The
interface insulation plays a key role in the long-distance
high-voltage direct current (HVDC) cables. In this paper, four core–shell
ZnO suspensions formed by different alkane coating were prepared for
spraying on the factory joint interface. The chemical, electrical,
and simulation studies were performed on synthesized nanoparticles
and factory joint samples. Results show that the alkane-coated ZnO
exhibits a noticeable surface halo and the thermal weight loss ratio
increases with the increase of the alkane chain. Moreover, with the
increase in the sprayed C1-ZnO concentration (coated by trimethoxymethylsilane)
from 0.005 to 0.1 wt%, the insulating properties of the samples show
an increasing trend at first and then decrease. Furthermore, as the
encapsulated alkane chain increases, a very small concentration of
0.01 wt% of ZnO suspension (C6-ZnO) coated with hexyltrimethoxysilane
was found to be a highly effective spray reagent, which can significantly
reduce the DC electrical conductivity, increase the DC breakdown strength,
and remarkably inhibit the space charge accumulation at the interface.
The microscopic characterization showed a good dispersion of nanoparticles
at the interface. The space charge simulation and molecular simulation
results elucidated the mechanism of the interfacial nanoparticles
to suppress the space charge and insulation property improvement.
This approach provides a new solution for realizing 500 kV or higher
voltage DC cables to achieve long-distance connections and breakpoint
repairs or improve other polymer interface insulation.