Matrix-embedded metamaterial coating, coated article having matrix-embedded metamaterial coating, and/or method of making the same

A method of making a coated article comprising a low-E coating supported by a glass substrate, the method comprising:

• forming a first matrix layer comprising a matrix material, directly or indirectly on the substrate;
• forming a continuous and uninterrupted donor layer over and contacting the first matrix layer, the donor layer comprising one or more source material(s) selected from the group consisting of:
• Ag, Al, Au, AZO, Be, C, Cr, Cu, ITO, Ni, Pd, Pt, RuO2, Ti, and W;
• and
• following formation of the donor layer, forming a second matrix layer comprising the matrix material over and contacting the donor layer, wherein the first and second matrix layers have thicknesses differing from one another by no more than 20%;
• wherein the coated article with at least the first and second matrix layers and the donor layer thereon are heat treatable to cause the source material(s) in the donor layer to self-assemble into a synthetic layer comprising a discontinuous collection of formations distributed in the matrix material, the formations having a major distance no larger than 300 nm, the synthetic layer having resonance in a frequency range suitable for the low-E coating.

A method of making a coated article comprising a low-E coating supported by a glass substrate, the method comprising:

• having a plurality of layers formed on the substrate, the layers including:
• (a) a first matrix layer comprising a matrix material, directly or indirectly on the substrate, (b) a donor layer comprising Ag over and contacting the first matrix layer, and (c) a second matrix layer comprising the matrix material over and contacting the donor layer, wherein the first and second matrix layers have thicknesses differing from one another by no more than 20%;
• and
• heat treating the coated article with at least the first and second matrix layers and the donor layer thereon to cause the Ag in the donor layer to self-assemble into a discontinuous collection of formations distributed in the matrix material in forming a metamaterial inclusive layer, the metamaterial inclusive layer having resonance in a selected frequency range suitable for the low-E coating.

An intermediate article, comprising:

• a glass substrate;
• a first matrix layer comprising a matrix material, located directly or indirectly on the substrate;
• a donor layer comprising Ag located over and contacting the first matrix layer;
• and
• a second matrix layer comprising the matrix material located over and contacting the donor layer, wherein the first and second matrix layers have thicknesses differing from one another by no more than 20%;
• wherein the intermediate article is heat treatable with at least the first and second matrix layers and the donor layer thereon to cause the Ag in the donor layer to self-assemble into a discontinuous collection of formations distributed in the matrix material in forming a metamaterial inclusive layer that emits resonances in a desired wavelength range based at least in part on the formations located therein.