PATENT DOCUMENT

Publication Number: US-9977464-B2
Application Number: US-201514836943-A
Country: US
Kind Code: B2

Title: Sapphire cover for electronic devices

Abstract:
A cover for an electronic device and methods of forming a cover is disclosed. The electronic device may include a housing, and a cover coupled to the housing. The cover may have an inner surface having at least one of an intermediate polish and a final polish, a groove formed on the inner surface, and an outer surface positioned opposite the inner surface. The outer surface may have at least one of the intermediate polish and the final polish. The cover may also have a rounded perimeter portion formed between the inner surface and the outer surface. The rounded perimeter portion may be positioned adjacent the groove. The method for forming the cover may include performing a first polishing process on the sapphire component using a polishing tool, and performing a second polishing process on the groove of the sapphire component forming the cover using blasting media.

Claims:
What is claimed is: 
     
       1. An electronic device comprising:
 a housing; 
 a monolithic cover coupled to the housing, the cover comprising:
 an inner surface having an intermediate polish or a final polish, the final polish exhibiting a roughness distinct from the intermediate polish; 
 a groove formed on the inner surface; and 
 an outer surface positioned opposite the inner surface, the outer surface having the intermediate polish or the final polish and defining a rounded perimeter portion surrounding an interior portion of the cover; and 
 
 a decorative ink formed within the groove on the inner surface and having a substantially uniform thickness, the decorative ink comprising:
 a first ink layer; and 
 a second ink layer, wherein 
 
 the first ink layer and the second ink layer partially overlap at a transition point between the groove and an adjoining smooth portion of the inner surface. 
 
     
     
       2. The electronic device of  claim 1 , wherein the cover is formed from a sapphire material. 
     
     
       3. A cover for an electronic device, comprising:
 an inner surface defining a groove and an adjoining smooth portion; 
 a first ink layer positioned on the smooth portion; and 
 a second ink layer positioned on the groove and having a material composition that is distinct from a material composition of the first layer, wherein 
 the second ink layer partially overlaps the first ink layer at an overlap region along a transition point separating the groove and the smooth portion. 
 
     
     
       4. The cover of  claim 3 , wherein:
 a thickness of the first and second ink layers is substantially uniform along the inner surface; and 
 a thickness of the overlap region is greater than the thickness of the first and second ink layers at the transition point. 
 
     
     
       5. The cover of  claim 4 , wherein the thickness of the overlap region varies by a visually imperceptible amount at the transition point. 
     
     
       6. The cover of  claim 3 , wherein the first and second ink layers form a substantially seamless transition along the transition point. 
     
     
       7. The cover of  claim 3 , wherein:
 the inner surface comprises at least one of an intermediate or final polish; and 
 the first and second ink layers are applied over the at least one of the intermediate or final polish. 
 
     
     
       8. The cover of  claim 7 , wherein:
 the cover further comprises an outer surface positioned opposite the inner surface; and 
 the outer surface comprises the final polish. 
 
     
     
       9. The cover of  claim 8 , wherein:
 the intermediate polish is formed by at least one of a polishing brush or blasting media contacting the inner or outer surfaces; and 
 the final polish is formed by a compliant polishing pad contacting the inner or outer surfaces. 
 
     
     
       10. The cover of  claim 3 , wherein the cover is formed from an annealed sapphire material. 
     
     
       11. A cover for an electronic device, comprising:
 an annealed sapphire structure, comprising:
 an inner surface defining a groove and an adjoining smooth portion and having an intermediate polish; and 
 an outer surface defining an exterior of the electronic device and having a final polish; 
 
 a first ink layer positioned along the smooth portion and having a first tapered section at a transition region; and 
 a second ink layer positioned along the groove and having a second tapered section at the transition region and formed along the first tapered section, wherein 
 the first and second tapered sections of the corresponding first and second ink layers define a substantially uniform thickness along the transition region. 
 
     
     
       12. The cover of  claim 11 , wherein
 the smooth portion and the groove abut one another along the inner surface. 
 
     
     
       13. The cover of  claim 12 , wherein the ink layer comprises:
 a first ink layer substantially positioned on the groove; and 
 a second ink layer substantially positioned on the smooth portion. 
 
     
     
       14. The cover of  claim 11 , wherein:
 the first and second tapered sections are complimentary tapered sections; and 
 the substantially uniform thickness is substantially similar to a thickness of the first ink layer along the smooth portion and a thickness of the second ink layer along the groove. 
 
     
     
       15. The cover of  claim 11 , wherein the inner surface is configured for attachment with a housing of the electronic device. 
     
     
       16. The cover of  claim 11 , wherein at least one of the intermediate or final polish is formed from one of a chemical or mechanical polishing process.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a non-provisional patent application of and claims the benefit of U.S. Provisional Patent Application No. 62/129,707, filed Mar. 6, 2015, and titled “Sapphire Cover for Electronic Devices,” and U.S. Provisional Patent Application No. 62/042,533, filed Aug. 27, 2014 and titled “Sapphire Cover for Electronic Devices,” the disclosures of which are hereby incorporated herein by reference in their entirety. 
     FIELD 
     The disclosure relates generally to electronic devices, and more particularly to a cover for an electronic device and methods of forming the cover for the electronic device. 
     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 screens or displays utilized by the user to interact (e.g., through input/output operations) with the electronic devices and/or receive information therefrom. 
     Conventionally, these screens or displays are made from reinforced or modified glass. However, these glass screens may still be susceptible to damage. Specifically, these conventional screens may scratch, chip or crack when an undesirable impact event or force (e.g., drop, crushed) occurs with the electronic device. Damage to the screens 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. 
     The use of the crystalline form of alumina (Al 2 O 3 ) (e.g., corundum), commonly known as sapphire, is becoming a viable option for replacing the glass screen or display. Specifically, with improved manufacturing processes of single crystal sapphire, and the improved functional characteristics (such as hardness and strength) of sapphire over glass, sapphire may be an acceptable replacement material for conventional glass screens and displays. However, the same chemical/elemental characteristics that make sapphire an often-superior material choice over glass may also make the manufacturing of sapphire difficult. That is, due to sapphire&#39;s hardness, processing or shaping sapphire may be difficult. For example, where the sapphire display includes curved or non-planar surfaces, conventional polishing techniques and processes may fall short of providing an adequate or desired polish on the curved or non-planar surfaces of the sapphire. 
     Thus, an improved process for forming and/or polishing a sapphire component including curved or non-planar surfaces may be useful. 
     SUMMARY 
     A method of forming a cover for an electronic device. The method comprises performing a first polishing process using a polishing tool on a planar surface of the sapphire component and/or a groove formed in the sapphire component adjacent the planar portion. The method also comprises performing a second polishing process on the groove of the sapphire component using blasting media. 
     A method of forming a cover for an electronic device. The method comprises forming a groove on an inner surface of a sapphire component, performing at least two intermediate polishing processes on the groove of the sapphire component, annealing the sapphire component, and performing a final polishing process on at least a portion of the annealed sapphire component. 
     An electronic device comprising a housing, and a cover coupled to the housing. The cover may comprise an inner surface having at least one of an intermediate polish, or a final polish, a groove formed on the inner surface, and an outer surface positioned opposite the inner surface. The outer surface may comprise at least one of the intermediate polish, or the final polish. The cover may also comprise a rounded perimeter portion formed between the inner surface and the outer surface. The rounded perimeter portion may be positioned adjacent the groove. 
     A method for applying a decorative ink to a cover for an electronic device. The method comprises pad printing ink on at least a portion of a planar surface of the cover. The portion of the planar surface may be positioned adjacent a groove formed in the cover. The method may also comprise positioning a masking structure on the cover adjacent the groove. The masking comprising a protective film placed on the planar surface, a spacer coupled to a portion of the protective film, and a rigid top component coupled to the spacer. The rigid top component may be positioned over the ink pad printed on at least the portion of the planar surface of the cover. Additionally, the method may comprise directly applying ink to the groove formed in the cover, and diffusively applying ink to at least a portion of the ink pad printed on at least the portion of the planar surface of the cover. 
    
    
     
       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, and in which: 
         FIG. 1  depicts an illustrative perspective view of a wearable electronic device according to embodiments. 
         FIG. 2  depicts an enlarged cross-section view of a portion of the electronic device of  FIG. 1  taken along line  2 - 2 , according to embodiments. 
         FIGS. 3 and 4  depict enlarged cross-section views of a portion of the electronic device of  FIG. 1  taken along line  2 - 2 , according to additional embodiments. 
         FIG. 5  depicts a flow chart of an example process for forming a cover for an electronic device, according to embodiments. 
         FIG. 6A  depicts a cross-sectional view of sapphire material for forming a cover of an electronic device as depicted in  FIGS. 1 and 2 , according to embodiments. 
         FIGS. 6B and 6C  depict cross-sectional views of the sapphire material of  FIG. 6A  undergoing lapping, laser cutting and machining processes for forming the cover for an electronic device as depicted in  FIGS. 1 and 2 , according to embodiments. 
         FIG. 6D  depicts a cross-sectional view of the sapphire material of  FIG. 6A  undergoing intermediate polishing processes for forming the cover for an electronic device as depicted in  FIGS. 1 and 2 , according to embodiments. 
         FIG. 6E  depicts a cross-sectional view of the sapphire material of  FIG. 6A  subsequent to performing the intermediate polishing processes as depicted in  FIG. 6D , according to embodiments. 
         FIG. 6F  depicts a cross-sectional view of the sapphire material of  FIG. 6A  subsequent to performing a final polishing process for forming the cover for an electronic device as depicted in  FIGS. 1 and 2 , according to embodiments. 
         FIG. 6G  depicts a cross-sectional view of the sapphire material of  FIG. 6A  undergoing a preliminary pad printing process for forming the cover for an electronic device as depicted in  FIGS. 1 and 2 , according to embodiments. 
         FIG. 6H  depicts a cross-sectional view of the sapphire material of  FIG. 6A  undergoing a decorative ink application process for forming the cover for an electronic device as depicted in  FIGS. 1 and 2 , according to embodiments. 
         FIGS. 6I and 6J  depict cross-sectional views of the sapphire material of  FIG. 6A  undergoing a subsequent pad printing process for forming the cover for an electronic device as depicted in  FIGS. 1 and 2 , according to embodiments. 
         FIGS. 7A-7E  depict a cross-sectional view of sapphire material for forming a cover of an electronic device as depicted in  FIGS. 1 and 2 , undergoing a decorative ink application process, according to embodiments. 
         FIGS. 8A-8D  depict a cross-sectional view of sapphire material for forming a cover of an electronic device as depicted in  FIGS. 1 and 2 , undergoing a decorative ink application process, according to further embodiments. 
         FIGS. 9A-9D  depict a cross-sectional view of sapphire material for forming a cover of an electronic device as depicted in  FIGS. 1 and 2 , undergoing a decorative ink application process, according to additional embodiments. 
         FIG. 10  depicts a flow chart of an example process for applying a decorative ink to a cover for an electronic device, 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 to electronic devices, and more particularly to a cover for an electronic device and methods of forming the cover for the electronic device. 
     In particular embodiments, processes for forming a cover glass, a housing, or other external feature of an electronic device include performing multiple and distinct polishing processes on some or all of the surfaces of the sapphire material forming the cover. For example, planar portions of the cover may be polished using a variety of polishing processes, such as chemical mechanical polishing (CMP), diamond mechanical polishing (DMP), polishing using polishing pads and/or polishing using blasting media. The polishing processes described herein may reduce surface roughness, smooth a surface, and/or make a surface more reflective or visually uniform. Curved surfaces, such as a rounded perimeter portion or a groove formed within the sapphire material, may be polished using a two-part polishing process. The two-part polishing process may include polishing using polishing pads and polishing using blasting media. The blasting media may be a diamond encrusted resin-based material that may have elastic properties to avoid damaging the surface of the sapphire material during polishing. Additionally, at least a portion of the surfaces of the cover may be polished after an annealing process is performed on the sapphire material. By performing multiple polishing processes, and specifically utilizing a multi-part polishing process for the curved (or otherwise non-planar) surfaces of the sapphire material, the cover may be polished to a desired finish and/or may have desired visual properties when used within an electronic device. 
     In certain embodiments, additional operations may be performed on the sapphire material after it is shaped and polished. For example, an ink can be pad printed on a planar surface of the sapphire material adjacent the curved surface formed in the sapphire material. The planar portions that were previously pad printed are then masked using a masking structure, and the curved portion is exposed. Further ink is than applied to the curved portion, for example by spraying the ink onto the curved portion. This additional ink may be the same type of ink as previously applied, or it may be different. 
     These and other embodiments are discussed below with reference to  FIGS. 1-10 . 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. 1  shows an illustrative perspective view of a portable or wearable electronic device  100  (hereafter, “electronic device”), according to embodiments. Electronic device  100 , as shown in  FIG. 1 , may be implemented as a smart watch, although this is but one example of a suitable electronic device  100 . Electronic device  100  includes, amongst other components discussed herein, a cover  112  having a groove  128  formed therein. As discussed herein, cover  112  protects a display  104  and/or other internal components positioned within a housing  102  of electronic device  100 . Additionally as discussed herein, groove  128  may receive and/or house a communicative component of electronic device  100 , such as an antenna, to reduce the number of components positioned and/or requiring space within housing  102 . 
     For aesthetic, visual and/or protective purposes, groove  128  formed in cover  112  may be polished, inked and/or painted. The polishing, inking and/or painting of groove  128  may provide uniform surface polishes of cover  112 , to provide a uniform color or appearance to a user of electronic device  100  and/or to prevent the antenna positioned within groove  128  from being visible. The geometry of groove  128 , and specifically the curved surface forming groove  128 , may require unique processes for polishing, inking and/or painting the curved surface, when compared to the planar portions of cover  112 , as discussed herein. In one embodiment, groove  128  undergoes a two-part polishing process including performing an initial polishing step using a polishing tool, such as a brush, and subsequently providing a blast media to groove  128  to perform a subsequent polishing step. From there, and after polishing groove  128 , ink may be applied to groove  128  using a spray and/or pad printing process. This process ensures groove  128  has the unique geometry and/or the curved surface is polished and/or inked to a similar finish as the planar portions of cover  112 . 
     In another embodiment, an interior of cover  112  including groove  128  can be inked and/or painted using a two-step process. Initially, certain interior planar portions of cover  112  can be painted, and subsequently masked, leaving groove  128  exposed. Once masked, ink may be sprayed and/or directly applied to groove  128 , such that the masks prevent ink from being sprayed onto the previously painted planar portions of cover  112 . The ink sprayed on groove  128  may be applied such that the ink formed on groove  128  is even with the ink applied to the planar portions of cover  112  (e.g., the resulting ink layer has a thickness that is substantially uniform and lacking in transitions), and/or so there is a seamless transition between the ink applied to the curved portion of cover  112  forming groove  128  and the planar portions of cover  112 . Accordingly, the resulting ink layer covering both groove  128  and planar portions of cover  112  appears continuous and without any transition visible to the human eye. 
       FIG. 2  depicts an enlarged cross-section view of a portion of electronic device  100  of  FIG. 1  taken along line  2 - 2 , according to an embodiment. With respect to this particular embodiment,  FIG. 2  shows a cross-section view of a portion of housing  102  and cover  112  of electronic device  100 . A space or opening  118  may be formed between housing  102  and cover  112 ; the opening  118  may receive additional components of electronic device  100 . More specifically, opening  118  of electronic device  100  may receive and/or may provide space for certain or all internal components of electronic device  100 . In the non-limiting example of  FIG. 2 , display  104  is shown in phantom and may be positioned within at least a portion of opening  118  formed between cover  112  and housing  102 . As discussed herein with respect to  FIG. 1 , display  104  may be formed from any suitable user-interactive display technology, and may have touch-sensing functionality or may be associated with a touch sensor. Additionally, display  104  may be protected by cover  112  positioned above and/or coupled to display  104  positioned within a portion of opening  118  of electronic device  100 . The cover  112  may be transparent or translucent, fully or partially, in certain embodiments. 
     Cover  112  of electronic device  100  may be formed from a substantially annealed and polished sapphire material. That is, and as discussed herein, cover  112  may be formed from an annealed sapphire material having all or some portions of the surface polished prior to and/or subsequent to the annealing. By annealing the sapphire material, cover  112  may be provided with increased hardness, and/or may also have planar surfaces that may be more easily processed and/or may facilitate transparency in the sapphire material forming cover  112 . Additionally, the process of annealing the sapphire material may also fill in or seal cracks or other surface defects formed in the sapphire material during processing. 
     As shown in  FIG. 2 , cover  112  may be coupled to housing  102 . More specifically, a portion of cover  112  may be positioned above and, may be coupled to, a shelf portion  120  formed adjacent a perimeter of housing  102 . Shelf portion  120  may be formed substantially around the entire perimeter of housing  102 , and may receive and/or couple a portion of cover  112  to housing  102 . As shown in  FIG. 2 , cover  112  may be coupled to shelf portion  120  of housing  102  using an adhesive, such as adhesive tape. However, it is understood that cover  112  may be coupled to shelf portion  120  of housing  102  using any suitable coupling component or technique. In additional non-limiting examples, cover  112  of electronic device  100  may be coupled to housing  102  using chemicals, adhesives, bonding agents, laser welding, melting, and mechanical coupling components (snap-fit structures, detents, screws, and the like). 
     Cover  112 , as shown in  FIG. 2 , may define an inner surface  124 , and an outer surface  126  positioned opposite inner surface  124 . Inner surface  124  may be positioned adjacent to opening  118  and may not be exposed to a user of electronic device  100 . As shown in  FIG. 2 , and as discussed herein, display  104  (shown in phantom) may be positioned adjacent to and/or may be coupled to inner surface  124 . Outer surface  126  may be exposed to, and/or may be contacted by a user of electronic device  100  when the user is interacting with display  104 . 
     As shown in  FIG. 2 , cover  112  may have a groove  128  formed on inner surface  124 . More specifically, groove  128  may be formed on inner surface  124 , substantially around the entire perimeter of cover  112 . Groove  128  may be formed partially through a portion of cover  112 . 
     As a result of forming groove  128  on inner surface  124  of cover  112 , the thickness of cover  112  may vary. That is, as shown in  FIG. 2 , a first thickness (T 1 ) of cover  112  may be defined between inner surface  124  of groove  128  and outer surface  126 . This first thickness (T 1 ) may be substantially smaller than a second thickness (T 2 ) of a portion of cover  112  defined in a non-groove bearing region, such as above the display  104 . As discussed herein, the first thickness (T 1 ) may alter and/or affect various polishing processes performed on the sapphire material forming cover  112 . Additionally as discussed herein, groove  128  may be formed in cover  112  using a plurality of processes including laser-cutting groove  128  on inner surface  124 , and subsequently computer numerical control (CNC) machining the laser cut groove  128  formed in cover  112 . 
     Groove  128  may be formed in cover  112  for a variety of functions. In a non-limiting example, groove  128  may be formed in cover  112  to provide additional space within electronic device  100  for additional components. In the non-limiting example, groove  128  may receive and/or may house an antenna (not shown) of electronic device  100 , such that the antenna may be positioned within groove  128  of cover  112  without occupying space within opening  118  of electronic device  100 . The antenna may be used to share (e.g., send, receive) data collected and/or determined by the electronic device  100 . In another non-limiting example, groove  128  may provide a coupling surface for display  104 , where a portion of display  104  may be positioned within and/or coupled to groove  128  to position display  104  adjacent inner surface  124  of cover  112 . 
     In a further, non-limiting example, groove  128  may be formed within cover  112  to provide a visual boundary or border for display  104 . More specifically, and as shown in  FIG. 2 , a decorative ink  150  may be applied to inner surface  124  of groove  128  positioned substantially around the entire perimeter of cover  112 , such that the decorative ink  150  may provide an ink border around display  104  of electronic device  100 . As a result of forming groove  128  between display  104  and housing  102 , decorative ink  150  may be applied to inner surface  124  of groove  128  to provide a decorative border around display  104 , so a user of electronic device  100  may clearly identify the interactive area of display  104 . Decorative ink  150  may be visible through outer surface  126  as a result of the transparent properties of the sapphire material forming cover  112 . As discussed herein, decorative ink  150  may be applied to inner surface  124  of groove  128  using a plurality of pad printing processes and by spraying decorative ink within groove  128 . 
     Cover  112  may also include distinct portions. More specifically, as shown in  FIG. 2 , cover  112  may have a substantially planar or linear portion  132  and rounded perimeter portion  134 . Substantially planar portion  132  may be formed in the center of cover  112  (or as a center of the cover) such that display  104  may be completely visible and/or not distorted by cover  112 . That is, substantially planar portion  132  may be formed adjacent to the perimeter of cover  112 . Display  104  may be formed in substantial alignment with planar portion  132  of cover  112  to allow display  104  to be completely viewed by a user of electronic device  100 , without potentially altering the image of display  104  due to a curvature in cover  112  (e.g., rounded perimeter portion  134 ). 
     Rounded perimeter portion  134  may be formed around at least a portion of the perimeter of cover  112 . More specifically, and as shown in  FIG. 2 , rounded perimeter portion  134  may form the perimeter of cover  112 , and may be positioned adjacent to the perimeter of housing  102 . Rounded perimeter portion  134  may be positioned adjacent to groove  128  formed on inner surface  124 . As shown in  FIG. 2 , rounded perimeter portion  134  may be coupled to shelf portion  120 , and ultimately couple cover  112  to housing  102 . As discussed herein, planar portion  132  and rounded perimeter portion  134  of cover  112  may be formed in a shaping process of the sapphire material used to form cover  112 . That is, and as discussed herein, the sapphire material may be lapped, machined and/or laser cut to from planar portion  132  and rounded perimeter portion  134  of cover  112 . 
     Substantially all surfaces (e.g., inner surface  124 , outer surface  126 ) of cover  112  may be polished. More specifically, as shown in  FIG. 2 , both inner surface  124  and outer surface  126  of cover  112  may have an intermediate polish  136  and/or a final polish  138 . As discussed herein, intermediate polish  136  may be formed on a surface of cover  112  prior to performing an annealing process on the sapphire material forming cover  112 . Additionally as discussed herein, final polish  138  may be formed on a surface of cover  112  subsequent to performing the annealing process on the sapphire material forming cover  112 . 
     In a non-limiting example, as shown in  FIG. 2 , outer surface  126  of cover  112  may only have final polish  138 . That is, final polish  138  may substantially cover all of outer surface  126  of cover  112 , including both planar portion  132  and rounded perimeter portion  134 . Distinct from outer surface  126 , inner surface  124  of cover  112  may have both intermediate polish  136  and final polish  138 . More specifically, as shown in  FIG. 2 , inner surface  124  of planar portion  132  may have final polish  138 , and inner surface  124  of rounded perimeter portion  134  of cover  112  may have intermediate polish  136 . Additionally as shown in  FIG. 2 , intermediate polish  136  may also be formed on inner surface  124  including groove  128  of cover  112 . 
     The respective polishes (e.g., intermediate polish  136 , final polish  138 ) may be formed on distinct portions of cover  112  based on, at least in part, the material used to form cover  112 , the processes used to form cover  112 , and/or the dimensions of cover  112 . For example, dependent on the dimension of first thickness (T 1 ), and/or the difference between first thickness (T 1 ) and second thickness (T 2 ) of cover  112 , a portion or all of the surfaces (e.g., inner surface  124 , outer surface  126 ) of rounded perimeter portion  134  may or may not be polished during a final polishing process, as discussed herein. 
     As one example, certain surfaces may not be polished to avoid and/or prevent damage (e.g., breakage, cracking) to cover  112  during the final polishing process. That is, where first thickness (T 1 ) is below a predetermined threshold thickness inner surface  124  and/or outer surface  126  forming a part of rounded perimeter portion  134  of cover  112  may not be subject to a final polish  138 . The predetermined threshold thickness for cover  112  may be a minimal thickness of rounded perimeter portion  134 , including groove  128 , that may withstand the final polishing process to provide final polish  138  without damaging cover  112 . 
     In a non-limiting example, as shown in  FIG. 2  and discussed herein, cover  112  may be formed from an annealed sapphire material. Additionally as discussed herein, the first thickness (T 1 ) in cover  112  between groove  128  and outer surface  126  may be substantially smaller than the second thickness (T 2 ) in cover  112 . First thickness (T 1 ) may also be substantially equal to, or slightly above, a predetermined threshold thickness for cover  112 . As a result of the dimension of first thickness (T 1 ) of cover  112 , inner surface  124  forming part of rounded perimeter portion  134  of cover  112  may be subject to intermediate polish  136 , and not final polish  138 , to substantially prevent any damage to cover  112 . However, because first thickness (T 1 ) may be substantially equal to, or slightly above, a predetermined threshold thickness, a final polish may be performed or placed on outer surface  126  of rounded perimeter portion  134  without substantially damaging cover  112 . 
     In another non-limiting example, as shown in  FIG. 3 , all surfaces (e.g., inner surface  124 , outer surface  126 ) of cover  112  may include final polish  138 . That is, both inner surface  124  and outer surface  126  of planar portion  132  and rounded perimeter portion  134  of cover  112  may only have final polish  138 . In the non-limiting example shown in  FIG. 3 , all surfaces of cover  112  may have final polish  138  as a result of first thickness (T 1 ) of cover  112  being substantially above or greater than the predetermined threshold thickness, as discussed herein. As such, both inner surface  124  and outer surface  126  of cover  112  may undergo a final polishing process, as discussed herein, without potentially damaging cover  112 . 
     In an additional non-limiting example, as shown in  FIG. 4 , inner surface  124  and outer surface  126  of rounded perimeter portion  134  of cover  112  may include intermediate polish  136 . That is, both inner surface  124  and outer surface  126  of rounded perimeter portion  134  of cover  112  may only have intermediate polish  136 , and inner surface  124  and outer surface  126  of planar portion  132  may have final polish  138 . In the non-limiting example shown in  FIG. 4 , all surfaces of rounded perimeter portion  134  may include intermediate polish  136  as a result of first thickness (T 1 ) of cover  112  being substantially below or smaller than the predetermined threshold thickness, as discussed herein. As such, both inner surface  124  and outer surface  126  of rounded perimeter portion  134  of cover  112  may not undergo a final polishing process, as discussed herein, to prevent and/or avoid damaging cover  112 . 
       FIG. 5  depicts an example process for forming a cover for an electronic device. Specifically,  FIG. 5  is a flowchart depicting one example process  500  for forming a cover for an electronic device. In some cases, the process  500  may be used to form one or more covers  112  for electronic device  100 , as discussed above with respect to  FIGS. 1-4 . 
     In operation  502 , a sapphire component may be shaped. In a non-limiting example, a piece of sapphire material may undergo various shaping processes, to provide a beginning shape of a cover for an electronic device. The shaping of the sapphire component may be achieved by lapping the sapphire material to thin the component. Lapping of the sapphire material may also form planar portions of the sapphire component. The shaping may also be performed by forming a rounded perimeter portion on an outer surface and/or about the perimeter of the sapphire material. 
     As one non-limiting example, rounded perimeter portions may be formed on the sapphire material, adjacent to the planar portions, using a computer numerical control (CNC) machining process. As another example, the rounded perimeter portions may be formed by laser ablating material from the sapphire surface. The shaping process of the sapphire component may further include laser cutting a rough groove into an inner surface of the sapphire material, and subsequently machining the laser cut groove formed in the sapphire material. The machining of the laser cut groove may be accomplished using any suitable material removal process including, but not limited to, CNC machining, drilling, milling, and grinding. Additionally, the rounded perimeter portions and groove formed within the sapphire material may be positioned adjacent one another. That is, the groove may be positioned adjacent to and/or substantially within the rounded perimeter portions formed in the sapphire material. 
     In operation  504 , intermediate polishing processes may be performed on the sapphire component. At least two distinct polishing processes may be performed on portions of the sapphire component, although both need not be performed in a single embodiment. More specifically and by way of example, a first polishing process may be performed on the sapphire component using a polishing brush or other polishing tool, and a second polishing process may be performed on the sapphire component using blasting media. 
     In some embodiments, the first polishing process and the second polishing process may be performed at least on the surfaces of the rounded perimeter portions of the sapphire component, and the groove of the sapphire component. That is, inner and outer surfaces of the rounded perimeter portions, and the groove formed on the sapphire component, may undergo a polishing process using a polishing tool and blasting media. The polishing tool, such as a brush, used in the first polishing process may be any suitable, compliant polishing tool, one example of which is a pig hair brush or pad. The blasting media utilized in the second polishing process may be a diamond encrusted resin-based material, which is a material formed from resin and diamond pieces, fragments, particles and the like. The diamond particles may be encased or otherwise fully or partially contained within the resin. Other materials, such as sapphire, may be used in place of diamond in some embodiments. 
     The diamond encrusted resin-based material may be applied to the surfaces of the rounded perimeter portions of the sapphire component using a dispensing system that may dispense, apply, or otherwise provide the blasting media to the surfaces of the sapphire component with high force or pressure to polish the surface. For example, the diamond encrusted resin-based material may be blown or otherwise propelled toward the surface to be polished. In order to prevent damage to the surface of the sapphire component, the diamond encrusted resin-based material may have substantially elastic properties, and may substantially deform when first contacting the surface of the sapphire component. The rounded perimeter portions and the groove formed in the sapphire component may undergo the first polishing process (e.g., polishing tool) and second polishing process (e.g., blasting media) to ensure the non-linear and/or non-planar surfaces of the rounded perimeter portions and the groove are adequately polished. 
     Intermediate polishing processes may be performed in operation  504 . Specifically, other portions of the sapphire component may undergo distinct polishing processes when performing the intermediate polishing processes on the sapphire component. The planar portions of the sapphire component may be polished using a chemical mechanical polishing (CMP) process and/or a diamond mechanical polishing (DMP) process. These intermediate polishing processes may be performed on the remaining portions of the sapphire component to ensure that all surface of the sapphire component may have an intermediate polish. 
     In operation  506 , the sapphire component may be annealed. In a non-limiting example, the polished sapphire component may undergo an annealing process to strength the sapphire material used to form the cover for the electronic device. The annealing process may substantially fill or seal any cracks or damage of the sapphire component formed during the shaping processes of operation  502  and/or the polishing processes in operation  504 . 
     In operation  508 , a final polishing process may be performed on the sapphire component. In a non-limiting example, a final polishing process may be performed on the surface of at least a portion of the annealed sapphire component. The final polishing process may further include polishing the inner surface of the annealed sapphire component adjacent to, but not within, the groove, or polishing the inner surface of the annealed sapphire component including the groove. The groove may be finally polished using a compliant polishing pad, where at least a portion of the pad may contour into the groove, and polish the portion of the inner surface formed within the groove. In addition, the final polishing process may include polishing the outer surface of the annealed sapphire component adjacent to, but not on, the rounded perimeter portions, or polishing the outer surface of the annealed sapphire component including the rounded perimeter portions. Like the groove, the rounded perimeter portions may be polished using a compliant polishing pad that may contour around the rounded outer surface of the rounded perimeter portions of the sapphire component. 
     The portions of the surface that may undergo the final polishing process may be dependent, at least in part, on the dimension of the rounded perimeter portions formed in the sapphire component, and specifically, the thickness between the inner surface of the groove and the outer surface of the sapphire component. Where the thickness is smaller than a predetermined thickness threshold for the sapphire component, the final polishing of the rounded perimeter portions in operation  508  may damage the sapphire component forming the cover for the electronic device. 
     In optional operation  510 , a decorative ink may be applied to the sapphire component. In a non-limiting example, a decorative ink may be applied to the groove formed on the inner surface of the sapphire component, and/or portions of the cover positioned adjacent the groove. Applying the decorative ink to the groove and/or portions of the cover adjacent the groove may include performing a preliminary pad printing process in the groove. The preliminary pad printing process may provide an initial layer of ink and/or a decorative image to the surface of the groove. 
     Applying the decorative ink may also include covering a portion of the sapphire component positioned adjacent the groove with a protective mask, and subsequently spraying the groove with the decorative ink. The protective mask, covering the portions of the sapphire component adjacent the groove, may prevent any sprayed decorative ink from undesirably contacting or forming on the sapphire component outside of the groove. Finally, the applying of the decorative ink may include performing a subsequent pad printing process in the groove including the decorative ink. The subsequent pad printing process may provide the groove of the sapphire component with the final image, design and/or paint to be viewed by a user of the electronic device including the cover formed from the sapphire component. 
     The final polishing of at least a portion of the sapphire component in operation  508  may form the cover to be utilized and/or implemented within an electronic device. The optional operation  510  may be performed on the sapphire component to provide a cosmetic feature of the cover, as discussed herein. 
     It is understood that the processes discussed herein for forming polished cover  112  for electronic device  100  may be performed on other components having distinct features and/or geometries. That is, the processes discussed herein with respect to  FIG. 5  may be performed on a variety of components that may have features having non-planar and/or relatively tight or narrow tolerances that make conventional or traditional polishing processes difficult. Additionally, the processes discussed herein may also be performed on any alumina material, or substantially rigid material. 
     Turning to  FIGS. 6A-6J , cover  112  is shown undergoing various operations that may be performed in accordance with process  500  of  FIG. 5 . It is understood that similarly numbered components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. 
       FIG. 6A  depicts an enlarged, front cross-section view of a portion of sapphire material  140  that may be form cover  112  (see,  FIG. 6F ). As discussed herein, sapphire material  140  may undergo various shaping processes to form cover  112 . Sapphire material  140 , as shown in  FIG. 6A  may be cut from a large boule of sapphire material grown specifically to form cover  112 . Sapphire material  140  may be cut from a larger boule of material to a workable size that may undergo various processes to form a single cover  112  for electronic device  100 . As shown in  FIG. 6A , sapphire material  140  may be cut from the boule of material using any suitable cutting process including laser cutting and diamond cutting. 
     Additionally, surfaces of sapphire material  140  may undergo a lapping process. In a non-limiting example, as shown in  FIG. 6A , at least outer surface  126 , and in certain embodiments all surfaces, of sapphire material  140  may undergo a rough lapping process. The rough lapping process may remove any excess material formed on the surfaces of sapphire material  140  in order to make the surfaces of sapphire material  140  substantially flat and/or planar. The rough lapping process, and ultimately the planarization of the surfaces of sapphire material  140  may allow for easier subsequent processing on sapphire material  140 . 
       FIG. 6B  depicts sapphire material  140  that has undergone one or more machining processes to form a profile for cover  112 . For example, sapphire material  140  may undergo a machining process to form rounded perimeter portion  134 . The machining process may include a CNC machining process to remove material from sapphire material  140  to form rounded perimeter portion  134 . 
     Additionally, as shown in  FIG. 6B , groove  128  may be preliminarily formed in sapphire material  140  using a laser etching process. As shown in  FIG. 6B , and with comparison to  FIG. 6C , groove  128  formed in sapphire material  140  using the laser etching process may be a preliminary shape that may be subsequently processed and/or reshaped. 
     Turning to  FIG. 6C , sapphire material may be subsequently machined to form a final groove  128  on inner surface  124 . More specifically, rough groove  128 , shown in  FIG. 6B  may undergo additional CNC machining processes (e.g., rough CNC, fine CNC, and the like) to form a substantially final shape for groove  128  in sapphire material  140 . 
     Additionally as shown in  FIG. 6C , cavity  141  of sapphire material  140  may be formed using a machining process. In a non-limiting example, a CNC machining process may be performed opposite outer surface  126  to remove material from sapphire  140 . The CNC machining process may form cavity  141  adjacent inner surface  124  of sapphire material  140 . Additionally, cavity  141  may be formed adjacent and/or between groove  128  formed in sapphire material  140 . As discussed herein, cavity  141  may provide space within opening  118  of electronic device  100  to house components of electronic device  100 . 
     As shown in  FIG. 6C  and as discussed herein, the shaping of sapphire material  140 , and more specifically, the lapping, laser ablating and machining of sapphire material  140  to form groove  128 , may substantially reduce the thickness of cover  112  in rounded perimeter portion  134 . As shown in  FIG. 6C , the first thickness (T 1 ) between groove  128  and outer surface  126  may be substantially smaller than the second thickness (T 2 ) formed between inner surface  124  and outer surface  126  in planar portion  132  of cover  112 . Additionally, in the non-limiting example as shown in  FIG. 6C , the first thickness (T 1 ) may be substantially equal to, or slightly greater than, a predetermined threshold thickness for cover  112 . As discussed herein, the first thickness (T 1 ), when compared to the predetermined threshold thickness may affect further processing (e.g., final polishing process) of cover  112 . The shaping of sapphire material  140  to form the cover  112 , as shown in  FIGS. 6A-C , may correspond to operation  502  of  FIG. 5 . 
       FIG. 6D  shows sapphire material  140  undergoing intermediate polishing processes. In a non-limiting example, as shown in  FIG. 6D , sapphire material  140  forming cover  112  (see,  FIG. 6F ) may have undergone some of the intermediate polishing processes. As shown in  FIG. 6D , a portion of inner surface  124  may have undergone polishing processes to form intermediate polish  136  on a portion of inner surface  124 . More specifically, planar portion  132  of inner surface  122  may be polished using a chemical mechanical polishing (CMP) and/or a diamond mechanical polishing (DMP) process. 
       FIG. 6D  also shows sapphire material  140  currently undergoing a second polishing process using blasting media  142 . In a non-limiting example, inner surface  124  of rounded perimeter portion  134  is shown undergoing a polishing process that utilizes blasting media  142 . The blasting media  142  may be a diamond encrusted resin-based material or a diamond impregnated elastomer resin, that may contact inner surface  124  of sapphire material  140  under high-pressure to substantially polish inner surface  124 . The diamond-encrusted resin-based material may also have elastic properties, such that when the blasting media  142  is provided to the surface of sapphire material  140  under high-pressure and/or high-speeds, blasting media  142  may substantially deform to reduce the impact force of blasting media  142  on inner surface  124 . As shown in  FIG. 6D , blasting media  142  may be provided to inner surface  124  of rounded perimeter portion  134 , and specifically groove  128 , via dispensing nozzle  144 . Blasting media  142  may be dispensed via nozzle  144  and may subsequently slide or flow along inner surface  124  of groove  128  to form intermediate polish  136  on inner surface  124 . Subsequent to, or prior to, polishing inner surface  124  of rounded perimeter portion  134  using blast media  142 , inner surface  124  may undergo another polishing process using a polishing brush (not shown). The polishing brush or pad used to polish inner surface  124  of groove  128  may be any suitable polishing brush or pad that may be compliant and/or deformable such that the polishing brush or pad may polish the non-planar or curved surface of rounded perimeter portion  134  and/or groove  128 . By using blasting media  142  and the compliant polishing brush or pad (not shown) to polish inner surface  124  of rounded perimeter portion  134  and/or groove  128 , it may be ensured that inner surface  124  of rounded perimeter portion  134 , including groove  128 , may be adequately polished. That is, because of the compliant and/or deformable properties of blasting media  142  and the compliant polishing brush or pad, the non-planar surfaces of rounded perimeter portion  134  may be adequately polished using the processes discussed herein. 
     Also shown in  FIG. 6D , substantially all of outer surface  126  may have undergone polishing processes to form an intermediate polish  136  on outer surface  126 . In a non-limiting example, and similar to planar portion  132  of inner surface  124 , planar portion  132  of outer surface  126  may be polished using a CMP process and/or a DMP process. Additionally, outer surface  126  of rounded perimeter portion  134  may have undergone two polishing processes to form intermediate polish  136 , as similarly discussed and shown in  FIG. 6D  with respect to inner surface  124  of rounded perimeter portion  134 . That is, the two polishing processes performed on outer surface  126  of rounded perimeter portion  134  may include a first polishing process using a polishing brush or pad (not shown), and a second polishing process using blasting media  142 , as discussed herein. The intermediate polishing of sapphire material  140  forming cover  112 , as shown in  FIG. 6D , may correspond to operation  504  of  FIG. 5 . 
       FIG. 6E  depicts sapphire material  140  forming cover  112  after completion of the intermediate polishing processes shown in  FIG. 6D . All surfaces of sapphire material  140  forming cover  112  may have intermediate polish  136 . In a non-limiting example, both inner surface  124  and outer surface  126  of planar portion  132  and rounded perimeter portion  134  may only have intermediate polish  136 . 
     Additionally,  FIG. 6E  shows sapphire material  140  after an annealing process has been performed. More specifically, sapphire material  140 , including all surfaces within intermediate polish  136 , may undergo an annealing process to fill or otherwise seal any cracks or damage done to the sapphire material during the shaping processes or the polishing processes. The annealing of sapphire material  140  may also harden the sapphire. The annealing of sapphire material  140  generally corresponds to operation  506  of  FIG. 5 . 
       FIG. 6F  shows sapphire material  140  subsequent to the final polishing processes. In a non-limiting example, as shown in  FIG. 6F , sapphire material  140  forming cover  112  may have undergone final polishing processes to form final polish  138  on at least a portion of the surfaces of cover  112 . As shown in  FIG. 6F , outer surface  126  of cover  112  may only have final polish  138 . That is, final polish  138  may substantially cover all of outer surface  126  of cover  112  included in both planar portion  132  and rounded perimeter portion  134 . Distinct from outer surface  126 , inner surface  124  of cover  112  may have both intermediate polish  136  and final polish  138 . More specifically, as shown in  FIG. 6F , inner surface  124  of cover  112  included in planar portion  132  may have final polish  138  and inner surface  124  of rounded perimeter portion  134  of cover  112  may have intermediate polish  136 . Additionally as shown in  FIG. 6F , intermediate polish  136  may also be formed in groove  128  of cover  112 . Intermediate polish  136  formed on inner surface  124  of rounded perimeter portion  134  may be formed and remain through the annealing process of sapphire material  140 . That is, intermediate polish  136  may remain on inner surface  124  during the final polish process as a result of forming intermediate polish  136  on inner surface prior to annealing sapphire material  140  and/or not performing a final polishing process on inner surface  124  of rounded perimeter portion  134  after performing the annealing process. As discussed herein, the portions of surface of cover  112  that may or may not have final polish  138  may be dependent, at least in part, on thickness of cover  112  between groove  128  and outer surface  126 . 
     Similar to the intermediate polishing process discussed herein with respect to  FIG. 6D , the final polishing process may include a variety of polishing processes. That is, dependent upon the surface (e.g., inner surface  124 , outer surface  126 ) and/or the portion (e.g., planar portion  132 , rounded perimeter portion  134 ) of cover  112  being finally polished, the polishing process may vary. For example, as shown in  FIG. 6F  and as similarly discussed herein with respect to  FIG. 6D , outer surface  126  of planar portion  132  may be polished using a CMP and/or a DMP process, while outer surface  126  of rounded perimeter portion  134  may be polished using two distinct polishing processes; one process using a polishing brush or pad, and one process using blast media  142  (see,  FIG. 6D ). The final polishing process performed cover  112 , as shown in  FIG. 6F , may correspond to operation  508  in  FIG. 5 . 
       FIGS. 6G-6J  generally depict the process of applying a decorative ink (for example, as shown in  FIGS. 6H-6J ) into groove  128  formed in sapphire material  140 . The applying of the decorative ink to groove  128 , as shown in  FIGS. 6G-6J , may correspond to optional operation  510  in  FIG. 5 . 
     Prior to the application of the decorative ink, a preliminary pad printing process may be performed on groove  128  of cover  112 . In a non-limiting example, as shown in  FIG. 6G , a preliminary printing pad  146  may be aligned with groove  128 , and may move toward cover  112  to contact groove  128  during a preliminary pad printing process. Preliminary printing pad  146  may contain a decorative ink and/or a decorative image formed from ink, and may provide the ink/image to groove  128  by contacting inner surface  124  within groove  128 . A user or viewer of electronic device  100  may see decorative ink and/or decorative image through transparent cover  112 . The process may be considered preliminary insofar as another ink deposition process (e.g., a subsequent process) may be performed after the pad printing, at least in some embodiments. 
     The process of applying the decorative ink to groove  128  may also include covering a portion of sapphire material  140  positioned adjacent groove  128  with a protective mask  148 . That is, and as shown in  FIG. 6H , protective mask  148  may be disposed on and substantially cover inner surface  124  of cover  112 , except for the portion of inner surface  124  included in groove  128 . As discussed herein, protective mask  148  may substantially protect and/or prevent any sprayed decorative ink  150  from undesirably contacting or forming on inner surface  124 , other than in groove  128 . 
       FIG. 6H  depicts another process for applying decorative ink  150  into groove  128  of cover  112 . In a non-limiting example,  FIG. 6H  shows the process of spraying groove  128  with a decorative ink  150 . Decorative ink  150  may be sprayed or applied to inner surface  124  of groove  128  using sprayer  152 , to ensure all of inner surface  124  in groove  128  is covered by decorative ink  150 . As discussed herein, decorative ink  150  may form a second ink layer and/or second decorative image within groove  128 . 
     The applying of the decorative ink may finally include performing a subsequent pad printing process on groove  128  including decorative ink  150 . In a non-limiting example, as shown in  FIGS. 6I and 6J , a final or subsequent pad printing process may be performed on groove  128  using a distinct printing pad  154 . As shown in  FIG. 6I , prior to performing the final or subsequent pad printing process on groove  128 , protective mask  148  may be removed from inner surface  124  of cover  112 . However, it is understood that protective mask  148  may also be removed after the subsequent pad printing process on groove  128  to continue to protect inner surface  124  from undesirable decorative ink  150  application to a portion of inner surface  124 . 
     Similar to preliminary printing pad  146  as discussed herein with respect to  FIG. 6G , distinct printing pad  154  may be aligned with groove  128 , and may move toward cover  112  to contact groove  128  during a final or subsequent pad printing process. Distinct printing pad  154  may contain a final decorative ink layer and/or a final decorative image formed from ink, and may provide the ink/image to groove  128  by contacting inner surface  124  within groove  128 . Additionally, distinct printing pad  154  may contact groove  128  to remove any excess decorative ink that may be sprayed on inner surface  124  of groove  128  during the spraying process, as shown and discussed herein with respect to  FIG. 6H . The final decorative ink layer and/or final decorative image, as shown in  FIG. 6J , may be seen by a user of electronic device  100  (see,  FIG. 1 ) including cover  112 . 
     It is understood that sapphire material  140  forming cover  112  may undergo further processes subsequent to the polishing and/or painting of groove  128 , as discussed herein with respect to  FIGS. 6A-6J . That is, subsequent to the polishing of groove  128  and/or subsequent to the painting of groove  128 , cover  112  formed from sapphire material  140  may undergo further formation processes. Various portions and/or surfaces of sapphire material  140  forming cover  112  may undergo a plurality of processes including rough/fine CNC machining processes, DMP processes, lapping processes, chemical mechanical polishing (CMP) processes and/or coating processes. Each process performed on the various portions and/or surface of sapphire material  140  may aid the formation of cover  112 . In non-limiting examples, performing a fine CNC machining process within cavity  141  and/or on inner surface  124  may improve a surface finish on inner surface  124 , or performing a CMP on inner surface  124  within cavity  141  may reduce fogginess within cover  112 . In an additional non-limiting example, performing a DMP process on sidewalls of groove  128  in perimeter portion  134  may maintain edge shape to meet cosmetic tolerances for cover  112 . 
     Groove  128  and/or portions of cover  112  surrounding groove  128  may be painted or inked using distinct processes, such as those discussed above with respect to  FIGS. 6G-6J . In non-limiting examples shown in  FIGS. 7A-9D , groove  128  and the portions of cover  112  surrounding groove  128  may be painted or inked using two distinct processes, which includes pad printing, and spraying ink into groove  128  and portions of cover  112  surrounding groove  128 . As discussed herein, the non-limiting examples may also utilize a masking structure to prevent ink from being applied to undesired portions of cover  112 . 
     As shown in  FIG. 7A , cover  112  may initially have ink  150   a  applied to a portion of inner surface  124  adjacent groove  128 . In a non-limiting example, ink  150   a  formed on inner surface  124  may be formed adjacent groove  128  and may end or stop at a transition point  156  of cover  112 . Transition point  156  may be understood as the portion of cover  112  where inner surface  124  is no longer planar or parallel with outer surface  126 , but rather, transition point  156  may include the beginning of groove  128  formed in cover  112 . Additionally, transition point  156  may also separate planar portion  132  and rounded perimeter portion  134  of cover  112 . As such, ink  150   a  may only be applied on a planar portion of inner surface  124  of cover  112 . Ink  150   a  may be formed on inner surface  124  adjacent groove  128  using, for example, a pad printing process or a silk screening process. 
     Although discussed herein as ending at and/or aligned with transition point  156 , it is understood that ink  150   a  may stop prior to reaching transition point  156 . That is, ink  150   a  may not be aligned with transition point  156 , but rather, may end just prior to and/or adjacent to transition point  156  of cover  112 . 
     Once ink  150   a  is pad printed on inner surface  124  of cover  112 , a masking structure  158  may be placed over inner surface  124 . In a non-limiting example shown in  FIG. 7B , masking structure  158  may be formed over and/or on a portion of inner surface  124 , over at least a portion of the ink  150   a  and adjacent to the groove  128 . Masking structure  158  may be formed from a protective film  160  placed on the inner surface  124  of cover  112 , a spacer  162  coupled to the protective film  160 , and a rigid top component  164  positioned above spacer  162 . As discussed herein, masking structure  158  may allow ink to be sprayed into groove  128 , while simultaneously prevent ink from being sprayed on the entirety of ink  150   a  applied to inner surface  124 , and/or directly on inner surface  124 . Furthermore, and as discussed herein, masking structure  158  may also allow for there to be a smooth transition and/or a substantially uniform thickness between ink  150   a  that may be applied using a pad printing process and ink  150   b  (see,  FIG. 7C ) that may be applied using a spray process. In many embodiments, any transition between the inks  150   a ,  150   b  is not detectable to the human eye. 
     Protective film  160  may be coupled directly to inner surface  124  of cover  112 . Additionally, and as shown in  FIG. 7B , a portion of protective film  160  may also be coupled to and/or substantially cover a portion of ink  150   a , opposite groove  128  and transition point  156   a . Protective film  160  may cover the portion of ink  150   a  positioned opposite groove  128  to ensure that no ink may be sprayed directly onto inner surface  124  of cover  112  during a spraying process, as discussed herein. Protective film  160  may be coupled to inner surface  124 , and a portion of ink  150   a , using any suitable adhesive (not shown) having low tack properties and/or characteristics. Adhesive having low tack properties may be used to adhere or couple protective film  160  to inner surface  124  and/or ink  150   a  to prevent protective film  160  from becoming uncoupled from inner surface  124 . Additionally, the low tack properties of the adhesive used on protective film  160  may allow protective film  160  to be easily removed (i.e., no adhesive residue left on inner surface  124 ) and/or prevent protective film  160  from removing ink  150   a  from inner surface  124  when masking structure  158  is removed from cover  112 , as discussed herein. In some implementations, the protective film  160  is placed on the inner surface  124  and a portion of the ink  150   a  without the use of an adhesive. 
     Spacer  162  of masking structure  158  may be positioned between and/or coupled to protective film  160  and rigid top component  164 . Additionally, spacer  162  may couple rigid top component  164  to protective film  160 . In the non-limiting example, spacer  162  may be formed from any suitable double-sided adhesive that may couple rigid top component  164  to protective film  160 . As shown in  FIG. 7B , spacer  162  may only be coupled and/or formed between a portion of protective film  160  and rigid top component  164 . In the non-limiting example, spacer  162  may be positioned between protective film  160  and rigid top component  164  at a distance away from groove  128  and/or transition point  156 , and may not cover any portion of ink  150   a . As discussed herein, by not covering any portion of ink  150   a , spacer  162  may allow ink  150   b  applied by sprayer  152  (see,  FIG. 7C ) to be sprayed and/or formed over a portion of ink  150   a.    
     Rigid top component  164  may be coupled to the double-sided adhesive forming spacer  162  as discussed herein. As shown in  FIG. 7B , rigid top component  164  may extend to transition point  156 , and/or may be positioned directly adjacent groove  128  formed in cover  112 . Additionally, rigid top component  164  may be positioned above, but may not necessarily cover, ink  150   a  formed on inner surface  124  of cover  112 . That is, and as discussed herein, rigid top component  164  may not directly cover ink  150   a  because of the positioning of spacer  162  within masking structure  158 . However, rigid top component  164  may be positioned above ink  150   a , and may substantially prevent ink  150   a  from being sprayed directly onto the surface by sprayer  152  during an ink spraying process. Rigid top component  164  may be formed from any suitable rigid material that may hold its form during the spraying process discussed herein. In non-limiting examples, rigid top component  164  may be formed from a glass sheet, a fiberglass sheet or a reinforced plastic sheet. 
       FIG. 7C  shows a spraying process being performed on cover  112 . In a non-limiting example, and as similarly discussed herein with respect to  FIG. 6H , sprayer  152  may be utilized to apply ink  150   b  to cover  112 . Ink  150   b  sprayed or applied by sprayer  152  may be diffused as it is applied to cover  112 . As a result of diffusing ink  150   b , and as discussed herein, ink  150   b  may be applied directly to portions of cover  112  (e.g., groove  128 ), when sprayer  152  is positioned directly above the portion of cover  112 , and ink  150   b  may be indirectly applied to surrounding portions of cover  112  that are adjacent the portion of cover  112  that is receiving the directly applied ink  150   b.    
     As shown in  FIG. 7C , sprayer  152  may directly apply ink  150   b  into groove  128  of cover  112 . Sprayer  152  may also directly apply ink  150   b  to contact surface  166  of rounded perimeter portion  134  of cover  112 , which may be subsequently coupled to and/or contact shelf portion  120  of housing  102 , as similarly discussed herein with respect to  FIGS. 2-4 . Sprayer  152  may move in a direction (D) to spray, apply and/or cover groove  128  and contact surface  166  with ink  150   b . Sprayer  152  may make a single pass over groove  128  and contact surface  166 , or may make multiple passes over groove  128  and contact surface  166  when spraying and/or forming a uniform layer of ink  150   b  on cover  112 . 
     As discussed herein, rigid top component  164  of masking structure  158  may be positioned over ink  150   a  and may substantially prevent sprayer  152  from directly spraying ink  150   b  onto ink  150   a . However, because of sprayer&#39;s  152  ink-diffusive characteristics, a portion of ink  150   b  may be indirectly sprayed or deposited on a portion of ink  150   a , directly adjacent transition point  156 . In a non-limiting example shown in  FIG. 7D , as sprayer  152  moves toward ink  150   a  and masking structure  158 , respectively, ink  150   b  may be directly applied to groove  128  and transition point  156 . Additionally, ink  150   b  may be indirectly sprayed under rigid top component  164 , and may be applied to a small portion of ink  150   a  positioned adjacent transition point  156 . The amount of ink  150   b  that may be indirectly applied to ink  150   a  may be minimal and/or much less when compared to the amount of ink  150   b  applied directly to groove  128  and/or contact surface  166 . As discussed herein, rigid top component  164  may prevent ink  150   b  from being directly applied to ink  150   a  as sprayer  152  moves in a direction (D) toward and/or over rigid top component  164 . That is, because rigid top component  164  of masking structure  158  is positioned over ink  150   a  formed on inner surface  124 , ink  150   b  from sprayer  152  may not be directly sprayed or deposited on ink  150   a  when sprayer  152  is positioned directly above rigid top component  164 . 
       FIG. 7E  shows cover  112  after ink  150   a  is pad printed on inner surface  124  and ink  150   b  is sprayed on groove  128  and contact surface  166 . In the non-limiting example shown in  FIG. 7E , ink  150   a  and ink  150   b  may be substantially continuous on cover  112 . Additionally, ink  150   a  and  150   b  may include substantially uniform thicknesses throughout, and each thickness of ink  150   a  and ink  150   b  may be substantially equal to each other. However, as shown in  FIG. 7E , and discussed herein with respect to  FIG. 7D , an overlapping portion  167  of ink  150   b  adjacent transition point  156  may be indirectly deposited over ink  150   a . Overlapping portion  167  of ink  150   b  indirectly deposited on ink  150   a  may be minimal and/or negligible and may not affect the appearance and/or function of ink  150   a  and/or ink  150   b . Although shown as having a minimal and/or slight thickness increase where overlapping portion  167  of ink  150   b  is indirectly deposited on ink  150   a , ink  150   b  deposited on ink  150   a  may form a substantially smooth, gradual controlled and/or seamless transition between ink  150   a  and ink  150   b  of cover  112 . That is, by allowing a minimal amount of ink  150   b  to be indirectly deposited on ink  150   a , the transition between ink  150   a  and ink  150   b  may be substantially smooth and/or seamless, without changing, and specifically increasing, the thickness of the deposited ink significantly and/or over an extended length of ink  150   a.    
       FIGS. 8A-8D  show another non-limiting example for applying ink  150  to groove  128  and portions of cover  112  positioned adjacent to groove  128  using a pad printing process and a spraying process. It is understood that similarly numbered components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. 
     Distinct from the non-limiting example shown in  FIGS. 7A-7E , contact surface  166  may also undergo a pad printing process. In the non-limiting example shown in  FIG. 8A , ink  150   c  may be applied to at least a portion of contact surface  166  of cover  112  using a pad printing process similarly discussed herein with respect to  FIG. 7A  and ink  150   a . However, distinct from ink  150   a , which may include a uniform thickness, ink  150   c  pad printed on contact surface  166  of cover  112  may include a sloped portion  168 , which may have a gradually decreasing thickness. Sloped portion  168  may be formed in ink  150   c  during the pad printing process. As shown in  FIG. 8A , sloped portion  168  may be formed in only a portion of ink  150   c , however, it is understood that ink  150   c  may include sloped portion  168  formed over the entire length of ink  150   c . Additionally, distinct from ink  150   a , ink  150   c  formed on contact surface  166  may not end and/or be positioned directly adjacent transition point  156   b  (i.e., transition between planar portion of cover  112  and groove  128 ) of contact surface  166 . Rather, ink  150   c  may be positioned proximate and/or spaced a distance away from transition point  156   b . As discussed herein, the gradually decreasing thickness of ink  150   c  and ink  150   c  positioning with respect to transition point  156   b  may allow ink  150   b  to form a seamless transition over ink  150   c  on contact surface  166  and into groove  128 . 
     Turning to  FIG. 8B , masking structure  158  may also be utilized to prevent spraying ink  150   b  on portions of inner surface  124  of cover  112 . In the non-limiting example shown in  FIG. 8B , a protective fixture  170  may be secured to cover  112 . Similar to rigid top component  164 , protective fixture  170  may be positioned above, but may not directly cover ink  150   c , such that during a spraying process, ink  150   b  sprayed in groove  128  may also be sprayed and/or applied to ink  150   c , as discussed herein. In the non-limiting example shown in  FIG. 8B , protective fixture  170  may also extend over contact surface  166  only as far as ink  150   c , and may be secured to the side of cover  112  to prevent any ink  150   b  from being undesirably sprayed on outer surface  126  during the spraying process discussed herein. Protective fixture  170  may be formed from a substantially similar material (e.g., glass, fiberglass, reinforced plastic and so on) or from a material having substantially similar characteristics (e.g., rigid) as rigid top component  164  of masking structure  158 . 
       FIG. 8C  shows the ink spraying process performed on cover  112 . As similarly discussed herein with respect to  FIG. 7D  and masking structure  158 , the gap or space between ink  150   c  and protective fixture  170  may allow sprayer  152  to indirectly spray and/or apply ink  150   b  over at least a portion of ink  150   c . In the non-limiting example, ink  150   b  may be indirectly sprayed, applied and/or cover sloped portion  168  of ink  150   c  as sprayer  152  moves in a direction (D) toward protective fixture  170  and ink  150   c  on contact surface  166  of cover  112 . Additionally, the positioning of protective fixture  170  over ink  150   c  may prevent sprayer  152  from directly applying ink  150   b  to ink  150   c  when sprayer  152  is positioned directly above ink  150   c , and/or protective fixture  170 . 
     Turning to  FIG. 8D , the indirect spraying and/or applying of ink  150   b  to ink  150   c  having the gradually reducing thickness, may allow ink  150   b ,  150   c  formed on contact surface  166  to have a substantially uniform thickness. In the non-limiting example, and as similarly discussed herein with respect to  FIG. 7E , ink  150   a , ink  150   b  and ink  150   c  may all have a similar and/or uniform thickness after the pad printing and spraying process is performed on cover  112 . Additionally, as shown in  FIG. 8D , by forming ink  150   c  with sloped portion  168 , and subsequently applying overlapping portion  167   b  of ink  150   b  over sloped portion  168 , a substantially smooth, gradual controlled and/or seamless transition between ink  150   b  and ink  150   c  may be formed on contact surface  166  at overlapping portion  167   b.    
       FIGS. 9A-9D  show another non-limiting example for applying ink  150  to groove  128  and portions of cover  112  positioned adjacent to groove  128  using a pad printing process and a spraying process. Similar to  FIG. 8A , the non-limiting example in  FIG. 9A  may also pad print ink  150   c  on contact surface  166  of cover  112  prior to performing an ink spraying process. However, distinct from  FIG. 8A , ink  150   c  pad printed onto contact surface  166  may include a uniform thickness, similar to ink  150   a  formed on inner surface  124 . Also similar to ink  150   a , ink  150   c  formed on contact surface  166  may be formed directly adjacent groove  128 , and may end at transition point  156   b  of contact surface  166 , as shown in  FIG. 9A . 
     As shown in  FIG. 9B , masking structure  158  and protective fixture  170  may be utilized during an ink spraying process to prevent ink  150   b  from being sprayed on portions of cover  112  (e.g., portion of inner surface  124 , outer surface  126 ) which do not require ink  150 . In the non-limiting example shown in  FIG. 9B , and distinct from  FIG. 8B , protective fixture  170  may be positioned over and may directly cover at least a portion of ink  150   c  formed on contact surface  166 . Protective fixture  170  may directly contact and cover a portion of ink  150   c , such that the covered portion of ink  150   c  may not be sprayed and/or covered by ink  150   b  during the ink spraying process (see,  FIG. 9C ). 
     Also shown in  FIG. 9B , protective fixture  170  may not completely cover ink  150   c  formed on contact surface  166  because protective fixture  170  may not extend all the way to transition point  156   b . Rather, protective fixture  170  may be positioned proximate and/or spaced a distance away from transition point  156   b . As a result, the portion of ink  150   c  positioned directly adjacent transition point  156   b  may be exposed during the ink spraying process and may be covered by ink  150   b , as discussed herein. 
       FIG. 9C  shows the ink spraying process performed on cover  112 . During the ink spraying process, ink  150   b  may substantially be indirectly sprayed, applied and/or cover the exposed portion of ink  150   c  formed on contact surface  166 . In the non-limiting example, protective fixture  170  positioned directly on ink  150   c  may only prevent sprayer  152  from directly or indirectly applying ink  150   b  to the covered portions of ink  150   c . However, because ink  150   c  extends to transition point  156   b , and protective fixture  170  does not, the exposed portion of ink  150   c  positioned adjacent groove  128  may be covered by ink  150   b.    
     In order to prevent substantial build-up of ink  150   b  on ink  150   c , and ultimately increase the thickness of ink  150  formed on cover  112 , the spray process may be modified. In a non-limiting example, sprayer  152  may have restricted movement in direction (D) toward contact surface  166 , such that sprayer  152  may never be positioned directly over contact surface  166 , and therefore may not directly spray ink  150   b  on the exposed portion of ink  150   c . In another non-limiting example where sprayer  152  makes multiple passes over groove  128  to apply ink  150   b , sprayer  152  may only pass over adjacent exposed portion of ink  150   c  and/or transition point  156   b  once to prevent over spraying ink  150   c.    
     Turning to  FIG. 9D , the spraying and/or applying of ink  150   b  to the exposed portion of ink  150   c , may allow ink  150   b ,  150   c  to form a substantially smooth, gradual controlled and/or seamless transition between ink  150   b  and ink  150   c  on contact surface  166 . In the non-limiting example, and as similarly discussed herein with respect to  FIG. 7E , ink  150   a , ink  150   b , and ink  150   c  may include substantially uniform thicknesses throughout, and each thickness of ink  150   a , ink  150   b , and ink  150   c  may be substantially equal to each other. However, and similar to indirectly applied ink  150   b  covering ink  150   a  at transition point  156   a , the overlapping portion  167   b  of ink  150   b  deposited on the exposed portion of ink  150   c  may be minimal and/or negligible and may not affect the appearance and/or function of ink  150   b  and/or ink  150   c . Although shown as having a minimal and/or slight thickness increase where overlapping portion  167   b  of ink  150   b  is deposited on ink  150   c , overlapping portion  167   b  of ink  150   b  deposited on ink  150   c  may form a substantially smooth, gradual controlled and/or seamless transition between ink  150   b  and ink  150   c  of cover  112 . That is, by allowing a minimal amount of ink  150   b  to be deposited on the exposed portion of ink  150   c , the transition between ink  150   b  and ink  150   c  may be substantially smooth and/or seamless, without changing, and specifically increasing, the thickness of the deposited ink significantly and/or over an extended length of ink  150   c.    
     Although depicted as different patterns and/or colors in  FIGS. 7A-9D , it is understood that ink  150   a ,  150   b ,  150   c  may be the same ink material, and may only be shown using different patterns and/or colors to indicate the distinct processes for forming ink  150   a ,  150   b ,  150   c . In another limiting embodiment, it may also be understood that ink  150   a ,  150   b ,  150   c  may represent different ink material for forming each of the ink portions on cover  112 . 
     The dimensions (e.g., length, thickness, and so on) of each component forming masking structure  158 /protective fixture  170  and/or the positioning of masking structure  158 /protective fixture  170  with respect to transition point  156   a  and transition point  156   b  may be based on, at least in part, the properties and/or characteristics of ink  150  and/or the spraying process performed on cover  112 . In non-limiting examples, the distance of gap formed between rigid top component  164  and ink  150   a , and/or the distance between rigid top component  164  and transition point  156   a  may be based on, but is not limited to, the size of sprayer  152 , the output (i.e., volume) of ink  150   b  dispensed by sprayer  152 , the distance between sprayer  152  and cover  112 , the number of passes for sprayer  152  to form ink  150   b  in groove  128 , characteristics and/or physical characteristics of ink  150  (e.g., viscosity, color, chemical composition, etc.) and so on. 
       FIG. 10  depicts an example process for applying decorative ink to a cover for an electronic device. Specifically,  FIG. 10  is a flowchart depicting one example process  1000  for applying decorative ink to a groove and/or other portions of a cover for an electronic device. In some cases, the process  1000  may be used to form one or more covers  112  for electronic device  100 , as discussed above with respect to  FIGS. 7A-9D . 
     In operation  1002 , ink may be pad printed on at least a portion of a planar surface of the cover. The portion of the planar surface that may be pad printed may be positioned adjacent a groove formed in the cover. In operation  1004 , a masking structure may be positioned on the cover. The masking structure may be positioned adjacent the groove formed in the cover. The masking structure may include, a protective film coupled to the planar surface of the cover, a spacer coupled to a portion of the protective film, and a rigid top component coupled to the spacer. The rigid top component may be positioned over the ink pad printed on at least the portion of the planar surface of the cover, as discussed in operation  1002 . In operation  1006 , ink may be directly applied to the groove formed in the cover. In operation  1008 , ink may be indirectly applied to at least a portion of the ink pad printed on at least the portion of the planar surface of the cover. The indirect applying of the ink in operation  1008  may further comprise forming a seamless transition line between the pad printed ink on the portion of the planar surface and the indirectly applied ink. 
     Although the processes discussed herein are for forming a cover  112  for electronic device  100 , it is understood that the processed may be performed on any component of electronic device  100  including material substantially similar to cover  112 . In a non-limiting example, the processes discussed herein may be performed on housing  102 , where housing  102  is formed from a sapphire material. Housing  102  may be substantially opaque, but may still be processed and/or polished in a similar manner as discussed herein with respect to cover  112 . Likewise, the processes described herein may be used on features other than grooves; any suitable recess, depression or like feature may be formed, polished, and/or inked as described herein. 
     As discussed herein and shown in  FIG. 1 , electronic device  100  is implemented as a wearable electronic device, such as a watch. However, it is understood that electronic device  100  may be implemented as any other suitable electronic device, such as, for example, a smart phone, a laptop or desktop computer, a tablet computing device, a gaming device, a display, a digital music player, a health monitoring device, other forms of wearable computing devices (e.g., glasses, jewelry, and the like) and so on. Electronic device  100  may be configured to perform any a variety of functions, including providing health-related information or data such as, but not limited to, heart rate data, blood pressure data, temperature data, oxygen level data, diet/nutrition information, medical reminders, health-related tips or information, or other health-related data. The electronic device may optionally convey the health-related information to a separate electronic device such as a tablet computing device, phone, personal digital assistant, computer, and so on. In addition, electronic device  100  may provide additional information, such as, but not limited to, time, date, health, statuses of externally connected or communicating devices and/or software executing on such devices, messages, video, operating commands, and so forth (and may receive any of the foregoing from an external device), in addition to communications. 
     Electronic device  100  may include a housing  102  at least partially surrounding a display  104  and one or more buttons  106  or input devices. The housing  102  may form an outer surface or partial outer surface and protective case for the internal components of electronic device  100 , and may at least partially surround the display  104 . The housing  102  may be formed of one or more components operably connected together, such as a front piece and a back piece. Alternatively, the housing  102  may be formed of a single piece operably connected to the display  104 . Housing  102  may formed from a number of distinct materials including, but not limited to, corundum (commonly referred to as sapphire), metal, glass, ceramic and/or plastic. Additionally, housing  102  may include a decorative and/or coating layer that be disposed on the outer and/or or inner surface of housing  102 . The decorative layer and/or coating layer may be disposed on the surface(s) of housing  102  to protect the enclosure and/or provide a decorative feature (e.g., exterior color) for electronic device  100 . Housing  102 , similar to cover  112  discussed herein with respect to  FIGS. 2-10 , may also include a groove (e.g., groove  128 ) formed therein that may be formed, shaped, polished, inked and/or painted using similar processes discussed herein. 
     Housing  102  may also have recesses  108  formed on opposite ends to connect a wearable band  110  to electronic device  100 . Wearable band  110  may be used to secure wearable electronic device  100  to a user, or any other object capable of receiving electronic device  100 . In a non-limiting example where electronic device  100  is a smart watch, wearable band  110  may secure the watch to a user&#39;s wrist. In other non-limiting examples, electronic device  100  may be secured to another part of a user&#39;s body. 
     Display  104  may 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. Cover  112  may be positioned above the touchscreen of display  104  to protect display  104 , as discussed herein. 
     Button  106  may include any suitable input/output (I/O) device for electronic device  100 . Specifically, button  106  may include an actuation component in electronic and/or mechanical communication with the internal components of electronic device  100 , to provide user input and/or allow the user to interact with the various functions of electronic device  100 . In an embodiment, button  106  may be configured as a single component surrounded by housing  102 . Alternatively, button  106  may include a number of components, including an actuation component, in mechanical and/or electrical communication with one another and/or internal component of electronic device  100 . Button  106  may likewise include or be disposed near a sensor, such as a biometric sensor, touch sensor, or the like. Similar to housing  102  and/or cover  112 , button  106  may be formed from corundum or sapphire, and as such, may also include a groove (e.g., groove  128 ) or similar shape formed in at least a portion of button  106 . The groove formed in button  106  may be formed, shaped, polished, inked and/or painted using similar processes discussed herein with respect to groove  128  of cover  112  shown in  FIGS. 2-10 . 
     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: 20150826
Publication Date: 20180522
Grant Date: 20180522
Priority Date: 20140827
Inventors: MYLVAGANAM, Jeffrey C.
DE JONG, ERIK G.
MEMERING, DALE N.
CAI, XIAO BING
CHINNAKARUPPAN, PALANIAPPAN
LEE, Jong Kong
KAMIREDDI, SRIKANTH
KAMEI, SAWAKO
MIN, Feng
ZHANG, JING
DU, XIANG
LIU, Sai Feng
Assignee: APPLE INC
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Family ID: 54066218