JP5057613B2 - Semiconductor device and electronic equipment - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a semiconductor device having a circuit formed of a thin film transistor (hereinafter referred to as TFT) and a method for manufacturing the semiconductor device. For example, the present invention relates to an electro-optical device typified by a liquid crystal display panel and an electronic apparatus in which such an electro-optical device is mounted as a component.
[0002]
Note that in this specification, a semiconductor device refers to all devices that can function by utilizing semiconductor characteristics, and an electro-optical device, a semiconductor circuit, and an electronic device are all semiconductor devices.
[0003]
[Prior art]
In recent years, a technique for forming a thin film transistor (TFT) using a semiconductor thin film (having a thickness of about several to several hundred nm) formed on a substrate having an insulating surface has attracted attention. Thin film transistors are widely applied to electronic devices such as ICs and electro-optical devices, and development of switching devices for image display devices is urgently required.
[0004]
In a liquid crystal display device, in order to obtain a high-quality image, an active matrix type liquid crystal display device in which pixel electrodes are arranged in a matrix and a TFT is used as a switching element connected to each pixel electrode has attracted attention.
[0005]
Active matrix liquid crystal display devices are roughly classified into two types, a transmission type and a reflection type.
[0006]
In particular, the reflective liquid crystal display device has the advantage that it consumes less power because it does not use a backlight as compared with the transmissive liquid crystal display device, and is a direct-view display for mobile computers and video cameras. Demand for displays is increasing.
[0007]
The reflective liquid crystal display device uses the optical modulation action of liquid crystal to select the state in which incident light is reflected by the pixel electrode and output to the outside of the device and the state in which incident light is not output to the outside of the device Then, bright and dark display is performed, and an image is displayed by combining them. In general, a pixel electrode in a reflective liquid crystal display device is made of a metal material having a high light reflectance such as aluminum and is electrically connected to a switching element such as a thin film transistor (hereinafter referred to as TFT).
[0008]
Further, in the liquid crystal display device, TFTs using amorphous silicon or polysilicon as a semiconductor are arranged in a matrix, and an element substrate on which pixel electrodes, source lines, and gate lines connected to the TFTs are formed, and A liquid crystal material is sandwiched between a counter substrate having a counter electrode disposed opposite thereto. A color filter for color display is attached to the counter substrate. A polarizing plate is disposed as an optical shutter on each of the element substrate and the counter substrate to display a color image.
[0009]
[Problems to be solved by the invention]
In a reflection type liquid crystal display device, conventionally, after forming a pixel electrode, a surface such as a sandblasting method or an etching method is added to make the surface uneven, thereby preventing specular reflection and scattering reflected light. Was increasing the degree.
[0010]
In this invention, the unevenness | corrugation which prevents the specular reflection of a reflective electrode is formed, without increasing a process.
[0011]
[Means for Solving the Problems]
According to the present invention, in a method for manufacturing a reflection type liquid crystal display device, a convex portion for providing light scattering properties by providing irregularities on the surface of a pixel electrode is formed using the same photomask as that for forming a TFT. To do. Note that this convex portion is appropriately provided on the substrate in the pixel portion region other than the wiring and the TFT portion. Then, unevenness is formed on the surface of the pixel electrode along the unevenness formed on the surface of the insulating film covering the protrusion.
[0012]
The configuration of the invention disclosed in this specification is as follows.
A TFT including a semiconductor layer on an insulating surface, an insulating film on the semiconductor layer, and a gate electrode on the insulating film;
A plurality of protrusions on the insulating surface;
An interlayer insulating film that covers the TFT and the convex portion and has an irregular surface;
A pixel electrode electrically connected to the TFT and having a rough surface on the interlayer insulating film;
It is a semiconductor device characterized by having.
[0013]
In addition, an insulating film that covers at least the gate electrode of the TFT may be formed, and the pixel electrode may be formed in contact with the protruding portion that is not covered with the insulating film.
A TFT including a semiconductor layer on an insulating surface, an insulating film on the semiconductor layer, and a gate electrode on the insulating film;
A plurality of protrusions on the insulating surface;
A pixel electrode that is in contact with the convex portion and has an irregular surface and is electrically connected to the TFT;
It is a semiconductor device characterized by having.
[0014]
In each of the above-described configurations, the convex portion includes a material layer formed of the same material as the semiconductor layer of the TFT, a material layer formed of the same material as the insulating film of the TFT, and the same material as the gate electrode of the TFT It is characterized by being a laminate with a material layer formed in (1).
[0015]
Further, in each of the above structures, the convex portion is a laminate of a material layer formed of the same material as the insulating film of the TFT and a material layer formed of the same material as the gate electrode of the TFT. It is a feature.
[0016]
Further, a convex portion is formed on the insulating film on the semiconductor layer, an interlayer insulating film covering the convex portion is formed, and a pixel electrode having a concave and convex surface along the concave and convex portions on the surface of the interlayer insulating film is formed. The configuration of other inventions may be as follows:
A TFT including a semiconductor layer on an insulating surface, an insulating film on the semiconductor layer, and a gate electrode on the insulating film;
A plurality of protrusions on the insulating film;
An interlayer insulating film that covers the TFT and the convex portion and has an irregular surface;
A pixel electrode electrically connected to the TFT and having a rough surface on the interlayer insulating film;
It is a semiconductor device characterized by having.
[0017]
Alternatively, a convex portion may be formed on the insulating film on the semiconductor layer, and a pixel electrode having a concave and convex surface may be formed in contact with the convex portion.
A TFT including a semiconductor layer on an insulating surface, an insulating film on the semiconductor layer, and a gate electrode on the insulating film;
A plurality of protrusions on the insulating film;
A pixel electrode that is in contact with the convex portion and has an irregular surface and is electrically connected to the TFT;
It is a semiconductor device characterized by having.
[0018]
In each of the above structures, the convex portion is a material layer formed of the same material as the gate electrode of the TFT.
[0019]
Moreover, in each said structure, it has the convex part from which a height differs at least among these several convex parts, It is characterized by the above-mentioned.
[0020]
Further, each of the above-described configurations is characterized in that, among the plurality of convex portions, at least convex portions having different structures are provided.
[0021]
In each of the above structures, the semiconductor device is characterized in that the pixel electrode is a reflective liquid crystal display device made of a film containing Al or Ag as a main component or a laminated film thereof.
[0022]
Further, in each of the above configurations, a first light-shielding portion composed of a laminate of a first colored layer and a second colored layer;
A second light-shielding portion comprising a laminate of the first colored layer and the third colored layer;
The first light-shielding portion and the second light-shielding portion are formed so as to overlap between an arbitrary pixel electrode and a pixel electrode adjacent to the pixel electrode.
[0023]
In the above configuration, the amount of reflected light from the first light shielding portion and the amount of reflected light from the second light shielding portion are different from each other. Further, the first colored layer is red. Further, the second colored layer is blue. Further, the third colored layer is green. Further, the first light-shielding part and the second light-shielding part are provided on a counter substrate.
[0024]
The configuration of the invention for realizing the above structure is as follows.
Forming a semiconductor layer on the insulating surface;
Forming a first insulating film on the semiconductor layer;
Forming a conductive layer overlying the semiconductor layer on the first insulating film, and forming a convex portion having a stacked structure of the semiconductor layer, the first insulating film, and the conductive layer;
Forming a second insulating film covering the convex portion;
Forming a pixel electrode on the second insulating film,
The pixel electrode is a method for manufacturing a semiconductor device, wherein the pixel electrode overlaps with the convex portion and has a concave and convex surface. An example of the convex portion thus formed is a convex portion 900 in FIG.
[0025]
In addition, the configuration of another invention for realizing the above structure is as follows:
Forming a first insulating film on the insulating surface;
Forming a conductive layer on the first insulating film to form a convex portion having a laminated structure of the first insulating film and the conductive layer;
Forming a second insulating film covering the convex portion;
Forming a pixel electrode on the second insulating film,
The pixel electrode is a method for manufacturing a semiconductor device, wherein the pixel electrode overlaps with the convex portion and has a concave and convex surface. An example of the convex portion thus formed is a convex portion 901 in FIG. 20, and the first insulating film forming the convex portion has the same top shape as the conductive layer.
[0026]
In addition, the configuration of another invention for realizing the above structure is as follows:
Forming a conductive layer on the insulating surface and forming a convex portion made of the conductive layer;
Forming an insulating film covering the convex portion;
Forming a pixel electrode on the insulating film,
The pixel electrode is a method for manufacturing a semiconductor device, wherein the pixel electrode overlaps with the convex portion and has a concave and convex surface.
[0027]
In the manufacturing method of the present invention, the semiconductor device is a reflective liquid crystal display device in which the pixel electrode is a film containing Al or Ag as a main component or a laminated film thereof.
[0028]
In the manufacturing method of the present invention, a TFT is formed in the same process as that of the convex portion.
[0029]
In the manufacturing method of the present invention, the pixel electrode is connected to a TFT formed in the same process as the convex portion.
[0030]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below.
[0031]
FIG. 4 shows the configuration of the present invention. Here, a reflection type liquid crystal display device will be described as an example.
[0032]
In the pixel portion 407, the convex portions 701 and 702 are formed at the same time as the pixel TFT in the pixel portion 407, the surface of the insulating film formed thereon is uneven, and the surface of the pixel electrode 169 formed thereon is uneven. It is characterized by having a part.
[0033]
As shown in FIGS. 1 to 3, the convex portions 701 and 702 are formed using a mask pattern at the time of forming a semiconductor layer or a mask pattern at the time of forming a gate wiring. The protrusions 701 and 702 can be obtained with high reproducibility when manufactured using a photomask. Here, an example in which the semiconductor film, the insulating film, and the conductive film formed at the time of manufacturing the pixel TFT are stacked as the protrusions 701 and 702 is shown, but there is no particular limitation. Single layers or combined stacks can be used. For example, a convex portion made of a stacked film of a semiconductor film and an insulating film or a convex portion made of a conductive film can be formed. That is, it is possible to form convex portions having a plurality of types of heights without increasing the number of steps. Further, the convex portions adjacent to each other are separated from each other by 0.1 μm or more, preferably 1 μm or more.
[0034]
In addition, although the example which formed the convex part from which a magnitude | size differs here was shown, it does not specifically limit. Note that it is desirable that the size of the convex portion is random because scattered light is scattered more. For example, the cross section in the radial direction may be a polygon or a shape that is not symmetrical. For example, any of the shapes shown in FIGS. 6A to 6G may be used. Moreover, you may arrange | position a convex part regularly or irregularly. Note that the arrangement of the convex portions is not particularly limited as long as it is a region below the pixel electrode serving as the display region of the pixel portion, and the size of the convex portion (area viewed from the upper surface) is not particularly limited, but is 1 μm. ² ~ 400μm ² Within the range, preferably 25-100 μm ² If it is.
[0035]
The insulating film covering the convex portions 701 and 702 formed in this manner has irregularities on the surface, and the surface of the pixel electrode 169 formed thereon is also irregular. The height of the convex portion of the pixel electrode 169 is 0.3 to 3 μm, preferably 0.5 to 1.5 μm. Due to the unevenness formed on the surface of the pixel electrode 169, it was possible to scatter light when reflecting incident light as shown in FIG.
[0036]
Note that an inorganic insulating film or an organic resin film can be used as the insulating film. The curvature of the unevenness of the pixel electrode can be adjusted by the material of the insulating film. In addition, the curvature radius in the convex part of this pixel electrode is 0.1-4 micrometers, Preferably it is 0.2-2 micrometers. In addition, when an organic resin film is used as the insulating film, a film having a viscosity of 10 to 1000 cp, preferably 40 to 200 cp is used, and the surface is sufficiently affected by the projections 701 and 702 to be uneven. Use. However, if a solvent that hardly evaporates is used, irregularities can be formed even if the viscosity of the organic resin film is low.
[0037]
Thus, the present invention can form the pixel electrode 169 having irregularities on the surface without increasing the number of manufacturing steps.
[0038]
Although the example shown here is a top gate type TFT, it can also be applied to a bottom gate type TFT.
[0039]
The present invention having the above-described configuration will be described in more detail with the following examples.
[0040]
【Example】
[Example 1]
Here, a method for simultaneously manufacturing a pixel portion and TFTs (n-channel TFT and p-channel TFT) of a driver circuit provided around the pixel portion on the same substrate will be described in detail. Here, while explaining mainly using FIGS. 9-11, the manufacturing method of the reflective electrode which has unevenness in FIGS. 1-3 simultaneously is demonstrated. 1 to 3 are manufacturing process diagrams of the pixel portion (pixel TFT, convex portion, holding capacitor), and FIGS. 9 to 11 show the pixel portion (pixel TFT, holding capacitor) and the TFT of the driving circuit. FIG.
[0041]
First, in this embodiment, a substrate 100 made of glass such as barium borosilicate glass represented by Corning # 7059 glass or # 1737 glass or aluminoborosilicate glass is used. Note that as the substrate 100, a quartz substrate, a silicon substrate, a metal substrate, or a stainless steel substrate on which an insulating film is formed may be used. Further, a plastic substrate having heat resistance that can withstand the processing temperature of this embodiment may be used.
[0042]
Next, a base film 101 made of an insulating film such as a silicon oxide film, a silicon nitride film, or a silicon oxynitride film is formed over the substrate 100. Although a two-layer structure is used as the base film 101 in this embodiment, a single-layer film of the insulating film or a structure in which two or more layers are stacked may be used. As the first layer of the base film 101, a plasma CVD method is used, and SiH _Four , NH _Three And N ₂ A silicon oxynitride film 102a formed using O as a reactive gas is formed to a thickness of 10 to 200 nm (preferably 50 to 100 nm). In this embodiment, a silicon oxynitride film 101a having a film thickness of 50 nm (composition ratio Si = 32%, O = 27%, N = 24%, H = 17%) is formed. Next, as the second layer of the base film 101, a plasma CVD method is used, and SiH _Four And N ₂ A silicon oxynitride film 101b formed using O as a reaction gas is stacked to a thickness of 50 to 200 nm (preferably 100 to 150 nm). In this embodiment, a silicon oxynitride film 101b (composition ratio Si = 32%, O = 59%, N = 7%, H = 2%) having a thickness of 100 nm is formed.
[0043]
Next, semiconductor layers 102 to 106 are formed over the base film. The semiconductor layers 102 to 106 are formed by forming a semiconductor film having an amorphous structure by a known means (a sputtering method, an LPCVD method, a plasma CVD method, or the like), and then performing a known crystallization process (laser crystallization method, heat A crystalline semiconductor film obtained by performing a crystallization method or a thermal crystallization method using a catalyst such as nickel) is formed by patterning into a desired shape. The semiconductor layers 102 to 106 are formed to a thickness of 25 to 80 nm (preferably 30 to 60 nm). There is no limitation on the material of the crystalline semiconductor film, but the crystalline semiconductor film is preferably formed of silicon or a silicon germanium (SiGe) alloy. In this example, a 55 nm amorphous silicon film was formed by plasma CVD, and then a solution containing nickel was held on the amorphous silicon film. This amorphous silicon film is dehydrogenated (500 ° C., 1 hour), then thermally crystallized (550 ° C., 4 hours), and then laser annealing treatment is performed to improve crystallization. Thus, a crystalline silicon film was formed. Then, semiconductor layers 102 to 106 were formed by patterning the crystalline silicon film using a photolithography method.
[0044]
Further, after forming the semiconductor layers 102 to 106, a small amount of impurity element (boron or phosphorus) may be doped in order to control the threshold value of the TFT.
[0045]
When a crystalline semiconductor film is formed by laser crystallization, a pulse oscillation type or continuous emission type excimer laser, YAG laser, YVO _Four A laser can be used. When these lasers are used, it is preferable to use a method in which laser light emitted from a laser oscillator is linearly collected by an optical system and irradiated onto a semiconductor film. Crystallization conditions are appropriately selected by the practitioner. When an excimer laser is used, the pulse oscillation frequency is 30 Hz and the laser energy density is 100 to 400 mJ / cm. ² (Typically 200-300mJ / cm ² ). When a YAG laser is used, the second harmonic is used and the pulse oscillation frequency is 1 to 10 kHz, and the laser energy density is 300 to 600 mJ / cm. ² (Typically 350-500mJ / cm ² ) Then, when the laser beam condensed linearly with a width of 100 to 1000 μm, for example 400 μm, is irradiated over the entire surface of the substrate, the superposition ratio (overlap ratio) of the linear laser light at this time is 80 to 98%. Good.
[0046]
Next, a gate insulating film 107 that covers the semiconductor layers 102 to 106 is formed. The gate insulating film 107 is formed of an insulating film containing silicon with a thickness of 40 to 150 nm by using a plasma CVD method or a sputtering method. In this embodiment, a silicon oxynitride film (composition ratio: Si = 32%, O = 59%, N = 7%, H = 2%) with a thickness of 110 nm is formed by plasma CVD. Needless to say, the gate insulating film is not limited to the silicon oxynitride film, and another insulating film containing silicon may be used as a single layer or a stacked structure.
[0047]
When a silicon oxide film is used, TEOS (Tetraethyl Orthosilicate) and O ₂ The reaction pressure is 40 Pa, the substrate temperature is 300 to 400 ° C., and the high frequency (13.56 MHz) power density is 0.5 to 0.8 W / cm. ² And can be formed by discharging. The silicon oxide film thus manufactured can obtain good characteristics as a gate insulating film by subsequent thermal annealing at 400 to 500 ° C.
[0048]
Next, as illustrated in FIG. 9A, a first conductive film 108 with a thickness of 20 to 100 nm and a second conductive film 109 with a thickness of 100 to 400 nm are stacked over the gate insulating film 107. In this example, a first conductive film 108 made of a TaN film with a thickness of 30 nm and a second conductive film 109 made of a W film with a thickness of 370 nm were stacked.
The TaN film was formed by sputtering, and was sputtered in a nitrogen-containing atmosphere using a Ta target. The W film was formed by sputtering using a W target. In addition, tungsten hexafluoride (WF ₆ It can also be formed by a thermal CVD method using In any case, in order to use as a gate electrode, it is necessary to reduce the resistance, and the resistivity of the W film is desirably 20 μΩcm or less. The resistivity of the W film can be reduced by increasing the crystal grains. However, when there are many impurity elements such as oxygen in the W film, the crystallization is hindered and the resistance is increased. Therefore, in this embodiment, the sputtering method using a target of high purity W (purity 99.9999% or purity 99.99%) is sufficient so that impurities are not mixed from the gas phase during film formation. By forming the W film in consideration, a resistivity of 9 to 20 μΩcm could be realized.
[0049]
In this embodiment, the first conductive film 108 is TaN and the second conductive film 109 is W. However, the present invention is not particularly limited, and any of these is selected from Ta, W, Ti, Mo, Al, and Cu. You may form with an element or the alloy material or compound material which has the said element as a main component. Alternatively, a semiconductor film typified by a polycrystalline silicon film doped with an impurity element such as phosphorus may be used. The first conductive film is formed of a tantalum (Ta) film, the second conductive film is a W film, the first conductive film is formed of a tantalum nitride (TaN) film, and the second conductive film is formed. The first conductive film may be formed of a tantalum nitride (TaN) film, and the second conductive film may be a Cu film.
[0050]
Note that FIG. 9A corresponds to FIG. 1A and the same reference numerals are used. As illustrated in FIG. 1A, in the pixel portion 407, semiconductor layers 301 a to 301 d are formed at the same time as the semiconductor layer 105.
[0051]
Next, resist masks 110 to 115 are formed using a photolithography method, and a first etching process is performed to form electrodes and wirings. The first etching process is performed under the first and second etching conditions. As an etching gas, Cl ₂ , BCl _Three , SiCl _Four , CCl _Four Chlorine gas or CF represented by _Four , SF ₆ , NF _Three Fluorine gas such as O ₂ Can be used as appropriate. In this embodiment, an ICP (Inductively Coupled Plasma) etching method is used, and CF is used as an etching gas. _Four And Cl ₂ And O ₂ The gas flow ratio was 25/25/10 (sccm), and 500 W RF (13.56 MHz) power was applied to the coil-type electrode at a pressure of 1 Pa to generate plasma and perform etching. . 150 W RF (13.56 MHz) power is also applied to the substrate side (sample stage), and a substantially negative self-bias voltage is applied. The W film is etched under this first etching condition so that the end portion of the first conductive layer is tapered.
[0052]
Thereafter, the resist masks 110 to 115 are not removed and the second etching condition is changed, and the etching gas is changed to CF. _Four And Cl ₂ The gas flow ratio is 30/30 (sccm), and 500 W of RF (13.56 MHz) power is applied to the coil-type electrode at a pressure of 1 Pa to generate plasma and etching for about 30 seconds. Went. 20 W of RF (13.56 MHz) power is also applied to the substrate side (sample stage), and a substantially negative self-bias voltage is applied. CF _Four And Cl ₂ Under the second etching condition in which is mixed, the W film and the TaN film are etched to the same extent. Note that in order to perform etching without leaving a residue on the gate insulating film, it is preferable to increase the etching time at a rate of about 10 to 20%.
[0053]
In the first etching process, the shape of the mask made of resist is made suitable, and the end portions of the first conductive layer and the second conductive layer are tapered due to the effect of the bias voltage applied to the substrate side. It becomes. The angle of this taper portion is 15 to 45 °. Thus, the first shape conductive layers 117 to 122 (first conductive layers 117 a to 122 a and second conductive layers 117 b to 122 b) composed of the first conductive layer and the second conductive layer by the first etching treatment. Form. Reference numeral 116 denotes a gate insulating film, and a region that is not covered with the first shape conductive layers 117 to 122 is etched and thinned by about 20 to 50 nm.
[0054]
Then, a first doping process is performed without removing the resist mask, and an impurity element imparting n-type conductivity is added to the semiconductor layer. (FIG. 9B) The doping process may be performed by an ion doping method or an ion implantation method. The condition of the ion doping method is a dose of 1 × 10 ¹³ ~ 5x10 ¹⁵ atoms / cm ² The acceleration voltage is set to 60 to 100 keV. In this embodiment, the dose is 1.5 × 10 ¹⁵ atoms / cm ² The acceleration voltage was 80 keV. As an impurity element imparting n-type, an element belonging to Group 15, typically phosphorus (P) or arsenic (As), is used here, but phosphorus (P) is used. In this case, the conductive layers 117 to 121 serve as a mask for the impurity element imparting n-type, and the first impurity regions 123 to 127 are formed in a self-aligning manner. The first impurity regions 123 to 127 have 1 × 10 ²⁰ ~ 1x10 ^{twenty one} atoms / cm ^Three An impurity element imparting n-type is added in a concentration range of.
[0055]
Note that FIG. 9B corresponds to FIG. 1B, and the same reference numerals are used. As shown in FIG. 1B, in the pixel portion 407, the first shape conductive layers 303 to 306 are formed simultaneously with the first shape conductive layer 120 by using masks 302a to 302d made of resist.
[0056]
Next, a second etching process is performed as shown in FIG. 9C without removing the resist mask. The second etching process is performed under the third and fourth etching conditions. Similarly, as the third etching condition, the ICP etching method is used, and the etching gas is CF. _Four And Cl ₂ Each gas flow ratio is 30/30 (sccm), 500 W RF power (13.56 MHz) is supplied to the coil-type electrode at a pressure of 1 Pa, plasma is generated, and etching is performed for about 60 seconds. Went. 20 W RF (13.56 MHz) power is applied to the substrate side (sample stage), and a lower self-bias voltage is applied than in the first etching process. CF _Four And Cl ₂ Under the third etching condition in which is mixed, the W film and the TaN film are etched to the same extent.
[0057]
Then, the resist mask is not removed and the etching condition is changed to the fourth etching condition. _Four And Cl ₂ And O ₂ The gas flow ratio is 25/25/10 (sccm), and 500 W of RF (13.56 MHz) power is applied to the coil-type electrode at a pressure of 1 Pa to generate plasma for about 20 seconds. Etching was performed. 20 W RF (13.56 MHz) power is applied to the substrate side (sample stage), and a lower self-bias voltage is applied than in the first etching process. The W film is etched under this fourth etching condition.
[0058]
In this way, the W film is anisotropically etched under the third and fourth etching conditions, and the TaN film is anisotropically etched at a slower etching rate than the W film to form the second shape conductive layers 129 to 134 ( First conductive layers 129a to 134a and second conductive layers 129b to 134b) are formed. Reference numeral 128 denotes a gate insulating film, and a region not covered with the second shape conductive layers 129 to 134 is etched to a thickness of about 10 to 20 nm.
[0059]
CF for W and TaN films _Four And Cl ₂ The etching reaction by the mixed gas can be estimated from the generated radicals or ion species and the vapor pressure of the reaction product. When the vapor pressures of W and TaN fluoride and chloride are compared, WF, the fluoride of W ₆ Is extremely high, other WCl _Five , TaF _Five , TaCl _Five Are comparable. Therefore, CF _Four And Cl ₂ With this mixed gas, both the W film and the TaN film are etched. However, an appropriate amount of O is added to this mixed gas. ₂ When CF is added _Four And O ₂ Reacts to CO and F, and a large amount of F radicals or F ions are generated. As a result, the etching rate of the W film having a high fluoride vapor pressure is increased. On the other hand, TaN has a relatively small increase in etching rate even when F increases. Also, since TaN is more easily oxidized than W, ON ₂ When Ta is added, the surface of TaN is somewhat oxidized. Since the TaN oxide does not react with fluorine or chlorine, the etching rate of the TaN film further decreases. Therefore, it is possible to make a difference in the etching rate between the W film and the TaN film, and the etching rate of the W film can be made larger than that of the TaN film.
[0060]
Note that FIG. 9C corresponds to FIG. 1C, and the same reference numerals are used. As shown in FIG. 1C, in the pixel portion 407, the second shape conductive layers 307 to 310 are formed simultaneously with the second shape conductive layer 132.
[0061]
Next, after removing the resist mask, a second doping process is performed as shown in FIG. In this case, an impurity element imparting n-type conductivity is doped as a condition of a high acceleration voltage by lowering the dose than in the first doping process. For example, the acceleration voltage is 70 to 120 keV, and in this embodiment, the acceleration voltage is 90 keV. ¹² atoms / cm ² Then, a new impurity region is formed in the semiconductor layer inside the first impurity region formed in FIG. 9B. Doping is performed using the second shape conductive layers 129b to 133b as masks against the impurity elements so that the impurity elements are also added to the semiconductor layers below the tapered portions of the second conductive layers 129a to 133a.
[0062]
Note that the resist mask may be removed before the second doping process.
[0063]
Thus, the third impurity regions 140 to 144 overlapping the second conductive layers 129a to 133a, and the second impurity regions 135 to 139 between the first impurity regions 145 to 149 and the third impurity region are formed. Form. The impurity element imparting n-type conductivity is 1 × 10 6 in the second impurity region. ¹⁷ ~ 1x10 ¹⁹ atoms / cm ^Three 1 × 10 in the third impurity region. ¹⁶ ~ 1x10 ¹⁸ atoms / cm ^Three So that the concentration becomes. Note that the third impurity regions 140 to 144 have a change in the concentration of the impurity element imparting n-type contained in at least a portion overlapping with the second shape conductive layers 129a to 133a. That is, the concentration of phosphorus (P) added to the third impurity regions 140 to 144 gradually decreases from the end of the conductive layer to the inside in the region overlapping with the second shape conductive layer. Become. This is because the concentration of phosphorus (P) reaching the semiconductor layer changes due to the difference in film thickness of the tapered portion.
[0064]
Note that FIG. 10A corresponds to FIG. 2A and the same reference numerals are used. As shown in FIG. 2A, in the pixel portion 407, a third impurity region 311 is formed.
[0065]
Then, new resist masks 150 to 152 are formed, and a third doping process is performed as shown in FIG. By this third doping treatment, fourth impurity regions 153 to 158 to which an impurity element imparting a conductivity type opposite to the one conductivity type is added to the semiconductor layer that becomes the active layer of the p-channel TFT are formed. . Using the second shape conductive layers 130 and 133 as masks against the impurity element, an impurity element imparting p-type conductivity is added to form a fourth impurity region in a self-aligning manner. In this embodiment, the impurity regions 153 to 158 are diborane (B ₂ H ₆ ) Using an ion doping method. In the third doping process, the semiconductor layer forming the n-channel TFT is covered with masks 150 to 152 made of resist. By the first doping process and the second doping process, phosphorus is added to the impurity regions 153 to 158 at different concentrations, and the concentration of the impurity element imparting p-type in each of the regions is 2 ×. 10 ²⁰ ~ 2x10 ^{twenty one} atoms / cm ^Three By performing the doping treatment so as to become, no problem arises because it functions as the source region and drain region of the p-channel TFT.
[0066]
Note that FIG. 10B corresponds to FIG. 2B, and the same reference numerals are used. As shown in FIG. 2B, in the pixel portion 407, the regions of the semiconductor layers 301a to 301d are also covered with a mask 152 made of resist, but there is no particular limitation, and at least the pixel TFT (n-channel TFT) The semiconductor layer may be covered.
[0067]
Through the above steps, impurity regions are formed in the respective semiconductor layers. The second shape conductive layers 129 to 132 overlapping the semiconductor layer function as gate electrodes. Reference numeral 134 functions as a source wiring, and 133 functions as a second electrode for forming a storage capacitor.
[0068]
Next, the resist masks 150 to 152 are removed, and a first interlayer insulating film 159 covering the entire surface is formed. The first interlayer insulating film 159 is formed of an insulating film containing silicon with a thickness of 100 to 200 nm by using a plasma CVD method or a sputtering method. In this embodiment, a silicon oxynitride film with a thickness of 150 nm is formed by a plasma CVD method. Needless to say, the first interlayer insulating film 159 is not limited to the silicon oxynitride film, and another insulating film containing silicon may be used as a single layer or a stacked structure.
[0069]
Next, as shown in FIG. 10C, a step of activating the impurity element added to each semiconductor layer is performed. This activation process is performed by a thermal annealing method using a furnace annealing furnace. As the thermal annealing method, it may be performed at 400 to 700 ° C., typically 500 to 550 ° C. in a nitrogen atmosphere having an oxygen concentration of 1 ppm or less, preferably 0.1 ppm or less. The activation treatment was performed by heat treatment. In addition to the thermal annealing method, a laser annealing method or a rapid thermal annealing method (RTA method) can be applied.
[0070]
In this embodiment, simultaneously with the activation treatment, nickel used as a catalyst during crystallization is gettered to impurity regions 145 to 149, 153, and 156 containing high-concentration phosphorus, and mainly channel forming regions. The nickel concentration in the semiconductor layer is reduced. A TFT having a channel formation region manufactured in this manner has a low off-current value and good crystallinity, so that high field-effect mobility can be obtained and good characteristics can be achieved.
[0071]
Further, an activation process may be performed before the first interlayer insulating film 159 is formed. However, when the wiring material used for 129 to 134 is weak against heat, an interlayer insulating film (insulating film containing silicon as a main component, for example, a silicon nitride film) is formed to protect the wiring and the like as in this embodiment. After that, it is preferable to perform an activation treatment.
[0072]
Furthermore, a heat treatment is performed at 300 to 550 ° C. for 1 to 12 hours in an atmosphere containing 3 to 100% hydrogen to perform a step of hydrogenating the semiconductor layer. In this embodiment, heat treatment was performed at 410 ° C. for 1 hour in a nitrogen atmosphere containing about 3% hydrogen. This step is a step of terminating dangling bonds in the semiconductor layer with hydrogen contained in the interlayer insulating film. As another means of hydrogenation, plasma hydrogenation (using hydrogen excited by plasma) may be performed.
[0073]
Alternatively, the semiconductor layer may be hydrogenated by performing heat treatment (heat treatment at 300 to 550 ° C. for 1 to 12 hours) using hydrogen contained in an interlayer insulating film formed of a silicon nitride film. In this case, if heat treatment is performed at 410 ° C. for 1 hour in a nitrogen atmosphere, dangling bonds in the semiconductor layer can be terminated by hydrogen contained in the interlayer insulating film.
[0074]
In the case where a laser annealing method is used as the activation treatment, it is desirable to irradiate a laser beam such as an excimer laser or a YAG laser after the hydrogenation.
[0075]
Next, a second interlayer insulating film 160 made of an organic insulating material is formed on the first interlayer insulating film 159. In this embodiment, an acrylic resin film having a thickness of 1.6 μm is formed. Next, patterning is performed to form contact holes that reach the source wiring 134 and contact holes that reach the impurity regions 145, 147, 148, 153, and 156.
[0076]
In the driver circuit 406, wirings 161 to 166 that are electrically connected to the first impurity region or the fourth impurity region are formed. Note that these wirings are formed by patterning a laminated film of a Ti film having a thickness of 50 nm and an alloy film (alloy film of Al and Ti) having a thickness of 500 nm.
[0077]
In the pixel portion 407, a pixel electrode 169, a gate wiring 168, and a connection electrode 167 are formed. (FIG. 11) With this connection electrode 167, the source wiring 134 is electrically connected to the pixel TFT 404. In addition, the gate wiring 168 is electrically connected to the first electrode (second-shaped conductive layer 133). In addition, the pixel electrode 169 is electrically connected to a drain region of the pixel TFT, and is further electrically connected to a semiconductor layer functioning as one electrode forming a storage capacitor. Further, as the pixel electrode 169, it is preferable to use a material having excellent reflectivity such as a film containing Al or Ag as a main component or a laminated film thereof.
[0078]
11 and 3 correspond to each other, and the same reference numerals are used. As shown in FIG. 3, in the pixel portion 407, the pixel electrode 169 having the convex and concave portions on the surface can be formed by the convex portions 701 and 702. The radius of curvature of the uneven protrusion formed on the surface of the pixel electrode 169 is 0.1 to 4 μm, preferably 0.2 to 2 μm.
[0079]
As described above, the driver circuit 406 including the n-channel TFT 401, the p-channel TFT 402, and the n-channel TFT 403, and the pixel portion 407 including the pixel TFT 404 and the storage capacitor 405 can be formed over the same substrate. In this specification, such a substrate is referred to as an active matrix substrate for convenience.
[0080]
The n-channel TFT 401 of the driver circuit 406 includes a channel formation region 170, a third impurity region 140 (GOLD region) overlapping the second shape conductive layer 129 forming the gate electrode, and a second impurity region formed outside the gate electrode. Impurity region 135 (LDD region) and a first impurity region 145 functioning as a source region or a drain region. The p-channel TFT 402 includes a channel formation region 171, a fourth impurity region 155 that overlaps with the second shape conductive layer 130 that forms a gate electrode, a fourth impurity region 154 that is formed outside the gate electrode, and a source region Alternatively, the fourth impurity region 153 which functions as a drain region is provided. The n-channel TFT 403 includes a channel formation region 172, a third impurity region 142 (GOLD region) overlapping with the second shape conductive layer 131 forming the gate electrode, and a second impurity region formed outside the gate electrode. 137 (LDD region) and a first impurity region 147 functioning as a source region or a drain region.
[0081]
The pixel TFT 404 in the pixel portion includes a channel formation region 173, a third impurity region 143 (GOLD region) overlapping the second shape conductive layer 132 forming the gate electrode, and a second impurity formed outside the gate electrode. A region 138 (LDD region) and a first impurity region 148 functioning as a source region or a drain region are provided. Further, an impurity element imparting p-type conductivity is added to each of the semiconductor layers 156 to 158 functioning as one electrode of the storage capacitor 405 at the same concentration as that of the fourth impurity region. The storage capacitor 405 is formed of the second electrode 133 and the semiconductor layers 156 to 158 using an insulating film (the same film as the gate insulating film) as a dielectric.
[0082]
In the pixel structure of this embodiment, the end of the pixel electrode overlaps with the source wiring so that the gap between the pixel electrodes is shielded from light without using a black matrix.
[0083]
A top view of a pixel portion of an active matrix substrate manufactured in this embodiment is shown in FIG. In addition, the same code | symbol is used for the part corresponding to FIGS. A chain line AA ′ in FIG. 11 corresponds to a cross-sectional view taken along the chain line AA ′ in FIG. Further, a chain line BB ′ in FIG. 11 corresponds to a cross-sectional view taken along the chain line BB ′ in FIG.
[0084]
Further, according to the steps shown in this embodiment, the number of photomasks necessary for manufacturing the active matrix substrate is five (semiconductor layer pattern mask, first wiring pattern mask (first electrode 132, second electrode 133). , Source wiring 134), p-type TFT source and drain region formation pattern mask, contact hole formation pattern mask, second wiring pattern mask (including pixel electrode 169, connection electrode 167, and gate wiring 168)) It can be. As a result, the process can be shortened, and the manufacturing cost can be reduced and the yield can be improved.
[0085]
[Example 2]
In this embodiment, a process for manufacturing an active matrix liquid crystal display device from the active matrix substrate manufactured in Embodiment 1 will be described below. FIG. 4 is used for the description.
[0086]
First, after obtaining the active matrix substrate in the state shown in FIG. 3 in accordance with Embodiment 1, an alignment film 408 is formed on the active matrix substrate shown in FIG. 4 and a rubbing process is performed. In this embodiment, before the alignment film 408 is formed, columnar spacers for maintaining the substrate interval are formed at desired positions by patterning an organic resin film such as an acrylic resin film. Further, instead of the columnar spacers, spherical spacers may be scattered over the entire surface of the substrate.
[0087]
Next, the counter substrate 410 is prepared. In accordance with Embodiment 1, colored layers 411 and 412 and a planarizing film 413 are formed on the counter substrate 410. The red colored layer 411 and the blue colored layer 412 are partially overlapped to form the second light shielding portion. Although not shown in FIG. 4, the first light-shielding portion is formed by partially overlapping the red colored layer and the green colored layer.
[0088]
Next, a counter electrode 414 was formed in the pixel portion, an alignment film 415 was formed on the entire surface of the counter substrate, and a rubbing process was performed.
[0089]
Then, the active matrix substrate on which the pixel portion and the drive circuit are formed and the counter substrate are bonded together with a sealant. A filler is mixed in the sealing agent, and two substrates are bonded to each other with a uniform interval by the filler and the columnar spacer. Thereafter, a liquid crystal material 409 is injected between both substrates and completely sealed with a sealant (not shown). A known liquid crystal material may be used for the liquid crystal material 409. In this way, the active matrix liquid crystal display device shown in FIG. 4 is completed.
[0090]
In this embodiment, the substrate shown in Embodiment 1 is used. Therefore, in FIG. 5 showing a top view of the pixel portion of Example 1, at least the gap between the gate wiring 168 and the pixel electrodes 169 and 177, the gap between the gate wiring 168 and the connection electrode 167, and the connection electrode 167 and the pixel electrode 169. It is necessary to shield the gap. In this embodiment, the counter substrate is bonded so that the first light-shielding portion and the second light-shielding portion overlap each other at the position where light should be shielded.
[0091]
FIG. 12 is a simplified diagram showing a part of a pixel portion of the completed liquid crystal display device. In FIG. 12, the colored layer (B) 12 is formed so as to overlap with the pixel electrode 169 indicated by a chain line. Further, the second light shielding unit 16 shields light between the pixel electrode 169 and the adjacent pixel electrode 177. The second light shielding portion 16 is formed by overlapping the colored layer (B) and the colored layer (R). The second light shielding unit 16 also shields the pixel TFT of the adjacent pixel (R). Further, an end portion of the colored layer (B) 12 and an end portion of the colored layer (G) 11 are formed on the source wiring 134 indicated by a dotted line. Moreover, the 1st light-shielding part 15 overlaps and forms the colored layer (G) and the colored layer (R). In FIG. 12, patterning is performed so that the end of the colored layer (B) overlapping the source wiring is in contact with the end of the colored layer (G). Similarly, patterning was performed so that the end of the colored layer (R) overlapping the source wiring and the end of the colored layer (G) were in contact with each other.
[0092]
In this way, the number of steps can be reduced by shielding the gaps between the pixels with the first light shielding part 15 or the second light shielding part 16 without forming a black mask.
[0093]
[Example 3]
The structure of the active matrix liquid crystal display device (FIG. 4) obtained by using Example 2 will be described with reference to the top view of FIG. In addition, the same code | symbol was used for the part corresponding to FIG.
[0094]
The top view shown in FIG. 7 includes a pixel portion, a driving circuit, an external input terminal 203 to which an FPC (Flexible Printed Circuit Board: Flexible Printed Circuit) is pasted, and a wiring 204 that connects the external input terminal to the input portion of each circuit. The formed active matrix substrate 201 and the counter substrate 202 on which a colored layer or the like is formed are bonded to each other with a sealant 200 interposed therebetween.
[0095]
On the upper surface of the gate wiring side driving circuit 205 and the source wiring side driving circuit 206, a light shielding portion 207 in which a red coloring layer and a blue coloring layer are laminated on the counter substrate side is formed. In addition, the colored layer 208 formed on the counter substrate side over the pixel portion 407 is provided with a colored layer of each color of red (R), green (G), and blue (B) corresponding to each pixel. In actual display, a color display is formed with three colors of a red (R) colored layer, a green (G) colored layer, and a blue (B) colored layer. The arrangement of the colored layers of these colors is arbitrary. Shall.
[0096]
FIG. 8A shows a cross-sectional view of the external input terminal 203 shown in FIG. The external input terminal is formed on the active matrix substrate side, and the gate wiring through the interlayer insulating film 210 is formed by the wiring 209 formed in the same layer as the pixel electrode in order to reduce interlayer capacitance and wiring resistance and prevent defects due to disconnection. Are connected to a wiring 211 formed in the same layer.
[0097]
Further, an FPC composed of a base film 212 and a wiring 213 is bonded to the external input terminal with an anisotropic conductive resin 214. Further, the mechanical strength is increased by the reinforcing plate 215.
[0098]
FIG. 8B shows a detailed view thereof, and shows a cross-sectional view of the external input terminal shown in FIG. An external input terminal provided on the active matrix substrate side is formed of a wiring 211 formed in the same layer as the first electrode and the source wiring, and a wiring 209 formed in the same layer as the pixel electrode. Of course, this is only an example of the configuration of the terminal portion, and it may be formed with only one of the wirings. For example, in the case where the wiring 211 is formed using the same layer as the first electrode and the source wiring, it is necessary to remove the interlayer insulating film formed thereover. The wiring 209 formed of the same layer as the pixel electrode has a two-layer structure of a Ti film 209a and an alloy film (Al / Ti alloy film) 209b. The FPC is formed of a base film 212 and a wiring 213. The wiring 209 and the wiring 209 formed in the same layer as the pixel electrode include a thermosetting adhesive 214 and conductive particles 216 dispersed therein. Are bonded together with an anisotropic conductive adhesive consisting of: to form an electrical connection structure.
[0099]
The active matrix liquid crystal display device manufactured as described above can be used as a display portion of various electronic devices.
[0100]
[Example 4]
In this example, the example shown in Example 2, that is, the arrangement of colored layers provided on the counter substrate (FIG. 12) is shown in detail.
[0101]
FIG. 13A shows an example in which the first light-shielding portion 15, the second light-shielding portion 16, and the pixel openings 17 to 19 are formed by appropriately forming the three colored layers 11 to 13. Yes. In general, the colored layer is formed using a color resist made of an organic photosensitive material in which a pigment is dispersed.
[0102]
The first light shielding part 15 and the second light shielding part 16 are formed so as to shield the gap between the pixels. Accordingly, the incident light is absorbed by the first light-shielding part 15 and the second light-shielding part 16 and is recognized as almost black by the observer. Further, the first light shielding portion 15 and the second light shielding portion 16 are formed so as to overlap pixel TFTs (not shown here) of the element substrate, and serve to protect the pixel TFTs from external light.
[0103]
The first light shielding portion 15 is formed by laminating a green colored layer 11 and a red colored layer 13. The red colored layer 13 is patterned in a lattice pattern. The green colored layer 11 is patterned in the same shape (stripe shape) as before.
[0104]
The second light shielding portion 16 is formed by laminating a blue colored layer 12 and a red colored layer 13. The blue colored layer 12 is patterned into a shape that partially overlaps the adjacent red colored layer 13.
[0105]
Note that FIG. 13B illustrates a cross-sectional structure in which the first light-blocking portion and the second light-blocking portion in FIG. 13A are cut by a chain line (A1-A1 ′). As shown in FIG. 13B, a colored layer 13 is laminated so as to cover the colored layers 11 and 12 on the counter substrate 10, and the colored layer 13 is covered with a planarizing film 14.
[0106]
Also, a laminated film (first light shielding portion 15) of the green colored layer 11 and the red colored layer 13, a laminated film (second light shielding portion 16) of the blue colored layer 12 and the red colored layer 13, The respective reflectivities of the laminated film of the green colored layer and the blue colored layer are shown in FIG.
[0107]
As shown in FIG. 29, R + B + Al (corresponding to the second light shielding portion 16) has a reflectance of about 35% in the wavelength region of 400 to 450 nm, and functions sufficiently as a light shielding mask. R + G + Al (corresponding to the first light shielding portion 15) has a reflectance of about 50% near 570 nm, but functions sufficiently as a light shielding mask.
[0108]
In addition, the non-single-crystal silicon film forming the active layer of the TFT tends to absorb light in the wavelength region of 500 nm. In the wavelength region of 500 nm, the first light-shielding part 15 and the second light-shielding part 16 can suppress the reflectance to 10% or less, so that deterioration of the TFT due to light can be suppressed.
[0109]
As described above, this embodiment is characterized in that the light shielding mask is formed of the laminated film (R + B or R + G) formed of two colored layers. As a result, the step of forming the black matrix can be omitted, and the number of steps is reduced.
[0110]
Note that, in the pixel opening, as in the conventional example (reflectance of a single layer) shown in FIG. 30, the blue colored layer exhibits a reflectivity exceeding 90% near 450 nm. The green colored layer shows a reflectance exceeding 90% at around 530 nm. The red colored layer shows a reflectance exceeding 90% at 600 to 800 nm.
[0111]
However, the cross-sectional view illustrated in FIG. 13B is an example and is not particularly limited. For example, after the colored layer (R) is first formed, the colored layer (B) and the colored layer (G) are stacked. The colored layer (G) may be formed first, then the colored layer (R) may be formed, and then the colored layer (B) may be laminated, or the colored layer (B) may be formed first. After that, the colored layer (R) may be formed, and then the colored layer (G) may be laminated.
[0112]
FIG. 14 shows the positional relationship between the wiring between the pixel electrodes, the pixel electrode, and the coloring layer. In FIG. 14A, the end surfaces of the colored layer (B) 58 and the colored layer (R) 59 are in contact with each other above the source wiring 50 so as to shield light between the pixel electrode 51 and the pixel electrode 52. An example in which the contact surface exists on the source wiring is shown. In FIG. 14A, 53 and 55 are alignment films, 54 is a liquid crystal, 56 is a counter electrode, and 57 is a flattening film.
[0113]
Note that the structure is not limited to the example illustrated in FIG. 14A, and a structure illustrated in FIGS. 14B and 14C may be employed in consideration of a shift during patterning of the colored layer. FIG. 14B shows a colored layer (R) 69 such that the end of the colored layer (B) 68 partially overlaps above the source wiring 60 so as to shield light between the pixel electrode 61 and the pixel electrode 62. It is an example which forms. In FIG. 14C, the colored layer (B) 78 and the colored layer (R) 79 are not in contact with each other above the source wiring 70 so as to shield light between the pixel electrode 71 and the pixel electrode 72. This is an example.
[0114]
[Example 5]
In this embodiment, a method for manufacturing an active matrix substrate different from that in Embodiment 1 will be described with reference to FIGS. In Example 1, an impurity region is formed by adding an impurity element imparting n-type in a self-aligning manner. In this example, the number of masks is increased by one to form a source region or a drain region of an n-channel TFT. It is characterized by that.
[0115]
Since other configurations have already been described in the first embodiment, the first embodiment is referred to for the detailed configuration, and the description thereof is omitted here.
[0116]
First, the same state as in FIG. 9A is obtained according to the first embodiment. The drawing corresponding to FIG. 9A is FIG. 15A, and the same reference numerals are used. Note that FIG. 15A and FIG. 18A correspond and the same reference numerals are used. As shown in FIG. 18A, in the pixel portion 803, the semiconductor layers 600a and 600b are formed at the same time as the semiconductor layer 105.
[0117]
Next, resist masks 601 to 607 are formed by photolithography, and a first etching process for forming electrodes and wirings is performed. As an etching gas, Cl ₂ , BCl _Three , SiCl _Four , CCl _Four Chlorine gas or CF represented by _Four , SF ₆ , NF _Three Fluorine gas such as O ₂ Can be used as appropriate. In this embodiment, the ICP etching method is used, and the etching gas is CF. _Four And Cl ₂ Etching was performed by generating 500 W of RF (13.56 MHz) power to the coil-type electrode at a pressure of 1 Pa to generate plasma. 20 W of RF (13.56 MHz) power is also applied to the substrate side (sample stage), and a substantially negative self-bias voltage is applied. CF _Four And Cl ₂ Under the etching conditions in which is mixed, both the W film and the TaN film are etched to the same extent. Note that in order to perform etching without leaving a residue on the gate insulating film, it is preferable to increase the etching time at a rate of about 10 to 20%.
[0118]
By the first etching process, the ends of the first conductive layer and the second conductive layer are tapered due to the effect of the bias voltage applied to the substrate side. The angle of this taper portion is 15 to 45 °. Thus, the W film and the TaN film are etched to form first shape conductive layers 608 to 613 (first conductive layers 608a to 613a and second conductive layers 608b to 613b). Reference numeral 614 denotes a gate insulating film, and a region not covered with the first shape conductive layers 608 to 613 is etched by about 20 to 50 nm to form a thinned region. (Fig. 15 (B))
[0119]
Note that FIG. 15B corresponds to FIG. 18B, and the same reference numerals are used. As shown in FIG. 18B, in the pixel portion 803, the first shape conductive layers 903 to 906 are formed simultaneously with the first shape conductive layer 611 using masks 902a to 902d made of resist.
[0120]
Next, a second etching process is performed without removing the resist masks 601 to 607. CF as etching gas _Four And Cl ₂ And O ₂ Etching was performed by generating 500 W of RF (13.56 MHz) power to the coil-type electrode at a pressure of 1 Pa to generate plasma. 20 W RF (13.56 MHz) power is applied to the substrate side (sample stage), and a lower self-bias voltage is applied than in the first etching process. The W film is etched under these etching conditions.
[0121]
The W film is anisotropically etched by the second etching process, and the TaN film as the first conductive layer is slightly etched at a slower etching rate than the W film, so that the second shape conductive layers 615 to 620 are formed. (First conductive layers 615a to 620a and second conductive layers 615b to 620b) are formed. Reference numeral 621 denotes a gate insulating film, and a region not covered with the second shape conductive layers 615 to 620 is etched and thinned.
[0122]
Next, a first doping process is performed. The doping process may be performed by ion doping or ion implantation. In this case, an impurity element imparting n-type is doped as a high acceleration voltage condition. As an impurity element imparting n-type, an element belonging to Group 15, typically phosphorus (P) or arsenic (As), is used here, but phosphorus (P) is used. For example, the acceleration voltage is set to 70 to 120 keV, and the impurity regions (A) 622 to 626 are formed. (FIG. 15C) Doping uses the second shape conductive layers 615 to 619 as masks against the impurity elements, and the impurity elements are also added to the semiconductor layers below the tapered portions of the second conductive layers 615a to 619a. Doping as is done. Thus, among the impurity regions (A) 622 to 626 formed in a self-aligned manner, the impurity regions overlapping with the conductive layers 615 to 619 are 622b, 623b, 624b, 625b, and 626b, and do not overlap with the conductive layers 615 to 619. The impurity regions are 622a, 623a, 624a, 625a, and 626a.
[0123]
Note that FIG. 15C corresponds to FIG. 18C, and the same reference numerals are used. As illustrated in FIG. 18C, in the pixel portion 803, the second shape conductive layers 907 to 910 are formed at the same time as the second shape conductive layer 618. As shown in FIG. 18C, an impurity region (A) 911 is formed in the pixel portion 803.
[0124]
Next, after removing the resist mask, the gate insulating film 621 is selectively removed using the conductive layers 615 to 619 as masks to form insulating layers 627a, 627b, and 627c. Alternatively, the resist mask used for forming the second shape conductive layers 615 to 619 may be removed simultaneously with the formation of the insulating layers 627a, 627b, and 627c. (Fig. 15D)
[0125]
Note that FIG. 15D corresponds to FIG. 18D, and the same reference numerals are used.
[0126]
Next, resist masks 628 and 629 are formed by photolithography, and then a second doping process is performed. In this case, the semiconductor layer is doped with an impurity element imparting n-type as a condition of a low acceleration voltage by raising the dose amount compared to the first doping treatment. Impurity regions (B) 630 to 634 have 1 × 10 ²⁰ ~ 1x10 ^{twenty one} atoms / cm ^Three An impurity element imparting n-type is added in a concentration range of. (FIG. 16 (A))
[0127]
Note that FIG. 16A and FIG. 19A correspond and the same reference numerals are used.
[0128]
In this manner, impurity regions (B) 630, 632, and 633 that become the source region or drain region of the n-channel TFT can be formed. In the pixel portion, a region 636 that does not overlap with the conductive layer 618 is formed between the impurity region (A) 625 b that overlaps with the conductive layer 618 and the impurity region 633. This region 636 functions as an LDD region of the n-channel TFT. Further, the impurity element added to the impurity regions (B) 631 and 634 is added in order to reduce the nickel concentration in the semiconductor layer which mainly becomes a channel formation region in a later gettering step.
[0129]
Then, after removing the resist masks 628 and 629 as in the first embodiment, new resist masks 637 to 639 are formed, and a third doping process is performed. (Fig. 16B)
[0130]
Note that FIG. 16B corresponds to FIG. 19B, and the same reference numerals are used.
[0131]
By this third doping treatment, impurity regions (C) 640 to 644 in which an impurity element imparting a conductivity type opposite to the one conductivity type is added to the semiconductor layer that becomes the active layer of the p-channel TFT. . The second conductive layers 616 and 619 are used as masks against the impurity element, and an impurity element imparting p-type is added to form an impurity region (C) in a self-aligning manner. In this embodiment, the impurity regions (C) 640 to 644 are diborane (B ₂ H ₆ ) Using an ion doping method. Similarly to Example 1, phosphorus is added to the impurity regions (C) 640 to 644 at different concentrations, and the concentration of the impurity element imparting p-type is 2 × 10 2 in any of the regions. ²⁰ ~ 2x10 ^{twenty one} atoms / cm ^Three By performing the doping treatment so as to become, no problem arises because it functions as the source region and drain region of the p-channel TFT.
[0132]
Next, the resist masks 637 to 639 are removed as in Example 1, and a first interlayer insulating film 645 covering the entire surface is formed. The first interlayer insulating film 645 is formed of an insulating film containing silicon with a thickness of 100 to 200 nm using a plasma CVD method or a sputtering method.
[0133]
Next, as shown in FIG. 16C, a step of activating the impurity element added to each semiconductor layer is performed. This activation process is performed by a thermal annealing method using a furnace annealing furnace. The thermal annealing method may be performed at 400 to 700 ° C., typically 500 to 550 ° C. in a nitrogen atmosphere. In addition to the thermal annealing method, a laser annealing method or a rapid thermal annealing method (RTA method) can be applied.
[0134]
In this embodiment, simultaneously with the activation treatment, nickel used as a catalyst during crystallization is gettered to the impurity regions (B) 630 to 634 containing high concentration phosphorus, and mainly the channel formation region. The nickel concentration in the resulting semiconductor layer is reduced. A TFT having a channel formation region manufactured in this manner has a low off-current value and good crystallinity, so that high field-effect mobility can be obtained and good characteristics can be achieved.
[0135]
Note that FIG. 16C corresponds to FIG. 19C, and the same reference numerals are used.
[0136]
Further, the activation treatment may be performed before the first interlayer insulating film 645 is formed. However, in the case where the wiring material used for the second shape conductive layers 615 to 619 is weak against heat, an interlayer insulating film (an insulating film containing silicon as a main component; For example, the activation treatment is preferably performed after the silicon nitride film) is formed.
[0137]
Through the above steps, impurity regions are formed in the respective semiconductor layers. The second shape conductive layers 615 to 618 overlapping with the semiconductor layer function as gate electrodes. Reference numeral 620 functions as a source wiring, and 619 functions as a second electrode for forming a storage capacitor.
[0138]
Further, a heat treatment is performed at 300 to 550 ° C. for 1 to 12 hours in a nitrogen atmosphere containing 3% hydrogen to perform a step of hydrogenating the semiconductor layer. Further, heat treatment may be performed in an atmosphere containing 3 to 100% hydrogen. As another means of hydrogenation, plasma hydrogenation (using hydrogen excited by plasma) may be performed.
[0139]
Alternatively, the semiconductor layer may be hydrogenated by performing heat treatment (heat treatment at 300 to 550 ° C. for 1 to 12 hours) using hydrogen contained in an interlayer insulating film formed of a silicon nitride film. In this case, if heat treatment is performed at 410 ° C. for 1 hour in a nitrogen atmosphere, dangling bonds in the semiconductor layer can be terminated by hydrogen contained in the interlayer insulating film.
[0140]
In the case where a laser annealing method is used as the activation treatment, it is desirable to irradiate a laser beam such as an excimer laser or a YAG laser after the hydrogenation.
[0141]
Next, a second interlayer insulating film 646 made of an organic resin material is formed on the first interlayer insulating film 645. In this embodiment, an organic resin material is used, but there is no particular limitation, and an insulating film containing silicon (a silicon oxynitride film, a silicon oxide film, a silicon nitride film, or the like) may be used as a single layer or a stacked structure. Next, patterning is performed to form a contact hole reaching the source wiring 134 and contact holes reaching the impurity regions (B) and (C) 630, 632, 633, 640, and 643.
[0142]
Then, wirings 647 to 652 that are electrically connected to the impurity region (B) or the impurity region (C), respectively, are formed in the driver circuit. Note that these wirings are formed by patterning a laminated film of a Ti film having a thickness of 50 nm and an alloy film (alloy film of Al and Ti) having a thickness of 500 nm.
[0143]
In the pixel portion, a pixel electrode 656, a gate wiring 654, and a connection electrode 653 are formed. (FIG. 17) With this connection electrode 653, the source wiring 620 is electrically connected to the pixel TFT. The gate wiring 654 is electrically connected to the first electrode (second-shaped conductive layer 618). In addition, the pixel electrode 656 is electrically connected to the drain region of the pixel TFT and further electrically connected to the semiconductor layer 643 functioning as one electrode forming the storage capacitor.
[0144]
As described above, a driver circuit including an n-channel TFT, a p-channel TFT, and an n-channel TFT, a pixel portion including a pixel TFT and a storage capacitor can be formed over the same substrate. In this specification, such a substrate is referred to as an active matrix substrate for convenience.
[0145]
The semiconductor layer of the n-channel TFT of the driver circuit includes a channel formation region, an impurity region (A) 622b (GOLD region) that overlaps with the second shape conductive layer 615 forming the gate electrode, and an impurity that functions as a source region or a drain region. A region (B) 630 is included. The semiconductor layer of the p-channel TFT includes a channel formation region, an impurity region (C) 642 that overlaps with the second shape conductive layer 616 forming the gate electrode, and an impurity region (C) 640 that functions as a source region or a drain region. have. The semiconductor layer of the n-channel TFT includes a channel formation region, an impurity region (A) 624b (GOLD region) that overlaps with the second shape conductive layer 617 forming the gate electrode, and an impurity region that functions as a source region or a drain region. (B) 632 is included.
[0146]
The semiconductor layer of the pixel TFT in the pixel portion includes a channel formation region, an impurity region (A) 625b (GOLD region) overlapping with the second shape conductive layer 618 forming the gate electrode, and an impurity region 636 formed outside the gate electrode. (LDD region) and an impurity region (B) 633 which functions as a source region or a drain region. In addition, an impurity element imparting p-type conductivity is added to each of the semiconductor layers 643 and 644 functioning as one electrode of the storage capacitor at the same concentration as the impurity region (C). The storage capacitor is formed using the second electrode 619 and the semiconductor layers 643 and 644 using the insulating layer 627c (the same film as the gate insulating film) as a dielectric.
[0147]
Further, according to the process of Example 2 using the active matrix substrate manufactured in this example, the liquid crystal display device shown in FIG. 20 is obtained. As shown in FIG. 20, convex portions 900 and 901 having different heights are formed in the pixel portion 803. The convex portions 900 and 901 can be formed without increasing the number of masks. In FIG. 20, when the semiconductor layer is patterned, a mask that does not form a semiconductor layer is used for the convex portion 901, so that the height of the convex portion 901 is lower than the convex portion 900 by the film thickness of the semiconductor layer.
[0148]
By doing so, the height difference of the unevenness formed on the surface of the pixel electrode can be increased without increasing the number of manufacturing steps, and the reflected light can be scattered.
[0149]
Note that this embodiment can be combined with any of Embodiments 1 to 4.
[0150]
[Example 6]
In this embodiment, a method for manufacturing an active matrix substrate different from that in Embodiment 1 will be described with reference to FIGS. Although the gate electrode manufacturing method and the doping order are different from those in the first embodiment, the steps after the activation treatment are the same.
[0151]
First, according to Example 1, after performing the 1st etching process, the 1st doping process is performed and the state of FIG. 9 (B) is obtained. FIG. 21A is the same as FIG. 9B and uses the same reference numerals.
[0152]
Next, a second etching process is performed without removing the resist mask. CF as etching gas _Four And Cl ₂ And O ₂ Then, the W film is selectively etched. At this time, the second conductive layers 701b to 706b are formed by the second etching process. On the other hand, the first conductive layers 117a to 122a are hardly etched, and the first conductive layers 701a to 706a are formed. Next, a second doping process is performed to obtain the state of FIG. Doping is performed using the first conductive layers 701a to 706a as masks against the impurity element so that the impurity element is added to the semiconductor layer below the tapered portion of the second conductive layer. In this manner, impurity regions 707 to 711 overlapping with the second conductive layer are formed. The concentration of phosphorus (P) added to the impurity region has a gentle concentration gradient according to the film thickness of the tapered portion of the second conductive layer. Note that, in the semiconductor layer overlapping the tapered portion of the second conductive layer, the impurity concentration is slightly lower from the end of the tapered portion of the second conductive layer toward the inside, but the concentration is almost the same. . An impurity element is also added to the first impurity regions 123 to 127 to form impurity regions 712 to 716.
[0153]
Next, a third etching process is performed without removing the resist mask. In the third etching process, the tapered portion of the second conductive layer is partially etched to reduce a region overlapping with the semiconductor layer. In the third etching, CHF is used as an etching gas. _Three And using a reactive ion etching method (RIE method). Second conductive layers 717 to 722 are formed by the third etching. At this time, the insulating film 116 is also etched to form an insulating film 723.
[0154]
By the third etching, impurity regions (LDD regions) 707a to 711a that do not overlap with the second conductive layers 717 to 722 are formed. Note that the impurity regions (GOLD regions) 707b to 711b remain overlapped with the second conductive layers 717 to 721.
[0155]
In this way, in this embodiment, the impurity concentration in the impurity regions (GOLD regions) 707 b to 711 b overlapping with the second conductive layers 717 to 721 and the second conductive layer 717 are compared with those in the first embodiment. The difference between the impurity concentration in the impurity regions (LDD regions) 707a to 711a that do not overlap with .about.721 can be reduced, and the reliability can be improved.
[0156]
Next, after removing the resist mask, new resist masks 724 to 726 are formed, and a third doping process is performed. By this third doping treatment, impurity regions 727 to 732 to which an impurity element imparting a conductivity type opposite to the one conductivity type is added to the semiconductor layer that becomes the active layer of the p-channel TFT are formed. The first conductive layers 701b to 705b are used as masks against the impurity element, and an impurity element imparting p-type is added to form an impurity region in a self-aligning manner. In this embodiment, the impurity regions 727 to 732 are diborane (B ₂ H ₆ ) Using an ion doping method. In the third doping process, the semiconductor layer forming the n-channel TFT is covered with masks 724 to 726 made of resist. In the first doping process and the second doping process, phosphorus is added to the impurity regions 727 to 732 at different concentrations, and the concentration of the impurity element imparting p-type in each of the regions is 2 ×. 10 ²⁰ ~ 2x10 ^{twenty one} atoms / cm ^Three By performing the doping treatment so as to become, no problem arises because it functions as the source region and drain region of the p-channel TFT. In this embodiment, since a part of the semiconductor layer that becomes an active layer of the p-channel TFT is exposed, there is an advantage that an impurity element (boron) can be added more easily than in the first embodiment.
[0157]
Through the above steps, impurity regions are formed in the respective semiconductor layers.
[0158]
Next, the resist masks 724 to 726 are removed, and a first interlayer insulating film 733 is formed. The first interlayer insulating film 733 is formed of an insulating film containing silicon with a thickness of 100 to 200 nm using a plasma CVD method or a sputtering method. In this embodiment, a silicon oxynitride film with a thickness of 150 nm is formed by a plasma CVD method. Needless to say, the first interlayer insulating film 733 is not limited to the silicon oxynitride film, and another insulating film containing silicon may be used as a single layer or a stacked structure.
[0159]
Next, as shown in FIG. 22B, a step of activating the impurity element added to each semiconductor layer is performed. This activation process is performed by a thermal annealing method using a furnace annealing furnace. As the thermal annealing method, it may be performed at 400 to 700 ° C., typically 500 to 550 ° C. in a nitrogen atmosphere having an oxygen concentration of 1 ppm or less, preferably 0.1 ppm or less. The activation treatment was performed by heat treatment. In addition to the thermal annealing method, a laser annealing method or a rapid thermal annealing method (RTA method) can be applied.
[0160]
In this embodiment, simultaneously with the activation treatment, nickel used as a catalyst in crystallization is gettered into impurity regions 712 to 716, 727, and 730 containing high concentration phosphorus, and mainly channel forming regions. The nickel concentration in the semiconductor layer is reduced. A TFT having a channel formation region manufactured in this manner has a low off-current value and good crystallinity, so that high field-effect mobility can be obtained and good characteristics can be achieved.
[0161]
In addition, an activation process may be performed before forming the first interlayer insulating film. However, when the wiring material used is weak against heat, it is activated after an interlayer insulating film (insulating film containing silicon as a main component, for example, a silicon nitride film) is formed to protect the wiring and the like as in this embodiment. It is preferable to perform the conversion treatment.
[0162]
Furthermore, a heat treatment is performed at 300 to 550 ° C. for 1 to 12 hours in an atmosphere containing 3 to 100% hydrogen to perform a step of hydrogenating the semiconductor layer. In this embodiment, heat treatment was performed at 410 ° C. for 1 hour in a nitrogen atmosphere containing about 3% hydrogen. This step is a step of terminating dangling bonds in the semiconductor layer with hydrogen contained in the interlayer insulating film. As another means of hydrogenation, plasma hydrogenation (using hydrogen excited by plasma) may be performed.
[0163]
In the case where a laser annealing method is used as the activation treatment, it is desirable to irradiate a laser beam such as an excimer laser or a YAG laser after the hydrogenation.
[0164]
Subsequent steps are almost the same as those in the first embodiment. According to the first embodiment, the second interlayer insulating film, wirings connected to the respective semiconductor layers, and the like can be formed, and the state shown in FIG. 22C can be obtained. .
[0165]
Further, a liquid crystal display device can be obtained by following the steps of Example 2 using the active matrix substrate manufactured in this example.
[0166]
21 and 22 show the manufacturing steps for forming the driver circuit, the TFT of the pixel portion, and the storage capacitor. If the mask is changed as appropriate, a convex portion is formed in the pixel portion as shown in the first embodiment. In addition, irregularities can be formed on the surface of the pixel electrode.
[0167]
Note that this embodiment can be combined with any of Embodiments 1 to 4.
[0168]
[Example 7]
In Example 1, Example 5, and Example 6, an example of manufacturing a pixel electrode using a convex portion formed simultaneously with the manufacture of a top gate type TFT is shown. In this example, FIGS. 23 and 24 are used. An example of manufacturing a pixel electrode using a convex portion formed simultaneously with the manufacture of an inverted staggered TFT will be described.
[0169]
First, the gate wiring 1000 is formed using a first mask (first photomask). At this time, a metal layer 1001 is formed using the same material as the gate wiring in a region to be a display region.
[0170]
Next, the gate wiring 1000 and the metal layer 1001 are covered, and an insulating film (gate insulating film) 1002, a first amorphous semiconductor film, a second amorphous semiconductor film containing an impurity element imparting n-type, and A first conductive film is sequentially stacked. Note that a microcrystalline semiconductor film may be used instead of an amorphous semiconductor film, or a microcrystalline semiconductor including an impurity element imparting n-type instead of an amorphous semiconductor film including an impurity element imparting n-type. A membrane may be used. Further, these films can be formed using a sputtering method or a plasma CVD method in a plurality of chambers or in the same chamber without being continuously exposed to the atmosphere. By not exposing to the atmosphere, contamination of impurities can be prevented.
[0171]
Next, the first conductive film is patterned with a second mask (second photomask) to form a wiring made of the first conductive film (to be a source wiring and an electrode (drain electrode) later), and The second amorphous semiconductor film is patterned to form a second amorphous semiconductor film containing an impurity element imparting n-type, and the first amorphous semiconductor film is patterned to form a first non-crystalline semiconductor film. A crystalline semiconductor film is formed. Similarly, the first amorphous semiconductor film, the second amorphous semiconductor film containing an impurity element imparting n-type conductivity, and the first conductive film are also left over the metal layer 1001. Pattern. In this patterning, in order to improve the coverage of the second conductive film to be formed later, etching is performed such that the end portion is stepped as shown in FIG.
[0172]
Moreover, the shape of the metal layer 1001 and the laminate (convex portion) formed thereon is not particularly limited, and the radial cross section may be a polygon or a shape that is not symmetrical. For example, any of the shapes shown in FIGS. 6A to 6G may be used. Further, the metal layer 1001 and the laminate (convex portion) formed thereon may be arranged regularly or irregularly. The height of the metal layer 1001 and the laminate (convex portion) formed thereon is 0.3 to 3 μm, preferably 0.5 to 1.5 μm.
[0173]
Next, a resist mask is formed using a shadow mask in the terminal portion, and after the insulating film 1002 covering the pad portion of the terminal portion is selectively removed, the resist mask is removed. Further, instead of the shadow mask, a resist mask may be formed by a screen printing method to form an etching mask.
[0174]
Thereafter, a second conductive film is formed on the entire surface. Note that as the second conductive film, a reflective conductive film, for example, a material film made of Al or Ag is used.
[0175]
Next, the second conductive film is patterned with a third mask (third photomask) to form a pixel electrode 1004 made of the second conductive film, and the wiring is patterned to form the source wiring 1003 and the electrodes ( Drain region) 1009 and patterning the second amorphous semiconductor film containing an impurity element imparting n-type to form a source region comprising the second amorphous semiconductor film containing an impurity element imparting n-type 1008 and a drain region 1009 are formed, and the first amorphous semiconductor film 1006 is formed by removing part of the first amorphous semiconductor film.
[0176]
Next, an alignment film 1005 was formed and rubbed.
[0177]
With this configuration, the number of photomasks used in the photolithography technique can be three when the pixel TFT portion is manufactured.
[0178]
In addition, with such a structure, the insulating film formed over the metal layer 1001, the first amorphous semiconductor film, the second amorphous semiconductor film containing an impurity element imparting n-type conductivity, Since the pixel electrode 1004 is formed so as to cover the unevenness by the laminate (convex portion) made of the first conductive film, the surface of the pixel electrode 1004 is uneven without increasing the number of manufacturing steps. It can be made light scattering.
[0179]
Next, the counter substrate shown in Example 2 is prepared. In FIG. 23, reference numeral 1010 denotes a counter substrate, and colored layers 1011 and 1012, and a planarizing film 1013 are formed on the counter substrate 1010 in accordance with the second embodiment. The red colored layer 1011 and the blue colored layer 1012 are partially overlapped to form the second light shielding portion. Although not shown in FIG. 23, the first light-shielding portion is formed by partially overlapping the red colored layer and the green colored layer.
[0180]
Next, a counter electrode 1014 was formed in the pixel portion, an alignment film 1015 was formed on the entire surface of the counter substrate, and a rubbing process was performed.
[0181]
In addition, the active matrix substrate on which the pixel portion and the driving circuit are formed and the counter substrate are bonded together with a sealant. A filler is mixed in the sealing agent, and two substrates are bonded to each other with a uniform interval by the filler and the columnar spacer. Thereafter, a liquid crystal material 1016 is injected between both the substrates and completely sealed with a sealant (not shown). A known liquid crystal material may be used for the liquid crystal material 1016. In this way, the active matrix liquid crystal display device shown in FIG. 23 is completed.
[0182]
FIG. 24 is a diagram illustrating the arrangement of the pixel portion and the terminal portion of the active matrix substrate. A pixel portion 1111 is provided over a substrate 1110, and a gate wiring 1108 and a source wiring 1107 are formed to intersect with each other in the pixel portion, and an n-channel TFT 1101 connected to the gate wiring 1108 is provided corresponding to each pixel. The pixel electrode 1004 and the storage capacitor 1102 are connected to the drain side of the n-channel TFT 1101, and the other terminal of the storage capacitor 1102 is connected to the capacitor wiring 1109. The structures of the n-channel TFT 1101 and the storage capacitor 1102 are the same as those of the n-channel TFT or the storage capacitor shown in FIG.
[0183]
An input terminal portion 1105 for inputting a scanning signal is formed at one end portion of the substrate, and is connected to the gate wiring 1108 by a connection wiring 1106. Further, an input terminal portion 1103 for inputting an image signal is formed at the other end portion, and is connected to the source wiring 1107 by the connection wiring 204. A plurality of gate wirings 1108, source wirings 1107, and capacitor wirings 1109 are provided depending on the pixel density. Alternatively, an input terminal portion 1112 for inputting an image signal and a connection wiring 1113 may be provided, and the input terminal portion 1103 may be alternately connected to the source wiring. An arbitrary number of input terminal portions 1103, 1105, and 1112 may be provided, and the practitioner may determine as appropriate.
[0184]
Note that this embodiment can be combined with Embodiment 2 or Embodiment 4.
[0185]
[Example 8]
In this embodiment, an example in which a pixel electrode having unevenness on the surface is formed without increasing the number of manufacturing steps. For simplification, only differences from the seventh embodiment will be described below. In addition, the same code | symbol was used for the part corresponding to FIG.
[0186]
In this embodiment, as shown in FIG. 25, convex portions 1201 and 1202 having different heights are formed.
[0187]
The convex portions 1201 and 1202 can be formed by changing the mask of Example 7 without increasing the number of masks. In this embodiment, as shown in FIG. 25, when patterning the gate electrode, a mask that does not form a metal layer in the convex portion 1202 is used. Therefore, the height of the convex portion 1202 is greater than the thickness of the convex portion 1201. Min, it's getting lower. In this example, the mask used in the patterning of the metal layer used in Example 7 was changed, and two types of convex portions 1201 and 1202 having different heights were randomly formed at locations serving as display areas.
[0188]
By doing so, it is possible to increase the level difference of the unevenness formed on the surface of the pixel electrode 1200 without increasing the number of manufacturing steps, and to scatter reflected light.
[0189]
Note that this embodiment can be combined with Embodiment 2 or Embodiment 4.
[0190]
[Example 9]
In this embodiment, an example in which a pixel electrode having unevenness on the surface is formed without increasing the number of manufacturing steps. For simplification, only differences from the seventh embodiment will be described below.
[0191]
In this embodiment, as shown in FIG. 26, after forming the metal layers 1301a and 1301b and forming the insulating film 1302, the first amorphous film is formed on the insulating film 1302 at a pitch different from that of the metal layers 1301a and 1301b. This is an example in which a stacked body 1303 including a semiconductor film, a second amorphous semiconductor film containing an impurity element imparting n-type conductivity, and a first conductive film is formed.
[0192]
The metal layers 1301a and 1301b can be formed by changing the mask of Example 7 without increasing the number of masks. The metal layers 1301a and 1301b are formed by changing the first mask when forming the gate electrode 1300 of the seventh embodiment. Furthermore, the second mask of Example 7 is changed to form a stacked body 1303.
[0193]
By doing so, the size of the unevenness formed on the surface of the pixel electrode 1304 can be made different without increasing the number of manufacturing steps, the arrangement can be made random, and the reflected light can be scattered.
[0194]
Note that this embodiment can be combined with Embodiment 2, Embodiment 4, Embodiment 7, or Embodiment 8.
[0195]
[Example 10]
The TFT and the active matrix substrate formed by implementing any one of the first to ninth embodiments can be used for various electro-optical devices (active matrix liquid crystal display, active matrix EC display). That is, the present invention can be implemented in all electronic devices in which these electro-optical devices are incorporated in the display unit.
[0196]
Such electronic devices include video cameras, digital cameras, projectors (rear type or front type), head mounted displays (goggles type displays), car navigation systems, car stereos, personal computers, personal digital assistants (mobile computers, mobile phones) Or an electronic book). Examples of these are shown in FIGS.
[0197]
FIG. 27A illustrates a personal computer, which includes a main body 2001, an image input portion 2002, a display portion 2003, a keyboard 2004, and the like. The present invention can be applied to the display portion 2003.
[0198]
FIG. 27B illustrates a video camera, which includes a main body 2101, a display portion 2102, an audio input portion 2103, operation switches 2104, a battery 2105, an image receiving portion 2106, and the like. The present invention can be applied to the display portion 2102.
[0199]
FIG. 27C illustrates a mobile computer, which includes a main body 2201, a camera unit 2202, an image receiving unit 2203, operation switches 2204, a display unit 2205, and the like. The present invention can be applied to the display portion 2205.
[0200]
FIG. 27D illustrates a goggle type display including a main body 2301, a display portion 2302, an arm portion 2303, and the like. The present invention can be applied to the display portion 2302.
[0201]
FIG. 27E shows a player using a recording medium (hereinafter referred to as a recording medium) on which a program is recorded, and includes a main body 2401, a display portion 2402, a speaker portion 2403, a recording medium 2404, an operation switch 2405, and the like. This player uses a DVD (Digital Versatile Disc), CD, or the like as a recording medium, and can perform music appreciation, movie appreciation, games, and the Internet. The present invention can be applied to the display portion 2402.
[0202]
FIG. 27F illustrates a digital camera, which includes a main body 2501, a display portion 2502, an eyepiece portion 2503, an operation switch 2504, an image receiving portion (not shown), and the like. The present invention can be applied to the display portion 2502.
[0203]
FIG. 28A shows a cellular phone, which includes a main body 2901, an audio output portion 2902, an audio input portion 2903, a display portion 2904, operation switches 2905, an antenna 2906, and the like. The present invention can be applied to the display portion 2904.
[0204]
FIG. 28B illustrates a portable book (electronic book) which includes a main body 3001, display portions 3002 and 3003, a storage medium 3004, operation switches 3005, an antenna 3006, and the like. The present invention can be applied to the display portions 3002 and 3003.
[0205]
FIG. 28C illustrates a display which includes a main body 3101, a support base 3102, a display portion 3103, and the like. The present invention can be applied to the display portion 3103. The display of the present invention is particularly advantageous when the screen is enlarged, and is advantageous for displays having a diagonal of 10 inches or more (particularly 30 inches or more). Further, in order to form a display portion having such a size, it is preferable to use a substrate having a side of 1 m and perform mass production by performing multiple chamfering.
[0206]
As described above, the application range of the present invention is extremely wide and can be applied to electronic devices in various fields. Moreover, the electronic apparatus of a present Example is realizable even if it uses the structure which consists of what combination of Examples 1-9.
[0207]
【Effect of the invention】
According to the present invention, a pixel electrode having an uneven surface can be formed without increasing the number of steps.
[Brief description of the drawings]
FIGS. 1A to 1C are diagrams illustrating a manufacturing process of an AM-LCD (pixel portion). FIGS.
FIGS. 2A and 2B are diagrams illustrating a manufacturing process of an AM-LCD (pixel portion). FIGS.
FIGS. 3A and 3B are diagrams illustrating a manufacturing process of an AM-LCD (pixel portion). FIGS.
FIG. 4 illustrates a cross-sectional structure of an active matrix liquid crystal display device.
FIG. 5 is a diagram showing a top view of a pixel.
FIG. 6 is a diagram showing a top surface shape of a convex portion.
FIG. 7 is a diagram showing an external appearance of an AM-LCD.
FIG. 8 is a diagram showing a terminal portion of an AM-LCD.
FIGS. 9A and 9B are diagrams illustrating a manufacturing process of an AM-LCD. FIGS.
10A and 10B are diagrams illustrating a manufacturing process of an AM-LCD.
FIG. 11 is a diagram showing a manufacturing process of an AM-LCD.
FIG. 12 is a diagram illustrating a top view of an arrangement of a colored layer.
13A and 13B are a top view and a cross-sectional view of an arrangement of a colored layer.
FIG. 14 is a cross-sectional view of an arrangement of colored layers.
FIG. 15 illustrates a manufacturing process of an AM-LCD.
FIGS. 16A and 16B are diagrams illustrating a manufacturing process of an AM-LCD. FIGS.
FIG. 17 shows a manufacturing process of an AM-LCD.
18A and 18B are diagrams illustrating a manufacturing process of an AM-LCD (pixel portion).
FIG. 19 illustrates a manufacturing process of an AM-LCD (pixel portion).
FIG. 20 is a diagram showing a cross-sectional structure of an active matrix liquid crystal display device.
FIG. 21 shows a manufacturing process of an AM-LCD.
FIG. 22 shows a manufacturing process of an AM-LCD.
FIG. 23 is a cross-sectional view of an active matrix liquid crystal display device.
FIG. 24 is a diagram illustrating an arrangement of a pixel portion and a terminal portion of an active matrix substrate.
FIG 25 illustrates a cross-sectional structure diagram of an active matrix liquid crystal display device.
FIG. 26 is a cross-sectional view of an active matrix liquid crystal display device.
FIG 27 illustrates an example of an electronic device.
FIG 28 illustrates an example of an electronic device.
FIG. 29 is a graph showing the reflectance of stacked colored layers.
FIG. 30 is a graph showing the reflectance in a single layer of a colored layer.

Claims (9)

A semiconductor device having a TFT, a convex portion, a first insulating layer, a pixel electrode, a first colored layer, and a second colored layer,
The TFT includes a semiconductor layer including non-single crystal silicon, a second insulating layer, and a gate electrode.
The protrusion has a layer having the same material as the second insulating layer, and a layer having the same material as the gate electrode,
The first insulating layer is provided on the TFT and on the convex portion,
The first insulating layer has an uneven surface;
The pixel electrode is provided on the first insulating layer,
The pixel electrode has an uneven surface,
The first colored layer has a first region overlapping at least a part of the second colored layer;
The first colored layer is red;
The second colored layer is green;
The semiconductor device, wherein the first region has a region overlapping with at least part of the semiconductor layer. A semiconductor device having a TFT, a convex portion, a first insulating layer, a pixel electrode, a first colored layer, and a second colored layer,
The TFT includes a semiconductor layer including non-single-crystal silicon, a second insulating layer on the semiconductor layer, and a gate electrode on the second insulating layer,
The protrusion has a layer having the same material as the second insulating layer, and a layer having the same material as the gate electrode,
The first insulating layer is provided on the TFT and on the convex portion,
The first insulating layer has an uneven surface;
The pixel electrode is provided on the first insulating layer,
The pixel electrode has an uneven surface,
The first colored layer has a first region overlapping at least a part of the second colored layer;
The first colored layer is red;
The second colored layer is green;
The semiconductor device, wherein the first region has a region overlapping with at least part of the semiconductor layer. A semiconductor device having a TFT, a convex portion, a first insulating layer, a pixel electrode, a first colored layer, and a second colored layer,
The TFT has a gate electrode, a second insulating layer on the gate electrode, and a semiconductor layer having non-single-crystal silicon on the second insulating layer,
The protrusion has a layer having the same material as the gate electrode and a layer having the same material as the second insulating layer,
The first insulating layer is provided on the TFT and on the convex portion,
The first insulating layer has an uneven surface;
The pixel electrode is provided on the first insulating layer,
The pixel electrode has an uneven surface,
The first colored layer has a first region overlapping at least a part of the second colored layer;
The first colored layer is red;
The second colored layer is green;
The semiconductor device, wherein the first region has a region overlapping with at least part of the semiconductor layer. A semiconductor device having a pixel portion and a drive circuit portion ,
The pixel portion includes a first TFT, a convex portion, a first insulating layer, a pixel electrode, a first colored layer, and a second colored layer,
The drive circuit unit includes a second TFT, a third colored layer, and a fourth colored layer,
The first TFT comprises: a first semiconductor layer having a non-single-crystal silicon, a second insulating layer, a first gate electrode,
The convex portion is a layer having the same material as the second insulating layer, and a layer having the same material as the first gate electrode,
The first insulating layer, said a first TF T, provided on said projecting portion,
The first insulating layer has an uneven surface;
The pixel electrode is provided on the first insulating layer ,
The pixel electrode has an uneven surface,
The first colored layer has a first region overlapping at least a part of the second colored layer;
The first colored layer is red;
The second colored layer is green;
The first region has a region overlapping at least a part of the first semiconductor layer;
The second TFT includes a second semiconductor layer including non-single crystal silicon, a third insulating layer, and a second gate electrode.
Before the third colored layer SL is to have a second region that overlaps with at least a portion of the fourth colored layer,
The third colored layer is red;
The fourth colored layer is blue;
Said second region, and wherein a Rukoto to have a least a portion overlaps the region of the second semiconductor layer. A semiconductor device having a pixel portion and a drive circuit portion ,
The pixel portion includes a first TFT, a convex portion, a first insulating layer, a pixel electrode, a first colored layer, and a second colored layer,
The drive circuit unit includes a second TFT, a third colored layer, and a fourth colored layer,
The first TFT comprises: a first semiconductor layer having a non-single-crystal silicon, a second insulating layer on said first semiconductor layer, a first gate electrode on the second insulating layer Have
The convex portion is a layer having the same material as the second insulating layer, and a layer having the same material as the first gate electrode,
The first insulating layer, said a first TF T, provided on said projecting portion,
The first insulating layer has an uneven surface;
The pixel electrode is provided on the first insulating layer ,
The pixel electrode has an uneven surface,
The first colored layer has a first region overlapping at least a part of the second colored layer;
The first colored layer is red;
The second colored layer is green;
The first region has a region overlapping at least a part of the first semiconductor layer;
The second TFT includes a second semiconductor layer including non-single-crystal silicon, a third insulating layer on the second semiconductor layer, and a second gate electrode on the third insulating layer. Have
Before the third colored layer SL is to have a second region that overlaps with at least a portion of the fourth colored layer,
The third colored layer is red;
The fourth colored layer is blue;
Said second region, and wherein a Rukoto to have a least a portion overlaps the region of the second semiconductor layer. A semiconductor device having a pixel portion and a drive circuit portion ,
The pixel portion includes a first TFT, a convex portion, a first insulating layer, a pixel electrode, a first colored layer, and a second colored layer,
The drive circuit unit includes a second TFT, a third colored layer, and a fourth colored layer,
The first TFT has a front Symbol first gate electrode, a second insulating layer on said first gate electrode, a first semiconductor layer having a non-single-crystal silicon on said second insulating layer And
The convex portion includes a layer having the same material as the first gate electrode and a layer having the same material as the second insulating layer ,
The first insulating layer, said a first TF T, provided on said projecting portion,
The first insulating layer has an uneven surface;
The pixel electrode is provided on the first insulating layer ,
The pixel electrode has an uneven surface,
The first colored layer has a first region overlapping at least a part of the second colored layer;
The first colored layer is red;
The second colored layer is green;
The first region has a region overlapping at least a part of the first semiconductor layer;
The second TFT includes a second gate electrode, a third insulating layer on the second gate electrode, and a second semiconductor layer having non-single-crystal silicon on the third insulating layer. Have
Before the third colored layer SL is to have a second region that overlaps with at least a portion of the fourth colored layer,
The third colored layer is red;
The fourth colored layer is blue;
Said second region, and wherein a Rukoto to have a least a portion overlaps the region of the second semiconductor layer. In any one of Claims 1 thru | or 6 ,
The semiconductor device according to claim 1, wherein the uneven protrusion of the pixel electrode has a curvature radius of 0.1 μm to 4 μm. An electronic apparatus, comprising a semiconductor device according to any one of claims 1 to 7. Antenna, operation switches, electronic apparatus comprising: the battery or storage medium, and a semiconductor device according to any one of claims 1 to 7.

Images