Composite insulators operating in warm and humid climates are highly susceptible to microbial contamination, particularly the adhesion of green algae, which leads to the degradation of surface hydrophobicity and insulation performance. To address this issue, a ZnO/SiO₂ composite superhydrophobic coating was designed and fabricated in this study. Through the synergistic action of a primer–topcoat gradient architecture, the coating integrates a physical water-repelling barrier with the intrinsic antibacterial functionality of ZnO, enabling dual protection. The coating was fabricated by combining a sol–gel synthesis of ZnO/SiO₂ nanocomposites with a layered spraying process to build a primer–topcoat structure. The results show that the coating effectively suppresses the adhesion of green algae and the formation of biofilms through physical repulsion from the rough surface and chemical inhibition arising from the sustained release of Zn²⁺ ions and the photocatalytic generation of reactive oxygen species (ROS) by ZnO nanoparticles. Corrosion-resistance tests further confirm the coating’s stability under highly acidic and alkaline conditions. In addition to its antifouling and antibacterial capabilities, the coating also exhibits favorable electrical properties. Measurements indicate a relative permittivity of 2.39 and a resistivity of 9.7 × 10 ¹⁰ Ω·m under power-frequency conditions, demonstrating that the coating maintains good dielectric performance required for insulator applications. Collectively, this work presents a new protective strategy for composite insulators, offering the combined advantages of superhydrophobicity, long-term antimicrobial activity, and reliable electrical performance.
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