: ; In the formula, represents the actual apparent contact angle; represents the surface roughness factor; since the surface roughness factor has been reduced to below 60° in step 2.4, and , therefore , i.e., the compound is more easily spread on the microstructure surface, achieving good wetting; , represent the cosine values of and , respectively.

[0047] Step 3.4: Step curing and interfacial cross-linking; After the injection pressure is maintained in step 3.3, the mold is transferred into the curing oven as a whole, and a step curing program is executed: first, the temperature is maintained at 100°C for 30 minutes to preliminarily cross-link the rubber; then, the temperature is raised to 150°C for 60 minutes to complete the deep curing. During this process, the addition reaction between the vinyl group and the silicon-hydrogen group in the HTV occurs, forming a three-dimensional network structure. At the same time, the silicon-hydroxyl group in the rubber further condenses with the silane layer formed in step 2.4 to generate Si-O-Si covalent bonds, achieving chemical bonding. After curing, the mold is naturally cooled to room temperature, and the complete coated sample is obtained by demolding.

[0048] Step 4: Limitation analysis of traditional adhesive strength test and new test method; After obtaining the complete HTV coated sample in step 3, this step first evaluates the applicability of traditional adhesive strength test methods (such as peel strength and shear strength), and finds that they have problems such as uneven stress distribution and uncontrollable failure mode in thick coated layer structures, making it difficult to truly reflect the interfacial bonding quality.

[0049] Step 4.1: Implementation of traditional peel strength test and analysis of result deviation; According to the GB / T7122 standard, the 180° peel strength test is performed on the sample obtained in step 3.4. One end of the HTV coating layer is peeled off and clamped in the tensile testing machine, and peeled off at a speed of 100 mm / min. The peel force F is recorded. However, due to the thickness of the coating layer reaching 2.5 mm, significant bending stress is generated in the rubber layer during the peeling process, leading to failure occurring in the rubber body (cohesion failure) rather than at the interface (adhesion failure). At this time, the measured F value cannot truly reflect the interfacial bonding capacity, but is dominated by the mechanical properties of the rubber body.

[0050] Step 4.2: Stress concentration problem identification of shear strength test; After finding the failure of the peel test in step 4.1, the shear strength test (referring to ASTM D1002) is attempted. The sample is fixed in a special fixture, and a shear force perpendicular to the interface is applied. However, due to the rigidity of the porcelain body being much higher than that of the HTV, the stress is concentrated on the edge of the rubber layer during the shearing process, leading to local tearing rather than overall interfacial separation.

[0051] Step 4.3: Coating layer separation test; Based on the failure experience of steps 4.1 and 4.2, a new test method is proposed: cut a slit on the HTV coating layer of the sample along the axial direction, which penetrates the rubber layer but does not damage the porcelain body, then slowly peel off the rubber layer along both sides of the slit with hands or tools, and observe the porcelain surface state after peeling. If the interface is well bonded, the rubber layer is completely separated during peeling, and there are a large number of HTV debris and no smooth area on the porcelain surface; if the bonding is poor, the peeling path will follow the interface, exposing the original smooth glaze surface. This method avoids stress interference caused by mechanical loading and directly judges the bonding quality through the interface failure mode.

[0052] Step 4.4: Establishment of cutting test operation specification and evaluation criteria; According to the design principle of step 4.3, the specific operation process is formulated: use a sharp blade to cut a straight line with a length of ≥30 mm and a depth of ≥2.8 mm (slightly larger than the thickness of the coating layer) on the equatorial plane of the sample, ensuring that the blade tip does not touch the porcelain body. Then use tweezers to hold the rubber layer on one side of the slit and peel it off at a speed of ≤5 mm / s for at least 20 mm. After peeling, observe the porcelain surface state in the non-cut area with an optical microscope. Define the evaluation criteria: if the non-cut area has a continuous smooth porcelain surface length L > 5 mm, it is determined that the interface bonding is poor; if L ≤ 2 mm and the surface is covered with HTV residue, it is determined that the interface bonding is good.

[0053] Step 5: Water boiling aging test to verify interface durability; Based on the proposed and preliminary verified "coating layer cutting test" method in step 4, this step conducts a water boiling aging test on the mixed porcelain insulator treated with silane coupling agent and surface modifier to evaluate the long-term stability of the interface bonding under high temperature and high humidity conditions. This test aims to verify whether the proposed interface treatment process has the ability to resist water molecule penetration and interface hydrolysis, thereby supporting its reliable application in outdoor power equipment.

[0054] Step 5.1: Setting of water boiling aging test conditions; Based on the cutting test evaluation criteria established in step 4.4, select several complete HTV coating samples prepared in step three, immerse them completely in deionized water, and place them in a constant temperature water bath at a temperature of 95±2℃ for continuous boiling for 168 hours (7 days). This condition simulates the long-term high humidity and high temperature environment in tropical or subtropical regions, accelerating the process of water molecule diffusion to the HTV / porcelain interface. During the boiling process, water molecules may penetrate the interface through the micropores of the HTV body or interface defects, causing silicon-oxygen bond (Si–O–Si) hydrolysis and leading to bonding failure. This setting provides a unified accelerated aging benchmark for subsequent interface durability evaluation.

[0055] Step 5.2: Drying and surface state recovery of aged samples; After 168 hours of water boiling in Step 5.1, the sample is taken out, surface water is absorbed with filter paper, and placed in a constant temperature oven at 60°C for 24 hours to completely remove adsorbed water and capillary water, avoiding residual moisture interference in subsequent separation observation. During the drying process, if the interface has hydrolyzed and debonded, a micron-level gap will be formed between the HTV and the porcelain body, which cannot be closed after drying, thus exposing the smooth porcelain surface during the separation test. This step ensures that the sample is in a stable state, providing a prerequisite for objective evaluation.

[0056] Step 5.3: Water boiling and separation test execution and interface failure mode recording; According to the separation operation specification in Step 4.4, the aged sample after drying in Step 5.2 is subjected to a coating separation test. After cutting and peeling along the equatorial plane, the porcelain surface morphology in the non-cut area is observed. If the cooperatively treated sample still has no obvious smooth porcelain surface exposure (L≤2mm) after water boiling, it indicates that the interface remains intact in a high temperature and humidity environment, and the silane layer effectively blocks the erosion of water molecules on the original glaze; otherwise, if L significantly increases (such as L>10mm), it indicates that the interface hydrolysis is severe and the bonding fails. This observation result directly reflects the water hydrolysis resistance of the interface chemical bond.

[0057] Step 5.4: Interface hydrolysis kinetics analysis and protection mechanism explanation; Based on the failure mode in Step 5.3, an interface hydrolysis rate model is introduced to explain the protection mechanism of cooperative treatment. Let the hydrolysis rate constant of the untreated interface be and the hydrolysis rate constant of the interface treated by silane-modifier be , then the remaining bonding area ratio of the interface changes with time as follows: ; In the formula, represents the initial bonding area; Because the nano particles construct a tortuous diffusion path on the glaze surface, the water molecule penetration path length increases, the effective diffusion coefficient decreases, satisfying: ; In the formula, represents the water diffusion coefficient in pure HTV; represents the volume fraction of nano particles; represents the shape factor (for spherical particles ). At the same time, the Si–O–Si bond density in the silane layer is improved, so . Therefore, the cooperative treatment significantly delays The decay rate of the interface is so slow that the sample still maintains high interface integrity after 168 hours of water boiling.

[0058] Step 6: Dye penetration contrast test verifies interface tightness; On the basis of interface durability verification by water boiling aging in step 5, this step introduces a dye penetration test to further compare the interface tightness differences between traditional and synergistic treatment samples from the perspective of microscopic penetration paths. This test uses dye molecules as tracers to directly show the channels that water vapor or pollutants may invade, thereby indirectly evaluating the interface sealing performance.

[0059] Step 6.1: Dye solution preparation and penetration driving force setting; Based on the analysis of diffusion paths in step 5.4, a methylene blue aqueous solution with a mass fraction of 0.5% is prepared as the penetration medium. The diameter of the dye molecule is about 1.4 nm, close to the size of hydrated ions, which can effectively simulate the penetration behavior of small polar molecules in the environment. The two types of samples prepared in step 3.4 (one synergistically treated and the other only ethanol washed) are simultaneously immersed in the dye solution and kept at 60°C for 72 hours. Raising the temperature can accelerate molecular thermal motion, enhance the penetration driving force, and shorten the test period.

[0060] Step 6.2: Dye penetration depth and path visualization; After the penetration in step 6.1 is completed, the sample is taken out and rinsed with flowing deionized water for 30 minutes to remove adsorbed dye, and then the HTV coating layer is cut open along the axial direction to expose the HTV / porcelain interface. A high-power optical microscope or digital microscopic imaging system is used to observe the dye coloring condition in the interface area. If there are micropores, cracks, or weak boundary layers in the interface, the dye will penetrate along these defects, forming blue stripes or spots on the porcelain surface; if the interface is dense, there will be no dye penetration traces. This visualization result directly reflects the microscopic integrity of the interface.

[0061] Step 6.3: Penetration area quantification and comparative analysis; After obtaining the interface image in step 6.2, the image gray threshold segmentation method is used to calculate the dye penetration area ratio . Let the total interface area be , the dyed area be , then: ; For the only washed sample, is usually greater than 15%, indicating the existence of widespread interface defects; while for the synergistically treated sample, can be controlled below 2%. This difference is due to the fact that the nano particles fill the microscopic depressions of the glaze, and the silane layer seals the active hydroxyl groups, reducing the free volume of the interface, thereby inhibiting the diffusion of dye molecules.

[0062] Step 6.4: Correlation between the penetration path and the interface failure; Combining the results of step 6.3 with the results of step 5.3, the correlation between the dye penetration path and the actual interface failure is established. It is observed that the dye penetration concentration area is highly consistent with the exposed position of the polished porcelain surface after boiling, indicating that the dye path is the potential channel for water molecule intrusion. Therefore, a low value not only represents a dense interface, but also indicates excellent long-term aging resistance. This correlation verifies the feasibility of the dye penetration test as a rapid screening method, which can be used for prediction in the process optimization stage.

[0063] Step 7: Standardization of the coating layer separation test and control of operation consistency; Based on the effectiveness of the "coating layer separation test" proposed in step 4 and verified in steps 5 and 6, this step aims to transform the method into a standardized operation process that can be repeated and promoted, solving the evaluation bias caused by force, speed, and angle differences in manual operation, and ensuring its reliability in industrial quality control.

[0064] Step 7.1: Stripping force-displacement curve collection and feature point extraction; To quantify the stripping process, the manual stripping operation in step 4.4 is instrumented. The sample is fixed on a micro-tension testing platform, and the HTV layer at the cutout is clamped with a clamp, which is stripped at a constant speed of 1 mm / s. The relationship curve between the stripping force and displacement is recorded synchronously. Define the characteristic parameters: initial stripping force , average stripping force , and standard deviation of force fluctuation . If the interface bonding is good, the higher and the smaller, the curve is smooth; if the interface is weak, the lower and the larger, the curve is jagged. This data provides a basis for subsequent automated evaluation.

[0065] Step 7.2: Measurement of stripping path deviation angle and evaluation of interface continuity; While collecting mechanical data in step 7.1, a high-speed camera is used to record the dynamic stripping front. Define the stripping path deviation angle as the angle between the actual stripping direction and the ideal interface normal. If , it means that the stripping is along the interface, and the bonding is weak; if , it indicates that the stripping enters the HTV body, and the interface is strong. Calculate the time-averaged value of through image processing algorithms, and establish a regression relationship with L: ; wherein, , Both represent fitting constants; the formula links the mechanical behavior with the macroscopic morphology, improving the objectivity of the evaluation.

[0066] Step 7.3: Operator training and visual evaluation consistency calibration.

[0067] For scenarios that still require manual observation, develop a visual evaluation training procedure. Select 20 operators and have them independently evaluate the same set of known state samples (including good and bad samples). Calculate the evaluation consistency rate : ; wherein, represents the number of consistent evaluation opinions (or the number of people), indicating the number of times that multiple operators have the same evaluation result for the sample state; represents the total number of evaluations (or the total number of people), i.e., the total number of times that operators participating in the evaluation have evaluated the sample; Initially is usually less than 70%, and after three rounds of standard atlas learning and feedback, it can be improved to more than 95%. The standard atlas includes high-definition images of typical smooth porcelain surfaces of different lengths (L=0mm, 2mm, 5mm, 10mm, 20mm) and corresponding determination conclusions. This measure ensures the repeatability of manual evaluation.

[0068] Step 7.4: Preparation of cutting-off test operation instruction and process solidification;

[0069] Based on the results of steps 7.1 to 7.3, prepare the mixed porcelain insulator coating layer cutting-off test operation instruction, which clearly specifies: sample pretreatment requirements, cutting size tolerance (depth 2.8±0.1mm, length ≥30mm), peeling speed (≤5mm / s), observation area (5-25mm non-cutting area from the cut), evaluation threshold (L≤2mm is qualified) and image recording format. This document is used as an enterprise standard for trial implementation, laying the foundation for subsequent inclusion in industry standards.

[0070] Step 8: Process parameter optimization and interface bonding quality control system construction; This step focuses on the systematic optimization of key process parameters such as silane coupling agent concentration, nanoparticle content, and curing temperature, and constructs an interface bonding quality control system covering the entire chain of processing-coating-inspection, achieving a closed loop from laboratory methods to industrial application.

[0071] Step 8.1: Sensitivity analysis of key process parameters; Based on the collaborative processing flow of steps 2.1 to 2.4, select three core variables: silane concentration (1-3%), nanoparticle volume fraction (0.5-2.0%), curing temperature (60-100°C), and a designed orthogonal test L9. For each parameter combination, a sample was prepared, and after water boiling aging, a cutting test was performed with the length L of the smooth porcelain surface as the response index. The weight of each factor was determined by range analysis: the greatest impact (range Δ = 8.2 mm), followed by (Δ = 5.6 mm), the smallest impact (Δ = 3.1 mm). This result guided the subsequent parameter focus optimization.

[0072] Step 8.2: Optimal parameter combination determination and robustness verification; According to the analysis in Step 8.1, the following parameters were selected as the optimal combination: , , Thirty samples were prepared, and water boiling aging, dye penetration, and cutting tests were performed. The results showed that more than 95% of the samples had L ≤ 2 mm, , and the peeling force curve was smooth, indicating that this parameter combination not only had the best performance, but also had small batch-to-batch fluctuations, with process robustness. This combination was determined as the standard process window.

[0073] Step 8.3: Setting of quality control nodes in the whole process; After establishing the standard process in Step 8.2, three quality control nodes were set in the production line: 1. Contact angle detection after porcelain body pretreatment ( ); 2. Surface morphology inspection after collaborative treatment (AFM confirms uniform distribution of nanoparticles); 3. Full inspection of finished product cutting test (≥ 5 pieces per batch). Any unqualified node triggers rework or scrap.

[0074] Step 8.4: Establishment of quality data tracing and continuous improvement mechanism; Based on Step 8.3, a digital quality file system was established. Each product was bound to a unique code, and information such as processing parameters, test results, and operators was recorded. When interface failure occurs in the field, the code can be traced back to the production batch to analyze the root cause (such as abnormal pH of silane solution on a certain day), and feedback to the process parameter adjustment.

[0075] In summary, the present application forms an interface transition layer with micro-nano structure by coating a composite solution of silane coupling agent and surface modifier on the clean glaze, significantly enhancing the bonding reliability of HTV and porcelain enamel; the interface bonding quality is intuitively judged by observing the porcelain surface state in the non-cutting area through the adoption of the coating layer separation test instead of the traditional mechanical test, effectively avoiding the problem of uneven stress distribution in the thick layer structure; the long-term stability of the interface in harsh environment is systematically verified by combining the water boiling aging and dye penetration tests.

[0076] The method can accurately identify interface bonding defects, the optimized process parameters reduce the interface failure area after water boiling aging, significantly improve the service reliability and service life of the mixed porcelain insulator, and provide a strong guarantee for the safe and stable operation of the power equipment.

[0077] The basic principles, main features and advantages of the present application are shown and described above. Those skilled in the art should understand that the present application is not limited by the above examples, and the above examples and descriptions in the specification are only the principles of the present application. Without departing from the spirit and scope of the present application, various changes and improvements can be made to the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection required by the present application is defined by the appended claims and their equivalents.

Claims

1. A test method for the interface bonding mechanism of a composite porcelain insulator, characterized by, The method comprises the following steps: physically cleaning and chemically decontaminating the porcelain insulator substrate to obtain a clean glaze surface, and coating a composite solution of silane coupling agent and surface modifier synergistic effect on the obtained clean glaze surface to form an interface transition layer; injecting high-temperature vulcanized silicone rubber onto the surface of the porcelain insulator with the interface transition layer to obtain a complete coated sample, and performing a coating layer separation test on the obtained complete coated sample, and judging the interface bonding quality by observing the porcelain surface state in the non-cutting area; performing a water boiling aging treatment on the judged sample, and performing a coating layer separation test again on the water boiling aged sample to compare the interface state change; performing a dye penetration test on another batch of the same treated sample to assist in verifying the interface compactness, and determining the optimal interface treatment process parameter combination according to the results of the separation test and the dye penetration test.

2. The test method for the interface bonding mechanism of a hybrid porcelain insulator according to claim 1, characterized in that: physically cleaning and chemically decontaminating the porcelain insulator substrate to obtain a clean glaze surface, comprising: placing the porcelain insulator in a 40-kilohertz ultrasonic cleaning tank and cleaning it with 35-degree Celsius deionized water for 15 minutes; immersing the porcelain insulator cleaned by ultrasonic waves in a 3:1 mixed solvent of isopropyl alcohol and acetone for 10 minutes; placing the immersed porcelain insulator in a 60-degree Celsius constant temperature oven for drying for 30 minutes, and measuring the water contact angle on the surface of the dried porcelain insulator as an initial interface state quantitative index.

3. The test method for the interface bonding mechanism of a hybrid porcelain insulator according to claim 2, characterized in that: coating a composite solution of silane coupling agent and surface modifier synergistic effect on the obtained clean glaze surface to form an interface transition layer, comprising: dissolving γ-aminopropyl triethoxysilane in an ethanol-water mixed solvent at a volume fraction of 2% and adjusting the pH to 4.5 for hydrolysis; dispersing 20-nanometer average particle size silicon dioxide particles in deionized water at a mass fraction of 1.5% to form a suspension; mixing the hydrolyzed silane solution and the silicon dioxide suspension at a volume ratio of 4:1 and adding an interface active agent; applying the mixed composite coating liquid to the clean glaze surface by a spin coating process and curing it at 80 degrees Celsius for 1 hour.

4. The test method for the interface bonding mechanism of a hybrid porcelain insulator according to claim 3, characterized in that: injecting high-temperature vulcanized silicone rubber onto the surface of the porcelain insulator with the interface transition layer to obtain a complete coated sample, comprising: mixing two-component high-temperature vulcanized silicone rubber at a mass ratio of 10:1 and vacuum degassing; injecting the degassed high-temperature vulcanized silicone rubber into a mold containing the treated porcelain insulator at an injection pressure of 12 megapascals at 80 degrees Celsius; applying a 5-megapascal holding pressure for 60 seconds after injection, and then heating the mold according to a stepwise temperature program, holding it at 100 degrees Celsius for 30 minutes, and then heating it to 150 degrees Celsius for 60 minutes to complete vulcanization.

5. The test method for the interface bonding mechanism of a hybrid porcelain insulator according to claim 4, characterized in that: performing a coating layer separation test on the obtained complete coated sample, and judging the interface bonding quality by observing the porcelain surface state in the non-cutting area, comprising: using a blade to cut a straight line incision with a depth of 2.8 millimeters and a length of 30 millimeters along the equatorial plane of the sample, and using tweezers to hold one side of the incision at a speed of not more than 5 millimeters per second to uniformly peel off a length of 20 millimeters; observing the porcelain surface in the non-cutting area within a range of 5-25 millimeters from the incision using an optical microscope, and determining the interface bonding quality according to the length of the continuous smooth porcelain surface in the non-cutting area.

6. The test method for the interface bonding mechanism of a hybrid porcelain insulator according to claim 5, characterized in that: performing a water boiling aging treatment on the judged sample, comprising: completely immersing the judged sample in 95-degree Celsius deionized water and continuously boiling it for 168 hours; The water boiled sample is dried with filter paper to remove surface moisture, and the dried sample is placed in a constant temperature oven at 60 degrees Celsius for 24 hours to recover the surface state.

7. The test method for the interface bonding mechanism of a hybrid ceramic insulator according to claim 6, characterized in that: The water boiled sample is again subjected to the coating separation test to compare the interface state changes, including: The separation test operation is repeated on the dried recovered sample, and the length of the continuous smooth porcelain surface exposed after water boiling and aging is recorded; The recorded continuous smooth porcelain surface length is compared with the pre-aging data to evaluate the interface durability; When the continuous smooth porcelain surface length after water boiling and aging is not more than 2 millimeters, the interface is determined to have good hydrolysis resistance.

8. The test method for the interface bonding mechanism of a hybrid porcelain insulator according to claim 7, characterized in that: Another batch of the same treated sample is subjected to dye penetration test to assist in verifying the interface density, including: Prepare a 0.5% methylene blue aqueous solution as the penetration medium; Soak the sample in a 60 degrees Celsius methylene blue solution for 72 hours, and rinse the sample surface with flowing deionized water for 30 minutes; Observe the HTV and porcelain interface dye coloring by cutting the high temperature vulcanized silicone rubber coating along the axial direction.

9. The test method for the interface bonding mechanism of a hybrid ceramic insulator according to claim 8, characterized in that: Determine the interface bonding quality according to the continuous smooth porcelain surface length in the non-cutting area, including: When the continuous smooth porcelain surface length in the non-cutting area is not more than 2 millimeters and the surface is covered with high temperature vulcanized silicone rubber debris, it is determined that the interface bonding is good; When the continuous smooth porcelain surface length in the non-cutting area is more than 5 millimeters, it is determined that the interface bonding is poor; Perform water boiling and aging test on the sample with good interface bonding to verify long-term stability; Adjust the concentration of silane coupling agent and the ratio of surface modifier for the sample with poor interface bonding.

10. The test method for the interface bonding mechanism of a hybrid porcelain insulator according to claim 9, characterized in that: Determine the optimal interface treatment process parameter combination based on the results of the separation test and dye penetration test, including: Design an orthogonal test to adjust the silane coupling agent concentration in the range of 1% to 3%; Control the mass fraction of nano-silicon dioxide particles in the range of 0.5% to 2.0%; Set the interface transition layer curing temperature in the range of 60 degrees Celsius to 100 degrees Celsius; According to the length of the smooth porcelain surface after water boiling and aging and the area ratio of dye penetration, the optimal parameters are determined as silane coupling agent concentration 2.0%, nano-silicon dioxide mass fraction 1.5%, and curing temperature 80 degrees Celsius.

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