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Sapphire Glass Didn't Pass iPhone Drop Test According to Reports

SternisheFan notes reports about why Apple didn't use sapphire glass screens in the latest iPhones as many expected. Sapphire screens were part of the iPhone 6 design until the glass repeatedly cracked during standard drop tests conducted by Apple suppliers. So Apple abandoned its sapphire plans before the iPhone 6 product launch September 9. VentureBeat has learned that recent supplier channel checks by an IDC analyst yielded several reports of the sapphire failures and Apple's decision against using the glass material. As we heard on Tuesday in Cupertino, both the iPhone 6 and the larger iPhone 6 Plus will ship with screens made of "ion-strengthened" glass. This was apparently Apple's second choice. IDC analyst Danielle Levitas says it isn't clear when exactly the drop-test failures took place, or when Apple abandoned plans for sapphire-screened iPhones. She says the poor drop-test results, combined with the relative high cost of sapphire glass, could have made plans to ship sapphire glass phones too risky. One researcher who covers GT Advanced Technologies, the company that was to produce the glass for the iPhone 6, wrote in a research note earlier this week that plans for the sapphire screens were cancelled in August, just weeks before the September 9 launch. The new Apple Watches (except the "Sport" version) do use sapphire for their screens. Levitas believes that the glass for the smaller 1.5-inch and 1.7-inch watch screens was less likely to break in drop tests.

35 of 207 comments (clear)

  1. didn't have to be worse.. by zr · · Score: 4, Interesting

    ..might simply have been not appreciably better than glass alternatives.

    if true (this sounds like speculation) kudos apple for not releasing something just because they could.

    1. Re:didn't have to be worse.. by BarbaraHudson · · Score: 4, Funny

      ... but it WAS worse. It broke easier when dropped. And EVERYONE drops their phone at one point or another.

      When a visibly peeved Apple rep was asked for comment, they said "We found we couldn't drop it, so we dropped it. Now can you drop it?"

      --
      "Transparent" is a shit show that trades on every stereotype going. A man in drag is NOT a transsexual.
    2. Re:didn't have to be worse.. by Anonymous Coward · · Score: 5, Informative

      No, Apple didn't hype it, and never announced that they would use it on the phones. Lots of rumour sites saw apple buying a sapphire glass manufacturing company, and decided that 2+2=9.

    3. Re:didn't have to be worse.. by Charliemopps · · Score: 4, Interesting

      ..might simply have been not appreciably better than glass alternatives.

      if true (this sounds like speculation) kudos apple for not releasing something just because they could.

      Or it could have been stronger, just not in Apples application. The shape of the phone and/or the mounting may have caused the glass to flex in such a way that it shattered easier. I suspect this leak was intentional, and Apple is trying to target the technology so other phones can't use it as a selling point by saying "Look, we have stronger glass than apple!"

    4. Re: didn't have to be worse.. by GodInHell · · Score: 4, Insightful

      Removing features that degrade a tool should be praised. I say this as a dyed in the wool android fan boy.

    5. Re:didn't have to be worse.. by sl149q · · Score: 3, Insightful

      So if the referenced article is to be believed...

      Sometime early in August Apple decided to to with ion strengthened glass for the new iPhone 6 models. They then cancelled the orders for sapphire screens and did what... with only six weeks to go before launch, probably several weeks into full production, they placed an order for 10 million or so screens? Its not like you can phone Digikey and ask for 10 million screens and please have them here in 24 hours please and thank.

      Any decision about screens was made many months ago so that the Ion Screen manufacturer would have sufficient time to make them and ship them prior to when the iPhone 6's production needed to start. And initial production was probably in June.

      So more likely March or April.

    6. Re: didn't have to be worse.. by pr0fessor · · Score: 2

      Well I for one prefer a phone that doesn't shatter the first time I drop it. I know every one says "just get a case" but why on earth should I pay for phone and then a case... why not buy a phone with a better screen to begin with. Iphone and Ipod are already notorious for screens that crack when you look at them wrong.

      I'm frequently annoyed by how the quality of products keep going down while the prices go up and no one appears to realize it. I'm not just talking about apple pick almost any product and look at the difference in material used between now and 20 or 30 years ago. Things like handles on car doors made of plastic instead of die-cast aluminum.

       

  2. Ion strengthened? by Megol · · Score: 4, Insightful

    Isn't that what standard hardened glass is?

    1. Re:Ion strengthened? by SternisheFan · · Score: 5, Informative
      'Ion-Strengthened' is Gorilla Glass: http://www.forbes.com/sites/gr...

      CNET also covers this well, noting SapphireGlass costs $30 per unit versus $3 for Gorilla Glass. From the CNET article...

      Corning, which has repeatedly criticized the use of sapphire as a mobile-device display, says its testing found that though sapphire is harder to scratch than its Gorilla Glass, daily use of a sapphire display will produce tiny cracks in the material. Those cracks can easily proliferate and cause the display to break more easily over time than Gorilla Glass. As a major manufacturer of industrial crystals, Corning should know a thing or two about sapphire. It used to make tubes of it for high-temperature lighting during the 1960s and 1970s, according to Jeffrey Evenson, Corning's operations chief of staff.

      "As material guys, we think Gorilla has a lot more potential," Evenson said, who added that glass is much easier to manipulate into different forms, such as with the rounded Gorilla Glass display of the new Samsung Note Edge smartphone.

      http://www.cnet.com/news/why-t...

    2. Re:Ion strengthened? by ELCouz · · Score: 5, Informative

      No, regular hardened glass is tempered by quenching (heated in a furnace around 700C then quenched by rapid cooling)
      Disclamer: I work in a glass factory.

    3. Re:Ion strengthened? by SternisheFan · · Score: 4, Informative
      ION-EXCHANGE PROCESS Ion exchange is a chemical strengthening process where large ions are “stuffed” into the glass surface, creating a state of compression. Gorilla Glass is specially designed to maximize this behavior. The glass is placed in a hot bath of molten salt at a temperature of approximately 400 degrees C. Smaller sodium ions leave the glass, and larger potassium ions from the salt bath replace them. These large ions take up more room and are pressed together when the glass cools, producing a layer of compressive stress on the surface of the glass. Gorilla Glass’ composition enables the potassium ions to diffuse far into the surface, creating high compressive stress deep into the glass. This layer of compression creates the surface that is more resistant to damage.

      http://www.corninggorillaglass...

    4. Re:Ion strengthened? by TeknoHog · · Score: 3, Funny

      Regular glass doesn't contain any ions, in the same way that regular vegetables don't contain any genes.

      --
      Escher was the first MC and Giger invented the HR department.
    5. Re: Ion strengthened? by GodInHell · · Score: 3, Insightful

      That whooshing sound you hear is dozens of people reading your post and saying "this idiot knows nothing about genetics. "

    6. Re:Ion strengthened? by SpinyNorman · · Score: 4, Interesting

      Apple's Ion Strengthened Glass (which, confusingly, they call Ion-X Glass on the Apple Watch) might be Gorilla Glass, but could also be Ashai Glass's Draontrail-X Glass which is similarly ion strengthened or maybe a new product from a different manufacturer.

    7. Re:Ion strengthened? by CODiNE · · Score: 5, Interesting

      Speaking of glass with compressed surfaces. This has to be mentioned.

      http://en.m.wikipedia.org/wiki/Prince_Rupert's_Drop

      Beware iPhones with tails.

      --
      Cwm, fjord-bank glyphs vext quiz
    8. Re:Ion strengthened? by tlhIngan · · Score: 2

      Is that $3 to replace a scratched screen, including all the AR coatings? At that price they might as well include three spare glass plates with every phone in case you scratch one.

      That's the cost of the glass plate. (Note: Traditionally the iPhone uses Gorilla Glass, but for some reason I don't know why Apple and Corning couldn't come to a marketing arrangement. Probably because Apple traditionally doesn't hype up the products of its suppliers - so it may be Gorilla Glass, but Apple will never use the term).

      Don't forget modern phones have a touchscreen embedded on the plate, followed by a bit of regular glass, followed by the LCD fabricated right on the glass as well so the touchscreen and display form a single unmoving unit. Alas, this extra processing means your $3 plate now costs $20 to manufacture, and maybe $25 after amortizing defective displays.

      So no, the front glass is not just a single piece, it's the whole display assembly.

    9. Re:Ion strengthened? by AmiMoJo · · Score: 2

      In plain English the surface of glass is not perfect, there are invisible gaps and fractures. Normally when glass bends these points fail as the gaps are expanded and pulled open on the side that is stretched. Gorilla Glass has those gaps stuffed which puts the whole surface under pressure. When it bends it's now just relaxing instead of splitting.

      --
      const int one = 65536; (Silvermoon, Texture.cs)
      SJW, n: "Someone I don't like, and by the way I'm a fuckwit" - AC
    10. Re:Ion strengthened? by cdrudge · · Score: 2

      Because if you say the iPhone comes with Gorilla Glass, you've locked yourself into a single supplier of a trademarked item. If you just say ion-strengthened glass, you can use any supplier that can meet your requirements, not just Corning.

  3. Non story by Noah+Haders · · Score: 2, Informative

    Company tries two things, chooses the one that is better. News at 11.

    1. Re:Non story by OzPeter · · Score: 2

      Company tries two things, chooses the one that is better. News at 11.

      Nope ..

      News at 5, 6, 7, 8, 9, 10 AND 11 .. plus at 6AM, 7AM and 9AM there's a recap of the previous days related rumors and stories.

      And I say this typing on a MacBook with an iMac to my right, my iPad downstairs, my Nano in my gym bag and my iPod touch in a drawer.

      --
      I am Slashdot. Are you Slashdot as well?
    2. Re:Non story by SternisheFan · · Score: 2

      This may have been a large $$$ loss for Apple, the company has bet big on Sapphire Glass. Previous /. article, how-apples-billion-dollar-sapphire-bet-will-pay-off http://apple.slashdot.org/stor...

    3. Re:Non story by SternisheFan · · Score: 4, Interesting
      From the linked older NetworkWorld story, Apr 22, 2014 ...

      Apple is creating its own supply chain devoted to producing and finishing synthetic sapphire crystal in unprecedented quantities. The new Mesa, Ariz., plant, in a partnership with sapphire furnace maker GT Advanced Technologies (GTAT) of Merrimack, N.H., will make Apple one of the world’s largest sapphire producers when it reaches full capacity, probably in late 2014. By doing so, Apple is assured of a very large amount of sapphire and insulates itself from the ups and downs of sapphire material pricing in the global market.

      In keeping with long-standing practice, Apple has never publicly discussed the Arizona project or what it intends to do with such a vast amount of sapphire material. Rumors and more or less informed speculation have flourished in that silence.

      The Arizona project was revealed in November, with Apple paying $578 million for GTAT to install and run its advanced sapphire growth furnaces in a plant built and owned by Apple. The news triggered a frenzy of speculation that Apple planned to use sapphire crystal sheets to replace the glass currently used in touch displays for its 2014 iPhones, iPads or a new line of “wearables” such as the long-rumored iWatch, or all of the above.

      That’s only the tip of Apple’s investment. Once the 253-pound “hockey puck” shaped sapphire boules emerge from the furnaces, they’ll be shipped to Apple’s supply chain partners in Asia, including Biel Crystal Manufactory and Lens One Technology Co., for slicing, polishing, laser cutting, coating and eventual assembly.

      But to do all this, these companies, and Apple, will have to invest heavily in new equipment that can handle sapphire, since only diamond is harder, and handle it in the quantities that Apple will produce. That’s not a simple process.

      Natural sapphire is a gemstone variety of the mineral corundum, a crystalline form of aluminum oxide. Corundum is colorless, but in natural sapphires, various impurities create a range of colors: chromium makes the gem red, becoming a ruby; iron and titanium create the prized cornflower blue of a true sapphire.

      Synthetic sapphire is colorless, unless deliberately colored. GTAT’s ASF uses a variation of what’s called the Czochralski process, combining the melting of aluminum oxide, a seed sapphire crystal, and heat extraction to crystalize the alumina melt. [For more details, see the accompanying slideshow: “Why Apple’s sapphire plan is as hard as the mineral itself”] Like natural sapphire, the synthetic is incredibly hard and that hardness creates challenges for using it.

      “When the [sapphire] area is larger, with the increased hardness, it takes more aggressive abrasives to grind and polish it,” says Jennifer Stone-Sunderberg, who has a Ph.D. in solid state chemistry and crystal growth, and now consults in this field as a managing director of Crystal Solutions of Portland, Ore. “It’s time-consuming to polish something that hard.”

      Secondly, it means overcoming a surprising problem: despite its hardness, synthetic sapphire can be prone to fracturing, at almost any point in this finishing process, due to impurities or to the presence of unresolved strains in the crystalline structure.

      “That’s something that’s being very carefully measured and tested,” says Stone-Sunderberg. “Fracturing is probably of the highest concern. If a product is released with a more expensive touch screen [cover] and consumers experience fracturing, they’re going to be highly disappointed. It would be devastating to the sapphire industry.”

      Tackling these issues on this scale and schedule has never been attempted before.

      “GTAT and the rest of the Apple supply chain involved in this new sapphire component indeed have to execute an unprecedented - for the sapphire industry - r

    4. Re:Non story by SternisheFan · · Score: 2

      Couldn't Sapphire Glass still be used in phones, just by encasing it in a rubber gasket to absorb shocks?

    5. Re:Non story by SternisheFan · · Score: 2

      You realize that screens already don't break unless they land screen side down on something pointed?

      Micro-fracturing of SapphireGlass is the problem. Small cracks develop from the slight twisting of the phone's body due to it's extra hardness, which leads to full cracking of the glass. So a gasket to compensate for that stress seems to be needed, in my humble opinion.

    6. Re:Non story by RyuuzakiTetsuya · · Score: 2

      They're using sapphire in the Touch ID sensor, the rear camera and the apple watch.

      It's not even close to a loss.

      --
      Non impediti ratione cogitationus.
  4. Drop vs. Scratch by ZipK · · Score: 2

    Levitas believes that the glass for the smaller 1.5-inch and 1.7-inch watch screens was less likely to break in drop tests.

    Watches are less likely to be dropped than phones, making scratch resistance a higher priority.

  5. Re:Sapphire glass? by Anonymous Coward · · Score: 5, Informative

    One of the largest uses for artificial sapphire is supermarket barcode scanners. No one's putting it there because they feel a need to bling-out the supermarket. It's there because any surface that has stuff dragged across it all day, every day either needs to be incredible scratch-resistant or replaced way too often.

  6. Re:Just Apple? by shitzu · · Score: 2, Funny

    I dropped my iphone 5 from 2 meters (i leave it to the Americans to make out how many badger's kidneys it is) to a hard, stone floor. Glass intact.

  7. The screens may have cracked when dropped by JoeyRox · · Score: 2

    But at least they weren't scratched!

  8. How Gorilla/Sapphire Glass Is Made by SternisheFan · · Score: 4, Informative
    How Gorilla Glass Is Made

    The glass consists of a thin sheet of alkali-aluminosilicate. Gorilla Glass is strengthened using an ion-exchange process which forces large ions into the spaces between molecules on the glass surface. Specifically, glass is placed in a 400C molten potassium salt bath, which forces potassium ions to replace the sodium ions originally in the glass. The larger potassium ions take up more space between the other atoms in the glass. As the glass cools, the crunched-together atoms produce a high level of compressive stress in the glass that helps protect the surface from mechanical damage.

    http://chemistry.about.com/od/...

    How Sapphire Glass is made...

    http://www.businessinsider.com...

  9. Re:Why not gorilla like everyone else? by Solandri · · Score: 4, Informative

    Sure, Apple is all about marketing, and they loved to give that "2nd hardest material after diamond" pitch when introducing their watch

    Actually it's not. Moissanite (silicon carbide) is harder. 9.5 on the Mohs scale, vs 9 for sapphire/corundum, 10 for diamond. Its structure is the same as diamond, except it alternates between silicon and carbon atoms, the silicon-carbon bond being nearly as strong as a carbon-carbon bond. I first ran across it (as an opaque conglomerate of smaller crystals) as guides for fishing rods - the hardness prevents braided lines from gouging a groove in the guide. There are a bunch of other materials harder than corundum, but I believe moissanite is the only transparent one.

    Remember what your momma taught you - never trust a salesman.

  10. Re: Just Apple? by SternisheFan · · Score: 2
    There are 3 different versions of Gorilla Glass, I believe the Samsung Galaxy S5 uses the latest one. From Wikipedia...

    Gorilla Glass by 2010 had been used in approximately 20 percent of mobile handsets worldwide, about 200 million units.[9] The second generation, called "Gorilla Glass 2", was introduced in 2012. On October 24, 2012, Corning announced that over one billion mobile devices used Gorilla Glass.[10] Gorilla Glass 2 is 20 percent thinner than the original Gorilla Glass.[11]

    Gorilla Glass 3 was introduced at CES 2013. Gorilla Glass 3 is up to three times more damage resistant than Gorilla Glass 2, being better able to resist the deep scratches that weaken glass. It is also more flexible.[12] Gorilla Glass 3 is claimed to be 40% more scratch-resistant.[13] This is Corning's first glass to be designed through an atomic-scale modeling before anything was melted in laboratories, the optimal composition being predicted using rigidity theory.

    http://en.wikipedia.org/wiki/G...

  11. Reminds me of cars until the 1950s by Solandri · · Score: 4, Interesting

    Back in the 1920s-1940s as cars became more popular, more people started dying in car crashes. In response, the auto manufacturers did the obvious thing and started making the cars stronger and stronger. And people kept dying.

    It wasn't until the 1950s when the first controlled crash tests were done, that they discovered that the stronger car bodies were the worst possible thing you could do. They did nothing to reduce the kinetic energy of the occupants before impact. The car would hit, the strong body would stop moving almost instantly, and the occupants would keep flying forward at full speed until they hit the front of the car. This is what led to the crumple zones we have today - where the car body deliberately flexes and deforms to absorb crash energy, lessening the impact forces on the occupants.

    I think phones are going to go the same way. Rather than build the bodies and faces stronger and stronger to try to make them survive drops, they're going to be replaced with flexible screens once those come down in price and become commonplace. Bend and flex to absorb the impact energy, not try to stiffly resist it until something shatters. Scratches can be handled by a disposable plastic protector (I go through about one a year, so it's not at all inconvenient).

  12. Re:sport? by ArcadeMan · · Score: 2

    I'm thinking that's because athletes are more likely to hit their watches while doing activities.

  13. Re:Isn't it just "sapphire"? by Seraphim1982 · · Score: 2

    Because if you called it transparent alumina, people would accuse you of ripping off Star Trek.