This study demonstrates a cost-effective, thin, multifunctional
composite coating system with outstanding thermal insulation for thermal
management and heat shield applications, such as roofs, as well as
outstanding resistance to corrosion. The hydrophobic multifunctional
epoxy composite coating systems were designed with surface-modified
fillers to impart both reduced heat conduction and high infrared reflectance
in a thin coating with a 65–100 μm dry film thickness
(DFT). With a judicial combination of hollow microspheres (HMS) activated
and modified with silica (sHMS) and stearic acid-modified TiO2 (sMO), the developed composite coating attained the highest
thermal insulation property with a temperature drop of 21–31
°C at different distances below the coated panel, which is superior
to the values of temperature drop reported earlier. The high solar
reflectance of the composite coating in the near-infrared (NIR) region
exceeds 72% with a low thermal conductivity of 0.178 W m–1 K–1. After 720 h of exposure in a 3.5 wt % NaCl
solution, the composite coating revealed a corrosion protection efficiency
of 99%. The work demonstrates that high solar reflectivity and low
thermal conductivity must be active simultaneously to achieve superior
thermal shielding in a thin coating on a metal. A careful selection
of fillers and appropriate surface modifications ensures hydrophobicity
and proper distribution of the fillers in the coating for a high barrier
effect to prevent environmental deterioration. With these superior
performance parameters, the developed composite coatings make an essential
contribution to energy sustainability and the protection against environmental
degradation.