Well, this is interesting - in a bad way! Was definitely hoping that newer models had virtually eliminated the problem (based on my tests). Of course, of millions of phones, some will have issues. Can always hope that is the case with yours. If it happens on another exchange, that would be a heck of a coincidence though and I'd assume things are still a more serious problem.
Two things I have questions about. Just so I'm sure what you mean about doing my test:
The screen ALWAYS stayed off once you got down to 1 or 1.5 inches? That's a sizable difference. While I would think 1" would be, usually, okay, it may be possible, with the right placement and shape of the ear, that it could be insufficient. Not sure, but just maybe. I would think 1.5 inches would be virtually impossible to reach as long as it is on the ear.
Since it is your speaker phone coming on, I'm pretty confident it is the sensor though (dropped calls may not be).
If you don't mind spending the money, using Call Guard might at least give you some useful info - like how often you touch the screen when it comes on AND where you touch it.
My other question - and you may not know the answer - is what does the week number mean if it is refurbished?
That is, if they take a week 40 phone and refurbish it, does it keep the same week number, or do they change it to the refurbished week?
I would hope it keeps the same number because if it doesn't, figuring things out becomes far more difficult!
You've probably seen me post about this before, but I'm pretty conscious of how I'm moving the phone while talking. If I notice I've lifted it off my ear a little and put it back, I realize that could mimic test #3. Therefore, I'll deliberately move it several inches away for 2-3 seconds and then put it back on my ear. That resets things to the original distance.
One other thing, about Call Guard. True, it's a cludge, but mostly when you start the call and app. If you hang up by pressing the top button, you'll both end the call and quit Call Guard so at least that part is simple.