Dual-Functional Waterborne Polyurethane Composite Coatings Reinforced with Cu@CB and Basalt for Energy-Efficient...

Icing on engineering surfaces poses severe safety and energy challenges under extremely cold conditions. Here, we report a dual-functional waterborne polyurethane (2K-WPU) coating that combines active electrothermal deicing and passive superhydrophobic anti-icing within a single system. A Cu@carbon black (Cu@CB) network constructs a low-resistance pathway, enabling rapid Joule heating to 75.8 °C in 595 s at 0.0024 W cm^-2, cutting the complete ice-melting time to 1/3 of the control. Simultaneously, basalt flakes modified with KH-550 and stearoyl chloride generate a hierarchical micro/nano structure with ultralow surface energy, achieving a water contact angle of 155°, significantly delaying droplet freezing, reducing frost accumulation by ≈40%, and thereby providing effective passive anti-icing protection. Dynamic impact tests reveal that the electrothermal-superhydrophobic synergy facilitates rapid meltwater shedding, suppressing secondary icing, and ensures reliable anti/deicing under harsh conditions. This scalable, eco-friendly composite provides not only a promising strategy for low-energy, high-reliability anti/deicing in wind turbines, aircraft, and outdoor infrastructures but also a materials design paradigm that integrates conductive hybrids with mineral-based superhydrophobic fillers.