Simple Spray Preparation of Multifunctional Organic–Inorganic Hybrid Coatings for Surface Strengthening of Flat Thin-Sheet Materials

To enhance the mechanical performance and surface hydrophobicity of flat thin-sheet materials, we have developed a facile, environmentally benign, and low-cost synthesis strategy for fabricating a robust waterborne superhydrophobic coating with excellent mechanical reinforcement, via simple spray coating using a non-fluorinated material system (waterborne silicone–acrylic copolymer and silica sol). The functional coating exhibited excellent hydrophobicity (water contact angle: 150°) regardless of the compound of the substrates, which is primarily ascribed to the presence of abundant low-surface-energy methyl groups on the coating’s surface, along with the three-dimensional hierarchical network structure formed via the cross-linked silica network. Owing to the stable cross-linked structure and strong interfacial bonding between the acrylic polymer and silica network, the composite coating exhibited exceptional mechanical reinforcement, coupled with ultrahigh mechanical and chemical stability. Specifically, the maximum flexural fracture load of the modified materials increased from 119 N to 192 N, representing a 62.7% enhancement; similarly, the moisture-induced deflection of the samples had a significant increase from −14.5 mm to −3.01 mm, which confirmed that the mechanical properties of the modified sample and its deformation resistance under high humidity conditions have been significantly enhanced. Notably, the coating retained superior hydrophobicity and mechanical performance even after 50 abrasion cycles, as well as exposure to high-intensity UV radiation and corrosive acidic/alkaline environments. Furthermore, the composite functional coating demonstrated excellent self-cleaning and anti-fouling properties. This functional composite coating offers significant potential for large-scale industrial application.