PATENT DOCUMENT

Publication Number: US-10280504-B2
Application Number: US-201615269899-A
Country: US
Kind Code: B2

Title: Ion-implanted, anti-reflective layer formed within sapphire material

Abstract:
A sapphire structure including an ion-implanted, anti-reflective layer and a method of forming an ion-implanted, anti-reflective layer within a sapphire component is disclosed. The method includes forming an ion-implanted layer in a sapphire material at a first depth, and annealing the sapphire material to a second depth. The second depth may be greater than or equal to the first depth. The ion-implanted layer may have a first index of refraction, and the sapphire material may have a second index of refraction different from the first index of refraction.

Claims:
What is claimed is: 
     
       1. A method of forming an anti-reflective sapphire component comprising:
 forming an ion-implanted layer in a sapphire material at a first depth, the sapphire material having a composition; and 
 annealing the sapphire material to a second depth that is greater than or equal to the first depth to form an annealed layer between an exterior surface of the sapphire material and the ion-implanted layer; wherein 
 the ion-implanted layer has a first index of refraction and a composition including an amount of implanted ions greater than an amount of implanted ions in the annealed layer; and 
 the annealed layer has a similar composition to the composition of the sapphire material, and the annealed layer has a second index of refraction different from the first index of refraction. 
 
     
     
       2. The method of  claim 1 , wherein:
 the first index of refraction is less than the second index of refraction; and 
 a portion of the sapphire material below the ion-implanted layer has the second index of refraction. 
 
     
     
       3. The method of  claim 1 , wherein forming the ion-implanted layer comprises:
 implanting a first group of ions within the sapphire material to form a first section of the ion-implanted layer; and 
 implanting a second group of ions within the sapphire material to form a second section of the ion-implanted layer; wherein 
 the second section of the ion-implanted layer is positioned adjacent the first section of the ion-implanted layer. 
 
     
     
       4. The method of  claim 3 , wherein:
 the second group of ions and the first group of ions are implanted at the first depth; and 
 the first group of ions substantially encircles the second group of ions. 
 
     
     
       5. The method of  claim 1 , wherein forming the ion-implanted layer comprises:
 implanting a first layer of ions below an exterior surface of the sapphire material; and 
 implanting a second layer of ions below the exterior surface of the sapphire material and above the first layer of ions, the second layer of ions distinct from the first layer of ions. 
 
     
     
       6. The method of  claim 5 , further comprising:
 annealing the sapphire material prior to implanting the second layer of ions, thereby forming an intermediate, annealed layer ultimately positioned between the first layer of ions and the second layer of ions. 
 
     
     
       7. The method of  claim 6 , wherein annealing the sapphire material prior to implanting the second layer of ions comprises forming a top, annealed layer as the exterior surface of the sapphire material. 
     
     
       8. The method of  claim 1 , wherein annealing the sapphire material comprises locally annealing a portion of the sapphire material. 
     
     
       9. The method of  claim 1 , wherein annealing the sapphire material comprises forming a transition portion within the sapphire material that extends into the ion-implanted layer. 
     
     
       10. The method of  claim 1 , wherein the ion-implanted layer is formed at a thickness that is less than the first depth. 
     
     
       11. The method of  claim 1 , wherein:
 the ion-implanted layer is formed at a thickness within the sapphire material and defines an upper interface and a lower interface; 
 the thickness of the ion-implanted layer is configured to induce a quarter-wavelength phase shift between a first portion of light reflecting from the upper interface and a second portion of light reflecting from the lower interface. 
 
     
     
       12. A sapphire component comprising:
 an internal layer having a composition; 
 an ion-implanted layer formed between the internal layer and an exterior surface of the sapphire component, the ion-implanted layer having a first index of refraction and a composition including an amount of implanted ions greater than an amount of implanted ions in the internal layer; and 
 an annealed layer between the exterior surface and the ion-implanted layer, the annealed layer having a composition substantially similar to the composition of the internal layer and a second index of refraction that is different than the first index of refraction. 
 
     
     
       13. The sapphire component of  claim 12 , wherein the first index of refraction is lower than the second index of refraction. 
     
     
       14. The sapphire component of  claim 12 , wherein a thickness of the annealed layer is less than approximately 1 micron. 
     
     
       15. An electronic device comprising:
 a housing; 
 a display module positioned within the housing; and 
 a sapphire cover coupled to the housing and positioned over the display module, the sapphire cover comprising:
 an internal layer having a composition; 
 an ion-implanted layer formed within the sapphire cover above the internal layer and having a first index of refraction and a composition including an amount of implanted ions greater than an amount of implanted ions in the internal layer; and 
 an annealed layer positioned above the ion-implanted layer and forming an exterior surface of the sapphire cover, the annealed layer having a second index of refraction different than the first index of refraction and a composition substantially similar to the composition of the internal layer. 
 
 
     
     
       16. The electronic device of  claim 15 , wherein the ion-implanted layer comprises:
 a first section comprising a first group of ions implanted in the first section; and 
 a second section positioned adjacent the first section, the second section comprising a second group of ions implanted in the second section; wherein 
 the first group of ions is distinct from the second group of ions. 
 
     
     
       17. The electronic device of  claim 15 , wherein:
 the ion-implanted layer is a first ion-implanted layer; and 
 a second ion-implanted layer is positioned between the exterior surface and the first ion-implanted layer. 
 
     
     
       18. The electronic device of  claim 17 , wherein:
 the first ion-implanted layer is separated from the second ion-implanted layer by an intermediate annealed layer; and 
 the second ion-implanted layer is positioned between the intermediate annealed layer and a top annealed layer. 
 
     
     
       19. The electronic device of  claim 18 , wherein the intermediate annealed layer is compositionally similar to the annealed layer.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a nonprovisional patent application of and claims the benefit to U.S. Provisional Patent Application No. 62/232,990, filed Sep. 25, 2015 and titled “Ion-Implanted, Anti-Reflective Layer Formed within Sapphire Material,” the disclosure of which is hereby incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The disclosure relates generally to sapphire material, and more particularly, to a sapphire structure including an ion-implanted layer and a method of forming an ion-implanted layer within a sapphire structure. 
     BACKGROUND 
     Electronic devices continue to become more prevalent in day-to-day activities. For example, smart phones, tablet computers, and electronic devices continue to grow in popularity, and provide everyday personal and business functions to its users. These electronic devices may include displays utilized by the user to interact (e.g., through input/output operations) with the electronic devices and/or receive information therefrom. 
     Conventionally, these displays are made using reinforced or modified glass. However, these glass displays may still be susceptible to damage. Specifically, these conventional screens may scratch, chip or crack when an undesirable impact event or force (e.g., dropped, crushed) occurs with the electronic device. Damage to the screen of the electronic device may render the device partially or completely inoperable and/or may prevent the user from utilizing the electronic device for its intended purposes. 
     Therefore, it is desirable to form a cover that is both strong and has desired optical properties. 
     SUMMARY 
     A method of forming an anti-reflective sapphire component is disclosed. The method comprises forming an ion-implanted layer in a sapphire material at a first depth, and annealing the sapphire material to a second depth. The second depth is greater than or equal to the first depth. Additionally, the ion-implanted layer has a first index of refraction, and the sapphire material has a second index of refraction different from the first index of refraction. 
     A sapphire component comprising an ion-implanted layer formed within the sapphire component and below an exterior surface of the sapphire component is disclosed. The ion-implanted layer has a first index of refraction. The sapphire component also comprises an annealed layer positioned between the exterior surface and the ion-implanted layer. The annealed layer has a second index of refraction that is different than the first index of refraction. 
     An electronic device is disclosed. The electronic device comprises a housing, a display module positioned within the housing, and a sapphire cover coupled to the housing and positioned over the display module. The sapphire cover comprises at least one ion-implanted layer formed within the sapphire cover. The at least one ion-implanted layer has a first index of refraction. The sapphire cover also comprises an annealed layer positioned above the at least one ion-implanted layer and forming an exterior surface of the sapphire cover. The annealed layer has a second index of refraction different than the first index of refraction. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements: 
         FIG. 1A  shows an isometric view of a sapphire component, according to embodiments. 
         FIG. 1B  shows a side cross section view of the sapphire component of  FIG. 1A  taken along line  1 B- 1 B having an ion-implanted layer and a top, annealed layer, according to embodiments. 
         FIG. 2  shows a flow chart of an example process for forming an ion-implanted layer within a sapphire component, according to embodiments. 
         FIGS. 3A-3C  show a side view of a sapphire component undergoing a process for forming an ion-implanted layer within the sapphire component, as shown in  FIG. 2 , according to embodiments. 
         FIG. 4  shows a side view of a sapphire component having a group of ion-implanted layers and a group of annealed layers, according to embodiments. 
         FIG. 5  shows a side view of a sapphire component having an ion-implanted layer and a top, annealed layer, according to additional embodiments. 
         FIG. 6  shows a side view of a sapphire component having an ion-implanted layer and a top, annealed layer, according to further embodiments. 
         FIG. 7  shows a side view of a sapphire component having an ion-implanted layer and a top, annealed layer, according to another embodiment. 
         FIG. 8  shows a side view of a sapphire component having an ion-implanted layer and a top, annealed layer, according to an additional embodiment. 
         FIG. 9  shows an isometric view of an electronic device that may utilize the sapphire component having an ion-implanted layer and a top, annealed layer as discussed with respect to  FIGS. 1-8 , according to embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     The following disclosure relates generally to sapphire material, and more particularly, to a sapphire structure including an ion-implanted layer and a method of forming an ion-implanted layer within a sapphire structure. 
     In a particular embodiment, the sapphire material, structure or component can include an ion-implanted layer formed or positioned within the sapphire component and a top, annealed layer forming an exterior surface of the sapphire component. The ion-implanted layer may be positioned between the top, annealed layer and a remaining or materially unaltered, interior portion of the sapphire component. The top, annealed layer, which is substantially free from the ions implanted in the sapphire component, is annealed to substantially heal the annealed layer from surface defects (e.g., cracks, artifacts, breaks and so on) formed during the ion implantation process. The ion-implanted layer may be formed by performing an ion-implantation process on the sapphire material or component. Additionally, the top, annealed layer may be formed by performing an annealing process on the sapphire material, subsequent to performing the ion-implantation process. 
     The ion-implanted layer of the sapphire component may include distinct optical properties from the remaining portions of the sapphire component. One or more ion-implanted layers may be used to reduce the reflective properties of the sapphire to produce an anti-reflective sapphire component. In particular, by implanting or embedding ions into a layer or region of the sapphire component, the amount of light that is reflected off an ion-treated surface of the sapphire may be reduced as compared to an untreated sapphire surface. In some instances, the ion-implanted layer may include an index of refraction that is lower than the sapphire material, which forms the remaining portion of the sapphire component. The formation and/or inclusion of the ion-implanted layer having the lower index of refraction lowers the index of refraction for an initial layer of the sapphire component which light passes through. This may result in a sapphire component having a treated surface that is less reflective than an untreated surface. The reduction in the reflective characteristics of the sapphire component may improve functionality and usability of the sapphire structure when the sapphire structure is used, for example, as a cover for an electronic device. 
     An ion-implanted layer may reduce reflectivity of the sapphire component by absorbing at least some of the light incident on the surface of the sapphire component. In one example, the ion-implanted layer may increase the amount of light that passes through the top, annealed layer of the sapphire component, into the ion-implanted portion, and subsequently to the internal layer of the sapphire component. Once the light passes into and/or through the ion-implanted portion, the light may be absorbed and/or dispersed throughout and contained within the internal layer and/or ion-implanted layer without being reflected back through the top, annealed layer. In some cases, a significant amount of the incident light is absorbed and/or dispersed throughout the internal layer and/or ion-implanted layer, and the amount of light that is reflected off the sapphire component is reduced. 
     Further, the inclusion of the ion-implanted layer may reduce reflectivity of the sapphire component by creating a phase shift in the reflective light to cause a destructive phase interaction and/or to attenuate the light reflecting from the ion-implanted layer. In a non-limiting example, the ion-implanted layer includes a thickness that is a fraction of a center wavelength of the incident light, such that a first portion of light passing through the top, annealed layer to the ion-implanted layer reflects off a first or upper interface of the ion-implanted layer and second portion of light reflects off a second or lower interface of the ion-implanted layer. As a result of the specific thickness of the ion-implanted layer, the second reflective light may reflect with a quarter-wavelength phase shift from the first reflective light portion. The quarter-wavelength phase shift in the second reflective light portion may cause a destructive phase interaction with the first reflective light portion, which ultimately may reduce and/or substantially attenuate the amount of reflective light of the treated surface of the sapphire. The light incident light includes any visible light within the visible light spectrum (e.g., wavelengths between 390 nanometers (nm) and 700 nm). Additionally, the light reflected at a quarter-wavelength phase shift is also within the visible light spectrum, but as discussed above, is shifted a quarter-wavelength from the incident light. 
     The top, annealed layer of the sapphire component may heal, rework and/or restore the material of the sapphire component exposed to the ions of a sapphire material. During the ion-implantation process, the material positioned between the exterior surface and the ion-implanted layer may be compositionally altered when the ions pass through. For example, the lattice of the sapphire material may be broken, which may disrupt the crystalline structure of the material and/or may result in surface defects being formed in the portion of the sapphire component exposed to the ions. Additionally, the bombardment of ions creates cracks, breaks and/or other surface defects within the portion of the sapphire component exposed to the ions (e.g., the top layer). This material alteration and/or the formation of surface defects within the top layer may structurally and/or may physically weaken the sapphire component, and may degrade the optical characteristics (transparency, reflectivity, conductivity and so on) of the sapphire component. By annealing this materially altered portion, the portion of the sapphire structure positioned between the exterior surface and the ion-implanted layer may be restored to a substantially uniform crystalline state of the sapphire material, and as such may include the desirable physical properties associated with sapphire material, such as, hardness, scratch-resistance, optical transparency, and so on. Additionally, annealing the top layer exposed to ion-implantation heals the surface defects formed in the top layer and/or seals cracks formed therein to create a smooth, planar exterior surface for the sapphire component. 
     Additionally, the anti-reflective properties for the sapphire component may not be altered when the top, annealed layer of the sapphire component is scratched and/or cracked. Thus, the ion-implanted layer formed within the sapphire component may provide the sapphire component with improved anti-reflective properties. Because the ion-implanted layer is formed below the exterior surface of the sapphire component, the anti-reflective properties of the sapphire component cannot be altered or removed unless the ion-implanted layer is also altered or removed. As a result, the scratches and/or cracks formed within the top, annealed layer do not negatively impact, alter and/or change the improved anti-reflective properties of the sapphire component. 
     These and other embodiments are discussed below with reference to  FIGS. 1-9 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1A  shows an isometric view of a sapphire component. Sapphire component  100 , is shown in  FIG. 1A  as a sheet, but may take the form of any preform structure of sapphire material, for example, a wafer. As discussed herein, sapphire component  100  may take the form of a variety of components. In a non-limiting example, and as discussed herein, sapphire component  100  may be a cover positioned over a display of an electronic device (see,  FIG. 9 ). Sapphire component  100  can be a single component that is in a final shape prior to undergoing the processes discussed herein or, alternatively, is a larger sheet of material that will undergo suitable shaping processes subsequent to undergoing the processes discussed herein. 
       FIG. 1B  illustrates a side cross-section view of sapphire component  100  of  FIG. 1A  taken along line  1 B- 1 B. Sapphire component  100  has an ion-implanted layer and a top, annealed layer, according to some embodiments. As discussed herein, the various layers of sapphire component  100  include lower indexes of refraction than untreated sapphire material which results in improved anti-reflective (AR) properties for sapphire component  100 . The layers of sapphire component  100  also provide sapphire component  100  with the desired physical properties (e.g., strength, hardness and so on) associated with sapphire material. 
     Sapphire component  100 , as shown in  FIG. 1B , may be a piece of artificially grown or naturally occurring corundum, commonly referred to as sapphire, that may be processed to form the ion-implanted layer, and the top, annealed layer, and subsequently used in an electronic device, as discussed herein. The grown corundum used to form sapphire component  100  may be grown using any conventional growth process including, but not limited to: hydrothermal growth; vertical horizontal gradient freezing (“VHGF”); edge-defined film-fed growth (“EFG”); horizontal moving growth (e.g., Bridgman growth); and Kyropoulos growth. 
     Generally, sapphire (e.g., corundum) is an anisotropic material and/or includes anisotropic properties. As a result, the crystallographic orientation of the surfaces of components made from sapphire (e.g., sapphire component  100 ) may affect the physical properties and/or material characteristics (including strength, ductility, and/or elasticity) of the component. The crystallographic orientation of the various surfaces may be dependent on the growing processes used for creating sapphire material forming sapphire component  100  and/or the additional processes (e.g., ion-implantation, annealing) used to form sapphire component  100 . For example, the sapphire from which sapphire component  100  is formed may be grown using an EFG growth process. In the growth process, the seed crystal may include a plane (e.g., M-plane) orientation to yield sapphire that may allow for specific, desired planes to be utilized in components formed from the sapphire material. By knowing the orientation of the seed crystal used in the EFG growth process and ultimately knowing the crystallographic orientation of the grown sapphire material, manufacturers can cut the sapphire material in a specific direction to form sapphire component  100  with surfaces having specific crystallographic plane orientations or substantially desirable crystallographic plane orientations. 
     Knowing the specific plane crystallographic orientation for sapphire component  100  may be important when performing additional processes on sapphire component  100 . Because each plane orientation for sapphire material includes distinct physical characteristics, the operational parameters for the processes performed on the sapphire material may vary dependent on the plane orientation of the sapphire material. In non-limiting examples, the operational parameters for implanting ions within and/or annealing a portion of sapphire component  100  may directly depend on the crystallographic plane orientations of the sapphire material forming sapphire component  100 . 
     As shown in  FIG. 1B , sapphire component  100  may include an unaffected or unaltered interior layer  102  positioned adjacent to and/or internally from ion-implanted layer  104  and top, annealed layer  106 , where ion-implanted layer  104  separates unaltered interior layer  102  and top, annealed layer  106 . Additionally, unaltered interior layer  102  may be positioned opposite exterior surface  108  of sapphire component  100  to form a body or internal portion of sapphire component  100 . As discussed herein, unaltered interior layer  102  may include a portion of sapphire component  100  that remains substantially unaffected, unaltered and/or unchanged by the processes performed on sapphire component  100  to form ion-implanted layer  104  and top, annealed layer  106 . As such, it is understood that the material composition of unaltered interior layer  102  of sapphire component  100  is sapphire material and may remain sapphire material during the processing of sapphire component  100 , as discussed herein. 
     As shown in  FIG. 1B , sapphire component  100  may also include ion-implanted layer  104  positioned between unaltered interior layer  102  and top, annealed layer  106 . Ion-implanted layer  104  may include optical characteristics distinct from unaltered interior layer  102  and annealed layer  106 , respectively. In non-limiting examples, the distinct optical characteristics of ion-implanted layer  104  may include, but are not limited to, an index of refraction that is distinct or different from the index of refraction for top, annealed layer  106  and/or unaltered interior layer  102 . 
     The distinct optical characteristics of ion-implanted layer  104  may ultimately affect the optical properties of sapphire component  100 , including, but not limited to, reducing the reflective properties and/or characteristics of sapphire component  100  and/or providing sapphire component  100  with anti-reflective (AR) properties. The reduction in the reflective properties and/or providing sapphire component  100  with AR properties is achieved in a variety of ways. In a non-limiting example, and as discussed herein, the index of refraction for ion-implanted layer  104  is lower than the index of refraction for top, annealed layer  106  and/or interior layer  102  of sapphire component  100 . As a result, the overall index of refraction for sapphire component  100  is the average index of refraction for the various layers (e.g., top, annealed layer  106 , ion-implanted layer  104 , and so on) forming sapphire component  100 . As a result of ion-implanted layer  104  having an index of refraction lower than that of sapphire material, which is the material composition of top, annealed layer  106  and interior layer  102 , light pass through sapphire component  100  with a reduction in reflection of light. 
     In another non-limiting example, ion-implanted layer  104  absorbs distributes, disperses and/or dissipates the light passing through sapphire component  100 . In some implementations, light pass through top, annealed layer  106  of the sapphire component  100  to the ion-implanted layer  104  and subsequently to interior layer  102 . Once the light passes into ion-implanted layer  104  and/or the light is reflected back toward ion-implanted layer  104 , the light is dispersed, distributed and/or dissipated throughout sapphire component  100 , and specifically ion-implanted layer  104 , without reflecting through exterior surface  108 . While being dispersed and reflected within sapphire component  100  and/or ion-implanted layer  104 , the light is contained substantially within sapphire component  100 , and/or the amount of reflective light reflecting from sapphire component  100  is substantially reduced. 
     In a further non-limiting example, ion-implanted layer  104  creates a phase shift in the reflective light portions exposed to sapphire component  100  to cause a destructive phase interaction and/or to attenuate the light reflecting from ion-implanted layer  104  and/or sapphire component  100 . Ion-implanted layer  104  includes a particular or predetermined thickness and/or is formed a predetermined depth within sapphire component  100 , as discussed herein. As such, a light passing through ion-implanted layer  104  interacts and/or creates two reflective light portions reflecting from ion-implanted layer  104 . In a non-limiting example, the first reflective light portion reflects from an upper, first interface  110  of ion-implanted layer  104  and reflects toward top, annealed layer  106 . A second reflective light portion reflects from a lower, second interface  112  of ion-implanted layer  104  and also reflects toward top, annealed layer  106 . However, the thickness and/or depth for which ion-implanted layer  104  is formed, and the resulting distance between first interface  110  and second interface  112  of ion-implanted layer  104  creates a quarter-wavelength phase shift between the first reflected light portion and the second reflective light portion. The quarter-wavelength phase shift between the two reflective light portions cause a destructive phase interaction, which ultimately destroys both reflective light portions and/or substantially attenuates both reflective light portions as the light reflect from sapphire component  100 . 
     Ion-implanted layer  104 , as shown in  FIG. 1B , may be formed within sapphire component  100  and/or positioned a predetermined depth within sapphire component  100  and/or a predetermined distance (D 104 ) from exterior surface  108  of sapphire component  100 . The predetermined distance (D 104 ) for ion-implanted layer  104  may be dependent on the desired optical characteristics ion-implanted layer  104  requires to affect the optical properties (e.g., reflectivity) of sapphire component  100 . In a non-limiting example discussed herein, the predetermined depth (D 104 ) and/or thickness for ion-implanted layer  104  may create a quarter-wavelength phase shift in the reflective light reflecting from ion-implanted layer  104 , resulting in destructive phase interaction and/or attenuation of the reflective light. As discussed herein, the predetermined distance (D 104 ) may be based, at least in part, on the crystallographic orientation of sapphire component  100  and/or the operational and/or compositional parameters of the ion-implantation process performed on sapphire component  100  to form ion-implanted layer  104 . Similar to the predetermined distance (D 104 ), and as discussed herein, ion-implanted layer  104  is also formed to a predetermined thickness, that also influences and/or affects the optical and/or optical properties (e.g., reflectivity) of sapphire component  100 . 
     Sapphire component  100  may also include top, annealed layer  106 . As shown in  FIG. 1B , top, annealed layer  106  may be positioned proximate to unaltered interior layer  102 , and may be separated from unaltered interior layer  102  by ion-implanted layer  104 . Additionally, top, annealed layer  106  may form exterior surface  108  of sapphire component  100 . Top, annealed layer  106  may be formed within sapphire component  100  at a predetermined depth and/or may include a predetermined thickness (T 106 ). In non-limiting examples, the predetermined thickness (T 106 ) of top, annealed layer  106  may be less than approximately 1 micron (μm), and more specifically, may be between approximately 200 nanometers (nm) and approximately 900 nm. As discussed herein, the predetermined thickness (T 106 ) of top, annealed layer  106  may be based on the type of annealing process performed on sapphire component  100 , the operational parameters of the annealing process performed on sapphire component  100 , and/or the predetermined distance (D 104 ) ion-implanted layer  104  is positioned and/or spaced apart from exterior surface  108  of sapphire component  100 . 
     As discussed herein, top, annealed layer  106  may undergo an annealing process subsequent to the ion-implantation process performed on sapphire component  100 . The annealing process anneals the portion of sapphire component  100  positioned above ion-implanted layer  104  that may be materially and/or compositionally altered during the ion-implantation process. As a result of the annealing process, top, annealed layer  106  of sapphire component  100  may be materially and/or compositionally similar to unaltered interior layer  102 . In a non-limiting example, top, annealed layer  106  may be formed from sapphire material, similar to the sapphire material forming unaltered interior layer  102 . 
     The annealing of top, annealed layer  106  may heal, reflow, rework and/or restore the portion (e.g., top, annealed layer  106 ) of sapphire component  100  positioned adjacent ion-implanted layer  104  that may be exposed to and/or damaged during the ion-implantation process. When sapphire component  100  is bombarded with ions to form ion-implanted layer  104 , the portion of sapphire component  100  that the ions pass through to form ion-implanted layer  104  may be damaged (e.g. surface defects) and/or materially/compositionally altered. For example, the ions passing through the portion of sapphire component  100  positioned adjacent ion-implanted layer  104  may destroy and/or alter the lattice structure of the sapphire material forming top layer  106  of sapphire component  100 . In a non-limiting example, the disruption of the crystalline structure can cause top layer  106  of sapphire structure  100  to be an amorphous material. Additionally, the ions passing through top layer  106  may form surface defects, such as cracks, chips and/or breaks in sapphire component  100 . Performing the annealing process forms top, annealed layer  106  to have similar material and/or compositional properties or characteristics as unaltered interior layer  102  (e.g., sapphire material). Additionally, the annealing process may heal all surface defects and/or fill any cracks formed in top layer  106  during the ion-implantation process. As a result, the exterior surface of sapphire component  100  formed by top, annealed layer  106  may include all the positive and/or beneficial physical, chemical and/or transparent characteristics associated with sapphire material. Annealing top, annealed layer  106  of sapphire component  100 , top, annealed layer  106  may be restored to its original material composition of sapphire and, with that, the strength, optical clarity, and surface finish of top, annealed layer  106  may also be restored. 
       FIG. 2  depicts an example process  200  for forming an ion-implanted coating within a sapphire material or structure. This process may be used to form one of the various embodiments as discussed above with respect to  FIGS. 1, and 3A-7 . 
     In operation  202 , ions are implanted and/or embedded below an exterior surface of a sapphire material to form an ion layer. Ions are implanted within the sapphire material by providing accelerated ions to the sapphire material to achieve ion diffusion within the sapphire. Implanting ions within the sapphire material also includes providing accelerated ions to the sapphire material to achieve phase segregation within the sapphire component. The implantation of the ions within the sapphire material may be performed over the entire sapphire material, or may be implanted locally. In some instances, the entire sapphire material may undergo an ion-implantation process, or alternatively, only a select or local portion of the sapphire material can be implanted with ions, where only the select or local portion of the sapphire material requires an alteration in the optical properties and/or characteristics (e.g., improved anti-reflective properties), as discussed herein. 
     The ion layer is formed a first, predetermined depth within the sapphire material, and/or a predetermined distance away from the exterior surface of the sapphire material. The composition of the ions and/or operational parameters of the ion-implantation process affect the depth in which the ion layer is formed within the sapphire material. The predetermined distance is based, at least in part, on the crystallographic orientation of the sapphire material and/or the operational and/or compositional parameters of the ion-implantation process performed in operation  202  on the sapphire material. 
     Additionally, the ion layer has a first index of refraction that is different than a second index of refraction of the sapphire material. In a non-limiting example, the first index of refraction for the ion layer is lower than the second index of refraction for the remaining portions of the sapphire material. As discussed herein, the difference in the index of refraction for the ion layer may aid or contribute in improving the anti-reflective (AR) properties of the sapphire material. 
     The implanting of the ions within the sapphire material also includes ion-implanting a first group of ions within the sapphire material to form a first section of the ion layer, and ion-implanting a second group of ions within the sapphire material to form a second section of the ion layer. The second group of ions may be positioned adjacent the first group. In non-limiting examples, the first group of ions is positioned in a distinct layer above and/or below the second group of ions, or alternatively, the second group of ions is formed in the same layer as the first group of ions and is substantially encircled or surrounded within the same layer by the first group of ions. The second group of ions may be compositionally distinct, and/or may be applied to the sapphire material using distinct operational parameters. As such, the second section of the ion layer may be material distinct from the first section and, as a result, may include distinct reflective properties. 
     In response to implanting ions in operation  202 , a top, altered layer is formed within the sapphire material. The top, altered layer is formed adjacent the ion-implanted layer, and is separated from the unaltered interior layer of the sapphire material by the ion-implanted layer. Additionally, the top, altered layer forms the exterior surface of the sapphire material. The top, altered layer formed within the sapphire material as a result of implanting ions within sapphire material includes altered material and/or compositions when compared to the remaining portions of the sapphire material. Specifically, the ions passing through the sapphire material to form the ion-implanted layer form surface defects, such as cracks, chips and/or breaks in the altered layer of the sapphire material. As a result, the top, altered layer exposed to the ions may resemble an amorphous material having surface defects subsequent to the ion implantation process performed in operation  202 . 
     In operation  204 , the exterior surface of the sapphire material is annealed. The exterior surface and at least a portion of the top, altered layer of the sapphire material is annealed. Annealing the exterior surface and/or the top, altered layer of the sapphire material results in the formation of a top, annealed layer positioned adjacent the ion-implanted layer. This annealing process of operation  204 , which results in the formation of the top, annealed layer also includes the formation of the sapphire component having the anti-reflective layer, as discussed herein. That is, the process of annealing the top, altered layer formed in the sapphire material to form top, annealed layer includes forming the sapphire component having the anti-reflective layer. 
     The annealing of the exterior surface and/or the top, altered layer to form the top, annealed layer may also include altering the material and/or compositional characteristics or properties of the top, altered layer to be substantially similar to the material and/or compositional characteristics or properties of the unaltered interior layer of the now formed sapphire component. The annealing process may change or restore the top, altered layer from a layer of material having a damaged crystalline structure back to the uniform crystalline sapphire material, similar to the sapphire component prior to ion-implantation. As a result, the top, annealed layer of the sapphire material forms the exterior surface of the sapphire component, and includes a material (e.g., sapphire) similar to the unaltered interior layer of the sapphire component. 
     Additionally, the annealing process heals any surface defects or cracks forming in the top, altered layer during ion-implantation, as well as smooths the exterior surface. As discussed above, the reworking and/or reflowing of the material forming the top, annealed layer during the annealing process substantially fills and heals all surface defects formed in the sapphire component during the ion-implantation process performed in operation  202 . Additionally as a result of reworking and/or reflowing the material during the annealing process, the exterior surface of the sapphire component is also substantially made smooth and/or planar during the annealing process of operation  204 . 
     The exterior surface and/or the top, altered layer of the sapphire component may be annealed to a second, predetermined depth within the sapphire component. The second predetermined depth in which the exterior surface of the sapphire component is annealed also determines the thickness for the top, annealed layer. The second depth may be distinct from or substantially equal to the first predetermined depth for which ions are implanted within the sapphire component during operation  202 . In a non-limiting example, the annealing of the top, altered layer may include annealing down a second depth substantially equal to the first, predetermined depth of ion-implantation, such that the entire altered layer of the sapphire component is annealed to form the top, annealed layer. In the non-limiting example, the sapphire component includes the top, annealed layer forming the exterior surface of the sapphire component, the ion-implanted layer positioned adjacent the top, annealed layer, and the unaltered interior layer positioned adjacent to the ion-implanted layer, opposite the top, annealed layer. The entire top, altered layer is annealed to transform the top, altered layer into the top, annealed layer. 
     In another non-limiting example, the annealing of the top, altered layer may include annealing down a second depth substantially greater than the first, predetermined depth of ion-implantation, such that the entire top, altered layer of the sapphire component forms the top, annealed layer and anneals a portion of the ion-implanted layer of the sapphire component. The top, annealed layer of the ion-implanted layer of the sapphire component may be considered a transition portion of the sapphire component that is both annealed and includes implanted ions. In the non-limiting example, the sapphire component includes the top, annealed layer forming the exterior surface of the sapphire component, the transition portion positioned between the annealed layer and the ion-implanted layer, the ion-implanted layer and the unaltered interior layer positioned adjacent to the ion-implanted layer, opposite the top, annealed layer. 
     In an additional non-limiting example, the annealing of the altered portion may include annealing down a second depth substantially less than the first, predetermined depth of ion-implantation, such that only a portion of the top, altered layer of the sapphire component forms the top, annealed layer. As a result of only annealing a portion of the altered layer of the sapphire component, the sapphire component may include an unannealed portion of the top, altered layer which may be positioned between the top, annealed layer and the ion-implanted layer. The chemical and/or compositional properties of the unannealed portion of the top, altered layer may not be altered by the annealing process and, as such, may remain the same after the ion-implantation process is performed on the sapphire component. In the non-limiting example, the sapphire component includes the top, annealed layer forming the exterior surface of the sapphire component, the unannealed portion of the top, altered layer positioned between the top, annealed layer and the ion-implanted layer, and the unaltered interior layer positioned adjacent to the ion-implanted layer, opposite the top, annealed layer. 
     In a further non-limiting example, the entire sapphire component can undergo an annealing process. In the non-limiting example, the top, altered layer, the ion-implanted layer and the unaltered interior layer forming the sapphire component may undergo an annealing process. In the non-limiting example, the top, altered layer is converted to the top, annealed layer as similarly discussed herein. Specifically, the entire top, altered layer formed as a result of performing the ion-implantation process on the sapphire component is annealed to form the top, annealed layer. Additionally, the ion-implanted layer and unaltered interior layer may experience the annealing process, and as a result may undergo similar effects as discussed herein. For example, internal cracks or breaks formed in the ion-implanted layer and/or the unaltered interior layer as a result of the ion-implantation process in operation  202  may be healed and/or filled. 
     Any suitable annealing technique and/or annealing device can be used to perform the annealing process in operation  204 . In a non-limiting example where only the top, altered layer of the sapphire component undergoes the annealing process to form the top, annealed layer, the sapphire component experiences local or regional annealing using a suitable annealing device to achieve local annealing. In the non-limiting example, the local or regional annealing can be achieved by exposing the sapphire component to a laser annealing system, a flame annealing system or a flash-lamp annealing system for selectively annealing the top, altered layer of the sapphire component. In another non-limiting example where the entire sapphire component is annealed, the sapphire component can be inserted into an oven or furnace for heating the entire component. In either non-limiting example, the annealing process and/or the annealing device used to anneal the sapphire component anneals a minimal thickness and/or anneals down a minimal depth within the sapphire component to heal the defects and/or anneal the sapphire component without causing warpage and/or distortion within the sapphire component. 
     The formation of the ion-implanted layer in operation  202 , and the subsequent annealing in operation  204 , improves the anti-reflective (AR) properties in the exterior surface, the top, annealed layer and/or the ion-implanted layer of the sapphire component. The change in the index of refraction in the ion-implanted layer of the sapphire component may result in a change, and specifically a lowering, of the overall index of refraction of the sapphire component. As a result, the AR properties of the sapphire component are improved over untreated and/or unaffected sapphire material. Additionally, and as discussed herein, the ion-implanted layer can also create a phase shift within reflected light reflecting from the sapphire component and/or can absorb light passing through the sapphire component to also improve AR properties for the sapphire component. 
     Although shown and discussed as only being performed a single time, it is understood that the ion-implantation process performed in operation  202  and/or the annealing process performed in operation  204  can be performed more than once to form multiple ion-implanted layers and/or annealed layers within the sapphire component. In a non-limiting example, the sapphire component undergoes a first ion-implantation process, similar to operation  202 , to form a first ion-implanted layer within the sapphire component. Portions of the sapphire component formed between the first ion-implanted layer and the exterior surface are materially and/or compositionally altered due to the ion-implantation, as discussed herein. Subsequent to forming the first ion-implanted layer, an intermediate annealed layer is formed within the sapphire component between the first ion-implanted layer and the exterior surface of the sapphire component. The intermediate annealed layer is formed using an annealing process similar to operation  204 . Next in the non-limiting example, the sapphire component undergoes a second ion-implantation process similar to operation  202  to form the second ion-implanted layer. In addition to forming the second ion-implanted layer, the second ion-implantation process may form and/or define the intermediate annealed layer positioned between the first ion-implanted layer and the second ion-implanted layer. Finally, the sapphire component undergoes a second annealing process similar to operation  204  to form a top, annealed layer adjacent the second ion-implanted layer. As similarly discussed herein, the top, annealed layer formed during the second annealing process also forms the exterior surface of the sapphire component. 
       FIGS. 3A-3C  show a side view of a sapphire material undergoing the example process  200  for forming an ion-implanted, anti-reflective coating within a sapphire component  300  (see,  FIG. 3C ) as discussed herein with respect to  FIG. 2 . It is understood that similarly numbered and/or named components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. 
       FIG. 3A  shows a side cross-section view of a sapphire material  301  prior to being processed. Sapphire material  301  may have an exterior surface  308  and an interior layer  302  positioned adjacent exterior surface  308 . In a non-limiting example, sapphire material  301  may be prepared to undergo an ion-implantation process and an annealing process, similar to operations  202  and  204 , respectively. Prior to performing the ion-implantation process and annealing process on sapphire material  301 , and as shown in  FIG. 3A , the material and/or compositional properties of sapphire material  301  may be uniform throughout. The material and/or compositional properties of the interior layer  302  may be substantially identical to the material and/or compositional properties of sapphire material  301  at exterior surface  308 . 
       FIG. 3B  shows a side cross-section view of sapphire material  301  subsequent to performing an ion-implantation process, similar to that of the ion-implantation process of operation  202 . The ion-implantation process may be performed on sapphire material  301  in order to form ion-implanted layer  304  within sapphire material  301 . The ion-implantation process may provide additional energy to the exterior surface  308  of sapphire material  301  via the ions in order to achieve ion diffusion and/or phase segregation within sapphire material  301 . Ions may be directed toward and through exterior surface  308  to be implanted within sapphire material  301  to form ion-implanted layer  304 . This implantation of ions resulting in ion diffusion and/or phase segregation of ion-implanted layer  304  of sapphire material  301  may form a portion (e.g., ion-implanted portion) of sapphire material  301  having distinct optical characteristics when compared to interior layer  302 . In non-limiting examples, the distinct optical characteristics of ion-implanted layer  304  may include, but are not limited to, a distinct index of refraction. As discussed herein, forming ion-implanted layer  304  with a distinct index of refraction improves the anti-reflective (AR) properties of the sapphire component by lowering the overall index of refraction of sapphire material  301 , providing a layer capable of creating a wavelength phase shift for reflective light and/or providing a layer that absorbs, disperses and/or dissipates light emitted through sapphire material  301 . 
     As shown in  FIG. 3B , ion-implanted layer  304  may be formed within sapphire material  301  and/or positioned a first, predetermined depth or distance (D 304 ) from exterior surface  308  of sapphire material  301 . The predetermined depth or distance (D 304 ) for ion-implanted layer  304  may be dependent on the desired optical characteristics ion-implanted layer  304  requires to affect the optical properties (e.g., reflectivity) of sapphire material  301 . Additionally, the predetermined depth or distance (D 304 ) for ion-implanted layer  304  may be determined by the operational and/or compositional parameters of the ion-implantation process performed on sapphire material  301 . In a non-limiting example, the energy level, the acceleration and/or the temperature of the ions used in the ion-implantation process may determine the depth or distance (D 304 ) in which ion-implanted layer  304  is formed within sapphire material  301 . In another non-limiting example, the composition of each ion (e.g., nitrogen, silicon, aluminum, carbon, magnesium), which may be implanted or embedded through and/or within sapphire material  301  to form ion-implanted layer  304 , may determine the depth or distance (D 304 ) of ion-implanted layer  304 . 
     The predetermined depth or distance (D 304 ) in which ion-implanted layer  304  may be formed in sapphire material  301  may be a desired or optimal depth for providing sapphire material  301  with improved optical characteristics and/or lowering the index of refraction of sapphire material  301 . In a non-limiting example, predetermined depth or distance (D 304 ) may be the desired depth for providing sapphire material  301  with optimal anti-reflective (AR) characteristics, while also maintaining enough sapphire material above ion-implanted layer  304  (see, annealed layer  306 ;  FIG. 3C ) to protect sapphire material  301 , as discussed herein. The predetermined depth or distance (D 304 ) of ion-implanted layer  304  may be dependent, at least in part, on the overall dimensions (e.g., thickness, width) of sapphire material  301 , the purpose or utilization of sapphire material  301  within an electronic device, the formation of additional materials or layers on exterior surface  308  of sapphire material  301 , and so on. 
     The operational and/or compositional parameters of the ion-implantation process performed on sapphire material  301  may affect sapphire material  301  in a variety of other ways as well. In a non-limiting example, the operational and/or compositional parameters of the ion-implantation process performed on sapphire material  301  may affect and/or determine the chemical or material composition of ion-implanted layer  304  and/or altered layer  318  of sapphire material  301 , as discussed herein. In another non-limiting example, and in conjunction with the predetermined depth or distance (D 304 ) in which ion-implanted layer  304  is formed within sapphire material  301 , the operational and/or compositional parameters of the ion-implantation process may affect the optical characteristics of ion-implanted layer  304 . 
     Additionally, the crystallographic plane orientation of the sapphire material forming sapphire material  301  may affect and/or influence sapphire material  301  and/or ion-implanted layer  304 . In a non-limiting example, operational and/or compositional parameters of the ion-implantation process performed on sapphire material  301  may be based, at least in part, on the crystallographic plane orientation of sapphire material  301 . For example, where sapphire material  301  and/or exterior surface  308  are formed with an M-plane crystallographic orientation, which is associated with improved hardness for sapphire material  301 , the acceleration of the ions may be greater than the acceleration of the ions being implanted in a sapphire material having a different crystallographic orientation. In another non-limiting example, and distinct from or taken in conjunction with the influence on the operational and/or compositional parameters of the ion-implantation process, the crystallographic plane orientation of sapphire material  301  may affect or influence the optical characteristics of ion-implanted layer  304  formed in sapphire material  301 . For example, C-plane sapphire material may be the least reflective crystallographic orientation for sapphire material. 
     As shown in  FIG. 3B , performing the ion-implantation process on sapphire material  301  may result in the formation of top, altered layer  318 . Altered layer  318  may be formed between ion-implanted layer  304  and exterior surface  308  of sapphire material  301  as a result of ions passing through sapphire material  301  at exterior surface  308 . The material and/or compositional characteristics or properties of top, altered layer  318  may be altered and/or different from material and/or compositional characteristics or properties of ion-implanted layer  304  and interior layer  302  of sapphire material  301 . In a non-limiting example, the ions passing through altered layer  318  of sapphire material  301  to form ion-implanted layer  304  may alter and/or destroy the lattice structure of the sapphire material forming sapphire material  301 , which may result in the altering or changing of the material and/or compositional characteristics or properties of altered layer  318 . This may also result in top, altered layer  318  no longer having a crystalline material structure, but rather, top, altered layer  318  is an amorphous material after performing the ion-implantation process. 
     The processes performed on sapphire material  301  as shown and discussed herein with respect to  FIG. 3B  may correspond to operation  202  of the process  200  shown in  FIG. 2 . 
       FIG. 3C  shows a side cross-section view of sapphire component  300  subsequent to performing an annealing process on sapphire material  301  (see,  FIG. 3B ). The annealing process performed on sapphire material  301 , which corresponds to operation  204 , may anneal at least a portion of top, altered layer  318  ( FIG. 3B ) to form top, annealed layer  306  within sapphire material  301 . Top, annealed layer  306  may form exterior surface  308  and may be formed between exterior surface  308  of sapphire material  301  and ion-implanted layer  304 . The annealing process may be performed on sapphire material  301  using any suitable annealing technique that may selectively anneal portions of a material. In non-limiting examples, sapphire material  301  may be exposed to a laser or a flash-lamp for selectively annealing at least a portion of altered layer  318  of sapphire component  300  to form annealed layer  306 . 
     The formation of top, annealed layer  306  also forms sapphire component  300 , and/or transforms sapphire material  301  (see,  FIG. 3B ) to sapphire component  300  having an ion-implanted, anti-reflective layer as discussed herein. As such,  FIG. 3C  refers to the previously discussed sapphire material  301  as sapphire component  300 . 
     Top, annealed layer  306  may be formed from at least a portion of altered layer  318  of sapphire component  300 . In a non-limiting example shown in  FIG. 3C , and with comparison to  FIG. 3B , the entirety of altered layer  318  may be annealed to form annealed layer  306  in sapphire component  300 . Annealed layer  306  may also have a predetermined thickness (T 306 ) and/or may be formed from a predetermined depth within sapphire component  300 . In the non-limiting example shown in  FIG. 3C , the predetermined thickness (T 306 ) of top, annealed layer  306  may be the dimension or area between exterior surface  308  of sapphire component  300  and ion-implanted layer  304 , such that top, annealed layer  306  may substantially end where ion-implanted layer  304  begins. In additional non-limiting examples discussed herein, only a portion of altered layer  318  may be annealed, or alternatively, all of altered layer  318  and a portion of ion implanted layer  304  may be annealed when forming annealed layer  306 . The thickness (T 306 ) of annealed layer  306  may be dependent, at least in part, on the annealing technique used to form annealed layer  306  and/or the operational parameters of the annealing process. In non-limiting examples, the operational parameters may include, but are not limited to, the melting temperature of altered layer  318  and/or sapphire material  301 , the melting speed of altered layer  318  and/or sapphire material  301 , the exposure time for sapphire material  301 , and/or the dosage level of the annealing device (e.g., laser, flash-lamp, and so on) used to anneal sapphire component  300 . 
     As a result of annealing altered layer  318  to form annealed layer  306 , the material and/or compositional characteristics or properties of altered layer  318  may be changed to be substantially similar to the material and/or compositional characteristics or properties of the interior layer  302  of sapphire component  300 . The process of annealing altered layer  318  of sapphire component  300  may refurbish, reflow, rework and/or restore altered layer  318  to an annealed layer  306  made of sapphire material substantially similar to interior layer  302  and/or the original material composition of sapphire component  300 . As such, annealed layer  306  of sapphire component  300  forming exterior surface  308  of sapphire component  300  includes a material (e.g., sapphire) similar to interior layer  302  of sapphire component  300 . 
     The processes performed on sapphire material  301  as shown and discussed herein with respect to  FIG. 3C , may correspond to operation  204  of the process  200  shown in  FIG. 2 . 
     By annealing sapphire material  301  (see,  FIG. 3B ) to form annealed layer  306  formed from sapphire material, sapphire component  300  may have exterior surface  308  that has all of the physical, structural and/or compositional benefits of sapphire material. In a non-limiting example, annealed layer  306  forming exterior surface  308  may have the desired and physically beneficial hardness of sapphire material, which ultimately improves the strength and hardness of sapphire component  300 . In a non-limiting example, sapphire component  300  may be scratch resistant on exterior surface  308  as a result of annealed layer  306  being formed from sapphire material. 
     Additionally, top, annealed layer  306  may also include the reflective characteristics of interior layer  302  and/or sapphire material. However, because annealed layer  306  is positioned directly adjacent to ion-implanted layer  304 , which includes distinct optical characteristics (e.g., anti-reflective characteristics, reduced indexes of refraction), the overall reflective characteristic of sapphire component  300  may be reduced. As discussed herein, ion-implanted layer  304 , having distinct optical characteristics that relate to reducing reflective characteristics, may reduce the overall reflectiveness of annealed layer  306 , interior layer  302  and/or sapphire component  300 . In a non-limiting example, the reflective characteristics of the annealed layer  306  and ion-implanted layer  304  may be averaged to determine the reflective properties of sapphire component  300 . Because top, annealed layer  306  is formed from sapphire material and ion-implanted layer  304  has reflective characteristics lower than sapphire material, the average of the reflective characteristics of top, annealed layer  306  and ion-implanted layer  304  may also be lower than sapphire material. As a result, sapphire component  300  may have all of the physical benefits of sapphire material, while also having reflective characteristics lower than just sapphire material. 
       FIG. 4  shows a side cross-section view of a sapphire component  400  having two distinct ion-implanted layers  404   a ,  404   b  and two distinct annealed layers  406 ,  407 . It is understood that similarly numbered and/or named components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. 
     Sapphire component  400  includes a first ion-implanted layer  404   a  positioned directly adjacent unaltered interior layer  402 , and a second ion-implanted layer  404   b  positioned adjacent first ion-implanted layer  404   a . As shown in  FIG. 4 , first ion-implanted layer  404   a  may be positioned closest to unaltered interior layer  402 , and second ion-implanted layer  404   b  may be positioned adjacent exterior surface  408 . As similarly discussed herein, each of the two distinct ion-implanted layers  404   a ,  404   b  may be formed and/or positioned a predetermined depth or distance (D 404a , D 404b ) within sapphire component  400 . Specifically, first ion-implanted layer  404   a  may be positioned a first predetermined depth or distance (D 404a ) within sapphire component  400 , and second ion-implanted layer  404   b  may be positioned a second, distinct predetermined depth or distance (D 404b ) within sapphire component  400 . In a non-limiting example shown in  FIG. 4 , the first predetermined depth or distance (D 404a ) and the second predetermined depth or distance (D 404b ) may be distinct, where the first predetermined depth (D 404a ) is greater than the second predetermined depth (D 404b ). 
     In a non-limiting example shown in  FIG. 4 , first ion-implanted layer  404   a  and second ion-implanted layer  404   b  may be formed to have substantially the same thickness and/or may have the same material and/or compositional properties. Additionally in the non-limiting example, first ion-implanted layer  404   a  and second ion-implanted layer  404   b  may have substantially similar optical characteristics formed during the ion-implantation process, as discussed herein. However, it is understood that first ion-implanted layer  404   a  and second ion-implanted layer  404   b  may include distinct features from one another. In another non-limiting example, first ion-implanted layer  404   a  and second ion-implanted layer  404   b  may have distinct thicknesses, material and/or compositional properties and/or optical characteristics. As discussed herein, the predetermined depth or distance (D 404a , D 404b ), the thickness, material and/or compositional properties and optical characteristics (e.g., index of refraction) of the two ion-implanted layers  404   a ,  404   b  of sapphire component  400  may be dependent, at least in part, on the operational and/or compositional parameters of the ion-implantation process performed on sapphire component  400 . Additionally as discussed herein, first ion-implanted layer  404   a  and second ion-implanted layer  404   b  may be formed in sapphire component  400  to reduce the reflective properties of sapphire component  400 . 
     Sapphire component  400  may also have two distinct annealed layers  406 ,  407 . As shown in  FIG. 4 , intermediate, annealed layer  407  may be positioned between first ion-implanted layer  404   a  and second ion-implanted layer  404   b , and top, annealed layer  406  may be positioned adjacent intermediate annealed layer  407 . Top, annealed layer  406  may be separated from intermediate annealed layer  407  by second ion-implanted layer  404   b . As shown in  FIG. 4 , top, annealed layer  406  may form exterior surface  408  for sapphire component  400 . Although not shown, each of intermediate, annealed layer  407  and top, annealed layer  406  may be formed to have a predetermined thickness (T 406 , T 407 ), as similarly discussed herein with respect to  FIGS. 1 and 2 . The predetermined thicknesses (T 406 , T 407 ) for each of intermediate, annealed layer  407  and top, annealed layer  406  may be similar or distinct. In a non-limiting example shown in  FIG. 4 , a first predetermined thickness (T 407 ) for intermediate, annealed layer  407  may be smaller or thinner than a second predetermined thickness (T 406 ) for top, annealed layer  406 . However, it is understood that the predetermined thicknesses (T 406 , T 407 ) for each of intermediate, annealed layer  407  and top, annealed layer  406  may vary or be similar to improve the reflective properties and/or the physical properties of sapphire component  400 . As discussed herein, the two distinct annealed layers  406 ,  407  of sapphire component  400  may be formed from sapphire material similar to the sapphire material forming interior layer  402 . Additionally, and as discussed herein, the thickness, and material and/or compositional properties of the two annealed layers  406 ,  407  of sapphire component  400  may be dependent, at least in part, on the operational parameters of the annealing process performed on sapphire component  400 . 
       FIG. 5  shows a side cross-section view of sapphire component  500 . As discussed herein, sapphire component  500  includes interior layer  502 , ion-implanted layer  504  and annealed layer  506 , similar to the identically named portions of the sapphire structures discussed herein with respect to  FIGS. 1 and 3A-3C . Redundant explanation of these portions of sapphire component  500  is omitted for clarity. 
     Sapphire component  500  may also include transition portion  520 . As shown in  FIG. 5 , transition portion  520  may be positioned between ion-implanted layer  504  and top, annealed layer  506 . Transition portion  520  may be formed from an annealed segment of ion-implanted layer  504 . The transition portion  520  may be formed during the annealing process performed on sapphire component  500  to form top, annealed layer  506 . During the annealing process, the predetermined depth or thickness (T 506 ) of top, annealed layer  506  may be greater than the depth or thickness of altered material formed between exterior surface  508  and ion-implanted layer  504 . As a result, a portion of ion-implanted layer  504  may also be annealed to form transition portion  520 . Transition portion  520  may have similar or distinct optical characteristics and/or material and/or compositional properties or characteristics as ion-implanted layer  504  and/or top, annealed layer  506 . In a non-limiting example, the optical characteristics and the material or compositional characteristics of transition portion  520  may be distinct from the optical and material characteristics of both ion-implanted layer  504  and annealed layer  506 . 
       FIG. 6  shows a side cross-section view of sapphire component  600 , which includes similar portions and/or features as sapphire component  500 . However, distinct from sapphire component  500  of  FIG. 5 , sapphire component  600  does not include a transition portion  520  positioned between ion-implanted layer  604  and top, annealed layer  606 . Rather as shown in  FIG. 6 , sapphire component  600  includes altered portion  618  positioned between ion-implanted layer  604  and top, annealed layer  606 . As discussed herein, altered portion  618  may include a portion of sapphire component  600  that is exposed to and/or altered by ions passing through sapphire component  600  during the ion-implantation process. Altered portion  618  may be formed as a result of the ion-implantation process and may remain within sapphire component  600  as a result of the formation of top, annealed layer  606  during the annealing process performed on sapphire component  600 . Specifically during the annealing process, the predetermined depth or thickness (T 606 ) of top, annealed layer  606  may be less than the depth or thickness of altered portion  618  formed between exterior surface  608  and ion-implanted layer  604 . As a result, a portion of altered portion  618  may not be annealed when forming annealed layer  606  and may remain in sapphire component  600 . As discussed herein, altered portion  618  may have distinct optical characteristics and/or material and/or compositional properties or characteristics from ion-implanted layer  604  and/or top, annealed layer  606 . 
       FIG. 7  shows a sapphire component  700  having distinct sections  722 ,  724  of ion-implanted layer  704 . As shown in  FIG. 7 , ion-implanted layer  704  may include a first section  722  and a second section  724  positioned adjacent first section  722 . First section  722  and second section  724  of ion-implanted layer  704  may be positioned between top, annealed layer  706  and interior layer  702  of sapphire component  700 . The distinct sections  722 ,  724  of ion-implanted layer  704  may be formed by altering the operational and/or compositional parameters of the ion-implantation process. The first section  722  of ion-implanted layer  704  may be formed by implanting a first group of ions, and second section  724  of ion-implanted layer  704  may be formed by implanting a second group of ions. First section  722  formed from the first group of ions substantially encircle and/or surround second section  724  formed from the second group of ions. Specifically, the first group of ions forming first section  722  may be distinct, materially or compositionally, from the second group of ions forming second section  724 . In another non-limiting example, the composition of the first group of ions forming first section  722  may be distinct from or identical to the composition of the second group of ions forming second section  724 , but the operational parameters for forming first section  722  may be distinct from the operational parameters for forming second section  724 . In the non-limiting example, the energy level, the acceleration, the amount of ions and/or the temperature of the ions used in the ion-implantation process to form first section  722  of ion-implanted layer  704  may be distinct from those operational parameters used in the ion-implantation process to form second section  724 . 
     As a result of the distinction in the composition of the ions and/or operational parameters for forming first section  722  and second section  724 , the optical characteristics and/or the compositional characteristics for first section  722  and second section  724  may also be distinct. The first section  722  and second section  724  of ion-implanted layer  704  may include distinct indexes of refraction, and ultimately different anti-reflective (AR) characteristics. In a non-limiting example, first section  722  may include an inner or central portion of sapphire component  700 , and second section  724  may include a border or boundary portion of sapphire component  700 . In the non-limiting example, and based on the use or utilization of sapphire component  700 , the inner or central portion of sapphire component  700  may require higher anti-reflective (AR) characteristics than the border portions of sapphire component  700 . As such, the composition of the ions and/or operational parameters for forming first section  722  may be different than those forming second section  724 , such that first section  722  includes higher anti-reflective characteristics than second section  724 . 
       FIG. 8  shows a side cross-section view of sapphire component  800 , which includes similar features as the sapphire components discussed herein with respect to  FIGS. 1 and 5 . Specifically, as shown in  FIG. 8 , sapphire component  800  includes internal layer  802 , top, annealed layer  806  and ion-implanted layer  804  formed within sapphire component  800  between internal layer  802  and top, annealed layer  806 . However, distinct from the sapphire components previously discussed, top, annealed layer  806  is primarily formed of a transition portion  820 . As discussed herein with respect to  FIG. 5 , transition portion  820  includes material of sapphire component  800  that is implanted with ions and is subsequently annealed. In a non-limiting example shown in  FIG. 8 , top, annealed layer  806  is formed as transition portion  820 , such that the material composition of top, annealed layer  806  is an annealed portion of ion-implanted layer  804 . As a result, top, annealed layer  806  is not purely a sapphire material, as previously discussed, but rather is formed from annealed, ion-implanted sapphire material. 
     Top, annealed layer  806  formed as transition portion  820  is formed by first implanting ions within sapphire component  800  from exterior surface  808  to a predetermined depth (D 804 ) within sapphire component  800 . As a result, sapphire component  800  temporarily includes only internal layer  802  and ion-implanted layer  804 , which extends from exterior surface  808  to the predetermined depth (D 804 ) within sapphire component  800 . Next, sapphire component  800  undergoes an annealing process, as similarly discussed herein, to form top, annealed layer  806  having a predetermined thickness (T 806 ). However, because the portion of sapphire component  800  formed directly adjacent exterior surface  808  includes ion-implanted material, top, annealed portion  806  is formed from annealed, ion-implanted material (e.g., transition portion  820 ). 
       FIG. 9  shows an isometric view of an electronic device  900 . As discussed herein, electronic device  900  may include various components that may utilize the sapphire structures discussed herein with respect to  FIGS. 1 and 4-8 . As shown in  FIG. 9 , electronic device  900  is implemented as a mobile phone. Other embodiments can implement electronic device  900  differently, such as, for example, as a laptop or desktop computer, a tablet computing device, a gaming device, a display, a digital music player, a wearable computing device or display, a health monitoring device, and so on. 
     Electronic device  900  includes a housing  902  at least partially surrounding a display module, a cover  904  substantially covering the display module and one or more buttons  906  or input devices. Housing  902  can form an outer surface or partial outer surface and protective case for the internal components of the electronic device  900 , and may at least partially surround the display module positioned within an internal cavity formed by housing  902 . Housing  902  can be formed of one or more components operably connected together, such as a front piece and a back piece (not shown). Alternatively, housing  902  can be formed of a single piece operably connected to the display module. Housing  902  may be formed from any suitable material that may house and/or may protect the internal components of electronic device  900 , including the display module. In non-limiting examples, housing  902  may be formed from glass, sapphire or metal. 
     The display module may be substantially surrounded by housing  902  and/or may be positioned within an internal cavity formed by housing  902 . The display module can be implemented with any suitable technology, including, but not limited to, a multi-touch sensing touchscreen that uses liquid crystal display (LCD) technology, light emitting diode (LED) technology, organic light-emitting display (OLED) technology, organic electroluminescence (OEL) technology, or another type of display technology. The display module may be positioned within an internal cavity of housing  902  and may be substantially protected on almost all sides by housing  902 . 
     Cover  904  may be formed integral with and/or may be coupled to housing  902  to substantially cover and protect the display module. Cover  904  may cover at least a portion of the front surface of electronic device  900 . When a user interacts with the display module of electronic device  900 , the user may touch or contact cover  904 . Cover  904  of electronic device  900  may include the sapphire component discussed herein with respect to  FIGS. 1 and 4-7 , to reduce the reflective properties of the cover  904  formed from the sapphire component for electronic device  900 . In a non-limiting example shown in  FIG. 9 , the sapphire component discussed herein (see,  FIGS. 1-8 ) may form cover  904  coupled to housing  902  and positioned over the display module. By utilizing the sapphire component discussed herein to form cover  904  for electronic device  900 , cover  904  may have improved anti-reflective properties and/or characteristics, which may improve visibility, usability and/or operation of the display module of electronic device  900 . 
     Button  906  can take the form of a home button, which may be a mechanical button, a soft button (e.g., a button that does not physically move but still accepts inputs), an icon or image on a display, and so on. Further, in some embodiments, button  906  can be integrated as part of cover  904  of the electronic device  900 . Button  906 , like housing  902 , may be formed from any suitable material that may withstand an undesirable drop event that may occur with electronic device  900 . In non-limiting examples, button  906  may be formed from glass, sapphire or metal. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20160919
Publication Date: 20190507
Grant Date: 20190507
Priority Date: 20150925
Inventors: ROGERS, MATTHEW S.
YUEN, AVERY P.
ZHAO, Xianwei
Assignee: APPLE INC
CPC Classifications: [{"code": "C04B41/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "C23C14/48", "inventive": true, "first": true, "tree": "[]"}, {"code": "C23C14/081", "inventive": true, "first": false, "tree": "[]"}, {"code": "C23C14/48", "inventive": true, "first": true, "tree": "[]"}, {"code": "C04B41/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "C23C14/081", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 58408541