Thermo-Photo Dual-Curing Enables Dense Polymer Networks Toward Robust and Fluorine-Free Superhydrophobic Coatings

Superhydrophobic surfaces have demonstrated broad application prospects in fields such as antifouling, self-cleaning, and anti-icing. However, their insufficient mechanical durability has significantly hindered practical large-scale application. This study presents a highly durable fluorine-free superhydrophobic coating fabricated via a thermo-photo dual-curing mechanism. The modified silicone resin first undergoes thermally induced silanol condensation to form a primary network, then initiates free radical polymerization via UV light with butyl methacrylate to establish a secondary network. This interpenetrating dual-network firmly anchors micro‑/nano‑fillers, greatly improving wear resistance. Nano‑silica (n‑SiO₂) provides essential roughness, while surface‑modified h‑BN enhances mechanical robustness through its unique micro‑scale lamellar structure. Furthermore, the dual curing process enriches the surface with densely packed octyl/butyl chains, sharply lowering surface energy for fluorine‑free superhydrophobicity. The coating maintains superhydrophobicity after 66 m of abrasion with 1000‑grit sandpaper under 9.8 kPa and shows excellent chemical/thermal stability. It also exhibits low ice adhesion of 19.6 kPa and a ∼14‑fold longer ice delay time, confirming exceptional anti‑icing performance. When applied to an antenna hood, it suppresses rain‑induced signal attenuation, proving practical value in communication protection. Overall, this work provides a new material‑engineering strategy for durable and environmentally benign superhydrophobic coatings, with promising potential for scalable field applications.